ball mill vs vrm

Ball Mill VS VRM

Expecting Experts opinion regarding Advantage & Disadvantage (Quality, Production, Current consumption, Man power, etc.)

SUNILUnfollow Follow SUNIL

SUNIL SHARMA • ofcourse the VRM is more benifical than Ball Mill, But for cement grinding it may not be because we require HAG for hot air.

If your Economics permitts for this additional cost, Than you can choose VRM for Cement grinding also.

Secondly, The Initial cost is Approx. Thrice if compared with Ball mill, if you have good cement market permitts you for the payback within 2 Years.

Power consumption in ball mill is around 32-33 unit/ton, whereas in VRM it will be around 16-20 Unit/ton.

You Can eaisly control the quality or we can say the devation in req. quality is less with VRM if compared with BALL MILL.

September 30, 2011 • Unlike • Like

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HabiburUnfollow Follow Habibur

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Habibur Rahman • Thank you Mr. Sunil & Dr. Bapat for your comments. Here I can see VRM is better & have many advantages in all respects except solubility of Gypsum due to temperature. What about the manpower & maintenance? In my country I have seen at the very beginning after installation of VRM, they couldn't feed Slag along with Fly ash, why it may happen?

October 1, 2011 • Unlike • Like


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AtifUnfollow Follow Atif

Atif Munir • How about the maintenance of both mills ? especially wear parts (tables & rollers)

Do you prefer wear parts from original supplier or source OEM ?



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AlanUnfollow Follow Alan

Alan Gee • Wear depends upon material ground and fineness. VRM is not as flexible when making specialty products (high fineness, masonry, coarse grind). For commodity OPC, VRM is a very good option.


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LucianoUnfollow Follow Luciano

Luciano Morais • FLS type OK cement mills work with 65% the slag with CPIII Blaine of 4500 with high productivity and low power consumption It has excellent drying power and high efficiency separators The use of additives to optimize the grinding layer formation and improves the performance of the mill The design of the rollers allows a good comminution pressure low level of vibration



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LucianoUnfollow Follow Luciano

Luciano Morais • For additional information about the mill 25 -3 OK, did a project where the technical guarantee for 4500 Blaine had a yield of 47 ton / h OPC provided the mill reached 65 tons / h



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Habibur Rahman • Sorry, I did a mistake a portion! I said in comment "they couldn't feed Slag along with Fly ash" rather It should be "they couldn't feed FA along with Slag"



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DavidUnfollow Follow David

David Baird • The main advantage of a VCM over a ball mill is power consumption with the VCM system drawing around 67% of the ball milling system overall kwh/tonne A disadvantage of ball mill is when they are used for a range of cements. If you set up the ball mill to provide 9 kwh/tonne in chamber 1 at low blaine then this may raise to 12 -13 kwh/tonne at high blaine thereby wasting power. At higher blaine the VCM substitution factor tends to increase whilst the ball mill efficiency can reduce due to several factors including C1 power wastage. Capital cost - a lot of conflicting data on this but I would count a VCM costs around 5% to 15% higher installed cost than an equivalent ball milling system A disadvantage with the VCM is the need for an HGG unless the cement mill is located close to a clinker cooler and can use some higher grade exhaust gas from the mid point etc



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Habibur Rahman • Mr. David, seems HGG is higher grade exhaust gas & VCM vertical cement mill, right? Thanks for your valuable input.



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DavidUnfollow Follow David

David Baird • Hello VCM = Vertical Cement Mill HGG = Hot Gas Generator Most new VCM mills need an HGG to cope with start up etc I know of one project where the HGG was omitted but had to be bought later on In the last 9 years I have had to evaluate a lot of new cement mill projects and around 85% of these have been VCM and 15% Ball mills. So the Ball Mill seems to be fading away from new plant designs. Regards David



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RonaldUnfollow Follow Ronald

Ronald DuMond • Has anyone experienced premature bearing failure on VRM system classifier? If so, could you share ultimate resolution? Was it a change in grease specification for internal temperatures, was it an application/pump problem, inherent design or other? Please be as specific as you can. Thank you.

For comparison with ball mills; yes it was primarily specific power savings advantage for the VRM and ours is equipped with a gas fired hot air generator.



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Habibur Rahman • Mr. Devid, thanks for the elaboration of VCM & HGG and other inputs.



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Constantin DorelUnfollow Follow Constantin Dorel




Constantin Dorel Popescu • I am happy to hear from you about this question about ball mills and VRM, well, the capacity of a ball mill depends with the cube of the internal diameter mill and of course the power installed and if is in close circuit or open circuit, the biggest ball mill I have seen for grinding cement had a capacity of 340 tph. The VRM's are even more powerful since the work is not so big (due to the working principle the VRM has no to lift such huge grinding media) and therefore throughput is bigger and the installed power is much more used than in a ball mill , supple mentally the G force is acting here. The VRM's are superior to the ball mills and personally I think it would replace the ball mills with the time. The ball mills remained superior in the Particle Size Distribution .

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Constantin Dorel Popescu • As far as I know the biggest rotary cement ball mill is in Turkey In Nuh cement plant. I was visiting this cement mill, however it has 5.8 metres in diameter and 18.5 metres in length, the two-compartment UMS-type mill with a Stanex diaphragm is impressive. Side-driven by FLSmidth MAAG Gear’s Lateral Gear Drive, size LGD 80, the huge gear unit, is rated for a capacity of 10,100 kW at 13.62 rpm for the mill. The mill is as you see is a Mammoth and is difficult to say how is noising when starts. FLSmidth includes not only the impressive UMS mill, but also a SEPAX 560M separator and two FLSmidth Airtech baghouse filters However, I think it worth to see this installation.

What can I say is that the mill is given the best cement Portland quality that cannot be compared with any VRM (for the time being). I am curious how this mill can behave for other easier to grind types of cement.



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RavindranathUnfollow Follow Ravindranath

Ravindranath B • Ball Mill in combination with a Roller press gives better sp. power consumption comaared to a VCM. The disadvantage is no. of auxiliary machines are more compared to the VCM.



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FıratUnfollow Follow Fırat

Fırat Aslan • Dear all,

Vhttp://www.rucem.ru/yabbfiles/Attachments/Cementgrinding.pdf

there is a good paper comparing ball mill vs vertical mills.



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Constantin Dorel Popescu • I agree RP is a good alternative especially for upgrading the old ball mills plants



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Habibur Rahman • what's the basic & working difference between VRM & VCM?

Mr. Aslam, thank you so much for providing us a good link of F L SMIDTH



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FıratUnfollow Follow Fırat

Fırat Aslan • You're welcome Mr. Rahman, In VCM or OK Mills the rollers are designed to grind clinker two times in one pass. The first one is low pressure grinding and second one high-pressure. Operation of VCM mill with high blaine, say 4500 cm2/gr, can be very difficult. In vertical mill, the bed height above table is very important for efficient grinding. But in case of working with high blaine, the circulation factor will increase and also deviate too much. One other thing that should be evaluated is PSD. As it is mentioned before the PSD is steeper in VCM. 10-30 micron particles in cement are very important for stregth development. When PSD gets narrower the fine particles between 10-30



micron get lower so strength. in order to reach desired fine particles the cement can be overgrinded. This will cause more water consumption for mortar.



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Habibur Rahman • Mr. Aslam, what is OK mill? Could you pls differentiate between VCM & VRM?



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Ronald DuMond • An OK Mill mill is trade name for an FLSmidth VCM. Typically from my experience a VRM is a vertical roller mill producing raw meal, not finished cement product. Firtat's comments on cement quality for a VCM are very representaive of our experience.



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Habibur Rahman • are Ronald, thanks to clarify about OK mill. I know some companies s producing only finished cement using VRM! Are they wrongly naming the mill?



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Ronald DuMond • I guess not. A VRM describes the fundamental mill design, while VCM hones in on more specific application for cement production. Quite possibly dependent upon comminucation levels and regional/geographical/company or plant specific discussions.



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Habibur Rahman • Thanks Ronald for your clarification.






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SamuelUnfollow Follow Samuel

Samuel Owolabi • Vertical Roller Mill consume less power than Ball Mill but has to be properly maintained especially the hydraulic systems. Loesche Mill is fairly stable than FLS mill I had worked on. Depending on your application. I will recommend VRM for your raw meal.



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EmmanuelUnfollow Follow Emmanuel

Emmanuel Ike • The ball mill is less complicated, not so complex maintenance, cheaper to install in the overall, it depends on the capacity of the plant you have or want. The VRM could give you more tonnes in volume.



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K.KUnfollow Follow K.K

K.K Pandey • there are many Parameters for deciding whether to go for which type of mill, e.g power efficiency, simplicity about the design, available skill set. Ball is simple , low cost but less efficient in terms of productivity, wherein VRM is complex in design, high cost than ball mill, but efficient. Please state adject requirement.



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Sagar Raysoni likes this comment by James Kelly

Suitable materiel for temp range 1100-120 degree Centigrade and properties of weldable and fabricated also.: I suspect that no customers ask for 353 MA as it was never promoted in India and is no longer made. Until Outokumpu ceased production...


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Sagar Raysoni likes this comment by arun rao

Suitable materiel for temp range 1100-120 degree Centigrade and properties of weldable and fabricated also.: James, I agree with your comments. On a few ocassions I had recommended using HT or HU grades with a life guarantee. The plants were...

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