The cement roller press is a kind of grinding equipment applied for brittle materials, such as cement clinker, granular blast furnace slag, cement raw materials (limestone, sandstone, shale, etc.), gypsum, coal, quartz sand, iron ore, etc. It is designed according to the principle of bed grinding, the high-pressure load directly acts on the material layer through double rollers, which causes internal stress in particles and leads to cracks to achieve the purpose of grinding.
Roller Press In Cement Plant
The cement roller press has a high energy utilization rate and remarkable energy-saving effect in the material grinding process. In cement plant, cement roller press is a kind of important cement equipment used for clinker grinding. It is usually combined with a cement ball mill to form a high-efficiency cement grinding system because the practice shows that the grinding process with small grinding ratio and step-by-step completion is more energy-saving than that with large one-time completion.
Cement ball mill is a main cement grinding mill with a low energy utilization rate (only 3%-5%). Compared with the grinding energy consumption, most of its energy is consumed by collision heating and noise. Therefore, we usually adopt the cement roller press to replace the fine crushing and coarse grinding role of the ball mill. This increases the output of the ball mill system by 30-50%, and 20-35% of the extruded materials are smaller than 0.08mm, 65-85% are smaller than 2mm. Besides, a large number of cracks will be produced on all extruded materials, which will greatly reduce the energy consumption of materials in the next grinding process.
The grinding systems consisting of roller press and ball mill include a pre-grinding system, combined grinding system, semi-finishing grinding system, and finish grinding system.
Pre-grinding system: after the material is pulverized by the roller press, all or part of them with a good extrusion effect will enter the subsequent ball mill for further grinding. This system has the advantages of simple processes, less equipment, wide particle size distribution, and stable cement performance. But because the ground material is not classified, a large number of fine powders are back to the roller press, the power saving range is limited.
Combined grinding system: materials ground by cement roller press are divided into two parts by air classifier: coarse part and fine part. The fine part will enter the ball mill to be further ground into the finished product, the coarse part will return to the roller press to be ground again. Because the cement finished products are all ground by the ball mill, the finished products have wide particle size distribution and the cement performance is stable.
Semi-finishing grinding system: after ground by cement roller press, materials are divided into three parts through an air classifier: coarse, medium and fine, in which the coarse material is returned to roller press for re-grinding, the medium material is put into ball mill for further grinding, and the fine material is directly discharged as the finished cement product. Because the roller press and the ball mill are two completely independent circulation systems, they are easier to operate and control and are more energy saving.
Finish grinding system: this system only includes a cement roller press to complete the grinding of cement clinker. Materials ground by cement roller press are divided into two parts by air classifier: coarse part and fine part. The coarse part will return to the roller press to be ground again and the fine part will be discharged as the cement product.
Working Principle Of Cement Roller Press
The cement roller press is composed of two rollers that rotate synchronously in the opposite direction and a set of a hydraulic system. Its main structure includes a press roller system, transmission device, mainframe, hydraulic system, feeding device, and so on.
The two rollers of cement roller press, one is fixed and the other is movable, which are driven by a motor and a reducer to rotate at a relatively low speed. The movable roller bearing seat is connected with the hydraulic system. It can be moved along a horizontal direction to control the gap between the two rollers, while the fixed roller is installed in the inner chamber of the mainframe. When materials enter between the two rollers from above, pressure (50-300Mpa) is transferred to materials by the hydraulic system through oil cylinder, bearing seat, and rollers so that material particle size can be reduced by means of extrusion. After grinding, the fine particles less than 90μm account for about 20-30%. At the same time, there are many cracks in the coarse particles. In the process of further grinding, their energy consumption can be greatly reduced.
Specification Of Cement Roller Press
| Type | Roller Diameter(mm) | Roller Width(mm) | Feed Size(mm) | Output(t/h) | Power(kw) |
| G140-80 | 1400 | 800 | ≤65 | 290-360 | 2ⅹ250 |
| G140-100 | 1400 | 1000 | ≤65 | 350-420 | 2ⅹ560 |
| G150-100 | 1500 | 1000 | ≤70 | 420-500 | 2ⅹ710 |
| G150-110 | 1500 | 1100 | ≤70 | 460-550 | 2ⅹ710 |
| G160-120 | 1600 | 1200 | ≤75 | 590-680 | 2ⅹ900 |
| G160-140 | 1600 | 1400 | ≤75 | 690-780 | 2ⅹ1120 |
| G170-100 | 1700 | 1000 | ≤80 | 450-620 | 2ⅹ1000 |
| G170-120 | 1700 | 1200 | ≤80 | 630-730 | 2ⅹ1100 |
| G180-100 | 1800 | 1000 | ≤85 | 700-850 | 2ⅹ1000 |
| G180-120 | 1800 | 1200 | ≤85 | 850-1020 | 2ⅹ1200 |
| G200-120 | 2000 | 1200 | ≤90 | 950-1180 | 2ⅹ1600 |
| G200-160 | 2000 | 1600 | ≤90 | 1300-1580 | 2ⅹ1800 |
Why Choose AGICO Cement Roller Press
AGICO is a professional cement plant equipment supplier in China. The cement roller press is one of our hot-sales products in the cement grinding unit. Compared with other cement mills, the roller press produced by AGICO has the following advantages:
- Big crushing ratio (30-400), good material grinding effect, and more fine powder content.
- It adopts advanced roller structure and welding technology to greatly improve the service life of the roller surface, which can reach more than 8000 hours and reduce the operation cost.
- The roller press grinding system runs smoothly and reliably. The extrusion roller is forged with alloy steel and has a large bearing capacity.
- Its unique bearing structure design effectively solves various defects in operation.
- It has a safe and sensitive hydraulic system and a professional hydraulic accessory design. The constant pressure design concept and unique structure design make the hydraulic system more reliable and convenient for maintenance.
- The advanced detection and automatic control system ensures the safe operation of the roller press.
- It has a flexible adjusted feeding system and adopts an electric feeding device, which is convenient for production and operation.
Cement Roller Press Vs Cement Ball Mill
Cement ball mill and cement roller press are both the commonly used equipment for clinker grinding. But in the actual cement production process, the roller press has more advantages in different aspects, mainly reflected in the following points:
- High Grinding Efficiency & Energy- saving
In the cement ball mill, materials are subjected to a combined effect of extrusion and shear force, while, in cement roller press, materials are only subjected to extrusion force. The test results show that the strain produced by applying only pure extrusion is 5 times of the strain produced by shearing force in the grinding process of granular material. - Low Steel Consumption
When grinding cement, the abrasion of the ball mill is 300-1000 g/t, while that of the roller press is 0.5g/t, so it can meet the requirements of grinding white cement.
- Low Noise
The noise of the ball mill is more than 110d, while the cement roller press is about 80dB.
- Environmental Friendly
The special structure design of a cement roller press can effectively reduce the diffusion of harmful dust. Besides, it also produces relatively low noise, greatly improving workers’ working conditions.
- Small shape, lightweight, small footprint, easy to install, and can even be installed as a whole.
