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Breve análisis de las fugas de aire en los molinos verticales de crudo

Introduction: The Critical Role of Vertical Mills in Cement Production

Raw material vertical mills are essential grinding equipment in cement manufacturing, directly impacting production efficiency, energy consumption, and product quality. However, air leakage in vertical mills is a common yet costly issue, leading to:

✔ Higher power consumption (increased fan load)
✔ Reduced mill output (material loss & unstable grinding)
✔ Premature equipment wear (seal & pipe damage)
✔ Inconsistent product fineness (poor grinding performance)

This guide explores root causes of air leakage in molinos verticales de rodillos and provides engineered solutions to improve sealing, reduce downtime, and lower operating costs.

I. Major Impacts of Air Leakage in Vertical Roller Mills

1. Increased Energy Consumption

Air leakage causes heat loss, forcing mills to consume extra hot air to maintain temperature.
Higher fan power demand (e.g., circulating fan energy use spikes by 8.6 kWh/t).

2. Reduced Production Capacity

Escaping air carries away raw meal, decreasing mill load and lowering throughput.

3. Accelerated Equipment Wear

Dust ingress from leaks damages roller seals, bearings, and pipelines, increasing maintenance costs.

4. Poor Cement Quality

Uncontrolled airflow disrupts grinding efficiency, causing overly coarse or fine particles.

II. 5 Key Causes of Air Leakage in Vertical Mills

1. Worn or Damaged Seals

Roller seals, feeder sealsy shaft seals degrade over time, creating gaps.

2. Loose Pipe Connections

Poorly fitted ducts between mill & dust collector allow air escape.

3. Inefficient Locking Feeder Design

Segmented wheel feeders with incorrect gaps cause material spillage & pressure loss.

4. Weak Roller Seal Structure

Tradicional flat seals lack flexibility, failing under mill vibrations & temperature changes.

5. Flawed Slag Discharge System

Single-flap valves jam easily, while open chutes expose the mill to uncontrolled airflow.

III. Proven Solutions to Stop Vertical Mill Air Leakage

1. Upgrade to High-Performance Seals

✔ Replace standard seals con silicone wave seals for better elasticity & durability.

2. Reinforce Pipe Joints & Flanges

✔ Use high-temp gaskets y torque-check all bolts durante el mantenimiento.

3. Install Advanced Locking Feeders

✔ Switch to rotary feeders con adjustable gaps to balance material flow & sealing.

4. Optimize Roller Seal Design

✔ Implement labyrinth seals o pneumatic sealing systems for long-term reliability.

5. Redesign the Slag Discharge Port

✔ Replace flap valves con non-powered material curtain valves that use system pressure for automatic sealing.

IV. Case Study: 4500 t/d Cement Plant Saves 2.58M Yuan/Year

Problem: A TRM53.4 vertical mill suffered severe leaks, causing:

Oxygen levels at kiln tail: 10.3% (vs. ideal 5–7%)
Raw mill power use: 16.5 kWh/t
Low output temp: 45–55°C

Solutions Applied:

Installed wave-type roller seals.
Upgraded to a rotary locking feeder.
Modified slag discharge with pressure-sealed valves.

Results:

✅ Air leakage reduced by 60%
✅ Energy savings: 3.8 kWh/t
✅ Production increased by 12%
✅ Annual cost savings: ¥2.58 million

V. Conclusion: Maximize Mill Performance with Proper Sealing

Las fugas de aire en los molinos verticales de materias primas son un problema complejo y crítico. Las empresas deben abordarlo desde múltiples ángulos, incluidos el diseño, la instalación y el mantenimiento. Optimizando el diseño de los equipos, mejorando el mantenimiento y aumentando la eficacia del sellado, las empresas pueden reducir eficazmente las fugas de aire, aumentar la estabilidad operativa de los molinos verticales y mejorar la eficacia de la producción. Si tienes alguna pregunta sobre cómo mejorar el rendimiento de los equipos, no dudes en Contacto. Darko está aquí para ofrecerte soluciones y apoyo profesionales.