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 вертикальные валковые мельницы 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 seals, и 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
Traditional 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 с silicone wave seals for better elasticity & durability.
2. Reinforce Pipe Joints & Flanges
✔ Use high-temp gaskets и torque-check all bolts во время технического обслуживания.
3. Install Advanced Locking Feeders
✔ Switch to rotary feeders с adjustable gaps to balance material flow & sealing.
4. Optimize Roller Seal Design
✔ Implement labyrinth seals или pneumatic sealing systems for long-term reliability.
5. Redesign the Slag Discharge Port
✔ Replace flap valves с 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
Утечка воздуха в сырьевых вертикальных мельницах - сложная и критическая проблема. Предприятия должны решать ее с разных сторон, включая проектирование, установку и обслуживание. Оптимизировав конструкцию оборудования, улучшив техническое обслуживание и повысив эффективность уплотнений, компании смогут эффективно сократить утечку воздуха, повысить эксплуатационную стабильность вертикальных мельниц и эффективность производства. Если у тебя есть вопросы по поводу повышения эффективности работы оборудования, не стесняйся обращаться к нам. связаться с нами. Дарко здесь, чтобы предоставить тебе профессиональные решения и поддержку.
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