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Separator Dynamic Seal

This document summarizes an experience with a dynamic separator gap issue at an ATOX vertical roller mill (VRM). Due to a large gap between the static cover plate and rotor shelf, raw meal residue fineness was not controlled and the separator speed had to be increased to 90%, causing trips and increased rejects. Investigation found the gap was up to 25mm instead of the proper 0mm, allowing coarse material to bypass the separator. Welding a plate to close the gap resolved the issue and allowed proper fineness control. It is recommended to check for and close any vertical gaps to prevent similar problems.

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Dilnesa Ejigu
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1K views4 pages

Separator Dynamic Seal

This document summarizes an experience with a dynamic separator gap issue at an ATOX vertical roller mill (VRM). Due to a large gap between the static cover plate and rotor shelf, raw meal residue fineness was not controlled and the separator speed had to be increased to 90%, causing trips and increased rejects. Investigation found the gap was up to 25mm instead of the proper 0mm, allowing coarse material to bypass the separator. Welding a plate to close the gap resolved the issue and allowed proper fineness control. It is recommended to check for and close any vertical gaps to prevent similar problems.

Uploaded by

Dilnesa Ejigu
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOC, PDF, TXT or read online on Scribd
You are on page 1/ 4

ATC REPORT

Activity: EXPERIENCE SHARING


Dynamic Separator Gap
ATOX VRM

by (Jayaraman Chandrasekar)
ATC, (20/9/2006)

Distribution:
Region
BU
Plant
ATC
Other
Codification (refer to Document / Correspondence
Codification, PF/ATC900/MAE/030602)
TABLE OF CONTENTS

1. Failure / Experience.........................................................................................................3
2. Consequences.................................................................................................................3
3. Cause analysis / knowledge.............................................................................................3
4. Recommendations...........................................................................................................3
1. Failure / Experience
In one of the FLS ATOX VRM, the raw meal residue was not under control. The % material
retained on 90 microns was 22 – 35% and % retention on 212 microns were between 5 – 8%.
Since the fineness was not under control, the Dynamic separator speed was increased to 90%.

Due to the high separator speed the current was close to 100% and also the separator
vibrations were upto 25 mm/s

2. Consequences
The separator drive tripped due to high current several times and the commissioning
engineers (external) have removed the upper limit of the separator vibrations. (This is not a
good practice. ATC Engineer re-installed the vibrations tripping limits as per the original
settings).

Because of the high separator speed, the internal rejects to the Mill table has increased and
made the grinding operations further difficult. Again, coupled with all the other Mill problems,
this problem has worsened the stability of the operations.

3. Cause analysis / knowledge


On inspection inside the Separator, it was found that the seal gap of the cover plate to the
separator rotor was very high. The gap was found to be upto 25 mm, whereas the actual should
be 0 mm. Due to the poor workmanship, the gap is also not uniform throughout the
circumference. This would lead the coarse material also to escape from the bigger gaps as a
final product and also due to the higher speed, where the gaps are less; the fines will be re-
circulated internally to the Mill for further fine grinding.

A 30 mm plate was welded across the total separator cover plate to stop the by-pass of the
coarse getting carried away as final product.

The results were good and the plant could maintain a 90 micron residue around 18% and
212 microns around 1-2%.

4. Recommendations
It is recommended to check the vertical gap between the static cover plate and the rotor 1 st
shelf. It should be totally covered. If not, a plate has to be welded throughout the
circumference.

Page 3 of 4
Figure 1  Gap between the static cover plate and the Rotor 1st Shelf.

Figure 2  Another view of the gap and poor workmanship.

Page 4 of 4

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