This work concentrates on the energy consumption and grinding energy efficiency of a laboratory vertical roller mill (VRM) under various operating parameters. For design of experiments (DOE), the response surface method (RSM) was employed with the VRM experiments to systematically investigate the influence of operating parameters on the energy consumption and grinding energy efficiency. The prediction models of energy consumption (Ecs) and grinding energy efficiency (η) were established respectively with the operating parameters (loading pressure, rotation speed and moisture content). Analysis of variance (ANOVA) was performed to obtain useful knowledge in designing operating parameters. Moreover, the multi-objective optimization design (MOD) method was conducted to seek out the optimal parameters of the VRM, and a set of optimal parameters was gained based on the desirability approach by Design-Expert. It is proved that the optimized prediction results match the experimental results well, which indicates this research offers a reliable guidance for reducing energy consumption and improving grinding energy efficiency.
The vertical roller mill is an important crushing and grading screening device widely used in many industries. Its classification efficiency and the pressure difference determine the entire producing capacity and power consumption, respectively, which makes them the two key indicators describing the mill performance. Based on the DPM (Discrete Phase Model) and continuous phase coupling model, the flow field characteristics in the vertical roller mill including the velocity and pressure fields and the discrete phase distributions had been analyzed. The influence of blade parameters like the shape, number, and rotating speed on the flow field and classification performance had also been comprehensively explored. The numerical simulations showed that there are vortices in many zones in the mill and the blades are of great significance to the mill performance. The blade IV not only results in high classification efficiency but also reduces effectively the pressure difference in the separator and also the whole machine. The conclusions of the flow field analysis and the blade effects on the classification efficiency and the pressure difference could guide designing and optimizing the equipment structure and the milling process, which is of great importance to obtain better overall performance of the vertical roller mill.
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