How to Effectively Troubleshoot Common HPGR Roller Press Issues for Enhanced Cement Production

1. How to Address Roller Deviation in Roller Presses

Symptoms:
When the gap between the driving and non-driving side rollers exceeds 8mm, this leads to uneven roller wear, misalignment, and increased bearing temperatures.

Causes:

• Material segregation caused by differences in particle size or moisture.
• Loosening side baffles or unbalanced nitrogen pressure on one side.

Impact:
Roller deviation affects extrusion efficiency, shortens bearing life, increases side leakage, and accelerates wear on the roller surface.

Solutions:

• Use an SG mixer to improve material uniformity.
• Secure side baffles to minimize side leakage.
• Regularly monitor and adjust circulating load and material size distribution.

2. How to Resolve Roller Press Vibration and Ash Problems

Symptoms:
Severe vibration of the roller press can damage bins and rollers, while excessive ash bubbling creates a messy production environment.

Causes:

• Inadequate fine powder separation or a high circulating load.
• Feeding device issues that cause material leakage on the roll surface.

Impact:
Vibration and ash issues can damage equipment, shorten its lifespan, and negatively affect the working environment.

Solutions:

• Optimize the feeding system with an SG hyperbolic design for better material locking.
• Improve fine powder separation and ventilation to stabilize the roller press.
• Use high airflow intermittently to clear out accumulated fine powder.

3. How to Prevent Material Leakage at the Roll End

Symptoms:
Leakage of material at the roll ends, combined with high bucket lifting current and lower roll current.

Causes:

• Roller misalignment due to prolonged operation.
• Improper disc spring installation or weak top bar components.

Impact:
Material leakage reduces overall efficiency, increases circulating load, and impacts output quality.

Solutions:

• Switch to flexible topping devices like plate springs or high-elasticity disc springs.
• Conduct regular process inspections to ensure proper alignment and side stopper settings.

4. How to Maintain Stable Operation of a Roller Press

Symptoms:
Fluctuating bin levels, roll gap, and roller load, leading to lower equipment efficiency and production instability.

Causes:

• Excess fine powder in the material or uneven particle grading.
• High material moisture content affecting material flow.

Impact:
Unstable roller press operation leads to inconsistent output and decreased product quality.

Solutions:

• Optimize powder separation and air flow for better control of fine materials.
• Adjust roller gaps, bin levels, and air volume to restore operational balance.
• Implement an SG hyperbolic feeding device for better material bed formation.