How to Optimize HPGR Roller Press Performance with Proper Parameter Settings for Cement Production

HPGR Roller presses are key to energy-efficient cement grinding, but their performance relies heavily on properly configured parameters. Correct settings ensure consistent output, lower maintenance, and increased equipment lifespan. In this guide, Zigong Tianyi Industry, a leading provider of roller press parts (such as Carbide Button, cheek plate...), explains how to adjust critical parameters to enhance your cement production operations.

1. How to Set the Working Pressure for Maximum Efficiency

The working pressure of a roller press directly affects its performance:

• Factory Upper Pressure: Set to 12 MPa by default.
• On-Site Adjustments: Based on material characteristics, adjust pressure between 8.5-11 MPa.
• Projection Pressure: Should fall between 3000-6000 KN/m², depending on roller press specs and hydraulic configuration.

2. How to Manage Upper and Lower Limit Pressure Differences

• Pressure Difference: Set between 1.5-2.5 MPa, ensuring it stays under three times the pressure fluctuation value.
• Accumulator Pressure: Maintain it at around 60% of the upper limit pressure for system stability.

3. How Material Conditions Affect Roller Press Performance

Proper material conditions are vital for optimal extrusion:

• Material Size: Ensure over 95% of particles are less than 3% of the roll diameter, with no large particles exceeding 5%.
• Moisture Content: Control moisture at ≤1.5% to maintain a high-quality extrusion cake.

4. How to Choose the Right Feeding Device for Roller Presses

• Material Locking: Prevent leakage and pressure loss by selecting a feeding device with effective material locking.
• Recommended Design: An SG double-curve feeding device with four-side locking ensures smooth, uniform material distribution.

5. How to Adjust the Roll Gap for Consistent Operation

• Initial Roll Gap: Set depending on material properties and process requirements, typically between a few millimeters and a dozen millimeters.
• Dynamic Adjustments: Use an automatic adjustment system to stabilize the roll gap based on material volume and hydraulic pressure.

6. How to Set Hydraulic System Parameters for Stability

• Oil Pump Pressure: Adjust based on the roller press’s needs and hydraulic design to ensure sufficient squeezing force.
• Hydraulic Cylinder Flow: Set to regulate the speed of roll gap adjustments according to production demands.
• Cooling System: Ensure the hydraulic system is equipped with proper cooling to maintain oil temperature and prevent performance degradation.

7. How to Optimize Electrical Control System Parameters

• Motor Start/Stop: Set up a smooth start and stop process to reduce mechanical shock.
• Overload Protection: Configure overload protection to prevent damage from excessive loads.
• Interlocking Protection: Use interlocking protection to ensure synchronized operation between feeding, discharging, and hydraulic systems.

8. How to Monitor and Set Alarms for Real-Time Feedback

• Real-Time Monitoring: Install sensors to track roller press parameters like pressure, temperature, and vibration.
• Alarm Settings: Set alarms for critical parameters, alerting operators when values exceed safe limits.