{"id":9669,"date":"2026-07-09T11:36:00","date_gmt":"2026-07-09T03:36:00","guid":{"rendered":"https:\/\/www.clirik.com\/?p=9669"},"modified":"2026-07-09T11:52:36","modified_gmt":"2026-07-09T03:52:36","slug":"limestone-grinding-process-maximize-yield-cut-costs","status":"publish","type":"post","link":"https:\/\/www.clirik.com\/fr\/limestone-grinding-process-maximize-yield-cut-costs\/","title":{"rendered":"Limestone Grinding Process: Maximize Yield & Cut Costs"},"content":{"rendered":"
\n
\n

In order to achieve the most efficient limestone grinding process, the key lies in controlling several hard core indexes: the feed particle size must be less than 10mm; Whether it is a vertical roller mill (VRM) or a Raymon mill, it must be matched with accurate hydraulic roller pressure. In addition, an active rotary classifier should be equipped to accurately separate 200 to 400 powders while recovering coarse particles.<\/p>\n\n\n\n

Many factory owners burn money in vain every day for a simple reason-either regardless of the size of the feed, or the speed of the classifier will remain unchanged for ten thousand years. This will not only make your power consumption per ton (kW\/t) soar, but also jam the production capacity of the mill. Next, I will combine real factory data to teach you how to optimize your grinding system on the ground, so that your hourly output (TPH) can be improved immediately, while reducing electricity bills.<\/p>\n\n\n\n

C.P.S. Capacity Pyramid: Reinventing Your Grinding System<\/h2>\n\n\n\n

Many factory directors often put the cart before the horse, thinking all day about how to adjust the speed of the mill, but turning a blind eye to the upstream feed problem. When “taking the pulse” of limestone plants with poor efficiency, I usually use the “C.P.S. Capacity Pyramid (crushing size, pressure, separation)” to find out the production bottleneck. Remember one thing: before moving the spire, the base of the pyramid must be secured.<\/p>\n\n\n\n

C- Crushing Particle Size Optimization (10mm Hard Index)<\/h3>\n\n\n\n

The feed becomes smaller, the mill capacity will naturally become larger. If the 30mm limestone block is directly poured into Raymon mill, it is equivalent to forcing the grinding roller to do the rough work of the primary crusher, which not only has no grinding efficiency at all, but also causes the grinding ring to wear rapidly. You must install a closed-circuit system consisting of jaw breakage and cone breakage upstream to keep the feed size within 10mm. Our field test data is there: once the feed is reduced from 25mm to 10mm, even if the main motor does not add a little power, the output of the finished product can soar by 18%.<\/p>\n\n\n\n

\"A<\/figure>\n\n\n\n

P-Pressure And Roller Tension<\/h3>\n\n\n\n

The specific surface area of the finished product (Blaine specific surface area) depends on the pressure given by the hydraulic system. If the tension of the grinding roller is too weak, the original stone will slip directly from the grinding zone and accumulate into a huge cyclic load in the grinding chamber, directly blocking the air duct. On the other hand, if the hydraulic pressure is set too strong, the material is instantly broken, but the violent vibration caused will directly scrap the reducer bearing. Therefore, you have to calculate the true grindability (Bond Work Index) of the limestone in your own mine, and then set the most appropriate benchmark pressure based on this.<\/p>\n\n\n\n

S-Separation Speed (Dynamic Classification)<\/h3>\n\n\n\n

The speed of the classifier not only determines the particle size distribution (PSD) of the finished product, but is also directly linked to your electricity bill. If the turbine classifier turns too fast, the 200 mesh powder that was already qualified will be trapped in the mill and cannot get out, and will be abruptly ground into useless ultra-fine dust, which is a waste of electricity. The correct approach is to directly link the frequency converter (VFD) of the classifier with the control system of the induced draft fan. Once the air volume drops, the classifier can automatically slow down, which can not only ensure the stability of the cutting point, but also prevent material blockage.<\/p>\n\n\n\n

Depth Analysis Of Equipment: How To Choose Vertical Roller Mill (VRM) And Raymon Mill?<\/h2>\n\n\n\n

Choosing the wrong mill is equivalent to locking up your profit space and terminal market in advance. Whether it is sold to a power plant that does desulfurization (FGD) or a paint plant, you must match the equipment technology according to the customer’s actual mesh requirements.<\/p>\n\n\n\n

Why Does Raymon Mill Dominate The 200 Market?<\/h3>\n\n\n\n

If only standard 200 to 325 mesh industrial powder (such as basic agricultural lime or asphalt filler) is produced, the initial investment (CAPEX) of Raymonde mill is definitely the most cost-effective. This hanging roller mill is like a duck to water in a factory with a medium capacity (5 to 15 tons per hour). Its mechanical structure is very resistant to manufacturing and has a high fault tolerance rate. The mechanic in the factory can change the grinding roller and grinding ring in an afternoon at will. There is no need for a high salary to invite the original technical specialist to come over.<\/p>\n\n\n\n

Sprint For High Production Capacity Above 400 Mesh: Transition To Vertical Roller Mill (VRM)<\/h3>\n\n\n\n

If it is a high-capacity, ultra-fine powder operation with more than 400 meshes, the vertical roller mill can directly help you cut off 30% of the power consumption. VRM is an out-and-out “all-rounder” that integrates grinding, drying and grading in a compact body. Its fixed grinding discs and huge hydraulic rollers can produce extremely strong local shear forces, which is the only truly profitable option for large cement plants with production capacity requirements of more than 50 tons per hour. Moreover, its internal ventilation system can instantly pump the molding powder away, perfectly avoiding the common excessive grinding waste in the pendulum mill.<\/p>\n\n\n\n

Type de moulin<\/th>Target Fineness (Mesh)<\/th>Average Capacity (TPH)<\/th>Power Consumption (kW\/t)<\/th>CAPEX Level<\/th>Best Application<\/th><\/tr><\/thead>
Moulin Raymond<\/td>80\u2013325<\/td>3\u201320<\/td>18\u201335<\/td>Low<\/td>Paint, light FGD, fillers<\/td><\/tr>
VRM (Vertical Roller Mill)<\/td>80\u2013600<\/td>30\u2013400<\/td>12\u201325<\/td>High<\/td>Cement, large-scale FGD, power plants<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n

The Connoisseurs’ Demining: Two Expensive Mistakes That Eat Your Productivity.<\/h2>\n\n\n\n

Excessive Grinding Trap (Eating Electric Maniac)<\/h3>\n\n\n\n

Grinding more finely than the customer requires will not only reduce the output, but also squeeze out your profits. For example, when a customer buys limestone to solidify the soil, they obviously only need to 100 the purpose of the goods, but the operators in the factory set the classifier to 200 mesh in order to “get insurance. You should know that grinding 100 purpose powder into 200 mesh will directly double the power consumption and the output of the mill will plummet by nearly 40%. The solution is simple: hourly laboratory sampling must be strictly enforced to ensure that the particle size distribution is in line with the contract standards, even if it is 1 microns is a waste.<\/p>\n\n\n\n

Ignore Moisture Content (3% Blockage Red Line)<\/h3>\n\n\n\n

As long as the moisture in the limestone exceeds 3%, the grinding ring will be burnt and the blades of the classifier will suffer. The wet limestone powder is like a thick cement paste inside the mill. This paste will directly bury the grinding roller, causing the internal air volume to drop sharply, and finally can only trigger an emergency shutdown. Therefore, the raw ore must be stored in a covered yard. If the climate in your mining area is humid, the hot exhaust gas from the rotary kiln must be directly led to the base of the vertical mill and dried while grinding.<\/p>\n\n\n\n