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Fault Analysis of High-pressure Roller Press 



Source: internal company

Fault Analysis of High-pressure Roller Press 

 (1) Material granularity exceeds the standard
      The operation manual of the roller press requires that the average particle size of materials entering the roller press should be less than 30mm and not more than 50mm. Our company uses clinker, pozzolanic ash, small crushed stone, and gypsum for cement production, among which the granularity of clinker, pozzolanic ash, and gypsum can meet the requirements, while the small crushed stone is provided by small crushing in mines, and its granularity is unstable. When the crusher is replaced with a new hammerhead, the granularity of the small crushed stone is very small, which can meet the granularity requirements of the roller press. When the hammerhead is worn for a long time, especially in the later period, the granularity of small crushed stone in the crusher seriously exceeds the standard, with the average granularity reaching 60mm and the diameter exceeding 120mm, which causes the vibration of the roller press to increase and the system to jump and stop. 
(2) Safety pin failure
      The transmission form of the roller press is that the motor drives two grinding rollers to rotate through the reducer. In order to ensure the safe operation of the motor and prevent the damage of the roll surface, A mechanical pin is designed between the motor and the reducer, The coupling between the motor and the reducer is connected by three convex blocks and three concave blocks of the pin. When iron or large hard materials enter the roller press, the torque of the motor will rise sharply, and the acting force and reaction force between the concave block and the convex block of the pin will also increase. When the axial component of the reaction force F received by the convex block is greater than the elastic force set by the disc spring, the pin will move backward until it leaves the concave block and makes the main motor idle. The speed monitor for monitoring the rotation of the fixed roller immediately gives an alarm, which makes the whole roller press system jump and stop. If the safety pin is damaged or the disc spring fails, the safety pin will come out frequently and the system will jump and stop. 
(3) Hydraulic system failure 
     The failure or damage of components in the hydraulic system, such as nitrogen airbag, safety valve, and pressure relief valve, will cause vibration and stop of roller press. 
(4) Wear of roll surface  
      After the roller surface of the roller press is worn, the surface is uneven, which can not effectively extrude the materials. There are more granular materials and fewer cakes in the discharge, and the output of the mill decreases. The circulation in the roller press system is greatly increased, and more and more powder materials are produced, resulting in frequent "material punching" in the weighing bin, pressure lifting by the returning belt and the bucket into the weighing bin, and the system jumps and stops. 


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