A system and method for operating a milling apparatus with grinding rolls and a variety of sensors sensing various aspects of the milling process.

This invention relates to a process of comminution of iron ore or iron ore products (pellet feed, sinter feed, etc.) at natural moisture without the need to add water or to include a drying step in the process, that is technically and economically feasible. The comminution process of this invention uses at least one piece of equipment selected from the group consisting of roller press (HPGR), vertical roller mill (VRM), roller crusher (RC) and high acceleration screen of at least 10G.

This invention relates to a process of comminution of iron ore or iron ore products (pellet feed, sinter feed, etc.) at natural moisture without the need to add water or to include a drying step in the process, that is technically and economically feasible. The comminution process of this invention uses at least one piece of equipment selected from the group consisting of roller press (HPGR), vertical roller mill (VRM), roller crusher (RC) and high acceleration screen of at least 10G.

Systems and methods for monitoring the roll diameter and shock loads in a milling apparatus may include a frame, a pair of rolls including a movable first roll and a stationary second roll, roll supports configured to support the first roll on the frame in a movable manner and the second roll on the frame in a stationary manner, and a motor assembly configured to rotate at least one of the rolls. Embodiments of the systems may also include a wear sensing assembly configured to detect wear on at least one of the rolls of the pair of rolls. Embodiments of the systems may also include a shock sensing assembly configured to detect shock to at one of the rolls.

Systems and methods for monitoring the roll diameter and shock loads in a milling apparatus may include a frame, a pair of rolls including a movable first roll and a stationary second roll, roll supports configured to support the first roll on the frame in a movable manner and the second roll on the frame in a stationary manner, and a motor assembly configured to rotate at least one of the rolls. Embodiments of the systems may also include a wear sensing assembly configured to detect wear on at least one of the rolls of the pair of rolls. Embodiments of the systems may also include a shock sensing assembly configured to detect shock to at one of the rolls.

A method of comminuting the size of particles of frangible blast media from each particle's respective initial size to a size smaller than a desired maximum size includes directing a flow of entrained particles toward a gap, at a first location splitting the flow into at least a first and second flow, the particles are entrained in the first flow, the first flow travels through the gap and substantially no particles are entrained in the second flow, and rejoining the second flow with the first flow at a second location downstream of and proximal to the gap.

A method of comminuting the size of particles of frangible blast media from each particle's respective initial size to a size smaller than a desired maximum size includes directing a flow of entrained particles toward a gap, at a first location splitting the flow into at least a first and second flow, the particles are entrained in the first flow, the first flow travels through the gap and substantially no particles are entrained in the second flow, and rejoining the second flow with the first flow at a second location downstream of and proximal to the gap.

A roller mill module with a fixed grinding roller with a first grind surface rotatably supported within a grind area between a first drive end and a second drive end of a support structure; an adjustable grinding roller with a second grind surface rotatably supported within the grind area; the adjustable grinding roller movable with respect to the fixed grinding roller to adjust a grind gap between the first grind surface and the second grind surface; a drive shaft of the fixed grinding roller and a drive shaft of the adjustable grinding roller extending from the first and the second drive ends of the support structure; and a sample port provided in a front side of the support structure; a sample passage coupled to the sample port extending to a position below the grind area and opposite a sampler stop surface.

A roller mill module with a fixed grinding roller with a first grind surface rotatably supported within a grind area between a first drive end and a second drive end of a support structure; an adjustable grinding roller with a second grind surface rotatably supported within the grind area; the adjustable grinding roller movable with respect to the fixed grinding roller to adjust a grind gap between the first grind surface and the second grind surface; a drive shaft of the fixed grinding roller and a drive shaft of the adjustable grinding roller extending from the first and the second drive ends of the support structure; and a sample port provided in a front side of the support structure; a sample passage coupled to the sample port extending to a position below the grind area and opposite a sampler stop surface.

A fiber powder having a 50% particle diameter (d.sub.50) of 6 to 60 μm, characterized in that the fiber powder has a maximum particle diameter (d.sub.100) of 1,000 μm or less. It is preferred that a value ((d.sub.10.Math.d.sub.90)/d.sub.100) obtained by dividing by the maximum particle diameter (d.sub.100) a value which is obtained by multiplying a 10% particle diameter (d.sub.10) by a 90% particle diameter (d.sub.90) is 0.3 to 5.0, that the fiber powder has an extractable component content of 0.2 to 3.0% by weight based on the fiber weight, and that the fiber powder has a water content of 0.2 to 50% by weight. Further, it is preferred that the fiber powder is an organic material, or comprises a thermoplastic resin, and that the thermoplastic resin is a polyester resin or a polyamide resin.