Cement Production

Page 1
ReuterB
05 Sep 2005
S:\Dept\A715\Vortrge\Jakarta_2005\Engeln_ Jakarta 2005.ppt
Cement Production
From clinker storage to cement dispatch
Cement grinding systems
Composite cements
Ingo Engeln - Polysius/Germany
Page 2
ReuterB
05 Sep 2005
Cement Production
DOPOL
Stock piles
Additives
Packing
Loading
Coal
Clinker storage
POLAB AMT
POLAB
AOT
Crusher
POLAB CNA
POLRO
Blending bed
Limestone
Raw meal silo
QUADROPOL
Rawmeal
POLYCOM
REPOL
POLAB AMT
Cement silos
POLAB AMT
Clinker
Clinker
Clay
Gypsum
Ore
Sand
Bauxit
Tube mill
Cement
Page 3
ReuterB
05 Sep 2005
Cement Production
DOPOL
Stock piles
Additives
Packing
Loading
Coal
Clinker storage
POLAB AMT
POLAB
AOT
Crusher
POLAB CNA
POLRO
Blending bed
Raw meal silo
QUADROPOL
POLYCOM
REPOL
POLAB AMT
Tube mill
Cement silos
POLAB AMT
Page 4
ReuterB
05 Sep 2005
Clinker Storage
Page 5
ReuterB
05 Sep 2005
Scope of Polysius Comminution Technology

for Cement and Blast Furnace Slag
Ball mills
Vertical Roller Mill

DOROL
High-pressure grinding rolls

POLYCOM
Page 6
ReuterB
05 Sep 2005
Grinding technology
Cement
raw mat.
Cement
Coal
Tube and
autogenous mills
531
745
159
Roller mills
133
119
High-pressure grind- 19
ing rolls POLYCOM
148
330
112
Iron ore
82
Other *
materials
Total
412
1.929
25
283
54
232
82
665
Mills since 1950
High-efficiency
141
separators SEPOL
Separators since 1985
*e.g: Blast furnace slag, Thomasslag, Bauxite, Magnesite, Copper ore, Gold ore, Nickel ore, Gravel
12/04
Page 7
ReuterB
05 Sep 2005
Tube Mill
simple and well proven

machine
+
+
+
-
low maintenance
well proven cement quality
low investment costs
high energy consumption
Page 8
ReuterB
05 Sep 2005
Page 9
ReuterB
05 Sep 2005
Combiflex-Drive
Page 10
ReuterB
05 Sep 2005
Classifying Liners in 2nd Chamber
Page 11
ReuterB
05 Sep 2005
Process-technological disadvantages
of conventional diaphragms
High air speeds in the central
opening of the diaphragm.
Air flow transports material
far behind the diaphragm
Page 12
ReuterB
05 Sep 2005
New Intermediate Diaphragm DIAPOL
Page 13
ReuterB
05 Sep 2005
Page 14
ReuterB
05 Sep 2005
DIAPOL - process
separation of gas and material
low gas velocity, low pressure drop
material is being passed into the

grinding media charge of the 2nd
chamber directly behind the
diaphragm
higher capacity in chamber 1 and

chamber 2
avoided
pneumatic transport inside the
mill
too low material level before
and after the diaphragm
Page 15
ReuterB
05 Sep 2005
Tube Mill ( 5.0 m x 15.75 m)
Page 16
ReuterB
05 Sep 2005
Tube mill in closed circuit

with high-efficiency separator
Page 17
ReuterB
05 Sep 2005
Workshop assembly of a SEPOL-separator
Page 18
ReuterB
05 Sep 2005
SEPOL
Feed material
Separation air
Fines
Grits
ReuterB
05 Sep 2005
Typical Tromp-curve
100%
90%
80%
Separation degree
Page 19
Fines
70%
60%
50%
40%
Coarse
30%
20%
10%
0%
10
100
Particle size [ m ]
1000
Page 20
ReuterB
05 Sep 2005
Modular design concept

of the SEPOL ESV
Page 21
ReuterB
05 Sep 2005
modular assembly - SEPOL ESV 270/0

modules of building set
assembly 1
assembly 2
(fines outlet is above floor level)
(fines outlet is underneath floor level)
Page 22
ReuterB
05 Sep 2005
modular assembly - SEPOL ESV 270/4

modules of building set
assembly 3
(compact, 4 directly flanged cyclones, fines
outlet is above floor level)
Page 23
ReuterB
05 Sep 2005
ducting building set
Page 24
ReuterB
05 Sep 2005
standard machine arrangement (1)

SEPOL ESV/4 compact - with 4 directly flanged cyclones,
fines outlet above floor level
Page 25
ReuterB
05 Sep 2005

SEPOL ESV with 2 cyclones,
fines outlet above floor level
Page 26
ReuterB
05 Sep 2005

SEPOL ESV with 4 cyclones, fines outlet underneath floor level,
lower housing short version
Page 27
ReuterB
05 Sep 2005
New features of the SEPOL ESV

(improvements in details)
Page 28
ReuterB
05 Sep 2005
curved guide vanes
optimized wear protection
only 8 - 12 curved guide vanes each

easy to exchange
function is multipe approved
Page 29
ReuterB
05 Sep 2005
Sepol Rotor with Curved Guide Vanes

Advantages:
increased life time
decreased time for exchange
because of better accessibility
increased stability
Page 30
ReuterB
05 Sep 2005
flexible orientation of interfaces

feed material inlet chute and support frame turn about 360
Page 31
ReuterB
05 Sep 2005
feed material inlet chute

the design is available
according to various
inclinations (10-15)
of the air slides
radial clearance of
25mm to align the inlet
chute according to the
rotor
Page 32
ReuterB
05 Sep 2005
optimized rotor sealing
Rotor sealing
preassembled and attached to the
rotor
small sealing gaps
prepared for an optional confining air
seal
adapter ring to be welded
after aligning the rotor
application of ceramic wear lining

after erection of the rotor
Page 33
ReuterB
05 Sep 2005
optimized rotor sealing
the rotor sealing is

manufactured,
mounted, aligned and
tested in the POLYSIUS
workshop
Page 34
ReuterB
05 Sep 2005
Roller mills for OPC

and composite cements
Page 35
ReuterB
05 Sep 2005
Frequency rel. [%]
Grindability of clinker and slag acc. to Zeisel test
Slag
Clinker
30
35
40
45
Zeisel - 3000 Blaine [kWh/t]
50
Page 36
ReuterB
05 Sep 2005
Influence of grinding method on grain size

distribution
Gemeinsame Vermahlung in Rollenmhlen /
common grinding in vertical roller mills
Hufigkeit /Frequency
Hufigkeit /Frequency
gemeinsame Vermahlung in Rohrmhlen/

common grinding in tube mills
Kornfeinheit
Grain size
grob
coarse
Mahlbarkeit z.B.: Klinker/Clinker

Grindability e.g.: Httensand/Blast furnace
Zement/Cement
Klinker/Clinker
Httensand/Slag
Kornfeinheit
Grain size
grob
coarse
32 kWh/t bei 3000 cm/g nach/acc. to Zeisel

42 kWh/t bei 3000 cm/g nach/acc. to Zeisel
Page 37
ReuterB
05 Sep 2005
Compressive strength depending on grinding

fineness of clinker and blast furnace slag*
Compressive strength kp/cm
600
3% SO3 as Hemi hydrate
3% SO3 as Hemi hydrate
500
400 90 days
90 days
300
28 days
28 days
7 days
7 days
3 days
3 days
200
100
0
0
1000
2000
3000
4000
fineness of clinker in cm/g

fineness of slag = 4000 cm/g
5000 0
1000
2000
3000
4000
5000
Fineness of slag in cm/g

fineness of clinker = 4000 cm/g
* acc. to Schwiete u. Dlbor
Page 38
ReuterB
05 Sep 2005
Cement grinding plant
Aguascalientes
Page 39
ReuterB
05 Sep 2005
Decision criteria for the Polysius roller mill

Simple operation of the grinding plants
High operating economy
Allows flexible change-over between cement types
Grinding/drying of composite cements

with high content of moist additives
Page 40
ReuterB
05 Sep 2005
Cement grinding plant

280000 m/h, 100 C
73 mbar
CPO ( 95% Clinker, 5% gypsum )

Pozzolana Cement ( 27% pozzolana )
12000 m3/h
200 C
2800 kW
400 C
Page 41
ReuterB
05 Sep 2005
Operating data
* Cement type CPO
Normal
Operation
Test Run
Capacity
[t/h]
100
113
Residue on 45 m
[%]
1.88
1.95
Fineness (Blaine)
[cm/g]
3600
3850
Wm Mill
[kWh/t]
18.9
18.7
Wm Fan
[kWh/t]
8.9
6.1
Wm SEPOL
[kWh/t]
0.6
0.4
[kWh/t]
28.4
25.2
Wm
Mill; Fan; SEPOL
Grindability (3.000 Blaine/Zeisel)

Bonus
[kWh/t]
33.5
2.0
2.2
Page 42
ReuterB
05 Sep 2005
Modification of the separator rotor

100.00
100.00
100.00
90.00
90.00
90.00
80.00
80.00
80.00
70.00
70.00
70.00
60.00
60.00
60.00
50.00
50.00
50.00
40.00
40.00
40.00
30.00
30.00
30.00
20.00
20.00
20.00
10.00
10.00
YY
ZZ XX
10.00
0.00
0.00
Y
ZX
0.00
Old
New
Page 43
ReuterB
05 Sep 2005
Operating data
Grinding table speed
in comparison to raw material
[%]
Grinding force
[kN/m2]
ca. 600
Water injection
[%]
ca. 1.5
Grinding aid
[%]
0.03
Volume flow
[m3/h]
330000
p Fan
[mbar]
52
Gas passage velocity through separator rotor
[m/s]
2.95
Vibrations
[mm/s]
1.4
78
Page 44
ReuterB
05 Sep 2005
SEPOL RMC 435: Trompcurve
Selectivity; efficiency [%]
100
90
Separation curve
80
70
Efficiency curve
60
50
Reduced sep. curve
40
30
20
10
0
11
10
10
100
100
1000
1000
Particle size [m]
Page 45
ReuterB
05 Sep 2005
Mill internals after 6000 operating hours
After 14575 operating hours:

no intermediate rewelding required
uniform wear profile
extremely low wear rates
( <35% of the allowable wear reached )
Page 46
ReuterB
05 Sep 2005
Residue [%]
PSD Aguascalientes : Hidalgo

0.1
0.5
1
5
10
20
30
40
50
60
70
36,8
36,8
CPO II Hidalgo
80
CPO II Aguascalientes
90
95
1
10
100
Particle size [m]
Page 47
ReuterB
05 Sep 2005
Aguascalientes: Product quality

Cement type
Composition
Clinker
Gypsum
Fineness Sm acc. to Blaine
R 45 m
RRSB slope n
RRSB equivalent diam. d
Water demand
Setting time
Cement strength [EN 196]
1d
3d
7d
28 d
CPO
[%]
[%]
[cm/g]
[%]
[m]
[%]
[min]
[N/mm]
[N/mm]
[N/mm]
[N/mm]
95.5
4.5
3715
0.6
1.03
16.1
28
175/250
15.5
33.5
42.0
57.4
Page 48
ReuterB
05 Sep 2005
Cementos y Concretos Nacionales Aguascalientes

Plant extension with 2 further roller mills RMC 51/26
successfully commissioned in spring 2004
New plant with 2 further roller mills RMC 51/26 under

erection in Palamaritos, Puebla
Page 49
ReuterB
05 Sep 2005
Vertical Roller Mills - Cement and Slag Grinding

38 t/h
3500 Bl.
90 t/h
5000 Bl.
2 x 85 t/h
OPC 3200 Bl.
2 x 90 t/h
OPC 3600 Bl.
2 x 90 t/h
OPC 3600 Bl.
90 t/h
80 t/h 4200 Bl.
4400 Bl.
70 t/h
4500 Bl.
110 t/h
OPC 3000 Bl.
90 t/h
4500 Bl.
90 t/h
4000 Bl.
70 t/h
4400 Bl.
80 t/h
4300 Bl.
90 t/h
90 t/h 4300 Bl.
4200 Bl.
110 t/h
OPC 3000 Bl.
80 t/h
In operation (11)
4400 Bl.
Site (7)
New orders (2)
9/05
Page 50
ReuterB
05 Sep 2005
Combi grinding with static separator
STATOPOL C
POLYCOM
Finished product
Page 51
ReuterB
05 Sep 2005
Characteristics of Combi Grinding Plants
more than 150% increase in throughput compared to a single ball mill

possible
intermediate product fineness is typically between 1800 and 3500 cm/g
flexibility to grind different products with a variable speed drive
speed of rolls depending upon fineness of feed
energy saving of more than 50% compared to an equivalent ball mill for the
intermediate product
possible potential for additional energy savings by using adapted ball charge
can be applied for finish grinding, too
Page 52
ReuterB
05 Sep 2005
Process animation of STATOPOL C
Page 53
ReuterB
05 Sep 2005
Operating Principle of STATOPOL C

Feed
Fines
Feed valve
Separation air
Guide plates
Air-shutoff plates
Impact plates
Perforated plates
Tailings
Page 54
ReuterB
05 Sep 2005
Results of test work at R&D facilities of Polysius

1. Throughput remains nearly constant for 2,1 L/D 2,7
Optimal L/D-ratio of ball-mills in combi-grinding plants is clearly
below 3,0
A signifiant decrease of energy demand for ball-mills in combigrinding circuits can be realized
2. Lowering the ball charge from 30% to 20%

Specific power consumption could be decreased by 20%
Throughput is also accordingly decreased in the same range by 20%
Page 55
ReuterB
05 Sep 2005
Specific power consumption and throughput in relation to the

L/D-ratio for the fine feed material (3.000 cm/g)
18
2,4
15%
2,0
25%
Optimisation target to be decided:
spec. power consumption
12
1,6
throughput [t/h]
spec. power consumption [kWh/t]
20%
minimum specific power consumption

1,2
or
0,8
maximum capacity
0,4
Fine feed material:

3.000 cm/g
0,0
Parameter:
Ball charge filling ratio
throughput
0
1,5
2,0
2,5
3,0
L/D-Ratio [-]
3,5
4,0
Page 56
ReuterB
05 Sep 2005
POLYCOM principle of comminution
Pressure curve
Max. Pressure
Start of compression
(nip line)
Compression
zone
Grinding force
End of compression
Cake
Page 57
ReuterB
05 Sep 2005
POLYCOM - Wear Protection

Forged/hard faced
profiling
Bainite
profiling
profiling
Hard layer
Build up welding
Base material
Compound Cast
Base material
Base material
Page 58
ReuterB
05 Sep 2005
Compressive Strength of Wear Protection

compressive stress [MPa]
3.200
2.800
Compound cast
2.400
2.000
Operating conditions
damaging forged rolls.
1.600
Bainite
1.200
Local peak
800
Dynamic
Forged Steel
400
Static
0
0
0,4
0,8
1,2
1,6
compression rate [%]
2,4
2,8
Page 59
ReuterB
05 Sep 2005
Hard cast tyres

Welded profiles for optimum nip-in behaviour and low wear
only little maintenance needed
usable wear thickness approx. 60 mm
wear rates usually well below 1 mm per 1000 operating
hours
Page 60
ReuterB
05 Sep 2005
Worldwide use of Bainite (08.2005)

48 roller pairs worldwide
Weight
max. 22 t
Roll diameter
max. 2,05 m
Roll width
max. 1,30 m
Max. Operating time so far > 51.000 h
Page 61
ReuterB
05 Sep 2005
Features of Bainite POLYCOM Rolls

+
+
+
+
+
+
+
long service life

high compressive strength of the material
no fatigue even under high grinding pressures
no limitation for bigger diameters
short delivery times
simple profile welding and maintenance
low operating costs
but
weld repair not possible, except for profiles
At the time being:

Bainite tyres are the most cost-effective solution
Page 62
ReuterB
05 Sep 2005
Worldwide use of Compound Cast
(08.2005)
31 roller pairs worldwide
Weight
max. 12 t
Roll diameter
max. 1,7 m
Roll width
max. 1,0 m
Max. Operating time so far = 57.600 h
Page 63
ReuterB
05 Sep 2005
Cement Combi-Grinding Plant in USA
SEPOL
NSV 350
STATOPOL C
24/11-10
POLYCOM
20/13-9
2 x 1300 kW
Ball-Mill
5,0 m x 15,75 m
2 x 3000 kW (2 x CF 22)
Performance
250 t/h
@ 3800 cm/g
acc. to Blaine
Type II MA
Page 64
ReuterB
05 Sep 2005
Combi-Grinding Plant in USA - Operating Data

Warranted
Design Data
Performance
Data
Type of Cement (acc. to ASTM)

Clinker
Gypsum
PC Type I/II
[%]
95,0
[%]
5,0
Type II MA
96,0
4,0
Capacity
Fineness - Blaine
[t/h]
[cm/g]
220
3800
250
3800
Wm POLYCOM
Wm Tube mill
[kWh/t]
[kWh/t]
9,1
26,0
10,4
20,4
Wm
[kWh/t]
35,1
30,8
Page 65
ReuterB
05 Sep 2005
Combi-grinding for composite cement
Klinker/Clinker
Gips/Gypsum
Zwischen- Kalkstein/
produkt/ Limestone
Intermediate
product
Httensand/
Blast furnace
slag meal
Page 66
ReuterB
05 Sep 2005

Compressive strength after 2 d
Product fineness 3800 cm/g
N/mm
25
Clinker preground
to 2500 cm/g
20
15
10
5
20%
Common fresh feed

to tube mill
22%
24%
26%
limestone content
28%
30%
Page 67
ReuterB
05 Sep 2005

Compressive strength after 28 d
Product fineness 3800 cm/g
55
Clinker preground
to 2500 cm/g
N/mm
50
45
40
35
30
20%
Common fresh feed

to tube mill
22%
24%
26%
limestone content
28%
30%
Page 68
ReuterB
05 Sep 2005
Flowsheet of cement rotator system
Sepol
LM
Clin- Gyp- Limeker
sum stone
Ch. 1
Ch. 2
Page 69
ReuterB
05 Sep 2005
Case Study about different Cement grinding

systems for a Project in Middle East - Results
Type of Grinding System
Main Machinery
Ball mill
Roller mill
Combi-grinding
POLYCOM
2-chamber BM
5,4 x 16,5 m
RMC 66/31
Polycom 19/11-8
1-Ch BM 4,6 x 10,5 m
Investment Costs
[%]
100
133
125
Power Consumption
for whole mech. Equipment
[%]
100
65
78
Operating Costs
(Electrical power, process water, [%]
grinding aid)
100
81
77
Investment Costs:
- Battery limits: from mill inlet up to cement cooler outlet
- mechanical and electrical equipment, civil and structural steel works, incl. erection and commissioning
Page 70
ReuterB
05 Sep 2005
Choice of the right Grinding System...

...is depending on several preconditions:
Cement types to be produced (one or several)
+ Composites (e.g.: blast-furnace slag, pozzolana, limestone)
+ Feed moisture content
+ Grindability of feed material
+ Product Fineness
+ Product characteristics (workability, end-user specifics)
Desired throughput
Local energy prices
Skilled workforce available (plant operation and maintenance)
- Customers are telling us their particular needs
- Polysius advises and provides custom-tailored solutions

Cement Production

Transféré par

Informations du document

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

Cement Production

Transféré par

Droits d'auteur :

Formats disponibles

Page 1

S:\Dept\A715\Vortrge\Jakarta_2005\Engeln_ Jakarta 2005.ppt

S:\Dept\A715\Vortrge\Jakarta_2005\Engeln_ Jakarta 2005.ppt

Raw meal silo

S:\Dept\A715\Vortrge\Jakarta_2005\Engeln_ Jakarta 2005.ppt

Raw meal silo

S:\Dept\A715\Vortrge\Jakarta_2005\Engeln_ Jakarta 2005.ppt

S:\Dept\A715\Vortrge\Jakarta_2005\Engeln_ Jakarta 2005.ppt

Scope of Polysius Comminution Technology

Vertical Roller Mill

High-pressure grinding rolls

S:\Dept\A715\Vortrge\Jakarta_2005\Engeln_ Jakarta 2005.ppt

Mills since 1950

S:\Dept\A715\Vortrge\Jakarta_2005\Engeln_ Jakarta 2005.ppt

simple and well proven

S:\Dept\A715\Vortrge\Jakarta_2005\Engeln_ Jakarta 2005.ppt

S:\Dept\A715\Vortrge\Jakarta_2005\Engeln_ Jakarta 2005.ppt

S:\Dept\A715\Vortrge\Jakarta_2005\Engeln_ Jakarta 2005.ppt

Classifying Liners in 2nd Chamber

S:\Dept\A715\Vortrge\Jakarta_2005\Engeln_ Jakarta 2005.ppt

S:\Dept\A715\Vortrge\Jakarta_2005\Engeln_ Jakarta 2005.ppt

New Intermediate Diaphragm DIAPOL

S:\Dept\A715\Vortrge\Jakarta_2005\Engeln_ Jakarta 2005.ppt

S:\Dept\A715\Vortrge\Jakarta_2005\Engeln_ Jakarta 2005.ppt

separation of gas and material

low gas velocity, low pressure drop

material is being passed into the

higher capacity in chamber 1 and

S:\Dept\A715\Vortrge\Jakarta_2005\Engeln_ Jakarta 2005.ppt

Tube Mill ( 5.0 m x 15.75 m)

S:\Dept\A715\Vortrge\Jakarta_2005\Engeln_ Jakarta 2005.ppt

Tube mill in closed circuit

S:\Dept\A715\Vortrge\Jakarta_2005\Engeln_ Jakarta 2005.ppt

Workshop assembly of a SEPOL-separator

S:\Dept\A715\Vortrge\Jakarta_2005\Engeln_ Jakarta 2005.ppt

S:\Dept\A715\Vortrge\Jakarta_2005\Engeln_ Jakarta 2005.ppt

S:\Dept\A715\Vortrge\Jakarta_2005\Engeln_ Jakarta 2005.ppt

Modular design concept

S:\Dept\A715\Vortrge\Jakarta_2005\Engeln_ Jakarta 2005.ppt

modular assembly - SEPOL ESV 270/0

(fines outlet is above floor level)

(fines outlet is underneath floor level)

S:\Dept\A715\Vortrge\Jakarta_2005\Engeln_ Jakarta 2005.ppt

modular assembly - SEPOL ESV 270/4

S:\Dept\A715\Vortrge\Jakarta_2005\Engeln_ Jakarta 2005.ppt

ducting building set

S:\Dept\A715\Vortrge\Jakarta_2005\Engeln_ Jakarta 2005.ppt

standard machine arrangement (1)

S:\Dept\A715\Vortrge\Jakarta_2005\Engeln_ Jakarta 2005.ppt

standard machine arrangement (2)

S:\Dept\A715\Vortrge\Jakarta_2005\Engeln_ Jakarta 2005.ppt

standard machine arrangement (3)

S:\Dept\A715\Vortrge\Jakarta_2005\Engeln_ Jakarta 2005.ppt

New features of the SEPOL ESV

S:\Dept\A715\Vortrge\Jakarta_2005\Engeln_ Jakarta 2005.ppt

curved guide vanes

optimized wear protection

only 8 - 12 curved guide vanes each

S:\Dept\A715\Vortrge\Jakarta_2005\Engeln_ Jakarta 2005.ppt

Sepol Rotor with Curved Guide Vanes

S:\Dept\A715\Vortrge\Jakarta_2005\Engeln_ Jakarta 2005.ppt

flexible orientation of interfaces

S:\Dept\A715\Vortrge\Jakarta_2005\Engeln_ Jakarta 2005.ppt

feed material inlet chute