Cement Production [PDF]

Zitiervorschau

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Cement Production • From clinker storage to cement dispatch • Cement grinding systems • Composite cements Ingo Engeln - Polysius/Germany

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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

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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

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Clinker Storage

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Scope of Polysius Comminution Technology for Cement and Blast Furnace Slag Ball mills

Vertical Roller Mill DOROL®

High-pressure grinding rolls POLYCOM ®

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Grinding technology Cement raw mat.

Cement

Coal

Tube and autogenous mills

531

745

159

Roller mills

133

6

119

High-pressure grind- 19 ing rolls POLYCOM®

148

4

330

112

Iron ore

82

7

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

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Tube Mill

+

simple and well proven machine

+ + + -

low maintenance well proven cement quality low investment costs high energy consumption

3

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Combiflex-Drive

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Classifying Liners in 2nd Chamber

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Process-technological disadvantages of conventional diaphragms • High air speeds in the central opening of the diaphragm. • Air flow transports material far behind the diaphragm

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New Intermediate Diaphragm DIAPOL

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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

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Tube Mill (Ø 5.0 m x 15.75 m)

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Tube mill in closed circuit with high-efficiency separator

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Workshop assembly of a SEPOL-separator

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SEPOL Feed material

Separation air

Fines Grits

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Typical Tromp-curve 100% 90% 80%

Separation degree

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Fines

70% 60% 50% 40% Coarse

30% 20% 10% 0%

1

10

100

Particle size [ µm ]

1000

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Modular design concept of the SEPOL ESV

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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)

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modular assembly - SEPOL ESV 270/4 modules of building set

assembly 3 (compact, 4 directly flanged cyclones, fines outlet is above floor level)

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ducting building set

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standard machine arrangement (1) SEPOL ESV/4 compact - with 4 directly flanged cyclones, fines outlet above floor level

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standard machine arrangement (2) SEPOL ESV with 2 cyclones, fines outlet above floor level

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standard machine arrangement (3) SEPOL ESV with 4 cyclones, fines outlet underneath floor level, lower housing short version

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New features of the SEPOL ESV (improvements in details)

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curved guide vanes

•

optimized wear protection

• only 8 - 12 curved guide vanes each • easy to exchange • function is multipe approved

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Sepol Rotor with Curved Guide Vanes Advantages: • increased life time • decreased time for exchange because of better accessibility • increased stability

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flexible orientation of interfaces feed material inlet chute and support frame turn about 360°

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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

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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

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optimized rotor sealing

the rotor sealing is manufactured, mounted, aligned and tested in the POLYSIUS workshop

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Roller mills for OPC and composite cements

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Frequency rel. [%]

Grindability of clinker and slag acc. to Zeisel test

Slag Clinker

30

35

40

45

Zeisel - 3000 Blaine [kWh/t]

50

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Influence of grinding method on grain size distribution Gemeinsame Vermahlung in Rollenmühlen / common grinding in vertical roller mills

Häufigkeit /Frequency

Häufigkeit /Frequency

gemeinsame Vermahlung in Rohrmühlen/ common grinding in tube mills

Kornfeinheit Grain size

grob coarse

Mahlbarkeit z.B.: Klinker/Clinker Grindability e.g.: Hüttensand/Blast furnace

Zement/Cement Klinker/Clinker Hüttensand/Slag

Kornfeinheit Grain size

grob coarse

32 kWh/t bei 3000 cm²/g nach/acc. to Zeisel 42 kWh/t bei 3000 cm²/g nach/acc. to Zeisel

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Compressive strength depending on grinding fineness of clinker and blast furnace slag* Compressive strength kp/cm²

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 cm²/g fineness of slag = 4000 cm²/g

5000 0

1000

2000

3000

4000

5000

Fineness of slag in cm²/g fineness of clinker = 4000 cm²/g * acc. to Schwiete u. Dölbor

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Cement grinding plant

Aguascalientes

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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

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Cement grinding plant 280000 m³/h, 100 °C 73 mbar

CPO ( 95% Clinker, 5% gypsum ) Pozzolana Cement ( 27% pozzolana )

12000 m3/h 200 °C 2800 kW

400 °C

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Operating data * Cement type CPO

Normal Operation

Test Run

Capacity

[t/h]

100

113

Residue on 45 µm

[%]

1.88

1.95

Fineness (Blaine)

[cm²/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

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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

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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

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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 [µm]

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Mill internals after 6000 operating hours

After 14575 operating hours: •no intermediate rewelding required •uniform wear profile •extremely low wear rates ( 51.000 h

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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

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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

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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 cm²/g acc. to Blaine Type II MA

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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] [cm²/g]

220 3800

250 3800

Wm POLYCOM® Wm Tube mill

[kWh/t] [kWh/t]

9,1 26,0

10,4 20,4

Σ Wm

[kWh/t]

35,1

30,8

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Combi-grinding for composite cement

Klinker/Clinker Gips/Gypsum Zwischen- Kalkstein/ produkt/ Limestone Intermediate product

Hüttensand/ Blast furnace slag meal

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Combi-grinding for composite cement Compressive strength after 2 d Product fineness 3800 cm²/g

N/mm²

25

Clinker preground to 2500 cm²/g

20 15 10 5 20%

Common fresh feed to tube mill

22%

24%

26%

limestone content

28%

30%

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Combi-grinding for composite cement Compressive strength after 28 d Product fineness 3800 cm²/g 55

Clinker preground to 2500 cm²/g

N/mm²

50 45 40 35 30 20%

Common fresh feed to tube mill

22%

24%

26%

limestone content

28%

30%

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Flowsheet of cement rotator system

Sepol LM Clin- Gyp- Limeker sum stone

Ch. 1

Ch. 2

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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 Ø 5,4 x 16,5 m

RMC 66/31

Polycom 19/11-8 1-Ch BM Ø 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

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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