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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