WA Tech Seminar Bodrum 2012 GPSE 2 Rev 2
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Welding AlloysWelding AlloysTechnical Seminar Technical Seminar
forforCement IndustryCement Industry
Gebr. Pfeiffer Vertical Roller MillsGebr. Pfeiffer Vertical Roller Mills
BodrumBodrum Turkey, May 2012Turkey, May 2012
Part 2Part 2MPS and MVR MillsMPS and MVR Mills
ModernisationModernisation of old MPS mills of old MPS mills Directives for coal grinding plantsDirectives for coal grinding plants
SLS Classifier SLS Classifier Pressure accumulator technology Pressure accumulator technology
Design featuresDesign featuresof the PFEIFFER MPS millof the PFEIFFER MPS mill
www.gpse.de
MPS and MVRMPS and MVR
MVR vertical roller mill
MPS vertical roller mill
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515.05.2012
Design of MPS Design of MPS millmill
fine product
raw material
hot gas
reject material
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615.05.2012
Design of MPS Design of MPS millmill
seal air piping
pressure frame
pull rods
pressure yokes
grinding rollers
grinding table
nozzle ring
reject scrapers
hot gas channel
maintenance drive
reject chute
hydraulic cylinders
foundation frame
mill motor
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715.05.2012
Design of MPS Design of MPS millmill
one pressure frame for uniform load distribution to grin ding rollers,grinding bed and gearbox
large grinding roller diameter for optimum material i ntake and formationof stable material bed
roundish rollers and moulded table for stable grinding bed
closed mill housing for minimum false air leakage
high-efficiency classifier for sharp separation and low electric power consumption
patented MPS Lift-and-Swing System for easy exchange of wear parts through one single maintenance door in the mill housing
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815.05.2012
Design of MPS Design of MPS millmill
feed materialpressure frame
Lift-and-Swing-System
grinding roller
hydraulic tensioning cylinder
nozzle ring
gear box
grit cone
air or hot gases
grinding plate
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MPS MPS designdesign featurefeature : : maintenancemaintenance drivedrive
Maintenance Drive:
� fitted to main gearbox
� For positioning during removal of rollers and grinding plate
� Driving rollers and plate duringhardfacing, plus frequency converterfor welding speed adjustment
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� Direct start without auxiliary drive
� Use of standard motor possible,2nd shaft end not required
� Easy emptying of mill
� Inner grinding roller stop to keeproller in position of track duringlifting
MPS design feature: MPS design feature: LiftableLiftable grinding rollersgrinding rollers
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MPS design feature: MPS design feature: LiftableLiftable grinding rollersgrinding rollers
� Clearance in strap joints provides the flexibility degrees of freedom for the grinding operation
� Outer strap limits roller inclination to 12°during lifting
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MPS design feature: Torque supportMPS design feature: Torque support
� Reduced dynamic forces
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MPS design feature: Torque supportMPS design feature: Torque support
� Flow of force via intermediate boltonto shock absorbing system
� Absorption of transverse force via sliding bearing of intermediatebolt
� Bearing sealing provided by sealair (passive)
� Housing limit stop
intermediate bolts
pressure frameshock absorbingunit
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MPS MPS designdesign featurefeature : : WearWear protectionprotection
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MPS MPS designdesign featurefeature : : risingrising gas gas velocityvelocity
Profile of gas velocity
140 %
115 %
105 %
100 %
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MPS MPS designdesign featurefeature : : LiftLift --andand --SwingSwing SystemSystem
Replacement of rollers and Replacement of rollers and wear partswear parts
Design featuresDesign featuresof the new PFEIFFER MVR millof the new PFEIFFER MVR mill
for grindingfor grindinghigh throughput rateshigh throughput rates
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MPS and MVRMPS and MVR
MVR vertical roller mill
MPS vertical roller mill
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Design of Design of thethe MVR MVR millmill
MVR mill – main function groups
� SLS classifier� Housing with nozzle ring and
hotgas duct� Grinding table� Grinding rollers� Innovative roller suspension
Twin support� Active Redundancy� Standardization benefits through
common parts� One hydraulic system for operation
and maintenance� drive train options
Conventional driveup to 7 000 kW
MultiDrive ®
up to 12 000 kW
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DesignDesign
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Roller Roller suspensionsuspension
• Roller module consists of
• Roller with cylindrical wear parts
• Roller axle
• Roller arm
• Bearing stand
• Hydraulic tensioning cylinder
• Articulation piece, fork head and
anchorplate
• Two roller modules side by side on a
common twin support
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Roller Roller suspensionsuspension
• Guided motion – smooth run
• Grinding gap always in parallel
• Positive effects on energy transmission
• Tension cylinder also swings out roller for service
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Roller Roller suspensionsuspension
� Two roller modules side by side
on a common twin support
Rotation axisunder operationRotation axisunder maintenance
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Roller Roller suspensionsuspension
Advantage in plant layout:Advantage in plant layout:Wide angle between supports due to parallelly shifted axles
6060°°
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Modular Modular drivedrive designdesign withwith MultiDriveMultiDrive
Up to 12,000 kW with up to 6 identical drive modules.
The drive modules are a Siemens/Flender standardproducts, no special MultiDrivedesign.
With only 3 different drive modulesthe complete power range can becovered – strategic spare saving.
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FurtherFurther MultiDriveMultiDrive advantagesadvantages
- Reduced height requirement, lower feed point
- Bigger diameter of axial thrust bearing, thusoperation with minus 1 or 2 rollers possible.
- Table support designed to takeunbalanced radial forces
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Parallel Parallel grindinggrinding gapgap , , symmetricsymmetric tyrestyres
Parallel grinding gap in anyoperating point
Symmetric design allows the tyres to be flipped over
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GrindingGrinding elementselements exchangeexchange
Hydraulic control unit
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MVR millMVR mill
UnchangedUnchanged
• Process Design
• Safety Factors
• Levels of spec.
grinding force
• Nozzle ring
• Gas Velocity Design
• Classifier
• Wear Protection
Changed / ImprovedChanged / Improved
• Capacity Range
• Number of rollers
• Roller Suspension
• Flat Table
• Cylindrical Rollers
• Parallel Grinding Gap
• MultiDrive® with variable speed
• Active Redundancy
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The PFEIFFERThe PFEIFFER--MVR roller millMVR roller millEssential design featuresEssential design features
Symmetric wear partsSymmetric wear partsThe modular roller system with only 5 roller module s and symmetric tyresprovides capacities of up to 1 000 t/h. For an exte nded lifetime tyres can be turned in case of wear.
Active RedundancyActive RedundancyUp to 6 grinding rollers and 6 drive modules: mill operation continueseven if a roller or drive module is under maintenan ce.
Hydraulic system for operation and maintenanceHydraulic system for operation and maintenanceFor maintenance purposes no extra component is requ ired to swingthe rollers out of the mill.
Parallel grinding gapParallel grinding gapThe geometry of the grinding elements in combinatio n with our MVRsuspension system ensures a parallel grinding gap i n any operating point.
Modular drive designModular drive designUp to 12 000 kW with only 3 different types of driv e modules.A mill can be equipped with up to 6 identical drive modules.
Space saving twin supportSpace saving twin support1 support for 2 roller modules for ease of maintena nce work.
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MVR 6700 CMVR 6700 C--6 6 cementcement millmill
Country Iran France Ecuador Italy Turkey India China
MPS sizeMPS
4250 BCMPS
4750 BCMPS
4250 BCMPS
4250 BCMPS
4750 BCMPS
5600 BCMPS
5600 BC
Mixture 94% clinker6% gypsum
96% clinker4% gypsum
62% clinker35% pozzolana
3% gypsum
64% clinker18% slag
7% limestone6% gypsum
5% pozzolana
91% clinker4% limestone5% gypsum
71% clinker25% fly ash4% gypsum
100% slag
Throughputrate, tph
122 100 120 126 151 305 128
Fineness(acc.Blaine) , cm²/g
3000 4300 4000 4400 3800 3500 5000
Spec. powerconsumption,(Mill) , kWh/t
18 24 17 14 19 16 32
Calculatedthroughput withMVR 6700-C6
415 310 430 530 390 460 230
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SummarySummary -- ReferencesReferences
MVR 400Germany
MVR 1800Germany
MVR 3750 Bosnia-Herzegovina
MultiDrive®
France
MVR 5600 plusMultiDrive®
ModernisationModernisation and upgradingand upgradingofof
MPS millsMPS mills
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PossiblePossible ModernisationModernisation MeasuresMeasures
� Lift-and-Swing System
� SLS high efficiency classifier
� New components
� Grit extraction screw conveyor
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Upgrading by Pfeiffer LiftUpgrading by Pfeiffer Lift --andand --Swing SystemSwing System
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Upgrading by Pfeiffer LiftUpgrading by Pfeiffer Lift --andand --Swing SystemSwing System
� Short downtime
� Safe and easy handling
� One maintenance door only
� Low space requirement
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Upgrading with SLS classifierUpgrading with SLS classifier
classifierclassifiertypetype SLSSLS
classifierclassifiertypetype SLFSLF
replacedreplaced byby
byby choicechoice
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Upgrading with SLS classifierUpgrading with SLS classifier
Votorantim
for Santa Rita works, Brazil
MPS 3450
product rate:
absorbed power:
power consumption:
t/h
kW
kWh/t
180
1340
7.4
220
1430
6.5
(mill)
(mill)
beforeupgrading
afterupgrading
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Full scale upgradeFull scale upgradeGorazdzeGorazdze Cement in PolandCement in Poland
Gorazdze Cement, Gorazdze, PolandMPS 4150
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Full scale upgradeFull scale upgradeGorazdzeGorazdze Cement in PolandCement in Poland
ClassifierClassifier replacedreplaced
PressurePressure frameframe and and hydraulichydraulicunitunit replacedreplaced
Rollers Rollers replacedreplaced
NozzleNozzle ring ring replacedreplaced
GearboxGearbox replacedreplaced
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Full scale upgradeFull scale upgradeGorazdzeGorazdze Cement in PolandCement in Poland
(t/h) (kWh/t) %R0,09mm
Before upgrading: 300 4.5 18.0
Guaranteed values: 440 4.3 18.0
After upgrading: 461 4.5 15.8
Operating results
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UpgradingUpgrading byby gritgrit extractionextraction toto redundantredundant ball ball millmillLa Cemento National, Ecuador GuayaquilLa Cemento National, Ecuador Guayaquil
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UpgradingUpgrading byby gritgrit extractionextraction toto redundantredundant ball ball millmillLa Cemento National, Ecuador GuayaquilLa Cemento National, Ecuador Guayaquil
FinishedFinished productproduct
ClassifierClassifier gritsgrits
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UpgradingUpgrading byby gritgrit extractionextraction toto redundantredundant ball ball millmillLa Cemento National, Ecuador GuayaquilLa Cemento National, Ecuador Guayaquil
Product rate:
Extraction rate
Absorbed power
(MPS mill)
Power consumption:
(MPS mill)
380
-
3600
9.4
t/h
t/h
kW
kWh/t
520
125
3630
9.2
Operating results
before
upgrading
after
upgrading
New directivesNew directivesfor the design offor the design of
coal grinding plantscoal grinding plants(Based on EU standards)(Based on EU standards)
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Test of explosion pressure shock resistance Test of explosion pressure shock resistance filter housing with explosion flapfilter housing with explosion flap
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Design of coal grinding plantsDesign of coal grinding plants
CoalCoal characteristicscharacteristics
Lower Explosion Limit (LEL)
Maximum Explosion Pressure (MEP)
Maximum Rate of Explosion Pressure Rise
Limiting Oxygen Concentration (LOC)
Volatile Matter (VM)
The exact data are needed for rating the explosion venting!
Common range
15 – 125
6 - 10
40 – 140
12 - 16
15 - 35
g/m3
bar
bar m/sec
%
%
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Design of coal grinding plantsDesign of coal grinding plants
safetysafety conceptconcept
� Explosion-pressure-shock-resistant design of mill and classifier of up to 3.5 bar
� Decoupling of explosion areas through rotary locks, flame traps and safety shut-off dampers.
� Explosion venting (free and/or absorbed)
� Monitoring of CO, O2, dust emission and temperature
� Central vacuum cleaner for the building
� Inerting and fire fighting by CO2 flooding
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SafetySafety relevant relevant measuringmeasuring pointspoints
3
1
2
� Temperature� CO level� O2 level (plants operated under inert conditions)
1
� Temperature2
� Dust emission� CO level� O2 level
3
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Design of coal grinding plantsDesign of coal grinding plants
SafetySafety conceptconcept
� End-user classifies his plant into zones of explosion risk
� No risk of explosion in mill building thanks to central vacuum cleaner
� Necessity of defining explosion characteristics of coal
� Explosion pressure venting at mill inlet and outlet
� Dust emission measurement after filter
� Extra efforts in project documentation, manuals available at authorities
� Authorities assess conformity of machines with directive, especially mills not operated under inert conditions
� Increased efforts in quality control, including parts manufactured locally
� Equipment procured by end-user must comply with directive
Design featuresDesign featuresof the of the
PFEIFFER SLS classifierPFEIFFER SLS classifier
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5215.05.2012
High High efficiencyefficiency classifierclassifier SLSSLS
SLS classifier
the high efficiency lamella type classifier for Pfeiffer MPS mills
� different types designed for different applications
� SLS-B: for standard applications (cement raw material, limestone, etc.)
� SLS-BF: for very fine products (< 5% residue on 90 µm)
� SLS-BK: for coal and petcoke mills
� SLS-BC: for cement mills, slag mills and mills for cement additives
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louver
fine productdrive
grit cone
rotor
feed material
High High efficiencyefficiency classifierclassifier SLSSLS
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detail of annular gap
three-part wear ring
annular gap
gas outlet duct
submerged pipe
separating rotor
High High efficiencyefficiency classifierclassifier SLSSLS
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material inlet
High High efficiencyefficiency classifierclassifier SLSSLS
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electromechanical drive
reliable
easy to maintain
High High efficiencyefficiency classifierclassifier SLSSLS
Basic knowledge aboutBasic knowledge aboutpressure accumulatorspressure accumulators
to avoid damagesto avoid damages
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PhotosPhotos
Thank you!Thank you!
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