Welcome message from author
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
Typical existing situation Problems to be taken into account First Step New open Circuit Open circuit control Separator installation Comparison of results from step to step
Feed Material Wide Particle Size Distribution (d80 10 to 40 mm)
Crane feeding from stock pile Segregation Varying feed condition to the mill
Poor Control Equipment No or old weigh feeders
No electrical ear ( first chamber level control ) No power consumption control No ventilation and mill temperature control
Old Mill Internals Closed inlet ( ventilation ! )
Worn-out lining Closed diaphragms No or improper water injection Poor grinding media charge
coarse coarse
fines
Ventilation Control
Chamber Length
50 % 50 %
SAXMAX Grinding Ball Charge
33 % 67 %
Step Chute Feeder
PALProgressive Activating
Lining
BHC
Flow Control Diaphragm DFL
Classifying Lining
BHC Discharge Diaphragm
Air Cleaned BHC Water Injecion
Control via :
- Mill feed
- 1st chamber level
- Fineness
Weigh Feeders
Electrical Ear
t/h
Fineness
Water Injection
Power [ kW ]
T [C]
H2O67%33%
%
Mill Ventilation %
Ball Charge Level after Running Mill Empty
Chamber full of Material
Reduced Grinding Efficiency
Balls and Material inside Central Opening
Coarse Particles ( > 6 mm ) in Second Chamber
HEC High Efficiency ClassifierModular System to Fit into Existing Plants
Further increase of capacity Production of high Blaine and special cement Optimum product quality control
Cyclones
HEC Separator
Filter
Ball Mill
Control via :
Fresh Feed + Reject = Constant
Weigh Feeders
Reject Control
HEC-Separator
Dedusting and Cooling Filter
0
10
20
30
40
Old Situation New Open Circuit Closed Circuit
Prod
uctio
n [ t
/h ]
0
10
20
30
40
50
60
70
80
90
Spec
. Ene
rgy
[ kW
h/t ]
50 % Slag 62,5 % Slag
kWh/t
Tabelle1
CM1Verlustg/t
MKkWhkWh[-]tg/kWh504030t/h
K14246011204.485154060.80.07433.12060.6055.576.969.280.3514
K296104511204.4811708681.60.065.760.49210.2812.8517.140.6486
150516862742.48.88060.52715.8519.8126.42
CM5Verlustt/h
MKkWhkWh[-]tg/kWh403525
K14246010502.394831099.40.19248.08081.67319.2421.9830.780.5838
K296104510502.3910974997.550.065.760.52513.7115.6721.940.4162
150515806096.9513.84080.87632.9537.6552.71
CM5
h
10502.390.1924
Diagramm1
26.458.7
4335.5
5230
+62%
+97%
+21%
-39,5 %
-49%
-15,5%
CEM I 32,5 R approx. 3300 cm/g ( Blaine )
t/h
kWh/t
Production [ t/h ]
Spec. Energy [ kWh/t ]
CEM I 32,5 BalkL
26.458.7
4335.5
5230
&A
Page &P
t/h
kWh/t
Production [ t/h ]
Spec. Energy [ kWh/t ]
Tabelle2
CEM I 32,5 R3300 - 3500 Bl
t/hkWh/t
Old Situation26.458.71549.68
New Open Circuit4335.51526.51.6290.6050.395
Closed Circuit523015601.9700.5110.489
1.2090.8450.155
CEM III 32,5 NA3800 - 4000 Bl
t/hkWh/t
Old Situation19811539
New Open Circuit266015601.3680.7410.259
Closed Circuit324815361.6840.5930.407
1.2310.8000.200
Diagramm2
1981
2660
3248
+36,8%
+68,4%
+23,1%
-26 %
-41%
-20%
CEM III 32,5 NA approx. 3800 - 4000 cm/g ( Blaine )
Increase in Slag Content from 50 to 62,5 %
t/h
kWh/t
Production [ t/h ]
Spec. Energy [ kWh/t ]
CEM III NA
1981
2660
3248
t/h
58,7
Production [ t/h ]
Spec. Energy [ kWh/t ]
Tabelle3
0
10
20
30
40
50
60
Old Situation New Open Circuit Closed Circuit
Pro
duct
ion
[ t/h
]
0
10
20
30
40
50
60
Spe
c. E
nerg
y [ k
Wh/
t ]
kWh/t
Tabelle1
CM1Verlustg/t
MKkWhkWh[-]tg/kWh504030t/h
K14246011204.485154060.80.07433.12060.6055.576.969.280.3514
K296104511204.4811708681.60.065.760.49210.2812.8517.140.6486
150516862742.48.88060.52715.8519.8126.42
CM5Verlustt/h
MKkWhkWh[-]tg/kWh403525
K14246010502.394831099.40.19248.08081.67319.2421.9830.780.5838
K296104510502.3910974997.550.065.760.52513.7115.6721.940.4162
150515806096.9513.84080.87632.9537.6552.71
CM5
h
10502.390.1924
Diagramm1
26.458.7
4335.5
5230
+62%
+97%
+21%
-39,5 %
-49%
-15,5%
CEM I 32,5 R approx. 3300 cm/g ( Blaine )
t/h
kWh/t
Production [ t/h ]
Spec. Energy [ kWh/t ]
CEM I 32,5 BalkL
26.458.7
4335.5
5230
&A
Page &P
t/h
kWh/t
Production [ t/h ]
Spec. Energy [ kWh/t ]
Tabelle2
CEM I 32,5 R3300 - 3500 Bl
t/hkWh/t
Old Situation26.458.71549.68
New Open Circuit4335.51526.51.6290.6050.395
Closed Circuit523015601.9700.5110.489
1.2090.8450.155
CEM III 32,5 NA3800 - 4000 Bl
t/hkWh/t
Old Situation19811539
New Open Circuit266015601.3680.7410.259
Closed Circuit324815361.6840.5930.407
1.2310.8000.200
Diagramm2
1981
2660
3248
+36,8%
+68,4%
+23,1%
-26 %
-41%
-20%
CEM III 32,5 NA approx. 3800 - 4000 cm/g ( Blaine )
Increase in Slag Content from 50 to 62,5 %
t/h
kWh/t
Production [ t/h ]
Spec. Energy [ kWh/t ]
CEM III NA
1981
2660
3248
t/h
58,7
Production [ t/h ]
Spec. Energy [ kWh/t ]
Tabelle3
Stepwise systematic optimization shows the large potential of even old existing mills
Best results can be obtained in close cooperation between supplier and cement plant
DSD-Brockhausen EngineeringSnmek slo 2Stepwise Optimisation of Cement Mills Optimized Open Circuit and Closed Circuit OperationTypical Existing SituationSnmek slo 5Snmek slo 6Snmek slo 7Snmek slo 8Snmek slo 9Snmek slo 10Snmek slo 11Snmek slo 12Snmek slo 13Snmek slo 14
Related Documents
