11.30 dr stefan seemann, khd humboldt wedag gmbh
DESCRIPTION
11.30 Dr Stefan Seemann, KHD Humboldt Wedag GmbHTRANSCRIPT
14/03/2011
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COMFLEX ® – High Efficient and Flexible Comminution System
Dr. Stefan SeemannCologne, Germany
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COMFLEX ® – High Efficient and Flexible Comminution System
I. Introduction
II. Efficient Comminution
III. Competent Operation
IV. Process understanding and optimization
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Full line engineering
and equipment supply
Individual machines
Equipment packages
Spare parts and the full
range of plant services
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For cement plants KHD offers
Introduction Efficient Comminution
Competent Operation
Process Overview
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Operating Structure Overview
Introduction Efficient Comminution
Competent Operation
Process Overview
Efficient Comminution
*Other includes smaller operating entities such as China, Australia, EKOF
KHD Humboldt WedagInternational
EMEA (Cologne)
Russia/CIS (Dessau)
Americas (Atlanta) India (Delhi)
Other*
EMEA = Europe, Middle East and Africa
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Customers are served through
four Customer Service Centres
In addition large global players are
served through Key Account
Management
Centre of Excellence for
technology in Cologne
Corporate functions in Cologne
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Operating Structure Overview
Introduction Efficient Comminution
Competent Operation
Process Overview
Efficient Comminution
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COMFLEX ® – High Efficient and Flexible Comminution System
I. Introduction
II. Efficient Comminution
III. Competent Operation
IV. Process understanding and optimization
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Most Efficient Grinding System
Introduction Efficient Comminution
Competent Operation
Process Overview
Efficient Comminution
Ball MillVertical
Roller MillRoller Press
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Energy Saving (Example: Raw Material Grinding)
Introduction Efficient Comminution
Competent Operation
Process Overview
Efficient Comminution
energy consumption
Grindability
feedmoisture
energy saving RP vs VRM
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3 5 7 9 11Grindability
savi
ng R
P vs
. VR
M k
Wh/
t 0-6%
10%
feedmoisture
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10
12
14
16
18
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3 5 7 9 11
tota
l sys
tem
kW
h/t
0 -10%VRM
10%
Roller Press
0-6%
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Energy saving
Introduction Efficient Comminution
Competent Operation
Process Overview
Efficient Comminution
RM grinding1 CM grinding1 Total saving1
3000 tpd 9.600 kWh/d 6.300 kWh/d 15.900 kWh/d
5000 tpd 16.000 kWh/d 10.500 kWh/d 26.500 kWh/d
7000 tpd 22.400 kWh/d 14.700 kWh/d 37.100 kWh/d
Total saving1 $ per day2 $ per year3
3000 tpd 15.900 kWh/d 2.703 $ 891.990 $
5000 tpd 26.500 kWh/d 4.505 $ 1.486.650 $
7000 tpd 37.100 kWh/d 6.307 $ 2.081.310 $
1 2 kWh/t raw meal; cement - saving2 0,17 $/kWh3 330 day‘s per year
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Wear rate
Introduction Efficient Comminution
Competent Operation
Process Overview
Efficient Comminution
Roller Press VRM
Raw meal 0.2 to 1,5 gr/ton 2 to 5 gr/ton
cement 0.2 to 2 gr/ton 2 to 5 gr/ton
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KHD Products - Roller Press
Introduction Efficient Comminution
Competent Operation
Process Overview
Efficient Comminution
RP Size Roller diameter [mm]
Roller width [mm] Motor total[kW]
07 1700 900 1500
10 1700 1100 1800
13 1700 1400 2400
16 1700 1800 3200
18 2000 1800 4000
20 2200 1800 4600
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KHD Products - Roller Press
Introduction Efficient Comminution
Competent Operation
Process Overview
Efficient Comminution
Roller surface:
welded surface (CHF) with profiles
STUD-Lining, autogenous wear protection
Roller Presses sold:
clinker 176raw material 63Minerals 42Slag 18Burnt lime 10coal 1
Total 310
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COMFLEX ® – High Efficient and Flexible Comminution System
I. Introduction
II. Efficient Comminution
III. Competent Operation
IV. Process understanding and optimization
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Introduction Efficient Comminution
Competent Operation
Process Overview
Efficient Comminution
VSK-Separator
SEPMASTERLC, LSK (coal)
SEPMASTERVC
LS - Static Separator
V-Separator
Preferred Separator Types for COMFLEX®
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V-Separator - necessary for efficient grinding
Introduction Efficient Comminution
Competent Operation
Process Overview
Efficient Comminution
• Static separator for coarse cut
• KHD`s invention
• VS has become standard for RP-grinding circuits
• VS is multi-functional: separating, deglomerating,
drying, cooling
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V-Separator - necessary for efficient grinding
Introduction Efficient Comminution
Competent Operation
Process Overview
Efficient Comminution
air and fines
air
rejects
feed
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SEPMASTER SKS
Introduction Efficient Comminution
Competent Operation
Process Overview
Efficient Comminution
The original Sepmaster -
• features minimum height between
feed-inlet and rejects-outlet
This results in:
• Low bucket elevator height and best
choice for conversions
• Rotor bearings at both ends for
vibration-free run and
• Together with the drive on bottom no
influence by process heat
H m
in.
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COMFLEX ® – High Efficient and Flexible Comminution System
I. Introduction
II. Efficient Comminution
III. Competent Operation
IV. Process understanding and optimization
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Single machinery – How about the arrangement?
Introduction Efficient Comminution
Competent Operation
Process Overview
Efficient Comminution
Roller Press
V-Separator
SEPMASTER-SKS
Bringing Innovation in Layouts
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COMFLEX® - Location of V-Separator ?
Introduction Efficient Comminution
Competent Operation
Process Overview
Efficient Comminution
ClinkerRawMaterialWet BlastFurnace slag
Fines, dust, vapor,reactive slag
heating required forbag filter and vent-ducts,and bucket elevator
VS above Roller Press VS below Roller Press
Coarse, no dust,dried coarse slag
No problem
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COMFLEX® - Location of dynamic-Separator ?
Introduction Efficient Comminution
Competent Operation
Process Overview
Efficient Comminution
Fine SKS-rejectsand VS-rejects to be lifted byBucket elevator
SKS below Roller Press
Only coarseVS-rejects tobe lifted
Fines is liftedPneumaticallywithout additionalAir flow
SKS above Roller Press
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COMFLEX® - Location of dynamic-Separator ?
Introduction Efficient Comminution
Competent Operation
Process Overview
Efficient Comminution
SKS belowRoller Press
SKS aboveRoller Press
MechanicalConveyors canbe designed25 to 40%smaller
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COMFLEX® - High Efficient Grinding System for the Future
Introduction Efficient Comminution
Competent Operation
Process Overview
Efficient Comminution
COMFLEX®
COMminution system with Roller Press
FLEXible process for most applications
Fully Standardized
Special Layout
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COMFLEX® - Layout
Introduction Efficient Comminution
Competent Operation
Process Overview
Efficient Comminution
VS belowRoller Press
SKS aboveRoller Press
COMFLEX ®
Multi purpose Grinding Plant
• Slag up to 7000cm2/g Blaine• Limestone 10%R 90µm• Raw material 15% R 90µm• Additives (slag, limestone, fly ash)
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COMFLEX® - Layout
Introduction Efficient Comminution
Competent Operation
Process Overview
Efficient Comminution
VS belowRoller Press
Static Separatorabove Roller Press
COMFLEX ® forRaw Material Grinding
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COMFLEX® - Compact
Introduction Efficient Comminution
Competent Operation
Process Overview
Efficient Comminution
A
C
Rol
ler P
ress
floo
r lev
el
buck
et e
leva
tor h
eigh
t
B
build
ing
heig
ht
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COMFLEX® - Layout
Introduction Efficient Comminution
Competent Operation
Process Overview
Efficient Comminution
COMFLEX ® S (Single)300 t/h raw meal, 100 t/h slag120 t/h cement
COMFLEX ® D (Double)600 t/h raw meal200 t/h slag240 t/h cement
COMFLEX ® T (Triple)900 t/h raw meal300 t/h slag360 t/h cement
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Conclusion
Introduction Efficient Comminution
Competent Operation
Process Overview
Efficient Comminution
Lowest Specific Energy Consumption (more than 1 million $ of energy saving per year!)
With Stud-Lining Roller Surface Life of minimum 18,000 Hours without Maintenance
Highest production rates from one grinding station with COMFLEX ® D or COMFLEX ® T
Always more than 50% Availability with COMFLEX® D and COMFLEX® T
Standard equipment for raw- cement and slag-grinding with lowest investment in spare parts
with latest developments: – Greatly reduced building- and equipment cost– No dust and spillage from mechanical conveying
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To get more out of your cement plant, visit
www.khd.com
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