GRINDING AND SEPARATING TECHNOLOGY SYSTEMS

2

PSP EngineeringAbout usFrom a single machine to a complete line.

PSP Engineering has been supplying machines, equipment, processing lines and turnkey industrial plants for cement and lime production, treatment of ore, extracted stone, sand, gravel sand, coal and other materials, and also it has been applying certain technologies in the energy and chemical industries for more than 70 years.

With the process know-how and comprehensive service for turnkey projects including engineering services, project management, international transport, technical assistance during assembly and commissioning, warranty and after warranty service, PSP Engineering is a partner that brings knowledge, professionalism, relevant experience in “greenfi eld” and “brownfi eld” projects in the Czech Republic as well as in abroad.

Considering all technical-commercial aspects and abilities to face technological challenges, PSP Engineering is a competent and reliable business partner developing long-term relations with the customers.

EngineeringPreparing professional “tailor made” designs, PSP Engineering maximizes the utility value of the design while it minimizes investment and operating costs for machines and equipment. The design of the whole technology takes specifi c properties of materials processed and required quality of the fi nal product into account.

In designing, PSP Engineering utilizes a sophisticated designing software (CAD), computing (FEM) and testing (CAT) methods to improve parameters such as output, reliability and safety as well as to reduce operating costs. PSP products are in compliance with the EN standards.

After-sales supportOur after-sales & service department offers supplies of spare parts, service and after-sales support. The technological department is ready to manage challenges related to any customer’s problem.Activity, expertise, experience and positive approach of our designers, technologists, technical specialists and supervisors help to solve any task.

PSP Engineering supplies original spare parts in accordance to the existing documentation in given tolerances using the state-of-the-art technology in controlling production processes.

Technological aid in grinding systemsIn case a grinding plant does not work effectively, PSP Engineering offers technological support. It means an inspection on site with the mill survey and measurement of operating data of the grinding plant. Our specialists then analyze the operation data measured. The result of this is the so-called “fi nal report” where there are an evaluation of the current situation, offer of solution and specifi c recommendations leading to increase of capacity and reduction of energy consumption.

With an adequate amount of material delivered, PSP Engineering is able to simulate the grinding process in its pilot line. In addition, the attained representative process data may be assessed and material characteristics of samples may be checked in our laboratory. The laboratory is equipped with devices determining chemical and physical properties of material such as e.g. the laser CILAS.

3

PS

P E

NG

INE

ER

ING

- S

UM

MA

RY

MA

CH

INE

UN

ITS

MILLS

AIR SEPARATORS

AUXILIARY DEVICES

KTM VERTICAL ROLLER MILL ................................p. 41

PREMILL HORIZONTAL ROLLER MILL...........................p. 16

BM BALL MILL ........................................................p. 20

DYNAMIC SEPARATORS

VTP AIR SEPARATOR PRESEP .............................p. 26

LTR, LTR-R, LTR-U, LTR-M AIR SEPARATOR PRESEP .............................p. 30

DTIM, DTIMU, DTP INTEGRATED SEPARATOR ............................p. 32

VTR ROTARY AIR SEPARATOR ..............................p. 34

STATIC SEPARATORS

LVT BLADE AIR SEPARATOR ................................p. 36

KVT CASCADE AIR SEPARATOR ...........................p. 38

CEMENT COOLER ..........................................................................p. 40

CYCLONE ..........................................................................p. 42

SCREW CONVEYOR AND FEEDER ...............................................................p. 42

ROTARY FEEDER ..........................................................................p. 43

TABLE FEEDER ..........................................................................p. 43

SWINGING FLAP AND MECHANICAL DOUBLE FLAP ...................................p. 43

4

VE

RTI

CA

L R

OLL

ER

MIL

L K

TM

Basic informationThe vertical roller mill KTM is used for material grinding in many industrial branches where the fi nal fi ne product is technologically required.

Materials that can be ground in the mill KTM are e.g.:

lime, limestone, dolomite slag, cement material glass clay, bentonite coal, anthracite, coke, petroleum coke and

other fuels and other minerals up to the hardness degree

8 Mohse

KTMU that is designed for grinding of explosive materials and materials susceptible to burning and explosion is a variation of the mill KTM.

Hydro-pneumatic thrust allows fast change of thrust of runners by altering oil pressure in the hydraulic-pneumatic circuit

Instant change and continuous regulation of the fi nal product fi neness

Grinding process controlled by an automatic control system

Mill and separator make a reliable compact unit in operation. The outer circulation of grist (coarser material) from the separator back to the mill disappears.

Possibility of intensive drying of the material of high moisture

Fast exchange of runner casings and grinding segments of the grinding table without dismantling the grinding chamber and separator

Simple construction work for the machine anchoring

Low specifi c consumption of energy per one ton of material ground

Low maintenance costs

Main characteristics

Vertical Roller Mill KTM

5

VE

RTI

CA

L R

OLL

ER

MIL

L K

TM

Main data

Type Min. motor power

Max. motor power

Min. capacity

Max. capacity

[kW] [kW] [t/h] [t/h]

KTM 400 11 18,5 0,1 0,8KTM 800 37 55 2 5KTM 1000 55 90 4 8KTM 1200 90 132 6 12KTM 1400 132 200 9 18KTM 1600 200 315 12 24KTM 1800 315 400 20 38KTM 2000 400 500 29 50KTM 2200 500 630 39 64KTM 2400 630 800 49 78KTM 2600 800 900 62 98KTM 2800 900 1 100 83 133KTM 3000 1 000 1 450 101 172KTM 3400 1 450 1 900 125 224

Type Min. motor power

Max. motor power

Min. capacity

Max. capacity

[kW] [kW] [t/h] [t/h]

KTMU 1000 45 75 2 4KTMU 1200 75 110 3 7KTMU 1400 110 160 4 10KTMU 1600 160 250 6 14KTMU 1800 250 355 9 19KTMU 2000 355 450 14 28KTMU 2200 450 560 18 37KTMU 2400 500 630 24 47KTMU 2600 630 800 31 59KTMU 2800 800 1 000 42 81

Vertical roller mills

Coal vertical roller mills

6

Inlet material is supplied to the center of a rotating grinding table by a chute or screw. The grinding table is seated on a gearbox driven by an el. motor or on the mill inner bearing fi xed in its bottom segment. Conical grinding runners are pressed to the material by means of hydro-pneumatic thrust.

The material coming from the grinding table center under the runners is ground and falls over a retaining ring on its periphery.

There it is taken by airfl ow that is sucked from the bottom part of the mill through a distributing blade

ring up into the separator. The fi nal fi ne product that passed through the separator rotor is then taken by airfl ow to a cyclone or fi lter to be separated, the coarse fraction returns from the separator back onto the grinding table.

The mill works in the air-technical circuit with a fan and separating cyclone, with a de-dusting fi lter or process fi lter. This circuit is either closed or opened. The whole circuit works in under-pressure, so it is dust-free.

Designing Designing vertical mills KTM, the 3D designing software and fi nite element method are used.

Principle of operation

Wear protection of the mill working parts Designing the mill for grinding of abrasive materials, great attention is paid to inner working parts of the mill and separator:

Casings of grinding runners and grinding segments are cast of special material and possibly they are fi tted with anti-abrasive hard facing.

Armoring of the grinding chamber is made of wear-resistant armors and possibly they are fi tted with anti-abrasive hard facing.

Separator rotor, separator stator blades and other exposed parts are designed of wear-resistant material and possibly they are fi tted with anti-abrasive coats or hard facing.

VE

RTI

CA

L R

OLL

ER

MIL

L K

TM

7

ReconstructionReconstructing the formerly manufactured vertical mills and installing the highly effi cient separator, the grinding capacity may be increased by 10 - 40 % and the existing outlet grain size distribution is maintained without technological parameters of the mill circuit being modifi ed.

VE

RTI

CA

L R

OLL

ER

MIL

L K

TM

8

HRD systems to suppress explosionThe protective device HRD is a technology that can supply extinguishing agent to the protected equipment extremely quickly. Suppression of explosion by the HRD system does not allow penetration of fl ame or other material to the atmosphere, which guarantees maximum safety in the area.

Coal vertical roller mill KTMUThe coal mill KTMU is used mainly for coal grinding as a preparation for burning. This mill can work in under-pressure (it is standard) or over-pressure.

VE

RTI

CA

L R

OLL

ER

MIL

L K

TM

TIMEPRESSURE

Grinding of coal and other explosive materials requires observing of safety rules of operation: Materials can explode under the following conditions:1. Concentration of dispersed coal dust in the

atmosphere,2. Over limit content of O2 in the atmosphere for

the specifi c fuel,3. Initiation source of ignition.Explosion in coal grinding plants cannot be eliminated when there are more concurrent defects or when drying gas of high O2 content is used!

ACTIVE measures to prevent explosion Using of gas from the kiln line of low O2 content

as drying and carrying medium. Suppression of explosion in the very beginning

by a protective device HRD. Inertizing system CO2 eliminating O2 from the

area of a smoldering deposit. Monitoring of important quantities of dangerous

states even when the grinding plant is at rest. Connection of selected machines to the

emergency source of el. energy. Fire extinguishing system. System of cleaning with a central vacuum

cleaner.

PASIVE measures to prevent explosion Sizing of the machine to possible explosion

pressure.

9

Distribution of pressure air, inert gas CO2 and other media Central vacuum cleaner

Silo for storage of ground fuel incl. the safety fl ap

Dosing of the ground fuel to the rotary kiln burner

VE

RTI

CA

L R

OLL

ER

MIL

L K

TM

10

Manufacture of the mill KTM 3400 – Kazakhstan

VE

RTI

CA

L R

OLL

ER

MIL

L K

TM

11

Mill KTM 1000 without the separator

Manufacture of other types of mills

Bottom segment with the gearbox of the mill KTM 1200

Complete runner with the carrier (KTM 1900)

VE

RTI

CA

L R

OLL

ER

MIL

L K

TM

12

KTM 400 – Czechia

Reference

KTM 400 – Poland

KTM 800 – Poland KTM 1000 – Italy

VE

RTI

CA

L R

OLL

ER

MIL

L K

TM

13

KTM 1200 – Russia KTM 1400 – Slovenia

KTM 1400 – Czechia KTM 1600 – Lithuania

VE

RTI

CA

L R

OLL

ER

MIL

L K

TM

14

KTM 1800 – Hungary KTM 1800 – Croatia

KTM 1900 – Poland 2 x KTM 2300 – Turkey

VE

RTI

CA

L R

OLL

ER

MIL

L K

TM

15

Coal mills

KTMU 1200 – Lithuania KTMU 1200 – Turkey

6 x KTMU 1800 – Slovakia

VE

RTI

CA

L R

OLL

ER

MIL

L K

TM

16

HO

RIZ

ON

TAL

RO

LLE

R M

ILL

PR

EM

ILL Basic information

The horizontal roller mill PREMILL is used especially for grinding of silicate materials.

As the energy consumption is low, it can be used for pre-grinding of materials before tube mills.

It concerns mainly these materials:

ceramic material cement material slag quartz sand glass lime, limestone and other materials up to the hardness degree

8 Mohse

material - limestone material - clinker

Type Capacity

Capacity for

the product 0 - 3 mm

Motorpower

[t/h] [t/h] [kW]PM 370 2,5 2 15PM 600 10 ÷ 40 10 45 ÷ 75PM 800 20 ÷ 60 25 110 ÷ 160PM 1000 40 ÷ 110 40 160 ÷ 250PM 1200 80 ÷ 160 80 320 ÷ 400PM 1400 130 ÷ 230 130 400 ÷ 550

Type Capacity

Capacity for

the product 0 - 3 mm

Motorpower

[t/h] [t/h] [kW]PM 370 2 2 15PM 600 6 ÷ 10 6 45 ÷ 75PM 800 14 ÷ 40 16 110 ÷ 160PM 1000 27 ÷ 70 27 160 ÷ 250PM 1200 52 ÷ 105 52 320 ÷ 400PM 1400 85 ÷ 150 85 400 ÷ 550

Main data

The mill works independently in a simple line or in a circuit with a suitable separator (air separator or vibration screen).

Owing to relatively low specifi c pressures of grinding runners, admittedly, agglomerates are formed in grinding but they are not so fi rm so that it would be necessary to use a de-agglomeration unit before the material is separated.

Main characteristics Small built-up space Lower investment costs in comparison with classic equipment of similar capacities Low specifi c consumption of electric energy per one ton of material ground Easy installation Grinding surfaces of the roller and runners are made of quality wear-resistant material High reduction factor – per one pass up to ~ 20

Horizontal Roller Mill PREMILL

17

HO

RIZ

ON

TAL

RO

LLE

R M

ILL

PR

EM

ILL

Principle of operationPremill is a grinding machine where material is ground between a fi xed main grinding roller and three grinding runners. The main grinding roller is driven by a main drive and the fi rst grinding runner is usually driven by two el. gearboxes or it can be without a drive. The rotary movement of other two grinding runners is initiated by friction of the ground material between the main grinding roller and these grinding runners. Hydraulic cylinders produce thrust of grinding runners to the main roller.

The ground material is supplied to a hopper positioned in the mill upper part. The main grinding roller takes material from the hopper and brings it to the fi rst slot created by the rotating main roller and the fi rst grinding runner. The material layer height is regulated by a slide gate. The material ground is evenly distributed on the main grinding roller by lower grinding pressure of the fi rst grinding runner, it is formed and partially pre-ground. On leaving this area, the material is released. The released and redistributed material then enters the second slot between the main grinding roller and the second grinding runner. There the grinding runner applies medium grinding pressure in the second phase of grinding and the material grains are disintegrated, then the material is released again. After that the material greatly pre-ground is transported to the third slot where it is fi nished under the highest grinding pressure. Single pressures on grinding runners can be fl exibly changed for the optimum capacity

of the machine to be adjusted. The ground material is discharged in the mill bottom part through a discharge to the following transporting equipment.

18

Designing In designing horizontal mills PM, the 3D designing software and fi nite element method are used.

Wear protection of the mill working parts Designing the mill for grinding of abrasive materials, great attention is paid to inner working parts of the mill:

Casings of grinding runners are cast of special material and possibly they are fi tted with special hard facing.

Armoring of inner parts of the mill is fi tted with wear-resistant armors and possibly they are fi tted with special hard facing.

HO

RIZ

ON

TAL

RO

LLE

R M

ILL

PR

EM

ILL

19

ReferencePM 800 – Russia PM 800 – Russia

PM 370 – Slovakia

PM 1400 – Czechia

HO

RIZ

ON

TAL

RO

LLE

R M

ILL

PR

EM

ILL

20

Basic informationThe ball mill is used mainly:

for dry grinding of different materials such as cement material, clinker, slag, lime, ceramic materials and solid fuels

for wet grinding when the following technology requires material in the form of sludge. It concerns treatment of ores for the following technology of fl otation or preparation of limestone sludge for wet de-sulfurization of combustion products in energy and chemical industries.

BA

LL M

ILL

BM

Main characteristics Possibility of grinding to very high fi neness Optimum shape of the product grain Easy control of the process High capacity Robust structure Very low maintenance costs Relatively easy and simple operation

DivisionSeveral viewpoints for division of balls mills:

1. acc. to their use in the circuita. mechanicalb. pneumatic

2. acc. to their seating a. on pin bearingsb. on shoe-type bearings c. on roller bearings

3. acc. to the drivea. combined drive b. central drive c. counter-shaft drive

Ball Mill BM

21

BA

LL M

ILL

BM

Mill dia. Length total Drying chamber length Speed Motor power Mill capacity

[m] [m] [m] [min-1] [kW] [t/h]3,6 11,0 2,0 16,7 1 600 703,8 11,5 2,0 16,3 1 900 854,0 12,5 2,5 15,9 2 200 1004,2 13,0 2,5 15,5 2 600 1204,4 13,5 2,5 15,1 3 100 1404,6 14,5 3,0 14,8 3 600 1654,8 15,0 3,0 14,5 4 200 1905,0 15,5 3,0 14,2 4 800 2205,2 16,0 3,0 13,9 5 400 2505,4 16,5 3,0 13,6 6 200 2855,6 17,0 3,0 13,4 7 000 320

Mill dia. Length total Speed Motor power Mill capacity

[m] [m] [min-1] [kW] [t/h]3,4 11,0 17,2 1 600 453,6 11,5 16,7 1 900 553,8 12,0 16,3 2 300 654,0 12,5 15,9 2 700 754,2 13,0 15,5 3 200 904,4 14,0 15,1 3 800 1054,6 14,5 14,8 4 400 1254,8 15,0 14,5 5 000 1455,0 15,5 14,2 5 700 1655,2 16,0 13,9 6 500 1855,4 17,0 13,6 7 500 215

Main dataCement two-chamber mills

Mill design: seating on shoe-type bearings, combined drive with the gearbox DMG2. Assumed product: Portland cement 42.5, fi neness of grinding 3200 – 3300 Blaine

Mill design: seating on shoe-type bearings, integrated circuit drive with the gearbox DMG2.

Principle of operation1. Mechanical ball mill

With this mill the material is lifted mechanically through a discharging box. A bucket elevator then transports the material further to a dynamic separator VTP that forms the mechanical grinding plant together with the ball mill. This grinding plant is ideal for comminution of relatively dry materials to very high fi neness.

The mill itself can be equipped with a drying pre-chamber. The fi rst chamber using bigger balls for high effect of comminution is equipped with a lifting armoring. The second chamber using small balls for fi ne grinding is equipped with a classifi cation armoring.

A partition is equipped with a controllable fl ow of material ground for optimum fi lling of both chambers with material.

Raw mills with a drying chamber

22

2. Pneumatic ball mill

With this mill the material is lifted by airfl ow. The material is further taken to a dynamic separator LTR that forms a pneumatic grinding plant together with the ball mill. The pneumatic mill is equipped with only one chamber while it is possible to pre-arrange a drying chamber. The material supplied to the mill is ground and pneumatically transported to a highly effi cient dynamic separator. The fi nal product is collected in cyclones or fi lter.

The pneumatic mill is used for grinding and drying of very moistened materials. For drying there are great amounts and high temperatures of drying gas fl owing through the drying chamber, mill and separator.Simple design and reliability are advantages of pneumatic grinding plants.The pneumatic grinding plants are designed even for coal and petroleum coke grinding together with a highly effi cient separator LTR-U with pressure resistance up to 3.5 bar and safety fl aps.

BM 4,2 x 14,2 m – France

BA

LL M

ILL

BM

ReferenceBM 4,2 x 13,5 m – Spain

The material from the second chamber is supplied to a separation circuit through an outlet wall. In grinding warmer materials, water is sprayed into the 1st or 2nd chambers or both mill chambers. To increase grinding capacity and decrease specifi c consumption, a horizontal roller mill Premill may be pre-arranged. In case the grinding circuit is equipped with this horizontal mill, it is fi tted with one chamber with the classifi cation armoring i.e. without the partition.

23

BM 5,2 x 13,5 m – Mali

BM 2 x 4,5 m – Algeria

BM 4,4 x 14 m – Russia

BA

LL M

ILL

BM

24

BA

LL M

ILL

BM

FO

R W

ET

GR

IND

ING

Basic informationThe ball mill for wet grinding is used in the technology processing material in the form of sludge.

It concerns treatment of ores for the following technology of fl otation or preparation of limestone sludge for wet de-sulfurization of combustion products in energy and chemical industries.

Plants with the ball mill for wet grinding offer easily controllable and highly effective way of comminution. They consist of the ball mill and battery of cyclones connected in a circle.

Main characteristics High capacity Low consumption of energy (by 20 % more

effi cient than dry grinding) Low maintenance costs Easy control of the process Verifi ed technology

Principle of operationThe processed material is supplied to the mill by a belt-weighing feeder. Clear water is added in a constant ratio to the amount of material supplied. Metal residues or ball fragments are separated from the sludge on the Trommel screen at the mill discharge. The ground fi nal sludge fl ows by gravity to a sludge tank where it is diluted. The

sludge is supplied to a hydro-cyclone by a pump. The separated over-sized portion is returned back to the inlet chute of the mill and under-sized portion (product) fl ows to storage bins. In some cases a fl ow diverter is used in some circuits for wet grinding.

Ball Mill BM for Wet Grinding

25

BA

LL M

ILL

BM

FO

R W

ET

GR

IND

ING

Reference

BM 3.6 x 10 m – Czechia

BM 3.6 x 5.7 m – Liberia

26

AIR

SE

PAR

ATO

R P

RE

SE

P V

TPAir Separator PRESEP VTPBasic informationThe air separator PRESEP VTP is used as a separating unit in mechanical grinding circuits and separating lines.

There are many diverse modifi cations of this machine according to its use and material separated and namely:

in the building material industry (clinker, limestone, lime, slag etc.)

in the ceramic industry (sand, clay, fi lling matters, minerals, abrasives)

in the chemical industry (chemical products, synthetic powders, ores)

After verifi cation, it can be used even in different branches.

Main characteristics High effi ciency and sharpness of separation Tromp curve with the bypass less than 10%

and great steepness provides high yield and effi ciency of separation

Energy saving of the mill according to fi neness of separation up to 40%

Compact structure brings lower weight and smaller built-up space

Easy maintenance of the machine

Separator is suitable both for less abrasive materials and also for abrasive materials because the wear parts are protected against wear and they can be easily exchanged

Separated material can be effectively dried or cooled

Separation in the great grain size range from 2 to 300 μm

Adjustment of grain size distribution in operation

Improved grain size composition of material

27

AIR

SE

PAR

ATO

R P

RE

SE

P V

TP

Main data

Principle of operationThe separator consists of a spiral inlet box where air is supplied. It is directed through the built-in direction blades into the separation area. In the upper part the spiral box is connected to a cylindrical chamber into which the material is supplied by one up to four inlets. The supplied material falls freely onto a scattering disc.The disc scatters the material separated applying centrifugal force evenly on the cylindrical chamber wall periphery on which it slides to the separation area. The fi ne material is taken by airfl ow through a separating basket and it is brought to cyclones or fi lter by a discharging tube. The separator rotor is made of a separating basket and shaft and it is fi xed directly on the spiral box cover of the separator or intermediate piece. The separator is driven by an el. motor via a coupling, belt transmission or gearbox.The coarse material (grit) falls from the separation area to a lower discharging cone that must be protected against false air suction.

Type Amount supplied Air amount Motor

power

Material output at the cement fi neness

3200 Blaine

Material output at the mat. fi neness 12%

R 0.09mm[t/h] [m3/h] [kW] [t/h] [t/h]

VTP 500 7,7 4 300 7,5 3,1 4,1VTP 600 10,5 5 900 11 4,3 5,5VTP 700 15,2 8 400 11 6,2 8VTP 800 21 11 600 15 8,5 11VTP 950 27 15 000 18,5 11 14,5VTP 1100 39 21 700 30 16 20,5VTP 1300 58 32 100 37 24 31VTP 1500 76 42 200 45 31 40VTP 1650 96 53 000 55 39 50VTP 1800 117 64 800 75 47 61VTP 1950 140 77 900 90 57 74VTP 2100 166 91 900 110 67 87VTP 2250 194 107 600 132 79 102VTP 2400 224 124 300 160 90 117VTP 2550 252 139 700 200 102 133VTP 2700 286 158 700 200 116 150VTP 2900 324 180 200 250 132 172VTP 3100 386 214 800 315 157 214VTP 3300 443 246 100 315 179 233VTP 3400 486 263 000 315 196 256VTP 3600 528 293 500 350 214 278VTP 3900 628 349 000 400 255 331VTP 4200 736 409 200 450 299 388VTP 4500 846 470 000 500 344 447VTP 4900 1 014 564 000 630 412 536

28

Wear protection of the separator working parts

ReferenceVTP 3100 – Poland

The separators determined for separation of non-abrasive materials are usually not fi tted with protection against wear except for a rotor. The separators determined for separation of abrasive materials are equipped with a special protection against wear such as e.g.:

protection of the rotor scattering disc, shattering wall, chamber and discharging elbow with a ceramic lining (Densit, ceramic plates, etc.) or wear-resistant plates or CDP plates

directing blades are made of the wear-resistant plates or hard-faced plates

spiral box and part of the conical discharge are armored

rotor is fi tted with the protective anti-abrasion coating

cone of the separator bottom part is fi tted with retaining rings

AIR

SE

PAR

ATO

R P

RE

SE

P V

TP

29

VTP 1800 – Brazil

VTP 2700 – Poland

VTP 2100 – Turkey

VTP 700 – Turkey

AIR

SE

PAR

ATO

R P

RE

SE

P V

TP

30

AIR

SE

PAR

ATO

R P

RE

SE

P LT

RAir Separator PRESEP LTRBasic informationThe air separator PRESEP LTR is a dynamic air separator used in the circulation pneumatic grinding plants in combination with tube mills or in independent separation circuits.

There are three designs of this separator: LTRR – can be used most widely LTRU – for explosive materials LTRM – are designed with an additional upper

mechanical inlet of material

Main characteristics High effi ciency and sharpness of separation Tromp curve with the bypass less than 10%

and great steepness provides high yield and effi ciency of separation

Energy saving of the mill according to fi neness of separation up to 40 %

Compact structure brings lower weight and smaller built-up space

Low installation costs Easy maintenance of the machine

TypeGas fl owrate at inlet speed Motor power at

circumferential velocity 25 m/s

Separator output at the cement

fi neness 12-14% R0.09mm20 m/s 16 m/s

m³/h m³/h kW t/hLTR 580 9 500 7 600 5 5LTR 720 11 100 8 900 7,5 8LTR 820 13 700 11 000 9 10LTR 900 16 700 13 300 11 12LTR 1000 20 400 16 300 14 15LTR 1100 24 800 19 900 17 18LTR 1250 32 000 25 500 21 23LTR 1400 40 000 32 000 27 29LTR 1500 46 100 36 900 31 34LTR 1650 55 700 44 500 37 40LTR 1850 69 900 56 000 46 50LTR 2000 81 700 65 300 54 60LTR 2100 90 300 72 200 60 66LTR 2350 113 100 90 500 75 83LTR 2500 127 900 102 300 84 93LTR 2700 149 100 119 300 98 110LTR 3000 183 700 147 000 121 135LTR 3250 215 700 172 600 143 160LTR 3650 272 200 217 800 180 200

Main data

31

AIR

SE

PAR

ATO

R P

RE

SE

P LT

R

Principle of operationThe material with airfl ow is supplied through the separator bottom part into the area between outer and inner cones of the separator where speed of dusty air is reduced. Reducing speed, the coarsest particles return to the gas inlet piping along the outer cone wall. The dusty air is further directed through regulated fl aps to the separation area towards a rotor basket. Regulated fl aps are controlled by an adjusting screw. Turning the fl aps, sharpness of separation is infl uenced. The coarsest and heaviest particles fall from there directly to an inner conical chamber. Other fi ner particles together with dusty air are taken by airfl ow to rotor basket blades. The fi ne material is taken by airfl ow to cyclones or fi lter through a discharging tube. The coarse material (grit) falls from the separation area to the inner conical chamber due to centrifugal force and rotation of the rotor, from there it is taken to a discharging hopper in the separator bottom part. The separator rotor is driven by an el. motor either directly or via a belt transmission.With LTRM a portion of the material separated can be supplied to upper inlets on the scattering disc. The disc applying centrifugal force scatters the material evenly on the cylindrical chamber wall periphery on which it slides to the separation area.

ReferenceLTRR 720 – Czechia LTRU 1750 – Poland

LTRM 2500 – Spain

32

INTE

GR

ATE

D S

EPA

RAT

OR

Integrated separatorBasic information The integrated dynamic separator DT is an integral part of the mill KTM. It may be used for reconstructions of existing vertical mills. The separator structure signifi cantly prolongs the service life of the mill itself and reduces its wear. Fineness and sharpness of separation are controlled in several ways:- turning the stator blades (except for DTP)- changing the rotor speed by means of a

frequency converter - changing the air amount fl owing through the

separator

There are three designs of this separator: DTIM – can be used most widely DTIMU – for explosive materials DTP – for operations working in over-pressure

Main characteristics High effi ciency and sharpness of separation Possibility to separate material of the great

grain size range Easy adjustment of the product fi neness Low specifi c consumption of energy Improved grain size distribution of raw meal for

the following process of burning Possibility to take the coarse product at the grit

outlet from the separator Possibility to supply fi ne grist through the upper

part of the separator so that the material would be pre-separated before grinding

DTIM DTP in over-pressure

33

INTE

GR

ATE

D S

EPA

RAT

OR

Reference

DTIM 1500 – Czechia

DTIM 300 – Czechia

DTIM 1650 – Lithuania DTIM 2000 – Hungary

34

RO

TAR

Y A

IR S

EPA

RAT

OR

VTR

Rotary Air Separator VTRBasic informationThe air separator VTR is used for the material separation by airfl ow in the separation area. It always works in a closed mechanical circuit in a line with a mill (and possibly separator) without necessity to use an outer process fan with a fi lter.

The separator VTR is equipped with its own source of separating air – fan wheel, rotor and outlet of fi ne and coarse fractions.

Main characteristics Easy operation and maintenance Simple design and reliability Robust structure High effi ciency Integrated air circulation

Type Rotor dia. Motor power

Separator output at the cement

fi neness 15% R 0.09 mm

mm kW t/hVTR 1000S 1 000 7,5 1,5VTR 1500S 1 500 11 4VTR 2000S 2 000 15 8VTR 2500S 2 500 22 12VTR 3200S 3 200 37 20VTR 3600S 3 600 45 26VTR 4000S 4 000 55 32VTR 4500S 4 500 75 41VTR 5000S 5 000 90 51VTR 5600S 5 600 110 64

Main data

35

RO

TAR

Y A

IR S

EPA

RAT

OR

VTR

Principle of operationThe material is supplied to a scattering disc through a hopper from where the centrifugal force throws it to airfl ow in the separation area.

The fi ne material is taken by airfl ow through the rotor blades and then through a fan wheel to an outer part of the separator where it is separated from airfl ow by the centrifugal force and friction and slides into a discharging hopper of the fi ne product.

The coarse material (grit) falls from the separation area to a lower discharging cone. Inlet and outlet fl anges must be protected against false air suction.

ReferenceVTR 1500S – Lithuania

VTR 1000S – Russia

36

BLA

DE

AIR

SE

PAR

ATO

R L

VT

Blade Air Separator LVTBasic informationThe air separator LVT is a static air separator without a drive that is used in pneumatic grinding plants or in independent separation circuits.

There are many diverse modifi cations of this machine according to its use and material separated and namely:

in the building material industry (clinker, limestone, lime, slag etc.)

in the ceramic industry (sand, clay, fi lling matters, minerals, abrasives)

in the chemical industry (chemical products, synthetic powders, ores)

After verifi cation, it can be used even in different branches.

Main characteristics Low installation costs Minimum maintenance

Type Inlet fl ange dia.

Airfl ow amount at the inlet speed16 m/s 20 m/s

[mm] [m3/h] [m3/h]LVT 1 200 1 630 2 050LVT 2 225 2 080 2 600LVT 3 250 2 600 3 200LVT 4 290 3 300 4 000LVT 5 315 4 200 5 300LVT 6 355 5 400 6 800LVT 7 400 7 200 9 000LVT 8 450 8 800 10 800LVT 9 500 10 800 13 600LVT 10 560 13 600 17 000LVT 11 630 17 400 21 800LVT 12 710 22 100 28 700LVT 13 800 28 200 35 000LVT 14 900 35 800 44 600LVT 15 1 000 44 300 35 300LVT 16 1 120 56 600 70 600LVT 17 1 250 70 500 88 500

Main data

37

BLA

DE

AIR

SE

PAR

ATO

R L

VT

Principle of operationThe separator LVT separates coarse and fi ne particles from airfl ow in a lower part of the separator. Material is separated by changing speed and direction of airfl ow by means of regulation fl aps. Air with fi ne particles is sucked by airfl ow through a regulation tube in the separator upper part to a de-dusting device. Separated coarse fractions are returned back to the circuit through a discharge of coarse particles.

The separator is a static machine without a drive and it is fi tted with no apparatus of its own. Some types of separators LVT are equipped with servo drives for turning of blades. It is part of the technological line where under-pressure before and after the separator must be measured. This must be designed in the line project.

Reference

LVT 3600 – Turkey 2 x LVT 5200 – Czechia

38

CA

SC

AD

E A

IR S

EPA

RAT

OR

KV

TCascade Air Separator KVTBasic informationThe air separator KVT is a static cascade separator without a drive that is used especially:

in grinding plants with a semi-fi nish system with pre-grinding circuits fi tted with a roller mill or similar machinery

as an initial stage of separation of grinding plants with a fi nish grinding system fi tted with a roller mill or similar machinery

in circulation grinding plants fi tted with a ball mill or similar machinery for grinding of coarse material to the required fi neness.

The separator KVT is suitable for separation of material of particle size 0 – 5 mm and possibly clinker up to 2 000 Blaine.

Main characteristics No rotating parts Low installation costs Easy maintenance Pressure loss is approx. 50 % in comparison

with dynamic separators Suitable for high outputs using loading of

material up to 4 kg/m3

Separated material can be effectively dried or cooled

Suitable for abrasive materials Wear parts are effectively protected against

wear and they are easily exchangeable De-agglomeration of pieces

Main data

Type Amount of inlet Air amount

[t/h] [m3/h]KVT 300 40 12 000KVT 400 70 20 000KVT 500 100 28 000KVT 600 140 40 000KVT 700 170 50 000KVT 800 200 60 000KVT 900 240 70 000KVT 1000 280 85 000KVT 1100 330 100 000KVT 1200 360 110 000KVT 1300 390 120 000

Type Amount of inlet Air amount

[t/h] [m3/h]KVT 1400 420 130 000KVT 1600 500 160 000KVT 1800 600 180 000KVT 2000 670 200 000KVT 2200 740 220 000KVT 2400 800 240 000KVT 2600 870 260 000KVT 2800 940 280 000KVT 3000 1 000 300 000KVT 3300 1 100 325 000KVT 3600 1 200 350 000

39

CA

SC

AD

E A

IR S

EPA

RAT

OR

KV

T

Principle of operationThe material is supplied to the separator central part and falls down through a material inlet where it bumps into cascade partitions. In bumping, lumps and bigger pieces of material are de-agglomerated. The fi ne fraction is caught by gas and taken out through an outlet part while the coarse fraction continues downwards between partitions where it is de-agglomerated to smaller particles.The fi ne material and gas are brought from the outlet segment upper part to cyclones or separator where fi ne particles are separated from airfl ow. The coarse fraction is collected in a discharging hopper in the separator lower part from where it is returned for further processing. Separation is controlled by regulating the fl owing air amount and by adjusting angles of inlet and outlet blades. The material can be dried or cooled in the process of separation.

Reference

KVT 2400 – Slovakia KVT 1800 – China

KVT 300 – Czechia

40

Basic informationThe cooler CHC is used for indirect cooling of material ground to dust particles (e.g. cement and other non-sticking dust materials) by means of cooling water. Service water or water treated from natural resources is used for cooling.

The cooler is especially positioned behind a grinding line (e.g. cement grinding line etc.) before a dispatch storage of a fi nal product (silos, bins, etc.).

Main characteristics

Simple design and reliability Long service life Easy maintenance Low operating costs

CE

ME

NT

CO

OLE

R C

HC

Cement Cooler CHC

Type Dia. Casing height

Cooling area Output Drive

[m] [m] [m2] [t/h] [kW]CHC 1500 1,5 4,25 20 30 30CHC 2200 2,2 5,25 36 70 55CHC 2700 2,7 6,5 55 120 75CHC 3300 3,3 8,5 88 180 110

Main data

Principle of operationThe material is supplied through a lower tube to the casing inner area (cooler casing is positioned in the vertical position) where it is lifted up to a discharge tube by means of a rotating screw. Cooling water is supplied by a distributing piping with regulation valves to a spraying head positioned up on the casing. Water fl ows downwards on the casing outer surface into a collecting tub and so it cools the casing surface. The material is cooled so that heat is transferred through the cooler casing. Manholes in the casing upper cover and in the casing lower part are used for checking and cleaning of the cooler inner area. The cooler drive that drives a rotor with the screw is fi xed on an anchoring frame in the lower part. The cooler works without an operator and it is controlled by the central control system.

41

CE

ME

NT

CO

OLE

R C

HC

Reference

CHC 3300 – Czechia

CHC 2700 – Chile

CHC 2700 – Czechia

42

CycloneThe cyclone is a simple mechanical device. It is mainly used in the cement industry in grinding plants of cement and cement material as a process equipment processing large-volume amount of air of high dust content. The cyclone often used as the fi rst stage of de-dusting is capable to separate more than 80 % of particles bigger than 20 μm in average. Smaller particles that are not collected by the cyclone are then collected in more effi cient devices such as cloth bag fi lters or el. fi lters.

There are no movable parts in the cyclone. Its operation is easy with almost zero costs for maintenance.

AU

XIL

IAR

Y E

QU

IPM

EN

T

Screw Conveyor and FeederThe screw conveyor is used for a horizontal transport of powdered and fi ne-grained materials. It is used for materials of grain size 0 to 30 mm and the grain size distribution is usual for products of grinding and milling devices. The material transported must not be sticky, moisture of powdered materials should not exceed 1 % H2O, of grained materials 5 % H2O. When there is a portion of clay admixtures, moisture admissible is max. 3 % H2O. Temperature of the transported material is up to +200 °C.

The screw feeder is used for continuous feeding of powdered and fi ne-grained materials of a constant transporting amount. Materials are transported solely horizontally. If needed it is used as an air closure.

43

AU

XIL

IAR

Y E

QU

IPM

EN

T

Rotary FeederThe rotary feeder is used for an even feeding and possibly dosing of dry, loose materials that do not make clusters. The maximum grain size supplied is 5 mm. The maximum temperature of material supplied is 180 °C (for a short time up to 200 °C). The maximum admissible over-pressure on the rotor blade is 60 kPa. The real operation fi lling ranges between 70 to 85 % according to the grain size and physical properties of the material supplied. The rotary feeder drive consists of an el. motor with a frequency converter.

Mechanical Double FlapThe mechanical double fl ap is a device being used as a closure. It lets material into the working area and at the same time it prevents leakage of the transporting or drying medium. It is fi tted with two pairs of closing fl aps driven by a fl ange el. gearbox.

Table FeederThe table feeder is used for feeding of loose and fi ne-grained materials. It divides areas of different pressure. Amount of the material supplied can be changed by hand adjustment of a telescopic chute and scraper. According to the drive used, amount of the material supplied can be changed by changing rotations of the feeding plate either in place or remotely.

Swinging FlapThe swinging fl ap prevents suction of false air into the grinding circuit. It is especially positioned under an air-technical unit (mill, separator) or device (cyclone, fi lter) at the material outlet of these. The swinging fl ap can be either a one-blade or double-blade one. Safety operation and easy maintenance are the advantages of these swinging fl aps because they work without any drive on a principle of gravity.

44

APPL

ICAT

ION

OF M

ACHI

NES

AND

EQUI

PMEN

T IN

PRA

CTIC

E

Example 2The technological arrangement of the vertical mill KTM in the pneumatic circuit where the material is separated in cyclones and while it can be dried simultaneously. This alternative is suitable for mean fi neness of grinding while it is possible to save investment costs – installation of cyclones and smaller de-dusting fi lter rather than one big process fi lter.

Application of Machines and Equipment in Practice Example 1The technological arrangement of the vertical mill KTM in the pneumatic circuit where the material is separated in the process fi lter while it can be dried simultaneously. This alternative is suitable for grinding of products of high fi nal fi neness.

45

APPL

ICAT

ION

OF M

ACHI

NES

AND

EQUI

PMEN

T IN

PRA

CTIC

E

Example 3The technological arrangement of the grinding plant with the ball mill incl. pre-grinding in the roller mill Premill.

Example 4The technological arrangement of the raw material grinding plant with the ball mill incl. pre-grinding circuit fi tted with the roller mill Premill and separation in the separator LTR.

46

Example 5The technological arrangement of the mechanical grinding plant of cement with the ball mill BM, separator VTP, cyclones, de-dusting fi lter and fan.

Example 6The technological arrangement of the pneumatic grinding plant with the ball mill BM, separator LTR, cyclones and process fi lter.

APPL

ICAT

ION

OF M

ACHI

NES

AND

EQUI

PMEN

T IN

PRA

CTIC

E

Company and location:

Address:

Contacts: tel. / fax: e-mail:

SITE CONDITIONSCountry, destination: Elevation above sea level [m]:Ambient temperature [°C]: minimum .......... / maximum .......... / average ..........

REQUIREMENTS FOR PRODUCTProduction [t/h]: Temperature [°C]: Moisture [%]:Fineness, granulometry: (even using any defi nition)

PARAMETERS OF FEED MATERIALKind of material: Moisture [%]: Temperature [°C]:Grain size [mm]: minimum .......... / maximum .......... / medium .......... Specifi c density [kg/m3]:Bulk density [kg/m3]:Grindability: Hardgrove .......... / Bond Work Index [kWh/t] .......... / VTI .......... Abrasiveness:

OTHER INFORMATION:Kind of drying gas: combustion chamber / waste air from kiln / waste air from cooler Temperature of drying gas [°C]:etc.

Date: Signature:

This

form

is u

sed

for t

he s

pecifi c

atio

n of

bas

ic c

usto

mer

’s d

ata

for t

he q

uota

tion

of P

SP

Eng

inee

ring

to b

e el

abor

ated

.P

leas

e, c

opy

this

form

, fi ll

in th

e re

quire

d da

ta a

nd s

end

to th

e ad

dres

s or

its

scan

via

e-m

ail s

tate

d be

low

. Tha

nk y

ou.

Contact: PSP Engineering a. s., Kojetínská 3186/79, Přerov I. – Město, 750 02 PřerovCzech Republic tel.: +420 581 232 555, fax.: +420 581 232 905

e-mail: info@pspeng.cz

EN

QU

IRY

FOR

M

PSP Engineering a.s.Kojetínská 3186/79 Přerov I.- Město750 02 PřerovCzech RepublicTel.: +420 581 232 555Fax.: +420 581 232 905E-mail: info@pspeng.czwww.pspeng.com