loesche technical seminar_apr-15

Convening

Networking

Sharing knowledge

Technical Seminar Jakarta 2015

Jakarta, Indonesia, 21 - 23 April, 2015

Proceedings

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Final programme

21 April 2015

19:00 - 22:00 Informal get-together at Hotel Le Mridien Jakarta

22 April 2015 Technical Seminar at Hotel Le Mridien

08:30 - 09:00 Registration open: Coffee and networking

09:00 - 09.15 Welcome addressHendra Tjhai, Detlef Bluemke, PT Loesche Indonesia

09:15 - 09:30 Meet the delegates - Introduce yourself to the audience

09:30 - 10:30 Loesche vertical roller mills: State-of-the-art comminutionDetlef Bluemke, PT Loesche Indonesia

10:30 - 10:45 Coffee and networking

10:45 - 12:00 Process, operation & evaluation of Loesche grinding systemsChristian-Martin Ruthenberg, Loesche GmbH, Germany

12:00 - 13:00 Lunch and networking

13:00 - 14:00 Preventive maintenance - wear and repairStefan Wlfel, Loesche GmbH, Germany

14:00 - 15:00 Machine monitoringSebastian Muschaweck, Dr. Franz Muschaweck, DALOG Diagnosesysteme GmbH


15:30 - 17:00 World Caf - interactive workshopDr. Regina Krammer, Loesche GmbH, Germany

18:00 Departure from the Le Meridien Hotel to Segara Anchol for dinner

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Final programme

23 April 2015 Technical Seminar at Hotel Le Mridien

09:00 - 09:15 Welcome and summary of day 1Hendra Tjhai, PT Loesche Indonesia

09:15 - 10:15 Process parameters and plant optimisation: False air - often underestimatedChristian-Martin Ruthenberg, Loesche GmbH, Germany


10:30 - 12:00 Grinding aid: Advantages and operation optimisationDr. Pietro Recchi, Mapei

11:45 - 13:00 Lunch and networking

13:00 - 14.00 Lubricants - Functions and the importance of maintenanceMoch Mustofa, PT. Mitra Asmoco Utama

14:00 - 15:00 Pyroprocess evaluation - waste treatment with the new Rocket MillDr. Stefan Kern, A TEC Production & Services GmbH

15:00 - 15:15 Coffee & networking

15:15- 16:30 World Caf - interactive workshopDr. Regina Krammer, Loesche GmbH

16:30 - 17:00 Resumee of the two days and farewell

19:00 Dinner at the Hotel Le Mridien

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Jeane HaroOffice Manager, PT Loesche Indonesia

Main activities: Client relations Marketing Taking care about financial, administrative and

tax matters

email: [email protected]

Hendra TjhaiSales Engineer, PT Loesche Indonesia

Main activities: Client relation Spare part and after sales business Link in between clients in the Asian region and the

Loesche Group Engineering consultancy


Detlef BluemkeManaging Director, PT Loesche Indonesia

Main activities: Longterm experience as commissioning engineer

E,C&I and process worldwide for Loesche Head of Commissioning department and later de-

puty director of Technical Field Service at Loesche Since 2013 Managing Director of PT Loesche

Indonesia


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Christian-Martin RuthenbergTechnical trainer, LOESCHE GmbH, Germany

Main activities: Development of training concepts for customers Process auditing Training on process and operation of LOESCHE

grinding plants


Dr Regina KrammerDeputy Head Training Center, LOESCHE GmbH, Germany

Main activities: Development of blended learning concepts for

internal and external use Design of eLearning courses and computer supported

cooperative learning (CSCL) Knowledge management and communication


Theodora BrunsHead of Training Center, LOESCHE GmbH

Main activities: Development of blended learning concepts for

internal and external use Business development Customer service


In cooperation with LOESCHE Training Center, Germany:

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Lecturers

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Christian-Martin RuthenbergTechnical trainer, LOESCHE GmbH, Germany

Main activities: Development of training concepts for customers Training on process and operation of LOESCHE

grinding plants


Detlef BluemkeManaging Director, PtT Loesche Indonesia

Main activities: Longterm experience as commissioning engineer

E,C&I and process worldwide for Loesche Head of Commissioning department and later

deputy director of Technical Field Service at Loesche Since 2013 Managing Director of PT Loesche

Indonesia


Stefan WlfelHead of Installation, LOESCHE GmbH

Main activities: Worldwide execution of installation activities Management of the installation department of

Loesche GmbH, Germany Strategic development and resource planning of

installation supervisors


Sebastian MuschaweckHead of service, DALOG Diagnosesysteme GmbH

Main activities: Expert in rotating equipment reliability, vibration

analysis, inspection, and maintenance engineering Certified Vibration Analyst Category III Areas of expertise: cement machinery, large

gearboxes and extruder machinery


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Lecturers

Page 8

Dr. Pietro RecchiRegional Technical Manager Asia Pacific, MAPEI

Main activities: 7 years experience in cement additives for Mapei Masters degree in organic chemistry Main focus on providing technical support to our sales force

in the region Directly responsible for cement additives sales in Malaysia


Moch MustafaChief Lube Engineeer, PT. Mitra Asmoco Utama

Main activities: Leader of the engineering division Training for customers on lubrication practices Degree in mechanical engineering, active participant

of MASPI (Masyarakat Pelumas Indonesia) DELTA, WSML, BAT certification from ExxonMobil


Dr. Franz MuschaweckOwner and CEO, DALOG Diagnosesysteme GmbH

Main activities: Founder of DALOG Company Expert in rotating equipment vibration diagnostics,

reliability, trouble shooting, inspection, and maintenance engineering

Ph.D. in vibration diagnostics on gearboxes


Dr. Stefan KernProposal Engineer & Product Manager, A TEC Production & Services GmbH

Main activities: Area Sales Manager Doctoral studies: Chemical Engineering PhD thesis: Co-Gasification of coal and biomass/wastes in a

dual fluidized bed gasification system.


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About LOESCHE

Since 1906, LOESCHE GmbH has been constructing vertical roller grinding mills. Patented in 1928, our roller grinding mill technology has been continu-ally advanced and in the meantime is synonymous with LOESCHE GmbH.

The key competence of the company is the design and development of indi-vidual concepts for grinding and drying plants for the cement, steel and iron, power, ores and minerals industry. The service portfolio ranges from first con-cept to commissioning augmented by maintenance, repair, training as well as modernization of grinding plants and spare parts activities.

In April 2012, LOESCHE GmbH, Germany, has entered into a close coopera-tion agreement with pyroprocess specialist A TEC Holding GmbH, Austria. LOESCHE and A TEC will be partners for the realisation of plant improvement projects, environmental projects and will be in the position to offer complete process solutions.

Having taken over the specialised department Combustion Technology of UCON AG Containersysteme KG, Gelsenkirchen, in April 2012, LOESCHE offers thermal process technological solutions, thus covering another field of activi-ties with related products e.g. industrial burners and hot gas generators.

LOESCHE is a privately owned company with its headquarter located in Dusseldorf, Germany and is represented worldwide with more than 850 em-ployees, subsidiaries in the USA, Brazil, Spain, Great Britain, South Africa, India, United Arab Emirates, Indonesia, Russia and P.R. China as well as agents in more than 20 countries.

The LOESCHE Training Center was founded in 2008. A young, innovative team of editors, eLearning authors and technical trainers drafts and creates train-ings and eLearning courses, documents and manuals in accordance with the latest media-didactic principles, tailored to the needs and requirements of the customers.

When communicating learning content about all matters pertaining to LOESCHE technology the Training Center uses the principle of integrated learning (Blended Learning Concept) with the aid of the latest learning meth-ods and media. It combines online courses which are not tied to a specific time and place with traditional attending teaching and seminars in order to consolidate the knowledge so imparted in the best manner possible and with lasting effect.

For more information please refer to: www.loesche.com

LOESCHE GmbHHansaallee 243

D-40549 DuesseldorfTel.: +49-211-5353-0

Fax: +49-211-5353-500

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Detlef Blmke, Managing DirectorPT LOESCHE Indonesia


LOESCHE vertical roller mills State-of-the-art comminution

by Detlef Bluemke, PT Loesche Indonesia

Loesche vertical roller mills:State-of-the-art comminution

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3Technical Seminar Jakarta 2015 Loesche vertical roller mills_State-of-the-art comminution_Rev.A

Introduction

LOESCHE GmbH is a privately owned company founded 1906 in Berlin, Germany

Certified according to DIN EN ISO 9001 Main shareholder: Dr. Thomas Loesche Management: Dr. Thomas Loesche,

Dr. Joachim Kirchmann Rdiger Zerbe

Employees in Dsseldorf: 370 Employees worldwide: 958 Turnover 2014: Euro 500 millions worldwide

LOESCHE in brief


Table of contents

Introduction

Loesche vertical roller mill for cement grinding

Some comments on grindability

State-of-the-art cement grinding plant

Summary/Conclusions

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31 representative offices worldwide

Introduction


America

LOESCHE Equipamentos Ltda.Rio de Janeiro, Brazil

LOESCHE America, Inc.Pembroke Pines, Florida, USA

Europe

LOESCHE Energy SystemsHorsham, UK

LOESCHE Latinoamericana S. A.Madrid, Spain

LOESCHE GmbH (Head Office)Dsseldorf, Germany

LOESCHE Automatisierungs-technik GmbHLnen, Germany

LOESCHE ThermoProzess GmbHGelsenkirchen, Germany

LOESCHE OOOMoscow, Russia

Africa

LOESCHE South Africa (Pty.) Ltd.JohannesburgSouth Africa

LOESCHE Nigeria Ltd.Ibese, (Lagos) Nigeria

Asia

LOESCHE Middle EastTehran Branch OfficeTehran, Iran

LOESCHE Middle East FZEDubai, UAE

LOESCHEIndia (Pvt.) Ltd.New Delhi, India

LOESCHE Mills Ltd.Shanghai & Beijing, PRC

LOESCHE VietnamHo Chi Minh City, Viet Nam

~ 800 employees at 15 Loesche subsidiaries worldwide

PT Loesche IndonesiaJakarta, Indonesia

Introduction

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Material flow, feed materials, products

Introduction


America

A TEC Greco Projetos e Equipamentos LtdaSao Paulo, Brazil

Austria TEC S.A.de C.V. Puebla, Mexico

Europe

A TEC Sales Office Branch Poland Chelm, Poland

Greco Combustion Systems Europe GmbHKrems, Austria

A TEC Production & Services GmbH Gdersdorf/Krems, Austria

A TEC Plant Construction GmbH Eberstein, Austria

Asia

Sales & ConsultingA TEC Iraq OfficeErbil, Iraq

A TEC Asia Sdn. Bhd. Kuala Lumpur, MalaysiaA TEC Technology Services (Beijing), Co., Ltd. Beijing, China

~ 100 employees at 11 Loesche stakes worldwide

A TEC Group, Austria Aixprocess GmbH, Germany

Europe

Aixergee GmbHAachen, GermanyAixenviro GbrAachen, Germany

Aixprocess GmbHAachen, Germany

Introduction

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Cement grinding

Quarry Raw meal/Coalgrinding

Kiln Cement

Cement grinding as part of the process



Table of contents

Introduction




Summary/Conclusions

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Raw materialFly ashExternal material recirculation systemMetalProductGas flow

Material and gas flow of a clinker/slag grinding plant



1) Rotary feeder2) Mill table with grinding track3) Master roller4) Support roller5) Rocker arm6) Hydro-pneumatic spring system7) Bevel-planetary-gear box8) Electric motor9) Gas inlet10) Ring duct11) Louvre ring12) Classifier13) Grit cone14) Outlet duct to dedusting system

Working principle


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Grindability is the resistance of a material against the forces acting upon it during the grinding process usually given as specific energy consumptions (kWh/t)

Common grindability tests Zeisel Bond Grinding tests of machinery suppliers and cement manufacturers

Definition and common tests



Table of contents

Introduction




Summary/Conclusions

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LOESCHE grindability factors (MF, LF)

spec. energy consumption wear factor (vp)

The factors are used to determine the right mill and gear box size as well as asuitable material for the wear parts.

Loesche grindability test (2)



Flow sheet LM 3,6Laboratory mill LM 3,6

Loesche grindability test (1)


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Source: http://booksite.elsevier.com/samplechapters/9780750651035/9780750651035.PDF (2015-03-23)

100 um

belite

alitealite

Comminution process (2)



multiple material layers compressive and shear forces acting upon the particles crack initiation at weakest point of structure crack propagation perpendicular to lowest level of compressive forces

roller

grinding table



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phot

omic

rogr

aph

of c

linke

r; ni

tal e

tch

(Cam

pbel

l 199

9)

100 um

C4AFC3A

phot

omic

rogr

aph

of c

linke

r; ni

tal o

n K

HO

etc

h (C

ampb

ell 1

999)

100 um

belite

alitealite

belite

microcracks




100 um

belite

alitealite



Source: http://booksite.elsevier.com/samplechapters/9780750651035/9780750651035.PDF (2015-03-23)

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mineralogical composition (Vol. %) mechanical strength of minerals spatial distribution grain size, grain shape flaws in crystal lattice

from Siegesmund et al. (2010)

pore space geometry, spatial distribution open microcracks, grain boundaries porosity

Classification of microcracks

intra- inter- trans-granular

Influencing parameters



* SEM photographs clinker fracture surface (Campbell 1999)

euhedral alite in void

20 um 20 um

40 umfracture surface,

hard to grind clinker

alite belite

C4AF



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Lime Saturation Factor (LSF)The Lime Saturation Factor is a ratio of CaO to the other three main oxides. Applied to clinker, it is calculated as:

LSF=CaO/(2.8SiO2 + 1.2Al2O3 + 0.65Fe2O3)

Often, this is referred to as a percentage and therefore multiplied by 100.

The LSF controls the ratio of alite to belite in the clinker. A clinker with a higher LSF will have a higher proportion of alite to belite than will a clinker with a low LSF.

Typical LSF values in modern clinkers are 0.92-0.98, or 92%-98%.

Clinker microstructure



Clinker exhibits a wide range of compositions, microstructuresand physical properties C3S, C2S, C4AF, C3A contents mechanical properties of individual clinker minerals spatial distribution of minerals grain size, grain shape porosity microcracks

100 um

belite

alite

belite

200 um

alite

alite

belite200 um

alite

belite

200 um



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5 15 25 35 45

power consumption - mill [kWh/t]

Range of clinker grindabilities



Silica Ratio (SR)The Silica Ratio (also known as the Silica Modulus) is defined as: SR = SiO2/(Al2O3 + Fe2O3) A high silica ratio means that more calcium silicates are present in the clinker and

less aluminate and ferrite. SR is typically between 2.0 and 3.0.



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Table of contents

Introduction




Summary/Conclusions


Basically clinker grindability can be assessed by analysing the mineralogical composition and the clinker microstructure, however quantification bears many difficulties

The following general relationships can be used to qualitatively determine the clinker grindability

C3S content high good grindability C2S content high poor grindability grain size of C3S, C2S high poor grindability C2S clusters abundant poor grindability abundance of intragranular microcracks good grindability

Source: Hills, Linda M., Clinker Microstructure and Grindability: Updated Literature Review, SN2967,Portland Cement Association, Skokie, Illinois, USA, 2007, 15 pages.

Quantification of clinker grindability


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LM (2+2/3+3) withmodified s-rollers

Waste heat recovery systemfor slag grinding

LDC classifier with Vortex RectifierCompact design

General concept



Operational costs consumption of water, grinding aid fuel consumption (HGG) specific electrical energy consumption

Environmental impact consumption of resources (e.g. energy, water) emissions (e.g. CO2, NOx, dust)

Flexibility of the grinding system wide range of feed materials desired (blended cements) wide range of product finenesses high Blaine products

Investment costs (CAPEX)

Main aims


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Loesches green cement grinding plantCompact plant design comparison view 2



Loesches green cement grinding plantCompact plant design comparison view 1


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Source: A. Wolter (2010); TU Clausthal

Cement types produced in Loesche VRMs products according to EN 197-1 (2)



the cements are produced at various fineness's actual number of products much higher

(products ground without Loesche having operational data)

Flexibility


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Particle trajectories onto mill table are influenced by: centrifugal force friction between particle and mill table friction between particle and particle size and shape of particles

Standard position of S-roller

S-roller position (1)



LM 56.3+3 grinding efficiency


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Production values of LM 56.3+3 CS after installation of new S-rollers

Increase of through-put

Reduction inenergy consumption

-11,12%

8,21%

-7,17%

5,84%AV-Produkt BLL-Produkt

Clinker 82%Gypsum Type I(natural) 4%Limestone 7%Fly ash 7%

Clinker 65%Gypsum Type I(natural) 5%Limestone 25%Fly ash 5%

Increase of through-put

Energy savings - total

-25,00% -20,00% -15,00% -10,00% -5,00% 0,00% 5,00% 10,00%

CEM II/ A-L CEM II/ B-L

Low specific energy consumption due to S-roller position



Standard position of S-rollerChanged position of S-roller

Advantages better guidance of de-aerated material to M-rollers reduced level of mill vibration reduced amount of water for grinding bed formation increased through-put reduced specific power consumption

S-roller position (2)


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low dp leading to a reduced specificenergy consumption

LM 56.3+3 with LDC classifier


Vortex Rectifier

Rotor

Grit cone


Smooth operation and better material guideance


Production values of LM 56.3+3 CS after installation of new S-rollers

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Conventional design high velocity differences

LDC (new design) homogeneous velocity distribution

LDC classifier Vortex Rectifier (2)


Pathlines colored by velocity magniture (m/s) Pathlines colored by velocity magniture (m/s)


worldwide patented Vortex Rectifier vortex kinetic energy recuperation restores a linear flow in the ductwork

LDC classifier Vortex Rectifier (1)


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LDC classifier with Vortex Rectifier

Waste heat recovery systemfor slag grinding

~ 4-8% lowerEspec

~ 5-7% lowerEspec

reduced CAPEX

reduced thermal energy consumption

Compact design

LM (2+2/3+3) withmodified s-rollers

Features and achievements



Low specific energy consumption due to Vortex Rectifier


Central Europe LM 46.2+2

Product GGBS CEM I CEM II/B-M

Mill through-put (t/h) ~ 120 ~ 125 ~ 155Fineness (Blaine) 4100 4000 3400

spec. energy consumption

fan (kWh/t) 4.0 - 4.8 4.5 - 5.5 3.8 - 4.3total (kWh/t)

(mill, fan, classifier) 26 27 25 - 26 20 - 21

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Table of contents

Introduction




Cement types produced in Loesche VRMs

Summary/Conclusions


Environmental impact consumption of resources (e.g. energy, water) emissions (e.g. CO2, NOx)

Operational costs consumption of water, grinding aid fuel consumption (HGG) specific electrical energy consumption

Flexibility of the grinding system wide range of feed materials desired (blended cements) wide range of product finenesses high Blaine products

Investment costs (CAPEX)

Yes

Yes

Yes

Yes

as green as cement grinding can be


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State-of-the-artcement grinding plant

Presented byDetlef Blmke

PT Loesche [email protected]

www.loesche.com


Water and energy are the basis for life and the world as we know it today water as well as energy are not available unlimited both resources will become scarce and more expensive

Consequently saving energy and water is essential for ecologically and economically viable production - also or in particular in the cement industry

Preventive Maintenance and observation of operation behaviour is a must to keep grinding systems performing most efficient with the minimum waste of energy and resources

Water and energy precious resources


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Process, operation & evaluation of LOESCHE grinding systems

Ch.-M. Ruthenberg, Technical TrainerCorporate Service/Training Center Dept., LOESCHE GmbH


by Christian-Martin Ruthenberg, Loesche GmbH, Germany

Process, operation & evaluation of Loesche grinding systems

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3Technical Seminar Jakarta 2015 - Process, operation & evaluation_Rev.A

LOESCHE VRMs are mainly used in: Cement industry Coal fired power plants Iron making plants with blast furnace injection/ PCI (pulverised coal injection) Minerals and ore industry

Different LOESCHE mill types

Range of application

Clinker & slag millRaw material mill Coal/petcoke mill Mineral mill


Agenda


Processes inside a mill

Different process circuits

Control values

Evaluation of performance

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Differences

Feed material Moisture content Grain size distribution Flow characteristics Grindability


Illustration extract out of DWG 935021-00-3 LM 69.6 RM



Mill structure: LM 56.4 RM with LSKS 88

88

56 .4

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Agenda




Control values




Illustration extract out of DWG 935021-00-3 LM 69.6 RM

Differences

Machine Grinding force (according to grindability) Table speed (centrifugal force) Dam ring (grinding bed) S-rollers (deaeration) Louvre and armour ring (drying)

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Agenda




Control values



The LOESCHE VRM combines

Grinding mill drive, gearbox, table and

rollers

Drying Hot gas source: HGG, cooler, gas

pre-heater

Transportation Gas flow introduced by fan

Classifying LDC / LSKS

in one machine.

Classifying

GrindingDrying

Transportation

Clinker/slag mill


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Coal grinding plant with external inert gas source

Process circuits


Raw meal grinding plant

Process circuits

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Agenda




Control values



Damper Z1(Fresh air)

Damper R(Recirculation)

Damper S(Stack)

Hot gas generator

Process circuitsClinker/slag grinding plant

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Clinker/slag grinding plant

Mill differential pressure



Damper S(Stack)

Hot gas generator



Mill inlet pressure



Damper S(Stack)

Hot gas generator

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Damper S(Stack)

Hot gas generator


Process gas flow




Damper S(Stack)

Hot gas generator


Mill outlet temperature

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Agenda




Control values



Control Values

Raw material Coal Clinker

Inlet pressure

Differential pressure -

Outlet temperature

Gas flow

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Process evaluation



Damper S(Stack)

Hot gas generator



Construction


Commissioning Optimisation Performance Run

Operation

Improvements(according torequirements)

Audit Assessment

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23Technical Seminar Jakarta 2015 - Process, operation & evaluation_Rev.A22Technical Seminar Jakarta 2015 - Process, operation & evaluation_Rev.A

Summary

Different LOESCHE mill types Raw material, coal and clinker/slag mill

Processes inside a mill Grinding, drying, transport and classifying

Different process circuits Raw material, coal and clinker/slag mill

Control values Inlet pressure, differential pressure, outlet temperature and gas volume

Evaluation of performance Operation, audits and required improvements Essential knowledge of system, process and relations

Thank you for your attention

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Preventive maintenance Wear & repair

Stefan Wlfel, Head of Installation DepartmentLoesche GmbH


by Stefan Wlfel, Loesche GmbH, Germany

Preventive Maintenance - Wear and repair

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3Wear and repair Technical Seminar 2013 Rev.1

This presentation

gives you a guidance for problems encountered. helps you in order to plan your maintenance and conduct preventive

maintenance.

Therefore all companies have to find a way in coping with downtimesand scheduled maintenance intervalls.


Agenda

Main assembly groupsOverviewMill standTableM-Rocker arm/M-Rocker arm bearingM-Roller/M-Roller bearingS-RollerLever sealingSpring assemblyCabinetsN2 accumulatorsSwinging out rollersGrinding partsRecording wear of grinding partsHard facing of grinding partsMill driveClassifier/Classifier driveAuxiliarie parts

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5Q.. en Maintenance Rev.A

Visual check:

condition of bolts of bearingcaps

condition of weldings oil accumulations on

concrete foundation

condition of anchor bolts condition of gearbox

attachment bolts

Interval: weekly

Mill stand

Variant 1Superboltsystem

Variant 2Hydraulic tensionsystem

Illustration


Overview

M-RollerM-Rocker arm

Table

M-Spring assembly

Mill stand

Mill body incl. lining

Sealing airS-Spring assembly

S-Rocker arm

S-Roller

Mill gearbox

Mill drive

Example of aLOESCHE Mill LM 3+3

Illustration

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Visual check: axial bearing screws grease pipeline connections

Maintenance: change wear rings of sealing air

assembly check bearing clearance change bearings

Interval: visual check weekly

Maintenance: check bearings yearly check sealing air gap in 6 month shift interval according to the

specific wear behavior of themill

M-Rocker arm

Illustration


Visual checkcondition of: dam ring louvre- and armour ring clamping ring scrapers

Maintenance: repair by fill-up welding

and hard-facing replace worn parts

Interval: check wear monthly shift interval according to the specific

wear behaviour of the mill

Table

Illustration

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Visual check: attachment bolts of roller axle and tire wear of guard oil leakages

Maintenance: change wear rings of sealing air assembly change slip ring seal change worn wear parts clean air filter take oil samples for analysis


Maintenance: oil analysis every 3500 h change slip ring seal after 15000 h shift interval according to the specific wear

behavior of the mill

M-Roller

Illustration


M-Rocker arm bearing

Maintenance: change bearings

Interval: change bearing after 30000 h shift interval according to the specific

wear behavior of the mill.

Rebuilding of bearing seats is possible but not required, if bearings are replaced in good time

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Visual check: attachment bolts of roller axle and tire wear of guard oil leakages

Maintenance: change wear rings of sealing air assembly change slip ring seal change worn wear parts clean air filter take oil samples for analysis

Interval:visual check weeklyMaintenance:oil analysis every 3500 hchange slip ring seal after 15000 hshift interval according to the specific wearbehavior of the mill

S-Roller

Illustration


Maintenance: change bearings

Interval: change bearings after 30000 h Shift interval according to the specific

wear behavior of the mill

M-Roller bearing

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Spring assembly M-Roller

Spring assembly S-Roller

Visual check: attachment of clamping nuts grease connections condition of buffers condition of hyd. connections oil leakages condition of bellows condition of hyd. cylinders

Maintenance: change stop-plates of buffers change bellows check bearing clearance change gaskets of hyd. cylinders


Maintenance: shift interval according to the

specific wear behavior of the mill

Spring assembly

Illustration


M-Lever sealingVisual check: attachment bolts of lever sealing parts wear of lever sealing parts proper adjustment of gaskets and bellows

Maintenance: change worn parts


Maintenance: change worn parts according

actual wear shift interval according to the

specific wear behavior of themill

S-Lever sealing

Lever sealing

Components of M-Lever sealing

Illustration

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Filling valvePiston

accumulatorBladderaccumulator

Visual check: corrosion, damages on accumulators proper fixation of accumulators proper attachment of valve protection caps oil leakages

Maintenance: check nitrogen-pressure of all accumulators check proper attachment of valves change bladders, gaskets pressure tests acc. pressure-vessel regulations


Maintenance: check nitrogen pressure once a week,

if no pressure loss, check every 4 months,if no pressure drop check yearly

N2 accumulators

Oil

N2

Illustration


Visual check: oil levels oil flow (HSMS) oil leakages on cabinets and pipelines discoloration of oil

Maintenance: change oil filters, air filters change oil clean tank take oil samples for analysis

Interval: visual check daily

Maintenance: oil analysis every 3500 h refer to lubrication instructions

HSLM HSMS

HSSW

Typical pipe-connector

Cabinets

Illustration

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Typical wear pattern

Grinding parts

Visual check: check wear of tires with tire profile ruler check wear of grinding plate

Maintenance: change grinding parts welding of worn out sections of tires, grinding plant

and wear rings of dam ring

Interval: check wear monthly shift interval according to the specific wear

behavior of the mill

Grinding plate

Support

LevelTire profile ruler

Roller

approx.10mm


Taper pin connection

Swinging-out device

Flanged sleeve

Swinging out rollers

Visual check: check completeness and function of all

auxilliary parts Swing-out cylinder to be stored vertically

Maintenance:(prior to use of auxiliary parts): change oil bleed off air of swing-out cylinder clean tank

Important:Proper dismounting and mounting of taper pin-and flanged sleeve connectionof rocker arm-fork connection

Interval: Visual check: Prior to using auxilliary parts

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Wear on grit cone supports

Example to the right: The grit cone supporting tubes

show wear in the top part. There are 8 supporting tubes.

Only the four ones above the rollers show wear.


Wear on grit cone

Example to the right: Grit cone shows wear on two levels in front of

each roller. Wear positions and shapes are similar.

The top level wear is in the axis of each roller. The bottom level wear is about 50 cm ahead. End user didn't allow SINOMA to patch the

holes, as LOESCHE recommended.

Every time you have the chance of lookinginto the mill internals, you should check all parts in regards to wear (especially for theclassifier, louvre and amour ring, tires, andtable liners).

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Wear on guide vanes


Wear on rotor, guide vanes, and static guide vanes

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Wear on fixation pipes


Wear on guide vanes

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Wear on lever sealing

Examples to the right: The vertical lever sealing plates

show some wear. Vertical plates in front of the rollers

are worn on the upper part. Vertical plates behind the rollers are

worn in the lower part. The horizontal plates above roller

shaft show wear on the side in front of the roller.


Wear on mill body armour plates

Example to the right: The mill body armour

plates show wear on the welding openings, especially above 2m between the rollers.

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Wear on roller

Example to the right: Abnormal wear is observed at one

position on roller 1. During commissioning, the roller n1

faced some problems to turn freely, then rotation was better after the first maintenance.

Leading the roller to slip on the grinding bed always in the same angular position: the most likely cause of local wear.

Other rollers and other parts of roller 1 show normal shaped wear.


Wear on louvre ring

Examples to the right: Louvres in the area just behind the

rollers show significant wear. The wear is more distinct on the

external side. The wear in the remaining part of

the louvre ring is low.

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Hard-facing of grinding parts

Hard-facing of tires in situ (On site)


Recording wear of grinding partsZero measurement / wear measurementExample of recording measurements (zero measurement or wear measurement) of tire:

Example of recording measurements (zero measurement or wear measurement) of grinding plate:

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Flaps / guide vanes

Rotor blades

Separation gap

Visual check: check for proper attachment of bolts check for wear

Maintenance: replace worn parts repair worn parts by fill-up welding

Interval:Visual check weekly

Maintenance:Shift interval according to the specificwear behaviour of the mill

Classifier

Classifier drive

Classifier housing

Static flaps

Classifier rotor

Classifier grid cone

Top view

Illustration

LSKS


Visual check: abnormal noise during operation oil levels oil leakages

Maintenance: change, clean oil filters, air filters change oil take oil samples for analysis check coupling alignment check (change) compression parts of

coupling

Interval:Visual check daily

Maintenance:oil analysis every 1000 hrefer to lubrication instructions

Typical arrangement

Typical gearbox Typical lubrication unit

Typical coupling

Mill drive

Condition of gearbox attachment bolts

Illustration

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Auxiliary partsMain auxiliary parts:

(see also Swinging out device)

Auxiliary parts for table

Auxiliary parts for M-roller

Eye bolt

Cylinder

Lifter

Auxiliary parts for S-roller

Illustration

Hydraulic jack

Table support


Visual check: check for proper fixation of gearbox

and motor check oil level check for oil leakages check grease pipeline connections

Maintenance: change oil take oil samples for analysis check coupling alignment check (change) compression parts

of couplings

Oil analysis every 3500 hRefer to lubrication instructions

Classifier drive

Illustration

LSKS

Bearing cartridge

Classifier drive

Classifier

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Confidential. DALOG reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on the third parties.

More than just conventional Condition Monitoring Dr. Franz Muschaweck Sebastian Muschaweck

Certified ISO 9001: 2000 With product development

Technical Seminar Jakarta 2015 Jakarta, Indonesia, 21 23 April 2015

by Dr. Franz Muschaweck& Sebastian Muschaweck, DALOG Diagnosesysteme GmbH

More than just conventional Condition Monitoring

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DALOG Products and Services

Development of systems for

Precision Maintenance Avoiding machine failures by knowing the machine dynamic and therefore working towards a smoother operation.

Preventive Maintenance Unexpected machine failures should be reduced. Predictive Maintenance Condition Based Monitoring Knowing the health of your Machine at any time.


DALOG Diagnosesysteme GmbH

Since 2006 Representative Office Beijing, China Since 2012 Sales Office Coimbatore, India

Founded: 1998

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DALOG Applications World Wide


DALOG Products and Services

Vibrations and high Dynamic is a symptom the aim is to find the root cause for having a longer life cycle of the machines

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Stable Operation with DALOG Machine Protection Concept

High Dynamic Production FACTS!

Every 3rd VRM Gearbox > 2000 kW fails

60% of the gearboxes fail more than once

90% of the machine owners are not aware of the dynamic of the machine nor that it can be improved (its not healthy)

DALOG VRM Gearbox Facts!


DALOG D-MPC is applicable for:

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9

DALOG Mill Protection Concept D-MPC

Failure prediction!

Failure prevention!


Stable Operation with DALOG Mill Protection Concept

High Dynamic Production

DALOG VRM Chart

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DALOG Planetary bearing fault Planetary bearing fault detected Nov. 2011

Planetary bearing fault repaired March 2012 Bearing fault detected in November

Fault progressing monitored, spare parts and repair planed

Repair was done during annual shut down in march

No loss time and expensive secondary damage

Online Alarm sent to Operator

Alarm level


DALOG Condition Monitoring

Acceleration Sensor

What exactly is condition monitoring?

Early Gearbox failure detection of gears and bearings Planned Maintenance or repair works

Know the status of your machine at any time Avoid expensive secondary damages

Dalog has saved another gearbox in one sold-out market Feedback from our Client

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DALOG Torque Monitoring

Antenna Ring

Antenna Head

Strain Gage

What exactly is torque monitoring?

Early Gearbox failure detection direct measurement High Sensitivity of disturbed/ unstable Process operations instant alarming Detecting of Motor driving faults

Detecting of wear and grinding rollers / table faults

Do you know how your VRM is performing?


Single crack on tooth detected Severe secondary damage

avoided Temporary repair and further

operation Gears will be replaced in

upcoming annual shutdown

DALOG Single tooth crack

Single developing tooth crack

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Torque Sensor High Dynamic Indicating Table Liner Fault

Severe overload of gearbox!

Periodically shocks each of them introduced every time the rollers are passing the cracked table liner

DALOG Case Study VRM - DALOG


...online torque alarms informing the operator in real time about critical machine operation

Warning and Alarming via Torque Sensor

Torque Alarm 1 Torque Alarm 2 Torque Alarm 3 Torque Alarm 4 Torque Alarm 5

DALOG Torque Monitoring Torque Alarms...

High frequency torque measurment captures the dynamic proportion of the system unlike the motor power signal

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DALOG Process Monitoring

Torque Signal

Mill Operation Parameters

What exactly is process monitoring?

Root Cause Analysis Correlation of high resolution data of torque and process signals during high dynamic situations. Longer lifecycle of machine Detecting of Process and operational irregularities

Vibrations and High Dynamic are symptoms find the root cause!


- Reducing the load of the Gearbox due

to early rectification of the problem.

- Increasing the lifecycle of the Gearbox.

Grinding Table Example - Benefits

Early detection of the problem results in:


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Torque Signal before DALOG Monitoring

Torque Signal after Mill optimization

stable operations

unstable operations

DALOG Case Study Process Monitoring


Basic data Mill type Raw mill Mill size 220 t/h Installed motor power 1600 kW Nom. torque 14 kNm

Problem description

During DALOG commissioning it got observed that the mill is showing repetitive vibration patterns during operation.

Therefore unsettled operation combined with many Tdyn (Torque dynamic) and Timpact (Torque impact) alarms

Higher vibration and reduced production rate

18

DALOG Case Study VRM

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DALOG Reporting...

Reporting Independent and Objective Complete Report about the condition of the machine. Findings Conclusions Recommendations Trends, Analyse Statistics: Process stability Long term process trends

Profit from our Experience and Knowledge!


Analysis Torque vs. Mill Operation Parameters in High Resolution


Torque

Mill Feed

Mill DP

Hydraulic Press.

Motor Power

Mill Vibration.

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DALOG Monitoring

DALOG Implementation into the CCR Confidential. DALOG reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on the third parties.

DALOG Monitoring

DALOG Implementation into the CCR

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Our Customers:

DALOG in Cement Plants


DALOG Whats so special about us?

We have more than 200 condition monitoring systems for Vertical Roller Mills installed worldwide

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Thank You!

DALOG Diagnosesysteme GmbH Mhlbachstrae 21 86356 Neus / Germany Phone: +49 (0) 821 74 777 10 Fax: +49 (0) 821 74 777 19 E-Mail: [email protected] www.dalog.net


DALOG Quietly Running Machine

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Process parameters and plant optimization

Ch.-M. Ruthenberg, Technical TrainerCorporate Service/Training Center, Loesche GmbH


by Christian-Martin Ruthenberg, Loesche GmbH, Germany

Process parameters and plant optimization

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3Technical Seminar Jakarta 2015 - Process parameter_Rev.A

Classifying

GrindingDrying

Transportation

Clinker/ slag mill



Agenda


Process Parameters

Dependencies

Examples

Summary

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Flow

Pressure

Temperature

Speed

Constantlycontrolled &

stableConsistent

product


ClassifyingSpeed

GrindingPressure

DryingTemperature

TransportationFlow


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Process Parameters

Flow Material Reject Gas Water (Fuel) Product

Pressure Mill inlet vs. Outlet (dp mill) Filter inlet vs. Outlet (dp filter) Working and counter pressure (grinding force) Compressed air

Temperature Mill outlet gas Material Water Product


Agenda


Process Parameters

Dependencies

Examples

Summary

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Agenda


Process Parameters

Dependencies

Examples

Summary


Process Parameters

Speed and position Roller Classifier Damper Hopper filling

Drives Mill main Classifier Mill main fan

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Agenda


Process Parameters

Dependencies

Examples

Summary


Dependencies

Temperature

Speed

Flow

Pressure

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Examples Feed material change


Examples Filter differential pressure

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Examples scrapper wear


Examples Hopper segregation

Minimum value Max value

Limestone hopper level 6.85 m 10.23 m

Raw mill body vibration 7.81 mm/s 14.24 mm/s

Raw mill motor power 4536 kW 5490 kW

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Examples rotary valve


Examples lovre ring covers

Finding:3,38 m -> 88 m/sDesign:4,79 m -> 61,5 m/s

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Agenda


Process Parameters

Dependencies

Examples

Summary





Damper S(Stack)

Hot gas generator

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21Technical Seminar Jakarta 2015 - Process parameter_Rev.A20Technical Seminar Jakarta 2015 - Process parameter_Rev.A

Summary

Processes inside a mill transport, grinding, drying and classifying

Process parameters flow, pressure, temperature and speed

Dependencies flow, pressure, temperature and speed

Examples high complexity of possible measures


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Loesche Indonesia | VRM Seminar | 22-23 April, 2015

Cement Grinding Additives for Vertical Mills Product characteristics & Industrial case studies

Dr. Pietro Recchi | Regional Technical Manager Asia-Pacific

Grinding aid: Advantages and operation optimization

by Dr. Pietro Recchi, MAPEI

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VRM for cement production - advantages

The key advantages of vertical mills with respect to ball mills can be summed up in the following points: Significantly lower specific energy consumption (kWh/t) (*). One single machine for drying, grinding and separating. Compact and on-site assembling, thus avoiding logistical problems and

related costs. Great versatility, quick shift from one cement type to the other. Lower sensitivity for moisture in the raw materials (if sufficient drying energy is

available). Low noise levels, no housing is theoretically required. (*) for cement grinding, reductions by 30-40% can well be expected.

Vertical Roller Mills (VRMs) for cement production

Thanks to the necessity of continuous improvements in the cement grinding process and related cost reduction, Vertical Mills have been introduced to the cement industry. Although at first this technology was mainly used for grinding solid combustibles and kiln-feeding raw materials, recent technical improvements allowed vertical mills to become a competitive solution for finished cement grinding as well. Most probably, the market share of vertical mills will grow even further, probably becoming the main cement grinding system in new plants. The above statement was Mapeis Cement Additives Divisions vision in 2010.

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Vertical mills and traditional grinding aids

What happens when a traditional GA is used in a cement vertical mill?

Practical field experience has highlighted the fact that traditional grinding additives (GA) are much less efficient in vertical mills when compared with their utilization in ball mills. This loss of performance is caused by the different ventilation conditions inside the VM, which lead to the following problems: Stripping (*) of the GA Evaporation of the GA The two above mentioned issues are caused by the huge airflow and the high temperature. (*) Stripping is a physical process where one (or more) components from a liquid stream are removed by a vapour or vapour-like gaseous stream.

GA PERFORMANCE LOSS!

VRM for cement production disadvantages over BM

Known disadvantages of vertical mills over ball mills are: Particularly high SSA values are usually more challenging to achieve (*). Higher sensitivity for fine materials (the threshold is normally set around a maximum of 50% of material < 4 mm). Large amounts of water may have to be added to the grinding process in order to maintain low levels of vibration (**). An external heat source may be needed to order to ensure a proper gypsum de-hydration (particularly with cold clinker). Higher initial investment costs. (*) The achievable SSA ultimately depend upon a series of factors, among which the clinker mineralogy and microscopic structure is probably the most important one. (**) This is particularly true in case of particularly dusty/fine or over-burnt clinker.

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New formulations: Mapei VM grinding aids

As vertical mills are used more and more often in cement plants, Mapeis R&D developed specific grinding aids designed for this particular application. These products contain a blend of special high-boiling and low-volatility compounds that ensure their effectiveness by protecting traditional components (glycols, amines) from being influenced negatively by the harsh conditions inside vertical mills. This new product line consists of the following product types: Grinding Aids (MA.G.A./VM) Performance Enhancers (MA.P.E./VM) Workability Improvers (MA.P.E./VM W)

VRM and grinding aids: an impossible marriage?

Fortunately not! A synergic approach has been proven able to overcome the stripping and evaporation of the GAs inside vertical mills: New GA formulations, specifically designed for applications in vertical mills Innovative dosing point of GA

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New dosing technology: direct introduction

The grinding aid dosing point plays a crucial role in vertical mills. Therefore Mapei has developed an innovative dosing system that maximises the effect of the GA, avoiding both stripping and evaporation. Usually, vertical mills are equipped with a water introduction system for the stabilisation of the grinding bed: by using the existing pipelines, we can make sure that the grinding aid is forced directly on the track and immediately comes in contact with the surface of the material to be ground.

Mapei VM grinding aids: an overview

MA.G.A./VM MA.P.E./VM MA.P.E./VM W

Typical Dosage 200 500 g/t 700 1,500 g/t 700 1,500 g/t

Mill Output

Strengths

Workability

CO2 reduction

Typical application All cement types Blended cements Blended cements

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New dosing technology: example of actual installation (1)New dosing technology: direct introduction

Water tank

Grinding Aid tank

Water Pump

Additive dosing pump

Fresh feed conveyor (traditional dosing point)

Vertical Mill

Finished product

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Cement Grinding Aids: Mechanism of action (process)

Once properly dosed on the grinding table, the GA is able to swiftly execute its primary task: to neutralize and disperse the electrostatic charges which form on the surface of ground material:

New dosing technology: example of actual installation (2)

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An example of the enhanced separator performance is shown below (Tromp curve):

Blank MA.G.A./VM 10

By pass 15% 9%

Imperfection 0,26 0,16

Acuity limit 18 m 21 m


Neutralization of the electrostatic charges results in a significant de-agglomeration of the ground cement particles; the immediate result is a neat improvement of the classification process by means of the separator. As a consequence, a decrease of the mill p (differential pressure) takes places shortly (within 5-15 min.) after the introduction of grinding aids to the VRM, and is a clear indication that the product is working correctly. Depending on the plant requirements, this decrease of the VRM circulating load can be subsequently used to: A) Increase the fresh feed B) Increase the separator speed C) A combination of the above

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Cement Grinding Aids: Mechanism of action (strengths)

On top of the de-agglomerating effect, certain specific GAs (strength enhancers) also chemically promote the cement hydration process, mainly influencing the first gel phase formation (i.e. aluminate based).

Time (min)

0 10 100 1000C-S-H

DRY CEMENT POWDER

+ H2O

FIRST GEL INTERMEDIATE

PHASE

SECOND GEL

Strengths enhancing

GA


The resulting positive impact on the cements PSD is shown below:

The effect is particularly evident in the 4-30 m range

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Pre-hydration of cement in VRM

A more sophisticated methodology to assess cement pre-hydration is TGA analysis. A sample of cement is heated from room temperature up to 1000C and the decreases of weight (due to release of water or CO2) are measured. It is then possible to quantify the amount of gypsum, calcium hydroxide, limestone, hydrated phases, etc. Hydration of tricalcium silicate produces a family of different compounds usually described as C-S-H (calcium silicate hydates). Water bound in such structures is usually lost over a wide range of temperatures, due to the extreme variety of compositions of the C-S-H. Generally speaking, we can associate the weight decrease between 200 and 400C to the water lost from C-S-H.


In some particular cases (e.g. when the clinker is particularly dusty), the plant may be forced to inject higher amounts of water to stabilize the grinding bed. While amounts of injected water < 1.5 2.0% (with respect to the VRM output) are considered to be safe, higher amounts may trigger cement pre-hydration inside the VRM. A quick and convenient method for assessing pre-hydration is the corrected loss-on-ignition (Wk) determination:

Wk = [LOI at 450 C] [LOI at 120 C] As a rule of thumb, Wk in excess of 0.3% indicates a pre-hydrated cement sample, for which substantial strengths losses at all ages are very likely to occur.

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Pre-hydration of cement in VRM (solution)

Compared to water, cement grinding aids have proven themselves to be more effective in stabilizing the grinding bed and reducing the VRM vibrations. Introduction of GAs usually permits a significant reduction of the % of injected water, thus minimizing the risks associated with cement pre-hydration.

% of injected

water 100-200C 200-400C 450-550C >600C

No additive 5.4 0.32% 0.19% 0.29% 1.35%

With MA.G.A./VM

1.7 0.26% 0.06% 0.27% 1.75%

Weight decreases at different temperatures evaluated using TGA


The following is a typical TGA graph of a moderately pre-hydrated cement sample:

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Key industrial case study (featured in ZKG; issue 3/2010)

These tests have been performed during the production of a CEM I type cement (according UNI EN 197-1). VRM characteristics: - Supplier/Model: confidential - Absorbed power: 3.500 kW; - Ventilation: 680.000 m3/h - p 50 mbar; - Water injection: 2,1% (referred to the initial fresh feed) - Roller pressure: 75 bar. During the tests the following parameters were kept constant: - GA dosage: 250 g/t (referred to the fresh feed in t/h) during test A, B and C; - Avg. vibration: between 2 and 4 mm/sec; - Blaine: 3.500 cm2/g


In order to verify the effectiveness of Mapeis grinding aids for vertical mills in comparison with traditional ones, our Technical Assistance Group performed a series of industrial evaluations: 1. Blank without any additive 2. Test A traditional GA dosed on the fresh feed conveyor 3. Test B traditional GA dosed on the grinding plate 4. Test C MA.G.A./VM 12 dosed on the grinding plate

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Accordingly, a notable reduction of the specific energy consumption (kWh/t) was observed:

A

B

C 32,0

30,1 29,5 28,1

0,0

5,0

10,0

15,0

20,0

25,0

30,0

35,0

40,0

Pow

er C

onsu

mpt

ion

(kW

h/t)

A B C


Effect on the VRMs hourly output (tph):

173 175

190 200

0

20

40

60

80

100

120

140

160

180

200

Mill

Out

put (

t/h)

A B

C

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The cements compressive strengths were enhanced at all ages (2days depicted):

25,4 25,6 26,6

28,0

0,0

5,0

10,0

15,0

20,0

25,0

30,0

2-da

ys S

tren

ghts

(MPa

) A B

C


On top of the higher output, the cement fineness was improved, too:

8,0 7,9 7,8

6,4

0,0

1,0

2,0

3,0

4,0

5,0

6,0

7,0

8,0

9,0

10,0

Resi

dual

s at 4

5

m (%

) A B

C

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The cements compressive strengths were enhanced at all ages (28 days depicted):

46,1 46,3 47,6 50,7

0,0

5,0

10,0

15,0

20,0

25,0

30,0

35,0

40,0

45,0

50,0

55,0

28-d

ays S

tren

ghts

(MPa

) A B

C


The cements compressive strengths were enhanced at all ages (7 days depicted):

37,0 38,1 38,7 39,1

0,0

5,0

10,0

15,0

20,0

25,0

30,0

35,0

40,0

45,0

7-da

ys S

tren

ghts

(MPa

) A B C

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Case study #2: Grinding station in Central America

Mill supplier/model: confidential Starting conditions: Low mill output with respect to nominal capacity (55 t/h vs. 80+ t/h) Low compressive strengths ( 20% lower than target) Extremely high amount of injected water (up to 7-8%) Unsuitable granulometry of the clinker (powderous clinker) A basic grinding aid from a local supplier was dosed in the traditional way

(conveyor belt)


Conclusions: The reference product dosed at a traditional dosing point shows little or no effects

on the production process and cement quality. When the same reference product is sprayed directly on the grinding track, certain

improvements can be seen, demonstrating the validity of the dosing methodology proposed by Mapei.

MA.G.A./VM 12 clearly stands out by showing strong improvements in terms of

production and cement quality; the specific formulation is clearly suitable for this application.

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Results of the preliminary industrial trial: Output was increased by >35% Early strengths were increased by 20% (1 day) and 10% (2 days) Water injection was reduced by 50% Grinding aid dosage was reduced by 30% with respect to reference

Additive: Dosage: Dosing system:

Injected water (%):

Mill output (t/h):

24h strengths (MPa):

48h strengths (MPa):

Reference 0,07% traditional 7.1 55-56 9.1 19.7

MA.G.A./VM 05

0,05% MAPEI direct 3.7 75-77 11.0 21.9


Customer requests: Increase the compressive strengths (especially early ones) by at least 15% Increase the mill output to at least 70 t/h

Proposed technical approach: Modification of dosing point (direct injection together with water flow) Industrial trial with MA.G.A./VM 05 dosed @ 500 g/t (0,05%)

Our achievements: Reduction of water % Improvement of compressive strengths Increase of the mill output

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Case study #3: Integrated plant in Eastern Europe (2012)

Customer requests: Increase the cement fineness, keep vibrations as low as possible

Proposed technical approach: Industrial trial with MA.G.A./VM 01, dosed @ 300 g/t (0,03%) together with the

water flow directly below the rollers

Our achievement: Facilitate the transition from CEM I 42.5 R to CEM I 52.5 R


Mill supplier/model: confidential Starting conditions: The plant is producing a CEM I 42,5 R cement blend (Blaine 3700 cm2/g) Mill output is close to nominal capacity ( 120 t/h) The plant wants to produce a CEM I 52,5 R (Blaine > 4100 cm2/g) Separator is already close to limit (99% of maximum rpm) Roller pressure may not be increased due to high vibration level (4-5 mm/s) Extremely high amount of water (up to 7%) is injected No grinding aid is used

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Case study #4: Integrated plant in North Africa (2012)

Mill supplier/model: confidential Starting conditions: The plant is producing an OPC-type cement blend (Blaine 2900 cm2/g) Normal mill output is 280 290 t/h (well below the nominal output) No grinding aid is normally used Another supplier made an industrial trial one week before Mapei


Results of the preliminary industrial trial: Fineness was increased up to 4.200+ cm2/g with no loss of output Average vibrations were decreased Amount of injected water was reduced by 40%

Additive: Dosage: Dosing system: Injected water (%):

Mill output (t/h):

Maximum fineness (cm2/g):

Average vibrations (mm/s):

No additive - - 7.0 120 122 3910 3.6 4.8

MA.G.A./VM 01 0,03% MAPEI direct 4.4 120 - 122 4213 2.1 3.2

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Results of the preliminary industrial trial: Hourly output was increased by 16% with respect to the blank (Hourly output was increased by 11% with respect to the reference product) Fineness of the finished product was not affected

Additive: Dosage: Dosing system: Injected water (%):

Mill output (t/h):

Average fineness (cm2/g):

No additive - - 1.1 280 284 2900

Reference 0,04% traditional 1.0 296 298 2912

MA.G.A./VM 02 0,035% MAPEI direct 1.0 328 - 330 2919


Customer requests: Increase the hourly output as much as possible, without decreasing the cements

fineness Proposed technical approach: Industrial trial with MA.G.A./VM 02, dosed @ 350 g/t (0,035 %) together with the

water flow directly below the rollers

Our achievement: Significantly increase the VRMs hourly output

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Case study #5: Integrated plant in SE Asia (2013-2015)

Customer requests: Increase the average 2 days strengths from 17-19 MPa to >24 MPa. Improve the workability of their OPC Proposed technical approach: After several lab and industrial trials, we developed and proposed the product

MA.P.E./VM 1001 W, to be dosed at 1.200 g/t according to our direct introduction methodology.

Our achievement: Strongly increase the 2 days compressive strengths Solve the workability issues


Mill supplier/model: confidential Starting conditions: The plant is producing OPC cement with their twin VRMs Average early compressive strengths are well below the market standard Workability issues are reported by several customers High amounts of injected water (> 5%) are negatively affecting the cements quality No grinding aid is used

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Case study #6: Integrated plant in SE Asia (2014)

Mill supplier/model: confidential Starting conditions: The plant is producing PCC (limestone based) with their recently installed

(2013) VRM Frequent VRM stops due to high average vibration level VRM output much lower than nominal one (100 110 tph vs. 125 tph) Low outlet temperature due to high % of injected water (5.1 m3/h) The plant was testing a traditional GA dosed on the fresh feeds conveyor

belt


Results after 14 months of regular utilization: The average 2-days strengths were increased from 17-19 MPa to 23-26 MPa. The plant is now injecting only 0.5% of water (sometimes none at all).

Additive: Dosage: Dosing system:

Injected water (%):

Mill output (t/h):

Average corrected

LOI

Average 2 days compressive

strengths:

No additive - - > 5.0% 140-150 > 0.4% 17-19 MPa

MA.P.E./VM 1001 W 0,12% MAPEI direct

max 0.5% 150+ < 0.2% 24-26 MPa

b

y LO

ESCH

E

Case study #5: Integrated plant in SE Asia (2014)

Results of the preliminary industrial trial: The VRM output was increased by 8% with respect to the reference GA Injected water was reduced by 45% Accordingly, outle

loesche technical seminar_apr-15

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