Modular Grinding Systems Attracting Everyone’s ?· Modular Grinding Systems – Attracting Everyone’s…

Download Modular Grinding Systems Attracting Everyone’s ?· Modular Grinding Systems – Attracting Everyone’s…

Post on 07-Sep-2018

212 views

Category:

Documents

0 download

Embed Size (px)

TRANSCRIPT

  • Modular Grinding Systems Attracting Everyones Attention

    Presented by

    Chris Oesch

    President

    Gebr. Pfeiffer, Inc.

  • Modular Grinding Systems

  • Features

    Produces all types of Cement, Slag, Coal, Limestone, Gypsum

    and other materials

    Considers efficient VRM technology

    Ideal for small- Meduim scale production

    Three plant sizes available for Clinker plus additional module

    plants for other materials

    Pre-assembled Modules in standard size

    Optimized Size ratio due to Compact Modular Design

    Flexible plant arrangement

    Flexible design of feed size and product transport

    Low plant construction height

  • Local Requirements

    Small Footprint for the plant (~ 350m)

    Access to transportation (Road, Rail, Harbour)

    MV or LV Line supply

    Consumables

    Plant personnel

  • Selection of Scope

  • Flowsheet

    Feed VRM Gas Route Storage/Packing

  • Scope of Equipment and Service Supply

    A. BASIC PLANT MODULES

    A. 1 Raw Material Dosing and 3(or as needed) Feed Hoppers

    A. 2 Raw Material Feeding to Mill

    A. 3 Mill, Classifier and Ancillaries

    A. 4 Dedusting, Hot Gas Generator and Fan

    A. 5 Product Transport and 2 (or as needed) Storage Silos

    A. 6 Electrical Controls, Drives, Lighting and Safety installations

  • Scope of Equipment and Service Supply

    B. OPTIONAL EQUIPMENT MODULES

    B. 1 Packing and Truck Loading

    B. 2 Bulk Loading Equipment

    B. 3 Sanitary Equipment

    B. 4 Office Equipment

    B. 5 Laboratory Equipment

    B. 6 Fuel Storage

    B. 7 Extended Product Storage Capacity

    B. 8 Power Generation

  • Scope of Equipment and Service Supply

    C. OPTIONAL SERVICE MODULES

    C. 1 Operator Training

    C. 2 Maintenance Training

  • Modular Grinding System

  • Modular Plant Components

  • Main Process Bag Filter

    Includes mill ancillaries and MCC room

  • Vertical Roller Mill

  • Performance Table

    GEBR. PFEIFFER MODULAR MILL MVR 1800 C-2

    Product Portland Cement

    CEM I Limestone Cement

    CEM II / B L Slag

    GGBFS

    Fineness acc. to Blaine 3500 4500 4000 5000 4000 4500

    Grindability kwh/t 19 25 15 19 24 27

    Production rate t/h 12 9 15 11,5 10 9

    Max Feed Grain Size mm 35

    Approx. yearly production rate t/a

    Installed Mill Motor Power KW 260

    Total installed Power KW 500

    Amount of Modules 9

  • Performance Table

    GEBR. PFEIFFER MODULAR MILL MVR 1800 C-4

    Product Portland Cement

    CEM I Limestone Cement

    CEM II / B L Slag

    GGBFS

    Fineness acc. to Blaine 3500 4500 4000 5000 4000 4500

    Grindability kwh/t 19 25 15 19 24 27

    Production rate t/h 24 18 30 23 20 18

    Max Feed Grain Size mm 35

    Approx. yearly production rate t/a 140.000 240.000

    Installed Mill Motor Power KW 560

    Total installed Power KW about 1000

    Amount of Modules 15

  • Performance Table

    GEBR. PFEIFFER MODULAR MILL MVR 2500 C-4

    Product Portland Cement

    CEM I Limestone Cement

    CEM II / B L Slag

    GGBFS

    Fineness acc. to Blaine 3500 4500 4000 5000 4000 4500

    Grindability kwh/t 19 25 15 19 24 27

    Production rate t/h 48 36 60 46 40 36

    Max Feed Grain Size mm 35

    Approx. yearly production rate t/a 280.000 480.000

    Installed Mill Motor Power KW 1100

    Total installed Power KW about 1600

    Amount of Modules 18

    Partial load operation possible on request in order to start with low production

    requirement -> Plant is ready to take up future increase of production

  • MVR Roller Mill Design

    Symmetric wear parts For an extended lifetime tyres can be turned in case of wear.

    Active Redundancy Up to 4 grinding rollers: mill operation continues even if two roller are

    under maintenance.

    Hydraulic system for operation and maintenance For maintenance purposes no extra component is required to swing the

    rollers out of the mill.

    Parallel grinding gap The geometry of the grinding elements in combination with our MVR

    suspension system ensures a parallel grinding gap in any operating point.

  • Active Redundancy

    4 grinding rollers:

    mill operation continues even if two

    rollers are under maintenance

    Availability during failure

    Pfeiffer C-4 with 2 roller out: >50%

  • MVR Installations

    country customer mill size tph fineness kW product year

    Turkey undisclosed client MVR 5000 C-4 - - 4000 cement 2015

    Bosnia-

    Herzegovina

    DD Fabrika Cementa Lukavac MVR 3750 160 12 % R 0.090 mm 1600 raw material 2007

    Turkey undisclosed client MVR 3750 R-3 - - 2000 raw material 2015

    Turkey undisclosed client MVR 3750 R-3 - - 2000 raw material 2015

    Africa undisclosed client MVR 3750 C-4 150 3300 cm/g acc. to Blaine 2900 cement 2016

    Americas Undisclosed Client MVR 2500 C-4 56 4700 cm/g acc. to Blaine 1246 cement 2016

    Germany Hauri KG, Btzingen MVR 1800 C 20 4600 cm/g acc. to Blaine 320 phonolite 2006

    Germany Hauri KG, Btzingen MVR 1800 C-2 21 3000 cm/g acc. to Blaine 250 phonolite 2015

    Africa undisclosed client MVR 1800 C-4 25 4000 cm/g acc. to Blaine 520 cement 2016

  • Product Quality

    VRM vs Ball Mill

  • MVR 1800 C-4 for cement grinding

    Hans G. Hauri Mineralstoffwerk,

    Germany

    MVR 1800 C-4

    15 tph Cement

    400 kW installed

    In Operation since 2007

  • Comparison of Mill Systems

    VRM vs HPGR (Cement)

    VRM HPGR + BM

    Recirculation Reject 10 - 20 % 400 to 500 % of fresh feed

    Feed moisture up to more than 25 % up to max. 5 %

    Various feed

    material

    very flexible and adjustable for a wide

    range of feed material

    not as much flexible as VRM

    Wear sinter cast,

    chromium cast alloy iron

    hardfaced,

    stud liners very sensitive to oversized

    lumps, break-out of tyre

    Arrangement simple,

    advantage of drying, grinding, classifying

    in one machine

    complicated,

    single machines (RP, static separator,

    dynamic separator)

    Layout VRM foundation on ground level HPGR is not located on ground floor,

    with Comflex system located on upper floor

    due to arrangement, high loads!

  • Comparison CEM I (Balaji / India)

    Plant A Data 2013 MVR BM

    Type CEM I CEM I

    R 0,045 mm 6.8 % 8.4 %

    Blaine* 2910 cm/g 2910 cm/g

    Lasergranulometer d = 24.2 m, n= 0.99 d = 25.2 m, n= 0.97

    Water demand* 26.5 % 26.2 %

    Compressive strength*

    2 d 20.6 MPa 18.7 MPa

    7 d 36.8 MPa 36.5 MPa

    28 d 58.1 MPa 59.4 MPa

    *tests in acc. to EN 196

  • Comparison CEM I (Balaji / India)

    Plant A Data 2014 MVR HPGR + BM

    Type CEM I CEM I

    Blaine* 2940 2900

    Water demand* 29.4 % 30.3 %

    IST 170 min 190 min

    Compressive strength*

    1 d 21.3 MPa 21.0 MPa

    3 d 40.5 MPa 40.4 MPa

    7 d 51.4 MPa 51.8 MPa

    28 d 63.7 MPa 62.6 MPa

    *tests in acc. to IS 4031-6

  • Economic Feasibility

    VRM vs Ball Mill Grinding System

  • Maintenance Cost

    Long term comparison of maintenance cost from 2004 to 2010 including wear parts replacement

    Cement International 02/2015, 38ff. Flacher, A.: Benefits and potentials of cement grinding with vertical roller mills

  • Specific Energy Consumption

    BM closed circuit Semi finish HPGR + BM VRM

    Mill 30.9 14.2 15.5

    HPGR - 9.0 -

    Aux + Fan 4.1 6.7 7.6

    Total 35.0 29.9 23.1

    kWh/t

    for Cement with 10 % limestone @ 3600 Blaine*

    * based on FLS-figures given 2012 at Petrochem, Russia

  • Specific Energy Consumption

    Cement International 02/2015, 38ff. Flacher, A.: Benefits and potentials of cement grinding with vertical roller mills

  • Comparison HPGR+BM vs. VRM CEM I w. 5 % Limestone HPGR + BM MPS 4500 BC

    Product rate 127 t/h 146 t/h

    GA 260 ml / t 55 ml / t

    Fineness 3500 Blaine

    MPS -- 19.2 kWh/t

    HPGR 8.5 kWh/t --

    BM 19.6 kWh/t --

    Sep 1.1 kWh/t 1.1 kWh/t

    Fan 3.4 kWh/t 9.5 kWh/t

    BE (HPGR & BM discharge) 1.6 kWh/t 0.1 kWh/t

    total 34.2 kWh/t 29.9 kWh/t

    all figures are counter values both mill systems are operating with grinding aid Both systems are installed at the same plant -> same feed materials

  • Specific Power Consumption (kWh/t) OPC BM vs. VRM

    0

    10

    20

    30

    40

    50

    60

    70

    80

    90

    2000 2500 3000 3500 4000 4500 5000 5500

    SP

    C in

    kW

    h/t

    (m

    ill, se

    pa

    rato

    r, f

    an)

    Spec. Surface area Blaine in cm/g

    OPC

    BM

    VRM

  • Electrical Operating Cost (CEM I at 3400 Bl.)

    Grinding System Ball Mill Vertical Roller Mill

    Specific Power cons. (*) Kwh/t Mill 36,0 18,5

    Kwh/t Classifier 1,1 1,1

    Kwh/t Bucket Elevator 1,6 0,1

    Kwh/t Fan 3,1 7,5

    Kwh/t Total 41,8 27,2

    Effective Production Capacity t / h 30 30

    Effective absorbed power KW eff 1.254 816

    Operating Hours / year h / year 7.500 7.500

    Consumed power / year Kwh / year 9.405.000 6.120.000

    Price for Power Euro / Kwh eff 0,1 0,1

    Price for Power Euro / year 940.500 612.000

    Years Considered Years 5 5

    Total Cost for Power EURO 4.702.500 3.060.000

    ~ 1.650.000 in 5 years!

  • Current Installation

  • Feed System

  • Mill Unit

  • Filter and Fan

  • Modular Grinding Systems

    Summary

  • Main Advantages

    1. High reliability & availability

    2. Economic - operation cost - VRM

    3. Low investment risk, fast market entry, quick pay-

    off (ROI)

    4. Manageable costs for erection and commissioning

    5. Easy access to small and fluctuating markets

    6. Plant Mobility -> Future relocate

    7. Fast Track Project realization/Operation in different

    environment conditions possible

  • Modular Grinding Systems Attracting Everyones Attention

    Thank you!

Recommended

View more >