MODERNISING CEMENT GRINDING PLANTS WITH TSV™ … Grinding Separators.pdf · Fives FCB - March...

Fives FCB - March 2009 1

Fives

MODERNISING CEMENT GRINDING PLANTS WITH TSV™ SEPARATOR

Driving Progress


The Fives FCB’s SEPARATOR

TTTTurbo

SSSSéparateur

Ventilé

TSVTSVTSVTSV™™™™



1 TSV™ general and specific features

2 Sizing basis for modernisation of plants

3 Case studies

- 3.1 Single line circuit plant

- 3.2 Two lines circuit plant

4 References





3 Case studies



4 References



FEED FEED

GASES+CEMENT

REJECTS

GASES

Operating principleOf TSV™

Operating principleOf TSV™

FEED





GUIDE VANES

TURBINE BLADES



GUIDE VANES

TURBINE BLADES

DRAG FORCECENTRIFUGAL FORCE

The fineness of product is controlled:

- the rotation speed of the turbine = rpm

- the gas flow through the separator = m3/h


Patented turbine blades shape

TFc

DRAG FORCE

T = ½ r S Cx Vr2

CENTRIFUGAL

FORCE

FC = m w2 R

T = FC for one particle size:d50 =cut size of the Tromp curve

Vr = Vg - Vp = Vg =Radial speed of gases==> (L2/L1)a = b*(R1/R2)

R2 R1

L1

L2


Typical Tromp curves of dynamic separators

Lower by pass

---> better grinding efficiency of the mill

Steep slope of selection curve

---> Perfect quality control of cement grain size

Strong reduction of coarse particles ensuring better compressive strength


Examples of Sieve Grain Size Analysis with separator TSV™

Rosin Rammler Diagram

60

5

0,1 0,5

20

30

15

35

55

1

10

50 45 40

25

90

65 70 75 80

85

91 92 93 94 95 96

97

98

9910 µm 100 µm 1000 µm

Cumulative wt% retained

CEM I 52,5R 4740 Blaine - Chelm slope = 1,47

CEM I 3000 Blaine - Jbel Oust slope = 1,30

CEM II A-L 3500 Blaine - Jbel Oust slope = 1,15

High Rosin Rammler slope with the complete elimination of the coarsest particles:

>> better compressive strength

>> allows lower Blaine target value for the same strength values



GUIDE VANES

TURBINE BLADES

VORTEX BREAKER


Patented vortex breaker of the TSV™

WITHOUT VORTEX BREAKER WITH VORTEX BREAKER


Power saving with TSV™

Cement type CEM I TSVPLANTS Blaine d80 tph Size - type Absorbed

PowerkWh/t

Luanda CIMANGOLA 3320 33 µm 120 3600-HF 10 kW 0.08 Chelm Poland CEMEX 4470 17.3 µm 55 3200-HF 51 kW 0.93

Recent examples

of TSV™power consumption





3 Case studies



4 References




* Mill audit expertise, mill internal inspection

* Existing separator performances evaluation

( Tromp curve, circulating load, GSD of cement)

* Mill power available

* Feed data, (components, moisture, temperature)

* Grindability test


FCB INDEX GRINDABILITY TEST

kWh

GrainsizeDistribution AND Energy

Grinding specific energy S.E. = f (fineness)

0

10

20

30

40

50

0 1 2 3 4 5

Fineness (Blaine, R40µm...)

kWh/t

Ball charge: 250 kg

material : 30 kg



t0 t1 t2 t3 t4 t5 t6 t7 t8 t9 t10 t11 t12 t13 t14 t15 t16 t17 t18 t19 t20Tamis 0.0 3,0 6,1 9,1 15,2 21,3 26,4 30,4 35,5 40,6 45,6 50,7

20 40,2 35,2 31,0 28,4 24,1 20,232 22,6 18,7 13,2 9,8 7,8 6,140 96,5 91,6 82,7 71,3 46,0 27,3 17,4 12,4 7,3 4,7 2,9 2,150 17,0 8,1 4,6 2,3 0,8 0,363 62,2 30,8 10,3 3,8 1,8 0,4 0,280 22,1 3,8 1,1 0,390100 92,0 84,1 71,4 52,6 14,7 1,4 0,2125 0,5160 41,8 3,2200250 87,1 72,3 55,0 29,6 0,6315 24,2400 15,2500 82,6 58,5 36,6630 5,9800 23,9

1000 75,1 39,9 17,5 1,5125016002000 59,0 20,6 5,53150 45,2 10,4 2,24000 32,3 5,7 0,75000 17,4 3,2 0,25600 11,1 2,0d80 4792 2047 914 350 84,9 47,6 35,68 30,7 26,3 24,1 22,1 20,1

Blaine 2920 3100 3600 3910 4120 4470Tamisage Alpine selon NF X11.640 de Juillet 1979 - Sinex se lon NF X11.501 de Déce mbre 1970 Blaine e n c m²/g selon NF EN 196-6 d' août 1990

Sieve grain size analysis:

Cumulative residue on sieve for samples taken durin g the test



We determine the following relationships:

Grinding Specific Energy in an optimised ball mill plant in closed circuit with the TSV™ separator.

Grinding Specific Energy in an optimised ball mill plant in closed circuit with the TSV™ separator.





3 Case studies



4 References


SIMPLE CLOSED CIRCUIT


First case study : data

CEMEX-RMC : Chelm - PolandBall Mill n°9 φ 4 φ 4 φ 4 φ 4m * 12 m 2750 kW

BEFORE MODIFICATIONStatic separatorcyclones

Filter type E.S.P.Mill Fan motor 40 kW

Bucket elevator 75 kWDynamic SeparatorCVΦ 7100/6300

Separator motor 250 kWSeparator Fan motor 40 kW

Installed power of auxiliaries (fans +SEP ) 310 kW

AFTER MODIFICATIONSeparator type TSV HF 3200

Separator motor 90 kWBucket elevator not changed

Filter type jet pulse bag filterFilter area 1805 m2

Fan design capacity 136 000 m3/hExhaust fan motor 360 kW


Chelm RMC CEMEX PLANT Mill n°9 : results 1

Blainefrom 1st Gen. to TSV 3700 4500

Output +21 % +28 %Mill kWh/t - 20 % - 30 %

Type of cement CEM II B-V

composition 66 % clinker + 6 % gypsum + 26 % fly ash + 2 % slag

Before With TSV (g) (g) (m)

Output tph 80 97 67 70.9 Fineness according Blaine3700 3700 4500 4470

Mill consumption kWh/tonne (*) 31 25 36.2 34.5 Main motors consumption:

Mill + TSV + Elevator + Fan (kWh/tonne)

40.2

(*) at electrical sub-station counter, (g) guaranteed value, (m) measured during performances tests

21 % output increase guaranteed

fcb grindability test results was: S.E.= 0.76 + 1.779 * blaine1.932

21 % calculated output

increase guaranteed

28 % calculated output

increase realised


Chelm RMC CEMEX PLANT Mill n°9 : results 2

Type of cement CEM I

composition 94 % clinker + 6 % gypsumBefore With TSV

(g) (g) (m)Output tph 60 65 54.5 54.5

Fineness according Blaine3300 4000 4500 4460Mill consumption kWh/tonne (*) 36 37.2 44.5 44.7

Main motors consumption:Mill + TSV + Elevator + Fan

(kWh/tonne)

40.2

(*) at electrical sub-station counter,(g) guaranteed value,(m) measured during performances tests

PURE CEMENT (CEM I)

at 4500 Blaine with only

45 kWh/tonneat ball mill

motor


First case study: Obtained Tromp curve

Selectioneff ic iency

cut size = d50 = 19.4 µm

d25 = 15 µm

d75 = 25.5 µm

Selection curveobtained in ChelmCement type CEMI

4500 Blaine

Acuity = Sharpness Index(Laser Reduced values)

= d25/d75 = 0.59


2nd case study: data

CIMPOR – Jbel Oust TunisiaBall Mills n°1 and n°2 φ 4 φ 4 φ 4 φ 4m * 13.5 m 2 * 1450 kW

BEFORE MODIFICATIONStatic separatorSS φ 2.8m

Filter type E.S.P.Mill Fan motor 75 kW

Bucket elevator 75 kWDynamic SeparatorTSU-D/SEGO φ 6500

Separator motor 70 kW (dispersion plate)Separator Fan motor 200 kW

Installed power of auxiliaries (fans +SEP ) 345 kW

AFTER MODIFICATIONSeparator type TSV HF 3200

Separator motor 90 kWBucket elevator not changed

Filter type jet pulse bag filterFilter area 1850 m2

Fan design capacity 136 000 m3/hExhaust fan motor 450 kW


2nd case study: installation of the TSV™2nd case study: installation of the TSV™


2nd case study: installation of the TSV™

Jbel Oust - 3D view


2nd case study

Jbel Oust – TSV™ view


2nd case study: top floor view

Jbel Oust - Top floor view

- dismantling the existing equipment (static and dynamic separators, electrofilter, fan, stack,..)

- erection of new equipment (TSV™, bag filter, fan, gas ducts, material transport,…)

- connections

- electrical and intrumentation equipment installatio n and cabling

- No-load tests

- PLC implementation

Total duration of stoppage (without production) was less than 30 days


2nd case study: production results

CIMPOR TUNISIA JBEL OUST

CEMENT GRINDING PLANTS N° 1 AND N° 2

Type of cement CEM II A-L 32.5 CEM I 42.5

composition 78 % ck + 4% gypsum+ 18 % limestone

93 % ck + 4% gypsum+ 3 % limestone

average values for plants 1 and 2old modernised old modernised

Output tph 93 109.9 ( +18%) 88 101 ( +15%)Fineness R40µm 28% 27 % 26% 21 %Fineness Blaine 3520 3100 3000

Grinding aid yes no yes noMill kW 2720 2790 2720 2700

Mill consumption (kWh/t) 29.2 25.4 ( -15%) 30.9 26.7 ( -14%)Outlet mill elevator kW 44 46

Separator kW 6 11Fan kW 305 258

Cement transport elevator kW 22 21Here above listed motors consumption

(kWh/tonne)28.8 30.1

15 % of production increase for CEM I 42.5

≅ 15 % of specific power consumption

decrease

Grinding aid

no more

needed





3 Case studies



4 References


Two lines circuit with separator TSV™

Lichtenburg: Two gas circuit grinding plant


The Fives FCB’s separator TSV™

Lichtenburg: TSV™ with Volute Air Inlet


Lichtenburg

RSA

Lafarge plant

TSV™ 4500HF

motor requirement 110 kW

(132 kW installed)

160 tph of cement 3220 Blaine

84% ck - 6% gypsum - 10% slag

33 kw absorbed power

Example of two lines flow sheet diagram with TSV™


Flash dryer and separator TSV™


The combination flash dryer and TSV™

Sacci Testi Italy


The combination flash dryer and TSV™

Sacci Testi Italy


Flash Dryer and TSV™

type of cement CEM IV/B-Mcomposition of cement 54 % clinker + 5% gypsum + 5% limestone + 26 % Fly Ash

mill main sizes diameter 4 m * (3.27 m + 5.48 m) + dryer l = 3.27mmill installed power 3600 kW

Mill Absorbed Power 3045 kWBEFORE UPGRADING AFTER UPGRADING WITH TSV +

FLASH DRYERMoisture of fly ash max 25 % max 25 %

Moisture of total feed ≈ 9.5 % max 11.2 %Capacity of the plant 85 t/h ≥≥≥≥ 120 t/h (guarantee figure)

Sacci Testi Italy





3 Case studies



4 References


The Fives FCB’s separator TSV™

YEAR of ORDER

TYPE CUSTOMER - SITE COUNTRY NbMill (1)

t/h MATERIAL

205 2007 TSV 4500 HF HOLCIM - APASCO Hermosillo Mexico 3 H 83 Cement202 2007 TSV 5500 BF HOLCIM - APASCO Hermosillo Mexico 1 B 272 raw meal201 2007 TSV 4500 HF CEMENTOS MOCTEZUMA SA de CV - Apazapan ** Mexico 2 H 105 cement199 2007 TSV 5500 BF CEMENTOS MOCTEZUMA SA de CV - Apazapan ** Mexico 1 H 225 raw meal198 2007 TSV 4000 HF CEMEX Egypt - Assiut Egypt 1 B* 145 cement197 2007 TSV 1800 BF QATALUM Qatar 1 R 26 calcined petcoke196 2007 TSV 1800 HF QATALUM Qatar 1 B 9 calcined petcoke195 2007 TSV 800 HF SILICON SMELTERS LTD - Polokwane South Africa 1 R 4 Silicium194 2007 TSV 6000 HF RIZHAO JINGHUA - Rizhao China 1 H 148 Steel slag193 2007 TSV 3000 HF CEMENTIR - Taranto Italy 2 B* 56 cement191 2007 TSV 3200 HF CEMEX - Chelm Poland 2 B* 97 cement189 2007 TSV 3600 HF CEMEX - Rudniki Poland 1 B* 113 cement188 2007 TSV 2400 HF CEMEX - Rudniki Poland 1 B* 52 cement187 2007 TSV 1400 BF SOPROLIF - EDF - ENDESSA France 1 B 20 limestone186 2007 TSV 3200 THF CONFIDENTIAL Indonesia 1 105 limestone185 2006 TSV 4500 HF LALITHA CEMENT - Andhra Pradesh India 1 H 100 cement184 2006 TSV 5500 BF LALITHA CEMENT - Andhra Pradesh India 1 H 225 raw 183 2006 TSV 5000 BF QNCC - Umm Bab 4 Qatar 1 B 220 raw182 2006 TSV 4000 HF QNCC - Umm Bab 4 Qatar 1 B 115 cement181 2006 TSV 4500 HF CEMEX / CEMENTOS BAYANO Panama 1 H 135 cement180 2006 TSV 4000 HF LAFARGE ASLAN CIMENTO - Darica Turkey 1 B* 125 cement179 2006 TSV 1600 MF LAFARGE FRANGEY France 1 E* 6 petcoke178 2006 TSV 1200 MF CEMENTI ROSSI - Piacenza*** Italy 2 * Coal176 2006 TSV 800 HF PICA France 2 2 Charcoal174 2006 TSV 2200 HF CONFIDENTIAL France 2 29 limestone172 2005 TSV 1400 BF SOHAR ALUMINIUM Oman 1 R 15,7 calcined petcoke171 2005 TSV 1400 HF SOHAR ALUMINIUM Oman 1 B 5,25 calcined petcoke170 2005 TSV 1600 MF LANZHOU China 1 B 12 calcined petcoke169 2005 TSV 1200 MF RUSAL for KRAZ Russia 1 B 6 calcined petcoke168 2005 TSV 1800 HF CEMENTI LAURIANO*** Italy 1 * cement167 2005 TSV 1200 MF CEMENTI ROSSI - Pederobba*** Italy 2 coal165 2005 TSV 4500 HF KONYA CIMENTO - Konya Turkey 1 H 105-115 cement

REFERENCE LISTTSV™ SEPARATORS


Wear protection

CONSTRUCTION MATERIAL

LINERS

Anti-abrasion steel (ABRO 4000)

Ceramic

Bi-metal

Ni-hard

Example of wear protection for TSV™ in mixt feed configuration for cement

grinding


TSV™ range of applications

- large scale of grain size of products : from d50 = 8 µm( TSV™ type THF) to d50 = 150 µm (TSV™ type TBF).

- from ∅ 1.4 m to ∅ 8 m

- various industrial applications (coal, petcoke, raw mix, cement, slag,…)

- combined with all types of mills (ball mill, vertical mills, Horomill®


MODERNISING CEMENT GRINDING PLANTS WITH TSV™ SEPARATOR

THANK YOU

for attention

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MODERNISING CEMENT GRINDING PLANTS WITH TSV™ … Grinding Separators.pdf · Fives FCB - March...

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