Product Brochure

www.pfister.de

Product Brochure

Rotor Weighfeeder Pfister

FRW / SRW

Highly accurate and reliable gravimetric feeding of

pulverised fuel

Whether kiln feeding, additive feeding to the raw or finish mill or cement pre-loading, the robust design

of the Pfister FRW is ideal for dosing powdered bulk materials such as raw meal, fly ash, bypass dust or

cement products with high dosing constancy and precision. Due to the integration of weighing and dos-

ing the system is easy to operate and thus extremely reliable.

Pfister FRW + ProsCon®: the innovative solution for metering powdered materials.

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History

FLSmidth Pfister has more than 110 years of

experience in manufacturing industrial weigh-

ing equipment and is part of the FLSmidth

group since 1998.

The Rotor Weighfeeder technology was invented

by FLSmidth Pfister in 1984 to feed pulverised

coal to the cement burning process and it is

now time tested and state of the art technol-

ogy. More than 1,700 systems are in operation

world-wide.

Out of the long experience, FLSmidth Pfister

developed the Pfister FRW for non-explosive

pulverised material. Since the first installation

in 1997, more then 200 systems have been

installed world-wide for different applications

and materials.

How does the system work?

What are the benefits?

What are the dimensions?

How ist the system installed?

What are the technical facts?

Is there further information?

Pages 3-4

Pages 5-7

Page 8

Pages 9-10

Page 15

Page 16

All Pfister weighfeeders are

Engineered

Designed

Assembled

Tested

in Augsburg—Germany

The usual applications kiln feed

cement blending

mill feeding (fine grained materials)

General Principle

The Pfister FRW is used for extracting fine

grained bulk material out of a storage silo and

feed it with high accurate feedrate on an

airslide or any other transport media.

The usual bulk materials raw meal

cement

fly-ash

slag

additives

other fine or pulverised materials

What applications are there? Pages 11-14

Mill feeding and Kiln feeding. The application for rotor weighfeeder FRW.

Historic Pfister scale. Ludwig Pfister,

founder of the company in 1894.

Contend

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The Function Principle

The pulverised material is transported in

the chambers of the rotor wheel (1) inside

the feeder from the inlet (2) towards the

outlet (3) . At the outlet, the chambers are

completely emptied. The rotor is driven by

a variable speed drive (4) . The rotor hous-

ing (5) cover the rotor and provides a com-

pletely closed and dust tight system. It is

suspended on a eccentric weighing axis (A-

A) through the middle of inlet and outlet.

The third point is suspended with a tow-

bar (6) at a load cell which weighs the gra-

vimetric bulk material content inside the

rotor. That means that the rotor weigh-

feeder measures real kilograms and is

therefore a true scale. At the outlet, the

material falls out of the feeder by gravity.

The gravimetric measuring value provides infor-

mation on the bulk material mass in the rotor

weighfeeder before the material leaves the

feeder. The loading of the rotor in relation to

the angular section is stored by the weighing

electronics. The speed of the rotor is controlled

inverse to the loading of the rotor at the outlet.

The Weighing Electronics ProsCon®

The electrical controller calculates the required

speed of the motor for the time of the dis-

charge. It uses the set feedrate and the meas-

ured bulk material mass for the calculation of

the angular speed of the rotor (see chart). Less

material in the rotor results in a higher angular

speed, more material in a lower speed.

With this principle, so-called prospective control

ProsCon®, the rotor weighfeeder achieves a

highly accurate compensation of variation in

rotor loading and material density. This results

in an extremely accurate feedrate with varia-

tions of less then ±0.5% for short- and long-

term.

Pfister FRW. A-A eccentric weighing axis. 1: rotor wheel, 2: bulk material inlet, 3: outlet, 4: variable speed drive, 5: rotor housing, 6: tow-bar to load cell, 7: Pfister CPI control box, 8: air-supply for purge air, 9: weighing bearing, 10: suspension frame.

1

4

5

2

3

6 7

A

A 8

How does the system work?

9

10

To achieve high accurate feeding, angular speed of rotor is controlled invers to rotor weighfeeder loading.

Function Principle

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1

MT

M

4 5process interface

CPI

Motor Control Center

FC

6 feeder

controllerCSC

CAN

2 3 Power supply

To plant control system

Pfister Rotor Weighfeeder Controller

All data are collected in the:

Pfister CPI—Can Process Interface (at feeder (5))

and transferred via CAN-Bus to the:

Pfister CSC—Can System Controller (in MCC (6))

The communication between the Pfister CSC

and the plant control system can either be via:

Serial-Interface (ModBus RTU).

Network-Interface.

(Profi-Bus DP, Device Net)

Analog/Digital-Hardwired Interface. Electronic control 1: pre-bin, 2: shut-off gate, 3: flow-control gate or star-feeder, 4: rotor weighfeeder FRW, 5: Pfister CPI, 6: Pfister CSC

Reactive, Follow-up Control.

Reactive Control Compared to Pfis-

ter’s Proactive Control Strategy

Other feeders are based on a reactive control

(follow-up) rather then a proactive control.

Deviations in feedrate is measured and the pre-

feeding is adjusted. The measured deviation is

already sent to the process. This also requires a

very fine and sensitive pre-feeding device.

With the proactive Pfister rotor weighfeeder, the

material mass is measured before it leaves the

rotor weighfeeder. That means that the speed

of the rotor is adjusted before the material gets

discharged into the system, not the other way

round.

Pfister Prospective Control ProsCon® (Forward looking / pro-active)

Function Principle

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What are the benefits?

Less Maintenance and Longer Opera-

tion Hours Because of...

Smart design with only one moving part, the

rotor wheel inside.

Completely dust tight.

Less wear because of slow speed of the ro-

tor. 4 to 8 rounds per minute.

Only one bearing which is additionally purge-

air sealed. No rollers or idlers.

All measuring parts and the motor are lo-

cated on the outside of the system.

Because of the minimal amount of parts, the

system is extremely reliable and problem

free. Less parts reduce maintenance work.

Only steel in contact with bulk material.

It is not necessary to clean the rotor weigh-

feeder since no spillage is possible.

Benefits in Installation Because of...

Compact design with minimal installation

height.

It is not necessary to have a highly accurate

and constant pre-feeding.

Less necessary height of the pre-bin. The

special installation shown on the right is run-

ning since 7 years without any problems. It

is designed for a feedrate of 160 t/h with a

total height of only 5.1 meters. Pleas see

standard under chapter “Installation”.

It is no additional dedusting necessary.

Simple and intuitive operation.

The rotor weighfeeder is an advanced

mechatronic system. However it is very sim-

ple to operate. The communication to the

local plant control system is flexible and

works absolutely reliable.

Optional remote process display RPD.

Special pre-bin and Pfister FRW. Feedrate 160 t/h, total height 5.1m. 1: pre-bin filling, 2: pre-bin, 3: pre-bin content measuring, 4: material extraction devices, 5: rotor weighfeeder, 6: aeration bottom.

Benefits

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High Accuracy in Dosing Because of…

No influence of pre-bin extraction property

on the dosing quality.

Air-flow or the flow characteristics of the

bulk material have no influence on the dos-

ing quality.

Proactive rather then reactive dosing and

feeding. The feedrate gets adjusted before

material leaves the feeder, not the other

way round.

High measuring load.

The design enables a high material layer

and therefore a high measuring load in the

weighing section. The material mass in the

rotor weighfeeder is around ten times higher

then with a traditional belt weighfeeder.

Easy online calibration.

If the pre-bin is placed on load-cells, it is

easily possible to perform online-calibration.

That means comparing the static weighing

of the pre-bin with the continuous gravimet-

ric weighing of the rotor weighfeeder. This

redundant principle give highest accuracy

and optimal calculation of total throughput.

No shooting or relative movement of the

bulk material possible.

Immediately Adjustable Feedrate

Because of its design, the rotor weighfeeder

supplies its high dosing-accuracy in a range

from 10% to 100% of maximum feedrate.

The ProsCon® control strategy ensure virtually

no reaction time in changes of the feedrate.

This is especially necessary for cement blending

or mill-feeding if mixing-ratio or the overall load

needs to be changed immediately.

Higher Accuracy for Kiln Feed Re-

sults in...

High accuracy of feeding prevents over-

feeding and cyclone block-ups.

Because of the short pass-through time of

the raw-meal through the pre-heater, it is

necessary to have a high sort-term accu-

racy. The more accurate and stable the

feeding into a continuous process, the

closer the whole process can be operated

to its best performance.

Possibly visible improvement of output,

pressure and emission characteristics of

the whole cement burning process.

Smoother operation of the whole process.

Higher Accuracy in Dosing for Ce-

ment Blending Results in...

More accurate cement/filler mixture. The

mixing ration is more accurate and there-

fore closer to the allowed limits.

Highest possible amount of filler in the

cement, for example fly-ash or limestone,

with steady quality.

Benefits

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Technical Assistance by Telesupport

With an optional modem, experienced

FLSmidth Pfister technicians have remote ac-

cess to controller parameters, control logic

and sensoric interface. This makes online help

possible for trouble shooting and interpreting

events and system messages.

Modern Maintenance Management

FLSmidth Pfister’s experience in maintenance

management has been helping cement plants to

make the cement production process more effi-

cient for many years.

Modern Maintenance Management reduces wear

Online trouble shooting with optional modem

The Benefits of MMM:

Cost saving pre-planning of kiln outages.

Regular check-up support; less overall

downtimes.

Support in spare parts management.

Replacement of crucial parts at the right

time.

All maintenance measures carried out by

experienced Pfister specialists.

Reduce overall service cost.

Maintenance contracts are available.

FLSmidth Pfister—Augsburg

WWW

Modem on site

Pfister CSC in MCC

Pfister CPI at feeder

Service and Support

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Rotor Weighfeeder Pfister FRW / SRW Series

Type Rotor Ø Height Feedrate* Feedrate* Weight (min.) (raw meal, max.) (cement, max.) (approx.)

Pfister FRW 4.10 1000 mm 1470 mm 40 t/h 60 t/h 2.000 kg

Pfister FRW 4.14 1400 mm 1700 mm 120 t/h 180 t/h 3.300 kg

Pfister FRW 4.18 1800 mm 1700 mm 300 t/h 350 t/h 4.900 kg

Pfister FRW 4.20 2000 mm 2000 mm 450 t/h 480 t/h 6.900 kg

Pfister FRW 4.22 2200 mm 2200 mm 600 t/h 700 t/h 9.200 kg

*feedrate depending on bulk material density.

Rotor Weighfeeder Dimensions Here: Type Pfister FRW 4.18, Feedrate max. 350 t/h

What are the dimensions?

Side view, Pfister FRW 4.18.

Top view, Pfister FRW 4.18.

Dimensions

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Typical installation of Pfister FRW.

Pfister supplies: 1: pre-bin engineering, 2: pre-bin con-

tent measurement units, 3: pre-bin bottom aeration, 4:

pre-bin bulk material extraction devices, 5: bulk material

dosing with Pfister FRW.

2

1

3 4 5

Installation of Pfister FRW with material extraction devices star-feeder or flow-control gate. - Star-feeders for feedrates between 0 t/h and maximum 30-35 t/h. - Flow-control gates start from feedrates of minimum 3 t/h.

star-feeder

flow-control gate

How ist the system installed?

Installation

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Installation of three Pfister SRWs for online cement blending. In this special case it is not necessary to use a pre-feeding device because of small feedrates.

Pfister SRW in the cement blend-ing installation. In this case without pre-feeding device, the feeder is directly extracting out of the bulk material silo. .

Cement Blending

Pre-ground clinker

Fly ash Limestone meal

Installation

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Application for Kiln-Feed at a Cement Plant in Romania

Pfister FRW with pre-feeding devices. 1: Pre-bin, 2: shut-off gate, 3: flow-control gate, 4: discharge spout, 5: rotor weighfeeder, 6: aeration pipes

Pfister FRW for kiln feed. 1: concrete pre-bin, 2: extraction box, 3: extraction de-vices, 4: rotor weighfeeder, 5: aeration pipes.

1st Installtion in 1996 for Kiln-Feed at a Cement Plant in Germany

1

3

6

2

4

5

1

3 2

4

5

Applications

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Replacement of a 25 Years Old Pfister Belt Weighfeeder for Kiln-Feed at a Cement Plant in Lybia

New Installation: Pfister FRW with for 120 t/h. Old Installation: Pfister Belt weighfeeder.

Application for Cement-Blending at a Cement Plant in Germany

Applications

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Replacement of an old feeding system in Spain

New Installation: Pfister FRW 4.18. Feedrate 250 t/h.

Application for Feeding Mill Residues back into the Cement Mill in Austria

Applications

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Application for Slag Dosing

Pfister FRW for slag dosing. 1: diverter box, 2: shut-off gate, 3: flow-control gate, 4: discharge spout, 5: rotor weighfeeder.

1

3

4

2

5

Applications

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Pfister FRW / SRW

Application: Highly accurate, gravimetric

feeding of all kind of pulverised bulk materials.

Design:

The rotor weighfeeder is engineered, designed,

assembled and tested in Germany.

Certification:

DIN EN ISO 9001:2000

Feedrate: 1.0 t/h to 700 t/h

Feedrange: 10% to 100%

Accuracy: ± 0.5%

over the complete feedrange

Electronic Controller:

Pfister CSC controller with proactive control

strategy ProsCon®

Electronics Temperature Range:

Standard: 0°C to +40°C

With heater*: -20°C to +40°C

With cooler*: 0°C to +55°C *installed in local electric cabinet

Interface to Plant Control System: Serial-Interface (ModBus-RTU).

Network-Interface.

(Profi-Bus DP, DeviceNet)

Analog/Digital-Hardwired Interface.

What are the technical facts?

Applications

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Pfister DRW Pulverized fuels

Pfister FRW Powdered products

Pfister TRW-K Crushed raw coal

Pfister TRW Coarse products

Pfister VRW Powdered products

Pfister TRW-S Alternative fuels

To see to the contend of your interest please click on the links below on our website:

Press articles http://www.flsmidth.com/Pfister/English/News/Pfister+news/Press+archive.htm

Special-interest articles http://www.flsmidth.com/Pfister/English/Special+interest+articles/Special-interest+articles.htm

Brochures http://www.flsmidth.com/Pfister/English/Downloads/Datasheets+and+Brochures/Brochures/Brochures.htm

Product datasheets http://www.flsmidth.com/Pfister/English/Downloads/Datasheets+and+Brochures/Datasheets/Datasheets.htm

Product animations http://www.flsmidth.com/Pfister/English/Downloads/Product+animations/Product+animations.htm

Applications

www.pfister.de

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Contacts

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Contacts

Sales Department: sales@pfister.de Technology Department: engineering@pfister.de Service Department: service@pfister.de Transweigh India Ltd. 124, ABCD, Govt. Industrial Estate Kandivli (W) Mumbai - 400 067 India T. + 91 22 2868 2311 F. + 91 22 2868 2145 sales@transweigh-india.com FLSmidth Pfister GmbH China Western Part of Songshan Road Qingdao Airport Industrial Zone Chenyang District 2661g09 Qingdao P. R. China T. +86 532 877 60380 F. +86 532 877 56852 pfister-china@pfister.de

FLSmidth Pfister GmbH Staetzlinger Str. 70 86165 Augsburg Germany T. +49 821 7949 0 F. +49 821 7949 524 www.pfister.de Branches offices & joint ventures FLSmidth Pfister Inc. 2158 Avenue C, Suite 201 Bethlehem, PA18017-2148 U.S.A. T. +1 610 2645110 F. +1 610 2645537 pfistera@ptd.net FLSmidth Pfister Ltda. Rua Vigário J.J. Rodrigues, 905 - c.j. 51 13.201 - 490 Jundiai S.P., Brazil T. +55 11 45266744 F. +55 11 45875711 pfister@pfister-la.com.br FLSmidth Pfister GmbH Malaysian Branch C-3A15, Centre Wing Metropolitan Office Suite Metropolitan Square, Jalan PJU 8/1 Damansara Perdana 47820 Petaling Jaya Selangor Malaysia T. +60 3 7728 2039 F. +60 3 7727 2039 pfismal@streamyx.com FLSmidth Pfister GmbH 6, Rue de Bretagne 38070 St. Quentin Fallavier France T. +33 474 955544 F. +33 474 945075 pnl@pfister.fr