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grinding
We know how
www.claudiuspeters.com
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Claudius Peters – Unparalleled Expertise in Grinding
About us
Claudius Peters Projects GmbH, Germany and ClaudiusPeters Technologies SAS, France are part of the TechnologiesDivision of Claudius Peters Group GmbH, headquartered inBuxtehude, near Hamburg, offering technologies in the fieldof materials handling and processing and providing turnkeyor semi-turnkey systems to a wide range of industries.Claudius Peters Group GmbH is a wholly owned subsidiaryof Langley Holdings plc, a privately controlled UKengineering group, with regional offices in the Americas,Europe, China and the Far East.
Since 1906, Claudius Peters has enjoyed a worldwidereputation for excellence in grinding, drying and calciningtechnology. This type of technology requires years ofexperience and a thorough knowledge of raw materialcharacteristics under the most extreme processingspecifications.
Claudius Peters has supplied more than approximately 800ball ring mills, including 500 in various coal applications,making us one of the most recognized companies in grindingtechnology. We are capable of supplying the necessaryconsulting or audit for a specific application to a completenew or modified coal milling and drying system.
In the 1960s, Claudius Peters engineers optimized thecapacity of the ball ring mills by developing the EM grindingmechanism.
The EM-Mills range in operating capacity from 1 to 130t/hwhich typically meets the specific requirements of variousindustries such as power plants, cement plants, steel plants,coal gasification plants and various other grinding plants forgrinding of minerals.
Claudius Peters continues to invest in research anddevelopment:
● Wear resistant grinding element improvements
● Dynamic classifiers
● Test grinding plant at our facility for grindingapplication
The Claudius Peters EM-Mill is a ball ring mill for the grindingof all kinds of coal, gypsum, limestone, bentonite, clay,phosphate and other mineral materials.
‘the EM mill is designed to grind, dry,calcine and classify all within one unit’
Claudius Peters EM-Mills –Investment in Constant Performance
The characteristic features of EM-Mills are:
● Minimal sound emissions
● High productivity
● Low maintenance requirements
● Self adjusting hydraulic tensioning unit
● Mill inlet temperature up to 650 °C / 1200 °F
● No material remaining inside the mill duringstandstill
The gearbox and all inner mill parts are easily accessible formaintenance purposes. The grinding elements (balls andrings) can easily be replaced due to open access of the largemaintenance doors.
The grinding fineness of the material can be externallyregulated while the mill is operating. Waste materials suchas metal parts and pyrites are rejected from the mill duringoperation.
The robust design with no bearings or lubrication pointsinside the grinding zone, permits the highest hot gastemperatures for achieving the optimum drying conditions.
EM110-7115 with dynamic classifier
Gas-tight reject box
Generously sized drive for increased servicereliability.
Casing pressure shock resistant up to 3.5 bar g.Large mill doors to facilitate replacement ofgrinding elements.
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EM - Grinding Mechanism
The Functions
The Claudius Peters range of EM-Mills grind,dry, classify and transport material within asingle compact unit. The mills are the focalpoint of every Claudius Peters grinding andcalcining plant.
The wet material is fed into the center of therotating mill yoke and is distributed evenlybetween the grinding balls and lower ring.
The grinding forces are generated with ahydraulic cylinder system implemented for alloperating conditions. The ground material isforced off the outer edge of the grinding ring,where it is entrained into the gas stream,dried and carried up to the classifier.
As the gas stream is carrying the discharged product, thepulverized particles are carried to the classifier and theheavier oversized particles fall out of the gas stream andback into the grinding zone.
The classifier cuts the material by separating and dischargingthe pulverized particles of a certain fineness or less fromlarger materials. Oversize particles are rejected from theclassifier and recirculated back to the grinding zone. Bothstatic and dynamic classifiers have been specificallydesigned for the EM-Mills, and are selected according to therequired fineness and accuracy specification.
Working Range of EM-Mills
● Processing of hard, bituminous and lignite coals,other fossil fuels and minerals
● Up to 25% moisture content in the raw material
● Fineness between 1% and 50% residue on 0,09 mm
Shock-absorbing, self-adjusting hydraulic system: Pressure and wearoptimization for low energy consumption.
Static or dynamic classifiers can be adjusted toobtain the exact desired product fineness.
Maintenance Free Marathon Runners
The grinding mechanism design of theEM-Mill is based on a giant axial ballbearing. While the milling rolls of aconventional roller mill are stationary, theballs in the EM-Mill can move freelybetween the grinding rings. The ballsremain symmetrically round throughouttheir service life. The geometry of thegrinding mechanism guarantees aconstant throughput and finenessthroughout the operating service life.
During operation, a material bed layerforms between the balls and the grindingrings. When the mill shuts down, thematerial bed layer is reduced and theballs sweep the remaining product from the milling ring trackavoiding build-up. This creates the safest possible conditionsin the mill during shut down. It is possible to operate the millsafely without any feed.
Unlike many other mills, the EM-Mill’s grinding elementsfunction maintenance free. Additional costs and unscheduled
downtime for sealing, lubrication, oil changes andreplacement of internal bearings are not required as well asequipment modifications and adjustments.
A wear life up to 40,000 hours can be achieved by employinghighly wear resistant materials for the grinding elements.
Stationary Operating
Grinding elements after 25,000 hours maintenance free operation.
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EM-Characteristics, Economical and Energy Efficient
The axial forces are absorbed with a rockersegment bearing in the upper part of thehousing. By selecting the optimum ratio betweensegment bearing diameter and supportinghousing walls, only very small bowing stressesoccur. The oil enters through nozzles between thesegments. During operation, oil pressure, oiltemperature, flow and differential pressure in thefilter are constantly monitored. The amount ofgear oil is checked through an inspection glassin the housing.
Spiral-toothed bevel spur gears are typicallyused within the gearbox. The drive is designedto be quickly restarted following an emergencystop of the grinding plant without having to clearthe grinding chamber.
The grinding mechanism is able to withstandforeign particles between the grinding surfaceswithout stoppage. When the ball and rings comeinto contact with these obstacles, the resultingshock force is completely absorbed bytensioning springs without straining the hydraulicsystem.
The grinding balls automatically reject any foreign particle offthe grinding ring track, and the scraper conveys them to thereject box.
Heavy duty gear
The gearbox is equipped with an electric oil heater, which isactivated when the oil temperature drops below 15oC. The millcannot be started if the oil temperature is lower than 15oC.
Claudius Peters Classifiers – the Finest
The classifier performs the fineness separation work in thegrinding process. In addition to the precise adjustability ofproduct fineness, it is necessary for the classifier to create aproduct with steep particle size distribution by rejectingcoarse material back to the grinding zone.
The Claudius Peters static and dynamic classifiersspecifically developed for our EM-Mills meet theserequirements. Both classifier types are custom engineeredto suit the required operational air quantities.
Dynamic Classifier
In recent years, the demand from various industries to obtainoptimum burnout of coal dust for pulverized fuel firedinstallations has continued to rise. Additionally, manygovernmental agencies have issued strict environmentalprotection measures concerning nitrogen oxide (NOx)emissions. These two factors have led to stricter tolerancerequirements on the classifier’s performance.
The DSK dynamic classifier combines technical capabilitieswith reliable solutions. Our experience has proven that theDSK type dynamic classifier significantly improves the NOxvalue and the unburnt carbon content in the ashes.Furthermore, a dynamic versus static classifier can increasethe throughput of up to 20% if required.
As in the static classifier, the coal dust particles are alsosubjected to a vortex flow. However in a dynamic classifier,this vortex is produced by a motor driven rotor. The finenessof the material passing the classifier is directly related to thespeed of the rotor.
Economic operation is guaranteed by many technicalfeatures:
● Reproducibility of fineness adjustment
● Staged series of unit sizes
● Central raw feed inlet for materials with highmoisture
● Generously sized rotor bearing designed for morethan 50,000 operating hours
● Automatic bearing lubrication system is available
Static Classifier
The adjustment to the required fineness is achieved byadjusting the openings to the classifier guide vanes, eithermanually or motor driven. The product to air mixture comingfrom the milling section flows through these vanes and formsa vortex. The resulting centrifugal forces cause the heavieroversize particles to separate from the air stream and fallback again into the grinding mechanism.
In our experience, with coal applications, the EM-Millsequipped with static classifiers
reach grinding finessesof less than 7% residueon 0.09mm.
Dynamic Classifier Type DSK
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Reliability in Coal Grinding
Safety
Claudius Peters grinding plant can operate under a varietyof safety criteria.
In the safest process, inert operation, the oxygen level islowered to less than 10% under all operating conditions. Allvalues of O2 and CO are continuously monitored andoptimized automatically, thereby preventing dust explosions.
Alternatively when inert operation is not possible, for instancein power station service, the pressure shock resistant milldesign (up to 3.5 bar g) guarantees the highest possibleoperational safety.
The ball ring grinding mechanism of the EM-Mills cleans itselfautomatically during the shutting down phase. Therefore,self-ignition of coal built up on the grinding ring track iseffectively prevented.
Claudius Peters milling and grinding plants comply withsafety regulations according to VDI 2263, VDI 3673, VGBR200 and Guideline 94/9/EC as well as NFPA 68, 69 and 85.
Economy
Every size of Claudius Peters EM-Mill is designed tomaximize economic efficiency. Maintenance free grindingelements keep operational cost to a minimum. Thethroughput and product fineness remain constant throughoutthe service life of the grinding elements due to the effectivesize of the grinding surface remaining the same in all wearconditions. This ensures an optimum, constant, and specificenergy consumption for each ton of coal that is ground.
EM-Mills do not require a sealing air fan when operating atsub-atmospheric pressures.
Coal Milling, Drying and Injection Plant for a Blast Furnace
Adding value - economic coal preparation process for low rank coals
Due to the high moisture content of so called “low rank coals(moisture content up to 60%)” the requested residualmoisture will be achieved in a two-step drying system only.Prior to the coal milling and drying plant a raw coal pre dryingplant will be installed.
● In a first step the pre-crushed coal (< 25 mm) willbe dried to approximately 20% moisture usinghigher temperatures than allowed for pulverizedcoal at a reasonable airflow and a low pressure drop
● In a second step the coal will be ground to therequested fineness and dried from about 20 %moisture to the required residual moisture at themaximum allowed temperature for pulverized coals
Combination of the two steps is the most economical andsafe solution for the design of coal preparation plants for lowrank coals.
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3D model of Coal Grinding Plant
Flow diagram of Coal Preparation Plant
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Proven Technology in the Gypsum – and Minerals Industry
The EM-Mill can operate on a wide range of applications andis optimized in design for material specific requirements.Various tasks such as the grinding of dry limestone rock tothe full calcination of gypsum is served by Claudius Petersproven technology. In the minerals industry, Claudius Petershas supplied approximately 200 mills since 1960, includinginstallations of more than 90t/h product capacity in one singlemill for these applications.
The Claudius Peters Mill design allows the high temperaturesnecessary for the calcination of certain materials such asgypsum. This ensures the economic advantage of combiningthe simultaneous grinding, classifying, drying and/orcalcining in one compact unit. The high EM-Mill inlet gastemperature results into a lower energy consumption due tolow gas volumes and the direct heat transfer from the hot gasto the material. Low material retention time in the mill allowsfast reaction of the installed control circuits and provides auniform product quality as well as fast and easy changes incharacteristics such as product fineness.
In the gypsum industry the EM-Mill is the preferred grindingand calcining technology for finished products such asGypsum Wallboard.
The mill calcining system alone or combinations withClaudius Peters Flash Calciners, Kettles and Coolers allowus to engineer the optimal system for the required productquality and system performance.
EM65-592 Gypsum Calcining System with Claudius Peters Fluid Bed Cooler
● Simple operation and maintenance
● Maintenance free grinding elements
● No bearings inside the mill
● Inlet temperatures up to 650°C, optimalperformance
● Highest lifetime of grinding elements
● Ultrafine grinding with optional dynamic classifier
● Combination and integration of other ClaudiusPeters equipment, providing maximum flexibility
Working Principle of Claudius Peters EM-Mill
Claudius Peters Gypsum Rotary Drum Cooler
The Technical Center– Experience by Research
For the grinding of raw materials, most new or modifiedapplications require a series of grinding tests before plantdesign can be finalized.
These tests will accurately determine the grindability andwear behaviour of the respective product. In particular, rawmaterial blends compared to pure raw materials may behavequite differently in the grinding process. While passingthrough the grinding cycle, specific components within thematerial mix may considerably influence the throughputcapacity and wear behaviour of the system.
In the technical center Claudius Peters has installed acomplete grinding plant with an average throughput of about1 t/h. This plant can be used for testing of the grindingbehaviour of various materials and for tailor-made design ofthe milling – and drying process.
In addition all kinds of pneumatic conveying test facilitiesincluding 5 km pneumatic conveying line to determine thematerial characteristics for conveyance, storage and packingof the pulverized products are installed at the technicalcenter.
Claudius Peters Technical Center
Dynamic classifier - test grinding mill (EM 17)
Test grinding mill (EM 17)
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CALCINING | COOLING | DISPATCH
DOSING | DRY BLENDING | DRYING
GRINDING | PACKING
PNEUMATIC CONVEYING
PULVERIZED FUEL SUPPLY
SILO SYSTEMS
STOCKYARD SYSTEMS
ALUMINA HANDLING SYSTEMS
MARINE POWDER HANDLING
TURNKEY PROJECTS
We know how
Claudius Peters (do Brasil) Ltda.Rua das Figueiras | 474 | 3º andar |Bairro Jardim | Santo André | SP |CEP 09080-300 | BrasilTel: +55 (11) 3092-8030 Fax: +55 (11) [email protected]
Claudius Peters (China) Ltd.Unit 1706-1706 |17/F Laws Commercial Plaza |788 Cheung Sha Wan Road |Lai Chi Kok | Kowloon |Hong KongTel: +852 2544 1848Fax: +852 2854 [email protected]
Branch Office:7/F | Office Block |Hong Kong Macau Centre |No. 2 Chaoyangmen Bei Da Jie |Beijing 100027 | P. R. ChinaTel: +86 10 6501 3831Fax: +86 10 6501 [email protected]
Claudius Peters (India) Pvt. Ltd.Unit 408 | 4th Floor | Peninsula Plaza |A/16 Fun Republic Lane |Off Link Road | Andheri West |Mumbai 400 053 |IndiaTel: +91 (22) 2674 [email protected]
Claudius Peters (Italiana) srlVia Verdi 2 |I-24121 Bergamo |ItalyTel: +39 0 35 237 196Fax: +39 0 35 237 [email protected]
Claudius Peters (România) S.R.L.Str. Oituz Nr. 25C | et 2 |550337 Sibiu |RomâniaTel: +40 (0) 369 407 036Fax: +40 (0) 369 407 [email protected]
Claudius Peters (Asia Pacific) Pte. Ltd.25 International Business Park |#04-13/14 German Centre |Singapore 609916T +65 6562 9100F +65 6562 9109E [email protected]
Claudius Peters (Ibérica) S.A.Paseo de la Habana | 202 Bis Bj |E-28036 Madrid |SpainTel: +34 91 413 36 16Fax: +34 91 519 69 [email protected]
Claudius Peters (UK) Ltd.Unit 10 | Thatcham Business Village |Colthrop Way | Thatcham |Berkshire | RG19 4LW |United KingdomTel: +44 (0) 1635 872139Fax: +44 (0) 1635 [email protected]
Claudius Peters (Americas) Inc.445 West Bush Turnpike |Richardson | Texas 75080 |USATel: +1 972 386 4451Fax: +1 972 386 [email protected]
HEADQUARTERS
Claudius Peters Projects GmbHSchanzenstraße 40 |DE-21614 Buxtehude | GermanyTel: +49 (0) 4161 706-0Fax: +49 (0) 4161 [email protected]
Claudius Peters Technologies SAS34 Avenue de Suisse |F-68316 Illzach | FranceTel: +33 (0)3 89 31 33 00Fax: +33 (0)3 89 61 95 [email protected]
The information contained within this brochure is deemed to be correct at the timeof going to press. Due to the policy of continued improvement, we reserve the rightto change any specification without prior notice.ERRORS & OMISSIONS EXCEPTED
CP Grinding GB October 2012/Issue 3/JWN www.claudiuspeters.com
