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Green Cement ech 2009, 7t h & 8 th of M ay, No votel Hyderab ad

Upgrading of Ball Mill Cement GrindingSystems with POLYCOM®

by Dr. -Ing. Robert Schnatz

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Green Cement ech 2009, 7t h & 8 th of M ay, No votel Hyderab ad

Scope of Polysius - Cement Grinding TechnologyBall mills

High-pressure grinding rollsPOLYCOM ®

Vertical mills:

Dynamic separator SEPOL®

DOROLQUADROPOL®

Cement cooler

Static dynamicseparatorSEPOL ®HR

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Ball Mill Combined Grin-ding Plant

Rollermill

+ proven technology + proven technology + proven technology

+ simple maintenance + high flexibility + high drying capability

+ Cement quality ac-cepted by clients

+ Cement quality ac-cepted by clients

+ lowest energy demand

+ lowest Investment cost

+ low energy cost + for blast-furnace slag: leading technology at the market

+ high throughput rates possible

- lowest flexibility! - more complex layout - higher investment cost

- low drying capacity! - higher investment cost - high cement finenesses not possible

- highest energy cost - more complex maintenance

- cement quality not accepted overall

Assets and Drawbacks of the Grinding Systems

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Ball Mill w/ Separator (ZemSi)

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Combined Grinding Plant, Example

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Case studyBall mill

– current production 120 tph @ 3000 cm²/g– specific power consumption of total system 40 kWh/t– grinding media consumption 80 g/t– liner life time compartment 1 = 30.000h; 2 = 50.000h

Combi grinding upgra de– new production 230 tph @ 3000 cm²/g– specific power consumption of total system of 28 kWh/t– grinding media consumption < 20 g/t– liner life time single compartment: > 80.000h

Finish grinding operation– capacity of 100 tph @ 3000 cm²/g– specific power consumption of total system of 19 kWh/t

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Finish Grinding, Example

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Finish -Grinding Plant

Combined Gri n-ding Plant

Rollermill

+ proven technology + proven technology + proven technology

+ simple maintenance + high flexibility + high drying capability

+ lowest energy demand + Cement quality ac-cepted by clients

+ low energy demand

+ lowest Investment cost

+ lower energy demand + for blast-furnace s lag: leading technology at the market

+ high flexibility + high throughput rates possible

- limited throughput - more complex layout - higher investment cost

- high cement f ineness dif-ficult to obtain

- higher investment cost - high cement finenesses not possible

- more complex maintenance

- cement quality not accepted overall

Assets and Drawbacks of the Grinding Systems

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Separator too small!Replacement or addition of a 2nd one

Long Plant Downtime during Erection

Plant up-grade with Static Separator

Static separator

POL YCOM®

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• Compact De sign - lowBuilding Height

• High intermediate Fineness -High Blaine cements

• Finished Product Extraction -no 2nd separator needed(Plant Upgrades)

• High Separation Efficiency• Robu stness against Wear -

easy and cheap lining

SEPOLθ HR + POLYCOMθ for Cement and Raw Grinding

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Intermediate productand air

Aeration floor

Air supply duct

Aeration floor

Separating air

Feed material

Grit I

• Modular design

• Wear resistance

• Heat resistance

Demands:

SEPOLθ HR – The Concept

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Outlet bend

Intermediate productand air

Grit II

Air

Product

SEPOLθ HR – The Concept

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SEPOLθ HR – The Concept

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POLYCOM

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POLYCOM® - Wear Protection

BainiteForged/hardfaced Compound Cast

profiling

Build up welding

Base material

profiling

Base material

profiling

Hard layer

Base material

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146 roller pairs worldwide

Weight max. 28 t

Roll diameter max. 2,1 m

Roll width max. 1,6 m

Max. Operating time so far > 60.000 h

Worldwide use of bainite (08.2008)

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87 roller pairs worldwide

Weight max. 12 t

Roll diame ter max. 1,7 m

Roll width max. 1,0 m

Max. Operating time so far > 60.000 h

Worldwide use of compound cast (08.2008)

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Industrial Applications - Plant Layout

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Summary• Semi-finish grinding (combi-grinding) plants:

Throughput increase 50 - 200 %• Energy savings combi-grinding plant (cc ball mill system):

20 - 40 %• Energy savings Finish grinding plant: > 50 %• Plant downtime in case of an upgrade is less than a week.• POLYCOM and SEPOL HR – have latest wear protection

materials• Extensive R&D studies resulted in further optimisation of the

ball mill operation. Thus the specific energy consumption is further reduced.

• POLYCOM and SEPOL HR are proven heavy duty equipment for the cement industry.

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Upgrading of Ball Mill Cement GrindingSystems with POLYCOM®

by Dr. -Ing. Robert Schnatz

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Ball mill

Grinding aid

SEPOL grits

Inter media te pr oduct

L/D ratio = 2.3 only!

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Ball mill inlet

Air slide

Fine Ball Charge: 12 – 25 mm, low filling ratio: < 28 %

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Static dynamic Separator concept

Feed materia l

Hot gas

Grits

Produc t

Process gas

STA

TOSE

PD

ynam

ic S

EPO

L LM

C