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Sc hnatz R 04 M ay 2009 C:\Daten\Vom _Netz \Ind ien\Green Cem entec h2009\GCT 2009-05-07.pptPage 1
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
Sc hnatz R 02 M rz 2005 Sc hnatz R D:\Daten\Vom _Netz \taiwan-02-04\grinding-al l .ppt04 M ay 2009 C:\Daten \Vom _Netz \Indien\Green Cem entec h2009\GCT 2009-05-07.pptPage 2
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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Green Cement ech 2009, 7t h & 8 th of M ay, No votel Hyderab ad
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
Sc hnatz R 04 M ay 2009 C:\Daten\Vom _Netz \Ind ien\Green Cem entec h2009\GCT 2009-05-07.pptPage 4
Green Cement ech 2009, 7t h & 8 th of M ay, No votel Hyderab ad
Ball Mill w/ Separator (ZemSi)
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Sc hnatz R 02 M rz 2005 Sc hnatz R D:\Daten\Vom _Netz \taiwan-02-04\grinding-al l .ppt04 M ay 2009 C:\Daten \Vom _Netz \Indien\Green Cem entec h2009\GCT 2009-05-07.pptPage 5
Green Cement ech 2009, 7t h & 8 th of M ay, No votel Hyderab ad
Combined Grinding Plant, Example
Sc hnatz R 04 M ay 2009 C:\Daten\Vom _Netz \Ind ien\Green Cem entec h2009\GCT 2009-05-07.pptPage 6
Green Cement ech 2009, 7t h & 8 th of M ay, No votel Hyderab ad
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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Sc hnatz R 02 M rz 2005 Sc hnatz R D:\Daten\Vom _Netz \taiwan-02-04\grinding-al l .ppt04 M ay 2009 C:\Daten \Vom _Netz \Indien\Green Cem entec h2009\GCT 2009-05-07.pptPage 7
Green Cement ech 2009, 7t h & 8 th of M ay, No votel Hyderab ad
Finish Grinding, Example
Sc hnatz R 04 M ay 2009 C:\Daten\Vom _Netz \Ind ien\Green Cem entec h2009\GCT 2009-05-07.pptPage 8
Green Cement ech 2009, 7t h & 8 th of M ay, No votel Hyderab ad
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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Sc hnatz R 29 J u l 2004 Schnatz R D:\Daten\Vom _Netz \Kesov er\Static_Dy nam ic _Separator.ppt04 M ay 2009 C:\Daten\Vom_Netz \Ind ien\Green Cementec h2009\GCT 2009-05-07.pptPage 9
Green Cement ech 2009, 7t h & 8 th of M ay, No votel Hyderab ad
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®
Sc hnatz R 29 J u l 2004 Schnatz R D:\Daten\Vom _Netz \Kesov er\Static_Dy nam ic _Separator.ppt04 M ay 2009 C:\Daten\Vom_Netz \Ind ien\Green Cementec h2009\GCT 2009-05-07.pptPage 10
Green Cement ech 2009, 7t h & 8 th of M ay, No votel Hyderab ad
• 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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Green Cement ech 2009, 7t h & 8 th of M ay, No votel Hyderab ad
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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Green Cement ech 2009, 7t h & 8 th of M ay, No votel Hyderab ad
Outlet bend
Intermediate productand air
Grit II
Air
Product
SEPOLθ HR – The Concept
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Sc hnatz R 04 M ay 2009 C:\Daten\Vom _Netz \Ind ien\Green Cem entec h2009\GCT 2009-05-07.pptPage 13
Green Cement ech 2009, 7t h & 8 th of M ay, No votel Hyderab ad
SEPOLθ HR – The Concept
Sc hnatz R 04 M ay 2009 C:\Daten\Vom _Netz \Ind ien\Green Cem entec h2009\GCT 2009-05-07.pptPage 14
POLYCOM
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Green Cement ech 2009, 7t h & 8 th of M ay, No votel Hyderab ad
POLYCOM® - Wear Protection
BainiteForged/hardfaced Compound Cast
profiling
Build up welding
Base material
profiling
Base material
profiling
Hard layer
Base material
Sc hnatz R 04 M ay 2009 C:\Daten\Vom _Netz \Ind ien\Green Cem entec h2009\GCT 2009-05-07.pptPage 16
Green Cement ech 2009, 7t h & 8 th of M ay, No votel Hyderab ad
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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Sc hnatz R 04 M ay 2009 C:\Daten\Vom _Netz \Ind ien\Green Cem entec h2009\GCT 2009-05-07.pptPage 17
Green Cement ech 2009, 7t h & 8 th of M ay, No votel Hyderab ad
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)
Sc hnatz R 04 M ay 2009 C:\Daten\Vom _Netz \Ind ien\Green Cem entec h2009\GCT 2009-05-07.pptPage 18
Green Cement ech 2009, 7t h & 8 th of M ay, No votel Hyderab ad
Industrial Applications - Plant Layout
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Sc hnatz R 04 M ay 2009 C:\Daten\Vom _Netz \Ind ien\Green Cem entec h2009\GCT 2009-05-07.pptPage 19
Green Cement ech 2009, 7t h & 8 th of M ay, No votel Hyderab ad
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.
Sc hnatz R 04 M ay 2009 C:\Daten\Vom _Netz \Ind ien\Green Cem entec h2009\GCT 2009-05-07.pptPage 20
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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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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Green Cement ech 2009, 7t h & 8 th of M ay, No votel Hyderab ad
Static dynamic Separator concept
Feed materia l
Hot gas
Grits
Produc t
Process gas
STA
TOSE
PD
ynam
ic S
EPO
L LM
C
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