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Martin Schneider, Dsseldorf, Germany CSI / TERI / ECRA Forum New Delhi, 19/20 September 2008
Extraction and blending Raw material grinding Raw material homogenisation Clinker production Cement grinding Conveying, packing, loading
total demand
~ 110 kWh/tcement
grinding system ball mill vertical roller mill high pressure grinding rolls Horomill
Horomill (70 %)
specific surface
Chronology: Manual comminution Hammer mechanism Edge runner Ball mill Vertical roller mill High pressure grinding rolls Horomill (ca. 1512) (ca. 1800) (ca. 1890) (ca. 1930) (ca. 1985)
ball mill
F F
VRM
friction
F F
HPGR
F F
compression
F
impact
ball mill
F F
friction
F F
compression
F
Intermediate diaphragm
Coarse grinding chamber Lifter plate lining 100 mm 60 mm balls Discharge diaphragm
Ball mill
Advantages combined drying and grinding reliable - long service life wide PSD high fineness good for abrasive materials
Disadvantages for high moisture external drying necessary high energy demand no explicit stress area
Objectives Lower grinding energy demand than ball mills Comminution to a large extent by using the compression Comminution in an explicit compression zone
grits
separator
grinding roller
mill feed
grinding table
Feed up to 60 mm Grinding pressure from 50 to 400 MPa Compacted cakes up to 40% fines and coarse particles
Compacted cakes
Disadvantages: - Drying capacity is limited to 4 % feed moisture - Application only for non-abrasive raw materials, due to wear of deglomerator
Pregrinding
Semi-finish grinding
Finish grinding
Horomill
12 HPGR
Speed: Limited to 1 - 1,5 m/s because of vibrations Bed thickness: Low
6
Speed:
18
Upper value not yet known Bed thickness: 2 to 3 times HPGR
Parameter product fineness (Blaine) RRSB slope specific energy demand (closed circuit)
Unit cm/g --
%
*)
100
open - closed circuit
60 to 70
50 to 60
70
--
hardfaced rolls
a g/t
100
clinker
0,1 0,1
10
100
1000
10000
100000
Impact
Pahl: Zerkleinerungstechnik
P/M M
~2,00
Vertical roller mill
M P/M M M
1,00
Modified horizontal roller mill: linear correlation also for high circumferential speed (limit not yet known)
P/M M M
Modified horizontal roller mill
0,0
1,0
operating point
2,0
3,0
Throughput [t/h]
10
HPGR:
8
Operation point not adjustable Independent adjustment of grinding force and thickness of grinding bed not possible
6
related grinding force power demand
Bond index
Comminution only by compression Compression of a grinding bed with defined thickness Independent adjustment of grinding force and thickness of grinding bed Low specific energy demand
Comminution by compression
Summary (1)
Ball mill High energy consumption Reliable - long service life of the wearing parts Limitation in feed moisture at high feed moisture external drying necessary High pressure grinding rolls High energy savings Limitation in feed moisture with external drying no limitation in material moisture Maximum achievable fineness 4 000 cm/g (clinker)
Summary (2)
Vertical roller mill High energy savings Very high material moisture contents (up to 25 %) can be processed Low wear costs Maximum achievable fineness 4 500 Blaine for OPC
Summary (3)
Horizontal roller mill (Horomill) Energy savings of 30 to 40 % Maximum achievable fineness 4 000 Blaine for OPC and 4 800 Blaine for slag
No comminution without energy input Highest efficiency of comminution by compression Objectives Optimisation of known grinding processes necessary Development of new comminution processes: comminution by compression in an explicit stress area Comminution in one process without postrefining