PREBLENDING OF RAW MATERIAL

A Cement Works Beneficiation Sequence

Raw Materials Preblending Learning Objectives

Knowledge of the major concepts in raw material pre-blending Knowledge of impacts on performance of preblending systems Knowledge of basic concepts in raw mix composition

Preblending Concept How to eat a Black Forest Cake? Stacking Reclaiming Methods (1) Conical-Shell stacking stacking side reclaiming front reclaiming

Method two Stacking Reclaiming Chevron stacking Windrow stacking front reclaiming front reclaiming

Method three : Strata stacking

different types of stackers : Tripper belt Side stacker Reversing belt

=============================================================== ============================ Different types of Reclaimers :

Scraper Chain type side reclaimer

Portal type reclaimer

Bridge type with Harrow

Scraper Chain Arrangements

For sticky materials

Schade type Portal Front Reclaimer

=============================================================== ===========================================

System Configuartions Preblending Systems Stacker/Reclaimer Configurations

SIDE RECLAIMER CONICAL SHELL FRONT RECLAIMER

CHEVRON CHEVCON

WINDROW

Not applied

Longitudinal Preblending System Configuration

=============================================================== ======================== Preblending Efficiency Influencing Factors Longitudinal preblending bed:

Periodicity of input fluctuations, sequence of alimentation Length/width ration (pile geometry) Method of stacking Travel speed of stacker Stacking capacity Method of reclaiming

=============================================================== ==================== Circular Preblending Systems

Circular Preblending System Chevcon Stacking

Pile geometry

Reclaimers Bridge type with Scraper Activator

Preblending Efficiency Influencing Factors Circular preblending bed:

Periodicity of input fluctuations, sequence of alimentation Diameter (pile cross section) Method of stacking Stacking angle Travel speed of stacker Stacking capacity

Direct Mill Feed + Lower investment costs + Less equipment / maintenance + - Possible exclusively with circular preblending systems - Variable reclaimer speed for mill feed conveyor system

Only recommended in cases of raw mix composition is not demanding, i.e. one characteristic only to control

=============================================================== ========================= Comparison Longitudinal/Circular Preblending Longitudinal - Discontinuous process - End cone problem - Important foot print - High investment - Direct mill feed not possible + all equipment easily accessible

+ more tolerant regarding periodicity of input fluctuation Circular + Continuous process + No end cone problem + Smaller foot print + Lower investment + Direct mill feed possible - Underground installation difficultly accessible - Input needs always to be close to set-point Damping of Chemical Fluctuation inlet fluctuations outlet fluctuations adjacent pile systems outlet fluctuations separate pile systems outlet fluctuations continuous systems

=============================================================== =========================================================

Knowledge of impacts on performance of preblending systems

Impacts on performance System design & sizing

Longitudinal pre-blending systems o Number of layers: > 250 o Length/width ratio: > 4 : 1 o Reversing points: fixed/variable o Uniformity (sLSF ex mill) < 3.0 o Method of reclaiming o Circular pre-blending systems o Number of layers: > 250 o Uniformity (sLSF ex mill) < 3.0 o Method of reclaiming

Impacts on Performance Blending efficiency

e =: blending efficiency n =: number of layer A =: cross section of pile vs =: stacker speed q =: stacking rate

Always complete formation of a pile as blending efficiency is lost at reduced pile cross section In case of a low number of layers consider stacker speed-up, observing normal working speed (vs =: 20 up to 30 m/min) Do not push crusher performance to the limit

Impacts on Performance The end-cone problem Segregation with fixed stacker reversing points

Coarse particles tend to roll down the slope of a pile On start-up of a new pile a few layers only are cut by the reclaimer Predominately coarse material is reclaimed at the beginning

Impacts on Performance The end-cone problem

The Problem:

Peak disturbances when cutting new piles

Solutions:

Correcting the disturbance by means of additive proportioning is symptom fighting Improved layering solves the problem at its source

Impacts on Performance The end-cone problem The solution:

Optimum layering in the end-cones of longitudinal systems i.e. operation of the stacker with variable reversing points All layers open on inner pile end Adjusted layer thickness on outer pile end

============================================================= Variable Stacker rev. Points Requirements

Sensors/Encoders for the determination of angles, travel distances, speeds, stacker position Actors for stacker operation

Variable Stacker rev. Points Reference Points The following reference point sensors need to be fixed to the rails

Marks for absolute pile ends (as safety switches) Mark for the center position between both piles Reference distance to correct encoder result for slippage of wheels

=============================================================== ===================== Variable versus Fixed Stacker Reversing Points Pre-blending system

Reduced compositional peak disturbances when starting product reclaim from new piles Reduced compositional variations out of longitudinal pre-blending systems

Blending Silo

Reduced compositional peak type disturbances going into the blending silo Reduced compositional variations out of blending silos

=============================================================== =============== Impacts on Performance Material activation

Optimum material activation

i.e. rather use bows than pins for materials activation by the harrow

Impacts on Maintenance Chain transition

Design of transition of the reclaimer chain to the delivery chute to be based on o a guided rail design rather than a sprocket wheel

Impacts on Maintenance Loosening the bottom

Prevent compaction of system floor as to prevent damaging the scraper blades while relocating the reclaimer to a new pile o i.e. installation of loosening teeth at shovels and harrow

Prevent operation of reclaimer bridge in oblique position o by loosening the side piles o by cleaning the rails

Longitudinal Preblending Systems Layouts

Knowledge of basic concepts in raw mix composition

Pre-Blending Pile Systems Concepts

Component preblending + allows for independent operation of quarries + allows for meeting different requirements regarding component crushing + ease of handling of critical components + less stringent control required

more equipment, high investment

Integrated preblending + less equipment + lower investment -coordinated quarrying/crushing stringent chemical control of feed is indispensable ======================================================= Proportioning of major components

out of preblending system(s) via mill feed bin(s) directly out of preblending system (for circular systems only)

Proportioning of minor components

out of preblending system(s) (in case portion in mix > 5%) via mill feed bin (in case portion in mix < 5%)

Uniformity Goals raw meal uniformity: without preblending: sLSF: < 4.0 with preblending: sLSF: < 3.0 Kiln feed uniformity: sLSF: < 1.2 BF cont blending silos: up to 5:1

BF homogenizing silos: > 5:

A Cement Works Beneficiation Sequence

Searched by : mohammed abdo