PRAGUE 13-15 June 2016 Hosokawa Alpine …

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Hosokawa Alpine Aktiengesellschaft, Augsburg, GermanyMinerals & Metals Division

Mr. Dietmar Alber

IM 23PRAGUE

13-15 June 2016

Processing developments: What are the innovations in mineral processing?

• What are the developments in producing finer products into the market?

• What part do quality and consistency play in technological advancements and market desires?

• What technological innovations are helping to increase efficiency and cut costs in processing?

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Topic & Discussion

> Formation of the Hosokawa Micron Corp., Osaka: 1916> Shares are traded at the stock markets of Osaka und Tokyo> Production locations worldwide in 5 countries> 16 R&D and test centres worldwide at 11 locations> ca. 355 Mio. EUR consolidated turnover (Financial Year 2014/2015)> ca. 1500 employees worldwide

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HOSOKAWA MICRON Group

HOSOKAWA MICRON Corporation, Osaka, Japan

> Formation of the Hosokawa Alpine, Augsburg: 1898> Since 1987 part of Hosokawa Micron Group> Huge production facilities> Huge R&D and test centres with 65 pilot systems> ca. 152 Mio. EUR consolidated turnover (Financial Year 2014/2015)> ca. 650 employees in Augsburg, Germany

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HOSOKAWA ALPINE Augsburg, Germany

HOSOKAWA Alpine, Augsburg, Germany

• Strong trend towards finer products even into submicron range

• Dry processing of these fine powder down into the submicron rage

• Increase processing efficiency

• Reduce specific energy consumption

• “contamination free” processing for High End applications

• Apply wet processing for ultrafine products & products in submicron range

• Master tailored particle size distributions & “shaping” of particles

• Trend to much bigger sized production capacities

• Optimized investment and running cost

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General Trends in the Industrial Mineral Filler Industry

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Industrial minerals are geological materialswhich are mined for their commercial value, which are not fuel, not sources of metals. They are used in their natural state or after benefication.

Industrial Mineral Fillers are a variety ofprocessed industrial minerals that may beirregular, fibrous or platy in shape and whichare typically used in large volume in paper, plastic, paint and rubber industries.

Definition Industrial Mineral Filler

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High-Tech Mineral Powders

For High-Tech Products

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Typical Industrial Mineral Fillers

> Calcium Carbonate> Talcum> Barite> Kaolin> Wollastonite> Bentonite> Diatomite> Aluminium oxide> Silica & Quarz> Zirconsilicates

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Typical Industrial Mineral Fillers

> Calcium Carbonate =>> Talcum> Barite> Kaolin> Wollastonite> Bentonite> Diatomite

Common Sizes of Industrial Mineral Fillers

• standard products: D97 = 20 – 160 µm

• ultrafine products: D97 = 5 – 20 µm

• superfine products: D97 < 5 µm=>

Dry Processed GCC at D97 < 2 – 10 µm

Energy Efficient Dry Processing of Ultrafine GCC fillers

below D97 = 10 µm

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11

grinding 1500 B.C.

classification anno 950 A.C.

History of Powder Processing

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13

VS

ALPINE Super Orion Ball Mill SO-SF

ALPINEAgitated Ball Mill ATR

both working in closed circuit with High Efficient Ultrafine Classifiersand able to process ultrafine and superfine GCC fillers

Working Principals, Limits andEnergy Considerations

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ALPINE Super Orion Ball Mill SO-SF

ALPINEAgitated Ball Mill ATR

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ALPINE Superfine Ball Mill Systems

GCC dry grinding down to D97 = 3.2 µm on Superfine Ball Mill Systems

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ball mill revolution (r.p.m.)

number of grinding chambers

selections of grinding media sizing of the grinding media

L/D ratio of the ball mill drum

selection of mill lining

mill discharge system

ball mill filling level

Processing Parameters of Dry running ball mills

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Screen-Shot 1000 TTD withSO-SF 270/660 Superfine Ball Mill

SO-SF 270/660

1000 TTD

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Typical values ofSuperfine Ball Mill Systems SO-SF

Ball mill: SO-SF 270/660, 710 kW DriveClassifier: 1000 TTD

Products: D97 = 3,5 µm, (70 % < 2.0 µm) 1,800 kg/hD97 = 10 µm, (D50 = 2.3 µm) 7,300 kg/h

Fineness of 80 % < 2.0 µm possible

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Innovation – ALPINE TTD Classifier

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highly air dispersedfeed material, targeting directly tothe classifier wheel

coarse material reject outlet

coarse material classifierwith secondary classifyingair inlet,

double flooded fine material outlet

One Classfier for all finenesses 3 – 45 µm

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GCC dry grinding

down to D50 = 0.8 µm (D97 = 2,2 µm)

ALPINE Agitated Ball Mill ATR Systems

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Agitated Ball Mill Systems up to D50 = 0.8 µm

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Energy-efficient GrindingTypical technical data:

Mill diameter: 900 mmMill height: 4.5 mDrive unit: 400 kWGrinding bin volume: 2 m3 lGrinding media: ceramic

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Advantages of Agitated Ball Mill Systems

High fineness High capacity Compact design Iron-free grinding Low peripheral speed Low grinding media wear Low operation costs Optimum energy utilisation

Designated for products D97 = 2.2 – 10 µm

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Sine Qua Non ConditionHigh Tech Ultrafine Classifier up to D97 = 2.5 µm

Reaching very high fineness Highest possible output Very sharp top cut Excellent fines yield Ability of air dispersing Lowest energy

consumption Reliability in daily rough

operation in mineralindustry

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Calcite Processing with ATR(Analysed with Rhodos laser)

0,0

10,0

20,0

30,0

40,0

50,0

60,0

70,0

80,0

90,0

100,0

0,1 1,0 10,0Fines in Microns

Pass

in %

ATR-Product

Calcite Processing

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0

100

200

300

400

500

600

700

800

900

1000

1 2 3 4 5 6 7 8

SO+TTD kWh/t

ATR+ATP/NG kWh/t

Comparison Specific Energy Consumption

SO-SF versus ATR system including classification

kWh/t

D97 = x µm

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Comparison Specific Energy Consumption

SO-SF versus ATR system including classification

D97 µm SO+TTD kWh/t ATR+ATP/NG kWh/t

2,2 720

2,5 615

3 950 550

3,7 750 425

5 385 260

8 192 187

10 147 155

20 97 120

Calculation example for D97 = 5,0 µm: SO-SF system additional 120 kWh/t x 7200 h/a = 864.000 kWh/a at one ton of product per hour => 0,12 ct/kW => 103.680 €/t = 259.200 €/a for 2,5 t/h production capacity of a 900 ATR system

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Comparison Specific Energy Consumption

SO-SF versus ATR system including classification

D97 µm SO+TTD kWh/t ATR+ATP/NG kWh/t

2,2 720

2,5 615

3 950 550

3,7 750 425

5 385 260

8 192 187

10 147 155

20 97 120

Calculation example for D97 = 3,0 µm: SO-SF system additional 400 kWh/t x 7200 h/a => 2.880.000 kWh/a at one ton of product per hour => 0,12 ct/kW => 345.600 €/t = => 414.720 €/a for 1,2 t/h production capacity of a 900 ATR system

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ALPINE Pulvis PVDry Agitated – Classifier Mill for ultrafine and submicron powders

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0,0000010,000010,00010,0010,010,111010010001 m 1 mm10 mm100 mm 10 nm100 nm1 µm10 µm100 µm 1 nm

agitated wet mills

wet ball mills

pan mills

dry ball mills

Table roller mills

classifier mills

impact miulls

jet mills

dry agitated classifier mills

impact crushers

crushers

wet

dry

Particel size

Pulvis

Working Range for PULVIS

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Innovation „Pulvis“Dry Agitated Classifier Millfor ultrafine and submicron powders

Key Points of Pulvis>Highest achievable fineness in dry

processing>Low specific grinding energy>Compact desing and plant >Low contamination>For soft and hard minerals>Highly wear protected>Alternativ for Jet Mills solutions

Air

Fines

Feed

Mill

Classifier

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PULVIS PV Models

Size PV-150 PV-250 PV-450 PV-600 PV-800 PV-1000

Mill Drive [kW] 0.75 2.2 11 18.5 37 75

Classifier Drive [kW] 1 1 3.7 7.5 15 30

PV-150 PV-800

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Applications of PULVIS

Products:>Soft and Hard Minerals>Ceramics>Batterie Raw Materials>Metall Oxide>Pigments, Graphit

Energy Efficient Wet Processing of Ultrafine GCC fillers

below D97 = 10 µm

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Alpine Wet Agitated Ball Mill Line ANR-CL

The heart ofyour process

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ALPINE Agitated Vertical Ball Mill ANR-CL

Model Volume GrindingChamber

Drive

250 ANR-CL 70 ltr 15 kW

500 ANR-CL 550 ltr 110 kW

630 ANR-CL 1100 ltr 200 kW

710 ANR-CL 1570 ltr 315 kW

800 ANR-CL 2400 ltr 500 kW

900 ANR-CL 3200 ltr 630 kW

1000 ANR-CL 4400 ltr 1000 kW

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Wet Grinding with the ANR-CLTypical production capacities for 710 ANR-CL (315 kW drive):

- C60: 5,5 t/h @ 45 kWh/t* (grinding energy)

- C75: 3,1 t/h @ 80 kWh/t* (grinding energy)

- C90: 2,0 t/h @ 120 kWh/t* (grinding energy)

- C95: 1,6 t/h @ 150 kWh/t* (grinding energy)

- C98: 1,3 t/h @ 180 kWh/t* (grinding energy)Typical solids contents:

C60: 60 – 75 %C75 – C98: max. 78 %

* = medium hardness

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Advantages ANR-CL:• steep particle size distribution

• 1-step grinding up to 90% < 2 µm

• 2-step grinding up to 99% < 2 µm

• 4 motor motor drive (water cooled at 1 gearbox

• low foot print – less space

• 400 oder 690 V possible (no expensive high voltage !)

• start up by F/C

• variable stirrer speed for operation

• stirrer shaft direct connected to gear box

• no inlet screen – no blockage

• classifier wheel on top keeps grinding beads back

• low cooling power

• quick and easy installation (plug and play)

• low maintenance cost

ANR-CL – Advantages

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Dry – Wet – Coated - GCC

Dry: AWM Wet: ANR-CL (s) Drying & Coating LGM

30mm D99 = 45 µm 60 to 98 % < 2 µm coated powder

Drying & Coating on Long Gap Mill; LGM

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Example LGM 20:

Drying of 7,5 t/h GCC slurry C 90

Optional caoting simultan

Energy Efficient Wet Processing of Ultrafine Hard Minerals

below D97 = 10 µmdown to Nano Size

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Wet grindingof

Soft and Hard

Minerals

Alpine Hydromill 400 AHM

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Circuit Grinding Process for Nano Size

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From Laboratory Mill 90 AHM to 800 AHM (315 kW)

Technical data 90 AHM:

Grinding chamber volume :90 AHM: 1.10 Liter90/3 AHM: 0.50 Liter90/1 AHM: 0.25 LiterDrive: 2.2 kWMax speed: 4200 rpm

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PICO-Liq Agitated Wet Mill

For processing of 1 gram of powder

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0

10

20

30

40

50

60

70

80

90

100

0,01 0,1 1 10

particle size [µm]

Q3

[%]

feed5 kWh/kg15 kWh/kg25 kWh/kg

Wet Milling of Nano-scaled ParticlesAnalyzed by Dynamic Light Scattering

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15 kWh/kg

0 kWh/kg

25 kWh/kg

5 kWh/kg

Wet Milling of Nano-scaled ParticlesVisualized by Transmission Electron Microscope

Processing developments: What are the innovations in mineral processing?

• What are the developments in producing finer products into the market?

• What part do quality and consistency play in technological advancements and market desires?

• What technological innovations are helping to increase efficiency and cut costs in processing?

48

Left Topic

Quality and consistency:

- Are a must and driver of technological advancements and is a market desire

- Target quality of powders need top quality of processing equipment

- Highest availability of processing equipment is a must and a precondition of mineral producers from their market/customers

- Consistency includes quickest service, global service networkand easy maintenance

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• Strong trend towards finer products even into submicron range

• Dry processing of these fine powder down into the submicron rage

• Increase processing efficiency

• Reduce specific energy consumption

• “contamination free” processing for High End applications

• Apply wet processing for ultrafine products & products in submicron range

• Master tailored particle size distributions & “shaping” of particles

• Trend to much bigger sized production capacities

• Optimized investment and running cost

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Summarizing Trends in theIndustrial Mineral Filler Industry

Thank

you very much

for

your attention !