14/03/2011

1

COMFLEX ® – High Efficient and Flexible Comminution System

Dr. Stefan SeemannCologne, Germany

1

2

COMFLEX ® – High Efficient and Flexible Comminution System

I. Introduction

II. Efficient Comminution

III. Competent Operation

IV. Process understanding and optimization

14/03/2011

2

Full line engineering

and equipment supply

Individual machines

Equipment packages

Spare parts and the full

range of plant services

3

For cement plants KHD offers

Introduction Efficient Comminution

Competent Operation

Process Overview

4

Operating Structure Overview

Introduction Efficient Comminution

Competent Operation

Process Overview

Efficient Comminution

*Other includes smaller operating entities such as China, Australia, EKOF

KHD Humboldt WedagInternational

EMEA (Cologne)

Russia/CIS (Dessau)

Americas (Atlanta) India (Delhi)

Other*

EMEA = Europe, Middle East and Africa

14/03/2011

3

Customers are served through

four Customer Service Centres

In addition large global players are

served through Key Account

Management

Centre of Excellence for

technology in Cologne

Corporate functions in Cologne

5

Operating Structure Overview

Introduction Efficient Comminution

Competent Operation

Process Overview

Efficient Comminution

6

COMFLEX ® – High Efficient and Flexible Comminution System

I. Introduction

II. Efficient Comminution

III. Competent Operation

IV. Process understanding and optimization

14/03/2011

4

7

Most Efficient Grinding System

Introduction Efficient Comminution

Competent Operation

Process Overview

Efficient Comminution

Ball MillVertical

Roller MillRoller Press

8

Energy Saving (Example: Raw Material Grinding)

Introduction Efficient Comminution

Competent Operation

Process Overview

Efficient Comminution

energy consumption

Grindability

feedmoisture

energy saving RP vs VRM

0

1

2

3

4

5

3 5 7 9 11Grindability

savi

ng R

P vs

. VR

M k

Wh/

t 0-6%

10%

feedmoisture

6

8

10

12

14

16

18

20

3 5 7 9 11

tota

l sys

tem

kW

h/t

0 -10%VRM

10%

Roller Press

0-6%

14/03/2011

5

9

Energy saving

Introduction Efficient Comminution

Competent Operation

Process Overview

Efficient Comminution

RM grinding1 CM grinding1 Total saving1

3000 tpd 9.600 kWh/d 6.300 kWh/d 15.900 kWh/d

5000 tpd 16.000 kWh/d 10.500 kWh/d 26.500 kWh/d

7000 tpd 22.400 kWh/d 14.700 kWh/d 37.100 kWh/d

Total saving1 $ per day2 $ per year3

3000 tpd 15.900 kWh/d 2.703 $ 891.990 $

5000 tpd 26.500 kWh/d 4.505 $ 1.486.650 $

7000 tpd 37.100 kWh/d 6.307 $ 2.081.310 $

1 2 kWh/t raw meal; cement - saving2 0,17 $/kWh3 330 day‘s per year

10

Wear rate

Introduction Efficient Comminution

Competent Operation

Process Overview

Efficient Comminution

Roller Press VRM

Raw meal 0.2 to 1,5 gr/ton 2 to 5 gr/ton

cement 0.2 to 2 gr/ton 2 to 5 gr/ton

14/03/2011

6

11

KHD Products - Roller Press

Introduction Efficient Comminution

Competent Operation

Process Overview

Efficient Comminution

RP Size Roller diameter [mm]

Roller width [mm] Motor total[kW]

07 1700 900 1500

10 1700 1100 1800

13 1700 1400 2400

16 1700 1800 3200

18 2000 1800 4000

20 2200 1800 4600

12

KHD Products - Roller Press

Introduction Efficient Comminution

Competent Operation

Process Overview

Efficient Comminution

Roller surface:

welded surface (CHF) with profiles

STUD-Lining, autogenous wear protection

Roller Presses sold:

clinker 176raw material 63Minerals 42Slag 18Burnt lime 10coal 1

Total 310

14/03/2011

7

13

COMFLEX ® – High Efficient and Flexible Comminution System

I. Introduction

II. Efficient Comminution

III. Competent Operation

IV. Process understanding and optimization

14

Introduction Efficient Comminution

Competent Operation

Process Overview

Efficient Comminution

VSK-Separator

SEPMASTERLC, LSK (coal)

SEPMASTERVC

LS - Static Separator

V-Separator

Preferred Separator Types for COMFLEX®

14/03/2011

8

15

V-Separator - necessary for efficient grinding

Introduction Efficient Comminution

Competent Operation

Process Overview

Efficient Comminution

• Static separator for coarse cut

• KHD`s invention

• VS has become standard for RP-grinding circuits

• VS is multi-functional: separating, deglomerating,

drying, cooling

16

V-Separator - necessary for efficient grinding

Introduction Efficient Comminution

Competent Operation

Process Overview

Efficient Comminution

air and fines

air

rejects

feed

14/03/2011

9

17

SEPMASTER SKS

Introduction Efficient Comminution

Competent Operation

Process Overview

Efficient Comminution

The original Sepmaster -

• features minimum height between

feed-inlet and rejects-outlet

This results in:

• Low bucket elevator height and best

choice for conversions

• Rotor bearings at both ends for

vibration-free run and

• Together with the drive on bottom no

influence by process heat

H m

in.

18

COMFLEX ® – High Efficient and Flexible Comminution System

I. Introduction

II. Efficient Comminution

III. Competent Operation

IV. Process understanding and optimization

14/03/2011

10

19

Single machinery – How about the arrangement?

Introduction Efficient Comminution

Competent Operation

Process Overview

Efficient Comminution

Roller Press

V-Separator

SEPMASTER-SKS

Bringing Innovation in Layouts

20

COMFLEX® - Location of V-Separator ?

Introduction Efficient Comminution

Competent Operation

Process Overview

Efficient Comminution

ClinkerRawMaterialWet BlastFurnace slag

Fines, dust, vapor,reactive slag

heating required forbag filter and vent-ducts,and bucket elevator

VS above Roller Press VS below Roller Press

Coarse, no dust,dried coarse slag

No problem

14/03/2011

11

21

COMFLEX® - Location of dynamic-Separator ?

Introduction Efficient Comminution

Competent Operation

Process Overview

Efficient Comminution

Fine SKS-rejectsand VS-rejects to be lifted byBucket elevator

SKS below Roller Press

Only coarseVS-rejects tobe lifted

Fines is liftedPneumaticallywithout additionalAir flow

SKS above Roller Press

22

COMFLEX® - Location of dynamic-Separator ?

Introduction Efficient Comminution

Competent Operation

Process Overview

Efficient Comminution

SKS belowRoller Press

SKS aboveRoller Press

MechanicalConveyors canbe designed25 to 40%smaller

14/03/2011

12

23

COMFLEX® - High Efficient Grinding System for the Future

Introduction Efficient Comminution

Competent Operation

Process Overview

Efficient Comminution

COMFLEX®

COMminution system with Roller Press

FLEXible process for most applications

Fully Standardized

Special Layout

24

COMFLEX® - Layout

Introduction Efficient Comminution

Competent Operation

Process Overview

Efficient Comminution

VS belowRoller Press

SKS aboveRoller Press

COMFLEX ®

Multi purpose Grinding Plant

• Slag up to 7000cm2/g Blaine• Limestone 10%R 90µm• Raw material 15% R 90µm• Additives (slag, limestone, fly ash)

14/03/2011

13

25

COMFLEX® - Layout

Introduction Efficient Comminution

Competent Operation

Process Overview

Efficient Comminution

VS belowRoller Press

Static Separatorabove Roller Press

COMFLEX ® forRaw Material Grinding

26

COMFLEX® - Compact

Introduction Efficient Comminution

Competent Operation

Process Overview

Efficient Comminution

A

C

Rol

ler P

ress

floo

r lev

el

buck

et e

leva

tor h

eigh

t

B

build

ing

heig

ht

14/03/2011

14

27

COMFLEX® - Layout

Introduction Efficient Comminution

Competent Operation

Process Overview

Efficient Comminution

COMFLEX ® S (Single)300 t/h raw meal, 100 t/h slag120 t/h cement

COMFLEX ® D (Double)600 t/h raw meal200 t/h slag240 t/h cement

COMFLEX ® T (Triple)900 t/h raw meal300 t/h slag360 t/h cement

28

Conclusion

Introduction Efficient Comminution

Competent Operation

Process Overview

Efficient Comminution

Lowest Specific Energy Consumption (more than 1 million $ of energy saving per year!)

With Stud-Lining Roller Surface Life of minimum 18,000 Hours without Maintenance

Highest production rates from one grinding station with COMFLEX ® D or COMFLEX ® T

Always more than 50% Availability with COMFLEX® D and COMFLEX® T

Standard equipment for raw- cement and slag-grinding with lowest investment in spare parts

with latest developments: – Greatly reduced building- and equipment cost– No dust and spillage from mechanical conveying

14/03/2011

15

To get more out of your cement plant, visit

www.khd.com

29