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COMFLEX® GRINDING
SYSTEM
1
2
Comflex system consumes less
energy compared with other
grinding systems, for:
Raw materials
Cement Clinker
Blast Furnace Slag
Minerals
COMFLEX® =
COMminution + FLEXibility
3
Why?
COMFLEX®Products Compact Systems References
COMFLEX®
Why we are doing the layout not like others?
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COMFLEX® - Where to place the V-Separator?
COMFLEX®Products Compact Systems References
Fines, dust, vapor,
reactive slag
Clinker
________________________
Moist raw
Material
_______________________
Wet slag
V-Separator above
Roller Pressheating of
chutes, bucket
elevators, vent
pipes and bag
filters
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COMFLEX® - Where to place the V-Separator?
COMFLEX®Products Compact Systems References
Fines, dust, vapor,
reactive slag
Clinker
________________________
Moist raw
Material
_______________________
Wet slag
V-Separator above
Roller Pressheating of
chutes, bucket
elevators, vent
pipes and bag
filters
No fines, no dust,
dried coarse slag
V-Separator below
Roller Press
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COMFLEX®Products Compact Systems References
COMFLEX® - Where to place the SEPMASTER?
Fine SKS-
rejects
and VS-rejects
to be lifted by
Bucket elevator
SKS below
Roller Press
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COMFLEX®Products Compact Systems References
COMFLEX® - Where to place the SEPMASTER?
Fine SKS-
rejects
and VS-rejects
to be lifted by
Bucket elevator
SKS below
Roller Press
Fine
SKS-rejects
are lifted by
process air
Only coarse
V-Separator
rejects
are lifted
mechanically
SKS-
rejects
are directly
fed to the
Roller
Press
SKS above
Roller Press
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COMFLEX®Products Compact Systems References
COMFLEX® - Basic Circuit
COMFLEX®
main equipments:
1. Roller Press
2. V-Separator
3. SEPMASTER
4. Material lifting
a. Pneumatic
b. Mechanical
5. Airchute or belt conveyor
1
2
3
4
a4
b
5
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COMFLEX®Products Compact Systems References
COMFLEX® - Flowsheet
product
fresh
feed
metal
separation
product collection
in bag filter or in
cyclones
basic COMFLEX
circuit
Gas inlet
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COMFLEX®Products Compact Systems References
Summary - COMFLEX®
1600 t/h
500 t/h
2500 t/h
900 t/h
500 t/h
Conventional Finish-Grinding:
Mechanical conveying of fines:
Problems with coating and spillage
Limited to lower feed moisture
not suitable for grinding slag
up to 60% larger bucket elevator
COMFLEX®
Pneumatic lifting of fines, mechanical lifting
of dried coarse material:
No problems with coating and spillage
Most suitable for moist material and slag
simple operation with less equipment
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Products of COMFLEX® - System
COMFLEX®Products Compact Systems References
Roller Press
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COMFLEX®Products Compact Systems References
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COMFLEX®Products Compact Systems References
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Roller Press - Standard Sizes
COMFLEX®Products Compact Systems References
RP
Size
[MN]
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
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Roller Press - Configuration
COMFLEX®Products Compact Systems References
Configuration Standard Options
Frame design Swing Frame (RPS) Standard Frame (RPZ)
Roller design Shaft and bandage Solid roller
Roller surface Welded (CHF) STUD-Lining
Roller drive
Double Drive Mono-Drive
Constant speed;
Cardan shaft, fluid
coupling
Variable speed; cardan
shaft, safe-set
coupling
Bearing lubrication Grease lubrication Forced oil lubrication
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Roller Press - Surface Options
COMFLEX®Products Compact Systems References
CHF - Complete Hard Facing
STUD-Lining - after 17 000 hours operation
without maintenance
Line-Profiles
Inserted
hard metal-studs
Ground material
between studs is
Autogenous Wear
Protection
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Stud Lining / Wear Measurements / SLAG-Grinding
17,000 hours
COMFLEX®Products Compact Systems References
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Products in COMFLEX® - System
COMFLEX®Products Compact Systems References
Separator
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Separator Product Line
COMFLEX®Products Compact Systems References
SEPMASTER
VCLS - Static
Separator
V-
Separator
Preferred Separator Types for COMFLEX®
VSK-
SeparatorSEPMASTER
LC, LSK (coal)
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COMFLEX®Products Compact Systems References
V-Separator Compact
width
[mm ]Type 5 Type 6
800
1000
1200
1400
1600
1800
2000
2200
2400
2600
2800
3000
5 meter
VS
VS-Compactfeed
air
V-Separator features:
separation, deglomeration, drying or cooling
no moving parts
maintenance-free operation for years
VS-Compact - additional features:
height saving of at least 5 meter
reduced equipment- and civil cost
V-SEPARATOR and VS-Compact
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Airchute
COMFLEX®Products Compact Systems References
Airchute Prototype
R&D Center Cologne
Standard Sizes
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Main parts
COMFLEX®Products Compact Systems References
1
2
3
4
5
6
6
Airchute- Main parts:
1. Inlet section
2. Outlet section
3. Regular section, 2000 mm length
4. Variable section
5. Venting
6. Air entry
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COMFLEX®Products Compact Systems References
Layouts
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COMFLEX® - Compact
COMFLEX®Products Compact Systems References
COMFLEX S
150t/h OPC, 110 t/h slag,
430 t/h raw meal
COMFLEX D
300t/h OPC, 220 t/h slag, 860 t/h raw meal
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COMFLEX® Raw Mill - Standard Range
COMFLEX®Products Compact Systems References
COMFLEX
Index:
C…cement
R…raw
material
S…Single
D…Double
T…Triple
RP-Size:
07 to 20
easy to grind
difficult to grind
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COMFLEX® Cement Mill – Standard Range
COMFLEX®Products Compact Systems References
COMFLEX
Index:
C…cement
R…raw
material
S…Single
D…Double
T…Triple
RP-Size:
07 to 20
easy to grind
low fineness
difficult to grind
high fineness
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COMFLEX® – References
COMFLEX®Products Compact Systems References
Orders of 30 COMFLEX systems consist of 35 Roller Presses and 20 ball millsR… Raw Material C… Cement S… Slag
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Examples of Grinding Package For new Production Lines
COMFLEX®Products Compact Systems References
Grinding Package for New Production Line
Order, India: Raw- and Cement- and Slag-Mills
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COMFLEX® - References
COMFLEX®Products Compact Systems References
D
R
order: India - COMFLEX Compact for raw material and slag
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COMFLEX®Products Compact Systems References
CEM I 42.5 R
Before After COMFLEX
Clinker [%] 89
Gypsum [%] 6.4
Limestone [%] 4.6
Fineness [Blaine] 3,821 3,777 3,606
Production [tph] 62 190 90
Spec. Power [kWh/t] 43.3 31.8 30.0
COMFLEX® - References – Denizli, Turkey – Cement Grinding
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COMFLEX®Products Compact Systems References
CEM I 42.5 R
Before After COMFLEX
2 day strength [MPa] 25.8 28.6 32.9
7 day strength [MPa] 40.3 41.9 46.1
28 day strength [MPa] 52.6 54.2
Fineness [Blaine] 3,821 3,777 3,606
Initial setting time [min] 143 150 162
Final setting time [kWh/t] 188 227 244
Water demand [%] 28.7 29.0 29.4
COMFLEX® - References – Denizli, Turkey – Cement Grinding
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COMFLEX®Products Compact Systems References
COMFLEX® - References – Raw Material Grinding
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Conclusions
COMFLEX®Products Compact Systems References
Standard, proven Components
Lower Specific Energy Consumption compared with Ballmill and VRM
Different Options for Roller Surface
Flexibility for different Products
Excellent drying Capability
Always 50% Availability with COMFLEX® D
To get more out of
your cement plant, visit
www.khd.com
Thank You