GUIDE VANES AND ROTOR

LV POCKET VANE ARRANGEMENT

LV POCKET VANE ARRANGEMENT

GUIDE VANESROTOR BLADESGRIT CONESEAL RINGCROSS SECTIONAL VIEW OF CLASSIFYING ZONE

PHOTO OF LV POCKETS

SQUARE BARROTOR CONESEAL RINGBLADESLV ROTOR ASSEMBLY

REMARKS:3 AND OVER5030LESS THAN 3H (mm)ROTOR DIAMETER (m)HHASTANDARD OUTER and INNER SEAL for LV CLASSIFIERLV CLASSIFIER SEAL

Force Balance that Determines Separation in HEC SeparatorFORCE BALANCE

DESIGNLV CLASSIFIER FEATURES

OPERATION / PROCESSLV CLASSIFIER FEATURES

LV POCKETS

(

Two stage classification - Collects Coarser Material reduces load on Rotor due to bottom feeding

PRESSURE DROP

(

(

Lower Pressure Drop than other Separators

Lesser KWH/T in Fan

OPERATION / PROCESSLV CLASSIFIER FEATURES

Uniform Distribution of Material in Gas Stream due to bottom feeding

Optimum Material to Separation Air ratio results in higher efficiency than conventional high efficiency Separators

Proven Track record of LV Classifier

Consistent product fineness for large period of operation due to less wear

430 Nos. of LV Classifier in operation for various applications

MATERIAL OF CONSTRUCTION ROTOR BLADES MILD STEEL WITH CERAMIC SPRAY FOR 100 MM HEIGHT FROM BOTTOM GUIDE VANES MILD STELL WITH CHROMIUM CARBIDE HARD FACING CLASSIFIER CASING CERAMIC TILES IN CASE OF CEMENT AND FLY ASH APPLICATIONS BOTTOM DUCT MILD STEEL WITH CERAMIC LINERS OUTLET DUCT MILD STELL WITH CERAMIC LINERS GRIT CONE MILD STEEL WITH HARD FACING OR CERAMIC LINERS FOR FLY ASH/CLINKER/SLAG APPLICATIONS GRIT CONE MILD STEEL FOR RAW MATERIAL GRINDING

LV CLASSIFIER FOR VERTICAL MILL

LV TECHNOLOGY CLASSIFIER FORVERTICAL ROLLER MILL

CLASSIFIERProductNew feedVERTICAL MILLGritFrom nozzle ring and mill housingMATERIAL TRANSPORT IN VRM

LV Technology addresses the problems found in existing vertical mill systems by:Improving Separator Performance

Optimizing airflow-reducing volume to >600gm/m3

Reducing Internal Material Circulation

Reducing Pressure Drop

Reducing Fan Power

Increasing Grinding Efficiency

TableTo classifierNew feed andclassifier returnExternalcirculationMill bodyRollerHot gasDam ringArmor ringNOZZLE RING AND DAM RING

No Coarse in the FinesandNo Fines in the Coarse Proper return of coarse rejects to tableReduction of throughput under rollersSEPARATOR MODIFICATIONS ENSURE

The concept of the separator is to improve the gas and material flow in vertical mills by:

Unique design of guide vanes - LV pocket Unique design of rotor The design of the grit funnel

The concept is based on the idea:

Allow more material to be directed to the classifier by optimising the gas speed Avoid fines returning to the grinding table and excessive internal material circulation in the mill body by installation of the LV Pocket

Decreases the pressure loss in the mill body and separator. An effect of the reduction of internal material circulationLV CLASSIFIEFR SUMMARY

BEFORE AND AFTER MODIFICATION

Birla corporation (LM 36.40 SATNA Cement Works) INDIA

THE MODIFICATIONS :- Replacement of existing rotor assembly Replacement of guide vanes Modification of classifier housing and inner cone Replacement of grit cone and roof Adjustment of armour ring and nozzle ringVERTICAL RAW MILL UP-GRADATION RESULTS

DescriptionBefore ModificationGuaranteedAfter ModificationProduction (tph)225240241Product Residue on 90 mic (%)Product Residue on 212 mic (%)18-203.5-4182.020.042.0Specific Power consumption kwh/t(Mill+ESP Fan)15.6514.1514.15

EXAMPLE OF MODIFICATION

New Cage Rotor Profile Guide VanesHousing ModificationAfterBeforeExisting Rotor Profile Modified Grit ConeFeed Chute ExtensionExisting Grit ConeTYPICAL MODIFICATION OF CLASSIFIER

Mangalam Cement INDIA

THE MODIFICATIONS :- Replacement of existing rotor assembly Replacement of guide vanes Modification of classifier housing and inner cone Replacement of grit cone Adjustment of nozzle and armour ringVERTICAL RAW MILL (KP 46/23) UPGRADATION RESULTS

DescriptionBefore ModificationGuaranteedAfter ModificationProduction (tph)189215220Product Residue on 212 mic (%)8 to 95 to 65 to 6Specific Power consumption kwh/t(Mill + ESP Fan)171615.5

Manikgarh Cement Works INDIATHE MODIFICATIONS :- Replacement of existing rotor assembly Replacement of guide vanes Modification of classifier housing and inner cone Replacement of grit coneVERTICAL COAL MILL (LM21.20D) UPGRADATION RESULTS

DescriptionBefore ModificationGuaranteedAfter ModificationProduction (tph)283133Product Residue on 90 mic (%)18 to 1918 to 1918 to 19Specific Power consumption kwh/t(Mill+Mill Fan)19.51817.77

Birla Corporation Limited INDIA

THE MODIFICATIONS :-Static Separator to High efficiency LV ClassifierVERTICAL COAL MILL (MPS-140) UPGRADATION RESULTS

DescriptionGuaranteedAfter ModificationProduction (tph)7.57.5Product Residue on 90 mic (%)2.02.0

Jaypee Cement Limited INDIA

THE MODIFICATIONS :-Static Separator to High efficiency LV ClassifierVERTICAL COAL MILL (RMK25/12/35) UPGRADATION RESULTS

DescriptionBefore ModificationGuaranteedAfter ModificationProduction (tph)3235.236.2Product Residue on 90 mic (%)18 - 2018 2016 -18

EXISTINGMODIFIED BY LVExisting Rotor Profile New Rotor Profile New housing, if necessaryMODIFICATION OF ATOX MILL

Zuari Cement Limited INDIATHE MODIFICATIONS :- Replacement of existing rotor assembly, top & bottom rings for rotor blade Replacement of guide vanes, upper & lower rings for guide vanes Modification of classifier housing and inner cone Replacement of grit cone Adjustment of nozzle and armour ringVERTICAL RAW MILL (ATOX-45) UPGRADATION RESULTS

DescriptionBefore ModificationGuaranteedAfter ModificationProduction (tph)250265273Product Residue on 90 mic (%)23 to 2523 to 2523 to 25Specific Power consumption kwh/t(Mill + Classifier + Fan)15.9---14.99

INSTALLATION BENEFITS OF LV CLASSIFIER

Vertical Roller Mills:

10 - 30 % Increased production1.0 5.0 kWh/t Saving in power consumption of both mill and fanVibration level decreasing Cement strength increases

LV CLASSIFIER FOR BALL MILLS

Gravity Discharge

Air Swept TYPE OF BALL MILL CIRCUITS

LV CLASSIFIER

FOR

GRAVITY DISCHARGE BALL MILLS

TYPICAL FLOW SHEET

LV BALL MILL CLASSIFIER

LV CLASSIFIER, 1 - INLET

LV CLASSIFIER, 2 - INLETS

LV CLASSIFIER, 2 INLETS (2ND GENERATION)

CLASSIFIER CIRCUIT

CEMENT MILL MODIFICATION

CEMENT MILL INSTALLATION

CEMENT MILL UP-GRADE

Holcim (Lanka) Limited SRILANKA

THE MODIFICATIONS :-Close circuited the system with LV Classifier Mill venting system upgraded with additional bag filter and fanClassifier Venting system Classifier feeding system & reject handling product conveying system were newly installed. CEMENT MILL UP-GRADATION RESULTS

RUHUNU CEMENT WORKS MILL NO 1DescriptionBefore ModificationGuaranteedAfter ModificationProduction (tph)23.525.626.2Specific Surface (cm2/gm)3300+/-10036003550 - 3600Specific Power consumption kwh/t31.9 (Mill + Mill Fan)33 (Mill + Classifier+Mill Fan+Classifier Fan+Bagfilter Fan)29.87 (Mill + Classifier+Mill Fan+Classifier Fan+Bagfilter Fan)

Holcim (Lanka) Limited SRILANKA

THE MODIFICATIONS :-Close circuited the system with LV Classifier Mill venting system upgraded with additional bag filter and fanIn Chamber 1 lifting liners were installed for 4.05 m length New partition and discharge diaphragm grates were installed CEMENT MILL UP-GRADATION RESULTS

RUHUNU CEMENT WORKS MILL NO 2 DescriptionBefore ModificationGuaranteedAfter ModificationProduction (tph)28.230.633.5Specific Surface (cm2/gm)3300+/-10036003550 - 3600Specific Power consumption kwh/t30.9 (Mill + Mill Fan)33 (Mill + Classifier+Mill Fan+Classifier Fan+Bagfilter Fan)29.4 (Mill + Classifier+Mill Fan+Classifier Fan+Bagfilter Fan)

Holcim (Lanka) Limited SRILANKA

THE MODIFICATIONS :-Replaced the HEYD Christian Peiffer separator with LV technology High Efficiency Classifier. Separator venting system upgraded with additional bag filter and fanMill Internals retained the same. CEMENT BALL MILL UP-GRADATION RESULTS

PALAVI CEMENT WORKS MILL NO 1 DescriptionBefore ModificationGuaranteedAfter ModificationProduction (tph)35.74043.75Specific Surface (cm2/gm)3600+/-10036003600+/-100Specific Power consumption kwh/t32.8 (Mill + Mill Fan)31.2 (Mill + Classifier+Mill Fan+Classifier Fan+Bagfilter Fan)29.89 (Mill + Classifier+Mill Fan+Classifier Fan+Bagfilter Fan)

CEMENT BALL MILL UP-GRADATION RESULTS

Birla Corporation Limited Cement:Raebareli - INDIA

THE MODIFICATIONS :-

Close circuited two ball mills with single LV classifierCEMENT BALL MILL UP-GRADATION RESULTS

DescriptionBefore ModificationAfter Modification After Modification with pregrinderProduction (tph)30 X 235 X 250 X 2Specific Surface (cm2/gm)31003100 3100 Power consumption kwh(Mill + Mill vent fan power)153315331533 Power consumption kwh(Classifier + Classifier fan power)---445447

Madras Cements Limited INDIA

THE MODIFICATIONS :- Replacement of Sepax Separator with LV Technology classifier byutilizing sepax drive shaft assembly. Replacement of rotor assembly Replacement of guide vanes Replacement of classifier housing and inner cone Replacement of grit coneRAW BALL MILL UP-GRADATION RESULTS

DescriptionBefore ModificationGuaranteedAfter ModificationProduction (tph)142152158Product Residue on 90 mic (%)17 to 1917 to 1917 to 19Specific Power consumption kwh/t(Mill)11.610.610.5

Kakatiya Sugar & Industries Limited INDIA

THE MODIFICATIONS :- Replacement of O-Sepa classifier with LV Technology classifier Installation of additional Bag Dust Collector Module Installation of New FanRAW BALL MILL UP-GRADATION RESULTS

DescriptionBefore ModificationGuaranteedAfter ModificationProduction (tph)394445Product Residue on 90 mic (%)Product Residue on 212 mic (%)203-3.5203-3.5201.5Specific Power consumption kwh/t(Mill + Classifier + Fan)23.732221

RAW BALL MILL UP-GRADATION RESULTS

LV CLASSIFIER

FOR

AIR SWEPT BALL MILL

LV CLASSIFIER FOR AIR SWEPT BALL MILLS

Rotor ConeGuide VaneRotor BladeGrit Cone(Reject Outlet)Gas Entry(Mill Outlet)Casing &Support PointLV CLASSIFIER CROSS SECTION

Madras Cements Limited INDIA

THE MODIFICATIONS :- Static Separator to High Efficiency LV Classifier COAL BALL MILL UP-GRADATION RESULTS

DescriptionBefore ModificationGuaranteedAfter ModificationProduction (tph) ( Pet coke 100% )778Product Residue on 90 mic(%)10 to 125 to 64 to 5

JK Lakshmi Cements Limited INDIA

THE MODIFICATIONS :- Static Separator to High Efficiency LV ClassifierCOAL BALLMILL UP-GRADATION RESULTS

DescriptionBefore ModificationGuaranteedAfter ModificationProduction (tph)(Pet coke 100% )12.51414.5Product Residue on 90 mic(%)2.221.8

Specific Power consumption kwh/t(Mill + E.S.P. Fan)49.64747

Sri Vishnu Cement Limited INDIA

THE MODIFICATIONS :- Static Separator to High Efficiency LV Classifier

COAL BALLMILL UP-GRADATION RESULTS

DescriptionBefore ModificationGuaranteedAfter ModificationProduction (tph)32.854444Product Residue on 90 mic(%)17.061716.08

Specific Power consumption kwh/t(Mill + Fan)342826.4

LV SPIRAL CYCLONE

DIFFERENT CYCLONE SIMULATION RESULTS

SPIRAL CYCLONE SIMULATION

LV SPIRAL CYCLONE

RAW MILL CYCLONE MODIFICAION

KCP Limited Macherala INDIA LV CYCLONE

DescriptionBefor InstallationAfter InstallationProduction (tph)130138Gas Flow (Km3/hr)210210No of Cyclones42Cyclone Dia (m)3.14.8Pressure Drop (mm wg)220110Fan Speed (rpm)760740Fan Power kwh760680

Birla Corporation Limited Satna INDIA LV CYCLONE

DescriptionBefor InstallationAfter InstallationProduction (tph)241266Gas Flow (Km3/hr)340460No of Cyclones42Cyclone Dia (m)3.65.4Pressure Drop (mm wg)200110

Madras Cements Limited R.R.Nagar INDIA OPERATING DATA LV CYCLONE

DescriptionBefor InstallationAfter InstallationProduction (tph)142158Gas Flow (Km3/hr)360345No of Cyclones42Pressure Drop (mm wg)150100

Preheater (pressure loss, efficiency)Calciner (fuel burn out, retention time, mixing)Gas transport (fans, cooling tower, filter)Kiln (speed, volume)Cooler (inlet, fan flows, grate plates)Fuel system (capacity) KILN UP-GRADES

PRE-HEATER MODIFICATION AT SHAHROUD CEMENT

THE MODIFICATIONS:Remove refractory in top stage and LV Cyclone (insulation outside) Enlarge inlet area to bottom stage cycloneCentral pipe installed in bottom stage cycloneIncrease height of calciner and modify tert. air inlet to calciner Change position of calciner gas burnersFurther modifications: Kiln speed up from 3.0 4.2 rpm, new fixed grate cooler inlet. KILN UP-GRADE - SHAHROUD , IRAN

CHANGE OF TOP CYCLONES AT CHINFON HAIPHONG

THE MODIFICATIONS: Additional EP filter fan (in parallel to existing) Fixed cooler inlet New classifier for Raw mill (production up 17 %) New classifier for Coal mill (production + reduced fineness) Decrease top stage pressure loss from 19.5 mbar to 7 mbar (Reduced ID-fan kWh/t by ~ 11% ~ 200 250 KW) KILN UP-GRADE RESULTSCHINFON HAIPHONG

DescriptionBeforeAfter step 1After new LV top cyclonesProduction (tpd)430046504650 (4800)Heat cons. (kcal/kg)815800800Dp preheater (mbar)687654

KILN UP-GRADE RESULTSJK LAKSHMI CEMENT - INDIA

THE MODIFICATIONS :- Increased inlet height of cyclone 5 by 1 Meter Increased inlet height of cyclone 6 by 1 Meter Installation of immersion tube in cyclone 6 KILN UP-GRADE RESULTSJK LAKSHMI CEMENT - INDIA

DescriptionBeforeModificationAfter ModificationRemarksProduction (tpd)34003520Increased by 120 tpdPre-Heater outletStatic Pressure (mmwg)907824Reduced by 83 (mmwg)Pre-Heater Fan Specific PowerKwh/t Clinker14.4614.31Reduced by 0.15 kwh/t clinker

KILN UP-GRADE RESULTSMAIHAR CEMENT - INDIA

THE MODIFICATIONS PROPOSED :- Introducing Secondary firing in riser duct. LV cyclone in stage 2&3 To Modify Riser Duct from stage-4 outlet to stage-2 inlet. KILN UP-GRADE GUARANTEED RESULTSMAIHAR CEMENT - INDIA

DescriptionPresentGuaranteedRemarksProduction (tpd)17502000UnderexecutionSpecific Fuel ConsumptionKcal/Kg.Cl840828

CALCINER TYPE - 1

Cylindrical section in order to favor the whirlpool effectDivergence section to reduce upward flow energyTangential intersection in order to increase initially whirlpool speed CALCINER TYPE - 2

Calciner Type -1 CALCINER FLOW PATTERNS Calciner Type -2

SLICE CONTOUR / HORIZONTAL PLANE Calciner Type -1Calciner Type -2

LV CALCINER AND DOWNDRAFT CYCLONE