Modular Grinding Systems – Attracting Everyone’s Attention

Presented by

Chris Oesch

President

Gebr. Pfeiffer, Inc.

Modular Grinding Systems

Features

• Produces all types of Cement, Slag, Coal, Limestone, Gypsum

and other materials

• Considers efficient VRM technology

• Ideal for small- Meduim scale production

• Three plant sizes available for Clinker plus additional module

plants for other materials

• Pre-assembled Modules in standard size

• Optimized Size ratio due to Compact Modular Design

• Flexible plant arrangement

• Flexible design of feed size and product transport

• Low plant construction height

Local Requirements

• Small Footprint for the plant (~ 350m²)

• Access to transportation (Road, Rail, Harbour)

• MV or LV Line supply

• Consumables

• Plant personnel

Selection of Scope

Flowsheet

Feed VRM Gas Route Storage/Packing

Scope of Equipment and Service Supply

A. BASIC PLANT MODULES

A. 1 Raw Material Dosing and 3(or as needed) Feed Hoppers

A. 2 Raw Material Feeding to Mill

A. 3 Mill, Classifier and Ancillaries

A. 4 Dedusting, Hot Gas Generator and Fan

A. 5 Product Transport and 2 (or as needed) Storage Silos

A. 6 Electrical Controls, Drives, Lighting and Safety installations

Scope of Equipment and Service Supply

B. OPTIONAL EQUIPMENT MODULES

B. 1 Packing and Truck Loading

B. 2 Bulk Loading Equipment

B. 3 Sanitary Equipment

B. 4 Office Equipment

B. 5 Laboratory Equipment

B. 6 Fuel Storage

B. 7 Extended Product Storage Capacity

B. 8 Power Generation

Scope of Equipment and Service Supply

C. OPTIONAL SERVICE MODULES

C. 1 Operator Training

C. 2 Maintenance Training

Modular Grinding System

Modular Plant Components

Main Process Bag Filter

Includes mill ancillaries and MCC room

Vertical Roller Mill

Performance Table

GEBR. PFEIFFER MODULAR MILL – MVR 1800 C-2

Product Portland Cement

CEM I Limestone Cement

CEM II / B – L Slag

GGBFS

Fineness acc. to Blaine 3500 4500 4000 5000 4000 4500

Grindability kwh/t 19 25 15 19 24 27

Production rate t/h 12 9 15 11,5 10 9

Max Feed Grain Size mm 35

Approx. yearly production rate t/a

Installed Mill Motor Power KW 260

Total installed Power KW 500

Amount of Modules 9

Performance Table

GEBR. PFEIFFER MODULAR MILL –MVR 1800 C-4

Product Portland Cement

CEM I Limestone Cement

CEM II / B – L Slag

GGBFS

Fineness acc. to Blaine 3500 4500 4000 5000 4000 4500

Grindability kwh/t 19 25 15 19 24 27

Production rate t/h 24 18 30 23 20 18

Max Feed Grain Size mm 35

Approx. yearly production rate t/a 140.000 – 240.000

Installed Mill Motor Power KW 560

Total installed Power KW about 1000

Amount of Modules 15

Performance Table

GEBR. PFEIFFER MODULAR MILL – MVR 2500 C-4

Product Portland Cement

CEM I Limestone Cement

CEM II / B – L Slag

GGBFS

Fineness acc. to Blaine 3500 4500 4000 5000 4000 4500

Grindability kwh/t 19 25 15 19 24 27

Production rate t/h 48 36 60 46 40 36

Max Feed Grain Size mm 35

Approx. yearly production rate t/a 280.000 – 480.000

Installed Mill Motor Power KW 1100

Total installed Power KW about 1600

Amount of Modules 18

Partial load operation possible on request in order to start with low production

requirement -> Plant is ready to take up future increase of production

MVR Roller Mill Design

Symmetric wear parts For an extended lifetime tyres can be turned in case of wear.

Active Redundancy Up to 4 grinding rollers: mill operation continues even if two roller are

under maintenance.

Hydraulic system for operation and maintenance For maintenance purposes no extra component is required to swing the

rollers out of the mill.

Parallel grinding gap The geometry of the grinding elements in combination with our MVR

suspension system ensures a parallel grinding gap in any operating point.

Active Redundancy

4 grinding rollers:

mill operation continues even if two

rollers are under maintenance

Availability during failure

Pfeiffer C-4 with 2 roller out: >50%

MVR Installations

country customer mill size tph fineness kW product year

Turkey undisclosed client MVR 5000 C-4 - - 4000 cement 2015

Bosnia-

Herzegovina

DD Fabrika Cementa Lukavac MVR 3750 160 12 % R 0.090 mm 1600 raw material 2007

Turkey undisclosed client MVR 3750 R-3 - - 2000 raw material 2015

Turkey undisclosed client MVR 3750 R-3 - - 2000 raw material 2015

Africa undisclosed client MVR 3750 C-4 150 3300 cm²/g acc. to Blaine 2900 cement 2016

Americas Undisclosed Client MVR 2500 C-4 56 4700 cm²/g acc. to Blaine 1246 cement 2016

Germany Hauri KG, Bötzingen MVR 1800 C 20 4600 cm²/g acc. to Blaine 320 phonolite 2006

Germany Hauri KG, Bötzingen MVR 1800 C-2 21 3000 cm²/g acc. to Blaine 250 phonolite 2015

Africa undisclosed client MVR 1800 C-4 25 4000 cm²/g acc. to Blaine 520 cement 2016

Product Quality

VRM vs Ball Mill

MVR 1800 C-4 for cement grinding

Hans G. Hauri Mineralstoffwerk,

Germany

MVR 1800 C-4

• 15 tph Cement

• 400 kW installed

• In Operation since 2007

Comparison of Mill Systems

VRM vs HPGR (Cement)

VRM HPGR + BM

Recirculation Reject 10 - 20 % 400 to 500 % of fresh feed

Feed moisture up to more than 25 % up to max. 5 %

Various feed

material

very flexible and adjustable for a wide

range of feed material

not as much flexible as VRM

Wear sinter cast,

chromium cast alloy iron

hardfaced,

stud liners very sensitive to oversized

lumps, break-out of tyre

Arrangement simple,

advantage of drying, grinding, classifying

in one machine

complicated,

single machines (RP, static separator,

dynamic separator)

Layout VRM foundation on ground level HPGR is not located on ground floor,

with Comflex system located on upper floor

due to arrangement, high loads!

Comparison CEM I (Balaji / India)

Plant A – Data 2013 MVR BM

Type CEM I CEM I

R 0,045 mm 6.8 % 8.4 %

Blaine* 2910 cm²/g 2910 cm²/g

Lasergranulometer d‘ = 24.2 µm, n= 0.99 d‘ = 25.2 µm, n= 0.97

Water demand* 26.5 % 26.2 %

Compressive strength*

2 d 20.6 MPa 18.7 MPa

7 d 36.8 MPa 36.5 MPa

28 d 58.1 MPa 59.4 MPa

*tests in acc. to EN 196

Comparison CEM I (Balaji / India)

Plant A – Data 2014 MVR HPGR + BM

Type CEM I CEM I

Blaine* 2940 2900

Water demand* 29.4 % 30.3 %

IST 170 min 190 min

Compressive strength*

1 d 21.3 MPa 21.0 MPa

3 d 40.5 MPa 40.4 MPa

7 d 51.4 MPa 51.8 MPa

28 d 63.7 MPa 62.6 MPa

*tests in acc. to IS 4031-6

Economic Feasibility

VRM vs Ball Mill Grinding System

Maintenance Cost

• Long term comparison of maintenance cost from 2004 to 2010 including wear parts replacement

Cement International 02/2015, 38ff. Flacher, A.: Benefits and potentials of cement grinding with vertical roller mills

Specific Energy Consumption

BM closed circuit Semi finish HPGR + BM VRM

Mill 30.9 14.2 15.5

HPGR - 9.0 -

Aux + Fan 4.1 6.7 7.6

Total 35.0 29.9 23.1

kWh/t

for Cement with 10 % limestone @ 3600 Blaine*

* based on FLS-figures given 2012 at Petrochem, Russia

Specific Energy Consumption

Cement International 02/2015, 38ff. Flacher, A.: Benefits and potentials of cement grinding with vertical roller mills

Comparison HPGR+BM vs. VRM CEM I w. 5 % Limestone HPGR + BM MPS 4500 BC

Product rate 127 t/h 146 t/h

GA 260 ml / t 55 ml / t

Fineness 3500 Blaine

MPS -- 19.2 kWh/t

HPGR 8.5 kWh/t --

BM 19.6 kWh/t --

Sep 1.1 kWh/t 1.1 kWh/t

Fan 3.4 kWh/t 9.5 kWh/t

BE (HPGR & BM discharge) 1.6 kWh/t 0.1 kWh/t

total 34.2 kWh/t 29.9 kWh/t

all figures are counter values both mill systems are operating with grinding aid Both systems are installed at the same plant -> same feed materials

Specific Power Consumption (kWh/t) OPC – BM vs. VRM

0

10

20

30

40

50

60

70

80

90

2000 2500 3000 3500 4000 4500 5000 5500

SP

C in

kW

h/t

(m

ill, se

pa

rato

r, f

an)

Spec. Surface area – Blaine in cm²/g

OPC

BM

VRM

Electrical Operating Cost (CEM I at 3‘400 Bl.)

Grinding System Ball Mill Vertical Roller Mill

Specific Power cons. (*) Kwh/t Mill 36,0 18,5

Kwh/t Classifier 1,1 1,1

Kwh/t Bucket Elevator 1,6 0,1

Kwh/t Fan 3,1 7,5

Kwh/t Total 41,8 27,2

Effective Production Capacity t / h 30 30

Effective absorbed power KW eff 1.254 816

Operating Hours / year h / year 7.500 7.500

Consumed power / year Kwh / year 9.405.000 6.120.000

Price for Power Euro / Kwh eff 0,1 0,1

Price for Power Euro / year 940.500 612.000

Years Considered Years 5 5

Total Cost for Power EURO 4.702.500 € 3.060.000 €

Δ ~ 1.650.000 € in 5 years!

Current Installation

Feed System

Mill Unit

Filter and Fan

Modular Grinding Systems

Summary

Main Advantages

1. High reliability & availability

2. Economic - operation cost - VRM

3. Low investment risk, fast market entry, quick pay-

off (ROI)

4. Manageable costs for erection and commissioning

5. Easy access to small and fluctuating markets

6. Plant Mobility -> Future relocate

7. Fast Track Project realization/Operation in different

environment conditions possible

Modular Grinding Systems – Attracting Everyone’s Attention

Thank you!