Quadropol QMC-RD World’sfirst vertical roller mill with driven rollers · 2016. 12. 28. · 7th International VDZ Congress, 26 September 2013. Quadropol RD –World’s first VRM

ThyssenKrupp�Resource�Technologies�

Quadropol QMC-RD

World’s first vertical roller mill with driven rollers

Dr. Thomas Schmitz

7th International VDZ Congress, 26 September 2013

Quadropol RD – World’s first VRM with driven rollers

26 September 2013

VDZ Congress 2013 – Dr. Thomas Schmitz

2 ThyssenKrupp�Resource�Technologies

InnovativedriveconceptfortheQuadropolcementmillInnovativedriveconceptfortheQuadropolcementmillInnovativedriveconceptfortheQuadropolcementmillInnovativedriveconceptfortheQuadropolcementmill

Roller-driveconcept

fordemanding

operatingconditions,due

tohighcementfineness

andhighthroughput

Traditionaltabledrive Innovativerollerdrive

Table-driveconceptfor

conventionaloperating

conditionsataverage

cementfineness

Themarketdemands:

• Evergreaterunits

• Unitsthatcangrindeverfinercements

• Unitsthatcangrindgreatvarietyofcementtypes


26 September 2013



Bettermaterialpull-incapabilityoftheroller-driveconcept

Tabledrive Rollerdrive

Roller

Material

layer

Velocityprofile

Table

� Therollerspeedisalwayslowerthan

thetablespeed

� Materialispushedinto thegrinding

gapbythemovementofthetable

�Therollerisspeedalwayshigherthan

thetablespeed

�Materialisdrawninto thegrindinggap

bythemovementofroller


26 September 2013



Lowerpowerandtorqueofgearunits

nroller≈

2xntable

Powerloweredaccordingtothenumberofdrives

Speedincreasedaccordingtodiameteroftableandroller

Torqueloweredaccordingtochangedpowerandspeed

PmotorRD ≈

xPmotorTD1

3

TRD ≈

xTTD16

ExampleonaRDmillwith3rollers:

► Standard gear unit sizes can be applied.►Gear units very similar to the ones well proven in Polycom applications.


26 September 2013



Lowerpowerandtorqueofgearunits

P motor

[kW]

n table

[rpm]

Torque

[kNm]

4500 21.6 1989

7200 19.2 3575

10200 18.7 5216

P motor

[kW]

n roller

[rpm]

Torque

[kNm]

3x1500 37.2 385

4x1800 35.3 487

6x1700 42.0 388

Table-driven Roller-driven

QMC51/25

- 3

QMC64/30

- 4

QMC68/27

- 6

► RD concept assures low drive torques even at high capacities.


26 September 2013



►Maintenance on mill drive possible at continued production.

Operationstillpossiblewith

onepassiveroller

(atreducedthroughput)

Dismounted gear

unit and coupling

Highoperationalreliability

Millswith4or6rollers:

Operationstillpossiblewithtwo

opposingrollersliftedorremoved


26 September 2013



DesignofRDrollerunits

Cardan shaft

Motor

Hydraulic cylinder

Torque sensor

Drive shaft

Planetary and bevel gear

Grinding roller

SafeSet


26 September 2013



DesignoftheQuadropolRD

Separator

Grit cone

Roller unit

Feed chute

Mill housing

Gas inlet

Foundation

Motor

Grinding table


26 September 2013



Smoothoperationbydamping– TransmissionofForces

Rollerunit

FoundationTable bearing/

Gear unit

Grindingtable

► Smooth and low-vibration operation.

• Fulldampingofrollerunitsby

foundation

• Millhousingcompletelyfree

ofgrindingforces


26 September 2013



Smoothoperationbydamping– TransmissionofForces– RoughRunning

Rollerunit

Foundation

Grindingtable

Zerogap

~10mm

Tablebearing/

Gearunit

• Fulldamping

ofrollerunits

byfoundation

• Millhousingcompletelyfree

ofgrindingforces

► No contact between roller and table – Table bearing protected.

• If,foranyreason,the

grindingbedisdestroyed,all

forcesaredirectlyfedviaa

stopperintothefoundationof

therollerunit.


26 September 2013



Scale-up:Fromlaboratoryteststomarketintroductionin2steps

Tablediameter:0.6m

Installeddrivepower:60kW

Conceptdevelopment

atR&Dlaboratory

2008-2010 2011 2012

• Newdriveconceptwastested

• Considerablysmootherrunningdemonstrated

• Increasedgrindingefficiency


26 September 2013




Tablediameter:0.6m


Tablediameter:3.2m


Conceptdevelopment

atR&Dlaboratory

Industrialtests

ofsinglecomponents

2008-2010 2011 2012

Confirmationof

• Mechanicalfunctionality

• Resultsoflabresults


26 September 2013




Tablediameter:0.6m


Tablediameter:3.2m


Tablediameter:5.1m


Conceptdevelopment

atR&Dlaboratory

Industrialtests

ofsinglecomponents

Introductiontomarket,

1stindustrialplant

2008-2010 2011 2012


26 September 2013



QuadropolQMC51/25-3RD– Firstindustrialplant– Lagunas

Lagunas,

Mexico

ProductspecificationCPC-30RS

Clinker: 75%

Gypsum: 5%

Pozzolana: 10%

Limestone: 10%

Productfineness: <3%R0.045mm

(~450m²/kg)

CooperativaLaCruzAzulS.C.L.

Lagunas,Mexico


26 September 2013



Millperformance

(designdata)

Throughput:

175tph

Specificpower

consumption:@counter,maindrives

mill,fan,separator

28kWh/t



26 September 2013




Tablediameter: 5100mm Rollerdiameter: 2500mm

InstalledPower: 3x1500kW Typeofdrive: VVVFdrive

Mainequipmentdata:


26 September 2013



Guarantee

175 t/h

< 3%

28.0 kWh/t

Mill throughput

Residue 45µm

Specific power consumption

4500 cm²/gProduct fineness

YesGrinding aid

10/2012

Performancetest

178 t/h

2.6%

26.9 kWh/t

4560 cm²/g

No

12/2012

6weeksfromfirststartuntil

successfulfinishof

performanceguaranteetest

27.9 kWh/t

August2013

204 t/h

2.4%

4630 cm²/g

No

08/2013

Furtherprocessoptimisation

QuadropolQMC51/25-3RD– Firstindustrialplant– LagunasFast-trackcommissioningforprototypeinstallation


26 September 2013



Mill throughput:

175 t/h ►11 min

after start-up

Mill throughput:

190 t/h ►25 min

after start-up

Grinding pressure:

max.►5 min

after start-up

Vibration at roller

units < 1.5 mm/s

Vibration at table

bearing < 0.5 mm/s

QuadropolQMC51/25-3RD– Firstindustrialplant– LagunasFastandextremelysmoothautomaticstart-upoftheQuadropol-RD


26 September 2013



Productportfolio:

CEMI52.5N

Productfineness: 440m²/kg

HolcimFrance

LaRochelle,France

Startofcommissioning:

10/2013

LaRochelle,

France

GGBF


CEMI52.5N


QuadropolQMC48/24-3RD– Secondindustrialplant– LaRochelle


26 September 2013



Throughput:

75– 110tph

QuadropolQMC48/24-3RD– Secondindustrialplant– LaRochelle

Tablediameter: 4800mm

Rollerdiameter: 2400mm

InstalledPower: 3x1300kW Typeofdrive: VVVFdrive

Mainequipmentdata:


26 September 2013



QuadropolQMC64/30-4RD– Thirdindustrialplant– PalmardelBravo

PalmardelBravo,

MexicoProductspecificationCPC-30RS

Clinker: 75%

Gypsum: 4%

Pozzolana: 13%

Limestone: 8%

Productfineness: <3%R0.045mm

(~420m²/kg)

CycnadeOriente,S.A.deC.V.

PalmardelBravo,Mexico

Startofcommissioninginsummer2015


26 September 2013



Throughput:265–320tph

QuadropolQMC64/30-4RD– Thirdindustrialplant– PalmardelBravo

Tablediameter: 6400mm

Rollerdiameter: 3000mm

Installedpower: 4x1800kW Typeofdrive: VVVFdrive

Mainequipmentdata:


26 September 2013



Conclusion

• Thyssenkrupp ResourceTechnologiesoffersaninnovativedriveconcept

thatallowsthereliableoperationoflargeverticalmills.

• TheRDconceptprovidesadvantagesintermsofplantavailability

• TheRDconceptshowsprocess-technologicaladvantagesandallowsa

highlyefficientcomminution process

• ThefirstRDinoperationproveditsutilisability andoperationalreliability

robustly.

Documents

Quadropol QMC-RD World’sfirst vertical roller mill with driven rollers · 2016. 12. 28. · 7th International VDZ Congress, 26 September 2013. Quadropol RD –World’s first VRM