MASTER Presentation VRM PFEIFFER
MASTER Presentation VRM PFEIFFER
presentation of
MPS grinding technology
Company data
GEBR. PFEIFFER AG
TP/ Ne- 08 / 05
sales organisation
GEBR. PFEIFFER AG
TP/ Ne- 08 / 05
order structure
GEBR. PFEIFFER AG
TP/ Ne- 08 / 05
TP/ Ne- 08 / 04
our competence
GEBR. PFEIFFER AG
simulation of gas flows calculation of strength
of structural members
CFD: FEM:
Computational Fluid Dynamics Finite Element Method
TP/ Ne- 08 / 04
Pfeiffer MPS
grinding technology
TP/ Ne- 08 / 04
12
10
projection
8 7 sold
within 6 months
6
4
2
0
1994 1996 1998 2000 2002 2004 2006
year
TP/ Ne- 07 / 05
12
10
8
6
4
2
0
2000 2001 2002 2003 2004 2005 2006
year
TP/ Ne- 07 / 05
Polysius
FLS
15 %
33 %
TP/ Ne- 08 / 05
design of MPS-mill
• easy control
TP/ Ne- 08 / 04
• large grinding roller diameter for optimum material intake and formation of
stable material bed
raw material
hot gas
reject material
TP/ Ne- 08 / 04
design
GEBR. PFEIFFER AG
TP/ Ne- 08 / 04
• uncomplicated maintenance
• no wear
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TP/ Ne- 08 / 04
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TP/ Ne- 08 / 04
TP/ Ne- 01 / 05
grinding
GEBR. PFEIFFER AG
tension hydraulic
TP/ Ne- 01 / 05
grinding
special function: preliminary filling cylinder GEBR. PFEIFFER AG
tension hydraulic
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maintenance
GEBR. PFEIFFER AG
tension hydraulic
TP/ Ne- 01 / 05
TP/ Ne- 08 / 04
intermediate bolts
• bearing sealing provided by seal
air (passive)
N2
oil
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TP/ Ne- 08 / 04
140 %
115 %
105 %
100 %
TP/ Ne- 08 / 04
submerged pipe
separating rotor
three
-part
wear annular gap
ring
• reliable
• easy to maintain
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classifier drive
GEBR. PFEIFFER AG
TP/ Ne- 08 / 04
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oil
seal air
ducting
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wear protection
GEBR. PFEIFFER AG
1 MPS vertical roller mill
4
3 2 vibration trough conveyor
2
5 6 3 bucket elevator
5
4 material chute
4
10 5 magnet separator
7 1
8 6 metal detector
7 silo
4
8 dosing conveyor
9
9 material reject box
2
10 metering equipment
TP/ Ne- 08 / 04
torque support
liftable rollers
auxilliary drive
TP/ Ne- 08 / 04
design changes
GEBR. PFEIFFER AG
air guide cone with liners
ported air ring table one-piece
clamping ring
roller
axle
clamping ring
roller
axle
clamp peace
roller
axle
clamp peace
roller
axle
Lift-and-
Swing-System
grinding roller
nozzle ring
air or hot gases
gear box
grinding plate hydraulic tensioning cylinder
TP/ Ne- 08 / 04
Lift-and-
Swing-System
grinding roller
nozzle ring
air or hot gases
gear box
grinding plate hydraulic tensioning cylinder
TP/ Ne- 08 / 04
Lift-and-
Swing-System
grinding roller
air or
nozzle ring hot gases
gear box
grinding plate hydraulic tensioning cylinder
TP/ Ne- 08 / 04
articulation
GEBR. PFEIFFER AG
TP/ Ne- 08 / 04
articulation
GEBR. PFEIFFER AG
TP/ Ne- 08 / 04
articulation
GEBR. PFEIFFER AG
drive
fine product
feed material
rotor
louver
grit cone
TP/ Ne- 08 / 04
feed material
rotor
louver
grit cone
TP/ Ne- 08 / 04
rotor
louver
feed material
grit cone
TP/ Ne- 08 / 04
feed material
rotor
louver
grit cone
TP/ Ne- 08 / 04
TP/ Ne- 08 / 04
• Lift-and-Swing System
• new components
TP/ Ne- 07 / 05
modernisation measures
GEBR. PFEIFFER AG
GEBR. PFEIFFER AG
TP/ Ne- 08 / 04
by choice
TP/ Ne- 07 / 05
TP/ Ne- 07 / 05
1000
900
800
dust load in g/m³
700
600
500
400
300
MPS-mills with SLS-classifier
200
Mills with competitors' classifier
100
0
4 5 6 7 8 9 10 11 12
spec. power consumption in kWh/t
TP/ Ne- 07 / 05
TP/ Ne- 07 / 05
rollers replaced
gearbox replaced
TP/ Ne- 07 / 05
TP/ Ne- 07 / 05
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classifier grits
TP/ Ne- 01 / 05
before after
upgrading upgrading
product rate: 380 520 t/h
TP/ Ne- 07 / 05
process technology
process technology
GEBR. PFEIFFER AG
GEBR. PFEIFFER AG
abrasive components
GEBR. PFEIFFER AG
TP/ Ne- 08 / 04
grinding roller
GEBR. PFEIFFER AG
Gujarat Ambuja, India - MPS 5600 B
5400 kW
material: cement raw material
in operation since 2001
guarantee actual
product rate: 480 566 t/h
TP/ Ne- 08 / 04
feed moisture 14 12 14 %
power consumption: 6.5 5.1 5.1 kWh/t
(mill)
power consumption: 10.7 9.1 - kWh/t
(fan)
fineness
R 0.090 mm: 12 11.1 14 %
TP/ Ne- 08 / 04
fineness
R 0.090 mm: 18 19 %
R 75 µm
TP/ Ne- 08 / 04
coal grinding
New directives
for the design of
coal grinding plants
The exact data are needed for rating the explosion venting!
TP/ Ne- 07 / 05
Zone 20
Explosive atmosphere exists permanently, over long periods of time or
frequently (about > 1 000 h/a).
Equipment to be used: Category 1 = very high safety level
Zone 21
Explosive atmosphere exists occasionally (about 10 to 1 000 h/a).
Equipment to be used: Category 2 = high safety level
Zone 22
Explosive atmosphere should normally not occur but if, then only briefly
(about < 10 h/a).
Equipment to be used: Category 3 = normal safety level
TP/ Ne- 07 / 05
3 • dust emission
• CO level
2 • O2 level
1 • temperature 1
• CO level
• O2 level (plants operated under inert conditions)
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material: coal
in operation since: 1998
finished product rate: 24.5 t/h
feed moisture: 13 %
grindability: 50 HGI
power consumption (mill): 10.9 kWh/t
fineness: 10 % R0.090 mm
residual moisture: 0.8 %
TP/ Ne- 08 / 04
coal grinding
GEBR. PFEIFFER AG
Holnam Midlothian, TX / USA
MPS 200 BK, 250 kW
material: coal
in operation since: 2000
finished product rate: 20 t/h
feed moisture: 12 %
grindability: 50 HGI
power consumption (mill): 10.1 kWh/t
fineness: 10 % R0.090 mm
residual moisture: 0.9 %
TP/ Ne- 08 / 04
coal grinding
GEBR. PFEIFFER AG
Blue Circle Cement, Calera / USA
MPS 250 BK, 520 kW
TP/ Ne- 08 / 04
material: coal
in operation since: 2005
finished product rate: 12.6 t/h
feed moisture: 9.3 %
grindability: 61 HGI
power consumption (mill): 8.2 kWh/t
fineness: 10 > 0.09 mm
residual moisture: 1.8 %
TP/ Ne- 01 / 06
coal grinding
GEBR. PFEIFFER AG
39 m to product silo
MPS mill
TP/ Ne- 01 / 06
R 4.0 mm - 60.5 %
R 8.0 mm - 42.5 %
R 16.0 mm - 23.0 %
R 31.5 mm - 8.6 %
TP/ Ne- 08 / 04
sponge coke
GEBR. PFEIFFER AG
mat. no. 03062
R 0.500 mm - 95.5 %
R 1.000 mm - 92.2 %
R 2.000 mm - 79.0 %
R 5.000 mm - 13.7 %
TP/ Ne- 08 / 04
shot coke
GEBR. PFEIFFER AG
mat. no. 03006
R 0.090 mm - 96.6 %
R 0.200 mm - 57.2 %
R 0.500 mm - 17.5 %
R 5.000 mm - 6.0 %
fluid coke
GEBR. PFEIFFER AG
GEBR. PFEIFFER AG
• easy control
• low pressure loss due to optimized nozzle ring and external material
circulation
cement production
GEBR. PFEIFFER AG
customer mill size output t/h fineness kW product year
Tenghui Cement, Chongqing, China 1 x MPS 5600 BC 200.0 3200 Blaine 4850 cement 2004
Tenghui Cement, Hechuan County, China 1 x MPS 5600 BC 120.0 5000 Blaine 5300 blast furnace slag 2003
via Humboldt Wedag ZAB, Jing Yang, China 1 x MPS 5000 BC 300.0 15 % R 0.090 mm 3000 cement 1995
Payvand Golestan Cem. Co., Golestan, Iran 2 x MPS 4250 BC 120.0 3000 Blaine 2500 cement 2005
Shargh Cement Co., Mashad, Iran 2 x MPS 4250 BC 120.0 3000 Blaine 2500 cement 2005
Neyzar Qom Cement Co., Qom, Iran 2 x MPS 4250 BC 120.0 3000 Blaine 2500 cement 2005
Gilan Sabz Cement Co., Deylaman, Iran 2 x MPS 4250 BC 120.0 3000 Blaine 2500 cement 2004
Lar Sabzevar Cement Co., Sabzevar, Iran 2 x MPS 4250 BC 120.0 3000 Blaine 2500 cement 2004
Holcim Cementi S.p.A., Merone, Italy 1 x MPS 4250 BC 120.0 4000 Blaine 2500 cement 2003
Hegmatan Cement Co., Hegmatan, Iran 2 x MPS 4250 BC 120.0 3000 Blaine 2500 cement 2003
Tehran Cement Company, Tehran, Iran 2 x MPS 4250 BC 120.0 3000 Blaine 2500 cement 2003
La Cementos National, Latacunga, Ecuador 1 x MPS 4250 BC 110.0 4 % R 0.045 mm 2200 cement 2000
Teutonia Zementwerk AG, Hannover, GER 1 x MPS 3750 C 75.0 11 % R 0,032 mm 1900 cement 1979
via Kobe Steel, Tokio, Cat Lai, Vietnam 1 x MPS 3070 B 50.0 13,1 % R 0,045 mm 900 pozzolana 1995
via FCB, Lille, INCSA, Costa Rica 1 x MPS 2800 B 45.0 15 % R 0,045 mm 650 pozzolana 2002
via RMC Group, Surrey/United Kingdom 1 x MPS 2500 BC 24.0 3500 Blaine 750 blast furnace slag 2001
Sagar Cement, for Bayyavaram, India 1 x MPS 2500 BC 20.0 3600 Blaine 600 slag/slag cement 1999
Hauri KG, Bötzingen, Germany 1 x MPS 200 BC 12.0 4600 Blaine 355 cement 1997
China Hunan Province, Hengyang, China 1 x MPS 160 C 10.0 250 cement 1986
China National Technical Import, Anqing, China
1 x MPS 140 C 7.5 200 cement 1986
TP/ Ne- 06 / 05
grinding of slag
GEBR. PFEIFFER AG
• OPC, PPC, etc. up to 4500* cm²/g
• blast furnace slag
up to 6000* cm²/g
• puzzolana
•slag cements
0 - 100 % clinker
• puzzolana cement
finish grinding
GEBR. PFEIFFER AG
product
central feeding
increasing flow velocity
liftable rollers
wear resistant lining
hardfaced grinding
elements
TP/ Ne- 08 / 04
TP/ Ne- 08 / 04
history
GEBR. PFEIFFER AG
72 t/h - grinding plant for cement with Pfeiffer MPS mill
edition: 1980 edition: 1996
history
GEBR. PFEIFFER AG
GEBR. PFEIFFER AG
• general design
• classifier
• overview
TP/ Ne- 07 / 05
Content
GEBR. PFEIFFER AG
Holcim (Italia), Merone plant MPS 4250 BC
guarantee Aug. 2004-
type: 32.5 II BM Feb. 2005
clinker 69.2 64.0 %
gypsum 5.7 6.0 %
slag 12.6 17.0 %
limestone 12.5 7.0 %
pozzolana: - 6.0 %
water sprayed into mill: 2.5 0.4 m³/h
Blaine: 4000 4400 cm²/g
throughput: 120 126 t/h
spec. power consumption
table: 16.5 13.6 kWh/t
fan: 6.0 7.0 - 4.5 kWh/t
classifier: 1.66 0.75 - 0.5 kWh/t
total: 28.15 25.35 - 22.7 kWh/t
spec. wear rate 8.0 3.3 g/t
(chromium alloy cast iron)
TP/ Ne- 08 / 04
• wear protection
TP/ Ne- 07 / 05
annular gap
submerged pipe
finished product
product 125 t/h
dust 0 t/h
moisture 0,3 %
heat flow -1.050E03 MJ/h
fineness 4300 cm²/g
temperature after
clinker
classifier: abt. 90 °C
feed rate 83,2 t/h
gypsum
-3 mbar
heating necessary
feed rate 9,1 t/h
fresh air
limestone temperature 5 °C
feed rate 13,4 t/h gas flow 0 nm³/h
client:
recirculated gas Merone / Italy Feb. 2005
slag/puzzolana/flyash temperature 95 °C
feed rate 24,3 t/h gas flow 156562 nm³/h
gas flow 218683 m³/h
material:
heat flow 19930,3 MJ/h MPS 4250 BC CEM II BM 32,5
file-name:
mill inlet hot gas generator Gebr. Pfeiffer AG PCP70000000000000
temperature 143 °C temperature 420 °C Kaiserslautern
recirculated material gas flow 182378 nm³/h gas flow 25816 nm³/h
029V017
date name designation:
water injection temperature 85 °C gas flow 288842 m³/h heat flow 15179,8 MJ/h 2005-07-
water rate 1200 l/h feed rate 62,5 t/h heat flow 35110,2 MJ/h heat power 4216,6 MJ/h
draw
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22.22.22
Rei
hoffmann
balance sheet
TP/ Ne- 07 / 05
finished product
product 165 t/h
temperature 70 °C
moisture 0 %
heat flow 6930,0 MJ/h
fineness 3800 cm²/g
clinker 120 °C
fresh air 40 °C
-5 mbar cement 70 °C
fresh air
temperature 40 °C
gas flow 331385 nm³/h
client:
recirculated gas Grinding cooling
temperature 68 °C
gas flow 60871 nm³/h
gas flow 77034 m³/h
material:
heat flow 5381,0 MJ/h MPS 5300 BC OPC 3800 cm²/g
file-name:
mill inlet Gebr. Pfeiffer AG
water injection temperature 44 °C Kaiserslautern
temperature 5 °C recirculated material gas flow 392256 nm³/h
date name designation:
water rate 2052 l/h temperature 70 °C gas flow 464747 m³/h 2005-07-
heat flow 0 MJ/h feed rate 82,5 t/h heat flow 22589,8 MJ/h
draw
edit
18
22.22.22
Rei
hoffmann
balance sheet
TP/ Ne- 07 / 05
grinding-cooling: OPC
GEBR. PFEIFFER AG
sulfate adaptation
• temperature level in vertical roller mill lower than in ball mill. This reduces
dehydration of dihydrate
TP/ Ne- 07 / 05
sulfate adaptation
GEBR. PFEIFFER AG
TP/ Ne- 08 / 04
gypsum
feed rate 8.7 t/h
moisture 3 %
clinker 120 °C
fresh air 40 °C
-5 mbar cement 70 °C
gypsum >110°C
fresh air
temperature 40 °C
gas flow 382256 nm³/h
client:
Grinding cooling with gypsum conditioning
material:
MPS 5300 BC OPC 3800 cm²/g
file-name:
Gebr. Pfeiffer AG
water injection recirculated gas Kaiserslautern
temperature 5 °C recirculated material temperature 68 °C date name designation:
water rate 2052 l/h temperature 70 °C gas flow 20000 nm³/h 2005-07-
heat flow 0 MJ/h feed rate 82,5 t/h gas flow 27000 m³/h
draw
edit
18
22.22.22
Rei
hoffmann
balance sheet
TP/ Ne- 07 / 05
• less heat consumption than in the case of heating the whole grinding plant
• patent pending
TP/ Ne- 07 / 05
TP/ Ne- 07 / 05
compressive strength
setting time
TP/ Ne- 08 / 04
quality aspects
GEBR. PFEIFFER AG
Teutonia AG, Germany - MPS 3750 C
type: CEM III A 32,5 CEM III B 32,5
throughput: 52 75 t/h
compressive strength
setting time
quality aspects
GEBR. PFEIFFER AG
Teutonia AG, Germany - MPS 3750 C
type: CEM III A 32,5 CEM III B 32,5
slag: 52 75 %
throughput: 70 45 t/h
(NiHard IV)
TP/ Ne- 08 / 04
moisture: 7 %
throughput: 60 t/h
TP/ Ne- 08 / 04
grinding of slag
GEBR. PFEIFFER AG
Sagar Cement/Bayyavaram works/India
MPS 2500 BC
quality aspects
GEBR. PFEIFFER AG
Sagar Cement/Bayyavaram works/India
June-Dec. 2000 July 2000
type: slag cement slag cement
slag: 48 48 %
(NiHard IV)
TP/ Ne- 08 / 04
operation data
GEBR. PFEIFFER AG
Gebr. Pfeiffer AG, Kaiserslautern
TP/ Ne- 08 / 04
TP/ Ne- 08 / 04
TP/ Ne- 08 / 04
air slide
two-way
chute
additive
feed
bins bag filter
fan
screw
proportioning pump
belt conveyor
scales
metal
detector rotary
overbelt airlock
feed magnetic two-way screw rotary
conveyor separator chute conveyor airlock
belt
clinker
feed rotary
metal bin airlock
collection
hopper metal
detector
MPS
roller mill
hot gas
generator
magnetic
separator
metal from cooler/ kiln 4
receptaclex
TP/ Ne- 08 / 04
material: TM - C2 cement
clinker: 95.0 %
gypsum: 5.0 %
guaranteed values
GEBR. PFEIFFER AG
Tenghui Cement, Hechuan County/China
MPS 5600 BC
guaranteed values
GEBR. PFEIFFER AG
TP/ Ne- 08 / 04
testing - MPS 40 BC
GEBR. PFEIFFER AG
specific power consumption at mill drive of MPS-BC
40
min-/ max-range
specific power consumption, kWh/t
32 average of
all tested OPC
28
24
20
16
12
2500 2750 3000 3250 3500 3750 4000 4250 4500
specific surface (Blaine), cm²/g
TP/ Ne- 08 / 04
OPC grindability
GEBR. PFEIFFER AG
specific wear rate with hardfaced wear parts
7,0
min-/ max-range
6,0
of all tested OPC
specific wear rate, g/t
5,0
4,0 average of
all tested OPC
3,0
2,0
1,0
0,0
2500 2750 3000 3250 3500 3750 4000 4250 4500
specific surface (Blaine), cm²/g
TP/ Ne- 08 / 04
TP/ Ne- 08 / 04
scale up
mill selection with the help of test results GEBR. PFEIFFER AG
specific power consumption at mill drive of MPS-BC
50
min-/ max-range
specific power consumption, kWh/t
35
30
25
20
3500 3750 4000 4250 4500 4750 5000 5250 5500
specific surface (Blaine), cm²/g
TP/ Ne- 08 / 04
slag grindability
GEBR. PFEIFFER AG
specific wear rate with hardfaced wear parts
16
min-/ max-range
of all tested blast
14
furnace slags
specific wear rate, g/t
average of
12 all tested blast
furnace slags
10
4
3500 3750 4000 4250 4500 4750 5000 5250 5500
specific surface (Blaine), cm²/g
TP/ Ne- 08 / 04
ß (friction factor)
GEBR. PFEIFFER AG
Pab = ß · z · FW · vU
¶ · dS · nS
Pab = ß · z · Fsp · dW · bW · 60
ß = friction factor ¶ · dS · nS
z = number of rollers vU = 60
Fsp = specific grinding force – (kN/m²)
dW = roller diameter – (m) FW = Fsp · dW · bW
bW = roller working width – (m)
dS = grinding bowl diameter (roller path) – (m)
nS = grinding bowl speed – (min-1)
vU = circumferential speed (m/s)
FW = specific roller force (kN/roller)
TP/ Ne- 04 / 06
TP/ Ne- 08 / 04
stability of process
GEBR. PFEIFFER AG
parameters for quality control
• mixture of feed
• (grinding aid)
TP/ Ne- 08 / 04
quality control
GEBR. PFEIFFER AG
TP/ Ne- 08 / 04
TP/ Ne- 08 / 04
floating
intermediate
shaft
self-aligning pinions
TP/ Ne- 08 / 04
TP/ Ne- 08 / 04
TP/ Ne- 08 / 04
TP/ Ne- 08 / 04
wear profile
GEBR. PFEIFFER AG
hardwelded after operation
TP/ Ne- 08 / 04
wear profile
GEBR. PFEIFFER AG
TP/ Ne- 08 / 04
foundation
GEBR. PFEIFFER AG
ball mill vertical roller mill
gypsum grinding
gypsum grinding
GEBR. PFEIFFER AG
Via Knauf, Iphofen
for Kungur I, Russia, 200 kW
grinding / calcining
supplied: 2002
fineness: 30 % R0.063 mm
TP/ Ne- 08 / 04
gypsum grinding
GEBR. PFEIFFER AG
Via Knauf, Iphofen
for Kungur II, Russia, 200 kW
grinding / calcining
supplied: 2004
fineness: 30 % R0.063 mm
TP/ Ne- 08 / 04
gypsum grinding
GEBR. PFEIFFER AG
TP/ Ne- 08 / 04
gypsum grinding
2 x MPS 200 GC supplied in 2002 and 2004 GEBR. PFEIFFER AG
TP/ Ne- 06 / 04
Pfeiffer SLV
high efficiency separator
SLV rotor
fine product
coarse product
TP/ Ne- 08 / 04
TP/ Ne- 08 / 04
Pfeiffer
Triplex dryer TRT
wet material
infeed
hot
gas
inlet
Thank you !
Barbarossastraße 50-54
P.O. Box 3080
67618 Kaiserslautern
Phone: ..49-631-4161-0
Fax: ..49-631-4161-290
e-mail: [email protected]
homepage:www.gpag.com