GEBR. PFEIFFER INC Competence in Cement
CLINKER & RAW MEAL GRINDING SWING MILL MPS2500BC
Progress is our tradition
GEBR. PFEIFFER INC established in 1864 mid-range private company more than 140 years of competence in: grinding, separating, drying,calcining and hydrating more than 2000 MPS mills m ills worldwide grinding: cement raw meal, m eal, coal, clinker,granulated clinker,granulated blast-furnace slag, pozzolana,limestone, pozzolana,limestone, clay, clay, gypsum ..... approx. 400 employees employ ees worldwide, with subsidiaries in USA and India annual turnover worldwide approx. 150 million € (200 million USD) company-owned workshops including foundry Gebr. Pfeiffer, Inc. Subsidiary in Florida •
•
•
•
•
•
•
•
•
MPS raw mill
MPS coal mill
MPS raw mill
>131
MPS coal mill
>64
MPS cement mill
>40
45 - 720 t/h 8 - 100 t/h 12 - 220 t/h
MPS cement mill 400 - 5600 kW 110 - 1650 kW 355 - 5600 kW TP/ Ne-06 / 05
r e f er er e n c e s i n t h e c e m e n t i n d u s t r y f r o m 1 99 99 4 o n w a r d s i n O p e r at at i o n
GEBR. PFEIFFER INC
Test Centre in KL, Germany Test Station for testing of various materials, for capacity, wear life, power.
TP/ Ne-08 / 04
t es tin g -
MPS 40 B C an d w e a r d e t er m i n a t i o n eq u i p m e n t
GEBR. PFEIFFER INC
GEBR. PFEIFFER, Inc.
Cement / Slag and Raw Meal / Pozzolan Grinding
Progress is our tradition
fine product
Clinker Feed
hot gas
Recycle discharge TP/ Ne-08 / 04
Design GEBR. PFEIFFER INC
essen tial desig n features of Pfeiffer MPS mills •
•
•
•
•
•
•
•
•
•
•
MPS5600B C Clink er/Slag m ill
central feed of clinker and classifier grits high specific roller force for optimum grinding one pressure frame for uniform load distribution to grinding rollers, grinding bed and gearbox large grinding roller diameter for optimum material intake and formation of stable material bed continuous measuring of the grinding bed thickness low pressure loss due to optimized nozzle ring and external material circulation rounded profile rollers and moulded table for stable grinding bed low table speed for a very low vibration level closed mill housing for minimum false air leakage high-efficiency classifier for sharp separation and low electric power consumption patented MPS Lift-and-Swing System for quick and easy exchange of wear parts through one single maintenance door in the mill housing
TP/ Ne-08 / 04
GEBR. PFEIFFER Inc
•
central feed through grit cone
•
hardfaced table and roller liners
•
ceramic lining of classifier
•
hardfaced classifier blades
•
Ni-hard IV nozzle ring
•
high specific grinding force
•
low air velocity TP/ Ne-08 / 04
design of cement mill GEBR. PFEIFFER INC
TP/ Ne-08 / 04
r otar y lo c k - DSZ GEBR. PFEIFFER INC
TP/ Ne-08 / 04
Holc im (Italia) SpA , Meron e plant GEBR. PFEIFFER INC
TP/ Ne-08 / 04
r e p l ac e m e n t o f w e ar p a r t s w i t h Pfeiffer Lift-and -Swin g Sy stem
GEBR. PFEIFFER INC
Sagar Cement/Bayyavaram works/India MPS 2500 BC material:
CEM III A 32,5
in operation since:
2000
finished product rate:
24.3 t/h (48% HOS)
power consumption: (mill) -
19.3 kWh/t -
power consumption: (mill and fan) -
26.6 kWh/t -
Sm (Blaine)
3600 cm²/g
specific wear: lifetime of grinding elements:
5 - 5.5 g/t 2200 h (welding sequence) TP/ Ne-08 / 04
g r i n d i n g o f c l i n k e r an d s l a g GEBR. PFEIFFER INC
Mill Unit Data MPS2500BC Table Diameter Roller diameter Classifier Rotor Diameter Table wear elements Roller weight/wear roller Mill gearbox power Classifier Gearbox •
•
•
•
•
•
•
•
•
= 2,500mm = 1,360mm (3 Rollers) = SLS2250BC = 2,250mm = 3,150kg = 7,500kg / 1,450kg per roller = 900kw = 75kw
TP/ Ne-08 / 04
GEBR. PFEIFFER INC
ADVANTAGES OF MPS SWING MILL
Mill in operation for coal, clinker since 1999 and the raw mill version since 1963 Mill is designed for Clinker / Slag grinding Raw Meal / Pozzolana grinding with dynamic loads reduced -> additional safety factor in raw grinding No need for internal mechanical changes No need for table speed change Same parallel position of roller and table for different material bed depth Raw mill and clinker mill airflow within 10% of each other -> velocities through the mill are not compromised Operation within 10% of ideal parameters -> no waste of power
MPS MILL OPERATION
Main motors and operation remain in on position(running) during change over Expected change over time (< 1 hour) to clean out system, build up hydraulic pressure (or reduce) and change separator speed and feed rate Due to airflow being so close, the separator will also be efficient in both grinding phases, that means no additional DP or overgrinding MPS mills run at lower table linear speed than other mills, therefore the mill is so low with regards to vibration Mill foot print and physical size is smaller than all other rocker arm type mills, and needs only one access point for maintenances, not 3 +2 points per flat table mill
Progress is our tradition
Blaz Jurko Gebr. Pfeiffer, Inc. +1-305-458-3347
[email protected]
TP/ Ne-08 / 04
GEBR. PFEIFFER INC
GEBR. PFEIFFER INC
OPTIMIZED CEMENT PLANTS
WHY OUR SOLUTION OCP Global Economy’s deceleration
and increase on the execution of Infrastructure Projects in the so called Developing Countries.
Highly
competitive situation paradigms within this Sector.
Atractive
alternative consumers.
for
and
major
the
cement
Low
investment costs per unit of installed capacity implementing State-of-the Art technology ($/tpa).
Significative
share of locally supplied engineering and components in the solution.
Optimization
products.
of the addition of cementitious
PROPOSAL IMSACOL has developed a solution that we have called OCP, according to the following characteristics: –
The OCP concept developed in the scenarios: A.
B.
–
Fixed Capacity Plants with
can be different -
Cement
capacities between 100 and 500 tpd. Variable Capacity - Cement Plants with low production capacities between 300 and 1,000 tpd, but designed for a quick and unexpensive increase of capactiy.
Implementation of Main Equipment supplied by western companies with State-of-the-Art technology.
FIXED CAPACITY PLANT ELEMENTS •
High Efficiency - Vertical Roller Mill, used for double purpouse (“Swing Mill”).
•
•
•
•
•
•
•
Pre-heating Tower fit to production capacity. Conveying equipment fit to production capacity. Multi-Cell Silo for Cement and Raw Meal State-of-the-Art Clinker Cooler, adjusted to the required clinker production capacity. Usage of alternative fuels in the process Addition of cementitious materials in the final product Integrated filter for different materials.
VARIABLE CAPACITY PLANT High Efficiency - Vertical Roller Mill, used for double purpouse (“Swing Mill”).
•
•
Pre-heating Tower, ready for increase of up to double the initial capacity,
•
Conveying equipment overdimensioned
•
State-of-the-Art Clinker Cooler. •
Usage of alternative fuels.
•
Integrated filter.
•
Multi-Cell Silo for Cement and Raw Meal
•
•
Phase 2 additional Multi-Cel Silo for Cement and Cement Additives Phase 2 additional Swing Mill
OCP Concept Start
with 1 Swing Mill Rest of Plant already designed for upgrade capacity Low Initial Capital Cost Low Upgrade Capital Cost Short Upgade Implementation Schedule / During Regular Plant Shutdown Customized Cement grinding according to market demand
OCP Operation One Integrated Baghouse Filter for Pyro Process and Grinding Process Swing Mill operating alternatively for: Raw Meal grinding Cement Grinding Cement Additives Grinding (Pozzolana, Slag, Limestone, etc.) Plant Energy Efficiency at most advanced State-Of-The-Art technological level Optional and already designed use of alternative fuels Filter designed for minimal change over. Material handling equipment running during change over. The change over can be performed during high electrical demand/costs hours, in order to optimize energy savings.
Fixed = Phase 1 Variable TYPICAL LAYOUT
Variable Phase 2 TYPICAL LAYOUT
Fixed = Phase 1 TYPICAL FLOW SHEET
CA
A
C
F
Variable Phase 2 TYPICAL FLOW SHEET
CA
A
C
F
CONCLUSION
–
–
–
–
A great simplification of the Plant Layout. Simple operation with State-of-the-Art Western Technologies Low cost alternative without sacrificing plant equipment quality Use of Highest Energy and Thermal Efficiency Equipment according to international Standards
–
Short Term Project Execution
–
Competitive Operating Costs
–
Eco-Friendly Operating Including Alternate Fuels and Cement Additives
TECHNOLOGIES In our developments we involve locally supplied engineering and construction services, along with the most trusted and effcient technologies from recognized suppliers, with whom we have arranged commercial strategic alliances.
