150rue 231011 Exberfa Raw Mill Investigation

INVESTIGATION OF RAW MILL ARGOS PLANT SABANAGRANDE BARRANQUILLA, COLOMBIA CODEWORD: EX-BERFA
INVESTIGATION PERIOD: COMPILER: REPORT-NUMBER: DISTRIBUTION:
19/10/2011 27/10/2011 Jens Rsch Victor Penner 150/12-258/2011 ARGOS, FERROTEC, 150, 011, 012, 300, 600, 775
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POLYSIUS POLYSIUS
C:\Daten\ANLAGEN\Exberfa1\150Rue_231011_Exberfa_Raw_Mill_Investigation.doc
Address: Polysius AG, Graf-Galen-Strasse 17, 59269 Beckum-Neubeckum, Germany Phone: +49 2525 99-0 Telefax: +49 2525 99-2100 E-Mail: polysius@thyssenkrupp.com Internet: www.polysius.com Chairman of Supervisory Board: Dr. Niclas Mller Executive Board: Dr.-Ing. Detlev Rose, Chairman, Dr. Friedrich-Wilhelm Dierkes, Dr.-Ing. Detlev Kupper, Dipl.-Ing. Norbert Patzelt Trade Register: Amtsgericht Mnster HRB-Nr. 7717 Registered Office: Beckum-Neubeckum
Table of Contents
1. Summary 2. Process data

2.1 Measurement results 2.2 Control room screen 2.3 Heat balance
3. Findings
3.1 Particle size of Caliza (limestone) 3.2 Feeding of bricks 3.3 High and fluctuating moisture of feed materials 3.4 Handling difficulties 3.5 Iron particles 3.6 Direct operation (raw mill off) 3.7. High percentage of false air with 42 %
4. Main modifications
4.1 Inner dam ring 4.2 Reduction of the roller carrier movement in the guide brackets 4.3 Centralizing of the material discharge point on the grinding table 4.4 Reversing of the separator turning direction 4.5 Readjustment of the separator guide vanes
5. Further mechanical deficiencies/recommendations

5.1 Grinding table 5.2 Hydraulic 5.3 Gearbox 5.4 Flaps direct operation 5.5 Scraper system 5.6 Recirculation duct 5.7 Nitrogen accumulator 5.8 Uniform distribution of hot gas before mill 5.9 Monitoring of wear
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1. SUMMARY
In 2005 in Sabanagrande, Barranquilla, Colombia a cement plant was put into operation, which mainly consisted of used equipment: - reclaimer (MIAG, 1961) Teutonia Cement, Germany - kiln (KHD, 1961) Teutonia Cement, Germany - cooler (Claudius peters, 1961) Teutonia Cement, Germany - raw mill (POLYSIUS, 1991; Ex-Berfa) Schwenck, Germany - coal mill (POLYSIUS, 1979, Ex-Rekom) Holcim, Reking, Schweiz - cement mill (POLYSIUS, 1961, Ex-Elzem) Elsa Zement- und Kalkwerk Neubeckum Since 2006 this cement plant belongs to the cement producer ARGOS. This vertical roller mill for raw material grinding was originally designed as a coal mill for a German cement factory of Schwenck in Bernburg, Germany (code word Berfa, delivered in 1993 but never operated). The raw mill is of the type RM 27/13/230. The production rate of the raw mill was in a range of approx. 50 t /h (feed rate: 55 t/h) at a fineness of R (75 m) = 18 % to 22 % recently. ARGOS is looking for measures to increase the production of the raw mill in order to increase the clinker production of the kiln (actual maximum possible kiln feed rate: 80 t/h). Furthermore the high vibration level of the mill should be reduced in order to protect the damaged RENK gearbox. POLYSIUS investigated the raw mill between October 19th and 27th. Different modifications were carried out: - Installation of a inner dam ring - Cutting of the external dam ring extension - Reduction of the roller carrier movement within the guide brackets - Centralizing of the material discharge point on the grinding table - Readjustment of the separator guide vanes - Reversing of the separator turning direction As a result of these measures a production increase of approx. 40 % could be achieved (feed rate: 75 to 80 t/h). The fineness was in a range of R (75 m) = 15 % to 20 % (average 18 %, R (90 m) = 12 %). The vibration level was estimated to be normal. The position of the two installed vibration sensors was incorrect and the indicated numbers were not representative. After the installation of new spare parts (page 4) and further optimization steps, e.g. the elimination of the false air, POLYSIUS estimates a further production increase of 20 % quite feasible. The actual operation revealed several fields of optimization. These points should be brought under control within a short term: 1. Particle size of Caliza (limestone) too high (frequently 80 mm to 200 mm rocks in Caliza). The maximum particle size should be 52 mm. - Hammer crusher in Barranquilla plant to be repaired. Possibly bars below crusher missing. - Sieving grate after mixing bed to be repaired 2. Feeding of bricks. The feeding of red bricks with sizes of 250 mm and more disturbs the formation of a homogeneous grinding bed and major vibration peeks are the consequence. - Elimination or pre-crushing of the bricks
C:\Daten\ANLAGEN\Exberfa1\150Rue_231011_Exberfa_Raw_Mill_Investigation.doc 3 / 26
3. High and fluctuating moisture of feed materials (up to 15 % during raining season) - Longitudinal mixing bed to be equipped with a roof. 4. Moist and sticky Caliza creates handling difficulties at raw material bins. - Side walls of the bins to be equipped with stainless steel plates. 5. High amount of huge iron particles entering the raw mill. Only a metal detector is existing but no material extraction flap. Responding of the metal detector has the consequence that the transport belts are stopped and iron pieces are manually removed. This measure is dangerous since metal pieces can be overlooked. 6. During stoppage times of the raw mill the hot kiln gases have to bypass the raw mill through the direct way duct to the filter. Presently it is a common practice to guide the hot kiln waste gases of more than 250 C through the mill system. This operation presents a high risk for the grinding roller tires. Grinding roller temperatures above 200 C were monitored. Material fatigue and temperature shocks after re-feeding the mill can not be excluded. Tire fractures are the consequence, which happened three time during the last 12 month. 7. High percentage of false air with 42 %. The main false air sources could be identified. 8. Operation of air to air heat exchanger after preheater tower during compound operation (raw mill on). When the mill is operated the cooling air fans of the air to air heat exchanger in the preheater tower of the kiln have to be switched off in order to gain sufficient heat capacity for the raw material grinding. The temperature after mill should be in a range of greater 90 C, preferably in a range of 100 to 110 C. Next steps Next to the a.m. optimization points especially the poor mechanical condition of the raw mill needs to be overhauled. The proper mechanical condition is the basis for further production increase and for the stabilization of a smooth and gentle operation. The following mechanical changes are mandatory: 1. Installation of the new gearbox. 2. Installation of new guide brackets with material deflectors (material ploughs) 3. Installation of a new hydraulic unit, tie rods and new design of tie rod sealing 4. New roller carrier with confining air system (wear protected design) 5. New grinding table liner segments 6. New grinding table scraper system in combination with a new inlet shaft sealing. 7. New vibration sensors and correct position (to be confirmed) 8. Replacing the triple pendulum flap valve by a heated rotary coarse feed valve 9. Iron detection and discharge system at mill feed belt Once the mechanical condition is under control, further process optimization steps can be undertaken. The grinding bed was adjusted to a height of approx. 60 mm. This is under normal condition too high (increased power consumption reduced throughput), in this case it serves to protect the damaged grinding table liner segments and the damaged gearbox. The grinding rollers are inclined to the center of the grinding table (reduced throughput). These points can be solved after the mechanical renovation.
Guarantee/ installed
Exberfa October / 2011
Exberfa 27/10/2011 75,0 10,1 1,00 68,2 12,0 18,00 12,00 1,0000 68,2 520
Mill feed Raw material moisture Raw meal moisture Product dry Reference fineness Fineness Fineness Fineness Correction Factor Product dry, 12% R 90 m Power consumption Mill motor counter Fan motor counter Bucket elevator counter Separator counter Specific power consumption Mill motor shaft Fan motor shaft Bucket elevator shaft Separator shaft Total Mill shaft Wm-Mhle-Welle (12 % R 90 m) k-grinding table (at actual fineness) Hydraulic pressure Spec. Grinding Force Delta P Mill Filter Fan
t/h % % t/h %R90m %R75m %R90m % t/h kW kW kW kW kWh/t kWh/t kWh/t kWh/t kW kWh/t kW/m^2.5 bar kN/m mbar mbar % damper Nm/h m/h C mbar m/kg m/kg Nm/h m/h C mbar % % % l/h l/h % m m/s t/h rpm mm mm mm/s 670 817 13
55 10,1 1 50,0 12 18 12 1,0000 50,0 500
7,09 0,00 0,00 0,00 7,09 483,60 7,09 40,37 135,00
specific. air volume at R(90 m) at actual fineness specific. air volume at R(90 m) = 12% Gas volume before mill
False air total system (dry) False air mill (dry) False air "after mill - before fan" (dry) Water injection Water from material Total water Nozzle ring area Velocity of gas in nozzle ring Bucket elevator load Recirculation factor Guidevane position Separator speed Internal damring Grinding bed height Vibration
43,4 19,7 100 139684 202503 91,4 -78,2 2,970 2,970 76630 165363 306,2 -15,1 42,7 24,1 18,6 0 6825 9,10 1,11 41,38
141 max
65 80 20 65 1,0
Table 1: Results
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2. Process data
Total False Air: 42.7 % (dry)

139,684 Nm/h 202,503 m/h C 91.4 -78.2 mbar 135,739 Nm/h 180,623 m/h C 88.4 -3.1 mbar
False Air: 18.6 % (dry)
2.1 Measurement results
0%
100 %
Caliza 1
calculated
Caliza 2 100 %
Mineral del hierro
68.11 t/h 1.0 % H2O

measured
R (75 m) = 18 % R (90 m) = 12 %
34.9 %
63.9 %
1.2 %
measured not closing completely
C 94.2 -58.5 mbar 0%
calculated
3,406 4,663 Nm/h m/h 0%
indicated
6 / 26
80 rpm
False Air: 24.1 % (dry)
indicated
calculated
75.0 t/h 10.1% H2O 65
38,000
m/h
calculated
0 l/h
not installed
76,630 Nm/h 165,373 m/h 100 %

p Hydr. = 135 bar Vibration: 1.0 mm/s measured
C 234 -15.1 mbar
measured
Pic 1: Measurement results

M
520 kW
73,129 Nm/h 158,661 m/h 315 C -5.4 mbar
2.2 Control room screen
Pic 2: Control room screen

2.3 Heat balance

Heat Balance
Project / Customer Comments ARGOS Sabanagrande Condition 27.10.2011
Run case Engineer Ambient data Elevation relative humidity ambient pressure ambient temperature water in ambient air 0m 80% 1011 mbar 30 C 3,34% Hot gas generator Air excess number 1013 mbar Fuel name Hu Gas 3,19 Gas 1 7600 kcal/Nm
Heat input
Solid materials Total production Raw material Water in Raw material Gypsum Water in Gypsum Limestone Water in Limestone Dust in Kiln gas Total wet material feed Gases Hot gas Fresh air Kiln gas Cooler gas User defined gas Recirculation gas Gas at system inlet False air (39,0%) Conveying gas Sources Power absorption Water injection Total Heat Input moisture 1,00% 100,00% 10,10% 0,00% 0,00% 0,00% 0,00% 0 g/Nm 10,10% actual Volume 0 m/h 0 m/h 158.019 m/h 0 m/h 0 m/h 4.663 m/h 165.373 m/h 60.595 m/h 0 m/h mass 68.106 kg/h 67.425 kg/h 7.575 kg/h 0 kg/h 0 kg/h 0 kg/h 0 kg/h 0 kg/h 75.000 kg/h normal Volume 0 m/h 0 m/h 73.225 m/h 0 m/h 0 m/h 3.406 m/h 76.630 m/h 54.477 m/h 0 m/h quantity 520 kW 0 kg/h specific heat 0,8291 4,1849 0,8800 4,1804 0,8392 4,1804 1,0248 1,1681 specific heat 1,4308 1,3109 1,5161 1,3089 1,3083 1,4010 1,5105 1,3109 1,4010 specific heat 4,1849 Temp. 20,0 C 20,0 C 30,0 C 30,0 C 30,0 C 30,0 C 315,0 C 20,0 C Temp. 785,8 C 30,0 C 315,0 C 0,0 C 0,0 C 100,0 C 306,2 C 30,0 C 100,0 C Temp. 20,0 C Enthalpy 0 kJ/h 0 kJ/h 0 kJ/h 0 kJ/h 0 kJ/h 0 kJ/h 0 kJ/h 0 kJ/h Enthalpy 0 kJ/h 0 kJ/h 32.750.065 kJ/h 0 kJ/h 0 kJ/h 381.693 kJ/h 33.131.759 kJ/h 714.144 kJ/h 0 kJ/h Enthalpy 1.872.000 kJ/h 0 kJ/h 35.717.902 kJ/h kcal/kgProd. %
0,00 0,00 0,00 114,85
0,00 0,00 0,00 91,69
p 0 mbar 0 mbar 0 mbar 0 mbar 0 mbar 0 mbar -15 mbar 0 mbar 0 mbar
1,34 2,50
1,07 2,00
6,57 125,26
5,24 100,00
10,10%
Heat output
Solid materials Product Water in Product Grits Water in Grits Dust from Kiln Gas Total wet material output Gases Fan exhaust gas Stack exhaust gas Sinks Radiation losses Evaporation heat Total Heat Output Gas Mass Balance Error moisture 1,00% 0,00% 1,00% actual Volume 202.503 m/h 182.284 m/h actual Volume mass 67.425 kg/h 681 kg/h 0 kg/h 0 kg/h 0 kg/h 68.106 kg/h normal Volume 139.684 m/h 136.279 m/h quantity 110 m 6.894 kg/h specific heat 0,8585 4,2011 0,8585 4,2011 0,8953 specific heat 1,3992 1,3992 specific value 30 kJ/(mCh) 5181 kJ/kg H2O Temp. 96,4 C 96,4 C 96,4 C 96,4 C 91,4 C Temp. 91,4 C 91,4 C Temp. 91,4 C 20,0 C T 5 C 5 C Enthalpy 4.422.339 kJ/h 218.594 kJ/h 0 kJ/h 0 kJ/h 0 kJ/h Enthalpy 13.954.872 kJ/h 13.614.644 kJ/h Enthalpy 202.620 kJ/h 16.919.477 kJ/h 35.717.902 kJ/h 0 kJ/h 15,51 0,77 12,38 0,61
p -78 mbar
48,94
39,07
0,71 59,34 125,26
0,57 47,37 100,00
0 m/h Heat Balance Error
Table 2: Heat balance
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3. Findings
3.1 Particle size of Caliza (limestone)
The particle size of Caliza (limestone) is too high. A high portion of Caliza rocks in the range 80 mm to 200 mm can be found frequently. The maximum particle size should be 52 mm (4 % of DRolller = 1300 mm). - Hammer crusher in Barranquilla plant has to be repaired. Possibly are bars below the crusher missing. The Barranquilla plant is 30 km away. All raw materials are delivered with trucks to the Sabangrande plant. - Sieving grate after mixing bed shows huge gaps and should be repaired (PIC 5)
PIC 3: Caliza rocks in feed
PIC 4: Caliza feed
PIC 5: Sieving grate before raw material bins

3.2 Feeding of bricks

The feeding of red bricks with sizes of 250 mm and more disturbs the formation of a homogeneous grinding bed and major vibration peeks are the consequence. - Elimination or pre-crushing of the bricks
PIC 6: Bricks in Arcilla
PIC 7: Bricks
3.3 High and fluctuating moisture of feed materials

The moisture is up to 15 % during raining season - Longitudinal mixing bed (MIAG reclaimer) needs to be equipped with a roof.
PIC 8: Open raw material storage
PIC 9: Open longitudinal mixing bed

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PIC 10: Open Caliza mixing bed
PIC 11: Caliza 2 with high moisture
PIC 12: Caliza 2 with high moisture
11 / 26
3.4 Handling difficulties

Moist and sticky Caliza creates handling difficulties at raw material bins - Side walls of the bins to be equipped with stainless steel plates.
PIC 13: Raw material bins
3.5 Iron particles

A high amount of huge iron particles is entering the raw mill. Only a metal detector is existing but no material extraction flap. A responding metal detector has the consequence that the transport belts are stopped and iron pieces are manually removed. This measure is dangerous since metal pieces can be overlooked. - An automatic iron detection and discharge system at the mill feed belt should be installed, especially to avoid further mechanical damage at the grinding tools
PIC 14: Iron particles found on grinding table
PIC 15: Iron detector

12 / 26
3.6 Direct operation (raw mill off)

During stoppage times of the raw mill the hot kiln gases have to bypass the raw mill through the direct way duct to the filter. Presently it is a common practice to guide the hot kiln waste gases of more than 250 C through the mill system. This operation presents a high risk for the grinding roller tires. Grinding roller temperatures above 200 C were monitored. Material fatigue and temperature shocks after re-feeding the mill can not be excluded. Tire fractures, which are most properly a result of high vibration and material fatigue, are the consequence. This happened three times during the last 12 month.
PIC 16: Broken tire
PIC 17: Broken tire
PIC 18: Broken tire

3.7. High percentage of false air with 42.7 % (Table 3).

The main false air sources could be identified: - Triple pendulum flap valve for feed (PIC 19) - Grinding table sealing (PIC 20) - Tie rod lead through to the mill interior (PIC 21, 22) - Pendulum flap valve to bucket elevator (PIC 23) - Fresh air damper before filter (PIC 25) - Mill outlet duct damper (PIC 25) - Fan (8.9 % false air, Table 3, PIC 24) -
Point
Date
CO2 %
O2 % 9,32 10,17 9,59 10,06 9,785
CO % 0,000 0,000 0,000 0,000 0,00
N2 % 74,58 75,43 74,21 74,24 74,62
Nox
lamda False Air % %
Hotgas duct
27.09.11
16,1 14,4 16,2 15,7 15,60
138 133 157 169 149,25
1,8872 2,0293 1,9461 2,0399 1,9737
before Mill
27.09.11
14 13,9 16,2 16 15,025
11,47 12,00 10,66 10,62 11,188
0,000 0,000 0,000 0,000 0,000
74,53 74,1 73,14 73,38
149 149 146 149
2,3751 2,5591 2,2139 2,1952
right
73,7875 148,250 2,3277
after Mill
27.09.11
9,4 9,3 11,1 11,4 9,350
14,16 14,20 13,85 13,61 14,180
0,000 0,000 0,000 0,000 0,000
76,44 76,5 75,05 74,99 76,47
95 99 101 97 97
3,2991 3,3146 3,2707 3,1523 3,3068
24,1
after Filter
27.09.11
7,4 6,7 9,8 10,2 8,525
15,78 16,22 14,69 14,40 15,273
0,000 0,000 0,000 0,000 0,000
76,82 77,08 75,51 75,4
85 85 80 86
4,4009 4,7994 3,7296 3,5520 4,0647
18,6
76,2025 84,000
Stack
27.09.11
8,2 7,8 8,000
15,53 15,93 15,730
0,000 0,000 0,000
76,27 76,27 76,27
89 78 84
4,2738 4,6673 4,4619 Total:
8,9
42,7
Table 3: Gas analyses

PIC 19: Triple pendulum flap valve
PIC 20: Grinding table sealing
PIC 21: Tie rod sealing
PIC 22: Worn tie rod
15 / 26
PIC 23: Not functioning pendulum flap valve
PIC 24: Fan shaft
PIC 25: False air points after damper and fresh air damper not closing completely
16 / 26
4. Main modifications 4.1 Inner dam ring
PIC 26: Original dam ring condition
PIC 27: Internal dam ring
The external dam ring extension was removed and a inner dam ring at the lower side of the basic dam ring installed.
4.2 Reduction of the roller carrier movement in the guide brackets

The guide brackets were extremely worn and out of shape. The gap between roller carrier guide pin and bracket wall was up to 30 mm (max. 10 mm). Sine the wear material was made from casted steel it was not possible to re-weld it. Instead of that 10 mm steel plates were inserted and welded with a cross-plate.The guide brackets need to be replaced in a medium term.
PIC 28: Guide brackets highly worn and trapezoidal widened out
PIC 29: Guide brackets

17 / 26
4.3 Centralizing of the material discharge point on the grinding table For the centralization of the material feed point on the grinding table, the extension of the grit cone with a funnel was necessary.
PIC 30: Extension of grit cone
18 / 26
4.4 Reversing of the separator turning direction

Originally the rotor turning direction was anti-clockwise (left arrow). Due to the inclination of the rotor blades the rotor cage was working as a paddle wheel, shoveling the coarse particles inside the rotor. With the clockwise turning the separation efficiency is improved, which is resulting in higher finenesses at lower rotor speed.
PIC 31: Rotor direction
4.5 Readjustment of the separator guide vanes

The guide vane arrangement was changed according to the rotor direction from anti-clockwise to clockwise.
PIC 32: Guide vanes original

PIC 33: Guide vanes modified

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5. Further mechanical deficiencies/recommendations 5.1 Grinding table
PIC 34: Disrupted edge of grinding table segment
PIC 35: Disrupted edge of grinding table segment
The grinding table segments show disrupted edges, most properly resulting from foreign bodies on the grinding table and a high radial clearance of the roller carrier within the guide brackets.
5.2 Hydraulic
The hydraulic unit needs to be replaced. The precise adjustment of the hydraulic pressure was not possible, e.g. at a setpoint of 150 bar the mill was operated with only 129 bar.
PIC 36: Hydraulic

5.3 Gearbox
PIC 37: Damaged RENK gearbox
There are actually two vibration sensors installed, at the inlet shaft and at the upper part of the gearbox. The upper sensor showed a vibration level of 5 mm/s, which is most likely due to the damaged gearbox. The correct position, where the vibration sensor should be installed is at the base frame of the gearbox (indicated with an arrow). Here the manual measurement of the vibrations showed a level around 1 mm/s, which is in a normal range. The vibration sensor at the inlet shaft showed a level of 1.7 mm/s.
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5.4 Flaps direct operation

The direct way damper is not completely closed at 100 % indication. The measurement showed that there is still a bypass stream of 38,000 m/h through the direct way duct during compound operation (raw mill on). This volume flow is missing in the mill system and reduces the lifting capacity inside the mill. ARGOS stated that in the area of the direct way damper always dust accumulation occurs, which constricts the complete closing of the damper. The position of the damper is located in a quite horizontal gas duct. As an alternative it can be recommended to re-activate the existing guillotine gate and/or to redesign the direct way duct.
PIC 38: Direct way duct
PIC 39: Direct way duct

PIC 40: Overview
5.5 Scraper system
PIC 41: Scraper
ARGOS installed 4 scrapers over the whole circumference according their own design. The mill should be equipped according the original POLYSIUS design. The original POLYSIUS design has 24 scrapers.
5.6 Recirculation duct

The recirculation duct usually serves to adjust the correct negative pressure before mill, which is normally in a range of -4 mbar. Actually the pressure before mill was measured with -15.1 mbar. The recirculation duct damper was fully closed. A lower negative pressure (-4 instead of -15 mbar) relieves the mill fan, more gases can be sucked through the system and the increased gas flow allows a higher production rate. The actual design of the duct is too long, includes an unused fan and unnecessary Venturi nozzle. This increases the pressure drop. It is recommended to rebuild the recirculation duct as short as possible as shown in PIC 43. In the actual case with the high false air portion the high temperature of the inlet hot gases are of higher importance than the correct adjustment of the pressure. It seems that a certain portion of false air is entering the mill through the recirculation duct.
PIC 42: Recirculation duct
PIC 43: Recirculation duct rebuild proposal

5.7 Nitrogen accumulator

The nitrogen accumulator on the working side - motor side is smaller than on the bucket elevator side. The original piston accumulator should be installed.
PIC 44: Piston accumulator
5.8 Uniform distribution of hot gas before mill

According the original design the hot gases are entering the mill from the front side (arrow PIC 45). ARGOS installed an additional gas duct, which allows an additional entering of hot gases from the backside (PIC 46). According ARGOS information this additional gas duct improved the throughput rate and operation conditions. The necessity of a further equalization of the hot gas distribution under the mill can not be estimated at this point of time. A test with closing of the existing additional hot gas duct can be undertaken.
PIC 45: Not functioning pendulum flap valve
PIC 46: Fan shaft

25 / 26
5.9 Monitoring of wear

For the monitoring of the grinding table and roller wear POLYSIUS will deliver special templates. With the aid of these templates wear progress numbers at certain points over the whole roller respectively table profile have to be monitored. The evaluation of these numbers (free POLYSIUS service) shows the wear rate and the wear progress. Furthermore information regarding the remaining lifetime of the roller respectively grinding table can be derived.
Table Roller
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150rue 231011 Exberfa Raw Mill Investigation

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150rue 231011 Exberfa Raw Mill Investigation

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INVESTIGATION OF RAW MILL ARGOS PLANT SABANAGRANDE BARRANQUILLA, COLOMBIA CODEWORD: EX-BERFA

INVESTIGATION PERIOD: COMPILER: REPORT-NUMBER: DISTRIBUTION:

1. Summary 2. Process data

5. Further mechanical deficiencies/recommendations

Exberfa October / 2011

55 10,1 1 50,0 12 18 12 1,0000 50,0 500

7,09 0,00 0,00 0,00 7,09 483,60 7,09 40,37 135,00

Total False Air: 42.7 % (dry)

False Air: 18.6 % (dry)

2.1 Measurement results

Mineral del hierro

68.11 t/h 1.0 % H2O

measured not closing completely

75.0 t/h 10.1% H2O 65

76,630 Nm/h 165,373 m/h 100 %

C 234 -15.1 mbar

Pic 1: Measurement results

73,129 Nm/h 158,661 m/h 315 C -5.4 mbar

2.2 Control room screen

Pic 2: Control room screen

2.3 Heat balance

0,00 0,00 0,00 114,85

0,00 0,00 0,00 91,69

0,71 59,34 125,26

0,57 47,37 100,00

0 m/h Heat Balance Error

Table 2: Heat balance

PIC 3: Caliza rocks in feed

PIC 4: Caliza feed

PIC 5: Sieving grate before raw material bins

3.2 Feeding of bricks

PIC 6: Bricks in Arcilla

3.3 High and fluctuating moisture of feed materials

PIC 8: Open raw material storage

PIC 9: Open longitudinal mixing bed

PIC 10: Open Caliza mixing bed

PIC 11: Caliza 2 with high moisture

PIC 12: Caliza 2 with high moisture

3.4 Handling difficulties

PIC 13: Raw material bins

3.5 Iron particles

PIC 14: Iron particles found on grinding table

PIC 15: Iron detector

3.6 Direct operation (raw mill off)

PIC 16: Broken tire

PIC 17: Broken tire

PIC 18: Broken tire

3.7. High percentage of false air with 42.7 % (Table 3).

O2 % 9,32 10,17 9,59 10,06 9,785

CO % 0,000 0,000 0,000 0,000 0,00

N2 % 74,58 75,43 74,21 74,24 74,62

lamda False Air % %

16,1 14,4 16,2 15,7 15,60

138 133 157 169 149,25

1,8872 2,0293 1,9461 2,0399 1,9737

14 13,9 16,2 16 15,025

11,47 12,00 10,66 10,62 11,188

0,000 0,000 0,000 0,000 0,000

74,53 74,1 73,14 73,38

149 149 146 149

2,3751 2,5591 2,2139 2,1952

73,7875 148,250 2,3277