14/03/2011

COMFLEX High
Efficient and Flexible
Comminution System
Dr. Stefan Seemann
Cologne, Germany

COMFLEX High Efficient and Flexible Comminution System

I.

Introduction

II.

Efficient Comminution

III. Competent Operation

IV. Process understanding and optimization

14/03/2011

Introduction

Efficient
Comminution

Competent
Operation

Process
Overview

For cement plants KHD offers

Full line engineering
and equipment supply
Individual machines
Equipment packages
Spare parts and the full
range of plant services

Introduction

Efficient
Comminution

Competent
Operation

Process
Overview

Operating Structure Overview

KHD Humboldt Wedag

International

EMEA
(Cologne)

Russia/CIS
(Dessau)

Americas
(Atlanta)

India (Delhi)

Other*
*Other includes smaller operating entities
such as China, Australia, EKOF
EMEA = Europe, Middle East and Africa
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Introduction

Efficient
Comminution

Competent
Operation

Process
Overview

Operating Structure Overview

Customers are served through
four Customer Service Centres
In addition large global players are
served through Key Account
Management
Centre of Excellence for
technology in Cologne
Corporate functions in Cologne

COMFLEX High Efficient and Flexible Comminution System

I.

Introduction

II.

Efficient Comminution

III. Competent Operation

IV. Process understanding and optimization

14/03/2011

Efficient
Efficient
Comminution
Comminution

Introduction

Competent
Operation

Process
Overview

Most Efficient Grinding System

Vertical
Roller Mill

Ball Mill

Roller
Press

Efficient
Efficient
Comminution
Comminution

Introduction

Competent
Operation

Process
Overview

Energy Saving (Example: Raw Material Grinding)

energy consumption

energy saving RP vs VRM

VRM

18

010%

16

10%

14

0-6%

12
feed
moisture

10
8

Roller Press
6
3

7
9 11
Grindability

saving RP vs. VRM kWh/t

total system kWh/t

20

0-6%
4

10%
3
2
feed
moisture
1
0
3

5
7
9 11
Grindability

14/03/2011

Introduction

Efficient
Efficient
Comminution
Comminution

Competent
Operation

Process
Overview

Energy saving
RM grinding1

CM grinding1

Total saving1

3000 tpd

9.600 kWh/d

6.300 kWh/d

15.900 kWh/d

5000 tpd

16.000 kWh/d

10.500 kWh/d

26.500 kWh/d

7000 tpd

22.400 kWh/d

14.700 kWh/d

37.100 kWh/d

Total saving1

$ per day2

$ per year3

3000 tpd

15.900 kWh/d

2.703 $

891.990 $

5000 tpd

26.500 kWh/d

4.505 $

1.486.650 $

7000 tpd

37.100 kWh/d

6.307 $

2.081.310 $

2 kWh/t raw meal; cement - saving

0,17 $/kWh
3 330 days per year
2

Introduction

Efficient
Efficient
Comminution
Comminution

Competent
Operation

Process
Overview

Wear rate

Raw meal

cement

Roller Press

VRM

0.2 to 1,5 gr/ton

2 to 5 gr/ton

0.2 to 2 gr/ton

2 to 5 gr/ton

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14/03/2011

Efficient
Efficient
Comminution
Comminution

Introduction

Competent
Operation

Process
Overview

KHD Products - Roller Press

RP Size

Roller diameter
[mm]

Roller width [mm]

Motor total
[kW]

07

1700

900

1500

10

1700

1100

1800

13

1700

1400

2400

16

1700

1800

3200

18

2000

1800

4000

20

2200

1800

4600

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Introduction

Efficient
Efficient
Comminution
Comminution

Competent
Operation

Process
Overview

KHD Products - Roller Press

Roller surface:
welded surface (CHF) with profiles
STUD-Lining, autogenous wear protection
Roller Presses sold:
clinker
raw material
Minerals
Slag
Burnt lime
coal

176
63
42
18
10
1

Total

310
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14/03/2011

COMFLEX High Efficient and Flexible Comminution System

I.

Introduction

II.

Efficient Comminution

III. Competent Operation

IV. Process understanding and optimization

13

Introduction

Efficient
Comminution

VSeparator

Competent
Operation

SEPMASTER
VC

Process
Overview

LS - Static
Separator

SEPMASTER
LC, LSK (coal)

VSKSeparator

Preferred Separator Types for COMFLEX

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14/03/2011

Introduction

Efficient
Comminution

Process
Overview

Competent
Operation

V-Separator - necessary for efficient grinding

Static separator for coarse cut

KHD`s invention
VS has become standard for RP-grinding circuits
VS is multi-functional: separating, deglomerating,
drying, cooling

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Introduction

Efficient
Comminution

Competent
Operation

Process
Overview

V-Separator - necessary for efficient grinding

air and fines

feed
air

rejects
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14/03/2011

Introduction

Efficient
Comminution

Competent
Operation

Process
Overview

SEPMASTER SKS
The original Sepmaster -

features minimum height between

feed-inlet and rejects-outlet

H min.

This results in:

Low bucket elevator height and best
choice for conversions

Rotor bearings at both ends for

vibration-free run and

Together with the drive on bottom no

influence by process heat
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COMFLEX High Efficient and Flexible Comminution System

I.

Introduction

II.

Efficient Comminution

III. Competent Operation

IV. Process understanding and optimization

18

14/03/2011

Introduction

Efficient
Comminution

Competent
Operation

Process
Overview

Single machinery How about the arrangement?

Roller Press
V-Separator
SEPMASTER-SKS

Bringing Innovation
in Layouts
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Introduction

Efficient
Comminution

Competent
Operation

Process
Overview

COMFLEX - Location of V-Separator ?

VS above Roller Press

Clinker

heating required for

bag filter and vent-ducts,
and bucket elevator

VS below Roller Press

No problem

Raw
Material
Wet Blast
Furnace slag

Fines, dust, vapor,

reactive slag

Coarse, no dust,
dried coarse slag

20

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14/03/2011

Introduction

Efficient
Comminution

Competent
Operation

Process
Overview

COMFLEX - Location of dynamic-Separator ?

SKS below Roller Press

SKS above Roller Press

Fines is lifted
Pneumatically
without additional
Air flow

Fine SKS-rejects
and VS-rejects
to be lifted by
Bucket elevator

Introduction

Efficient
Comminution

Competent
Operation

Only coarse
VS-rejects to
be lifted
21

Process
Overview

COMFLEX - Location of dynamic-Separator ?

SKS below
Roller Press

SKS above
Roller Press

Mechanical
Conveyors can
be designed
25 to 40%
smaller

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14/03/2011

Introduction

Efficient
Comminution

Competent
Operation

Process
Overview

COMFLEX - High Efficient Grinding System for the Future

COMFLEX
COMminution system with Roller Press
FLEXible process for most applications

Fully Standardized
Special Layout

23

Introduction

Efficient
Comminution

Competent
Operation

Process
Overview

COMFLEX - Layout

SKS above
Roller Press

COMFLEX
Multi purpose Grinding Plant
Slag up to 7000cm2/g Blaine
Limestone 10%R 90m
Raw material 15% R 90m
Additives (slag, limestone,
fly ash)

VS below
Roller Press

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14/03/2011

Introduction

Efficient
Comminution

Competent
Operation

Process
Overview

COMFLEX - Layout
COMFLEX for
Raw Material Grinding

Static Separator
above Roller Press

VS below
Roller Press

25

Introduction

Efficient
Comminution

Competent
Operation

Process
Overview

COMFLEX - Compact

building height

bucket elevator height

Roller Press floor level

26

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14/03/2011

Introduction

Efficient
Comminution

Competent
Operation

Process
Overview

COMFLEX - Layout
COMFLEX S (Single)
300 t/h raw meal,
100 t/h slag
120 t/h cement

COMFLEX D (Double)
600 t/h raw meal
200 t/h slag
240 t/h cement

COMFLEX T (Triple)
900 t/h raw meal
300 t/h slag
360 t/h cement

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Introduction

Efficient
Comminution

Competent
Operation

Process
Overview

Conclusion
Lowest Specific Energy Consumption (more than 1 million $ of energy saving
per year!)
With Stud-Lining Roller Surface Life of minimum 18,000 Hours without
Maintenance
Highest production rates from one grinding station with COMFLEX D or
COMFLEX T
Always more than 50% Availability with COMFLEX D and COMFLEX T
Standard equipment for raw- cement and slag-grinding with lowest investment
in spare parts
with latest developments:
Greatly reduced building- and equipment cost
No dust and spillage from mechanical conveying
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14/03/2011

To get more out of

your cement plant, visit

www.khd.com

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