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I Optimisation with TSV

by Loc Pottier & Philippe Niel, Fives FCB, France
Figure 1: 3D model of twofilter circuit

Fives FCBs TSV third generation high efficiency classifier , with more than 210 references,is a recognised piece of equipment which has received wide acceptance in the field of cement grinding, as well as raw meal, solid fuel, and mineral grinding. When looking to increase production capacity, energy cost savings and improvements in product quality, replacing an old generation classifier with a state-of-the-art efficient model is one way to reach these objectives while keeping the capital investment to a minimum.
and from f1.4m to f8m. Its specific features are: the selection basic concept with the patented shape of rotor blades the patented anti-vortex system. The blade shape ensures the equilibrium between centrifugal force and drag force in the whole volume located between the blade and not only in the selection area at the inlet. For one particle diameter, which corresponds to the d50 (= cut size) of the selection curve of the classifier, drag force and centrifugal force are balanced during the transfer from the inlet, in the selection of volume, to the outlet of the blade. The result is a very steep slope of the selection curve around the d50:acuity = d25/d75 = 0.4 to 0.6. Besides, the drastic
Figure 3: Chelm cement plant installation mills N8, N9 and N10

he TSV (Turbo Sparateur Ventil) belongs to the thirdgeneration of dynamic classifiers. Its particular design has seen it applied and well-proven in a large range of industrial products, from graphite to cement, and from silicon to solid fuels, with a cut size ranging from 8m (TSV type THF) to 500m (TSV type TBF),

Figure 2: 3D model of singlefilter circuit



Figure 4: TSV with air-anddust volute inlet

flash dryer is directly fed with fly ash, as a secondary feed point. Operated in this mode, the classifier is fed both from the top (discharge by bucket elevator) and the bottom. Following modification, the mill output is able to achieve 120tph of CEM IV with a maximum feed moisture content of 11 per cent, which means 25 per cent moisture content of the fly ash.

High quality cement

There is no doubt that converting an open-circuit to closed-circuit with the use of a classifier brought a significant improvement in the quality of cement. The best quality control and grinding efficiency have been achieved with the introduction of the third-generation classifier TSV. The combination of the excellent acuity and the drastic reduction of coarse particles in the final product allows for a revision of the targeted fineness. Figure 6 shows an example of a comparison between grain size analysis of cements obtained with the first-generation dynamic classifier and TSV. The modernisation Cementirs Taranto plant, dealing with CEMII AS (15 per cent slag), is a good example of a TSV industrial application. The initial
Figure 5: combination of flash dryer and TSV at the Sacci Testi cement plant

reduction of coarse particles in the final product ensures a better early compressive strength and consequently enables the user to lower the Blaine target value. The second patented characteristic of the Fives FCB classifier is the inside plates of the turbine which recover the dynamic pressure of the rotating gases before leaving the separator. This patented Vortex breaking system provides: low pressure drop in the classifier extremely low power consumption of the classifier.

Installation flexibility
In the usual configuration, material is fed from the top of the classifier and air is fed in at the bottom. When operated with a ball mill, this arrangement corresponds to a two-filter circuit (see Figure 1). However, the TSV capability goes much further. A material feed on the top and bottom of the classifier, plus an air feed means that it can be operated in a single-filter circuit mode. Dedusting of the mill is then carried out through the classifier (see Figure 2). Such an arrangement was selected by Cemexs Chelm plant in Poland for the modernisation of cement Mill N9 (2002) and subsequently cement Mill N8 and 10 (2007). The aim of this project (on top of the 20-25 per cent capacity increase and the new production of a pure CEM I at 4500 Blaine) was to locate all the new equipment relevant to the classifier inside the existing building (see Figure 3), in a shortened shutdown period (for full details of this project see ICR December 2004). This capability of the TSV to be fed from the bottom is naturally applied to the

full air swept system, as commonly met when grinding solid fuels. An additional, optional feature of the TSV is the lateral air feed which allows considerable extension of the classifiers field of implementation in a modernisation project. Even in an existing building, with reduced available height and area, an efficient solution can be met. This particular arrangement was chosen by Titans Kosjeric plant in Serbia, for modernisation of the cement mill with the main production being CEM II/A-M (P-Q). A significant hot gas generator is present in the mill building, reducing the possible layout for classifier gas ducts. A TSV 3600 HF with lateral gas inlet (see Figure 4) was selected, in combination with cyclones and recirculation fan. Furthermore, depending on the moisture of the feed material, the TSV classifier can be associated with a flash dryer. As an example, a recent project at the Sacci Testi plant in Italy involved a bi-rotator mill for the production of CEM IV/B-M (54 per cent clinker, 36 per cent fly ash, five per cent limestone). The 3600kW mill measured f4m x L13m (+3.2m drying chamber) and was operated in a two-bag filter system, with a static classifier at the mill gas outlet and a second-generation classifier for final classification. Before modification, the mill output was 75tph of CEM IV, with a fresh feed maximum moisture content of 9.5 per cent. The modification consists of replacing the existing second-generation classifier with a TSV with the addition of its associated filter and fan, and installing a flash dryer located bellow the classifier, in the gas stream (see Figure 5). This


installation with ball mill plus firstgeneration classifier was producing a 4100 Blaine cement with a R32m sieve residue = 11.5 per cent (annual average). After modification with TSV, the guaranteed fineness values (Blaine 3800 and R32m 5 per cent) gave compressive strength results higher than those recorded before modification (see Table 1). As a consequence, the producer changed its fineness target values from R32m = five per cent to 6-7 per cent, leading to final potential capacity of around 62tph, which meant a gain of +26 per cent. Other possible benefits of the cement quality improvement are the production of new types of cement, either with wider fineness range or higher additive content (limestone, fly ash, pozzolan, slag etc). Classification efficiency remains a constant subject of investigation and is a part of Fives FCB research and development programme. When particular configuration or material are met, CFD modelling is used to anticipate the classification parameters. Figure 7 is a view of gas speed distribution modelling at the classification inlet area.

Table 1: production of CEM II AS 42.5 (15% slag) Cementir, Taranto, Italy

Before 49 50 4100 11.5 25 37.3 49.3 With TSV 58 42.2 3920 4.9 26.8 39.5 50.5

Mill output (tph) Mill consumption (kWh/t) Blaine (cm2/g) R32m sieve (%) Compressive strength: 2 days (MPa) 7 days 28 days
Figure 7: model of TSV gas inlet distribution

A cost-effective solution
A concern when dealing with high performing technology might be maintenance cost and the availability of equipment. The third-generation classifier TSV is designed with particular attention to these aspects, considering both the effects of wear and the mechanical reliability. Each section of the classifier is protected with regard to the type of product to be classified, ranging from

wear resistant base plates, up to ceramic lining, including hard faced plates, or Nihard casting. The latest improvements in this deal with the protection of the rotating seal of the biggest classifiers.
Figure 6: GSD comparison

As the bearings are calculated for a lifetime of 100,000h and operate with an efficient greasing system, this gives complete classifier reliability. For instance, a bearing replacement in the frame of a preventive maintenance programme was recently planned after 70,000h (operating) on a TSV 3600 HF dedicated to cement grinding.

Fives FCB is recognised as a turnkey equipment supplier bringing to its customers innovative, efficient and reliable technologies. The integration of a TSV in a grinding circuit, whether it be in a new plant or a modernisation project, is a perfect example of sustainable development in the cement industry. It reduces the specific electrical consumption, allows for higher amounts of cement additives and consecutive reduction of equivalent specific CO2 emission. __________________________ I

TSV your cement requires a first class classifier


Get the highest quality for your raw meal, cement, solid fuels or minerals with the Fives FCB 3rd generation separator: Easy installation High resistance to wear Minimal by-pass Tromp curve very steep Very low pressure drop Extremely low power consumption TSV: more than 200 machines installed worldwide To Save Value. Thanks to the TSV and to other innovative solutions, Fives FCB designs today the cement plants of the future: more efficient, more environnementally friendly and more economical.

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