Advanced cement grinding with ‘reduced circuit’: Florian Grassl, PM-Technologies GmbH (Austria)
Filmed at Cemtech Europe 2015, 20-23 September, Intercontinental Hotel, Vienna, Austria.
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Thanks for your introduction, ladies and gentlemen I want to welcome you, today I want to tell you some facts about the plants cement grinding with ball mills and high efficiency classifiers. At the beginning I just want to give you a short overview about the company profile of PM-Technologies.
PM-Technologies was founded in the early years of the 1990s in Austria. Today we're operating on the worldwide market as an engineering partner and assistance supplier to the cement, and the mineral industry. We're able to handle a complete turnkey projects including the delivery, the commissioning, direction work, but we also do smaller scopes for example only basic engineering, process engineering, design study.
So this is always depending on the demand of each customer of each project. The main competence of PM-Technologies was since the beginning the optimization of existing systems this means we do not like to deliver complete new green field plants this is not our approach. Our approach is really depthtinisation[sp] of such plants, of old plants of new plants it is our target to bring every plant to its optimum solution, to its optimum performance, apart from the grinding systems which the actual title of today.
We have the second main focus and this is the optimization of kiln and preheater plants. So only a short introduction the requirements in the cement industry especially for this kiln plants. There can be very different from one customer to the other from one market to the other. It can be for example of a classic clinker production increase.
It can be use of alternative fuels like today in Central Europe increase in emission limits. So the demands are very individual and this tasks we want to find an individual solution for this demands. The first step when we are requested for help is always a very detailed bottleneck evaluation re-engineering of this existing operation, of the conditions this individual plant.
Then we have different solutions for example we do modifications at the second stages. We have solution for new consim lime of optimization of consim. We have in the lower pre-heat area the step 2 hot meal bypass system. It is very useful if you have problems in operation, or if you want to use SNCR system.
We have solutions for chlorine bypass system, gas kiln system and also hot meal bypass system, they cleaning in the chamber, cleaning in the sealing, this can be very important. And we have all this key equipment you need in the preheater for example this potential theoretic the guideline for the upper cyclone stages So let us come to the grinding plants.
As an introduction to this topic, I want to tell you how PM Technologies entered this field and it started with the development of a new and a unique classifier that is called the Classiclon it was initially developed for the mineral industry that means it was used for producing high quality powders for ultra fine powders different minerals like chips or a limestone or synthetic powders and the new idea of this classifier you can see here in the picture it is ADS router to technology ADS stands for Aero Dynamics Seperation and this is because our plates they look a little bit like the wing of an aeroplane this means we do not use just flat bars or bench bars or even round steel we really use this shaped plates and the idea was very simple, every classified has this one key part, it has this one most important part, we call it the heart of the machine and it was intention if we managed to improve this part, the total classifier performance will increase and this is the rest of out of this development.
So what is not the principle? What is the difference between a conventional router and this ADS technology You see here the comparison between a conventional router at an upper picture and the ADS plate. When you think now about the physic principle of classification, this is always the difference of the draft force it is caused by the outflow and of the centrifugal force which is caused by the turning router and every particulate to choose depending on it's size if it follows the draft force into the router, then it is in the fine fraction.
Or if it follows, if it is rejected by the centrifugal force, then it is rechecked at the classifier. And then you see here now the comparison, the airflow, the ground force in the conventional machine, it is very a straight way, it is a very easy way, it enters directly to router inside.
At ADS plate it makes a curve. This means the airflow has to overtake the router. Also the particle has to overtake the router.
PM-Technologies was founded in the early years of the 1990s in Austria. Today we're operating on the worldwide market as an engineering partner and assistance supplier to the cement, and the mineral industry. We're able to handle a complete turnkey projects including the delivery, the commissioning, direction work, but we also do smaller scopes for example only basic engineering, process engineering, design study.
So this is always depending on the demand of each customer of each project. The main competence of PM-Technologies was since the beginning the optimization of existing systems this means we do not like to deliver complete new green field plants this is not our approach. Our approach is really depthtinisation[sp] of such plants, of old plants of new plants it is our target to bring every plant to its optimum solution, to its optimum performance, apart from the grinding systems which the actual title of today.
We have the second main focus and this is the optimization of kiln and preheater plants. So only a short introduction the requirements in the cement industry especially for this kiln plants. There can be very different from one customer to the other from one market to the other. It can be for example of a classic clinker production increase.
It can be use of alternative fuels like today in Central Europe increase in emission limits. So the demands are very individual and this tasks we want to find an individual solution for this demands. The first step when we are requested for help is always a very detailed bottleneck evaluation re-engineering of this existing operation, of the conditions this individual plant.
Then we have different solutions for example we do modifications at the second stages. We have solution for new consim lime of optimization of consim. We have in the lower pre-heat area the step 2 hot meal bypass system. It is very useful if you have problems in operation, or if you want to use SNCR system.
We have solutions for chlorine bypass system, gas kiln system and also hot meal bypass system, they cleaning in the chamber, cleaning in the sealing, this can be very important. And we have all this key equipment you need in the preheater for example this potential theoretic the guideline for the upper cyclone stages So let us come to the grinding plants.
As an introduction to this topic, I want to tell you how PM Technologies entered this field and it started with the development of a new and a unique classifier that is called the Classiclon it was initially developed for the mineral industry that means it was used for producing high quality powders for ultra fine powders different minerals like chips or a limestone or synthetic powders and the new idea of this classifier you can see here in the picture it is ADS router to technology ADS stands for Aero Dynamics Seperation and this is because our plates they look a little bit like the wing of an aeroplane this means we do not use just flat bars or bench bars or even round steel we really use this shaped plates and the idea was very simple, every classified has this one key part, it has this one most important part, we call it the heart of the machine and it was intention if we managed to improve this part, the total classifier performance will increase and this is the rest of out of this development.
So what is not the principle? What is the difference between a conventional router and this ADS technology You see here the comparison between a conventional router at an upper picture and the ADS plate. When you think now about the physic principle of classification, this is always the difference of the draft force it is caused by the outflow and of the centrifugal force which is caused by the turning router and every particulate to choose depending on it's size if it follows the draft force into the router, then it is in the fine fraction.
Or if it follows, if it is rejected by the centrifugal force, then it is rechecked at the classifier. And then you see here now the comparison, the airflow, the ground force in the conventional machine, it is very a straight way, it is a very easy way, it enters directly to router inside.
At ADS plate it makes a curve. This means the airflow has to overtake the router. Also the particle has to overtake the router.
