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COMFLEX High
Efficient and Flexible
Comminution System
Dr. Stefan Seemann
Cologne, Germany
I.
Introduction
II.
Efficient Comminution
14/03/2011
Introduction
Efficient
Comminution
Competent
Operation
Process
Overview
Introduction
Efficient
Comminution
Competent
Operation
Process
Overview
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
4
14/03/2011
Introduction
Efficient
Comminution
Competent
Operation
Process
Overview
I.
Introduction
II.
Efficient Comminution
14/03/2011
Efficient
Efficient
Comminution
Comminution
Introduction
Competent
Operation
Process
Overview
Ball Mill
Roller
Press
Efficient
Efficient
Comminution
Comminution
Introduction
Competent
Operation
Process
Overview
VRM
18
010%
16
10%
14
0-6%
12
feed
moisture
10
8
Roller Press
6
3
7
9 11
Grindability
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 $
Introduction
Efficient
Efficient
Comminution
Comminution
Competent
Operation
Process
Overview
Wear rate
Raw meal
cement
Roller Press
VRM
2 to 5 gr/ton
0.2 to 2 gr/ton
2 to 5 gr/ton
10
14/03/2011
Efficient
Efficient
Comminution
Comminution
Introduction
Competent
Operation
Process
Overview
Roller diameter
[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
11
Introduction
Efficient
Efficient
Comminution
Comminution
Competent
Operation
Process
Overview
176
63
42
18
10
1
Total
310
12
14/03/2011
I.
Introduction
II.
Efficient Comminution
13
Introduction
Efficient
Comminution
VSeparator
Competent
Operation
SEPMASTER
VC
Process
Overview
LS - Static
Separator
SEPMASTER
LC, LSK (coal)
VSKSeparator
14/03/2011
Introduction
Efficient
Comminution
Process
Overview
Competent
Operation
15
Introduction
Efficient
Comminution
Competent
Operation
Process
Overview
feed
air
rejects
16
14/03/2011
Introduction
Efficient
Comminution
Competent
Operation
Process
Overview
SEPMASTER SKS
The original Sepmaster -
H min.
I.
Introduction
II.
Efficient Comminution
18
14/03/2011
Introduction
Efficient
Comminution
Competent
Operation
Process
Overview
Bringing Innovation
in Layouts
19
Introduction
Efficient
Comminution
Competent
Operation
Process
Overview
Clinker
Raw
Material
Wet Blast
Furnace slag
Coarse, no dust,
dried coarse slag
20
10
14/03/2011
Introduction
Efficient
Comminution
Competent
Operation
Process
Overview
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
SKS above
Roller Press
Mechanical
Conveyors can
be designed
25 to 40%
smaller
22
11
14/03/2011
Introduction
Efficient
Comminution
Competent
Operation
Process
Overview
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
24
12
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
26
13
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
www.khd.com
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