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Schenck Process GmbH 2006

Seite 1
Dust_Meal_GB.ppt

Schenck Process - Dosing systems for dust and meal

Flow Rate Measurement Systems


MUTISTREAM B

MUTISTREAM G

MULTICOR S

m
m

Schenck Process GmbH 2006


Seite 2

impact plate principle


Dust_Meal_GB.ppt

Fc

deflection chute principle

coriolis principle

Solids Flow Meter MULTISTREAM B Inline' measuring of bulk solids flows

Compact inline measuring system based on the


impact plate principle, for the continuous
acquisition of flow rates and totalized amounts of
up to 100t/h.
The range of bulk solids is from pulverized to
granular:

Schenck Process GmbH 2006


Seite 3

Compact, in line installation


Low-priced measuring unit with optionally
integrated measuring electronics
Dust-tight stainless steel housing

Dust_Meal_GB.ppt

MULTISTREAM B
Application features:

Cost-effective
Closed system, dust-tight
IN LINE installation
Electronics local
Maintenance free
Little assembly and adjustment work
needed

User benefits:

Easy Start Up, just connect power and


Signal out
Schenck Process GmbH 2006
Seite 4

Easy Service and Maintenance


Easy to clean

Dust_Meal_GB.ppt

MULTISTREAM B80

695

Inlet

1400

Impact plate

110

600

Housing for
the electronics

180

Schenck Process GmbH 2006


Seite 5

Fastening points

Discharge
200
Dust_Meal_GB.ppt

The impact plate principle

Detection of the horizontal component of


the reaction force (no measuring bias
due to material build-ups)
Excellent accuracies with constant
material properties and in constant
environmental conditions

Schenck Process GmbH 2006


Seite 6

Total height of the MULTISTREAM B: 1,4 m


Weight: 50 kg
Flange dimension Inlet/Outlet: 200 mm

FRH

FH

FRV
FV

FR

FR : Friction force of the product particle


F : Reaction force of the product particle
G : Gravitational force

Dust_Meal_GB.ppt

MULTISTREAM G
Solid flow meters are used for
continous measurment or feeding of
free flowing bulk solids from pulverized
to granulated using the deflector
principle.

Application features:

Schenck Process GmbH 2006


Seite 7

High throughput rate


Easy cleaning
Option check system
Customers benefits:
Very low maintenance
Easy installation
No dust emission
Dust_Meal_GB.ppt

MULTISTREAM G
~550

der
Prefee

20

Inlet chute

560

20

Schenck Process GmbH 2006


Seite 8

600

1360

Opening for
maintenance
work

Load cell

Pivot point
Dust_Meal_GB.ppt

Measuring chute

MULTISTREAM G
Measuring principle

F (V2 sin2 V1 sin1) m


V2: velocity at chute inlet
V1: velocity at chute discharge
Chute

1: discharge angle

Measured force

Schenck Process GmbH 2006


Seite 9

2: inlet angle

Pivot point
Dust_Meal_GB.ppt

Schenck Process GmbH 2006


Seite 10

MULTISTREAM G in the field

Dust_Meal_GB.ppt

MULTISTREAM comparison chart


Max. feed volume
[m/h]
Nominal flow rate
[t/h]
max. measuring
range
Accuracy (related to
nominal feed rate)
Operating pressure
[mbar]
Admissible pressure
variation

B80

G400

G750

G1250

80

400

700

1250

5 - 100

1:5
+/- 2,0%

+/- 2 mbar
10 % > 90 micron max 10 mm
(single parts up to 30mm)
free-flowing to slightly sluggish, non-adhesive

Schenck Process GmbH 2006


Seite 11

Bulk density
Max. material
temperature

-2 to - 8

-20 to +25

Grain size
Flow properties

20 - 1000 90 - 1000 200 - 1000

min. 0.4 kg/dm


70C

Note: for details please refer to sales release

Dust_Meal_GB.ppt

100C

Schenck Process GmbH 2006


Seite 12

MULTICOR

The mass flow meter for high flow rates


Dust_Meal_GB.ppt

CORIOLIS - Feeder - MULTICOR-S and K


Worldwide more then 1000 systems installed

Schenck Process GmbH 2006


Seite 13

high control accuracy through


high speed acquisition of
measured data
accuracy 0,5% related to the
actual feed rate
feed constancy 1% within
10 seconds
CORIOLIS measuring principle
immune to external

gravity
discharge

direct feed into


pneumatic
conveying tube
10bar-pressure-proof
design for coal dust

Dust_Meal_GB.ppt

CORIOLIS - Principle
- one step ahead
R

P
M

AC-drive with
integrated speed
transducer

= radius of measuring wheel [m]


= angular velocity [1/s]
= feed rate [t/h]
= torque = FC R

P =

load cell

M
R2

FR

Schenck Process GmbH 2006


Seite 14

FZ

FC

FC = CORIOLIS-force
FZ = centrifugal force } no influence on the
FR = friction force
} measuring result
Dust_Meal_GB.ppt

Premise to high accuracy:

Constant rotor speed


Constant effective outer diameter of measuring wheel

Advantages of the coriolis principle

no effect on accuracy by different bulk solid characteristics

Schenck Process GmbH 2006


Seite 15

Dust_Meal_GB.ppt

friction
flow rate
height of drop

MULTICOR Options:
Measuring wheel:

Housing:

different number of blades, open


and closed version
coatings
Hard coat
Tungsten carbide
PTFE-coatings
Rubber PTFE

Schenck Process GmbH 2006


Seite 16

Dust_Meal_GB.ppt

service opening
second inlet
rubber coating of housing inside
(to avoid grain break, noise, as a
resistant coating - up to 80C)
ceramic coating of housing inside
(high resistant coating - up to 130C)
noise insulation
flow guide

CORIOLIS - Feeder
- highly accurate and reliable MULTICOR-S

MULTICOR-S is used for the


measuring of the flow rate of
bulk solids up to 800 cbm/h.

Special features:

Schenck Process GmbH 2006


Seite 17

direct mass flow


measurement
enclosed, dustproof system
no dust emission
low headroom
easy installation

Dust_Meal_GB.ppt

MULTICOR-S types

Schenck Process GmbH 2006


Seite 18

S40 to S160

Dust_Meal_GB.ppt

S300

S800-R

Schenck Process GmbH 2006


Seite 19

MULTICOR S - Feed rates


Type S40

Type S80

Type S160

Type S260

max. 20 t/h
max. 40 m/h

max. 60 t/h
max. 80 m/h

max. 150 t/h


max. 160 m/h

max. 150 t/h


max. 260 m/h

2 4

15

Dust_Meal_GB.ppt

40

80

160

260 m/h

Schenck Process GmbH 2006


Seite 20

MULTICOR S - Feed rates

10

Type S 300

Type S800R

max. 300 t/h


max. 300 m/h

max. 600 t/h


max. 800 m/h

15

30

Dust_Meal_GB.ppt

300

450

800 m/h

MULTICOR comparison table


Max. feed volume [m/h]
range absolute flow rates [t/h]

S80

S160

S300

40

80

160

300

800

1 - 20

2 - 60

10 - 150

30 - 300

120 - 600

max. measuring range


Accuracy (related to actual
feed rate)
Operating pressure [mbar]

1:5

0,5%

1% *1

-10 to +30

-5 to + 10

-25 to +25

5 mbar

min. Grain Size

10% > 90 micron / 5000 Blaine

max. Grain Size

5 mm
30mm

Flow properties

min. 0.3 kg/dm


free flowing to slightly sluggish, non-adhesive
130C

Max. material temperature


Motor Soft Start
pressurized air required

No

Dust_Meal_GB.ppt

100C
Yes

No

Note: for details please refer to sales release


with on-stream calibration (needs to be approved by SBV)
*2)
weighing module located outside
*1)

20mm

15mm

Bulk density

Schenck Process GmbH 2006


Seite 21

S800-R

1 : 10

Admissible pressure variation

Single particles allowed

*2)

S40

Yes

MULTICOR S 800 R Kiln Feed Results

Typical Kiln Feed Rate


Before Schenck Scale
After Schenck Scale

0.86
0.84
0.82
K iln fee d %

0.8
0.78
0.76
0.74
0.72
0.7
0.68

Decreased Variation

Increased Feed Rate

Schenck Process GmbH 2006


Seite 22

time (minutes) >

Actual results after replacing conventional deflection chute flow meter.

Dust_Meal_GB.ppt

18 References MULTICOR S 800 R

Schenck Process GmbH 2006


Seite 23

Customer

Country

delivery

Type

Feed rate

Material

Dyckerhoff Luxemburg
Dyckerhoff Amneburg

Luxemburg

Apr. 05

600t/h

130t/h

Germany

Nov. 05 350t/h

200t/h

Cement loading station


Blending cement & slag

Sinoma f. Tahamah Cem

Saudi Arabia

Jan. 06

600t/h

560t/h

Raw meal

Sinoma f. Tahamah Cem

Saudi Arabia

Jan. 06

600t/h

560t/h

Raw meal

Turnia Slowakai

Slowakia

Dez. 05 350t/h

190t/h

Raw meal

CBMI Italcimenti Malaga

Spain

350t/h

300t/h

Raw meal

VVM N.V. Van Eckhaut

Belgium

Mrz. 05
Jan. 06

350t/h

350t/h

Blending Flyash+Slagcement

PAC Lafarge Davenport

USA

Feb. 06 600t/h

350t/h

Raw meal

PAC f. Lehigh Edmonton AlbertaCanada

Feb. 06 350t/h

350t/h

Raw meal

Sinoma f. City Cement

Saudi Arabia

Jun. 06 600t/h

560 t/h

Raw meal

Sinoma f. City Cement

Saudia Arabia Jun. 06 600t/h

560 t/h

Raw meal

CBMI Holcim

Marokko

Aug. 06 350t/h

320t/h

Raw meal

PAC for Titan Roanoke

USA

Aug. 06 350t/h

350t/h

Raw meal

Mardin Cimento Sanayi

Aug. 06 350t/h

300t/h

Raw meal

HUBEI YA DONG CEMENT CO. Ltd.

Okt. 06

600t/h

IBAU Hamburg

Nov. 06

350t/h

280t/h

Raw meal

JIANGXI YA DONG CEMENT CO. Ltd.


China

Nov. 06

600t/h

600t/h

Cement

PAC Lehigh Leeds

USA

Nov. 06

300t/h

300t/h

Raw meal

bold:

delivered

Dust_Meal_GB.ppt

Germany

Schenck Process GmbH 2006


Seite 24

On-stream Calibration

Dust_Meal_GB.ppt

CORIOLIS KILN FEEDING SYSTEM


Multi-feeder calibration system

tc1
tc2

Calibration Weight
Check bin mcb

mcb1
mcb = mcb1 mcb2
mcb2

tc
tc1
tc2
mcb
mc_f1
mc_f2
mcftot

calibration time
calibration start
calibration stop
calibration weight check bin
material feed by feeder no.1
material feed by feeder no.2
mcf1 + mcf2

Calibration weight
measuring by bin
mcb
weighing system

corr_tot = mcb - mcftot

Schenck Process GmbH 2006


Seite 25

Kiln feed no.1

Calibration weight mcf


measuring by the total
Coriolis systems
Mcf_tot = mc_f1 + mc_f2

Kiln feed no.2

Dust_Meal_GB.ppt

Calibration
Feeder no.1
Calibration
of individual
feeder acc.
to actual
feed rate
Calibration
Feeder no.2

Prefeeders for Flow Meters

Schenck Process GmbH 2006


Seite 26

Dust_Meal_GB.ppt

Starfeeder/Rotary Feeder
Dosing valve
Screw
MULTICELL

Job-sharing for better results


Sizing mass flow
silo

Schenck Process GmbH 2006


Seite 27

Application/design according to
the feed rate and the used bulk
material
cement
raw meal
fly ash
filter dust
lime meal
coal dusts

Systems which integrate all of


these functions in one unit can
never be optimised for the variety
of requirements.
Dust_Meal_GB.ppt

Discharge

CORIOLIS

Conveying

Feeding System = Measuring system + controlled prefeeder

Silo

Prefeeder
Power
controller

Schenck Process GmbH 2006


Seite 28

Controller
Setpoint
t/h

Dust_Meal_GB.ppt

Comparison
set-actual

Position

Revolution

Flow gate Star feeder


Screw
Apron feeder

Measuring / Actual valve


BW
Qxv

DLM
Q

COR.
M
R

Different prefeeders for different requirements

Schenck Process GmbH 2006


Seite 29

good material flow characteristics


with silo aeration
==> flow-gate for feed rates
up to 800 m3/h
good material flow characteristics
with silo aeration, if required
==> starfeeder for feed rates
recommended up to 100 m3/h
poor material flow characteristics
without silo aeration
==> screw with integrated
agitator for feed rates
recommended up to 80 m3/h

Dust_Meal_GB.ppt

CORIOLIS - Feeder
- Kiln Feed high feed constancy for high clinker quality

position controlled flow-gate as


prefeeder
option: On-Stream-Calibration
via check bin

Schenck Process GmbH 2006


Seite 30

feed rates up to 800 m3/h

Dust_Meal_GB.ppt

Dosing valve

Maximum Feeding

Schenck Process GmbH 2006


Seite 31

Control Feeding High


Throughput

Control Feeding
Metering and Low
Capacity
Dust_Meal_GB.ppt

Dosing valves

Schenck Process GmbH 2006


Seite 32

Actuated by motor
Seperate shut of valve
necessary

Seperate drive unit with


contact output
necessary
Dust_Meal_GB.ppt

Actuated by integrated
pneumatic cylinder

Includes shut off


function

Position controller
included

Actuated by motor
Seperate shut of valve
necessary

Position controller
included

Generated with tiffGen

CEMAG
Z632.50089/B

1:25

16.12.99

Franzek

16.12.99

Faber

16.12.99

Faber

A0
6xa

637181

17.12.99

SATT

F007 970

Kontrollbunker 3000
CHECK BIN

F026 913

Schenck Process GmbH 2006


Seite 35

Mass flow meter MULTICOR with Dosing Valve

Dust_Meal_GB.ppt

Schenck Process GmbH 2006


Seite 36

Kiln Feed Common Problems

Material in the
pre-bin should be
good flowing

Dust_Meal_GB.ppt

No stiff flexible
connections at
the refill of weigh
hopper

Kiln feed Common Problems

Schenck Process GmbH 2006


Seite 37

Clogged connection to vent


of airslide after flow meter

Dust_Meal_GB.ppt

CORIOLIS-feeder
- loading station

Schenck Process GmbH 2006


Seite 38

accuracy of 2 % of
truck load
straight onto truck
without any detours
easy to integrate in
existing installations
low headroom required
fully automatic operation
of loading plant

Dust_Meal_GB.ppt

MULTICOR - loading station

Different kinds of Cement

ca.: 1500 mm

Schenck Process GmbH 2006


Seite 39

Typical feed rate: 250 t/h

Dust_Meal_GB.ppt

CORIOLIS-feeder

Cement

additive

- two functions in
one system
Simultaneous
weighing and mixing

cost reduction:
mixers are not required
high mix quality:
proven by tests performed
by Schenck and Plants

Schenck Process GmbH 2006


Seite 40

LIW-feeder

Dust_Meal_GB.ppt

Blending with MULTICOR


Control scheme
Fly-Ash

DISOCONT

Cement
PID

x
Actual value
cement

Preselection %
of Cement

Schenck Process GmbH 2006


Seite 41

DISOCONT

PID

Cement setpoint
Dust_Meal_GB.ppt

Actual value
Fly ash

Schenck Process GmbH 2006


Seite 42

Blending with Coriolis Feeding Systems

Dust_Meal_GB.ppt

Trial Results @ 20% Additive Addition

20%

SiO2
18.95
20.66
18.59
18.24

Al2O3
18.43
19.77
18.09
18.02

CaO
18.82
20.07
18.16
18.34

Ins
18.94
20.71
18.66
18.3

Mean
19.11
18.5775 18.8475 19.22333
Std Dev 1.073219 0.814918 0.861293 1.300013
% CV
5.61601 4.386587 4.569798 6.762682
Mean

= Sum of results / No. of samples

Std. Dev

= Measure of how wide values are dispersed from mean

% CV

= Standard deviation / mean x 100

Schenck Process GmbH 2006


Seite 43

Interpretation of %CV

Dust_Meal_GB.ppt

< 10%

= Excellent

10 15%

= Good

15 20%

= Fair

>20%

= Poor

Schenck Process GmbH 2006


Seite 44

References
Customer
Australian
Cement

Country
Australia

Application
Cement 100 t/h
Fly ash 50 t/h

Equipment
MULTICOR S160 / MULTICOR S 160

Rugby
Cement

United Kingdom

99,5% Cement /
0,5% chemical additive

MULTICOR / MULTIFEED

Seament

United Kingdom

92% Cement /
8% kiln dust

MULTICOR S300 / MULTICOR S160

Dyckerhoff

Germany

Blast furnace slag 60 t/h


Cement 140 t/h

MULTICOR S 80 / MULTICOR S 160

Seament

United Kingdom

92% Cement /
8% kiln dust

MULTICOR S300 / MULTICOR S160

Seament

United Kingdom

92% Cement /
8% kiln dust

MULTICOR S300 / MULTICOR S160

ISG

USA

Fly ash 100 t/h


Additive 3 t/h

MULTICOR S 160 / MechaTron

Van Eckhout
Dyckerhoff

Belgium
Germany

Cement / Fly ash /Sand


Blast furnace slag / Cement
sum feed rate 200 t/h

Mixer S800R 350 t/h


MULTICOR S 800 R

Labatlan /
Holcim
Dunman

Hungary

Cement 40 t/h / Fly ash 40 t/h /


4 x MULTICOR S 80
filter dust 40 t/h / lime meal 40 t/h 1 x MULTICOR S160
Cement / Fly ash
2 x MULTICOR S 160

Dust_Meal_GB.ppt

United Kingdom

Precise weighing and feeding


crucial for efficient cement production
Clay
Sand

Products:

Schenck Process GmbH 2006


Seite 45

Crusher relief
screen

Apron weigh feeder


Belt weigher

Limestone

Apron feeder
Limestone
crusher

Weighfeeder

Reclaimer wheel

Loss-in-weight feeder
MECHATRON

Return grits

Homogenization

Solids flow meter

Limestone

Separator

MULTICOR
CORIOLIS-feeder

Flow gates

Bucket elevator

Alternative:

Weighbridge
truck/trains

Alternative fuel
feeding
- Fuel Master Series

Belt weigher to be
installed in apron
conveyor

Kiln

MECHATRON
FE2SO4

Bucket
elevator

Vibration screen

Mill optimisation

Sand

Clay

Raw mill

Bin weighing

Loading automation

Sand

Clay

Clinker

Gypsum

Additive

Return
grits

Separator

Store
Cementmill

Cooler

Blaine value
Measurement

MULTICOR-K - Feeding
of pulverized coal
(10 bar pressure proof)
Cement

Cement

Cement

SCHENCK Fuel Master


Feeding of Alternative Fuels

BMH Product Line

DISOCONT - ONE electronic standard for the whole cement plant !


Dust_Meal_GB.ppt

NEW BMH Product Line

Bulk Reception Units (Road Rail Sea)

Schenck Process GmbH 2006


Seite 46

Stackers, Belt conveyors, Bucket Elevators, Storage Systems

Dust_Meal_GB.ppt

Thank you very much

Schenck Process GmbH 2006


Seite 47

for your attention !

Dust_Meal_GB.ppt