COMFLEX® GRINDING

SYSTEM

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2

Comflex system consumes less

energy compared with other

grinding systems, for:

Raw materials

Cement Clinker

Blast Furnace Slag

Minerals

COMFLEX® =

COMminution + FLEXibility

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Why?

COMFLEX®Products Compact Systems References

COMFLEX®

Why we are doing the layout not like others?

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COMFLEX® - Where to place the V-Separator?

COMFLEX®Products Compact Systems References

Fines, dust, vapor,

reactive slag

Clinker

________________________

Moist raw

Material

_______________________

Wet slag

V-Separator above

Roller Pressheating of

chutes, bucket

elevators, vent

pipes and bag

filters

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COMFLEX® - Where to place the V-Separator?

COMFLEX®Products Compact Systems References

Fines, dust, vapor,

reactive slag

Clinker

________________________

Moist raw

Material

_______________________

Wet slag

V-Separator above

Roller Pressheating of

chutes, bucket

elevators, vent

pipes and bag

filters

No fines, no dust,

dried coarse slag

V-Separator below

Roller Press

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COMFLEX®Products Compact Systems References

COMFLEX® - Where to place the SEPMASTER?

Fine SKS-

rejects

and VS-rejects

to be lifted by

Bucket elevator

SKS below

Roller Press

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COMFLEX®Products Compact Systems References

COMFLEX® - Where to place the SEPMASTER?

Fine SKS-

rejects

and VS-rejects

to be lifted by

Bucket elevator

SKS below

Roller Press

Fine

SKS-rejects

are lifted by

process air

Only coarse

V-Separator

rejects

are lifted

mechanically

SKS-

rejects

are directly

fed to the

Roller

Press

SKS above

Roller Press

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COMFLEX®Products Compact Systems References

COMFLEX® - Basic Circuit

COMFLEX®

main equipments:

1. Roller Press

2. V-Separator

3. SEPMASTER

4. Material lifting

a. Pneumatic

b. Mechanical

5. Airchute or belt conveyor

1

2

3

4

a4

b

5

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COMFLEX®Products Compact Systems References

COMFLEX® - Flowsheet

product

fresh

feed

metal

separation

product collection

in bag filter or in

cyclones

basic COMFLEX

circuit

Gas inlet

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COMFLEX®Products Compact Systems References

Summary - COMFLEX®

1600 t/h

500 t/h

2500 t/h

900 t/h

500 t/h

Conventional Finish-Grinding:

Mechanical conveying of fines:

Problems with coating and spillage

Limited to lower feed moisture

not suitable for grinding slag

up to 60% larger bucket elevator

COMFLEX®

Pneumatic lifting of fines, mechanical lifting

of dried coarse material:

No problems with coating and spillage

Most suitable for moist material and slag

simple operation with less equipment

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Products of COMFLEX® - System

COMFLEX®Products Compact Systems References

Roller Press

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COMFLEX®Products Compact Systems References

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COMFLEX®Products Compact Systems References

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Roller Press - Standard Sizes

COMFLEX®Products Compact Systems References

RP

Size

[MN]

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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Roller Press - Configuration

COMFLEX®Products Compact Systems References

Configuration Standard Options

Frame design Swing Frame (RPS) Standard Frame (RPZ)

Roller design Shaft and bandage Solid roller

Roller surface Welded (CHF) STUD-Lining

Roller drive

Double Drive Mono-Drive

Constant speed;

Cardan shaft, fluid

coupling

Variable speed; cardan

shaft, safe-set

coupling

Bearing lubrication Grease lubrication Forced oil lubrication

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Roller Press - Surface Options

COMFLEX®Products Compact Systems References

CHF - Complete Hard Facing

STUD-Lining - after 17 000 hours operation

without maintenance

Line-Profiles

Inserted

hard metal-studs

Ground material

between studs is

Autogenous Wear

Protection

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Stud Lining / Wear Measurements / SLAG-Grinding

17,000 hours

COMFLEX®Products Compact Systems References

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Products in COMFLEX® - System

COMFLEX®Products Compact Systems References

Separator

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Separator Product Line

COMFLEX®Products Compact Systems References

SEPMASTER

VCLS - Static

Separator

V-

Separator

Preferred Separator Types for COMFLEX®

VSK-

SeparatorSEPMASTER

LC, LSK (coal)

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COMFLEX®Products Compact Systems References

V-Separator Compact

width

[mm ]Type 5 Type 6

800

1000

1200

1400

1600

1800

2000

2200

2400

2600

2800

3000

5 meter

VS

VS-Compactfeed

air

V-Separator features:

separation, deglomeration, drying or cooling

no moving parts

maintenance-free operation for years

VS-Compact - additional features:

height saving of at least 5 meter

reduced equipment- and civil cost

V-SEPARATOR and VS-Compact

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Airchute

COMFLEX®Products Compact Systems References

Airchute Prototype

R&D Center Cologne

Standard Sizes

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Main parts

COMFLEX®Products Compact Systems References

1

2

3

4

5

6

6

Airchute- Main parts:

1. Inlet section

2. Outlet section

3. Regular section, 2000 mm length

4. Variable section

5. Venting

6. Air entry

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COMFLEX®Products Compact Systems References

Layouts

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COMFLEX® - Compact

COMFLEX®Products Compact Systems References

COMFLEX S

150t/h OPC, 110 t/h slag,

430 t/h raw meal

COMFLEX D

300t/h OPC, 220 t/h slag, 860 t/h raw meal

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COMFLEX® Raw Mill - Standard Range

COMFLEX®Products Compact Systems References

COMFLEX

Index:

C…cement

R…raw

material

S…Single

D…Double

T…Triple

RP-Size:

07 to 20

easy to grind

difficult to grind

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COMFLEX® Cement Mill – Standard Range

COMFLEX®Products Compact Systems References

COMFLEX

Index:

C…cement

R…raw

material

S…Single

D…Double

T…Triple

RP-Size:

07 to 20

easy to grind

low fineness

difficult to grind

high fineness

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COMFLEX® – References

COMFLEX®Products Compact Systems References

Orders of 30 COMFLEX systems consist of 35 Roller Presses and 20 ball millsR… Raw Material C… Cement S… Slag

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Examples of Grinding Package For new Production Lines

COMFLEX®Products Compact Systems References

Grinding Package for New Production Line

Order, India: Raw- and Cement- and Slag-Mills

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COMFLEX® - References

COMFLEX®Products Compact Systems References

D

R

order: India - COMFLEX Compact for raw material and slag

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COMFLEX®Products Compact Systems References

CEM I 42.5 R

Before After COMFLEX

Clinker [%] 89

Gypsum [%] 6.4

Limestone [%] 4.6

Fineness [Blaine] 3,821 3,777 3,606

Production [tph] 62 190 90

Spec. Power [kWh/t] 43.3 31.8 30.0

COMFLEX® - References – Denizli, Turkey – Cement Grinding

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COMFLEX®Products Compact Systems References

CEM I 42.5 R

Before After COMFLEX

2 day strength [MPa] 25.8 28.6 32.9

7 day strength [MPa] 40.3 41.9 46.1

28 day strength [MPa] 52.6 54.2

Fineness [Blaine] 3,821 3,777 3,606

Initial setting time [min] 143 150 162

Final setting time [kWh/t] 188 227 244

Water demand [%] 28.7 29.0 29.4

COMFLEX® - References – Denizli, Turkey – Cement Grinding

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COMFLEX®Products Compact Systems References

COMFLEX® - References – Raw Material Grinding

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Conclusions

COMFLEX®Products Compact Systems References

Standard, proven Components

Lower Specific Energy Consumption compared with Ballmill and VRM

Different Options for Roller Surface

Flexibility for different Products

Excellent drying Capability

Always 50% Availability with COMFLEX® D

To get more out of

your cement plant, visit

www.khd.com

Thank You