Post on 01-Jun-2018
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Mill Diaphragms
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Innovations fromChristian Pfeiffer:
giving you the lead.
Improving industrial grinding pro-
cesses with pioneering innovations
has been Christian Pfeiffers mis-
sion since its foundation in 1925.
Our companys unique develop-
ments include
the adjustable diaphragm
separator technology for
cement grinding.
From the research and develop-
ment stage to production and in-
stallation, as an industry pioneer
we have the advantage of decades
of experience. We draw on cutting-
edge knowledge and new findings
gained through close cooperation
with customers, research insti-
tutes and universities.
To optimally supply our interna-
tional customers, we oper-
ate production facili-
ties around the world
including one in
China. Our plants
all adhere to the
same high qual-
ity standards for
which Germany isrenowned.
Innovation and R&D
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Greater efficiency:all in the diaphragm.
By reducing energy consumption
and increasing efficiency, the
diaphragm is crucial to the profit-
ability of your system. It is the
diaphragm that regulates the
material filling level and the heat
exchange in the compartments.
The more intelligent the design,
the more economically efficient
the energy-intensive processes
within your mill.
Mill diaphragm
Installing a Pfeiffer-Monobloc guarantees many years of high grinding
plant availability and continuous finish material quality.
Adjustable material ow
control system, fully opened
(left), fully closed (right)
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The Monobloc:globally unique.
The sturdy Monobloc is making
industry history. With its extreme-
ly long service life, this diaphragm
has proven itself to be the most
sophisticated solution for modern
ball mills for many decades.
Its design is the only one of itskind in the world and is unbeaten
in stability. Comprising a self-sup-
porting U-ring for axial fixation
on the mill tube, it supports
the mill cylinder and
prevents deforma-
tions.
Another special
feature is the
oating xationof the intermedi-
ate diaphragms,
guaranteeing
stress-free fastening
to the mill shells.
No other mill diaphragm offers
such outstanding qualities as the
Monobloc often imitated, never
matched.
Stability and reliability of mill tube using
different intermediate diaphragm designs
Monobloc
Christian Pfeiffer Monobloc
Conventional diaphragm design
Christian Pfeiffer Monobloc
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Slotted plates:unrivalled dimensional
stability.
Your plants profitability will also
increase with the specially devel-
oped diaphragm plates from Chris-
tian Pfeiffer. The optimised design
includes innovative plate slots with
a small conical enlargement, en-
suring that the material is only for-
warded once it has been ground to
a suffi cient degree. Constant condi-
tions for material transfer are thus
guaranteed throughout the service
life and the plates do not clog!
Slotted plates from Christian
Pfeiffer are made from specially
treated, breakage resistant rolled
steel which is tempered up to 60
HRC. This process guarantees con-
sistent hardness across the entire
slotted plate, producing an excel-
lent material with an extremely
long lifetime.
An equally unique development is
the innovative fastening system
designed by our engineers. Bolts
with conical swages combined with
the special slotted plates from
Christian Pfeiffer allow effi cient
plate use up to a residual thicknessof 8 mm. Thanks to this design, we
can achieve a utilisation level of
75 % compared to conventional
systems, which only manage 60 %
(20 mm).
Fastening System
Slotted plates
Wear
plate
Hexagonal bolt Tear-off bolt
Diaphragm
structure
Wear zone
20 mm
Wear zone
8 mm
Cast plates CPB rolled steel plates
50 HRC 60 HRC
Conical slot shape and plate hardness
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Separate outlet:ground material below,
air at the top.
Conventional mill diaphragms
send most of the material through
the air ow into the second grind-
ing compartment in an
uncontrolled manner. The results
are energy loss and a high degree
of wear on the grinding media and
diaphragm plates. Large areas of
both compartments are left with-
out grinding material.
Mill diaphragms from Christian
Pfeiffer are the intelligent solution
to this problem. In the first grind-
ing compartment, the material
level is kept constant thanks to an
innitely adjustable ring, which
can be directly accessed and in-
dividually adjusted. In the second
grinding compartment, the
material falls down through sepa-
rate openings underneath the
air ow, along the diaphragm and
directly into the ball charge.
Air flow
Air velocity through ball mill
Optimized CPB-DesignConventional design
Material ow through intermediate diaphragm
10 m/s 20 m/s
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Increased air passage:improved cooling,
shorter retention times.
Our engineers have succeeded in
increasing the air passage sur-
face of the diaphragm without
compromising on stability. The re-
sult is 40% lower pressure loss
compared to conventional dia-
phragms.
This ingenuous design offers nu-
merous benefits through better
cooling of your grinding material,
more effective fines discharge and
shorter retention times without
the risk of overgrinding.
Minimal pressure loss
[m/s]
0.007.7615.5323.3013.06
Calculated air velocity above ball charge
v = 1.8 m/s v = 1.8 m/s
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Mechanical design and service life: Comparison ofconventional design to Christian Pfeiffer Monobloc
Basis: Closed circuit, ordinary cement production without pre-grinding system
Conventional design Christian Pfeiffer Monobloc
Structure Cast segments & individual-
ly bolted with a typical ser-
vicel life of 5 years
Welded free-standing steel
structure with servicel life in
excess of 10 years
Slotted plates
Material Cast Machined & heat-treated
special alloyed rolled steel
Hardness 42 - 48 HRC 52 - 59 HRC
Thickness 50 - 60 mm 40 - 70 mm
Slot width 10 - 15 mm 4 - 6 mm
Service life 5,000 - 7,000 hours
8 - 18 months
15,000 - 20,000 hours
> 36 months
Slot shape Peening over Constant
Material level No control Adjustable
Ventilation Restricted (higher p) Maximized (lower p)
Longer service life
Structure
Wear plates
1 x
1 x
2 x
2-4 x
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Precision engineering &process know-how: Basis
for design & fabrication
Our engineers primary goal is to
increase efficiency. Nowadays,
their comprehensive knowledge of
all details about the grinding pro-
cess leads to a significant increase
in production of many grinding
plants but with a reduced power
consumption.
Moreover, reliability is enhanced,
non-operation periods are kept to
a minimum and repair and main-
tenance costs are reduced.
Price
Useful life
Repairs
Maintenance
Carbon footprint
Quality
Energy
Efficiency
TCO Total Cost of Ownership
Total Cost of Ownership
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Our experts:specialists in all areas.
Since its early beginnings, our
company has been inuencing the
industrial grinding of cement.
Our engineers and design experts
can accordingly draw on an exten-
sive wealth of experience and
accumulated knowledge. State-of-
the art technology is also usedroutinely in our work.
For complete planning reliabili-
ty: all production processes are
CAD/CAM controlled.
For high precision: CNC machines
provide exact customization.
For long service life:
forces are structurally andmathematically simulat-
ed using the FEM
(Finite Element
Method).
Engineering
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Controlled quality:in-house production.
For all of our supplies and ser-
vices, our companys policy has
always been to implement and
strictly comply with our own high
quality standards as well as
national and international quality
standards and guidelines such as
DIN EN ISO 9001.
All product range components
that are directly relevant for
grinding and separation are
entirely manufactured by our own
production facilities. Theres a
good reason why we never pro-
cure parts from other manufac-
turers: we want to keep on provid-
ing you with a controlled level
of consistently high quality.
Production
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= Offices/Production facilities
= Agents/Representations
Christian Pfeiffer worldwide
Christian Pfeiffer Maschinenfabrik GmbH
Sudhoferweg 110-112 59269 Beckum, Germany
Phone: +49 2521 849-00 Fax: +49 2521 849-123
Email: office@christianpfeiffer.de
www.christianpfeiffer.net