Modular Grinding Systems – Attracting Everyone’s Attention
Presented by
Chris Oesch
President
Gebr. Pfeiffer, Inc.
Modular Grinding Systems
Features
• Produces all types of Cement, Slag, Coal, Limestone, Gypsum
and other materials
• Considers efficient VRM technology
• Ideal for small- Meduim scale production
• Three plant sizes available for Clinker plus additional module
plants for other materials
• Pre-assembled Modules in standard size
• Optimized Size ratio due to Compact Modular Design
• Flexible plant arrangement
• Flexible design of feed size and product transport
• Low plant construction height
Local Requirements
• Small Footprint for the plant (~ 350m²)
• Access to transportation (Road, Rail, Harbour)
• MV or LV Line supply
• Consumables
• Plant personnel
Selection of Scope
Flowsheet
Feed VRM Gas Route Storage/Packing
Scope of Equipment and Service Supply
A. BASIC PLANT MODULES
A. 1 Raw Material Dosing and 3(or as needed) Feed Hoppers
A. 2 Raw Material Feeding to Mill
A. 3 Mill, Classifier and Ancillaries
A. 4 Dedusting, Hot Gas Generator and Fan
A. 5 Product Transport and 2 (or as needed) Storage Silos
A. 6 Electrical Controls, Drives, Lighting and Safety installations
Scope of Equipment and Service Supply
B. OPTIONAL EQUIPMENT MODULES
B. 1 Packing and Truck Loading
B. 2 Bulk Loading Equipment
B. 3 Sanitary Equipment
B. 4 Office Equipment
B. 5 Laboratory Equipment
B. 6 Fuel Storage
B. 7 Extended Product Storage Capacity
B. 8 Power Generation
Scope of Equipment and Service Supply
C. OPTIONAL SERVICE MODULES
C. 1 Operator Training
C. 2 Maintenance Training
Modular Grinding System
Modular Plant Components
Main Process Bag Filter
Includes mill ancillaries and MCC room
Vertical Roller Mill
Performance Table
GEBR. PFEIFFER MODULAR MILL – MVR 1800 C-2
Product Portland Cement
CEM I Limestone Cement
CEM II / B – L Slag
GGBFS
Fineness acc. to Blaine 3500 4500 4000 5000 4000 4500
Grindability kwh/t 19 25 15 19 24 27
Production rate t/h 12 9 15 11,5 10 9
Max Feed Grain Size mm 35
Approx. yearly production rate t/a
Installed Mill Motor Power KW 260
Total installed Power KW 500
Amount of Modules 9
Performance Table
GEBR. PFEIFFER MODULAR MILL –MVR 1800 C-4
Product Portland Cement
CEM I Limestone Cement
CEM II / B – L Slag
GGBFS
Fineness acc. to Blaine 3500 4500 4000 5000 4000 4500
Grindability kwh/t 19 25 15 19 24 27
Production rate t/h 24 18 30 23 20 18
Max Feed Grain Size mm 35
Approx. yearly production rate t/a 140.000 – 240.000
Installed Mill Motor Power KW 560
Total installed Power KW about 1000
Amount of Modules 15
Performance Table
GEBR. PFEIFFER MODULAR MILL – MVR 2500 C-4
Product Portland Cement
CEM I Limestone Cement
CEM II / B – L Slag
GGBFS
Fineness acc. to Blaine 3500 4500 4000 5000 4000 4500
Grindability kwh/t 19 25 15 19 24 27
Production rate t/h 48 36 60 46 40 36
Max Feed Grain Size mm 35
Approx. yearly production rate t/a 280.000 – 480.000
Installed Mill Motor Power KW 1100
Total installed Power KW about 1600
Amount of Modules 18
Partial load operation possible on request in order to start with low production
requirement -> Plant is ready to take up future increase of production
MVR Roller Mill Design
Symmetric wear parts For an extended lifetime tyres can be turned in case of wear.
Active Redundancy Up to 4 grinding rollers: mill operation continues even if two roller are
under maintenance.
Hydraulic system for operation and maintenance For maintenance purposes no extra component is required to swing the
rollers out of the mill.
Parallel grinding gap The geometry of the grinding elements in combination with our MVR
suspension system ensures a parallel grinding gap in any operating point.
Active Redundancy
4 grinding rollers:
mill operation continues even if two
rollers are under maintenance
Availability during failure
Pfeiffer C-4 with 2 roller out: >50%
MVR Installations
country customer mill size tph fineness kW product year
Turkey undisclosed client MVR 5000 C-4 - - 4000 cement 2015
Bosnia-
Herzegovina
DD Fabrika Cementa Lukavac MVR 3750 160 12 % R 0.090 mm 1600 raw material 2007
Turkey undisclosed client MVR 3750 R-3 - - 2000 raw material 2015
Turkey undisclosed client MVR 3750 R-3 - - 2000 raw material 2015
Africa undisclosed client MVR 3750 C-4 150 3300 cm²/g acc. to Blaine 2900 cement 2016
Americas Undisclosed Client MVR 2500 C-4 56 4700 cm²/g acc. to Blaine 1246 cement 2016
Germany Hauri KG, Bötzingen MVR 1800 C 20 4600 cm²/g acc. to Blaine 320 phonolite 2006
Germany Hauri KG, Bötzingen MVR 1800 C-2 21 3000 cm²/g acc. to Blaine 250 phonolite 2015
Africa undisclosed client MVR 1800 C-4 25 4000 cm²/g acc. to Blaine 520 cement 2016
Product Quality
VRM vs Ball Mill
MVR 1800 C-4 for cement grinding
Hans G. Hauri Mineralstoffwerk,
Germany
MVR 1800 C-4
• 15 tph Cement
• 400 kW installed
• In Operation since 2007
Comparison of Mill Systems
VRM vs HPGR (Cement)
VRM HPGR + BM
Recirculation Reject 10 - 20 % 400 to 500 % of fresh feed
Feed moisture up to more than 25 % up to max. 5 %
Various feed
material
very flexible and adjustable for a wide
range of feed material
not as much flexible as VRM
Wear sinter cast,
chromium cast alloy iron
hardfaced,
stud liners very sensitive to oversized
lumps, break-out of tyre
Arrangement simple,
advantage of drying, grinding, classifying
in one machine
complicated,
single machines (RP, static separator,
dynamic separator)
Layout VRM foundation on ground level HPGR is not located on ground floor,
with Comflex system located on upper floor
due to arrangement, high loads!
Comparison CEM I (Balaji / India)
Plant A – Data 2013 MVR BM
Type CEM I CEM I
R 0,045 mm 6.8 % 8.4 %
Blaine* 2910 cm²/g 2910 cm²/g
Lasergranulometer d‘ = 24.2 µm, n= 0.99 d‘ = 25.2 µm, n= 0.97
Water demand* 26.5 % 26.2 %
Compressive strength*
2 d 20.6 MPa 18.7 MPa
7 d 36.8 MPa 36.5 MPa
28 d 58.1 MPa 59.4 MPa
*tests in acc. to EN 196
Comparison CEM I (Balaji / India)
Plant A – Data 2014 MVR HPGR + BM
Type CEM I CEM I
Blaine* 2940 2900
Water demand* 29.4 % 30.3 %
IST 170 min 190 min
Compressive strength*
1 d 21.3 MPa 21.0 MPa
3 d 40.5 MPa 40.4 MPa
7 d 51.4 MPa 51.8 MPa
28 d 63.7 MPa 62.6 MPa
*tests in acc. to IS 4031-6
Economic Feasibility
VRM vs Ball Mill Grinding System
Maintenance Cost
• Long term comparison of maintenance cost from 2004 to 2010 including wear parts replacement
Cement International 02/2015, 38ff. Flacher, A.: Benefits and potentials of cement grinding with vertical roller mills
Specific Energy Consumption
BM closed circuit Semi finish HPGR + BM VRM
Mill 30.9 14.2 15.5
HPGR - 9.0 -
Aux + Fan 4.1 6.7 7.6
Total 35.0 29.9 23.1
kWh/t
for Cement with 10 % limestone @ 3600 Blaine*
* based on FLS-figures given 2012 at Petrochem, Russia
Specific Energy Consumption
Cement International 02/2015, 38ff. Flacher, A.: Benefits and potentials of cement grinding with vertical roller mills
Comparison HPGR+BM vs. VRM CEM I w. 5 % Limestone HPGR + BM MPS 4500 BC
Product rate 127 t/h 146 t/h
GA 260 ml / t 55 ml / t
Fineness 3500 Blaine
MPS -- 19.2 kWh/t
HPGR 8.5 kWh/t --
BM 19.6 kWh/t --
Sep 1.1 kWh/t 1.1 kWh/t
Fan 3.4 kWh/t 9.5 kWh/t
BE (HPGR & BM discharge) 1.6 kWh/t 0.1 kWh/t
total 34.2 kWh/t 29.9 kWh/t
all figures are counter values both mill systems are operating with grinding aid Both systems are installed at the same plant -> same feed materials
Specific Power Consumption (kWh/t) OPC – BM vs. VRM
0
10
20
30
40
50
60
70
80
90
2000 2500 3000 3500 4000 4500 5000 5500
SP
C in
kW
h/t
(m
ill, se
pa
rato
r, f
an)
Spec. Surface area – Blaine in cm²/g
OPC
BM
VRM
Electrical Operating Cost (CEM I at 3‘400 Bl.)
Grinding System Ball Mill Vertical Roller Mill
Specific Power cons. (*) Kwh/t Mill 36,0 18,5
Kwh/t Classifier 1,1 1,1
Kwh/t Bucket Elevator 1,6 0,1
Kwh/t Fan 3,1 7,5
Kwh/t Total 41,8 27,2
Effective Production Capacity t / h 30 30
Effective absorbed power KW eff 1.254 816
Operating Hours / year h / year 7.500 7.500
Consumed power / year Kwh / year 9.405.000 6.120.000
Price for Power Euro / Kwh eff 0,1 0,1
Price for Power Euro / year 940.500 612.000
Years Considered Years 5 5
Total Cost for Power EURO 4.702.500 € 3.060.000 €
Δ ~ 1.650.000 € in 5 years!
Current Installation
Feed System
Mill Unit
Filter and Fan
Modular Grinding Systems
Summary
Main Advantages
1. High reliability & availability
2. Economic - operation cost - VRM
3. Low investment risk, fast market entry, quick pay-
off (ROI)
4. Manageable costs for erection and commissioning
5. Easy access to small and fluctuating markets
6. Plant Mobility -> Future relocate
7. Fast Track Project realization/Operation in different
environment conditions possible
Modular Grinding Systems – Attracting Everyone’s Attention
Thank you!
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