Objective
Minimizing of energy consumption for the crushing of cement clinker and additives through process engineering measures in the pre-grinding stage. Reduction of the specific energy requirements by approx. 20% per ground ton of feed material through the installation of a pre-crusher.
1. Achieved throughput of the clinker precrushing installation
It has to be distinguished between the maximum possible throughput and an optimum throughput taking into consideration an acceptable wear rate.
The optimized operation performance is 55 t/h finish product at a particle size of up to 3 mm.
2. Achieved throughput of the slag cement grinding installation
During continuous operation the following figures were achieved:
Cement type HOZ 35 - NW - HS-NA containing :
26% clinker
6% gypsum
68% high furnace sand
Cement fineness 4,300 cm2/g acc. to Blaine
Throughput of 11.74 t/h grinding installation
This represents a performance increase of 23.5% compared with the original situation.
3. Achieved energy saving of the grinding installation
The throughput of both of the slag cement grinding installations was increases from 19 t/h to 23.48 t/h. The energy consumption was reduced from 88.8 kWh/t to 73.2 kWh/t. Thus, the energy saving was 15.6 kWh/t.
4. The modernized precrushing andgrinding installation contains the following main components :
4.11 pce Horizontal Impact Crusher, type CPB HIC 130
1 pce Vibrating screen, type Haver & Boecker
2 pces HOZ one-chamber-mills
2 pces High Performances Separator, type QDK 16,5 N
as well as various peripherical installations.
The ball mill is the main grinding device of the cement production. Within the mill clinker and additives are being grinded and mixed. Referring to the ideal particle size fraction the grinding effect of a ball mill is only 6-9%. With the impact crusher the grinding effect may represent up to 40%. By transferring part of the grinding process from the ball mill to the impact crusher the energy saving effect amounts to a considerable 20%. The ball mill remains as a device for ultra fine grinding and mixing.
Cement clinker and additives are ground to cement, of the types PZ 35 and HOZ 35 in the cement plant Coswig-Wuelfarther Baustoff GmbH. The design of the mill is based on the grindability of the materials to be ground, i.e. cement clinker and additional components. Four mills, whose grinding chamber divisions and grinding charge filling rate are based on experience values and on a calculational basis, are in operation. A certain amount of energy is required for grinding in a crushing facility of this design. Through the relocation of a part of the crushing process onto a pre-crushing facility and through a changed technique for an optimal total design of the grinding facility, an increase in production with a simultaneous reduction in specific energy requirements is to be expected.
Programme(s)
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Multi-annual funding programmes that define the EU’s priorities for research and innovation.
Topic(s)
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Calls for proposals are divided into topics. A topic defines a specific subject or area for which applicants can submit proposals. The description of a topic comprises its specific scope and the expected impact of the funded project.
Call for proposal
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Procedure for inviting applicants to submit project proposals, with the aim of receiving EU funding.
Funding Scheme
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Funding scheme (or “Type of Action”) inside a programme with common features. It specifies: the scope of what is funded; the reimbursement rate; specific evaluation criteria to qualify for funding; and the use of simplified forms of costs like lump sums.
Coordinator
59269 BECKUM
Germany
The total costs incurred by this organisation to participate in the project, including direct and indirect costs. This amount is a subset of the overall project budget.