Objective
With use of updated generation of separators included new bag filters it is possible
- to improve granulometry of cement without overgrinding
- to increase cement fineness (for highest cement qualities)
- to compensate partly the unfavourable influence of the relative high alkali content of Karsdorf cement
- to increase degree of effectiveness of separating operation
- to get better control of cement quality (to produce several cements with different qualities and for different uses)
- to improve and to stabilize 28 d - strength of cement
- to decrease the exhaust dust amount
- in result of aforementioned improvements
* to save energy up to 4,5 kWh/t cement
* to save clinker up to 2,5%
* to grind cement up to 5000 cm2/g
* to decrease exhaust dust amount from appr. 100 mg/m3 N to 20 mg/m3 N.
1. 1st high efficiency separator (cement mill plant 3.4)
The first high efficiency separator is in operation since January 93.
After process problems at the beginning of operation the plant works with good results.
Two years of operation show
- the separator could have a some bigger capacity.
- control of separating operation is better than before (with old generation separator)
- the degree of effectiveness of separating operation is higher (less sufficient grinded particles are in material back flow)
- Mill equipped with high efficiency separator can produce cement with highest quality (CEM I 52,5 - R)
- The clincer - cement ratio was decreased.
Because ther are no basic data for cement mill plant 3.4 before installation of separator the comparison for saving of energy consumption should be done with cement mill 3.2 (nearly in the same situation like cement mill 3.4 before modernization).
2. 2nd high efficiency separator
To be expected the same results like for 1st separator plant.
The existing grinding plant consists of a 3 chamber ball mill and a separator (USZ 4500) with cyclones. The installation produces cement with a fineness of 3800 cm2/g without problems. Production of cement with a higher fineness (400 cm3/g) is not stable, and it is not possible to produce cement with a fineness of 5000 cm2/g. The main reason for the problems is the relatively low efficiency of the separator. Small particles are unnecessarily recirculated to the mill and part of the material is therefore ground to much.
With the installation of new separators it should be possible to increase the fineness of the cement, to reduce the energy consumption and to adjust the grain size distribution of the cement in order to compensate for the effect of the high alkali content of the clinker on the 28 days strength of the cement.
Two separator lines will be installed. The second line will be part of a new plant. Special features of the separators are the following :
- changed air and materials parts
- end product is removed via a separate new bag filter
- more powerful drive of the separator plates
- larger variability of the separator speed
Existing ball mills, bucket elevators and static separator will be used in future.
Programme(s)
Topic(s)
Call for proposal
Data not availableFunding Scheme
DEM - Demonstration contractsCoordinator
06638 KARSDORF
Germany