Poly Process

Page 1 L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Polycom\poly_process.
ppt 150
WEI, 140 CD
Process Training
POLYCOM
Krupp Polysius Corp.

Page 2 L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Polycom\poly_process.ppt 150
WEI, 140 CD
Content:
• Feed Hopper
• Material and Pressure Distribution
• Pressure Conditions
• Effects on Working Pressure
• Basic Sizing Calculations
• Finish Grinding Citcuits
• STATOPOL C
• Trouble Shooting

WEI, 140 CD
Feed Hopper

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Feed hopper

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Control of material feed
Weighing
device
Adjustable
guide plates
(Combi and
Finish grinding
only)

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POLYCOM Feed hopper

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Material and Pressure Distribution

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Principle of High-Pressure Grinding

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Magic square of grinding
max. grinding pressure (Schönert)
• Medium efficiency in fine • High efficiency in fine

particle comminution particle comminution
high
• High efficiency in coarse • Limited by mechanics
particle comminution and slope of particle size dist.
• Limited by mechanics
• High efficiency in coarse

• Low efficiency in fine and
particle comminution
low coarse particle comminution • Decreasing efficiency with
• Simple to achieve
fineness
wide narrow
particle size distribution of product

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Application range of processes
Spec. work,
Output increase
Combi
200%
Limits depend on
100% product fineness
Hybrid
0% Pre
0 20 40 60 80 100 ¥
Polycom kW/Ball Mill kW [%]

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Polycom material bed compression
Pressure curve
Start of compression
Max. Pressure (nip line)
Compression
zone
Grinding force End of compression
Cake

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Pressure distribution on the roll surface
Increased Static load Local peak load
pmax
300 MPa 600 MPa
Roll Material bed

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Fatigue life time of forged & hard faced sleeves
400
350
Clinker
max. static Pressure [MPa]
300
250
200
150 Higher peak loads

Raw material
100
50
0
0 4,000 8,000 12,000 16,000 20,000 24,000
Fatigue Life Time [h]

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RRSB inclination vs water demand
source: VDZ
35
34
water demand at a density of 2.919 g/cm³ [mass-%]
33
32
31
30
29
28
27
26
25
24
23
22
21
20
0.80 0.85 0.90 0.95 1.00 1.05 1.10 1.15 1.20
RRSB inclination [-]

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RRSB inclination vs circulation factor SEPOL
5.0
4.5
circulation factor SEPOL [-]
4.0
3.5
3.0
2.5
2.0
1.5
0.80 0.85 0.90 0.95 1.00 1.05 1.10 1.15 1.20
11/22/1999 9:00 11/22/1999 15:30 23.11.99. 11:30 11/24/1999 16:30 simulation

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RRSB inclination vs circulation factor (unseparated)
6.0 83,3
total feed rate POLYCOM / cake feed rate [%]

5.5 81,8
circulation factor (unseparated) [-]
5.0 80,0
4.5 77,8
4.0 75,0
3.5 71,4
3.0 66,7
2.5 60,0
2.0 50,0
0.80 0.85 0.90 0.95 1.00 1.05 1.10 1.15 1.20
11/22/1999 9:00 11/22/1999 15:30 23.11.99. 11:30 11/24/1999 16:30 simulation

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Pressure Conditions

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No grinding operation
poil = 0 pGas = pv pv = initial filling pressure
Piston accumulator
pGas
Pressure absorption crossbeam with pressure cylinder

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Polycom ready for grinding operation

poil = p0 = pGas SA = S 0 P0 = Hydraulic start-up pressure
FG = Basic force
S0 = Zero gap
SA = Working gap
S0
pGas
poil

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Grinding operation
poil = pA = pGas
SA
pGas
poil

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Effects on Working Pressure

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Effects of initial Nitrogen charge on working pressure

Soft spring effect
Stiff spring effect

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Effects of initial Nitrogen charge on working pressure

Normal spring effect

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Effects of initial gap width on working pressure

Soft spring effect
Stiff spring effect

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Effects of initial gap width on working pressure


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Effects of initial hydraulic pressure on working pressure

Soft spring effect
Stiff spring effect

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Effects of initial hydraulic pressure on working pressure


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Basic Sizing Calculations

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Process calculations
• Finish grinding P = power draw on the shaft [kW]

PBM , equiv  PPolycom  Bonus or
specific grinding work [kWh/t]
• Pre-, Hybrid and Combi grinding
PBM , equiv.  PBM , actual  PPolycom  Bonus
Bonus
Process clinker slag raw material
Pre Grinding 1,7 - 2,0 2,5 1,8
Hybrid Grinding 1,7 - 2,0 2,5 1,8
Combi Grinding 2,0 - 2,4 2,5 1,8
Finish Grinding 2,0 - 2,4 2,5 - 3,0 1,8
Vertical mill 1,6 2,3 1,8

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Finish Grinding Circuits

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Situation without Polycom
Finished product

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Pregrinding without cake recirculation
POLYCOM
Finished product

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Pregrinding with cake recirculation
POLYCOM
Fresh
Feed Finished product

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Pregrinding with cake recirculation
POLYCOM Finished product

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Characteristics of pregrinding
• Max. 15% increase in throughput compared to a single ball mill

• intermediate product with 800-1000 cm²/g (theoretical), with a very wide
particle size distribution
• with and without cake recirculation possible
• can be used to supply several ball mills
• intermittent operation with hopper for intermediate product for different finish
products possible
• very simple plant layout with minimal cost

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Production increase with hybrid grinding
Finished product
POLYCOM

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Characteristics of hybrid grinding
• Feeding of a portion of the ball mill separator tailings to the Polycom

• Max. 35% increase in throughput compared to a single ball mill for approx.
3200 cm²/g
• increase in throughput is limited by the fineness of the feed
• wide particle size distribution of the intermediate product
• intermediate product typically with 1500 cm²/g,
• difficult to supply several ball mills with feed
• simple plant layout with low investment

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Production increase through combi grinding with static

separator
STATOPOL C
Fineness Finished product

1500-2500cm²/g
POLYCOM

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Combi grinding with closed circuit mills
SEPOL NSV
Fineness Finished product

1500-3500cm²/g
POLYCOM

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Production increase through combi grinding with dynamic

separator
SEPOL NSV
Fineness
1500-3500cm²/g
Finished product
POLYCOM

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Characteristics of combi grinding

• Separate pregrinding in a closed circuit with static or high efficiency separator
• more than 150% increase in throughput compared to a single ball mill possible
• intermediate product typically with 1800 cm²/g to 3500 cm²/g
• narrow particle size distribution of the intermediate product
• can be applied for finish grinding, too
• can be used to supply several ball mills
• speed of rolls depending upon fineness of feed
• flexibility to grind different products with a variable speed drive
• energy saving of more than 50% compared to an equivalent ball mill for the
intermediate product
• drying or cooling capabilities with the separator
• possible potential for additional energy savings by using adapted ball charge

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Main control loops of grinding plant
• Constant filling level in Polycom hopper.

controlled by fresh feed rate
• Fineness of Polycom product is controlled by separator speed
(or with air flow rate of static separator)
• Max. grinding pressure is controlled by hydraulic pressure. Zero gap and
nitrogen pressure is fixed before.
• Adjustable guide vanes can control power draw and power distribution
between motors.
• Constant ball mill inlet mass flow

controlled by fresh feed rate to ball mill
• Fineness of ball mill product is controlled by separator speed
(or with mass flow rate and fineness at mill inlet for open circuit)

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Portfa
STATOPOL C
POLYCOM

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Influences on cement quality
• Number of separator passes and separator operation determines slope of

particle size distribution
• Steeper slope increases water demand of cement. No influence on water
demand of concrete observed.
• Higher cake recirculation rate decreases slope of particle size distribution
• C3A, degree of sulphation and type of sulphate carrier influence reactivity of
cement

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Influences on RRSB inclination of separator product

• Dfference between fineness of separator feed and separator product
– large difference: steep RRSB inclination of separator product
– small difference: flat RRSB inclination of separator product
• Feed rate to separator

– low feed rate: steep RRSB inclination of separator product
– high feed rate: flat RRSB inclination of separator product
• Separator air flow

– theoretically small influence on RRSB inclination of separator product
• Position of separator guide vanes

– tangential position: steep RRSB inclination of separator product
– radial position: flat RRSB inclination of separator product
– only effective for medium differences between fineness of separator feed
and product
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STATOPOL C

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Adjustment of the classic idea to current demands
• Low energy requirement
• High drying and cooling capacity
• Good disagglomeration properties
• Long service life
• Simple operation
• Low maintenance requirements

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Funktionsweise des STATOPOL C
Feed
Fines Separating air
Static concept:
- No moving parts
- No drive
- High availability
Use of gravity energy for disagglomeration
Fluidizing of material:
- High drying and cooling capacities
- High feed density in separating air
Rejects

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Tromp curve of STATOPOL C
100
90
SEPOL STATOPOL C
80
70
60
T [%]
Reduction of Increase of
50
separating air separating air
40
30
20
10
0
10 100 x [µm] 1000 10000

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Drying capacity of the Statopol C

Specific evaporation
Spezifische numbers in comparison
Verdampfungszahlen im Vergleich
500
drying room] h]
450 Steigrohrtrockner
Shaft dryer
/ mTrocknungsraum
evaporation number
400
spez. Verdampfungszahl
350
300
250
3
STATOPOL C
/ m^3
200
[kg water
Specific
150
[kg Wasser
100
50 Drum dryer
Trommeltrockner
0
250 300 350 400 450 500 550 600 650 700 750 800 850
HotHeißgastemperatur
gas temperature [ºC]
[°C]

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Sizing criteria for the STATOPOL C
Sizing criteria of the STATOPOL C are:
Separating air load: up to 4 kg/m³ based on feed amount

up to 1,1 kg/m³ based on fines amount
Circulation factor: 2-4
Drying capacities: 130 -270 kg water / m3h

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Energy savings by use of STATOPOL C
Energy consumption for separation of Polycom cakes, i.e. 100 t/h

High efficiency separator STATOPOL C
with disagglomerator
Disagglomeration 1,0 kWh / t 0,0 kWh / t
Bucket elevator 0,7 kWh / t 0,7 kWh / t
Circulation air 1,9 kWh / t 1,2 kWh / t
Separator drive 0,5 kWh / t 0,0 kWh / t
Spec. energy consumption: 4,1 kWh / t 1,9 kWh / t

Saving: 46 %

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Application field for the Statopol C

Separation
Separating air flow
300.000 m3/h
200.000 m3/h Statopol 20-9/8
Statopol 15-9/8
100.000 m3/h
Statopol 10-9/8
4 modular sizes
Statopol 7-9/8
Product
120 t/h 160 t/h 230 t/h 320 t/h

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Drying in Statopol C
[%]
moisture [%]
18
Fertiggutfeuchte
16 Heating 650 °C
Feuerung
Feuerung
Heating 300 °C
Feuerung
Heating 500 °C Drying controlled
Trocknungskontrolliert
14
to product
12
10
bez.
8
moisture related
Aufgabefeuchte
2
Sichtungskontrolliert
Separation controlled
Feed
0
0,42 0,52 0,62 0,72 0,82 0,92
Luftbeladung [kgair
Spec. separation Fertiggut
load [kg /product
m3 Sichtluft]
/ m3 sep. air]

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Bottleneck ball mill capacity
Product: 100 %

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Improvement of capacity with Polycom & Statopol C
STATOPOL C
Product
200 - 250 %
POLYCOM

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Improvement of capacity and energy saving
Before After
modification
modification
Process: Ball mill Combi

grinding
Product: 100 t/h 200 t/h
Power consumption
for grinding: 35 kWh / t 27 kWh / t
Product temperature: 100 °C 85 °C

Drying and finish grinding in the Polycom circuit

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Gyp- Clin- Slag

sum ker
POLYCOM
STATOPOL C

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Advantages of the STATOPOL C
Simple design,
no moved parts
• High availability
• Good energy requirement
• Low operating costs
Efficient heat and

material transfer
Low investment costs

Fast amortization

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Trouble Shooting

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Trouble shooting - Hydraulic system

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Trouble shooting - Drive unit

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Trouble shooting - Drive unit

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Trouble shooting - Feed hopper

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Trouble shooting - Feed hopper

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Page 1 L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Polycom\poly_process.

Krupp Polysius Corp.

• Material and Pressure Distribution

• Effects on Working Pressure

• Basic Sizing Calculations

• Finish Grinding Citcuits

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Control of material feed

Krupp Polysius Corp.

POLYCOM Feed hopper

Krupp Polysius Corp.

Material and Pressure Distribution

Krupp Polysius Corp.

Principle of High-Pressure Grinding

Krupp Polysius Corp.

Magic square of grinding

max. grinding pressure (Schönert)

• Medium efficiency in fine • High efficiency in fine

• High efficiency in coarse

Krupp Polysius Corp.

Application range of processes

Krupp Polysius Corp.

Polycom material bed compression

Grinding force End of compression

Krupp Polysius Corp.

Pressure distribution on the roll surface

Increased Static load Local peak load

300 MPa 600 MPa

Roll Material bed

Krupp Polysius Corp.

Fatigue life time of forged & hard faced sleeves

150 Higher peak loads

Fatigue Life Time [h]

RRSB inclination vs water demand

Krupp Polysius Corp.

RRSB inclination vs circulation factor SEPOL

11/22/1999 9:00 11/22/1999 15:30 23.11.99. 11:30 11/24/1999 16:30 simulation

Krupp Polysius Corp.

RRSB inclination vs circulation factor (unseparated)

total feed rate POLYCOM / cake feed rate [%]

11/22/1999 9:00 11/22/1999 15:30 23.11.99. 11:30 11/24/1999 16:30 simulation

Krupp Polysius Corp.

Krupp Polysius Corp.

Pressure absorption crossbeam with pressure cylinder

Krupp Polysius Corp.

Polycom ready for grinding operation

Krupp Polysius Corp.

Krupp Polysius Corp.

Effects on Working Pressure

Krupp Polysius Corp.

Effects of initial Nitrogen charge on working pressure

Stiff spring effect

Krupp Polysius Corp.

Effects of initial Nitrogen charge on working pressure

Krupp Polysius Corp.

Effects of initial gap width on working pressure

Stiff spring effect