Product Brochure

Rotor Weighfeeder Pfister DRW

Highly accurate and reliable gravimetric feeding of
pulverised fuel

The Pfister DRW is especially designed for dosing pulverised fuels such as petrol coke, lignite or coal
dust in the cement burning process. It even allows in-line-blending of a number of fuels into one com-
mon fuel feeding line. Integration of material extraction, weighing, dosing and material transfer into
the pneumatic conveying line makes it a compact system that provides accuracy and constancy. Pow-
ered by the innovative dosing strategy ProsCon, the mass flow is controlled in advance. Thus, high
short- and long-term accuracy and dosing stability are realised. Moreover, the outstanding constancy
of metering with Pfister DRW + ProsCon makes it possible to achieve low levels of carbon monoxide in
the kiln exhaust gas.
Pfister DRW + ProsCon: the innovative solution for metering pulverised fuels.

www.pfister.de
Content

What solutions are there? Pages 4-5

How does the system work? Pages 6-8

What are the benefits? Pages 9-12

What are the dimensions? Page 13

What applications are there? Pages 14-21

What are the technical facts? Page 22

Is there further information? Page 23

History
FLSmidth Pfister has more than 110 years of
experience in manufacturing industrial weigh-
ing equipment and is part of the FLSmidth
group since 1998.
The Rotor Weighfeeder technology was devel-
oped by FLSmidth Pfister in 1984 and it is now
time tested and state of the art in the cement-
production industry. More than 1,700 systems Historic Pfister scale.
are in operation world-wide. Ludwig Pfister,
founder of the company
FLSmidth Pfister additionally supplies know-how in 1894.
for equipment, related to the coal feeding proc-
ess. This is to ensure problem free material
handling and optimal pneumatic transport of
the coal.

Customised solution
Since fuels have a wide variety of material
characteristics it is a necessity to have various
installation solutions. Each one gives the opti-
mal and most economic result form case to
case.

All Pfister weighfeeders are

Engineered
Designed 1984Start of the rotor
weighfeeder technology
Assembled
Tested
in AugsburgGermany

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General Principle

General Principle
The Pfister DRW is used to extract pulverised
coal out of a storage silo and feed it with high
accuracy and consistency to the burner to sup-
port a optimal flame for stable cement clinker
production.

The Pfister DRW is a breakthrough in continu-

ous, gravimetric dosing of pulverised fuels such
as hard-coal, lignite or petrolcoke to the kiln
and calciner burners. These fuels will be re-
ferred to as coal.

This mechatronic system uses an operation

principle similar to a horizontal rotary valve.
The gravimetric content is measured and the
speed of the motor is adjusted to compensate
variation in bulk material characteristics.
To achieve the accuracy of coal feeding it is
necessary to supply the rotor weighfeeder con-
stantly with coal and after dosing, transport the
coal pneumatically to the burner.

4 3
4

5
5
8
6

2 7

Complete coal dosing and feeding system out of one hand

FLSmidth Pfister offers

Engineering for coal storage silo (1) material activator Pfister SGA (5)

Intermediate coal transport system (2) Calibration hopper (6)

Engineering for intermediate silo (3) Highly accurate rotor weighfeeder Pfister DRW (7)

Silo cone and cone aeration (4) Calculation of pneumatic transport pipe and blower
data (8)

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Different Solutions

Downpipe Solution
What solutions are there?
The coal is extracted out of a coal silo (1) , sup-
ported by an aeration system (2) . The rotor
weighfeeder (4) reliably doses the coal and the
transport air (5) discharges the machine and 1

blows the coal directly to the burner. The high

feed accuracy of the rotor weighfeeder ensures 2
a steady air/coal mixture for the burner.
This installation is using a down-pipe (3) to con- 5

nect the silo outlet with the rotor weighfeeder

(4) . Silo cones provided by FLSmidth Pfister can 3
either be welded or flanged to the silo and are
available in different sizes. These cones are in
stainless steel, surface treated and have an
4
inclination of 75 for optimal material flow and
prevention of material bridging or tunnel flow. Downpipe solution.
1: silo, 2: silo cone aeration, 3: down-pipe,
4: Pfister DRW, 5: pneumatic transport system.

Calibration-Hopper Solution Benefits of the Calibration-Hopper:

To provide safety in material flow and to give Online calibration of the rotor weighfeeder.
the possibility for online-calibration, FLSmidth Backpressure and leakage elimination.
Pfister offers a solution using an intermediate Therefore reduction of wear in the system.
buffer of coal in a calibration-hopper (5) . The
Safety in coal supply even with extremely
hopper cone is made in stainless steel and aer-
fine and moist material.
ated. The starfeeder (4) regulates the filling of
Longer feed distances for pneumatic trans-
the calibration-hopper and provides an air seal-
port.
ing back to the silo. Optional a agitator arm is
available to improve material flow.
How Online Calibration Works:
During an online-calibration cycle, the upper
shut-off gate (3) stops the filling of the calibra-
1
tion-hopper (5) . The bulk material content of
the calibration-hopper is measured by a
2
weight measurement unit at the bottom of the
3 system . After discharging a certain amount
(8)

of material in a certain time out of the calibra-

4 tion-hopper it is possible to compare the loss
5 of material in the hopper with the amount
calculated by the rotor weighfeeder . This
(7)

6 means comparing the static weighing of the

calibration-hopper with the dynamic weighing
7 of the rotor weighfeeder. The redundant prin-
ciple gives highest accuracy and optimal calcu-
8
lation of total coal consumption.

Calibration-hopper solution.
1: silo, 2: silo cone, 3/6: shut-off gates, 4: star feeder,
5: calibration hopper, 7: Pfister DRW,
8: weight measurement units.
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 Different Solutions

Several Systems Under One Coal Silo

For more economic operation of the cement
burning process, Pfister provides a material
activator Pfister SGA. This makes it possible to
install up to four rotor weighfeeders DRW under 1

one coal silo.

1 2

3
2
5
3

4
7
7

6
6

Pfister SGA with down-pipes Pfister SGA with calibration hoppers

1: silo, 2: silo cone, 3: material activator Pfister SGA, 4: downpipe, 5: calibration hopper, 6: Pfister DRW, 7: pneumatic transport.

Block-System Solution
A special and economic version of a coal silo
with an attached rotor weighfeeder is the so
called block-system. It can also be used for
online-calibration. The small size reduces coal
extraction problems.
1

This solution is useful if the burners are far

apart from the fine coal silo. It can easily be
placed near the front- or back-end firing of the
2
kilns.
It employs a intermediate silo with a volume of
up to 30m. The silo is directly connected to the
rotor weighfeeder and both together are placed
on weight measurement units. The silo is also
explosion proof of up to 10 bar, therefore no
3
explosion flap necessary.

Block-System Solution
1: filter, 2: intermediate coal silo,
3: Pfister DRW.

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Function Principle

How does the system work?

Functioning Principle of the

Rotor Weighfeeder
The rotor wheel inside, is the heart of the sys-
tem and supplies highly accurate and constant
coal feeding.
The weighing axis (A-A) is eccentric to the rotor
4
shaft, but through the middle of inlet (1), outlet
(2) and blower pipe (3) . The third point is sus-
pended at a load cell (4) which weighs the gra-
3
vimetric material content of the rotor. The pul-
verised coal is transported in the rotor cham-
bers from the inlet (1) to the outlet (2) . The coal
mass in the rotor wheel produces a force (F). The
transport air in the blower pipe (3) crosses the
rotor chambers at the outlet (2) and discharges
the coal.
The speed of the rotor wheel is controlled invers
to the measured force (F). 1
2

The measured gravimetric Force (F) provides

information on the bulk material mass in the
rotor weighfeeder before material discharge. Rotor weighfeeder weighing and dosing
principle
The loading of the rotor weighfeeder with the 1: inlet, 2: outlet, 3: blow-out pipe, A-A: Eccentric Weighing Axis,
related rotor position, is stored by the weighing F: material measuring force.
electronics. That means that the rotor weigh-
feeder measures real kilograms and is therefore
a true scale.

The weighing electronics

ProsCon
It calculates the required speed of the motor for
the time of the discharge. It uses the set
feedrate and the measured bulk material mass
to calculate the angular speed of the rotor (see
chart). Less material in the rotor results in a
higher angular speed, more material in a lower
speed.
With this pro-active principle, so-called prospec-
tive control ProsCon, the rotor weighfeeder
achieves a highly accurate compensation of
variations in rotor loading and material density.
This results in an extremely accurate feedrate To achieve high accurate feeding, angular speed of
for short- and long-term. rotor is controlled invers to rotor weighfeeder loading.

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Function Principle

FLSmidth Pfister Rotor Weighfeeder

Controller weight
1 transmitter
All Data are collected in the: NWT1

Pfister CPICan Process Interface, at the feeder (6)

and transferred via Can-Bus to the:

Pfister CSCCan System Controller, in MCC (7)

2
The communication between the Pfister CSC
aeration 3
and the plant control system can either be controller
4 AC
via:
Serial-Interface (ModBus RTU).
5
Network-Interface.
(Profi-Bus DP, Device Net)

Analog/Digital-Hardwired Interface. process feeder

interface CAN controller
CPI CSC

M T
AC

6 Local 7 Motor Control Center

Pfister CSC controller
Electronic control scheme for
calibration-hopper solution.
1: Material storage silo, 2: silo cone and
aeration, 3: shut-off gate, 4: star feeder,
5: calibration hopper, 6: rotor weighfeeder
and Pfister CPI, 7: Pfister CSC.

Reactive Control Compared to Pfis-

ters Proactive Control Strategy
Other feeders are based on a reactive control
(follow-up) rather then a proactive control.
Deviations in feedrate is measured and the pre-
feeding is adjusted. The measured deviation is
already sent to the process. This also requires a
very fine and sensitive pre-feeding device.
Volumetric feeding during Reactive,
refilling. Follow-up Control.

With the proactive Pfister rotor weighfeeder, the

material mass is measured before it leaves the
rotor weighfeeder. That means that the speed
of the rotor is adjusted before the coal gets
discharged into the system, not the other way
round. This eliminates CO peaks in the firing
process. Prospective Control ProsCon
(Forward looking / pro-active)

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Function Principle

Pneumatic Transport to the Burner

The pneumatic transport of the coal to the
burner is an essential part of the feeding sys-
tem. The rotor weighfeeder is directly con-
nected to a blower. Clean transport air is blown
with approximately 25m/s through the feeder
and transports the fuel the the burner. Pfister
supplies a calculation of the transport pipe and
blower, matching the individual installation.
From our experience we suggest strictly vertical
or horizontal pipes with either 0 or 90 inclina-
tion. It is also advisable to use a minimum
number of bends (min. 1.5m radius) and to
keep the pipe as short as possible.
The amount of transport air depends on coal
feedrate and length of the pipe.
Pfister calculations provides optimal fuel trans-
port to rule out material segregation in the
pipes which would cause pulsations and CO
peaks.
If necessary it is possible to feed different
fuels into one feedpipe as shown in the figure.
Further on FLSmidth Pfister provides to possi-
bility to feed different fuels into one feedpipe,
as shown below.

Mixing of two different fuels into one feedpipe.

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Benefits

What are the benefits?

Long Service Life and High Availability

This is achieved by a slow rotation speed of the
rotor, only 6-8 rounds per minute.
The only moving part, the rotor itself, is made
in a certain cast steel to minimise wear of both,
sealing plates and rotor. The wear varies with
material abrasiveness but requires under nor-
mal conditions a rework of the sealing plates
only every 2 to 3 years of service time. The
plates can be reworked 2 to 3 times until a
spare part is necessary.

Service work at Pfister rotor weigh-

feeder.

Simple & Intuitive Operator Interface

The rotor weighfeeder is an advanced mecha-
tronic system. However it is very simple to op-
erate the rotor weighfeeder. The communica-
tion to the local plant control system is flexible
and works reliable.

Optional operation process display,

RPD.
Minimal Air Back-Flow from pneu-
matic transport system to material
storage silo
The rotor is designed with many small cham-
bers, each one representing an air seal between
the pneumatic transport and the material stor-
age silo

Optimal flame Control

The rotor weighfeeder actively compensates
changes in material characteristics and supplies
a constant stream of coal to the burning proc- The rotor is the heart of the machine,
ess. small chambers prevent back pressure.
It supplies high short and long-term accuracy in
deviation of set- and actual feedrate. The stable
feeding results out of the pro-active control
strategy and permanent gravimetric weighing
and dosing (ProsCon, forward looking) .

Optimal flame control with Pfister DRW.

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Benefits

Eliminated CO-peaks
Stable feeding without peaks of fed coal elimi-
1,5
nates CO-peaks and therefore prevents filter
shut-downs.
1
CO %
0,5
Reduced Excess-Air Cushion
Because of the above mentioned reasons it is 0
possible to reduce the over supply of air closer 0,6 0,25
1,7 1
to the optimum, while the generation of CO and 3
2
4 O2 %
NOx is minimised (see chart).
Pfister
Rotor DRW
Weighfeeder DRW Continous Flow Measuring

Carbon monoxide (CO) development as a function of oxygen

Reliable Feeding excess (O2) during metered feeding of pulverised coal.
(source: Rotor weighfeeder plant test)
Pfister supplies know-how for the whole envi-
ronment of dosing and an integration of the
new system into the existing plant layout. Opti-
mised silo cones, material activators and cali-
bration-hoppers ensure reliable coal silo extrac-
tion. Accurate calculation of pneumatic trans-
port pipes ensure the transfer of the accurate
material stream from the rotor weighfeeder to
the burner flame.

Instantaneously Adjustable
Feedrate
Because of its design, the rotor weighfeeder
supplies its high accuracy in a range from 10%
to 100% of the maximum feedrate. This accu-
racy is related to the actual feedrate.
The ProsCon control strategy ensure virtually
no reaction time in changes of the feedrate.
This is especially necessary if the feedrate of
the primary fuel is adjusted to the insertion of
secondary fuels, which might change in quality
Feedrate of rotor weighfeeders are instantaneously
or is running out of supply. adjustable to provide stable and reproducible feeding.

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Service and Support

Excellent Service & Support

Whether putting new systems in operation or
requiring maintenance for equipment which is
already in operation FLSmidth Pfister service
technicians are trained and experienced in han-
dling all of our equipment. Thus FLSmidth Pfis-
ter may ensure that the production processes
will work smoothly from the beginning and fur-

FLSmidth Pfister supports with the

following services:
Yearly maintenance work on
Pfister DRW.
Pfister Rotor weighfeeders are 100% tested in
the FLSmidth Pfister work-shop before delivery.

World-wide FLSmidth Pfister representation

through several subsidiaries and agencies.

Training for operators and maintenance per-

sonal at FLSmidth Pfister in Augsburg or on
customers site.

24 hours technical telephone hotline.

Short notice support with service specialists.

Fast support with emergency spare parts.

Modern maintenance management.

Technical assistance by Telesupport. FLSmidth Pfister Workshop in AugsburgGermany.

Pfister DRWs ready to ship.

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Service and Support

Modern Maintenance Management The Benefits of MMM:

FLSmidth Pfisters experience in maintenance Cost saving pre-planning of kiln outages.
management has been helping cement plants to
Regular check-up support; less overall
make the cement production process more effi- downtimes.
cient for many years.
Support in spare parts management.

Replacement of crucial parts at the right

time.

All maintenance measures carried out by

experienced Pfister specialists.

Reduce overall service cost.

Maintenance contracts are available.

Modern Maintenance Management reduces wear

FLSmidth PfisterAugsburg

Technical Assistance by Telesupport

With an optional modem, experienced Pfister
technicians have remote access to controller
WWW parameters, control logic and sensoric inter-
face. This makes online help possible for trou-
Modem on site
ble shooting and interpreting events and sys-
tem messages.

Pfister CSC in MCC

Pfister CPI at feeder

Online trouble shooting with

optional modem

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Dimensions

What are the dimensions?

Rotor Weighfeeder Pfister DRW Series

Type Rotor Feedrate*(max.) Weight (max.)

Pfister DRW 4.10 1000 mm 12 t/h 4.000 kg

PfisterDRW 4.12 1200mm 20 t/h 5.350 kg
PfisterDRW 4.14 1400 mm 40 t/h 8.800 kg

*depending on fuel characteristics

Rotor Weighfeeder Dimensions

Here: Type Pfister DRW 4.10

Side view, Pfister DRW 4.10.

Top view, Pfister DRW 4.10.

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Applications

What applications are there?

Application at a Cement Plant in Germany

2
1

5
6

4
3

Above: Silo cone and outlet

Coal silo cone (1) with cone aeration
(2). Material activator Pfister SGA (3)

with additional second/third/fourth

outlet (4) and Pfister SGA aeration(5).
Pre-feeding devices shut-off gate (6)
and star feeder (7).

2 5

Below: Pfister DRW with calibration

hopper.
Calibration-hopper (1) with aeration (2). Pfister
DRW 4.10 (3) with below calibration measure-
4 ment units (4). Pneumatic transport pipe for
coal transport to burner (5).

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Applications

Application at a Cement Plant in Pakistan

Double coal silo.

Pfister DRW (1) with down-pipe (2), fresh air pipes from
blower (3) and transport air pipes to burner (4).

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Applications

Application at a Cement Plant in Germany

4
Local silo extraction unit (1) and new
shut-off gate (2), star-feeder (3) and motor
for pre-hopper agitator arm (4).

5
Pre-hopper top (5)
with service opening (6).

7
8

Pre-hopper cone (7)

with aeration (8).

Pfister DRW (9) 10

with calibration measurement units (10).

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Applications

Application at a Cement Plant in the USA

Silo cone (1) with aeration (2), manual

(3) and pneumatic shut-off gate(4).

6
Star feeder (5) feeding into calibration-hopper
(6) with agitator-arm motor and gear box(7).

Pfister DRW (8)

9
with calibration measurement units (9).

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Applications

Application at a Cement Plant in the USA

Pfister SGA (1)

with shut-off gates (2) and star-feeders (3)
feeding into below calibration-hoppers (4).

Pfister DRW (5)

with calibration-hoppers (6).

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Applications

Application at a Cement Plant in Great England

Coal Dosing Oil-shale Dosing

2
1
3

Aerated coal-silo cone (1) with material activa- Aerated silo cone (7) and star-feeder (8).

tor Pfister SGA (2) and shut-off gates (3).

Star-feeders (4) feeding into calibration-hoppers (5). Pfister DRW for oil-shale dosing (9).

Calibration-hoppers (5) Pfister DRW (6) .

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Applications

Application at a Cement Plant in Lebanon

Aerated silo cone (1) and material activator

Pfister SGA with three outlets (2). Shut-off gates
(3) and star-feeders (4)

Calibration-hoppers (5) Later on...

and Pfister DRW (6). Pfister SGA exchanged to four outlets and
four dosing systems below.
Feeding three kilns, one with main burner
and calciner burner.

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Applications

The Drawing shows three Pfister DRW (1) installed to feed coal to ro-
tary kiln main burner, calciner burner and riser duct.

Four Pfister DRW (1) for dosing of pulverised fuel at a thermal power plant in Germany.
Pre-hopper with 20m (2), material activator (3).

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Applications

What are the technical facts?

Pfister DRW

Application: Highly accurate, gravimetric feed- Feedrate: 0.6 t/h to 40 t/h

ing of pulverised fuel to the burners in the cement
Feedrange: 10% to 100%
production-process
Accuracy: 0.5%

Bulk material: Pulverised over the complete feedrange related to

the actual value.
Hardcoal
Lignite
Petrolcoke
Oil shale
Electronic controller:
Pfister CSC controller with proactive control
strategy ProsCon.
Design:
Machine is engineered, designed, assembled and
tested in Germany Electronics Temperature Range:
Standard: 0C to +40C

Certification: With heater*: -20C to +40C

DIN EN ISO 9001:2000 With cooler*: 0C to +55C

*installed in local electric cabinet at feeder
ATEX (94/9/EC) in categories II1/2D and II1/3D

Interface to Plant Control System:

Serial-Interface (ModBus-RTU).
Network-Interface.
(Profi-Bus DP, Device Net)
Analog/Digital-Hardwired Interface.

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Applications

To see to the contend of your interest please click on the links below on our website:

Press articles
http://www.flsmidth.com/Pfister/English/News/Pfister+news/Press+archive.htm

Special-interest articles
http://www.flsmidth.com/Pfister/English/Special+interest+articles/Special-interest+articles.htm

Brochures
http://www.flsmidth.com/Pfister/English/Downloads/Datasheets+and+Brochures/Brochures/
Brochures.htm

Product datasheets
http://www.flsmidth.com/Pfister/English/Downloads/Datasheets+and+Brochures/Datasheets/
Datasheets.htm

Product animations
http://www.flsmidth.com/Pfister/English/Downloads/Product+animations/Product+animations.htm

Pfister DRW Pfister FRW Pfister TRW-K

Pulverized fuels Powdered products Crushed raw coal

Pfister TRW Pfister VRW Pfister TRW-S

Coarse products Powdered products Alternative fuels

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Contacts

FLSmidth Pfister GmbH

Staetzlinger Str. 70
86165 Augsburg
Germany
T. +49 821 7949 0 Sales Department: sales@pfister.de
F. +49 821 7949 524 Technology Department: engineering@pfister.de
www.pfister.de Service Department: service@pfister.de

Branches offices & joint ventures

FLSmidth Pfister Inc.

2158 Avenue C, Suite 201
Bethlehem, PA18017-2148
U.S.A.
T. +1 610 2645110
F. +1 610 2645537
pfistera@ptd.net

FLSmidth Pfister Ltda.

Rua Vigrio J.J. Rodrigues,
905 - c.j. 51
13.201 - 490 Jundiai
S.P., Brazil
T. +55 11 45266744
F. +55 11 45875711
pfister@pfister-la.com.br

FLSmidth Pfister GmbH Transweigh India Ltd.

124, ABCD, Govt. Industrial Estate
Malaysian Branch
Kandivli (W)
C-3A15, Centre Wing
Mumbai - 400 067
Metropolitan Office Suite
India
Metropolitan Square, Jalan PJU 8/1
T. + 91 22 2868 2311
Damansara Perdana
F. + 91 22 2868 2145
47820 Petaling Jaya
sales@transweigh-india.com
Selangor
Malaysia
T. +60 3 7728 2039
F. +60 3 7727 2039 FLSmidth Pfister GmbH China
pfismal@streamyx.com Western Part of Songshan Road
Qingdao Airport Industrial Zone
Chengyang District
266109 Qingdao
FLSmidth Pfister GmbH
P. R. China
6, Rue de Bretagne
T. +86 532 877 60380
38070 St. Quentin Fallavier
F. +86 532 877 56852
France
pfister-china@pfister.de
T. +33 474 955544
F. +33 474 945075
pnl@pfister.fr

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