SEPARATOR TECHNOLOGY

I Optimisation with TSV

by Loïc Pottier & Fives FCB’s TSV™ third generation high efficiency classifier , with more
Philippe Niel, than 210 references,is a recognised piece of equipment which has received
Fives FCB, France wide acceptance in the field of cement grinding, as well as raw meal, solid
fuel, and mineral grinding. When looking to increase production capacity,
energy cost savings and improvements in product quality, replacing an old
generation classifier with a state-of-the-art efficient model is one way to
reach these objectives while keeping the capital investment to a minimum.

and from f1.4m to f8m. Its specific

Figure 1: 3D
model of two- features are:
filter circuit • the selection basic concept with the
patented shape of rotor blades
• the patented anti-vortex system.
The blade shape ensures the
equilibrium between centrifugal force and
drag force in the whole volume located
between the blade and not only in the
selection area at the inlet. For one particle
diameter, which corresponds to the d50
(= cut size) of the selection curve of the
classifier, drag force and centrifugal force
are balanced during the transfer from the
inlet, in the selection of volume, to the
outlet of the blade.
The result is a very steep slope of the
selection curve around the d50:acuity =
d25/d75 = 0.4 to 0.6. Besides, the drastic

T
he TSV™ (Turbo Séparateur Figure 3: Chelm cement plant installation – mills N°8, N°9 and N°10
Ventilé) belongs to the third-
generation of dynamic classifiers.
Its particular design has seen it applied
and well-proven in a large range of
industrial products, from graphite to
cement, and from silicon to solid fuels,
with a cut size ranging from 8µm (TSV™
type THF) to 500µm (TSV™ type TBF),

Figure 2: 3D
model of single-
filter circuit

DECEMBER 2008 ICR

SEPARATOR TECHNOLOGY

Figure 4: TSV™ with air-and-

flash dryer is directly fed with fly ash, as
dust volute inlet
a secondary feed point. Operated in this
mode, the classifier is fed both from the
top (discharge by bucket elevator) and the
bottom. Following modification, the mill
output is able to achieve 120tph of CEM
IV with a maximum feed moisture content
of 11 per cent, which means 25 per cent
moisture content of the fly ash.

High quality cement

reduction of coarse particles in the final
product ensures a better early compressive
strength and consequently enables the
user to lower the Blaine target value.
The second patented characteristic of
the Fives FCB classifier is the inside plates
of the turbine which recover the dynamic
pressure of the rotating gases before
leaving the separator. This patented
Vortex breaking system provides:
• low pressure drop in the classifier
• extremely low power consumption of
the classifier.
Installation flexibility
full air swept system, as commonly met
when grinding solid fuels.
An additional, optional feature of
the TSV™ is the lateral air feed which
allows considerable extension of the
classifier’s field of implementation in a
modernisation project. Even in an existing
building, with reduced available height
and area, an efficient solution can be met.
This particular arrangement was chosen
by Titan’s Kosjeric plant in Serbia, for
modernisation of the cement mill with
the main production being CEM II/A-M
(P-Q). A significant hot gas generator is
present in the mill building, reducing the
There is no doubt that converting an
open-circuit to closed-circuit with the
use of a classifier brought a significant
improvement in the quality of cement.
The best quality control and grinding
efficiency have been achieved with the
introduction of the third-generation
classifier TSV™. The combination of the
excellent acuity and the drastic reduction
of coarse particles in the final product
allows for a revision of the targeted
fineness. Figure 6 shows an example of a
comparison between grain size analysis of
cements obtained with the first-generation
dynamic classifier and TSV™.
The modernisation Cementir’s Taranto
plant, dealing with CEMII AS (15 per
cent slag), is a good example of a
TSV™ industrial application. The initial
Figure 5: combination of flash dryer and
TSV™ at the Sacci Testi cement plant

In the usual configuration, material is fed
from the top of the classifier and air is fed
in at the bottom. When operated with a
ball mill, this arrangement corresponds to
a two-filter circuit (see Figure 1).
However, the TSV™ capability goes
much further. A material feed on
the top and bottom of the classifier,
plus an air feed means that it can be
operated in a single-filter circuit mode.
Dedusting of the mill is then carried out
through the classifier (see Figure 2).
Such an arrangement was selected by
Cemex’s Chelm plant in Poland for the
modernisation of cement Mill N°9 (2002)
and subsequently cement Mill N°8 and
10 (2007). The aim of this project (on top
of the 20-25 per cent capacity increase
and the new production of a pure CEM I
at 4500 Blaine) was to locate all the new
equipment relevant to the classifier inside
the existing building (see Figure 3), in a
shortened shutdown period (for full details
of this project see ICR December 2004).
This capability of the TSV™ to be fed
from the bottom is naturally applied to the
possible layout for classifier gas ducts. A
TSV™ 3600 HF with lateral gas inlet (see
Figure 4) was selected, in combination
with cyclones and recirculation fan.
Furthermore, depending on the
moisture of the feed material, the TSV™
classifier can be associated with a flash
dryer. As an example, a recent project
at the Sacci Testi plant in Italy involved
a bi-rotator mill for the production of
CEM IV/B-M (54 per cent clinker, 36
per cent fly ash, five per cent limestone).
The 3600kW mill measured f4m x
L13m (+3.2m drying chamber) and was
operated in a two-bag filter system, with
a static classifier at the mill gas outlet and
a second-generation classifier for final
classification. Before modification, the
mill output was 75tph of CEM IV, with a
fresh feed maximum moisture content of
9.5 per cent. The modification consists of
replacing the existing second-generation
classifier with a TSV™ with the addition of
its associated filter and fan, and installing
a flash dryer located bellow the classifier,
in the gas stream (see Figure 5). This

ICR DECEMBER 2008


installation with ball mill plus first-
generation classifier was producing a 4100
Blaine cement with a R32µm sieve residue
= 11.5 per cent (annual average). After
modification with TSV™, the guaranteed
fineness values (Blaine ≥3800 and R32µm
≤5 per cent) gave compressive strength
results higher than those recorded
before modification (see Table 1). As a
consequence, the producer changed its
fineness target values from R32µm = five
per cent to 6-7 per cent, leading to final
potential capacity of around 62tph, which
meant a gain of +26 per cent.
Other possible benefits of the cement
quality improvement are the production
of new types of cement, either with wider
fineness range or higher additive content
(limestone, fly ash, pozzolan, slag etc).
Classification efficiency remains a
constant subject of investigation and
is a part of Fives FCB research and
development programme. When particular
configuration or material are met, CFD
modelling is used to anticipate the
classification parameters. Figure 7 is a
view of gas speed distribution modelling
at the classification inlet area.
A cost-effective solution
A concern when dealing with high
performing technology might be
maintenance cost and the availability of
equipment. The third-generation classifier
TSV™ is designed with particular attention
to these aspects, considering both the
effects of wear and the mechanical
reliability. Each section of the classifier
is protected with regard to the type of
product to be classified, ranging from
SEPARATOR TECHNOLOGY
Table 1: production of CEM II AS 42.5
(15% slag) Cementir, Taranto, Italy
Before With TSV™
Mill output (tph) 49 58
Mill consumption (kWh/t) 50 42.2
Blaine (cm2/g) 4100 3920
Rµ32m sieve (%) 11.5 4.9
Compressive strength: 2 days (MPa) 25 26.8
7 days 37.3 39.5
28 days 49.3 50.5
Figure 7: model of TSV gas inlet distribution
wear resistant base plates, up to ceramic As the bearings are calculated for a
lining, including hard faced plates, or Ni- lifetime of 100,000h and operate with
hard casting. The latest improvements an efficient greasing system, this gives
in this deal with the protection of the complete classifier reliability. For instance,
rotating seal of the biggest classifiers. a bearing replacement in the frame of a
preventive maintenance programme was
Figure 6: GSD comparison recently planned after 70,000h (operating)
on a TSV™ 3600 HF dedicated to cement
grinding.
Conclusion
Fives FCB is recognised as a turnkey
equipment supplier bringing to its
customers innovative, efficient and
reliable technologies. The integration of
a TSV™ in a grinding circuit, whether
it be in a new plant or a modernisation
project, is a perfect example of
‘sustainable development’ in the cement
industry. It reduces the specific electrical
consumption, allows for higher amounts
of cement additives and consecutive
reduction of equivalent specific CO2
emission. __________________________ I
DECEMBER 2008 ICR
 TSV
TM

your cement requires

a first class classifier

Get the highest quality for your raw meal, cement, solid fuels or
minerals with the Fives FCB 3rd generation separator:

• Easy installation
• High resistance to wear
• Minimal by-pass
• Tromp curve very steep
• Very low pressure drop
• Extremely low power consumption

TSV™: more than 200 machines installed worldwide To Save Value.

Thanks to the TSV™ and to other innovative solutions, Fives FCB

designs today the cement plants of the future: more efficient,
more environnementally friendly and more economical.

www.fivesgroup.com Driving Progress

50, rue de Ticléni - B.P. 376 - 59666 VILLENEUVE D’ASCQ Cedex - France - Tél : +33 (0)3 20 43 75 01 - Fax : +33 (0)3 20 43 75 13 - E-mail : fivesfcb@fivesgroup.com