Two in One Albert Suessegger, KHD-Humboldt Wedag AG, Germany, looks at the advantages and challenges of using a roller press. Introduction ‘The huge amount of energy used to grind cement and its raw materials has made the roller press a vital component of the industry. Consuming little more than half the energy of a tube rill the importance of the roller press cannot be ignored. Accordingly, its sales curve showed a steep incline right after news of the first operational machines had been reported. However, this trend did not continue at the same rate. There were setbacks, not only caused by changes in the investment climate, but also influenced by the learning curve that had to be followed in bringing the benefit of energy efficient grinding with the roller press to fruition. The first and most important task for development was to make the pressing force and roll surface match each other. Secondly, the auxiliary equipment needed adapting to the new operating conditions. More understanding of this situation is gained by taking a close look at what comes out of a roller press. In the discharge from the roller press, there is a fair amount of material larger than 1 mm and the particle shape is rather sharp edged. On top of this, the mater- ial is partly compacted and requires deglomeration to liberate the fine particles before classifying can take place efficiently Previously most separators were designed for, and operated in, a closed circuit with tube mills from which material over 1mm was rarely received. The grinding action in the tube mill is also known to deliver a rather rounded particle shape. Running the roller press with conventionally designed machines for deglomeration and separation can cause some disappointing life times for the wear parts. There were also frequent reports of undue vibration from the deglomerating machines. KHD overcame these setbacks by introducing the V- separator (VS). The VS is a static type classifier with an extremely robust design, due to there being no moving parts involved. Over 40 VS-units are now in operation, The success of the VS has laid a sound foundation for the company’s next step, a new generation of grinding plant equipped with the VSK-separator. Principle of operation The static part type VS Feed material enters the VS from above and cascades downward over a steeply declined array of steps. The cas- cading movement causes a repeated impact on the pass- ing material. This impact action efficiently liberates fines from agglomerates. Separating the fine particles from the coarse starts from this cascade and is completed by passing an array of upward pointing baffle plates. Classifying air enters this space transversely to the material flow, lifting the fine fraction in between the classifying baffles to the outlet for fines and air. The coarse fraction tumbles down and one } finally drops out at the classifier bottom. In the event of wet feed such as slag or pozzolana, the VS can be operated with hot gas for efficient drying Alternatively, hot feed can be cooled by an appropriate intake of fresh ait. Cut size is controlled by setting the air velocity via fan adjustment. The four main functions of the VS are as follows: © Classifying: all grossly oversized material is removed from the circuit for immediate return to the roller press. With no moving parts and a low air velocity, the V5-cascade performs the task of preseparation better than any dynamic separator. Not only does it require much less maintenance, it also saves energy by operating with a lower pressure drop and high- er product to air loading. With the VS in front, all equipment is located downstream, relieved from material load and weer. © Deglomeration: the impact action of the material cas cade is sufficient for deglomerating the partly com- pacted material when it is delivered by the roller press. © Heat transfer: the separator cascade provides effective heat transfer for either drying or cooling © Feed distribution: When passing through the VS, feed material is well spread and mixed with recycled mate- rial before entering the roller press. This creates the optimum intake condition at the pressing rolls, a pre- requisite for the quiet running of the roller press. These performance qualities make the VS especially suit- able for the following © Extracting fines from the feed material of very wide particle size distribution, which originate not only from roller presses but also from other crushing machines, such as jaw-, gyratory- and roller crushers. Inall these cases, the VS eliminates the high overhang of coarse material for an immediate return to the crushing machine. Only the remaining fine fraction is allowed to pass on for further processing. © Dedusting operations, where a dust free coarse prod- uct is required. © Drying or cooling. © Fines from the VS can be taken as a finished prod- uct when it is allowed to carry a portion of 15% or VSK separator in action WORLD CEMENT February 2003 84more of particles larger than 90 jim. This is the case in an increasing number of raw meal preparation plants, especially when grinding raw meal with the roller press. For a product finer than the above mentioned cut point specification, a dynamic separator should follow down stream from the VS. ‘Whilst previously this dynamic separator had to be ‘operated as a completely separate machine, both units can now be accommodated in one common housing, The cage wheel part type-SK (VS + SKS = VSK) The preclassfied fine fraction is airlifted from the VS, directly to the circumference of a horizontally arranged ‘age wheel. The air passes in between the cage bars of the rotating wheel, dragging all fine particles to the centre for discharge into the fines collecting system (cyclones or filter). The remaining medium fraction is prevented from entering the rotating cage by centrifugal force. It is skimmed off constantly at the periphery for discharge by gravity. This medium fraction can be discharged separately from the other two fractions of, if appropriate, run together with the VS-coarse for combined discharge “The cut size of the cage wheel ranges from 25 - 150 um and is decided by setting the cage wheel speed. The cage wheel is mounted on a horizontal shaft, sup- ported on roller bearings with design features including pressure loss through the VSk-separator which has been significantly reduced in comparison with conventionally designed dynamic separators. Access for inspection and removal of the cage wheel and drive is very easy. With the VSK-separator, five performing functions are combined in one unit. These are as follows: © Pre-classifying: all grossly oversized material is removed from the circuit for immediate return to the roller press. Therefore the dynamic classifier, located downstream, is relieved from much of the wear. © Mixing and spreading: both feed- and recycled-mate- rial to achieve the optimum intake condition at the high pressure grinding rolls. ‘© Deglomeration: the impact action of the material cas- cade is just right for effective deglomeration of the typical (compacted to slab shape) material as dis- charged by roller presses. © Effective heat transfer: when either drying or cooling. © Cut point for fine product: adjustable to cover the entire range as demanded by the cement manufacturer. Operational experience The VSK has passed various stages of development, start- ing from CFD-research and pilot scale operation before receiving approval for the up-scaling and design of large production size machines. The company has already received three orders for the \VSK from the cement industry. Of these units, the first has now been commissioned. It operates in the pre-grinding circuit of a 2-stage grinding plant with roller press and tube mill in southern Germany. Scale-up calculations from the pilot machine have been confirmed. Adjustments and alteration required during this fist period of commissioning were completed ina short time without any major expense. ‘The performance trials included the production of a roller press and VSK 62 to 140 th 46,9 to 36,4 kWhit variety of different cement grades ranging from 2850 - 6500 cmi/g according to Blaine. Plant output varies according to the fineness and composition, from 40 - 140 tph. ‘Two more VSK-separators, one for finish-grinding, and the other for grinding/drying of slag are presently under erection and were due for commissioning towards the end of 2002. The flexibility in plant-design that is offered by the \VSK is demonstrated by a flow sheet for upgrading a closed-circuit grinding plant. The existing separator at the tube mills eliminated, as it would not handle the two-fold increase in capacity brought by the roller press. Tube mill output is simply fed to the cage wheel part of the VSK. Here, the fine cement is taken out whilst the remaining medium fraction from both roller press and tube mills returned to the tube mill. ‘Additionally, the existing finish mill can carry on grind- ing whilst the pre-grinding circuit is erected. Conclusion \V5k-specific aspects of economy include: © Lower cost for investment (five functions in one unit). © Energy efficiency (classifying with the lowest possible airflow and pressure loss). © Great flexibility in plant design, avoiding downtime during erection. © Low expenditure for maintenance (low air velocity, ‘no moving parts apart from the cage wheel. © Excellent access for inspection and maintenance. ‘© With no rotating equipment for deglomeration, the \VSK also saves on wear and energy. For example, total energy consumption at a plant was reduced from 46.9 down to 36.4 kWhit Enquiry no: 13 WORLD CEMENT February 2003 cs