CPB Sem2012 p09 Coal Grinding Plants

3-days Training Course
September 24-26, 2012

Coal grinding plants
presented by Mr. Siegfried Spitaler
o General
o Grinding systems
o Safety regulations
o General Layout
o Process data
2 Coal grinding plants – September 24-26, 2012 © Christian Pfeiffer Maschinenfabrik GmbH
o General
o Grinding systems
o General Layout
o Process data
General
General:
o Thermal energy is an important cost factor in clinker burning.

o Economic independence from energy supply becomes more
and more important.
o With coal and pet coke are worldwide big resources available.
General
Calorific value of different fuels
Natural gas 8500 kcal/m³

Oil 9000-9500 kcal/kg
Pet coke 8000 kcal/kg
Coal 6500-7500 kcal/kg
General
General:
o volatile matter [%] of different coal
The higher the volatile content the higher the requirement

on special safety installations.
Lignite 40-50
Coal 25-32
Pet coke 5-12
o General
o Grinding systems
o General Layout
o Process data
Grinding systems
Vertical mill
Vertical roller mill Vertical ring ball mill
Grinding systems
Ball mill
VERTICAL MILL BALL MILL
 high availability
 compact design
 simple operation
 less specific energy  easy supply of wear- and spare
 higher drying capacity parts
 less ignition sources  start of the system without hot
 bigger maximum feed size gas possible
 less inerting volume  flexibility to grind various

material (coal, pet coke, etc.)
 better start-stop conditions
 less susceptible to vibrations
 simple material transport
o less drives  longer lifetime
o less complex control  using existing ball mills
Grinding systems
Coal grinding circuit, exemplary presented on ball mill
Due to advantages of ball

mill in respect to
 Availability
 Save operation
 Possibility of mill
conversion
we concentrate on the
ball mill design.
Grinding systems
Ball mill
Grinding systems
Ball mill
Explosion flaps
Air swept seperator
Grinding systems
Ball mill
Air swept ball mill system
Mill internals;
Grooved Liners
o 1/3 Activator Liners
o 2/3 Classifying Liners
Grinding systems
Ball mill
Air swept ball mill system
Dynamic air stream

separator
o Confined air sealing
system
o Central lubrication
system
o Vibration supervision
o Wear protection
o General
o Grinding systems
o General Layout
o Process data
Safety regulations
ATEX: production standards for security

ATEX = ATmosphére EXplosive
The aim of this directive is the free-trading of „ATEX“

equipment and protective systems within the EU, in
order to protect employees and equipment from
explosion risk in areas with an explosive atmosphere.
The basic safety features are as follows:

o Avoiding of explosive atmosphere (prim. Ex protection)
o Avoiding of ignition sources (sec. Ex protection)
o Reducing of the effect of an explosion (ter. Ex protection)
Safety regulations
Categories of equipment
There are two categories of equipment:

o I for coal mining and
o II for industrial applications.
Category II is applicable for coal grinding plants.
Safety regulations
ATEX Zones
The various areas of a coal grinding plant are classified into zones:
Zone Risk of explosion

Zone 20 continuously
Zone 21 time to time
Zone 22 seldom or never
Safety regulations
Example for explosion prevention in grinding plants

According ATEX regulations
Analogue ATEX:
Zone 20
Zone 21
Zone 22
Safety regulations
Surface temperature
Important factor for plant design
Class Max. surfacetemp

T1 450° C
T2 300° C
T3 200° C
T4 135° C
T5 100° C
T6 85° C
Safety regulations
Procedures for explosion protection
Inert atmosphere in grinding system

o Hot gas from pre-heater with 4-8 % O2 content
o Recirculation of exhaust gas (with water) via condensor
Gas analyser and inertizing system

o Gas analyser measures O 2 and CO content
o Inertizing is done with CO 2 or N 2
Pressure prove design

o Pressure resistant to 9 bar
o Reduced preassure resistant to 3,5 bar with Explosion flaps
o General
o Grinding systems
o General Layout
o Process data
General Layout
Ball mill circuit
Exit of explosion flaps

has to be outside
of the building.
Length of pipe:
max. 6 x pipe Ø
General Layout
Ball mill circuit
If possible locate coal dust

silos and dosing system
under collection filter.
Coal dust silos
Dosing system
General Layout
Vertical mill circuit
o General
o Grinding systems
o General Layout
o Process data
Process data
Grindability: Hardgrove Test (acc. to ASTM D 499)
On a grinding table are 8 grinding balls with a Ø of 1 inch

above a grinding ring with 29 kg which is driven by 0,2 kW.
Safety regulations
Specific power consumption with ball mills
Raw Specific power grinding HGI Fineness %

material + drying chamber Res / 90µm
Coal 28 kWh/t 42 12
Pet coke 45 kWh/t 35 3
Any questions?
Feel free to ask!
Thank you for your

kind attention.

CPB Sem2012 p09 Coal Grinding Plants

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3-days Training Course

September 24-26, 2012

o Thermal energy is an important cost factor in clinker burning.

Calorific value of different fuels

Natural gas 8500 kcal/m³

o volatile matter [%] of different coal

The higher the volatile content the higher the requirement

 less inerting volume  flexibility to grind various

Coal grinding circuit, exemplary presented on ball mill

Due to advantages of ball

Air swept seperator

Dynamic air stream

ATEX: production standards for security

The aim of this directive is the free-trading of „ATEX“

The basic safety features are as follows:

There are two categories of equipment:

Category II is applicable for coal grinding plants.

Zone Risk of explosion

Example for explosion prevention in grinding plants

Important factor for plant design

Class Max. surfacetemp

Procedures for explosion protection

Inert atmosphere in grinding system

Gas analyser and inertizing system

Pressure prove design

Ball mill circuit

Exit of explosion flaps

Ball mill circuit

If possible locate coal dust

Coal dust silos

Vertical mill circuit

Grindability: Hardgrove Test (acc. to ASTM D 499)

On a grinding table are 8 grinding balls with a Ø of 1 inch

Specific power consumption with ball mills

Raw Specific power grinding HGI Fineness %

Thank you for your

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