Product News
April 2011
Robert Krist, FLSmidth Pfister GmbH, Germany, introduces the application of Rotor
Weighfeeders in the main cement production processes
Throughout the cement manufacturing process,
continuous gravimetric dosing systems ensure an
accurate and stable material feed into the diverse
processes. Dosing of pulverised or alternative fuels, kiln
and mill feeding or preloading are typical areas where
FLSmidth Pfister Rotor Weighfeeder technology is being
utilised in more than 2000 installations worldwide. Some
typical applications are outlined here.
Figure 1. Rotor Weighfeeder Pfister DRW in explosion proof
design feeding 12 tph pulverised fuel directly to the burner.
>>
Installation examples
Precise dosing of pulverised fuels with
integrated pneumatic transport to the
main and calciner burner
The Rotor Weighfeeder DRW is designed for dosing
pulverised fuels, such as coal dust, petrol coke, lignite
or oil shale with direct feed into the cement burning
process. Integration of material extraction, weighing,
dosing and material transfer into the pneumatic
conveying line makes it a compact system that provides
outstanding accuracy and consistency. Moreover, the
consistency of metering with its proactive control
strategy ProsCon ® makes it possible to achieve low levels
of carbon monoxide in the kiln exhaust gases. This is
most important when using alternative fuels where the
coal feeding is then permanently adjusted. A wide feed
range up to 50 tph can be offered. In several cement
plants, up to four systems are installed under one silo.
Figure 1 shows a Pfister DRW 4.10 at a cement plant
that feeds up to 12 tph pulverised coal and petcoke.
The system is equipped with a calibration prehopper
including a stirrer inside to ensure the highest possible
material availability and safety. Online calibration during
operation can be easily executed. The pneumatic feed
distance reaches 110 m in total.
Feeding alternative fuels to the burners
The growth of the market has led to a great diversity
in the secondary or alternative fuels available. The
metering system used must therefore be designed
to be insensitive to permanently changing material
properties. Alternative fuels such as fluff, RDF, plastics,
tyres, industrial waste, or biomass (e.g. impregnated
sawdust, sewage sludge, wood chips or animal meal)
can be handled within one system. The multi-fuel Rotor
Weighfeeder TRW-S/D fulfils the high requirements
for a stable fuel dosing with high short and long-term >>
[Apr 11] Reprinted from worldcement.com
Product News

>> continued...
accuracy, outstanding reliability, a compact, closed and robust design. The
system provides a large feed range up to 25 tph, e.g. for light fluffy materials.
After the precise dosing at the rotor weighfeeder discharge, the fuels can either
be directly fed pneumatically into the burners or mechanically transported into
the calciner in-feed area.
Figure 2 shows an installation for wood powder with explosive potential.
The execution is in accordance to the ATEX regulation and has a shock
resistance design. The pneumatic feed distance is approximately 120 m. This
multifuel installation enables the customer to change the fuel type at any time.

Accurate kiln and mill feeding

The specific design of the FRW is ideal for dosing powdered bulk materials,
such as raw meal, flyash, bypass and kiln dust, additives or cement products
with high dosing consistency and precision. In combination with feed bins,
the system can be calibrated online to ensure reproducible feeding data. A
Figure 2. Rotor Weighfeeder Pfister
wide feed range from some 100 kg up to 800 tph can be executed in different
TRW-D in explosion proof design,
feeding 6 tph wood powder directly models.
to the main burner. Figure 3 shows a kiln feed FRW metering
250 tph raw meal to the preheater tower. From a
surge bin, the raw meal is pre-fed into the FRW.
Figure 3. Kiln >> The constant material flow leaving the Rotor
feed Rotor
Weighfeeder is then handed over to a bucket
Weighfeeder
Pfister FRW elevator to reach the preheater inlet and ensures a
dosing 250 tph stable and accurate kiln feeding.
raw meal to Figure 4 shows six additive feeding Pfister
the preheater FRWs at a finish mill. Each machine is metering
tower. up to 35 tph and the materials fed into the cement
mill are bypass dust and gypsum. Reproducible
dosing data ensure that all additives are kept in
the right range, resulting in a high cement quality.

Dosing of coarse products

Figure 4. Six additive Rotor Weighfeeders Pfister
FRW at a cement mill.
The robust design of the Rotor Weighfeeder TRW is suited to
metering coarse bulk materials with high constancy and precision.
Due to the integration of material extraction, weighing and dosing,
the system is easy to operate and thus extremely reliable. A wide
feed range up to 400 tph can be achieved with this weighfeeder. It
is also possible to match high material temperatures up to 200 °C,
as only a steel rotor is connected inside the feeder.
Figure 5 shows an installation at a finish mill feeding 50 tph
ground slag. Three further Pfister TRWs are feeding other
additives into the same mill and ensure a stable mill feeding
process. The completely closed installation provides a dust free
environment. >>

Reprinted from worldcement.com [Apr 11]

 Product News

>> continued...
Bulk preloading application
The Rotor Scale VRW can be utilised for fast and precise bulk
material preloading of fine or coarse materials, such as cement,
clinker, or green coke. These applications are an interesting
alternative in case it is not possible to equip loading positions
with platform scales. The loading rate is normally designed for
150 tph; higher feed rates are also executed.
Figure 6 shows a truck preloading plant where four Pfister
installations are in operation. Each scale is measuring the
cement load, ensuring a fast and accurate truck loading, with a
designed capacity for 150 tph.
Figure 7 shows a truck preloading installation for clinker.
The Rotor Scale is working on a load capacity of 150 tph
and the clinker is fed into the machine via a stair chute. The
enclosed design also reduces dust
Figure 5. Rotor Weighfeeder Pfister TRW emissions to a minimum.
dosing 50  tph ground slag.
Advantages
The proactive control strategy
Figure 6. Rotor >> ProsCon® provides a highly accurate
Scale Pfister VRW
fuel or material metering to ensure
preloading 150 tph
cement. a stable kiln firing and production
process. The modular concept
allows the highest possible flexibility
for using different materials in
respect to the wide range of feed
rate and variations in material
specifications and behaviour. The
dosing block itself can be integrated
into all engineering concepts, especially for modernisation
projects. The enclosed, modular and robust design makes
it convenient to operate and maintain the dosing system.
FLSmidth Pfister’s engineering know-how supports the
customer’s conception of building a suitable installation
with high efficiency and ROI.
The company also takes care to ensure an excellent
ratio of total cost of ownership (TCO) to its customers.
A modern maintenance management, technical after
sales service, 24 hour hotline, telesupport, customer
training, professional rework and customer optimised
spare part management are all part of FLSmidth Pfister’s
Figure 7. Rotor Scale measuring 150 tph clinker philosophy.
loading.

[Apr 11] Reprinted from worldcement.com