07 RP-RP in Various Mode

LEARNING MORE ABOUT
ROLLER PRESS
RP IN VARIOUS MODES
A TECHNICAL WORKSHOP BY
HUMBOLDT WEDAG INDIA
1
RP in Various Mode
I. Pre-Grinding by RP
II. Semi-Finish Grinding by RP
III. Grinding by RP with VS, SKS & VSK
IV. Slag Grinding in RP
V. Grinding by RP - COMFLEX SYSTEM
Lets learn more about the most efficient Grinding Technology-Roller Press 2
RP in Various Mode Overview
Semi-Finish Grinding with Comflex
Pre-Grinding Slag Grinding
Grinding VS & VSK System
Pre-Grinding by RP:
fresh
feed
finish
product
Specific grinding force: 9 N/mm2

Specific energy of Roller press: 3.5 to 7.0 kWh/t
Pre-Grinding by RP Pro and Cons:
(+) Simple arrangement
(+) Production upgrade of 20 to 35%
(+) Energy saving of 2 to 5 kWh/t
(-) Recirculation rate is limited
(-) Energy drawn by the RP is limited to 3.5 to 7.0 kWh/t
To transfer more grinding work to the RP, fines must be removed from the
circuit by a separator.
Semi-Finish Grinding by RP: In theYear 1992
fresh
feed
finish
product
semi-
finish
product

M-Type Circuit Specific energy of Roller Press: 8 to 20 kWh/t
2nd Generation Process Limitations
Feed moisture of material to RP max 6%.
Excessive wear in Separator & Chutes.
Coating in vertical conveying equipment and de-agglomerator.
2nd Generation Pros and Cons:
(+) High production upgrade of 40 to 150%
(+) energy saving against tube mill is 2 to 6 kWh/t
(-) High wear on:
deglomerator, dynamic separator, transfer chutes
(-) Large number of:
auxiliary equipment, motors, other electrical consumers, venting points,

chutes etc.
(-) Low drying capacity therefore limited application
Semi-Finish Grinding by RP, VS & SKS In theYear 1994
fresh
feed
finish
product
S -Type Circuit
Semi-Finish-Grinding by RP & VS
V- SEPARATOR LS- SEPARATOR
3
1
2
1- material feed
2- air inlet
3- fines+air outlet
4- rejects
4 4 1 2
Semi-Finish Grinding by RP with VS
V Separator has no moving parts thus no power consumption
Maintenance-free operation for years
Cut size between 0.1 and 1.5 mm
Performs 4 jobs
Fines separation (primary classification)
De-agglomeration of RP throughput
Drying or Cooling
Mixing of fresh feed and rejects
Semi-Finish Grinding by RP with VSK
fresh
feed
finish
product
V + SK = VSK ®
VSK® - SEPARATOR
material
feed
air- and
product
air
outlet
inlet
hot gas or fresh air
midlings
coarse
outlet
VSK-Separator
FIRST
VSK®- SEPARATOR
in R&D Center
Slag Grinding by RP & VSK
finish
fresh
product
feed
For Blast
furnace
slag
most efficient slag grinding system
Compact layout
Low specific energy consumption
3rd Generation Process Finish-Grinding

This image cannot currently be display ed.
feed bucket
Circuit bucket elevator elevator
Roller Press
SEPMASTER SKS
V-Separator
Roller Press operating conditions:
system fan
Limitations are turned into Benefits
No more drying limits

slag drying in V-Separator up to 18% moisture
No more wear problem

V-Separator avoids coarse material feed to dynamic separator
No more coating problem

V-Separator does the de-agglomeration job,
layout of V-Separator below Roller Press,
only dried rejects are conveyed
Product fineness up to 6000 cm2/g Blaine
Grinding by RP – COMFLEX SYSTEM
Machine Pre-condition for

COMFLEX
V-SEPARATOR
Well known features are:
maintenance-free operation
drying or cooling in the circuit
makes the overall system
efficient
SEPMASTER LC
further development of well

known Sepmaster SKS-L
COMFLEX - Machine Development
SEPMASTER LC
Excellent cut, low pressure drop
Fits very well with V-Separator
Air flow up to 2 Million m3/h
Best cyclone arrangement with overall

low pressure drop
SEPMASTER LC

low pressure drop
SEPMASTER LC

low pressure drop
SEPMASTER LC

low pressure drop
COMFLEX – Roller Press
Roller diameter: 1700 mm

Specific grinding force: < 5 N/mm2
Roller Press Standard Sizes:
RPS 5 - 140 / 80
RPS 7 - 170 / 90
RPS 10 - 170 / 110
RPS 13 - 170 / 140
RPS 16 - 170 / 180
RPS 20 - 220 / 180
COMFLEX - Availability
S - Single System…. for small to medium capacity
D - Double System…. for high capacity
 up to 1200 t/h raw meal
 up to 450 t/h cement or slag
 50% standby production during roll maintenance (Comflex-D)
COMFLEX – GRINDING ENERGY
12000
10000
Grinding Power kW
8000
6000
4000
2000
7 10 13 16
Roller Press size MN
COMFLEX® - Where to place the V-Separator?
V-Separator above V-Separator below

Roller Press Roller Press
heating of chutes,
bucket elevators,
vent pipes and
NO PROBLEM !
Clinker bag filters
________________________
Moist raw
Material
_______________________
Wet slag
Fines, dust, vapor, No fines, no dust,

reactive slag dried coarse slag
COMFLEX® - Where to place the V-Separator?
V-Separator below Roller Press
Special feature:
Better feed distribution
across the width of V-Separator
COMFLEX® - Where to place the SEPMASTER?
SKS below SKS above

SKS-rejects
are directly Fine
fed to the SKS-rejects
Roller Press are lifted by
process air
Only coarse V-
Fine SKS-rejects
Separator
and VS-rejects
rejects
to be lifted by
are lifted
Bucket elevator
mechanically
COMFLEX® - Where to place the SEPMASTER?
SKS below SKS above

Mechanical
Conveyors can
be designed
25 to 40%
smaller
COMFLEX® - Layout
COMFLEX ®
SEPMASTER
LC
Multi purpose Grinding
Plant
in Austria
Slag >6000 cm2/g Blaine

Roller Press Limestone 10%R 90µm
Raw material 15% R 90µm
Additives (slag, limestone,
V-Separator fly ash)
COMFLEX® - Layout
COMFLEX ® for
Raw Material Grinding
Static
LS-Separator
Roller Press
V-Separator
COMFLEX® - Layout
SEPMASTER SKS
gravity
chute COMFLEX ®
For PPC-Grinding
in India
Roller Press COMFLEX-circuit is

linked with a ball mill
(ball mill not shown)
V-Separator
gravity
chute
COMFLEX® - High Efficient Grinding System for the Future
COMFLEX® - Compact
Four Steps
to a Compact Layout
COMFLEX® - Compact Layout / Step 1
V-Separator Compact
Floor level
Roller
Press
VS-Compact
4.5 meter
height saving
Bucket elevator placed

in line with V-Separator
Chute between
V-Separator and
Bucket elevator:
6.5 meter
Height-saving
Roller Press feed chute bin

arranged parallel
Roller Press
Feed chute
3 meter
height saving
Air-chute
height saving:
4 meter
COMFLEX® - Compact
B C
Roller Press floor level
bucket elevator
building
height
height
COMFLEX® - Compact
bucket elevator height

present 46 m
new 29 m
Level of
Roller Press
present: 22 m
new: 10 m
COMFLEX® - Compact
COMFLEX ® S (Single) COMFLEX ® D (Double)

380 t/h raw meal, 100 t/h slag 760 t/h raw meal, 200 t/h slag
Thank you very much for your patient hearing.....
43

07 RP-RP in Various Mode

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LEARNING MORE ABOUT

II. Semi-Finish Grinding by RP

III. Grinding by RP with VS, SKS & VSK

IV. Slag Grinding in RP

V. Grinding by RP - COMFLEX SYSTEM

Specific grinding force: 9 N/mm2

Pre-Grinding by RP Pro and Cons:

(+) Simple arrangement

(+) Production upgrade of 20 to 35%

(+) Energy saving of 2 to 5 kWh/t

(-) Recirculation rate is limited

(-) Energy drawn by the RP is limited to 3.5 to 7.0 kWh/t

Semi-Finish Grinding by RP: In theYear 1992

Specific grinding force: 7 N/mm2

2nd Generation Process Limitations

Feed moisture of material to RP max 6%.

Excessive wear in Separator & Chutes.

Coating in vertical conveying equipment and de-agglomerator.

2nd Generation Pros and Cons:

(+) High production upgrade of 40 to 150%

(+) energy saving against tube mill is 2 to 6 kWh/t

(-) High wear on:

deglomerator, dynamic separator, transfer chutes

(-) Large number of:

auxiliary equipment, motors, other electrical consumers, venting points,

(-) Low drying capacity therefore limited application

Semi-Finish Grinding by RP, VS & SKS In theYear 1994

V- SEPARATOR LS- SEPARATOR

Semi-Finish Grinding by RP with VS

V Separator has no moving parts thus no power consumption

Maintenance-free operation for years

Cut size between 0.1 and 1.5 mm

Fines separation (primary classification)

Mixing of fresh feed and rejects

Semi-Finish Grinding by RP with VSK

Semi-Finish Grinding by RP with VSK

Semi-Finish Grinding by RP with VSK

hot gas or fresh air

Slag Grinding by RP & VSK

Slag Grinding by RP & VSK

Slag Grinding by RP & VSK

most efficient slag grinding system

Low specific energy consumption

3rd Generation Process Finish-Grinding

Roller Press operating conditions:

Specific grinding force: 6 N/mm2

Limitations are turned into Benefits

No more drying limits

No more wear problem

No more coating problem

Product fineness up to 6000 cm2/g Blaine

Grinding by RP – COMFLEX SYSTEM

Machine Pre-condition for

Well known features are:

further development of well

COMFLEX - Machine Development

Excellent cut, low pressure drop

Fits very well with V-Separator

Air flow up to 2 Million m3/h

Best cyclone arrangement with overall

COMFLEX - Machine Development

Excellent cut, low pressure drop

Fits very well with V-Separator