KHD-Part-2-From Raw Material Grinding To Kiln Feed Bin

Chapter 2
From Raw Material Grinding to Kiln Feed Bin

Version 07/2007
KHD Humboldt Wedag GmbH
Limestone / Clay
+ Corrective Components
CaCO3
SiO2 Gas Conditioning
Al2O3
Fe2O3
Raw Meal-Silo
• Homogenisation Waste Gas Cleaning
• Stock Piling
Thermal Process
•Pre-Heating Stack
•Calcination Cooler Waste Air

•Clinker Burning
Fuel Preparation
•Clinker Cooling
Pre-Blend Pile
Raw Material Grinding Cement
Finish Mill
Wednesday, January 28, 2009 2
2 From Raw Material Grinding to Kiln Feed Bin
2. 1 Overview about raw meal grinding technology

2. 2 Homogenisation Silo
2. 3 Kiln Feed – Dosing and Transport

Limestone / Clay
+ Corrective Components
CaCO3
SiO2 Gas Conditioning
Al2O3
Fe2O3
Raw Meal-Silo Waste Gas Cleaning

• Homogenisation
• Stock Piling
Thermal Process
•Pre-Heating Stack
•Calcination Cooler Waste Air

•Clinker Burning
Fuel Preparation
•Clinker Cooling
Pre-Blend Pile
Raw Material Grinding Cement
Finish Mill
2. 1 Overview about raw meal grinding technology

Objectives of raw material grinding
Fineness
Increasing the surface of the raw material (fineness) for a good reactivity in the kiln system. This is
necessary because of saving fuel costs and to maintain a clinker with good quality properties, e.g. free
lime content.
Typical demand on raw meal fineness
12 -15 % retaining on 90 µm sieve
2% retaining on 200 µm sieve
Drying
Drying of the raw material to utilise the Pre-Heater waste gas energy and to prevent clogging of raw meal
into the silo and transport devices to the kiln system.
Typical demand on raw meal humidity
Water in raw meal: <1%
Homogenisation
To maintain a homogenous product of the raw material mixture (limestone, shale, iron, sand….) after mill
before entering the homo silo.
Typical demand on raw meal homogeneity
Standard deviation of CaO mean value: < 1,0

Raw Material Mix to Raw Mill
From Blending Bed From Silo
Limestone Clay or Iron Sand

Shale
SiO2,
Al2O3,
Fe2O3
Belt Scale
Homogenisation Raw Mill X-Ray

Silo Analyser

2. 1. 1 Ball Mill

Ball Mill - Flowsheet for Raw Meal Grinding
Cyclone
Separator
Bag Filter
Feed
Product to Homo Silo
Classifier
Hot Gas
(from Pre-Heater
or Hot Gas Generator) Ball Mill
Bucket Elevator

2. 1. 2 Roller Press

Roller Press - Flowsheet for Raw Meal Grinding
Bag Filter
Bucket Elevator
Cyclone
Separator
Hot Gas
(from Pre-Heater Classifier
Raw Material or Hot Gas Generator)
Feed
Product to Homo Silo
Roller Press

2. 1. 3 Vertical Mill
Hot Gas

Vertical Mill - Flowsheet for Raw Meal Grinding

2. 1. 4 Classifier – KHD V Separator
3
1
2 1- material feed
2- air inlet
3- fines+air outlet
4- rejects

2. 1. 4 Classifier – KHD LS Separator

3
1- material feed
2- air inlet
3- fines+air outlet
4- rejects
4 1 2

2. 1. 4 Classifier – KHD VSK Separator
Material-
Material-
inlet Transportgas,
Finematerial, Hotgas
Product
Coarse Material
from dynamic Classif.
Coarse
Material, to mill
2. 2 Homogenisation Silo
Objectives of Homogenisation Silo
Homogenisation
Blending of fine product (raw meal) after raw mill to maintain a homogenous composition of
raw meal as kiln feed.
Typical demand on kiln feed homogeneity:
Standard deviation of CaO from mean value: < 0,3
Stockpiling
Stockpiling of kiln feed to maintain 24h/d of kiln operation if raw mill is not in operation.
Typical kiln feed capacity:
Kiln feed amount to maintain 24 – 48 h kiln operation

Homogenisation Silo

Blending Effect
The Blending effect of a modern Silo
is given to 10 – 20:1 (depending on homogeneity
of raw meal after raw mill).
The blending effect is generally determined as

the ratio between the standard deviation Sin of one
significant chemical parameter of the input (e.g. CaO)
and the standard deviation of the same parameter Sout
of the output from the homo silo, as follows:
Blending effect = Sin/ Sout

After discharging from the Homogenisation Silo the raw meal is entering the Kiln Feed Tank.
The Kiln Feed Tank works as a buffer before the raw meal is passing the Weight Feeder.
After Weight Feeder the raw meal is entering the Transport Device (e.g. Bucket Elevator,
Airlift) to the top of the Pre-Heater Tower, into the kiln system.


Rotary Weight Feeder (Pfister System)

The objective of the weight feeder is to maintain a defined flow of material into the system.
Raw Meal
Inlet
Load Cell
Motor
Kiln Feed Amount = f(Motor Speed) Raw Meal
Outlet

Air Slide
Air slides often used as transport device for fine, solid materials (kiln feed) in horizontal
direction. The airslide is inclined to maintain the material flow.

Bucket Elevator
Bucket elevators
are used for the
vertical transport
of bulk materials.

Air Lift System

Air Lift Systems are used for the vertical transport of
fine, bulk materials.
Compared to a bucket elevator the investment costs
are lower but the operational costs are higher
(compressed air and therefore electrical energy
demand).

Rotary Air Lock

Rotary Air Locks are used as a transfer or shut off device to feed fine materials
into a gas tight system, e.g. feeding of raw meal into the Pre-Heater.
Another function is to protect equipment (e.g. screw conveyor) which is

connected to a silo from the full load of the material column.
Scraper

From Homogenisation Silo to the Pre-Heater, Kiln System
From Homo Silo
Kiln Feed Tank Air Slide
Rotary Air Lock
Air Slide
To Pre-Heater
to
Weight Feeder
Bucket Elevator
(or Air Lift)

KHD-Part-2-From Raw Material Grinding To Kiln Feed Bin

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Chapter 2

From Raw Material Grinding to Kiln Feed Bin

•Calcination Cooler Waste Air

Raw Material Grinding Cement

2 From Raw Material Grinding to Kiln Feed Bin

2. 1 Overview about raw meal grinding technology

Wednesday, January 28, 2009 3

Raw Meal-Silo Waste Gas Cleaning

•Calcination Cooler Waste Air

Raw Material Grinding Cement

2. 1 Overview about raw meal grinding technology

Wednesday, January 28, 2009 5

Raw Material Mix to Raw Mill

From Blending Bed From Silo

Limestone Clay or Iron Sand

Homogenisation Raw Mill X-Ray

Wednesday, January 28, 2009 6

Wednesday, January 28, 2009 7

Ball Mill - Flowsheet for Raw Meal Grinding

Wednesday, January 28, 2009 8

Wednesday, January 28, 2009 9

Roller Press - Flowsheet for Raw Meal Grinding

Wednesday, January 28, 2009 10

Wednesday, January 28, 2009 11

Vertical Mill - Flowsheet for Raw Meal Grinding

Wednesday, January 28, 2009 12

2. 1. 4 Classifier – KHD V Separator

Wednesday, January 28, 2009 13

2. 1. 4 Classifier – KHD LS Separator

Wednesday, January 28, 2009 14

2. 1. 4 Classifier – KHD VSK Separator

Objectives of Homogenisation Silo

Wednesday, January 28, 2009 16

Wednesday, January 28, 2009 17

The blending effect is generally determined as

Blending effect = Sin/ Sout

Wednesday, January 28, 2009 18

2. 3 Kiln Feed – Dosing and Transport

Wednesday, January 28, 2009 19

2. 3 Kiln Feed – Dosing and Transport

Wednesday, January 28, 2009 20

Rotary Weight Feeder (Pfister System)

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Air Lift System

Wednesday, January 28, 2009 24

Rotary Air Lock

Another function is to protect equipment (e.g. screw conveyor) which is

Wednesday, January 28, 2009 25

From Homogenisation Silo to the Pre-Heater, Kiln System

From Homo Silo

Kiln Feed Tank Air Slide

Rotary Air Lock

Wednesday, January 28, 2009 26

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