Loesche Technical Seminar_apr-15

Technical Seminar Jakarta 2015

Jakarta, Indonesia, 21 - 23 April, 2015

Proceedings Convening Networking Sharing knowledge

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© by LOESCHE

Final programme 21 April 2015 19:00 - 22:00

Informal get-together at Hotel Le Méridien Jakarta

22 April 2015

Technical Seminar at Hotel Le Méridien

08:30 - 09:00

Registration open: Coffee and networking

09:00 - 09.15

Welcome address Hendra Tjhai, Detlef Bluemke, PT Loesche Indonesia

09:15 - 09:30

Meet the delegates - Introduce yourself to the audience

09:30 - 10:30

Loesche vertical roller mills: State-of-the-art comminution Detlef Bluemke, PT Loesche Indonesia

10:30 - 10:45

Coffee and networking

10:45 - 12:00

Process, operation & evaluation of Loesche grinding systems Christian-Martin Ruthenberg, Loesche GmbH, Germany

12:00 - 13:00

Lunch and networking

13:00 - 14:00

Preventive maintenance - wear and repair Stefan Wölfel, Loesche GmbH, Germany

14:00 - 15:00

Machine monitoring Sebastian Muschaweck, Dr. Franz Muschaweck, DALOG Diagnosesysteme GmbH

15:00 - 15:30


15:30 - 17:00

World Café - interactive workshop

© by LOESCHE

Dr. Regina Krammer, Loesche GmbH, Germany

18:00

Departure from the Le Meridien Hotel to Segara Anchol for dinner

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Final programme 23 April 2015

Technical Seminar at Hotel Le Méridien

09:00 - 09:15

Welcome and summary of day 1 Hendra Tjhai, PT Loesche Indonesia

09:15 - 10:15

Process parameters and plant optimisation: False air - often underestimated Christian-Martin Ruthenberg, Loesche GmbH, Germany

10:15 - 10:30


10:30 - 12:00

Grinding aid: Advantages and operation optimisation Dr. Pietro Recchi, Mapei

11:45 - 13:00

Lunch and networking

13:00 - 14.00

Lubricants - Functions and the importance of maintenance Moch Mustofa, PT. Mitra Asmoco Utama

14:00 - 15:00

Pyroprocess evaluation - waste treatment with the new Rocket Mill Dr. Stefan Kern, A TEC Production & Services GmbH

15:00 - 15:15

Coffee & networking

15:15- 16:30

World Café - interactive workshop Dr. Regina Krammer, Loesche GmbH

Resumee of the two days and farewell

19:00

Dinner at the Hotel Le Méridien

© by LOESCHE

16:30 - 17:00

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Organisers Detlef Bluemke

Hendra Tjhai

Main activities: • Longterm experience as commissioning engineer E,C&I and process worldwide for Loesche • Head of Commissioning department and later deputy director of Technical Field Service at Loesche • Since 2013 Managing Director of PT Loesche Indonesia

Main activities: • Client relation • Spare part and after sales business • Link in between clients in the Asian region and the Loesche Group • Engineering consultancy

Managing Director, PT Loesche Indonesia

email: [email protected]

Sales Engineer, PT Loesche Indonesia


Jeane Haro

Office Manager, PT Loesche Indonesia Main activities: • Client relations • Marketing • Taking care about financial, administrative and tax matters

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In cooperation with LOESCHE Training Center, Germany: Theodora Bruns

Dr Regina Krammer

Main activities: • Development of blended learning concepts for internal and external use • Business development • Customer service

Main activities: • Development of blended learning concepts for internal and external use • Design of eLearning courses and computer supported cooperative learning (CSCL) • Knowledge management and communication

Head of Training Center, LOESCHE GmbH


Deputy Head Training Center, LOESCHE GmbH, Germany


Christian-Martin Ruthenberg

Technical trainer, LOESCHE GmbH, Germany Main activities: • Development of training concepts for customers • Process auditing • Training on process and operation of LOESCHE grinding plants

© by LOESCHE


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Lecturers Detlef Bluemke

Christian-Martin Ruthenberg

Main activities: • Longterm experience as commissioning engineer E,C&I and process worldwide for Loesche • Head of Commissioning department and later deputy director of Technical Field Service at Loesche • Since 2013 Managing Director of PT Loesche Indonesia

Main activities: • Development of training concepts for customers • Training on process and operation of LOESCHE grinding plants

Managing Director, PtT Loesche Indonesia

Technical trainer, LOESCHE GmbH, Germany



Stefan Wölfel

Sebastian Muschaweck

Head of service, DALOG Diagnosesysteme GmbH

Main activities: • Worldwide execution of installation activities • Management of the installation department of Loesche GmbH, Germany • Strategic development and resource planning of installation supervisors

Main activities: • Expert in rotating equipment reliability, vibration analysis, inspection, and maintenance engineering • Certified Vibration Analyst Category III • Areas of expertise: cement machinery, large gearboxes and extruder machinery



© by LOESCHE

Head of Installation, LOESCHE GmbH

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Lecturers Dr. Franz Muschaweck

Dr. Pietro Recchi

Main activities: • Founder of DALOG Company • Expert in rotating equipment vibration diagnostics, reliability, trouble shooting, inspection, and maintenance engineering • Ph.D. in vibration diagnostics on gearboxes

Main activities: • 7 years experience in cement additives for Mapei • Master’s degree in organic chemistry • Main focus on providing technical support to our sales force in the region • Directly responsible for cement additives sales in Malaysia



Moch Mustafa

Dr. Stefan Kern

Main activities: • Leader of the engineering division • Training for customers on lubrication practices • Degree in mechanical engineering, active participant of MASPI (Masyarakat Pelumas Indonesia) • DELTA, WSML, BAT certification from ExxonMobil

Main activities: • Area Sales Manager • Doctoral studies: Chemical Engineering • PhD thesis: Co-Gasification of coal and biomass/wastes in a dual fluidized bed gasification system.

Owner and CEO, DALOG Diagnosesysteme GmbH

Chief Lube Engineeer, PT. Mitra Asmoco Utama

Proposal Engineer & Product Manager, A TEC Production & Services GmbH


© by LOESCHE


Regional Technical Manager Asia Pacific, MAPEI

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About LOESCHE Since 1906, LOESCHE GmbH has been constructing vertical roller grinding mills. Patented in 1928, our roller grinding mill technology has been continually advanced and in the meantime is synonymous with LOESCHE GmbH. The key competence of the company is the design and development of individual concepts for grinding and drying plants for the cement, steel and iron, power, ores and minerals industry. The service portfolio ranges from first concept to commissioning augmented by maintenance, repair, training as well as modernization of grinding plants and spare parts activities. In April 2012, LOESCHE GmbH, Germany, has entered into a close cooperation agreement with pyroprocess specialist A TEC Holding GmbH, Austria. LOESCHE and A TEC will be partners for the realisation of plant improvement projects, environmental projects and will be in the position to offer complete process solutions. Having taken over the specialised department “Combustion Technology” of UCON AG Containersysteme KG, Gelsenkirchen, in April 2012, LOESCHE offers thermal process technological solutions, thus covering another field of activities with related products e.g. industrial burners and hot gas generators.

When communicating learning content about all matters pertaining to LOESCHE technology the Training Center uses the principle of ‚integrated learning‘ (Blended Learning Concept) with the aid of the latest learning methods and media. It combines online courses which are not tied to a specific time and place with traditional attending teaching and seminars in order to consolidate the knowledge so imparted in the best manner possible and with lasting effect.

For more information please refer to: www.loesche.com LOESCHE GmbH Hansaallee 243 D-40549 Duesseldorf Tel.: +49-211-5353-0 Fax: +49-211-5353-500

© by LOESCHE

LOESCHE is a privately owned company with its headquarter located in Dusseldorf, Germany and is represented worldwide with more than 850 employees, subsidiaries in the USA, Brazil, Spain, Great Britain, South Africa, India, United Arab Emirates, Indonesia, Russia and P.R. China as well as agents in more than 20 countries. The LOESCHE Training Center was founded in 2008. A young, innovative team of editors, eLearning authors and technical trainers drafts and creates trainings and eLearning courses, documents and manuals in accordance with the latest media-didactic principles, tailored to the needs and requirements of the customers.

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Loesche vertical roller mills: State-of-the-art comminution by Detlef Bluemke, PT Loesche Indonesia

LOESCHE vertical roller mills State-of-the-art comminution

© by LOESCHE

Detlef Blümke, Managing Director PT LOESCHE Indonesia Technical Seminar Jakarta 2015

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Table of contents

Introduction

Introduction

LOESCHE in brief

Loesche vertical roller mill for cement grinding Some comments on grindability State-of-the-art cement grinding plant Summary/Conclusions  LOESCHE GmbH is a privately owned company founded 1906 in Berlin, Germany  Certified according to DIN EN ISO 9001  Main shareholder: Dr. Thomas Loesche  Management: Dr. Thomas Loesche, Dr. Joachim Kirchmann Rüdiger Zerbe

 Employees in Düsseldorf: 370  Employees worldwide: 958  Turnover 2014: Euro 500 millions worldwide 2

Technical Seminar Jakarta 2015 – Loesche vertical roller mills_State-of-the-art comminution_Rev.A

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Introduction

Introduction

~ 800 employees at 15 Loesche subsidiaries worldwide

31 representative offices worldwide

America

Europe

LOESCHE America, Inc. Pembroke Pines, Florida, USA

LOESCHE GmbH (Head Office)

LOESCHE Equipamentos Ltda. Rio de Janeiro, Brazil

LOESCHE Automatisierungstechnik GmbH Lünen, Germany

Düsseldorf, Germany

Africa LOESCHE South Africa (Pty.) Ltd. Johannesburg South Africa LOESCHE Nigeria Ltd. Ibese, (Lagos) Nigeria

LOESCHE ThermoProzess GmbH Gelsenkirchen, Germany LOESCHE Energy Systems Horsham, UK LOESCHE Latinoamericana S. A. Madrid, Spain LOESCHE OOO Moscow, Russia

LOESCHE India (Pvt.) Ltd. New Delhi, India LOESCHE Mills Ltd. Shanghai & Beijing, PRC LOESCHE Middle East FZE Dubai, UAE LOESCHE Middle East Tehran Branch Office Tehran, Iran LOESCHE Vietnam Ho Chi Minh City, Viet Nam PT Loesche Indonesia Jakarta, Indonesia

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Asia

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Introduction

Introduction

~ 100 employees at 11 Loesche stakes worldwide

Material flow, feed materials, products

A TEC Group, Austria

America

Europe

Aixprocess GmbH, Germany

Asia A TEC Asia Sdn. Bhd. Kuala Lumpur, Malaysia

Austria TEC S.A. de C.V. Puebla, Mexico

A TEC Production & Services GmbH Gödersdorf/Krems, Austria

A TEC Greco Projetos e Equipamentos Ltda Sao Paulo, Brazil

A TEC Plant Construction GmbH Eberstein, Austria

A TEC Technology Services (Beijing), Co., Ltd. Beijing, China

A TEC Sales Office Branch Poland Chelm, Poland

Sales & Consulting A TEC Iraq Office Erbil, Iraq

Europe Aixprocess GmbH Aachen, Germany Aixergee GmbH Aachen, Germany Aixenviro Gbr Aachen, Germany

Greco Combustion Systems Europe GmbH Krems, Austria

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Table of contents

Loesche vertical roller mill for cement grinding

Introduction

Cement grinding as part of the process

Loesche vertical roller mill for cement grinding Some comments on grindability State-of-the-art cement grinding plant

Quarry

Summary/Conclusions

8

Cement

Kiln


Cement grinding

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Raw meal/Coal grinding

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Working principle

Material and gas flow of a clinker/slag grinding plant

1) Rotary feeder 2) Mill table with grinding track

Raw material Fly ash External material recirculation system Metal Product Gas flow

3) Master roller 4) Support roller 5) Rocker arm 6) Hydro-pneumatic spring system 7) Bevel-planetary-gear box 8) Electric motor 9) Gas inlet 10) Ring duct 11) Louvre ring 12) Classifier 13) Grit cone 14) Outlet duct to dedusting system

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Table of contents

Some comments on grindability

Introduction

Definition and common tests

Loesche vertical roller mill for cement grinding Some comments on grindability

Grindability is the resistance of a material against the forces acting upon it during the grinding process – usually given as specific energy consumptions (kWh/t)

State-of-the-art cement grinding plant Summary/Conclusions

Common grindability tests  Zeisel  Bond  Grinding tests of machinery suppliers and cement manufacturers

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Loesche grindability test (1)

Loesche grindability test (2) LOESCHE grindability factors (MF, LF)  spec. energy consumption  wear factor (vp) The factors are used to determine the right mill and gear box size as well as a suitable material for the wear parts.

Laboratory mill LM 3,6

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Flow sheet LM 3,6

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Comminution process (1)

Comminution process (2) roller alite

alite

grinding table

belite

 multiple material „layers“ 100 um

 compressive and shear forces acting upon the particles  crack initiation at weakest point of structure  crack propagation perpendicular to lowest level of compressive forces

Source: http://booksite.elsevier.com/samplechapters/9780750651035/9780750651035.PDF (2015-03-23)

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alite

alite

belite 100 um

alite

alite C4AF C3A belite belite microcracks

100 um

100 um

photomicrograph of clinker; nital etch (Campbell 1999)


photomicrograph of clinker; nital on KHO etch (Campbell 1999)


Source: http://booksite.elsevier.com/samplechapters/9780750651035/9780750651035.PDF (2015-03-23) 18


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Influencing parameters Classification of microcracks

alite euhedral

belite C4AF

alite in void

intra-

20 um

20 um

from Siegesmund et al. (2010)

* SEM photographs clinker fracture surface (Campbell 1999)

fracture surface, hard to grind clinker

 mineralogical composition (Vol. %)

40 um

trans-

 pore space

 „mechanical“ strength of minerals

 geometry, spatial distribution

 spatial distribution

 open microcracks, grain boundaries

 grain size, grain shape

 porosity

 flaws in crystal lattice

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intergranular

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Clinker microstructure

Clinker microstructure alite

Lime Saturation Factor (LSF) The Lime Saturation Factor is a ratio of CaO to the other three main oxides. Applied to clinker, it is calculated as:

alite

belite

belite

 LSF=CaO/(2.8SiO2 + 1.2Al2O3 + 0.65Fe2O3)

200 um

100 um

 Often, this is referred to as a percentage and therefore multiplied by 100.

 Clinker exhibits a wide range of compositions, microstructures and physical properties

 The LSF controls the ratio of alite to belite in the clinker. A clinker with a higher LSF will have a higher proportion of alite to belite than will a clinker with a low LSF.

 C3S, C2S, C4AF, C3A contents  mechanical properties of individual clinker minerals

alite

 spatial distribution of minerals  grain size, grain shape  porosity  microcracks

belite

200 um

 Typical LSF values in modern clinkers are 0.92-0.98, or 92%-98%.

belite

200 um alite 22


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Clinker microstructure

Range of clinker grindabilities <== poor - grindability - good ==>

Silica Ratio (SR) The Silica Ratio (also known as the Silica Modulus) is defined as:  SR = SiO2/(Al2O3 + Fe2O3)  A high silica ratio means that more calcium silicates are present in the clinker and less aluminate and ferrite. SR is typically between 2.0 and 3.0.

5

15

25

35

45

power consumption - mill [kWh/t] 24


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Table of contents

Quantification of clinker grindability

Introduction

 Basically clinker grindability can be assessed by analysing the mineralogical composition and the clinker microstructure, however quantification bears many difficulties

Loesche vertical roller mill for cement grinding Some comments on grindability State-of-the-art cement grinding plant

 The following general relationships can be used to qualitatively determine the clinker grindability  C3S content high

good grindability

 C2S content high

poor grindability

 grain size of C3S, C2S high

poor grindability

 C2S clusters abundant

poor grindability

 abundance of intragranular microcracks

good grindability

Summary/Conclusions

Source: Hills, Linda M., Clinker Microstructure and Grindability: Updated Literature Review, SN2967, Portland Cement Association, Skokie, Illinois, USA, 2007, 15 pages. 26


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State-of-the-art cement grinding plant


Main aims

General concept Compact design

 Environmental impact

LDC classifier with „Vortex Rectifier“

 consumption of resources (e.g. energy, water)  emissions (e.g. CO2, NOx, dust)

 Operational costs

LM (2+2/3+3) with modified s-rollers

 consumption of water, grinding aid  fuel consumption (HGG)  specific electrical energy consumption

 Investment costs (CAPEX)  Flexibility of the grinding system  wide range of feed materials desired (blended cements)  wide range of product finenesses – high Blaine products

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Waste heat recovery system for slag grinding

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Loesche’s “green” cement grinding plant Compact plant design comparison view 1

Loesche’s “green” cement grinding plant Compact plant design comparison view 2

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Flexibility

Cement types produced in Loesche VRM´s  products according to EN 197-1 (2)

 the cements are produced at various fineness's  actual number of products much higher (products ground without Loesche having operational data) Source: A. Wolter (2010); TU Clausthal 32


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LM 56.3+3 grinding efficiency

S-roller position (1) Standard position of S-roller

Particle trajectories onto mill table are influenced by:  centrifugal force  friction between particle and mill table  friction between particle and particle  size and shape of particles 34


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S-roller position (2)

Low specific energy consumption due to S-roller position

Changed position of S-roller

Standard position of S-roller

Production values of LM 56.3+3 CS after installation of new S-rollers Increase of through-put

Reduction in energy consumption AV-Produkt Clinker 82% Gypsum Type I(natural) 4% Limestone 7% Fly ash 7%

CEM II/ A-L

Advantages  better guidance of de-aerated material to M-rollers  reduced level of mill vibration  reduced amount of water for grinding bed formation  increased through-put  reduced specific power consumption

5,84%

CEM II/ B-L

Increase of through-put

8,21%

-7,17% -11,12%

-25,00%

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-20,00%

-15,00%

Energy savings - total

-10,00%


-5,00%

0,00%

5,00%

10,00%

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© by LOESCHE


BLL-Produkt Clinker 65% Gypsum Type I(natural) 5% Limestone 25% Fly ash 5%

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Smooth operation and better material guideance

LM 56.3+3 with LDC classifier

Production values of LM 56.3+3 CS after installation of new S-rollers “Vortex Rectifier” Rotor

Grit cone

 low dp leading to a reduced specific energy consumption 44


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LDC classifier “Vortex Rectifier” (1)

LDC classifier “Vortex Rectifier” (2)

 worldwide patented “Vortex Rectifier”  vortex kinetic energy recuperation  restores a linear flow in the ductwork

Conventional design  high velocity differences

Pathlines colored by velocity magniture (m/s)

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Pathlines colored by velocity magniture (m/s)

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LDC (new design)  homogeneous velocity distribution

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Low specific energy consumption due to “Vortex Rectifier”

Features and achievements

Central Europe

LM 46.2+2

Product

GGBS

CEM I

CEM II/B-M

Mill through-put (t/h)

~ 120

~ 125

~ 155

Fineness (Blaine)

4100

4000

3400

fan (kWh/t)

4.0 - 4.8

4.5 - 5.5

3.8 - 4.3

total (kWh/t) (mill, fan, classifier)

26 – 27

25 - 26

20 - 21

LDC classifier with „Vortex Rectifier“

reduced CAPEX

~ 4-8% lower Espec LM (2+2/3+3) with modified s-rollers ~ 5-7% lower Espec

spec. energy consumption

reduced thermal energy consumption

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Waste heat recovery system for slag grinding

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© by LOESCHE


Compact design

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Table of contents

as “green” as cement grinding can be

Introduction

 Environmental impact

 consumption of resources (e.g. energy, water)  emissions (e.g. CO2, NOx)

 Operational costs

 consumption of water, grinding aid  fuel consumption (HGG)  specific electrical energy consumption

 Investment costs (CAPEX)


Yes

Some comments on grindability State-of-the-art cement grinding plant

Yes

Cement types produced in Loesche VRM´s Summary/Conclusions

Yes

 Flexibility of the grinding system

 wide range of feed materials desired (blended cements)  wide range of product finenesses – high Blaine products

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© by LOESCHE


Yes

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State-of-the-art cement grinding plant Water and energy – precious resources

 Water and energy are the basis for life and the world as we know it today


 water as well as energy are not available unlimited  both resources will become scarce and more expensive

 Consequently saving energy and water is essential for ecologically and economically viable production - also or in particular in the cement industry

Presented by Detlef Blümke PT Loesche Indonesia [email protected] www.loesche.com

 Preventive Maintenance and observation of operation behaviour is a must to keep grinding systems performing most efficient with the minimum waste of energy and resources

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Process, operation & evaluation of Loesche grinding systems by Christian-Martin Ruthenberg, Loesche GmbH, Germany

Process, operation & evaluation of LOESCHE grinding systems

© by LOESCHE

Ch.-M. Ruthenberg, Technical Trainer Corporate Service/Training Center Dept., LOESCHE GmbH Technical Seminar Jakarta 2015

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Agenda

Different LOESCHE mill types Range of application

Different LOESCHE mill types

LOESCHE VRMs are mainly used in:  Cement industry  Coal fired power plants  Iron making plants with blast furnace injection/ PCI (pulverised coal injection)  Minerals and ore industry

Processes inside a mill Different process circuits Control values

Raw material mill

Evaluation of performance

2

Technical Seminar Jakarta 2015 - Process, operation & evaluation_Rev.A

Coal/petcoke mill

Mineral mill

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Clinker & slag mill

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Mill structure: LM 56.4 RM with LSKS 88

Differences

56

Feed material  Moisture content  Grain size distribution  Flow characteristics  Grindability

.4

88

Illustration extract out of DWG 935021-00-3 LM 69.6 RM 4


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Agenda

Differences

Different LOESCHE mill types Processes inside a mill

Machine  Grinding force (according to grindability)  Table speed (centrifugal force)  Dam ring (grinding bed)  S-rollers (deaeration)  Louvre and armour ring (drying)

Different process circuits Control values Evaluation of performance

Illustration extract out of DWG 935021-00-3 LM 69.6 RM 6


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Processes inside a mill

Agenda

The LOESCHE VRM combines

Different LOESCHE mill types Processes inside a mill

Grinding

Different process circuits

 mill drive, gearbox, table and rollers  Hot gas source: HGG, cooler, gas pre-heater

Classifying


Transportation

Transportation  Gas flow introduced by fan

Control values

Classifying

Drying

Drying Grinding

 LDC / LSKS

in one machine. Clinker/slag mill 8


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Process circuits

Process circuits

Raw meal grinding plant

Coal grinding plant with external inert gas source

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Process circuits

Agenda

Clinker/slag grinding plant


Damper S (Stack)

Processes inside a mill Different process circuits

Damper R (Recirculation)

Control values Evaluation of performance

Damper Z1 (Fresh air)

Hot gas generator

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Mill inlet pressure

Mill differential pressure



Damper S (Stack)

Damper S (Stack)





Hot gas generator

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Hot gas generator

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Mill outlet temperature

Process gas flow



Damper S (Stack)

Damper S (Stack)





Hot gas generator

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Hot gas generator

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Control Values

Agenda Raw material

Coal

Clinker







Differential pressure





-

Outlet temperature







Gas flow







Inlet pressure

Processes inside a mill Different process circuits Control values Evaluation of performance

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Process evaluation Clinker/slag grinding plant

Damper S (Stack)

Improvements (according to requirements)


Audit Assessment Operation


Construction

Commissioning

Optimisation

Performance Run Hot gas generator

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Summary Different LOESCHE mill types 

Raw material, coal and clinker/slag mill

Processes inside a mill 

Grinding, drying, transport and classifying

Different process circuits 

Thank you for your attention

Raw material, coal and clinker/slag mill

Control values 

Inlet pressure, differential pressure, outlet temperature and gas volume

Evaluation of performance 

Operation, audits and required improvements



Essential knowledge of system, process and relations

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Preventive Maintenance - Wear and repair by Stefan Wölfel, Loesche GmbH, Germany

Preventive maintenance – Wear & repair

© by LOESCHE

Stefan Wölfel, Head of Installation Department Loesche GmbH Technical Seminar Jakarta 2015

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Agenda Main assembly groups This presentation

Overview Mill stand Table M-Rocker arm/M-Rocker arm bearing M-Roller/M-Roller bearing S-Roller Lever sealing Spring assembly Cabinets N2 accumulators Swinging out rollers Grinding parts Recording wear of grinding parts Hard facing of grinding parts Mill drive Classifier/Classifier drive Auxiliarie parts

 helps you in order to plan your maintenance and conduct preventive maintenance.  Therefore all companies have to find a way in coping with downtimes and scheduled maintenance intervalls.

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Wear and repair – Technical Seminar 2013 – Rev.1

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 gives you a guidance for problems encountered.

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Overview

Mill stand

Example of a LOESCHE Mill LM 3+3

Visual check:  condition of bolts of bearing caps  condition of weldings

Mill body incl. lining

 oil accumulations on concrete foundation

M-Roller M-Rocker arm

 condition of anchor bolts

Sealing air S-Spring assembly S-Rocker arm S-Roller Mill gearbox Mill drive

 condition of gearbox attachment bolts Interval: weekly

Table

 Variant 1 Superbolt system

M-Spring assembly Mill stand

Illustration

Illustration 4

Q………….. en Maintenance Rev.A

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 Variant 2 Hydraulic tension system

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Table

M-Rocker arm Visual check:  axial bearing screws  grease pipeline connections

Visual check condition of:  dam ring  louvre- and armour ring  clamping ring  scrapers

Maintenance:  change wear rings of sealing air assembly  check bearing clearance  change bearings

Maintenance:  repair by fill-up welding and hard-facing  replace worn parts

Interval:  visual check weekly Maintenance:  check bearings yearly  check sealing air gap in 6 month  shift interval according to the specific „wear behavior“ of the mill

Interval:  check wear monthly  shift interval according to the specific „wear behaviour“ of the mill

Illustration

Illustration 6


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M-Rocker arm bearing

M-Roller

Maintenance:  change bearings

Visual check:  attachment bolts of roller axle and tire  wear of guard  oil leakages

Interval:  change bearing after 30000 h  shift interval according to the specific ‚wear behavior‘ of the mill.

Maintenance:  change wear rings of sealing air assembly  change slip ring seal  change worn wear parts  clean air filter  take oil samples for analysis

Rebuilding of bearing seats is possible but not required, if bearings are replaced in good time

Interval:  visual check weekly Maintenance:  oil analysis every 3500 h  change slip ring seal after 15000 h  shift interval according to the specific „wear behavior“ of the mill Illustration 8


9

© by LOESCHE


Page 50

M-Roller bearing

S-Roller

Maintenance:  change bearings

Visual check:  attachment bolts of roller axle and tire  wear of guard  oil leakages

Interval:  change bearings after 30000 h  Shift interval according to the specific „wear behavior“ of the mill

Maintenance:  change wear rings of sealing air assembly  change slip ring seal  change worn wear parts  clean air filter  take oil samples for analysis Interval: visual check weekly Maintenance: oil analysis every 3500 h change slip ring seal after 15000 h shift interval according to the specific „wear behavior“ of the mill Illustration 10


11

© by LOESCHE


Page 51

Lever sealing

Spring assembly

Visual check:  attachment bolts of lever sealing parts  wear of lever sealing parts  proper adjustment of gaskets and bellows

Visual check:  attachment of clamping nuts  grease connections  condition of buffers  condition of hyd. connections  oil leakages  condition of bellows  condition of hyd. cylinders

M-Lever sealing

Maintenance:  change worn parts Interval:  visual check weekly Maintenance:  change worn parts according actual wear  shift interval according to the specific „wear behavior“ of the mill

Spring assembly S-Roller

Maintenance:  change stop-plates of buffers  change bellows  check bearing clearance  change gaskets of hyd. cylinders

Components of M-Lever sealing S-Lever sealing

Interval:  visual check weekly Maintenance:  shift interval according to the specific „wear behavior“ of the mill

Illustration

Illustration 12


13

© by LOESCHE


Spring assembly M-Roller

Page 52

Cabinets Visual check:  oil levels  oil flow (HSMS)  oil leakages on cabinets and pipelines  discoloration of oil

N2 accumulators HSMS

HSLM

Visual check:  corrosion, damages on accumulators  proper fixation of accumulators  proper attachment of valve protection caps  oil leakages Maintenance:  check nitrogen-pressure of all accumulators  check proper attachment of valves  change bladders, gaskets  pressure tests acc. pressure-vessel regulations

Maintenance:  change oil filters, air filters  change oil  clean tank  take oil samples for analysis Interval:  visual check daily Maintenance:  oil analysis every 3500 h  refer to lubrication instructions

HSSW

Filling valve

Piston accumulator

Interval:  visual check weekly

Typical pipe-connector

Maintenance:  check nitrogen pressure once a week, if no pressure loss, check every 4 months, if no pressure drop check yearly

N2 Oil Illustration

Illustration 14


15

© by LOESCHE


Bladder accumulator

Page 53

Swinging out rollers Visual check:  check completeness and function of all auxilliary parts  Swing-out cylinder to be stored vertically

Grinding parts Taper pin connection

Maintenance: (prior to use of auxiliary parts):  change oil  bleed off air of swing-out cylinder  clean tank

Visual check:  check wear of tires with tire profile ruler  check wear of grinding plate

Flanged sleeve

Swinging-out device

Maintenance:  change grinding parts  welding of worn out sections of tires, grinding plant and wear rings of dam ring Interval:  check wear monthly  shift interval according to the specific „wear behavior“ of the mill

Important: Proper dismounting and mounting of taper pinand flanged sleeve connection of rocker arm-fork connection

Level

Interval:  Visual check: Prior to using auxilliary parts

Support

Typical wear pattern

Tire profile ruler

approx. 10mm

Roller

Grinding plate

16


17

© by LOESCHE


Page 54

Wear on grit cone

Wear on grit cone supports

Every time you have the chance of looking into the mill internals, you should check all parts in regards to wear (especially for the classifier, louvre and amour ring, tires, and table liners).

Example to the right:  The grit cone supporting tubes show wear in the top part.  There are 8 supporting tubes. Only the four ones above the rollers show wear.

Example to the right:  Grit cone shows wear on two levels in front of each roller. Wear positions and shapes are similar.  The top level wear is in the axis of each roller.  The bottom level wear is about 50 cm ahead.  End user didn't allow SINOMA to patch the holes, as LOESCHE recommended.

18


19

© by LOESCHE


Page 55

Wear on rotor, guide vanes, and static guide vanes

20


21

© by LOESCHE


Wear on guide vanes

Page 56

Wear on guide vanes

22


23

© by LOESCHE


Wear on fixation pipes

Page 57

Wear on mill body armour plates

Wear on lever sealing

Examples to the right:  The vertical lever sealing plates show some wear.  Vertical plates in front of the rollers are worn on the upper part.  Vertical plates behind the rollers are worn in the lower part.  The horizontal plates above roller shaft show wear on the side in front of the roller.

Example to the right:  The mill body armour plates show wear on the welding openings, especially above 2m between the rollers.

24


25

© by LOESCHE


Page 58

Wear on louvre ring

Wear on roller

Example to the right:  Abnormal wear is observed at one position on roller 1.  During commissioning, the roller n°1 faced some problems to turn freely, then rotation was better after the first maintenance.  Leading the roller to slip on the grinding bed always in the same angular position: the most likely cause of local wear.  Other rollers and other parts of roller 1 show normal shaped wear.

Examples to the right:  Louvres in the area just behind the rollers show significant wear.  The wear is more distinct on the external side.  The wear in the remaining part of the louvre ring is low.

26


27

© by LOESCHE


Page 59

Recording wear of grinding parts Zero measurement / wear measurement

Hard-facing of grinding parts Hard-facing of tires in situ (On site)

Example of recording measurements (zero measurement or wear measurement) of tire:

Example of recording measurements (zero measurement or wear measurement) of grinding plate:

28


29

© by LOESCHE


Page 60

Hard-facing of grinding parts

Hard-facing of grinding parts

Hard-facing of tires in situ (On site)

Hard-facing of tires in situ (On site)

30


31

© by LOESCHE


Page 61

Mill drive Visual check:  abnormal noise during operation  oil levels  oil leakages Maintenance:  change, clean oil filters, air filters  change oil  take oil samples for analysis  check coupling alignment  check (change) compression parts of coupling

Classifier Typical gearbox

LSKS

Typical lubrication unit

Classifier housing

Maintenance:  replace worn parts  repair worn parts by fill-up welding

Typical arrangement

Typical coupling

Static flaps Classifier rotor

Interval: Visual check weekly

Classifier grid cone

Maintenance: Shift interval according to the specific „wear behaviour“ of the mill

Interval: Visual check daily Maintenance: oil analysis every 1000 h refer to lubrication instructions

Rotor blades Separation gap Top view

Condition of gearbox attachment bolts


33

© by LOESCHE

32

Flaps / guide vanes Illustration

Illustration Q………….. en Maintenance Rev.A

Classifier drive

Visual check:  check for proper attachment of bolts  check for wear

Page 62

Auxiliary parts

Classifier drive LSKS Visual check:  check for proper fixation of gearbox and motor  check oil level  check for oil leakages  check grease pipeline connections Maintenance:  change oil  take oil samples for analysis  check coupling alignment  check (change) compression parts of couplings

Main auxiliary parts:

Classifier drive

(see also Swinging out device)

Auxiliary parts for S-roller Eye bolt

Auxiliary parts for M-roller

Lifter

Bearing cartridge

Classifier Auxiliary parts for table

Hydraulic jack

Oil analysis every 3500 h Refer to lubrication instructions Cylinder Table support

Illustration 34


Illustration 35

© by LOESCHE


Page 63


36

© by LOESCHE


Page 64

More than just conventional Condition Monitoring by Dr. Franz Muschaweck& Sebastian Muschaweck, DALOG Diagnosesysteme GmbH

Technical Seminar Jakarta 2015 Jakarta, Indonesia, 21 – 23 April 2015

More than

just conventional Condition Monitoring

Dr. Franz Muschaweck Sebastian Muschaweck Certified ISO 9001: 2000 With product development

© by LOESCHE

© Confidential. DALOG reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on the third parties.

Page 65

DALOG® Diagnosesysteme GmbH

DALOG® Products and Services

Development of systems for Preventive Maintenance Unexpected machine failures should be reduced.

Founded: 1998 Since 2006 Representative Office Beijing, China Since 2012 Sales Office Coimbatore, India

Precision Maintenance Avoiding machine failures by knowing the machine dynamic and therefore working towards a smoother operation.


© by LOESCHE


Predictive Maintenance “Condition Based Monitoring” Knowing the health of your Machine at any time.

Page 66

DALOG® Products and Services

DALOG® Applications – World Wide

“Vibrations and high Dynamic is a symptom” the aim is to find the root cause for having a longer life cycle of the machines


© by LOESCHE


Page 67

DALOG® D-MPC® is applicable for:

DALOG® VRM Gearbox Facts!

FACTS!

High Dynamic Production

• Every 3rd VRM Gearbox > 2000 kW fails Stable Operation with • 60% of the gearboxes fail more than once • 90% of the machine owners are not aware of DALOG Machine Protection Concept the dynamic of the machine – nor that it can be improved (it‘s not healthy)


© by LOESCHE


Page 68

DALOG® VRM Chart

DALOG® Mill Protection Concept D-MPC®

High Dynamic Production

Failure prevention!

Stable Operation with

DALOG® Mill Protection Concept


9

© by LOESCHE


Failure prediction!

Page 69

DALOG® Condition Monitoring… „Dalog has saved another gearbox in one sold-out market“ Feedback from our Client

DALOG® Planetary bearing fault   

Acceleration Sensor

What exactly is condition monitoring?

Planetary bearing fault detected Nov. 2011

Bearing fault detected in November Fault progressing monitored, spare parts and repair planed Repair was done during annual shut down in march

No loss time and expensive secondary damage

Planetary bearing fault repaired March 2012

Online Alarm sent to Operator Alarm level

Early Gearbox failure detection of gears and bearings Planned Maintenance or repair works Know the status of your machine at any time Avoid expensive secondary damages


© by LOESCHE


Page 70

DALOG® Single tooth crack    

Single crack on tooth detected Severe secondary damage avoided Temporary repair and further operation Gears will be replaced in upcoming annual shutdown

DALOG® Torque Monitoring… „Do you know how your VRM is performing?“ Single developing tooth crack

Strain Gage

What exactly is torque monitoring?

Antenna Ring

Early Gearbox failure detection – direct measurement

Antenna Head

High Sensitivity of disturbed/ unstable Process operations – instant alarming Detecting of Motor driving faults


Detecting of wear and grinding rollers / table faults

© by LOESCHE


Page 71

DALOG® Torque Monitoring… Torque Alarms... „High frequency torque measurment captures the dynamic proportion of the system unlike the motor power signal“

...online torque alarms – informing the operator in real time about critical machine operation

DALOG® Case Study VRM - DALOG  Torque Sensor – High Dynamic Indicating Table Liner Fault Severe overload of gearbox!

Warning and Alarming via Torque Sensor

Torque Torque Torque Torque Torque

1 2 3 4 5

Periodically shocks each of them introduced every time the rollers are passing the cracked table liner


© by LOESCHE


Alarm Alarm Alarm Alarm Alarm

Page 72

DALOG® Case Study VRM - DALOG Grinding Table Example - Benefits

DALOG® Process Monitoring… „Vibrations and High Dynamic are symptoms – find the root cause!“ Torque Signal

Early detection of the problem results in:

-

Reducing the load of the Gearbox due to early rectification of the problem.

-

Increasing the lifecycle of the Gearbox.

What exactly is process monitoring? Root Cause Analysis Correlation of high resolution data of torque and process signals during high dynamic situations.

Mill Operation Parameters

Longer lifecycle of machine Detecting of Process and operational irregularities


© by LOESCHE


Page 73

DALOG® Case Study VRM  Basic data – Mill type – Mill size – Installed motor power – Nom. torque

DALOG® Case Study Process Monitoring  Torque Signal before DALOG Monitoring

Raw mill 220 t/h 1600 kW 14 kNm

 Problem description – During DALOG commissioning it got observed that the mill is showing repetitive vibration patterns during operation. – Therefore unsettled operation combined with many Tdyn (Torque dynamic) and Timpact (Torque impact) alarms

unstable operations

– Higher vibration and reduced production rate

stable operations

 Torque Signal after Mill optimization 18


© by LOESCHE


Page 74

DALOG® Case Study VRM - DALOG

DALOG® Reporting... „Profit from our Experience and Knowledge!“

 Analysis Torque vs. Mill Operation Parameters in High Resolution

Mill Feed

Reporting

Torque

Independent and Objective

Mill DP

Complete Report about the condition of the machine.

Hydraulic Press.

„Findings“ „Conclusions“ „Recommendations“

Motor Power

Trends, Analyse

Mill Vibration.

Statistics: Process stability Long term process trends


© by LOESCHE


Page 75

DALOG® Monitoring

DALOG Implementation into the CCR

DALOG Implementation into the CCR © Confidential. DALOG reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on the third parties.

© by LOESCHE


DALOG® Monitoring

Page 76

DALOG® What’s so special about us?

DALOG® in Cement Plants Our Customers:

We have more than 200 condition monitoring systems for Vertical Roller Mills installed worldwide…


© by LOESCHE


Page 77

DALOG® Quietly Running Machine

Thank You! DALOG® Diagnosesysteme GmbH Mühlbachstraße 21 86356 Neusäß / Germany Phone: +49 (0) 821 74 777 10 Fax: +49 (0) 821 74 777 19 E-Mail: [email protected] www.dalog.net © Confidential. DALOG reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on the third parties.

© by LOESCHE


Page 78

Process parameters and plant optimization by Christian-Martin Ruthenberg, Loesche GmbH, Germany

Process parameters and plant optimization

© by LOESCHE

Ch.-M. Ruthenberg, Technical Trainer Corporate Service/Training Center, Loesche GmbH Technical Seminar Jakarta 2015

Page 79

Agenda


Processes inside a mill Process Parameters Dependencies Examples

Transportation

Classifying

Drying

Grinding

Summary

Clinker/ slag mill 2

Technical Seminar Jakarta 2015 - Process parameter_Rev.A

3

© by LOESCHE


Page 80


Processes inside a mill Flow

Transportation Flow

Drying Temperature

Classifying Speed

Pressure

Constantly controlled & stable

Grinding Pressure

Consistent product

Temperature

Speed

4


5

© by LOESCHE


Page 81

Agenda

Process Parameters


Pressure

 Mill inlet vs. Outlet (dp mill)  Filter inlet vs. Outlet (dp filter)  Working and counter pressure (grinding force)  Compressed air

Process Parameters Dependencies Examples Summary

Flow

 Material  Reject  Gas  Water  (Fuel)  Product

6


 Mill outlet gas  Material  Water  Product

7

© by LOESCHE


Temperature

Page 82

Process Parameters

Agenda

Speed and position


 Roller  Classifier  Damper  Hopper filling

Process Parameters Dependencies Examples Summary

Drives

 Mill main  Classifier  Mill main fan

8


9

© by LOESCHE


Page 83

Dependencies

Agenda Processes inside a mill Process Parameters

Temperature

Dependencies Examples Summary

Pressure

Speed

Flow

10


11

© by LOESCHE


Page 84

Examples – Filter differential pressure

12


13

© by LOESCHE


Examples – Feed material change

Page 85

Examples – Hopper segregation

Examples – scrapper wear

Minimum value

Max value

Limestone hopper level

6.85 m

10.23 m

Raw mill body vibration

7.81 mm/s

14.24 mm/s

Raw mill motor power

4536 kW

5490 kW 14


15

© by LOESCHE


Page 86

Examples – lovre ring covers

Examples – rotary valve

Finding: 3,38 m² -> 88 m/s Design: 4,79 m² -> 61,5 m/s

16


17

© by LOESCHE


Page 87


Agenda Processes inside a mill

Damper S (Stack)

Process Parameters Dependencies


Examples Summary


Hot gas generator

18


19

© by LOESCHE


Page 88

Summary Processes inside a mill  transport, grinding, drying and classifying

Process parameters  flow, pressure, temperature and speed


Dependencies 

flow, pressure, temperature and speed

Examples 

high complexity of possible measures

20


21

© by LOESCHE


Page 89

Grinding aid: Advantages and operation optimization by Dr. Pietro Recchi, MAPEI

Loesche Indonesia | VRM Seminar | 22-23 April, 2015

Cement Grinding Additives for Vertical Mills Product characteristics & Industrial case studies

© by LOESCHE

Dr. Pietro Recchi | Regional Technical Manager Asia-Pacific

Page 90

Vertical Roller Mills (VRMs) for cement production

VRM for cement production - advantages

“Thanks to the necessity of continuous improvements in the cement grinding process and related cost reduction, Vertical Mills have been introduced to the cement industry. Although at first this technology was mainly used for grinding solid combustibles and kiln-feeding raw materials, recent technical improvements allowed vertical mills to become a competitive solution for finished cement grinding as well.

The key advantages of vertical mills with respect to ball mills can be summed up in the following points:

Most probably, the market share of vertical mills will grow even further, probably becoming the main cement grinding system in new plants.” The above statement was Mapei’s Cement Additives Division’s vision in 2010.

 Significantly lower specific energy consumption (kWh/t) (*).  One single machine for drying, grinding and separating.  Compact and “on-site” assembling, thus avoiding logistical problems and related costs.  Great versatility, quick shift from one cement type to the other.  Lower sensitivity for moisture in the raw materials (if sufficient drying energy is available).  Low noise levels, no housing is theoretically required.

© by LOESCHE

(*) for cement grinding, reductions by 30-40% can well be expected.

Page 91

VRM for cement production – disadvantages over BM Known disadvantages of vertical mills over ball mills are:  Particularly high SSA values are usually more challenging to achieve (*).  Higher sensitivity for fine materials (the threshold is normally set around a maximum of 50% of material < 4 mm).  Large amounts of water may have to be added to the grinding process in order to maintain low levels of vibration (**). An external heat source may be needed to order to ensure a proper gypsum de-hydration (particularly with ‘cold’ clinker).  Higher initial investment costs. (*) The achievable SSA ultimately depend upon a series of factors, among which the clinker mineralogy and microscopic structure is probably the most important one. (**) This is particularly true in case of particularly dusty/fine or over-burnt clinker.

Vertical mills and ‘traditional’ grinding aids What happens when a ‘traditional’ GA is used in a cement vertical mill? Practical field experience has highlighted the fact that ‘traditional’ grinding additives (GA) are much less efficient in vertical mills when compared with their utilization in ball mills. This loss of performance is caused by the different ventilation conditions inside the VM, which lead to the following problems:  “Stripping” (*) of the GA  Evaporation of the GA

GA PERFORMANCE LOSS!

The two above mentioned issues are caused by the huge airflow and the high temperature.

© by LOESCHE

(*) Stripping is a physical process where one (or more) components from a liquid stream are removed by a vapour or vapour-like gaseous stream.

Page 92

VRM and grinding aids: an impossible marriage?

New formulations: Mapei ‘VM’ grinding aids

Fortunately not!

As vertical mills are used more and more often in cement plants, Mapei’s R&D developed specific grinding aids designed for this particular application. These products contain a blend of special high-boiling and low-volatility compounds that ensure their effectiveness by protecting traditional components (glycols, amines) from being influenced negatively by the harsh conditions inside vertical mills.

A ‘synergic approach’ has been proven able to overcome the “stripping” and “evaporation” of the GAs inside vertical mills:  New GA formulations, specifically designed for applications in vertical mills

This new product line consists of the following product types:  Innovative dosing point of GA

© by LOESCHE

 Grinding Aids (MA.G.A./VM)  Performance Enhancers (MA.P.E./VM)  Workability Improvers (MA.P.E./VM W)

Page 93

Mapei ‘VM’ grinding aids: an overview

Typical Dosage Mill Output Strengths

MA.G.A./VM

MA.P.E./VM

MA.P.E./VM W

200 – 500 g/t

700 – 1,500 g/t

700 – 1,500 g/t

•••

••

•

••

•••

••

•

•••

••

•••

•

All cement types

Blended cements

Blended cements

Workability CO2 reduction

The grinding aid dosing point plays a crucial role in vertical mills. Therefore Mapei has developed an innovative dosing system that maximises the effect of the GA, avoiding both stripping and evaporation. Usually, vertical mills are equipped with a water introduction system for the stabilisation of the grinding bed: by using the existing pipelines, we can make sure that the grinding aid is ‘forced’ directly on the track and immediately comes in contact with the surface of the material to be ground.

© by LOESCHE

Typical application

New dosing technology: direct introduction

Page 94

New dosing technology: direct introduction Fresh feed conveyor (traditional dosing point)

New dosing technology: example of actual installation (1)

Finished product

Grinding Aid tank

Additive dosing pump

Water Pump Water tank

© by LOESCHE

Vertical Mill

Page 95

New dosing technology: example of actual installation (2)

Cement Grinding Aids: Mechanism of action (process)

© by LOESCHE

Once properly dosed on the grinding table, the GA is able to swiftly execute its primary task: to neutralize and disperse the electrostatic charges which form on the surface of ground material:

Page 96

Cement Grinding Aids: Mechanism of action (process) Neutralization of the electrostatic charges results in a significant de-agglomeration of the ground cement particles; the immediate result is a neat improvement of the classification process by means of the separator. As a consequence, a decrease of the mill Δp (differential pressure) takes places shortly (within 5-15 min.) after the introduction of grinding aids to the VRM, and is a clear indication that the product is working correctly. Depending on the plant requirements, this decrease of the VRM circulating load can be subsequently used to:

Cement Grinding Aids: Mechanism of action (process) An example of the enhanced separator performance is shown below (Tromp curve):

By pass

Blank

MA.G.A./VM 10

15%

9%

Imperfection

0,26

0,16

Acuity limit

18 µm

21 µm

© by LOESCHE

A) Increase the fresh feed B) Increase the separator speed C) A combination of the above

Page 97

Cement Grinding Aids: Mechanism of action (process) The resulting positive impact on the cement’s PSD is shown below:

Cement Grinding Aids: Mechanism of action (strengths) On top of the de-agglomerating effect, certain specific GAs (strength enhancers) also chemically promote the cement hydration process, mainly influencing the “first gel” phase formation (i.e. aluminate – based). Time

(min)

0

10

The effect is particularly evident in the 4-30 µm range

100

1000

C-S-H

Strengths enhancing GA

DRY CEMENT POWDER

FIRST GEL

“INTERMEDIATE PHASE”

SECOND GEL

© by LOESCHE

+ H2O

Page 98

Pre-hydration of cement in VRM In some particular cases (e.g. when the clinker is particularly ‘dusty’), the plant may be forced to inject higher amounts of water to stabilize the grinding bed.

Pre-hydration of cement in VRM A more sophisticated methodology to assess cement pre-hydration is TGA analysis.

While amounts of injected water < 1.5 – 2.0% (with respect to the VRM output) are considered to be ‘safe’, higher amounts may trigger cement pre-hydration inside the VRM.

A sample of cement is heated from room temperature up to 1000°C and the decreases of weight (due to release of water or CO2) are measured. It is then possible to quantify the amount of gypsum, calcium hydroxide, limestone, hydrated phases, etc.

A quick and convenient method for assessing pre-hydration is the “corrected loss-onignition” (Wk) determination:

Hydration of tricalcium silicate produces a family of different compounds usually described as C-S-H (calcium silicate hydates).

Wk = [LOI at 450° C] – [LOI at 120° C]

Water bound in such structures is usually lost over a wide range of temperatures, due to the extreme variety of compositions of the C-S-H. Generally speaking, we can associate the weight decrease between 200 and 400°C to the water lost from C-S-H.

© by LOESCHE

As a rule of thumb, Wk in excess of 0.3% indicates a pre-hydrated cement sample, for which substantial strengths losses at all ages are very likely to occur.

Page 99

Pre-hydration of cement in VRM The following is a typical TGA graph of a moderately pre-hydrated cement sample:

Pre-hydration of cement in VRM (solution) Compared to water, cement grinding aids have proven themselves to be more effective in stabilizing the grinding bed and reducing the VRM vibrations. Introduction of GAs usually permits a significant reduction of the % of injected water, thus minimizing the risks associated with cement pre-hydration. % of injected water

100-200°C

200-400°C

450-550°C

>600°C

No additive

5.4

0.32%

0.19%

0.29%

1.35%

With MA.G.A./VM

1.7

0.26%

0.06%

0.27%

1.75%

© by LOESCHE

Weight decreases at different temperatures evaluated using TGA

Page 100

Key industrial case study (featured in ZKG; issue 3/2010)

In order to verify the effectiveness of Mapei’s grinding aids for vertical mills in comparison with traditional ones, our Technical Assistance Group performed a series of industrial evaluations: 1. 2. 3. 4.

“Blank” – without any additive “Test A” – traditional GA dosed on the fresh feed conveyor “Test B” – traditional GA dosed on the grinding plate “Test C” – MA.G.A./VM 12 dosed on the grinding plate

Key industrial case study (featured in ZKG; issue 3/2010) These tests have been performed during the production of a CEM I type cement (according UNI EN 197-1). VRM characteristics: - Supplier/Model: confidential - Absorbed power: 3.500 kW; - Ventilation: 680.000 m3/h - ∆p 50 mbar; - Water injection: 2,1% (referred to the initial fresh feed) - Roller pressure: 75 bar.

© by LOESCHE

During the tests the following parameters were kept constant: - GA dosage: 250 g/t (referred to the fresh feed in t/h) during test A, B and C; - Avg. vibration: between 2 and 4 mm/sec; - Blaine: ≈ 3.500 cm2/g

Page 101

Key industrial case study (featured in ZKG; issue 3/2010) Effect on the VRM’s hourly output (tph):

180 160

Mill Output (t/h)

140 120 100 80 60

Accordingly, a notable reduction of the specific energy consumption (kWh/t) was observed: 190

173

175

B A

200

40,0

C

35,0 Power Consumption (kWh/t)

200

Key industrial case study (featured in ZKG; issue 3/2010)

30,0

A

29,5

BB

C

28,1

C

20,0 15,0 10,0

A

5,0 0,0

© by LOESCHE

0

30,1

25,0

40 20

32,0

Page 102

Key industrial case study (featured in ZKG; issue 3/2010) On top of the higher output, the cement fineness was improved, too:

Key industrial case study (featured in ZKG; issue 3/2010) The cement’s compressive strengths were enhanced at all ages (2days depicted):

10,0

30,0

9,0

7,0

8,0

7,9

7,8

A

B

25,0 6,4

6,0 5,0 4,0 3,0

C

2-days Strenghts (MPa)

Residuals at 45 μm (%)

8,0

20,0

25,4

25,6

A

26,6

B

28,0

C

15,0 10,0

2,0 1,0

5,0

0,0

© by LOESCHE

0,0

Page 103

Key industrial case study (featured in ZKG; issue 3/2010) The cement’s compressive strengths were enhanced at all ages (7 days depicted):

Key industrial case study (featured in ZKG; issue 3/2010) The cement’s compressive strengths were enhanced at all ages (28 days depicted): 55,0

45,0 37,0

38,1

30,0 25,0 20,0 15,0 10,0

A

B

C

50,0 45,0 40,0

46,1

46,3 A

47,6 B

50,7 C

35,0 30,0 25,0 20,0 15,0 10,0

5,0

5,0

0,0

0,0

© by LOESCHE


35,0

39,1


40,0

38,7

Page 104

Key industrial case study (featured in ZKG; issue 3/2010) Conclusions:  The reference product dosed at a traditional dosing point shows little or no effects on the production process and cement quality.  When the same reference product is sprayed directly on the grinding track, certain improvements can be seen, demonstrating the validity of the dosing methodology proposed by Mapei.

Case study #2: Grinding station in Central America Mill supplier/model: confidential Starting conditions:  Low mill output with respect to nominal capacity (55 t/h vs. 80+ t/h)  Low compressive strengths (≈ 20% lower than target)  Extremely high amount of injected water (up to 7-8%)  Unsuitable granulometry of the clinker (“powderous” clinker)  A basic grinding aid from a local supplier was dosed in the traditional way (conveyor belt)

© by LOESCHE

 MA.G.A./VM 12 clearly stands out by showing strong improvements in terms of production and cement quality; the specific formulation is clearly suitable for this application.

Page 105

Case study #2: Grinding station in Central America

Case study #2: Grinding station in Central America

Customer requests:

Results of the preliminary industrial trial:

 Increase the compressive strengths (especially early ones) by at least 15%  Increase the mill output to at least 70 t/h

   

Proposed technical approach:  Modification of dosing point (direct injection together with water flow)  Industrial trial with MA.G.A./VM 05 dosed @ 500 g/t (0,05%) Our achievements:

Additive:

Dosage:

Dosing system:

Injected water (%):

Mill output (t/h):

24h – strengths (MPa):

48h – strengths (MPa):

Reference

0,07%

traditional

7.1

55-56

9.1

19.7

MA.G.A./VM 05

0,05%

MAPEI direct

3.7

75-77

11.0

21.9

© by LOESCHE

 Reduction of water %  Improvement of compressive strengths  Increase of the mill output

Output was increased by >35% Early strengths were increased by 20% (1 day) and 10% (2 days) Water injection was reduced by ≈ 50% Grinding aid dosage was reduced by ≈ 30% with respect to reference

Page 106

Case study #3: Integrated plant in Eastern Europe (2012)


Mill supplier/model: confidential

Customer requests:

Starting conditions:

 Increase the cement fineness, keep vibrations as low as possible

 The plant is producing a CEM I 42,5 R cement blend (Blaine ≈ 3700 cm2/g)  Mill output is close to nominal capacity (≈ 120 t/h)  The plant wants to produce a CEM I 52,5 R (Blaine > 4100 cm2/g)

Proposed technical approach:

Our achievement:  Facilitate the transition from CEM I 42.5 R to CEM I 52.5 R

© by LOESCHE

 Separator is already close to limit (99% of maximum rpm)  Roller pressure may not be increased due to high vibration level (4-5 mm/s)  Extremely high amount of water (up to 7%) is injected  No grinding aid is used

 Industrial trial with MA.G.A./VM 01, dosed @ 300 g/t (0,03%) together with the water flow directly below the rollers

Page 107


Case study #4: Integrated plant in North Africa (2012)



 Fineness was increased up to 4.200+ cm2/g with no loss of output  Average vibrations were decreased  Amount of injected water was reduced by 40%


Dosage:

Dosing system:

Injected water (%):

Mill output (t/h):

Maximum fineness (cm2/g):

Average vibrations (mm/s):

No additive

-

-

7.0

120 – 122

3910

3.6 – 4.8

MA.G.A./VM 01

0,03%

MAPEI direct

4.4

120 - 122

4213

2.1 – 3.2

The plant is producing an OPC-type cement blend (Blaine ≈ 2900 cm2/g) Normal mill output is 280 – 290 t/h (well below the nominal output) No grinding aid is normally used Another supplier made an industrial trial one week before Mapei

© by LOESCHE

Additive:

   

Page 108



Customer requests:


 Increase the hourly output as much as possible, without decreasing the cement’s fineness

 Hourly output was increased by 16% with respect to the ‘blank’  (Hourly output was increased by 11% with respect to the reference product)  Fineness of the finished product was not affected

Proposed technical approach:  Industrial trial with MA.G.A./VM 02, dosed @ 350 g/t (0,035 %) together with the water flow directly below the rollers Our achievement:

Dosage:

Dosing system:

Injected water (%):

Mill output (t/h):

Average fineness (cm2/g):

No additive

-

-

1.1

280 – 284

2900

Reference

0,04%

traditional

1.0

296 – 298

2912

MA.G.A./VM 02

0,035%

MAPEI direct

1.0

328 - 330

2919

© by LOESCHE

 Significantly increase the VRM’s hourly output

Additive:

Page 109

Case study #5: Integrated plant in SE Asia (2013-2015)



Customer requests:


 Increase the average 2 days strengths from 17-19 MPa to >24 MPa.  Improve the workability of their OPC

 The plant is producing OPC cement with their twin VRMs  Average early compressive strengths are well below the market standard  Workability issues are reported by several customers  High amounts of injected water (> 5%) are negatively affecting the cement’s quality  No grinding aid is used

Proposed technical approach:  After several lab and industrial trials, we developed and proposed the product MA.P.E./VM 1001 W, to be dosed at 1.200 g/t according to our direct introduction methodology. Our achievement:

© by LOESCHE

 Strongly increase the 2 days compressive strengths  Solve the workability issues

Page 110


Case study #6: Integrated plant in SE Asia (2014) Mill supplier/model: confidential

Results after 14 months of regular utilization:  The average 2-days strengths were increased from 17-19 MPa to 23-26 MPa.  The plant is now injecting only 0.5% of water (sometimes none at all). Dosage:

Dosing system:

Injected water (%):

Mill output (t/h):

Average «corrected LOI»

Average 2 days compressive strengths:

No additive

-

-

> 5.0%

140-150

> 0.4%

17-19 MPa

MA.P.E./VM 1001 W

0,12%

MAPEI direct

max 0.5%

150+

< 0.2%

24-26 MPa

 The plant is producing PCC (limestone based) with their recently installed (2013) VRM    

Frequent VRM stops due to high average vibration level VRM output much lower than nominal one (100 – 110 tph vs. 125 tph) ‘Low’ outlet temperature due to high % of injected water (5.1 m3/h) The plant was testing a ‘traditional’ GA dosed on the fresh feed’s conveyor belt

© by LOESCHE

Additive:


Page 111

Case study #6: Integrated plant in SE Asia (2014)

Case study #5: Integrated plant in SE Asia (2014)

Customer requests:


 Increase the VRM output without compromising the PCC quality  Increase the outlet temperature to 110° C  Reduce the average vibration level and improve process stability

 The VRM output was increased by 8% with respect to the reference GA  Injected water was reduced by 45%  Accordingly, outlet temperature increased to 109° C

Proposed technical approach:

Additive:

Dosage:

Dosing system:

Injected water (m3/h):

Mill output (t/h):

R45 residue (%):

VRM outlet temperature (C°):

Reference

0.045%

traditional

5.1

110

10.8

101 - 102

MA.G.A./VM 108

0.04%

MAPEI direct

2.9

119

9.3

109

 Industrial evaluation of MA.G.A./VM 108 dosed at 400 g/t directly on top of the grinding table together with the water flow. Our achievements:

© by LOESCHE

 Increase the VRM output while keeping the same fineness  Reduce the % of injected water  Improve the overall stability of the grinding process

Page 112

Conclusions:

Thanks for your attention ;)

Cement grinding aids can (and should) be successfully used for the production of cement with VRMs, provided the correct dosing technology and specifically designed products are used. By doing so, the performances of GAs in terms of: i. ii. iii. iv. ...

Output and/or fineness increase Process stabilization Compressive strengths increase Workability improvement

© by LOESCHE

Are definitely comparable (and often superior) to the ones usually obtained on traditional grinding systems (ball mills).

Page 113

Lubricants - Functions and the importance of maintenance by Moch Mustofa, PT. Mitra Asmoco Utama

© by LOESCHE

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PT Mitra Asmoco Utama

PT Mitra Asmoco Utama • Established in 1992. • PT. Mitra Asmoco Utama is the sole Authorized Distributor of Mobil™ in Jakarta, West Java and Banten.

• Winner of Circle of Excellent Award from ExxonMobil in 2007, 2010, 2012 and 2013. • Highly experienced and competent in the lubricant and distribution field.

3

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PT Mitra Asmoco Utama

MAU Facilities

Warehouse:

Location : KBN Marunda, North Jakarta Size : 7,740m2 Capacity : 20 KB Location : Cikarang, West Java Size : 2,020m2 Capacity : 2 KB

5

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Page 116

Our Vision

Field Engineering Service Our team of Lube Engineers is ready to support our customer with their expertise :

To provide our customers With Quality Products, Quality Solutions and Ensure customer satisfaction.

• Lube training for customer • Engine inspection • Troubleshooting when emergency happened

7

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Page 117

Customers PT Mitra Asmoco Utama have been serving the packaging industry with Mobil products and technical expertise:

How Lubrication affects Machine Reliability & Productivity?

9

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Page 118

Lubricant and lubrication system overview

Proper Lubricant Selection What we should know ? • Lubricant Introduction :

– Basic lubricant production – Functions of lubricant – Lubrication regimes • Key Lubricant Parameters selections : – Viscosity – Lubricant types – Lubricant application

The most important to attention are : 1. Proper lubricant selection 2. OEM‟s (Original Equipment Manufacture) Recommendations 3. How to keep both oil & equipment performances

11

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Page 119

Lubricant Introduction

BASE OIL

LUBRICANT INTRODUCTION

ADDITIVE

- Mineral - Synthetic

13

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Mineral Oil Production 1.

Synthetic Oil Production

2.

1.

2.

3.

3.

4.

4.

15

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Base Stock Comparison Group I

Group III Mixture of variable length (C20-C40) and decreased number of saturated ring hydrocarbons (R).

R

Group II

A

H

Mixture of variable length (C20-C60) hydrocarbons with saturated ring (R), aromatic ring (A), and/or hetero atomic molecules (H) attached.

A H

Why Synthetic Are The Best ?

R H

A

R

R

Mixture of variable length (C20-C50) and saturated ring hydrocarbons (R).

R R

R

R

Group IV

R R

Group V A chemical reaction that makes organic esters and polyglycols. No wax molecules, no long- or short-chain hydrocarbons.

Polyalphaolefin (PAO) – mixture of oligomers from dimers to about 10-mers (~C20-C100)

Alcohol

+

R - OH

+n

Alkylene oxides

Polyalkylene oxide

O H-C-C-H H R1

H H R-O- C-C-O-H H R1 n

 Lower traction coefficient and less friction under heavy load  Lower operating temperature and oxidation with longer oil life 17

© by LOESCHE

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Characteristics Base Stock Comparison

Function of lubricant

19

© by LOESCHE

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Lubrication Regimes (stribeck curve)

KEY PARAMETERS LUBRICANT SELECTION

21

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Page 124

Viscosity Grade Chart

Viscosity Illustration : Proper Viscosity is a Function of Speed, Load and Temperature Viscosity :

High

High

High

Viscosity :

Low

Low

Low 23

© by LOESCHE

22

Page 125

Factors affect the viscosity

Variation of lubricant viscosity as a function of temperature and pressure mineral oil

Temperature A fluid's viscosity strongly depends on its temperature. Along with the shear rate, temperature really is the dominating influence. Pressure In most cases, a fluid's viscosity increases with increasing pressure. Compared to the temperature influence, liquids are influenced very little by the applied pressure

Reference :Thomas G. Mezger, 'The Rheology Handbook', 3rd revised Edition, (C) 2011 Vincentz Network, Hanover, Germany

25

© by LOESCHE

24

Pressure influence on viscosity: approx. +30 MPa in pressure => +10 % in viscosity

Page 126

Lubricant Types

Lubricant Application

Oils – Mineral Oil – Synthetic Oil • Greases – Soap (Calcium, Sodium, Barium, Aluminum, Lithium ) – Non soap (Urea, Clay, Polymers) • Dry/Solid Lubricants – Graphite – Molybdenum disulphide – PTFE and other similar polymers • Gases (usually used in gas bearing) – Air – Any gases which will not attack or decompose •

Note : „o‟ signify the additive is not in all formulations but is optional for specific applications. Reference: Machinery lubricant bulletin

27

© by LOESCHE

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Page 127

Industrial Hydraulic Oil Standards DIN 51524 H

ISO 6743 HH

HL (Part 1)

HL

HLP (Part 2)

HM

HVLP (Part 3) HV

Composition

Industrial Gear Oil Standards AGMA 9005

Field Application

Inhibitor (R&O)

Base Oil

System with no special requirements Base Oil,R&O, System with moderate VI=100 pressure Base Oil, R&O, Anti System with high pressure Wear, VI=100 and temperature Base Oil, R&O, Anti Wider temperature range than Wear, VI>140 HLP with HVI

DIN 51517 ISO 12925-1

Composition

C (Part 1)

Base Oil

CL (Part 2) CKB

Base Oil, R&O

CLP (Part Antiwear (EP) 3)

CKC

Compounded CGLP

CKD (CKC Plus) CKE (CKB Plus) CKS CKT

PAO, Ester, PAG+RO PAO, Ester, PAG+RO+EP

high load and temperature More sliding, wormgear Under extreme temp, ligt to moderate load Under very extreme temp, heavy load 29

© by LOESCHE

28

Base Oil, R&O, Anti Wear, EP Excellent oxidation/thermal stability Excellent friction modifier

Field Application For constant circulation and immersion lubrication For constant circulation and immersion lubrication Enclosed gear, for constant circulation and immersion lubrication, high load

Page 128

ASTM test method and the recommended value. The reader should refer to these methods for details of

A listing of recommended properties of new oil is shown in Table 1. Included with this listing are the the tests. The oil and is an Grade 32 (ISO VG 32) ASTM test method theInternational recommendedStandards value. TheOrganization reader should Viscosity refer to these methods for details of oil. The properties typical Standards of turbineOrganization lubricating oils exceptGrade for the the tests. Thelisted oil isare anrather International Viscosity 32oxidation (ISO VG test 32) requirements. oil. The properties listed are rather typical of turbine lubricating oils except for the oxidation test requirements.

Note that the values in Table 1 are only recommended values. Oil that has been shown to perform

successfully in the field may 1still usedrecommended even if all values Table havebeen not shown been satisfied. Note that the values in Table arebeonly values.in Oil that1has to perform successfully in the field may still be used even if all values in Table 1 have not been satisfied.

For several years there have been investigations to decide on appropriate (New Fluid) laboratory tests,

For several years there havebetween been investigations to give decidesatisfactory on appropriate (New Fluid) tests,and those long-term servicelaboratory in a turbine, which could distinguish fluids, which long-term between service in laboratory a turbine, and those and field which between which givecomplete satisfactory whichcould did distinguish not. To date, therefluids, has not been correlation testing which did not. To date, there has not been complete correlation between laboratory testing and field experience. experience.

OEM’s Recommendations

Lubricant characteristics required Table 1. Recommended Properties of High Temperature Lubricating Oil for Gas Turbines

Table 1. Recommended Properties of High Temperature Lubricating Oil for Gas Turbines (for New (for New Oil) Oil)

ASTM Test Method ASTM Test Method No.No.

• Most

of OEM’s Recommendations includes :

Current Current Recommended Recommended Value Value

Test Test

D287 D287

Gravity ( API) Gravity (o API)

29-39 29-39

D1500 D1500

ColorColor

2.0 (max.) 2.0 (max.)

o

– Lubricant characteristics required

D97 D97

PourPour PointPoint (oF/oC) (oF/oC)

+10/-12+10/-12 (max.) (max.)

D445

– Lubricant brands recommended

D974

Viscosity Viscosity 40oC (centistokes) 40oTotal C (centistokes) (TAN) Acid (TAN) Total Acid Number Number Rust prevention — A

0.20 (max.)

D445 D974

D665

– Lubricant operating conditions

D665

D93

– Lubricant service life recommended

D93

D130

D130

D892

D892 D943

D943

28.8-35.2

0.20 (max.)

Pass

Rust prevention — A

Pass

Flash point (COC) C) (oF/oFlash point (COC)

420/215 (min.)

Copper corrosion

1B (max.)

o

o

( F/ C)

Copper corrosion

Foam

Foam Turbine oil oxidation test (hrs)

420/215 (min.)

5,000 (min.)

5

5

31

© by LOESCHE

© General Electric Company, 2011. GE Proprietary Information. All Rights Reserved.

1B (max.)

50/0 (max.) 50/0 (max.) 50/0 (max.) 50/0 (max.) 50/0 (max.) 5,000 (min.) 50/0 (max.)

Turbine oil oxidation test (hrs)

© General Electric Company, 2011. GE Proprietary Information. All Rights Reserved.

30

28.8-35.2

Page 129

Filling Quantity First Change Further Changes Refilling Quantity Check Quantity / Refill Specifications of Lubricant:

Lubricant characteristics required

16.4 ltr. each 3000 h check oil-quality 17000 h or every 5 years see measuring-line every month Synthetic Oil CLP HC 220

200 g / Bearing 16000 h

-

16000 h

-

90 g / Bearing 8000 h Grease

30 g 4000 h Grease

Lubricant characteristics required Lubricant

Remarks

Appertaining Documents (Drawing-no. or Manual)

see SEW-gearbox manual chapter 8

Check also nameplate of gearbox for oil-viscosity and quantitiy

Supplier Manual (KREISEL / SEW)

Mill Fan DHRV 50-1800 K Components

Number of Components Filling Quantity First Change Further Changes

Refilling Quantity Check Quantity / Refill Specifications of Lubricant: Lubricant: Remarks Appertaining Documents (Drawing-no. or Manual)

Supplier Manual (KREISEL)

Supplier Manual (KREISEL)

Number of Groups: 1 each

Non-locating Bearing 1 each 6 ltr. (max.) each -

Locating Bearing 1 each 7.2 ltr. (max.) each -

every year (T < 80°C) every 3 months (T > 100 °C)

every year (T < 80°C) every 3 months (T > 100 °C)

Recommended oil for T < 80 °C (Bearing temperature)

Recommended oil for T < 80 °C (Bearing temperature)

Oil Level: Oil Level: 75 mm (min.) 75 mm (min.) 110 mm (max.) 100 mm (max.) every week every week Hydraulic Oil Hydraulic Oil HLP 68 HLP 68 see supplier manual see supplier manual page 21-22 page 21-22

Supplier Manual (VENTI-OELDE)

Supplier Manual (VENTI-OELDE)

33

© by LOESCHE

32

Mobil Mobil Mobiltemp 78 Mobiltemp 78 see supplier manual see supplier manual page 27 page 27

Page 130

Lubricant brands recommended

Lubricant brands recommended List of lubricants for LOESCHE-machines (except gearboxes): Mineral Oils (CLP) / Synthetic Oils (PG) Lubricant

Latest Technical Instruction TI 1000 – 1109 Lubricating Oil for type 2, 3, 4 and 6 GE Jenbacher engines Natural Gas

Bio Gas

Landfill Gas

Document-No.: 4.Q-2980-00-4 en Date / Revision: 2014-01-28 / Q2 Generated by: Gödde

Code-no. Viscosity ISO-VG in DIN 51519 lubrication at 40° C (mm²/s) instructions

Mineral Oil CLP 100 (CLP(CC)) Mineral Oil CLP 150 (CLP(CC))

M1

VG 100

Mobilgear 600 XP 100

-

M2

VG 150


-

Mineral Oil CLP 220 (CLP(CC))

M3

VG 220


Omala F 220


M4

VG 320


Omala F 320

GEARMASTER CLP 320


M5

VG 460


Omala F 460

GEARMASTER CLP 460


M6

VG 680


-

GEARMASTER CLP 680

Polyglycol Oil PG 100 (CLP PG) Polyglycol Oil PG 150 (CLP PG) Polyglycol Oil PG 220 (CLP PG) Polyglycol Oil PG 320 (CLP PG) Polyglycol Oil PG 460 (CLP PG)

S1

VG 100

Glygoyle 100

-

S2

VG 150

Glygoyle 150

Omala S4 WE 150

S3

VG 220

Glygoyle 220

Omala S4 WE 220

GEARMASTER PGP100 GEARMASTER PGP150 GEARMASTER PGP220 GEARMASTER PGP320 GEARMASTER PGP460

Polyglycol Oil PG 680 (CLP PG)

S4

VG 320

Glygoyle 320

Omala S4 WE 320

S5

VG 460

Glygoyle 460

Omala S4 WE 460

S6

VG 680

Glygoyle 680

Omala S4 WE 680

GEARMASTER CLP 100 GEARMASTER CLP 150 GEARMASTER CLP 220

GEARMASTER PGP680

CARTER EP 150 CARTER XEP 150 CARTER EP 220 CARTER XEP 220 CARTER EP 320 CARTER XEP 320 CARTER EP 460 CARTER XEP 460 CARTER EP 680 CARTER XEP 680 -

Optigear BM 100 Tribol 1100/100 Alpha SP 150 Optigear BM 150 Tribol 1100/150 Alpha SP 220 Optigear BM 220 Tribol 1100/220 Alpha SP 320 Optigear BM 320 Tribol 1100/320 Alpha SP 460 Optigear BM 460 Tribol 1100/460 Alpha SP 680 Optigear BM 680 Tribol 1100/680 -

CARTER SY 150

-

CARTER SY 220

Tribol 1300/220 Tribol 800/220 Tribol 800/320

CARTER SY 320 CARTER SY 460 CARTER SY 680

Tribol 1300/460 Tribol 800/460 Alphasyn PG 460

Tribol 800/680

Page 1 of 6

35

© by LOESCHE

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Page 131

Lubricant service life recommended ASTM and OEM Used Oil Limits

Source

Viscosity @ 40°C TAN

ASTM D4378

Ahistom - Gas and Steam

GE - Gas

Solar

MHI - Steam & Gas

Siemens/ Westinghouse

ASTM D4378

HTGD901117

GEK 32568f

ES9-224

MS04-MA-CL001 and CL002

K-8962-11

+/- 5% of new oil

Exceeds ISO VG Class

25 to 41

+20% or -10% of new oil

26 to 39

0.3 to 0.4 over new oil

RPVOT

< 25%

Water

> 0.1 %

Flash Point - ASTM D92

30°F drop from original

0.2 rise above new oil

0.4 < 25% of new

0.6 max for mineral oils; 0.8 0.4 increase over new for SHC > 25% of new oil

500 ppm

2,000 ppm max

Cleanliness

17/14

Abrupt Change

Demulsibility

30 minutes max

Metals

15-25 ppm: >30 ppm limit

Air Release

8 minutes for ISO VG 32

Rust Prevention - ASTM D665

Foam

> 25% of original

+/- 10% of new oil

OPTIMIZING OF MAINTENANCE PROGRAM

0.3 to 0.4 over new oil 25% of new oil 200 ppm max

light fail in D665A

Seq I exceeds 450/10

17/14 max

< 20 minutes Trend/consult

10 minutes max (guideline)

4 minutes max

Seq I - 300/10; Seq II - 300/10 (guideline)

Seq I - 400/10

37

© by LOESCHE

36

Page 132

Types of Maintenance

Types of Maintenance • Proactive Maintenance – Taken from preventive and predictive maintenance by analyzing the root cause, not only find the source of the problem but also look for the cause of the problem and to prevent the same problems recur.

•

Predictive Maintenance – Based on monitoring and measuring the condition of the assets to determine whether they will fail during some future period and then taking appropriate action to avoid the consequences of that failure

• Preventive Maintenance – Actions performed on a time- or machine-run-based schedule

•

Reactive/Breakdown Maintenance – “Run it till it breaks” maintenance mode. – No actions or efforts are taken to maintain the equipment as the designer originally intended to ensure design life is reached 39

© by LOESCHE

38

Page 133

The Human Body Parallel to Machine Maintenance

Source : Allied bulletin

MAITENANCE STRATEGY

TECHNIQUE NEEDED

COST PER HP PER YEAR

HUMAN BODY PARAREL

Proactive Maintenance

Monitoring and correction of failure root causes, e.g. contamination

$0.10

Cholesterol and blood pressure monitoring with diet control

Predictive Maintenance

Monitoring of vibration, wear debris

$8

Detection of hearth disease using EKG or ultrasonic

Preventive Maitenance

Periodic component replacement

$13

By-pass or Transplant surgery

Breakdown Maitenance

Large maintenance budged

$18

Heart attack or stroke

Source : Noria bulletin

Potential Failures – Where to Detect them ?

*power generation Example 41

© by LOESCHE

40

Page 134

Modern Maintenance Technologies Modern Maintenance Strategy

Early Identification of a Detect Source : Allied bulletin

Source : Noria bulletin 43

42

© Copyright Noria Corporation

272

Ref: JCF

© by LOESCHE

Success Elements of an Integrated Condition-based Maintenance Program

Page 135

Optimizing Investment in Equipment Reliability

Case Study 1 : Improper Lubricant Selection Previous conditions

• Using mineral ISO VG 150 • High temp oil around 60°C • Delay to reach peak oil pressure (250 bar) • Oil pump work harder • More oil leakage

New conditions

• Using Mobil Vacuoline 528 ISO VG 150 • Reduce oil temp from 60°C to 52°C • Fast to reach peak oil pressure (250 bar) • Oil pump work normal • Reduce energy loss

45

© by LOESCHE

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Page 136

Case Study 2 : Energy Efficiency

Q&A

47

© by LOESCHE

46

Page 137

Thank You

© by LOESCHE

48

Page 138

Pyroprocess evaluation - waste treatment with the new Rocket Mill by Dr. Stefan Kern, A TEC Production & Services GmbH

A TEC SOLUTION FOR AF

© by LOESCHE

THE FUTURE OF ALTERNATIVE FUEL PREPARATION

Page 139

OUTLINE Introduction The A TEC Rocket Mill Technical solutions for AF at main burner Reference project

Can we achieve 100% TSR with solid alternative fuels in cement plants? What is necessary to achieve the remaining percentage of substitution rate to achieve 100% TSR with solid AF? Where?

kiln burner

How?

• New kiln burner • Quality improvement of AF

© by LOESCHE

The A TEC kiln burner for up to 100 % solid AF

INTRODUCTION

Page 140

INTRODUCTION

A TEC ROCKET MILL

General requirements for using AF

General requirements for using AF Maximum reduction of fuel costs

High clinker quality

High clinker quality

Stable condition in operation

Stable condition in operation

Low maintenance

Low maintenance

CO2 reduction

CO2 reduction

© by LOESCHE

Maximum reduction of fuel costs

Page 141

A TEC ROCKET MILL

A TEC ROCKET MILL

Advantages of the A TEC Rocket Mill

General information

Quality improvement of fuel Reduction of inorganics (ash) Reduction of moisture (drying) Higher specific surface (improved shredding technology)

Rotating chains Screen with 15mm hole size Direct drive

© by LOESCHE

 Higher calorific value of final product

Two Grinding chambers

Page 142

A TEC ROCKET MILL

A TEC ROCKET MILL

Grinding tools

Advantages of the A TEC Rocket Mill

Four horizontally rotating chains Special chain links

Reduction of inorganics (ash) Easy discharge of inorganics

© by LOESCHE

Perforated screens

Page 143

A TEC ROCKET MILL

A TEC ROCKET MILL

Advantages of the A TEC rocket Mill

Higher specific surface (improved shredding technology)

Simultaneous drying in Rocket Mill

Samples below show final size < 15 mm

Total moisture reduction approx. 10 % Additional drying with process waste gas (optional)

Cutting Mill

Rocket Mill

30000 25000

LHV [kJ/kg]

20000 15000

Lower calorific heat value

10000 5000 0 45

40

35

30 25 20 Moisture [%]

15

10

5

© by LOESCHE

50

Page 144

A TEC ROCKET MILL Final Product The maximum size of final product with a screen with ø 15 mm is max. 15 mm approx. 50% < 5 mm.

Increased specific surface („fluffy“ like cotton) Drying effect during the grinding process approx. 10 %

Positive impact on pyroprocess Better burnout of AF in kiln

Higher substitution rates at kiln burner Stable sintering zone Higher clinker quality •

Reduction of Fe2+ content (brown clinker)

•

Less sulphur circulation

© by LOESCHE

Additional drying with process waste gas

ROCKET MILL - Clinker Process

Page 145

A TEC‘s TECHNICAL SOLUTIONS

ROCKET MILL WITH DRYING

Option 1: Improvement of existing main burner solid alternative fuel system

Assumption AF firing at main burner existing

Road Map Rocket Mill for AF preparation

© by LOESCHE

Higher AF rate with existing combustion equipment

Page 146

A TEC‘s TECHNICAL SOLUTIONS

OPTION 1 + STORAGE & FEEDING

Option 2: Installation of main burner AF system

Assumption Pre-treated AF material available

Road Map Rocket Mill for AF preparation A TEC main burner or main burner modification

© by LOESCHE

Storage, dosing and feeding system

Page 147

STORAGE & FEEDING

A TEC‘s TECHNICAL SOLUTIONS Option 3 Optimization of existing AF treatment plant

Assumption Existing AF treatment line

Road Map Replacement of several shredding/cutting stages by Rocket Mill

© by LOESCHE

A TEC main burner or main burner modification (optional)

Page 148

ROCKET MILL

A TEC ROCKET MILL

Existing Treatment Line pre-shredder > 300 mm

Fe separator

screen (opt.)

opt. heavy separation

< 300 mm

shredder

< 20 mm

< 20 mm

< 100 mm

Possible New Treatment Line pre-shredder > 300 mm

Fe separator

screen (opt.)

Technical data

fine shredder (cutting)

Final product size

< 15 mm

< 60 mm

Screen size

Ø 15mm

rectangular 40 x 50mm

Output size

< 15 mm / ~ 50% < 5 mm

< 60 mm / ~ 40% < 20 mm

Throughput

~ 6 t/h

~12 t/h

Specific power consumption

65 - 70 kWh/t < 15 mm final

40 - 55 kWh/t < 60 mm final

Dimension opt. heavy separation

Weight

Rocket Mill < 15 mm

< 300 mm

54.000 kg

Drive Unit

2 x 315 kW

Rotor Speed

~ 580 min-1

Capacity

~ 6 t/h < 15mm final product

Discharge

2 x Conveyor screws

© by LOESCHE

< 15 mm

8.530 x 4.160 x 6.000 l x b x h (mm)

Page 149

A TEC ROCKET MILL - RESULTS

A TEC ROCKET MILL - RESULTS

Coal savings on the existing system w&p with AF from the rocket mill

Maintenance & Wear costs

Due to the higher quality of AF produced with the rocket mill, the coal amount could be reduced.

Life time wear parts

Comparison of clinker production with same clinker quality and roughly same kiln feed:

Wear costs

Kiln Feed [t/h] Coal at Main Burner [t/h] Coal per Kiln feed [kg/t] April Juli

122,11 115,01

1,91 1,61

15,6 14,0

4 - 4,20

€/t

Time for changing one set of wear parts

approx. 1-2

h/unit

Maintenance/cleaning

5

h/week

required man power approx. 0,015

h/t

Maintenance

© by LOESCHE

This allows savings in coal consumption of around 200 kg/h with 120 t/h kiln feed.

chain approx. 250h chain fitting approx. 250h screen approx. 900h

Page 150

ADVANTAGES ROCKET MILL Size reduction from 200 mm to 15 mm in one grinding step Saving of one shredding step Easy to operate Easy to maintain No knifes

Drying effect during operation Separation of FE and non-FE materials

FLEXIFLAME ECO PRO® ADVANCED COMBUSTION TECHNOLOGY

Different output fuel particle sizes for main burner and calciner

© by LOESCHE

possible

Page 151

OLD TECHNOLOGY FOR SOLID ALTERNATIVE FUEL FIRING 1. Pipe beside the burner in the kiln hood

OLD TECHNOLOGY FOR SOLID ALTERNATIVE FUEL FIRING When higher substitution rates are attempted with old technology:

2. One or more pipes above the burner

• Unstable flame 3. One or more pipes inside the burner

• Wrong kiln thermal profile • Higher kiln inlet temperatures • Fuel falling onto clinker bed • Reduction zone near clinker • Excessive sulphur recirculation

60-70% Thermal Substitution Rate at Main Burner Possible •

Higher oxygen zone

•

No control

•

Lower mixing

• Rings formation • CO emissions • Cement Strength

•

High oxygen zone

•

Low control

•

Low oxygen zone

Low mixing

•

High control

•

High mixing

© by LOESCHE

•

Clinker quality, operational and environmental problems!!!

Page 152

OLD TECHNOLOGY FOR SOLID ALTERNATIVE FUEL FIRING

UNDERSTANDING SAF COMBUSTION

SECONDARY AIR • High oxygen availability: 95100% of required amount • Low control and mixing

•

Option 1 Option 2 Option 3

PRIMARY AIR Low oxygen availability: 812% of required amount • High control and mixing

High Oxygen

OR

High Control

!!!

COMBUSTION UNDERSTANDING

NEW CONCEPT

© by LOESCHE

NEW CONCEPT REQUIRED

Page 153



How do different Solid Alternative Fuel particles burn?

Importance of particle shape:  

area of sphere with the same volume  sphericity area of real particle

AERODYNAMIC AND BURNING CHARACTERISTICS Material

Wood cube

3D plastic

2D plastic

Slow ignition

Fast ignition

Super fast ignition

Low volatile

High volatile

High volatile

Long time burn out

Fast burn out

Very fast burn out

Keeps shape

Becomes a sphere

Forms droplets

High ash content

Low ash content

Low ash content

Sewage sludge Wood chips Fluff

Form grains chips foils

Length

Width

Height

[mm]

[mm]

[mm]

15,0 15,0

4,0 15,0

3,0 0,2

Diam. Superficial Area

Volume

Superf. Area Equiv. Sphere

[mm]

2

[mm ]

3

[mm ]

[mm2]

2,0

12,6 234,0 462,0

4,2 180,0 45,0

12,6 154,2 61,2

ᴪ 1,00 0,66 0,13

© by LOESCHE

Videos: Courtesy of LEAT Bochum / Aixergee

Page 154



Combustion Mechanism:

How to control different combustion mechanisms:

FLAME BOUNDARY

FLAME BOUNDARY

VOLATILES DIFUSION INTO OXYGEN VOLATILIZATION ON EXTERNAL LAYER

INDIVIDUAL PARTICLES COMBUSTION VOLATILES DIFUSION INTO OXYGEN

NO VOLATILIZATION ON INTERNAL LAYER

FLAME BOUNDARY VOLATILES DIFUSION INTO OXYGEN VOLATILIZATION ON EXTERNAL LAYER

NUMBER OF PARTICLES

REGION I EXTERNAL SHEAT COMBUSTION

REGION I

VOLATILIZATION ALSO ON INTERNAL LAYER

C+O2 = CO2

2H+½O2 = H2O REGION II

REGION IV

REGION III INTERNAL GROUP COMBUSTION

FLAME BOUNDARY

• Poor mixture between fuel and oxidant

between fuel and

• High oxygen, low velocity – secondary air induction

oxidant

• Combustion complementing

• Low oxygen (8-12%

velocity • Hot gas recirculation

INDIVIDUAL PARTICLES COMBUSTION

CLOUD DISPERSION

EXTERNAL RECIRCULATION:

• Intense mixing

comb. air), high

VOLATILIZATION ALSO ON INTERNAL LAYER

REGION II INTERNAL SHEAT COMBUSTION

INTERNAL RECIRCULATION:

• Ignition fuel zone • Flame stability

REGION IV INDIVIDUAL PARTICLE COMBUSTION

© by LOESCHE

Picture: Courtesy of Aixergee

Page 155

FLEXIFLAME ECOPRO® High Oxygen

Key Point

AND

High Control

FLEXIFLAME ECOPRO®

!!!

• Injection of solid alternative fuel through a ring channel

• Ring channel wide enough to avoid blockages • Even fuel and air distribution • Wear protection

New concept for solid alternative fuels injection:

• High momentum • High flame control

Through the burner: HIGH CONTROL

• Up to 100% solid alternative fuel

FLEXIFLAME ECOPRO®

© by LOESCHE

Near secondary air: HIGH OXYGEN

Main characteristics

Page 156

INTRODUCTION

PYROPROCESS EVALUATION

© by LOESCHE

LOESCHE Technical Seminar 21 – 23 April, 2015 Jakarta, Indonesia

Page 157

CEMENT PLANT SCHEME

OUTLINE Preheater Performance & Preheater Modification

Minimizing of coating / Blockage avoiding: Bypass Systems & Shock blowers

© by LOESCHE

Calciner Combustion & NOX / CO Control

Page 158

PH PERFORMANCE & MODIFICATION


• Increase of production capacity (clinker production)

• Reduction of fuel consumption • Reduction of electrical power consumption • Reduction of emissions (NOX, CO, SOx, dust)

ATEC “TRIPLE-E” (E3) Policy

© by LOESCHE

 optimized EFFICIENCY  optimized ENERGY BALANCE  ENVIRONMENTAL protection

Page 159


PH PERFORMANCE & MODIFICATION Typical Bottlenecks Down comer duct and GCT: - Pressure drop

- Separation efficiency - Pressure drop

Riser ducts:

- Meal distribution - Retention time

Calciner:

- Low NOx - Retention time - RSP calciner

Tertiary air duct:

- NOx Reduction - Pressure drop

© by LOESCHE

ID fan: - Fan capacity

Cyclones:

Page 160


PH PERFORMANCE & MODIFICATION Preventive Maintenance • Prevent false air in the system

© by LOESCHE

• Maintain proper operation of Pendulum Flaps

Page 161


© by LOESCHE


Page 162



A TEC Pendulum Flap

A TEC Splashbox

To avoid counter gas flow through meal pipes between two stages of the preheater. Proper working pendulum flap provides: • Reduction of gas flow through meal pipe • Improvement of cyclone separation efficiency • Reduction of specific heat consumption False air via meal pipe

+ 4% gas volume - 3% separation efficiency + 20 kJ/kgclinker

For meal distribution from meal pipe in gas riser duct Proper meal distribution on whole riser duct square area Maximized heat transfer gas -> meal Pressure drop reduction of riser duct • ideal position of the splash box is appr. 0.5 – 0.8 m above the cyclone ceiling • utilises approx. 65 – 75% of the riser duct cross section compared to standard splash box with < 50% • up to 4°C reduced temperature in riser duct depending on application

© by LOESCHE

No flap in bottom stage

• • • •

Page 163

PROJECT EXAMPLE (Dp) Project Example:

PROJECT EXAMPLE (Dp)

Cement Plant Este, Italy

RESULTS / REALIZED PARAMETERS Gas Quantity: Gas Temperature: Clinker Production:

Project Example:

BEFORE MODIFICATION

AFTER MODIFICATION

4-stage preheater

4-stage preheater

Difference

Cement Plant Este, Italy

Guarantee

250,000 Am³/h 520 °C 1,200 t/d

Pressure Drop Reduction:

1,300 t/d

+ 100 t/d 12 mbar

Static Pressure Drop: 23.0 mbar 44.5 mbar 21.5 mbar 55.0 mbar 16.0 mbar 71.0 mbar

22.0 mbar 34.0 mbar 12.0 mbar - 9.5 mbar 44.5 mbar 3.5 mbar - 12.5 mbar 48.0 mbar - 23.0 mbar

- 7.0 mbar - 8.0 mbar - 15.0 mbar

GENERAL ARRANGEMENT DRAWINGS

© by LOESCHE

Exit 2nd stage: Exit 3rd stage: D p 3rd stage: Exit 4th stage: D p hot gas duct: ID fan inlet

Page 164

BLOCKAGE AVOIDING

BLOCKAGE AVOIDING Reasons for the installation of a bypass system Operation of pyroprocess with high chlorine and alkali fuels and/or raw materials Avoiding build ups and heavy coating in the area of the kiln riser duct and meal pipe to the kiln

© by LOESCHE

Impact on clinker quality

Page 165

BLOCKAGE AVOIDING

BLOCKAGE AVOIDING

© by LOESCHE

Possible flowsheet of a standard Bypass System

Page 166

BLOCKAGE AVOIDING

BLOCKAGE AVOIDING

Shock blowers in the

operation without bypass original operation

Preheater / Precalciner system

© by LOESCHE

operation with bypass

Page 167

Theoretical Background 1. NOX formation 2. NOX reduction 1.Primary NOX reduction 2.Secondary NOX reduction

A TEC Proposal for < 200 mg/Nm³ NOX emissions

CALCINER COMBUSTION & NOX Thermal NOX formation

Oxidation of nitrogen from combustion air Occurs at high temperatures (> 1300 °C)

𝑁𝑁2 + 𝑂𝑂 → 𝑁𝑁𝑁𝑁 + 𝑁𝑁 𝑁𝑁 + 𝑂𝑂2 → 𝑁𝑁𝑁𝑁 + 𝑂𝑂 𝑑𝑑𝑑𝑑𝑑𝑑 𝑑𝑑𝑑𝑑

= 5,74 ∙ 1014 𝑒𝑒𝑒𝑒𝑒𝑒

−561000 𝑇𝑇

Fuel NOX formation

𝑁𝑁2 𝑂𝑂2

0,5

Depending on the nitrogen content of the fuel

Prompt NOX formation

900 NOX concentration (10 % O2), mg/Nm³

CALCINER COMBUSTION & NOX

700 500 300 100 800

1300

1800

Temperature, °C

Figure: Formation of thermal NOX vs. combustion temperature

© by LOESCHE

Caused by fuel radicals – not considerable here

Page 168



Primary NOX reduction

Fuel composition

Plant configuration

N content

Kiln type

H2O content Volatile matter

Raw material

NOX

Calciner Clinker cooler

Reduction of the combustion (peak) temperature Reduction of air amount in the hot combustion area

Suitable state of the art process modifications Low-NOX burner Staged combustion

etc.

Clinker spec. Free lime Avoid „overburning“

© by LOESCHE

moderate LSF

Preheater configuration

Avoiding NOX formation

Page 169



Low-NOX burner

Staged combustion for precalciner plants

low NOX levels

Burner operation for low NOX production:

• Lower amount of central air (PA) Posssible effects by operation of a classical low-NOX burner on the process:

• Flame length increases • Lower temperature • Risk of incomplete solid fuel combustion or char formation

 CO  CXHY (hydrocarbon radicals) CXHY + z NO = x CO2 + y/2 H2O +z/2 N2

Calciner l>1 Calciner l<1

 Active fuel nitrogen (NH3, HCN) • Complete oxidation in last “stage”

high NOX levels

Kiln l>1

© by LOESCHE

• Impact on clinker quality possible

• Creation of a reducing atmosphere to reduce NOX in calciner by:

Page 170



Fuel Combustion

Fuel Combustion

Volatile compounds CO CO2 H2 CH4 C2H2 C2H4 CXHY

H2O

drying

heat

+ O2  CO2 + H2O

Dry fuel

Bituminous coal

Wood

PE

~ 0 % (theor.)

~ 30 %

~ 85 %

~ 100 %

CO + O  CO2

char gasification O2

heat

Char

Fixed carbon (char)

Ash

Dominated by pyrolysis step: High release of CxHy radicals

© by LOESCHE

Raw fuel particle

pyrolysis

Influence of the volatile matter content of the fuel

Page 171



Fuel Combustion

Fuel Combustion

Influence of the volatile matter content of the fuel

Influence of the Nitrogen (N) content of the fuel

Char

Bituminous coal

Wood

PE „Fixed carbon“ Nitrogen

~ 0 % (theor.)

~ 30 %

~ 85 %

N

„Volatile“ Nitrogen e.g. H-C-N, high vol. N comp.

HCN, NH3

+ ox

NHi radicals

Primary oxidation to NO

+ ox

Oxidation to NO

+ NO

Reduction of NO NO + NH3  N2 + H2O

© by LOESCHE

Reducing zone dominated by CO formation

~ 100 %

Combustion

e.g. stable aromatic comounds

Page 172



Staged combustion for precalciner plants

Selective non-catalytic reduction (SNCR)

Split of tertiary air •

Creating reducing and oxidizing zone

•

Sufficient residence time

•

Maintaining high temperature in reducing zone • •

Fuel N: Equilibrium  NO reduction

•

Meal split

Use of high volatile fuels •

CXHY radicals more reactive for NO reduction

•

Fuel N: positive effect possible

 Ammonia (NH3)  Ammonia water  Urea (CH4N2O)

Limited temperature range

NH3 loss comb. to NOX

NH3 slip

Temperature too low •

Emission of NH3

Temperature too high •

Formation of additional NO

900

1000

Temperature, °C

1100

Figure: Influence of the temperature on the SNCR process

© by LOESCHE

•

Increased reaction speed for NO reduction

Injection of NOX-reducing agent NOX abatement, relative

•

Page 173



Selective non-catalytic reduction (SNCR) NO Reducing gross reactions

NH3 loss comb. to NOX

4 NH3 + 6 NO  5 N2 + 6 H2O

For NH3 injection: 800 – 1050 °C CH4N2O + 2 NO + 0,5 O2  2 N2 + CO2 + 2 H2O

For urea injection: 50 – 100 °C higher

NOX abatement, relative

NH3 slip

Basic reaction scheme with NH3 +NO +OH +O

NH2 +ox

NO

900

1000

Temperature, °C

1100

Figure: Influence of the temperature on the SNCR process

© by LOESCHE

NH3

N2

Page 174


CALCINER COMBUSTION & NOX A TEC Post Combustion Chamber CFD-modelling

Larger unburned fuel particles can stay in the upsteam section Expansion of residence time Eccentrically entrance downstream

upsteam

Velocity reduction upstream

downstream

Increase of cross section upstream

CALCINER

Installed at calciner top

A TEC PCC

The A TEC Post Combustion Chamber

© by LOESCHE

High turbulence

Page 175

THANK YOU

© by LOESCHE

www.atec-greco.com

Page 176

Loesche Technical Seminar_apr-15

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