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Welding Alloys Technical Seminar for Cement Industry Gebr.

Pfeiffer Vertical Roller Mills


Bodrum Turkey, May 2012

Part 2 MPS and MVR Mills Modernisation of old MPS mills Directives for coal grinding plants SLS Classifier Pressure accumulator technology

Design features of the PFEIFFER MPS mill

MPS and MVR

MVR vertical roller mill MPS vertical roller mill


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Design of MPS mill

fine product

raw material

hot gas

reject material
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Design of MPS mill

seal air piping pressure frame pull rods pressure yokes grinding rollers grinding table nozzle ring reject scrapers hot gas channel maintenance drive reject chute hydraulic cylinders foundation frame mill motor

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Design of MPS mill

one pressure frame for uniform load distribution to grinding rollers, grinding bed and gearbox large grinding roller diameter for optimum material intake and formation of stable material bed roundish rollers and moulded table for stable grinding bed closed mill housing for minimum false air leakage high-efficiency classifier for sharp separation and low electric power consumption patented MPS Lift-and-Swing System for easy exchange of wear parts through one single maintenance door in the mill housing

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Design of MPS mill


grit cone pressure frame feed material Lift-andSwing-System grinding roller nozzle ring air or hot gases

gear box
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grinding plate

hydraulic tensioning cylinder

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MPS design feature: maintenance drive

Maintenance Drive: fitted to main gearbox For positioning during removal of rollers and grinding plate Driving rollers and plate during hardfacing, plus frequency converter for welding speed adjustment

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MPS design feature: Liftable grinding rollers

Direct start without auxiliary drive Use of standard motor possible, 2nd shaft end not required Easy emptying of mill Inner grinding roller stop to keep roller in position of track during lifting

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MPS design feature: Liftable grinding rollers

Clearance in strap joints provides the flexibility degrees of freedom for the grinding operation Outer strap limits roller inclination to 12 during lifting

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MPS design feature: Torque support

Reduced dynamic forces

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MPS design feature: Torque support

Flow of force via intermediate bolt onto shock absorbing system

Absorption of transverse force via sliding bearing of intermediate bolt


intermediate bolts

Bearing sealing provided by seal air (passive)

Housing limit stop


shock absorbing unit
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pressure frame

MPS design feature: Wear protection

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MPS design feature: rising gas velocity

Profile of gas velocity

140 % 115 % 105 % 100 %

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MPS design feature: Lift-and-Swing System

Replacement of rollers and wear parts

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Design features of the new PFEIFFER MVR mill for grinding high throughput rates

MPS and MVR

MPS vertical roller mill

MVR vertical roller mill


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Design of the MVR mill

MVR mill main function groups SLS classifier Housing with nozzle ring and hotgas duct Grinding table Grinding rollers Innovative roller suspension Twin support Active Redundancy Standardization benefits through common parts One hydraulic system for operation and maintenance drive train options
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Conventional drive up to 7 000 kW

MultiDrive up to 12 000 kW

Design

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Roller suspension

Roller module consists of Roller with cylindrical wear parts Roller axle Roller arm Bearing stand Hydraulic tensioning cylinder Articulation piece, fork head and anchorplate

Two roller modules side by side on a common twin support

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Roller suspension

Guided motion smooth run Grinding gap always in parallel Positive effects on energy transmission Tension cylinder also swings out roller for service
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Roller suspension

Rotation axis under operation maintenance

Two roller modules side by side on a common twin support


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Roller suspension

60

Advantage in plant layout: Wide angle between supports due to parallelly shifted axles

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Modular drive design with MultiDrive

Up to 12,000 kW with up to 6 identical drive modules. The drive modules are a Siemens/Flender standard products, no special MultiDrive design. With only 3 different drive modules the complete power range can be covered strategic spare saving.

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Further MultiDrive advantages - Reduced height requirement, lower feed point - Bigger diameter of axial thrust bearing, thus operation with minus 1 or 2 rollers possible. - Table support designed to take unbalanced radial forces

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Parallel grinding gap, symmetric tyres

Parallel grinding gap in any operating point


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Symmetric design allows the tyres to be flipped over

Grinding elements exchange

Hydraulic control unit


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MVR mill

Unchanged Process Design Safety Factors Levels of spec. grinding force Nozzle ring Gas Velocity Design Classifier Wear Protection

Changed / Improved Capacity Range Number of rollers Roller Suspension


Flat Table Cylindrical Rollers Parallel Grinding Gap

MultiDrive with variable speed Active Redundancy

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The PFEIFFER-MVR roller mill Essential design features


Active Redundancy
Up to 6 grinding rollers and 6 drive modules: mill operation continues even if a roller or drive module is under maintenance.

Hydraulic system for operation and maintenance


For maintenance purposes no extra component is required to swing the rollers out of the mill.

Parallel grinding gap


The geometry of the grinding elements in combination with our MVR suspension system ensures a parallel grinding gap in any operating point.

Modular drive design


Up to 12 000 kW with only 3 different types of drive modules. A mill can be equipped with up to 6 identical drive modules.

Symmetric wear parts


The modular roller system with only 5 roller modules and symmetric tyres provides capacities of up to 1 000 t/h. For an extended lifetime tyres can be turned in case of wear.

Space saving twin support


1 support for 2 roller modules for ease of maintenance work.
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MVR 6700 C-6 cement mill

Country MPS size

Iran MPS 4250 BC


94% clinker 6% gypsum

France MPS 4750 BC


96% clinker 4% gypsum

Ecuador MPS 4250 BC

Italy MPS 4250 BC

Turkey MPS 4750 BC

India MPS 5600 BC


71% clinker 25% fly ash 4% gypsum

China MPS 5600 BC

Mixture Throughput rate, tph Fineness (acc.Blaine), cm/g Spec. power consumption, (Mill), kWh/t Calculated throughput with MVR 6700-C6
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64% clinker 62% clinker 18% slag 91% clinker 35% pozzolana 7% limestone 4% limestone 3% gypsum 6% gypsum 5% gypsum 5% pozzolana

100% slag

122 3000

100 4300

120 4000

126 4400

151 3800

305 3500

128 5000

18

24

17

14

19

16

32

415

310

430

530

390

460

230

Summary - References

MVR 400 Germany MVR 1800 Germany MVR 3750 BosniaHerzegovina MVR 5600 plus MultiDrive MultiDrive France
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Modernisation and upgrading of MPS mills

Possible Modernisation Measures

Lift-and-Swing System SLS high efficiency classifier New components Grit extraction screw conveyor

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Upgrading by Pfeiffer Lift-and-Swing System

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Upgrading by Pfeiffer Lift-and-Swing System

Short downtime

Safe and easy handling

One maintenance door only

Low space requirement

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Upgrading with SLS classifier

classifier type SLF

replaced by

classifier type SLS

by choice

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Upgrading with SLS classifier

Votorantim for Santa Rita works, Brazil MPS 3450 before after upgrading upgrading product rate: 180 220 t/h

absorbed power:
(mill)

1340

1430 kW

power consumption: 7.4


(mill)

6.5

kWh/t

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Full scale upgrade Gorazdze Cement in Poland Gorazdze Cement, Gorazdze, Poland MPS 4150

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Full scale upgrade Gorazdze Cement in Poland

Classifier replaced

Pressure frame and hydraulic unit replaced

Rollers replaced

Nozzle ring replaced

Gearbox replaced
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Full scale upgrade Gorazdze Cement in Poland

Operating results

(t/h) Before upgrading: Guaranteed values: After upgrading: 300 440 461

(kWh/t) 4.5 4.3 4.5

%R0,09mm 18.0 18.0 15.8

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Upgrading by grit extraction to redundant ball mill La Cemento National, Ecuador Guayaquil

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Upgrading by grit extraction to redundant ball mill La Cemento National, Ecuador Guayaquil

Finished product

Classifier grits
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Upgrading by grit extraction to redundant ball mill La Cemento National, Ecuador Guayaquil

Operating results

before upgrading Product rate: 380

after upgrading 520 t/h

Extraction rate

125

t/h

Absorbed power (MPS mill) Power consumption: (MPS mill)

3600

3630

kW

9.4

9.2

kWh/t

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New directives for the design of coal grinding plants (Based on EU standards)

Test of explosion pressure shock resistance filter housing with explosion flap

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Design of coal grinding plants

Coal characteristics
Common range Lower Explosion Limit (LEL) Maximum Explosion Pressure (MEP) Maximum Rate of Explosion Pressure Rise Limiting Oxygen Concentration (LOC) Volatile Matter (VM) 15 125 g/m3 6 - 10 bar 40 140 bar m/sec 12 - 16 % 15 - 35 %

The exact data are needed for rating the explosion venting!

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Design of coal grinding plants safety concept Explosion-pressure-shock-resistant design of mill and classifier of up to 3.5 bar Decoupling of explosion areas through rotary locks, flame traps and safety shutoff dampers. Explosion venting (free and/or absorbed) Monitoring of CO, O2, dust emission and temperature Central vacuum cleaner for the building Inerting and fire fighting by CO2 flooding

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Safety relevant measuring points

Temperature 3

3 2

Dust emission CO level O2 level

Temperature 1 CO level O2 level (plants operated under inert conditions)

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Design of coal grinding plants

Safety concept End-user classifies his plant into zones of explosion risk No risk of explosion in mill building thanks to central vacuum cleaner Necessity of defining explosion characteristics of coal Explosion pressure venting at mill inlet and outlet Dust emission measurement after filter Extra efforts in project documentation, manuals available at authorities Authorities assess conformity of machines with directive, especially mills not operated under inert conditions Increased efforts in quality control, including parts manufactured locally Equipment procured by end-user must comply with directive

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Design features of the PFEIFFER SLS classifier

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High efficiency classifier SLS

SLS classifier
the high efficiency lamella type classifier for Pfeiffer MPS mills different types designed for different applications SLS-B: for standard applications (cement raw material, limestone, etc.) SLS-BF: for very fine products (< 5% residue on 90 m) SLS-BK: for coal and petcoke mills SLS-BC: for cement mills, slag mills and mills for cement additives

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High efficiency classifier SLS

drive

fine product

feed material

rotor

louver

grit cone
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High efficiency classifier SLS

detail of annular gap

gas outlet duct

annular gap submerged pipe three-part wear ring separating rotor


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High efficiency classifier SLS

material inlet

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High efficiency classifier SLS

electromechanical drive

reliable

easy to maintain

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Basic knowledge about pressure accumulators to avoid damages

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Photos

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Barbarossastrae 50-54 P.O. Box 3080 67618 Kaiserslautern Phone: ..49-631-4161-0 Fax: ..49-631-4161-290 e-mail: kv-p@gpse.de homepage:www.gpse.de

Thank you!

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