Lv Seor 2perat.ppt

1

GUIDE VANES AND ROTOR

ROTATION Guide Vane LV Pocket

ROTOR

2

LV POCKET VANE ARRANGEMENT

3

LV POCKET VANE ARRANGEMENT

4

CROSS SECTIONAL VIEW OF CLASSIFYING ZONE

GUIDE GUIDE VANES VANES

SEAL SEALRING RING

ROTOR ROTOR BLADES BLADES GRIT GRIT CONE CONE

5

PHOTO OF LV POCKETS

6

LV ROTOR ASSEMBLY SQUARE SQUARE BAR BAR

SEAL SEALRING RING

BLADES BLADES

ROTOR ROTOR CONE CONE

7

LV CLASSIFIER SEAL STANDARD OUTER and INNER SEAL for LV CLASSIFIER

A

H

H

REMARKS: ROTOR DIAMETER (m)

H (mm)

LESS THAN 3

30

3 AND OVER

50

8

FORCE BALANCE Force Balance that Determines Separation in HEC Separator

9

LV CLASSIFIER FEATURES DESIGN DESIGN  FIXED GUIDE VANES

 Closed Casing  Possibility of false Air entry Elimated

 CLASSIFIER TOP HOUSING

 Geomentry accumulation

avoids

Dust

 LOW VELOCITY IN LV POCKETS  Less Wear  Lesser number of Guide Vanes due to Pocket Design

10

LV CLASSIFIER FEATURES OPERATION OPERATION/ /PROCESS PROCESS

 LV POCKETS



Two stage classification - Collects Coarser Material reduces load on Rotor due to bottom feeding

 PRESSURE DROP



Lower Pressure Drop than other Separators



Lesser KWH/T in Fan

11

LV CLASSIFIER FEATURES OPERATION OPERATION/ /PROCESS PROCESS  Uniform Distribution of Material in Gas Stream due to bottom feeding  Optimum Material to Separation Air ratio results in higher efficiency than conventional high efficiency Separators  Proven Track record of LV Classifier  Consistent product fineness for large period of operation due to less wear  430 Nos. of LV Classifier in operation for various applications

12

MATERIAL OF CONSTRUCTION ROTOR BLADES – MILD STEEL WITH CERAMIC SPRAY FOR 100 MM HEIGHT FROM BOTTOM GUIDE VANES – MILD STELL WITH CHROMIUM CARBIDE HARD FACING CLASSIFIER CASING – CERAMIC TILES IN CASE OF CEMENT AND FLY ASH APPLICATIONS BOTTOM DUCT – MILD STEEL WITH CERAMIC LINERS OUTLET DUCT – MILD STELL WITH CERAMIC LINERS GRIT CONE – MILD STEEL WITH HARD FACING OR CERAMIC LINERS FOR FLY ASH/CLINKER/SLAG APPLICATIONS GRIT CONE – MILD STEEL FOR RAW MATERIAL GRINDING

13

LV CLASSIFIER FOR VERTICAL MILL

14

LV TECHNOLOGY CLASSIFIER FOR VERTICAL ROLLER MILL

15

MATERIAL TRANSPORT IN VRM Product

CLASSIFIER

Grit From nozzle ring and mill housing New feed

VERTICAL MILL

16

LV Technology addresses the problems found in existing vertical mill systems by:



Improving Separator Performance



Optimizing airflow-reducing volume to >600gm/m3



Reducing Internal Material Circulation



Reducing Pressure Drop



Reducing Fan Power



Increasing Grinding Efficiency

17

NOZZLE RING AND DAM RING To classifier

New feed and classifier return Roller

Mill body

Armor ring

Dam ring

Hot gas External circulation

Table

18

SEPARATOR MODIFICATIONS ENSURE

No Coarse in the Fines and No Fines in the Coarse

Proper return of coarse rejects to table Reduction of throughput under rollers

19

LV CLASSIFIEFR SUMMARY The concept of the separator is to improve the gas and material flow in vertical mills by: • Unique design of guide vanes - LV pocket • Unique design of rotor • The design of the grit funnel The concept is based on the idea:  Allow more material to be directed to the classifier by optimising the gas speed  Avoid fines returning to the grinding table and excessive internal material circulation in the mill body by installation of the LV Pocket  Decreases the pressure loss in the mill body and separator. An effect of the reduction of internal material circulation

20

BEFORE AND AFTER MODIFICATION

21

VERTICAL RAW MILL UP-GRADATION RESULTS Birla corporation (LM 36.40 SATNA Cement Works) – INDIA THE MODIFICATIONS : Replacement of existing rotor assembly  Replacement of guide vanes  Modification of classifier housing and inner cone  Replacement of grit cone and roof  Adjustment of armour ring and nozzle ring Description

Before Modification

Guaranteed

After Modificatio n

225

240

241

Product Residue on 90 mic (%) Product Residue on 212 mic (%)

18-20 3.5-4

18 2.0

20.04 2.0

Specific Power consumption kwh/t (Mill+ESP Fan)

15.65

14.15

14.15

Production (tph)

22

EXAMPLE OF MODIFICATION After

Before

Housing Modification New Rotor Profile

New Grit Cone

Fresh Feed Entry

23

TYPICAL MODIFICATION OF CLASSIFIER

After

Before

Housing Modification Guide Vanes New Cage Rotor Profile

Modified Grit Cone

Existing Rotor Profile

Existing Grit Cone Feed Chute Extension

24

VERTICAL RAW MILL (KP 46/23) UPGRADATION RESULTS

Mangalam Cement – INDIA THE MODIFICATIONS : Replacement of existing rotor assembly  Replacement of guide vanes  Modification of classifier housing and inner cone  Replacement of grit cone  Adjustment of nozzle and armour ring Description

Before Modification

Guaranteed

After Modification

Production (tph)

189

215

220

Product Residue on 212 mic (%)

8 to 9

5 to 6

5 to 6

Specific Power consumption kwh/t (Mill + ESP Fan)

17

16

15.5

25

VERTICAL COAL MILL (LM21.20D) UPGRADATION RESULTS

Manikgarh Cement Works – INDIA THE MODIFICATIONS : Replacement of existing rotor assembly  Replacement of guide vanes  Modification of classifier housing and inner cone  Replacement of grit cone Description

Production (tph) Product Residue on 90 mic (%) Specific Power consumption kwh/t (Mill+Mill Fan)

Before Modification

Guaranteed

After Modification

28

31

33

18 to 19

18 to 19

18 to 19

19.5

18

17.77

26

VERTICAL COAL MILL (MPS-140) UPGRADATION RESULTS

Birla Corporation Limited – INDIA THE MODIFICATIONS :Static Separator to High efficiency LV Classifier

Description

Guaranteed

After Modification

Production (tph)

7.5

7.5

Product Residue on 90 mic (%)

2.0

2.0

27

VERTICAL COAL MILL (RMK25/12/35) UPGRADATION RESULTS

Jaypee Cement Limited – INDIA

THE MODIFICATIONS :Static Separator to High efficiency LV Classifier Description

Production (tph)

Product Residue on 90 mic (%)

Before Modification

Guaranteed

After Modification

32

35.2

36.2

18 - 20

18 – 20

16 -18

28

MODIFICATION OF ATOX MILL MODIFIED BY LV

New NewRotor Rotor Profile Profile

EXISTING

Existing Rotor Profile

New housing, if necessary

29

VERTICAL RAW MILL (ATOX-45) UPGRADATION RESULTS

Zuari Cement Limited – INDIA THE MODIFICATIONS : Replacement of existing rotor assembly, top & bottom rings for rotor blade  Replacement of guide vanes, upper & lower rings for guide vanes  Modification of classifier housing and inner cone  Replacement of grit cone  Adjustment of nozzle and armour ring Description

Before Modification

Guaranteed

After Modification

Production (tph)

250

265

273

Product Residue on 90 mic (%)

23 to 25

23 to 25

23 to 25

Specific Power consumption kwh/t (Mill + Classifier + Fan)

15.9

---

14.99

30

INSTALLATION BENEFITS OF LV CLASSIFIER Vertical Roller Mills:

10 - 30 % Increased production 1.0 – 5.0 kWh/t Saving in power consumption of both mill and fan Vibration level decreasing  Cement strength increases

31

LV CLASSIFIER FOR BALL MILLS

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TYPE OF BALL MILL CIRCUITS

• Gravity Discharge • Air Swept

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LV CLASSIFIER FOR GRAVITY DISCHARGE BALL MILLS

34

TYPICAL FLOW SHEET

BL

2.2.04

CSM

2.2.04

PROPOSED EQUIPMENT FLOW DIAGRAM FOR NEW CEMENT MILL WITH LV CLASSIFIER

3.2.04

LAKSHMI CEMENT LIMITED

EQP-LCL.CM4/2004

0

35

LV BALL MILL CLASSIFIER

36

LV CLASSIFIER, 1 - INLET

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LV CLASSIFIER, 2 - INLETS

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LV CLASSIFIER, 2 – INLETS (2ND GENERATION)

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CLASSIFIER CIRCUIT

40

CEMENT MILL MODIFICATION

41

CEMENT MILL INSTALLATION

42

CEMENT MILL UP-GRADE

43

CEMENT MILL UP-GRADATION RESULTS Holcim (Lanka) Limited – SRILANKA THE MODIFICATIONS :

Close circuited the system with LV Classifier



Mill venting system upgraded with additional bag filter and fan



Classifier Venting system – Classifier feeding system & reject handling product conveying system were newly installed.

RUHUNU CEMENT WORKS MILL NO 1 Description Production (tph) Specific Surface (cm2/gm) Specific Power consumption kwh/t

Before Modification

Guaranteed

After Modification

23.5

25.6

26.2

3300+/-100

3600

3550 - 3600

31.9 (Mill + Mill Fan)

33 (Mill + Classifier+Mill Fan+Classifier Fan+Bagfilter Fan)

29.87 (Mill + Classifier+Mill Fan+Classifier Fan+Bagfilter Fan)

44

CEMENT MILL UP-GRADATION RESULTS Holcim (Lanka) Limited – SRILANKA THE MODIFICATIONS : 

Close circuited the system with LV Classifier Mill venting system upgraded with additional bag filter and fan



In Chamber 1 lifting liners were installed for 4.05 m length



New partition and discharge diaphragm grates were installed

RUHUNU CEMENT WORKS MILL NO 2 Description Production (tph) Specific Surface (cm2/gm) Specific Power consumption kwh/t

Before Modification

Guaranteed

After Modification

28.2

30.6

33.5

3300+/-100

3600

3550 - 3600

30.9 (Mill + Mill Fan)

33 (Mill + Classifier+Mill Fan+Classifier Fan+Bagfilter Fan)

29.4 (Mill + Classifier+Mill Fan+Classifier Fan+Bagfilter Fan)

45

CEMENT BALL MILL UP-GRADATION RESULTS Holcim (Lanka) Limited – SRILANKA THE MODIFICATIONS :-



Replaced the HEYD Christian Peiffer separator with LV technology High Efficiency Classifier. Separator venting system upgraded with additional bag filter and fan



Mill Internals retained the same.



PALAVI CEMENT WORKS MILL NO 1 Description Production (tph) Specific Surface (cm2/gm) Specific Power consumption kwh/t

Before Modification

Guaranteed

After Modification

35.7

40

43.75

3600+/-100

3600

3600+/-100

32.8 (Mill + Mill Fan)

31.2 (Mill + Classifier+Mill Fan+Classifier Fan+Bagfilter Fan)

29.89 (Mill + Classifier+Mill Fan+Classifier Fan+Bagfilter Fan)

46

CEMENT BALL MILL UP-GRADATION RESULTS

47

CEMENT BALL MILL UP-GRADATION RESULTS Birla Corporation Limited – Cement:Raebareli - INDIA THE MODIFICATIONS :

Close circuited two ball mills with single LV classifier Description

Before Modification

After Modification

After Modification with pregrinder

30 X 2

35 X 2

50 X 2

Specific Surface (cm2/gm)

3100

3100

3100

Power consumption kwh (Mill + Mill vent fan power)

1533

1533

1533

---

445

447

Production (tph)

Power consumption kwh (Classifier + Classifier fan power)

48

RAW BALL MILL UP-GRADATION RESULTS Madras Cements Limited – INDIA THE MODIFICATIONS : Replacement of Sepax Separator with LV Technology classifier byutilizing sepax drive shaft assembly.  Replacement of rotor assembly  Replacement of guide vanes  Replacement of classifier housing and inner cone  Replacement of grit cone Description

Production (tph) Product Residue on 90 mic (%) Specific Power consumption kwh/t (Mill)

Before Modificatio n

Guarantee d

After Modificatio n

142

152

158

17 to 19

17 to 19

17 to 19

11.6

10.6

10.5

49

RAW BALL MILL UP-GRADATION RESULTS Kakatiya Sugar & Industries Limited – INDIA THE MODIFICATIONS : Replacement of O-Sepa classifier with LV Technology classifier  Installation of additional Bag Dust Collector Module  Installation of New Fan

Description

Before Modification

Guaranteed

After Modification

39

44

45

Product Residue on 90 mic (%) Product Residue on 212 mic (%)

20 3-3.5

20 3-3.5

20 1.5

Specific Power consumption kwh/t (Mill + Classifier + Fan)

23.73

22

21

Production (tph)

50

RAW BALL MILL UP-GRADATION RESULTS

51

LV CLASSIFIER FOR AIR SWEPT BALL MILL

52

LV CLASSIFIER FOR AIR SWEPT BALL MILLS

R.R

16/12/02 CSM

16/12/02 CSM

16/12/02

EQUIPMENT FLOW SHEET FOR COAL GRINDING CIRCUIT

SRI VISHNU CEMENTS 0

53

LV CLASSIFIER CROSS SECTION Rotor Cone Cone Rotor Guide Vane Vane Guide Casing & & Casing Support Point Point Support Rotor Rotor Blade Blade Grit Cone Cone Grit (Reject Outlet) Outlet) (Reject Gas Entry Entry Gas (Mill Outlet) Outlet) (Mill

54

COAL BALL MILL UP-GRADATION RESULTS Madras Cements Limited – INDIA

THE MODIFICATIONS :

Static Separator to High Efficiency LV Classifier Description

Before Modification

Guaranteed

After Modification

Production (tph) ( Pet coke 100% )

7

7

8

Product Residue on 90 mic (%)

10 to 12

5 to 6

4 to 5

55

COAL BALLMILL UP-GRADATION RESULTS JK Lakshmi Cements Limited – INDIA

THE MODIFICATIONS :

Static Separator to High Efficiency LV Classifier Description

Before Modification

Guaranteed

After Modificatio n

Production (tph) (Pet coke 100% )

12.5

14

14.5

Product Residue on 90 mic (%)

2.2

2

1.8

Specific Power consumption kwh/t (Mill + E.S.P. Fan)

49.6

47

47

56

COAL BALLMILL UP-GRADATION RESULTS Sri Vishnu Cement Limited – INDIA

THE MODIFICATIONS :

Static Separator to High Efficiency LV Classifier Description

Before Modification

Guaranteed

After Modification

Production (tph)

32.85

44

44

Product Residue on 90 mic (%)

17.06

17

16.08

34

28

26.4

Specific Power consumption kwh/t (Mill + Fan)

57

LV SPIRAL CYCLONE

58

DIFFERENT CYCLONE SIMULATION RESULTS

59

SPIRAL CYCLONE SIMULATION

60

LV SPIRAL CYCLONE

61

RAW MILL CYCLONE MODIFICAION

62

LV CYCLONE KCP Limited – Macherala INDIA Description

Befor Installation

After Installation

Production (tph)

130

138

Gas Flow (Km3/hr)

210

210

No of Cyclones

4

2

Cyclone Dia (m)

3.1

4.8

Pressure Drop (mm wg)

220

110

Fan Speed (rpm)

760

740

Fan Power kwh

760

680

63

LV CYCLONE Birla Corporation Limited – Satna INDIA

Description

Befor Installation

After Installation

Production (tph)

241

266

Gas Flow (Km3/hr)

340

460

No of Cyclones

4

2

Cyclone Dia (m)

3.6

5.4

Pressure Drop (mm wg)

200

110

64

OPERATING DATA – LV CYCLONE Madras Cements Limited – R.R.Nagar INDIA Description

Befor Installation

After Installation

Production (tph)

142

158

Gas Flow (Km3/hr)

360

345

4

2

150

100

No of Cyclones Pressure Drop (mm wg)

65

KILN UP-GRADES Preheater (pressure loss, efficiency) Calciner (fuel burn out, retention time, mixing) Gas transport (fans, cooling tower, filter) Kiln (speed, volume) Cooler (inlet, fan flows, grate plates) Fuel system (capacity)

66

PRE-HEATER MODIFICATION AT SHAHROUD CEMENT

67

KILN UP-GRADE - SHAHROUD , IRAN THE MODIFICATIONS:     

Remove refractory in top stage and LV Cyclone (insulation outside) Enlarge inlet area to bottom stage cyclone Central pipe installed in bottom stage cyclone Increase height of calciner and modify tert. air inlet to calciner Change position of calciner gas burners

Before

After

2400

2800

Heat cons. (kcal/kg)

750

740

Dp preheater (mbar)

54

58

CO preheater out (%)

0.30

0.10 – 0.15

Production (tpd)

Further modifications: Kiln speed up from 3.0 – 4.2 rpm, new fixed grate cooler inlet.

68

CHANGE OF TOP CYCLONES AT CHINFON HAIPHONG

69

KILN UP-GRADE RESULTS CHINFON HAIPHONG THE MODIFICATIONS: 

Additional EP filter fan (in parallel to existing)



Fixed cooler inlet



New classifier for Raw mill (production up 17 %)



New classifier for Coal mill (production + reduced fineness)



Decrease top stage pressure loss from 19.5 mbar to 7 mbar (Reduced ID-fan kWh/t by ~ 11% ~ 200 – 250 KW) Description Production (tpd) Heat cons. (kcal/kg) Dp preheater (mbar)

Before

After step 1

After new LV top cyclones

4300

4650

4650 (4800)

815

800

800

68

76

54

70

KILN UP-GRADE RESULTS JK – LAKSHMI CEMENT - INDIA 1

EXTEND IMMERSION TUBE

2

INCREASE THE HEIGHT

FL+58550 OF 5 STAGE CYCLONE AND INLET DUCT

FL+46950 A

A

3

INSTALL NEW IMMERSION TUBE

4

INCREASE THE HEIGHT OF 6 STAGE CYCLONE AND INLET DUCT

B

FL+32000

FL+26350

FL+17150

FL+12150

VIEW SCALE

B 1:175

MODIFIER INLET DUCT OF 6 STAGE CYCLONE

SECTION A-A SCALE

1:175

71

KILN UP-GRADE RESULTS JK – LAKSHMI CEMENT - INDIA THE MODIFICATIONS : Increased inlet height of cyclone 5 by 1 Meter  

Increased inlet height of cyclone 6 by 1 Meter Installation of immersion tube in cyclone 6

Description

Before Modification

After Modification

Remarks

Production (tpd)

3400

3520

Increased by 120 tpd

Pre-Heater outlet Static Pressure (mmwg) Pre-Heater Fan Specific Power Kwh/t Clinker

907

824

14.46

14.31

Reduced by 83 (mmwg)

Reduced by 0.15 kwh/t clinker

72

KILN UP-GRADE RESULTS MAIHAR CEMENT - INDIA

73

KILN UP-GRADE GUARANTEED RESULTS MAIHAR CEMENT - INDIA

THE MODIFICATIONS PROPOSED :

Introducing Secondary firing in riser duct.



LV cyclone in stage 2&3



To Modify Riser Duct from stage-4 outlet to stage-2 inlet.

Description

Present

Guaranteed

Production (tpd)

1750

2000

Specific Fuel Consumption Kcal/Kg.Cl

840

828

Remarks Under execution

74

CALCINER TYPE - 1

75

CALCINER TYPE - 2

Cylindrical section in order to favor the whirlpool effect

Tangential intersection in order to increase initially whirlpool speed

Divergence section to reduce upward flow energy

76

CALCINER FLOW PATTERNS

Calciner Type -1

Calciner Type -2

77

SLICE CONTOUR / HORIZONTAL PLANE

Calciner Type -1

Calciner Type -2

78

LV CALCINER AND DOWNDRAFT CYCLONE

79