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SUMMARY ZUSAMMENFASSUNG
Without any doubt, today´s grinding plants have to feature Die Mahlanlagen von heute sind durch den Einsatz hoch
highly efficient mills with high efficiency classifiers showing effizienter Mühlen, ausgerüstet mit Hochleistungssichtern,
low specific energy consumption and the highest possible gekennzeichnet, die sich durch einen niedrigen spezifischen
mechanical durability. However, that alone is not sufficient Energiebedarf und eine höchst mögliche Dauerverfügbarkeit
to create the highest conceivable standard. Concepts are auszeichnen. Allerdings reichen diese Merkmale allein nicht
required which are not only aimed at certain parts of a grind- aus, um dem denkbar höchsten Standard zu entsprechen.
ing plant and its process but which are part of a comprehen- Es sind Konzepte gefragt, die nicht nur auf Veränderungen
sive approach to creating competitive projects. This can only bestimmter Teile einer Mahlanlage und des Prozesses aus-
be done by keeping the main goals in mind, which are low gerichtet sind, sondern die generell das Ansinnen verfolgen,
TCO-values, as little as possible environmental impact and wettbewerbsfähige Produkte zu kreieren. Das ist nur dann
the highest safety standards. Any design detail of a grinding erreicht, wenn solche wichtigen Anforderungen wie niedrige
unit should follow this philosophy. With the innovative COPE TCO-Werte, kleinstmögliche Einwirkungen auf die Umwelt
drive and the “4+4” cement mills and 6-roller raw mills in und auch ein hoher Sicherheitsstandard Berücksichtigung fin-
combination with a common parts concept covering both of den. Jedes Designdetail einer Mahlanlage muss heute dieser
the mill types, the technical and commercial risks derived Philosophie folgen. Mit dem innovativen COPE-Antrieb, den
from single grinding unit solutions are significantly reduced. (4 + 4) Loesche Mühlen für die Zementmahlung und seinen
Unexpected and undesirable down-time of the grinding plant 6-Rollenmühlen für die Rohmaterialmahlung in Kombination
is avoided by built-in redundancy and an optimized spares mit einem Gleichteile-Konzept, werden die technischen
management. By employing the compact plant design which wie auch kommerziellen Risiken, die sich aus Ein-Mühlen-
can be adapted to the respective project specifics, the Lösungen ergeben, signifikant herabgesetzt. Unerwartete
CAPEX of an installation is significantly reduced whilst improv- und unerwünschte Stillstände einer Mahlanlage können
ing on process features at the same time. Supplementary to vermieden werden durch „eingebaute“ Redundanz und ein
this, the LM-Master control system increases the availability kluges Ersatzteilmanagement. Indem ein sehr kompaktes
of the grinding plant at high capacity levels and maintains a Anlagendesign zur Anwendung gelangt, das den jeweiligen
constant product quality. Many other issues, such as plant Projekterfordernissen anzupassen ist, wird die CAPEX einer
flexibility, separate versus intergrinding or variable speed ver- Installation signifikant reduziert bei gleichzeitiger Verbesse-
sus fixed speed etc., can be raised and also controversially rung charakteristischer Prozessmerkmale. Ergänzend dazu
discussed with respect to their purpose in contributing to
PROCESSING
PROCESSING
and depending on the region may have a greater effect. Water Mean roller diameter m ˜ 2.7
Product rate [t/h] as function of the LM size LM-CS models with product throughputs and drive power (approx. values)
LM 75.4+4 13000 kW
LM 70.4+4 9600 kW
LM 69.6 ~6900 kW
LM 60.6 ~5300 kW LM 63.3+3 7100 kW
LM 56.4 ~4200 kW LM 59.3+3 6200 kW
LM 53.6 ~3600 kW LM 56.3+3 5600 kW
LM 48.4 ~3100 kW
LM 46.4 ~2600 kW LM 53.3+3 4650 kW
Fineness
LM 45.4 ~2000 kW LM 56.2+2 4300 kW Fine Coarse
LM 41.4 ~1900 kW LM 48.2+2 3800 kW Cement
LM 38.4 ~1750 kW LM 46.2+2
~1600 kW 3450 kW
LM 35.4 GGBFS
LM 38.3 ~1400 kW LM 41.2+2 2700 kW
Fineness
LM 31.3 ~1200 kW Fine Coarse LM 35.2+2 1600 kW Difficult Easy
~700 kW Grindability
LM 31.2
LM 24.2 ~600 kW Difficult Easy
0 50 100 150 200 250 300 350 400 450 500 550 600
~450 kW Grindability
LM 21.2
Product throughput [t/h]
0 200 400 600 800 1000 1200 1400
Product throughput [t/h]
Figure 4: a) Sizes of Loesche cement raw material mills; b) Sizes of Loesche cement mills
PROCESSING
12.5 13.2
12
8 6.5 7.5 7.0
New features compared to LSKS: LDC
• Vortex rectifier 4
• Bearing cartridge LSKS
• Optimized guide vane 0
LM 46.2+2 LM 53.3+3 LM 56.3+3
• Enlarged classifying gap
• Improved velocity profile
CEM I, fineness 3500 cm2/g (Blaine)
20
16.1
16 14.2
Pressure drop
12
8.4 8.2
8
LDC
4
LSKS
0
LM 46.2+2 LM 56.3+3
Figure 5: LDC with Vortex Rectifier Figure 6: Pressure drop data of the LDC compared to the LSKS
Maximum limit
24700 mm
37305 mm
Time
ity. The design of the classifier has an influence upon the
particle size distribution (PSD) of the product and the inter-
nal circulation of the machine. The latter is one of the fac- Controlled variable Constraint variable Manipulated variable Disturbance variable
tors determining the pressure drop of the mill and related e.g. fineness, outlet e.g. vibration, e.g. feed, classifier e.g. feed moisture,
to this, the specific energy consumption at the fan as well temperature motor load speed, grinding grindability, wear
pressure
as the grinding efficiency.
PROCESSING
Bearing that in mind, Loesche re-designed its LSKS classi-
Figure 9: LM-Master control system
fier in 2008 and the LDC classifier (� Fig. 5), which repre-
sents the latest generation of dynamic classifier develop-
ment, was introduced to the market in 2009. Compared to 4 LM-Master control system
the former LSKS, the LDC exhibits enhanced process and
mechanical features of which the patented Vortex Rectifier Basically, there is no such thing as a modern grinding
is the most prominent. plant without a state-of-the-art control system. Loesche´s
approach to this is the LM-Master (� Fig. 9) which can be
By the beginning of 2015 some 35 classifiers of this type combined with most of the common PLCs and, in its basic
have been put into operation in combination with different version, works with standard instrumentation. The system
mills for raw material, slag and cement grinding. is aimed at an increased average production rather than at
the peak performance. To accomplish this, the LM-Master
The comparison of delta p-values over the classifier for the actively controls parameters such as the grinding pressure,
old and the new design shows a consistently reduced pres- water injection, gas flow and classifier speed. Always main-
sure drop for the LDC (� Fig. 6). In terms of product quality taining the product quality, the system finds the ideal com-
the particle size distribution (PSD) is in the same range as bination of process parameters to increase the availability
before with slopes of n = 0.90 to 1.05. of the mill at the highest possible throughput. In case the
throughput is not of highest priority, the LM-Master is capa-
For the purpose of retrofitting existing LSKS classifiers, the ble of optimizing for specific energy consumption as well.
LDC classifier comes in its LSVS-version adapted to the geo- Furthermore the vibration level and the absorbed power of
metrical situation in the respective grinding plant. Thus the the main drives are kept within the given limits. 3
Loesche GmbH
Hansaallee 243
40549 Düsseldorf
Tel. +49 - 211 - 53 53 - 0
Fax +49 - 211 - 53 53 - 500
Email: loesche@loesche.de