Presentation

for
Holcim
Presented by:
Thomas Leppak
Head of Customer Support
Customer Service
Thomas.Leppak@loesche.de
Agenda

ƒI Loesche Retrofits

ƒ A Classifier Type LDC (C/S mills and raw mills)

ƒ B Converted LSKS classifier to LDC (C/S mills and raw mills)
ƒ C Changed profile of M-tires (C/S mills)
ƒ D Exchange of S-roller tyre (C/S mills)
ƒ E Modified classifier LSKS (raw mills)
ƒ F False Air Entry
ƒ G Heat Utilisation System

ƒ II Summary

© by LOESCHE GmbH
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Loesche Retrofits
Classifier Type LDC (C/S- and Raw mills)

LSKS (old design) LDC (new design)

ƒ Bearing Cartridge
ƒ Vortex Rectifier
ƒ Optimized Guide Vane
ƒ Enlarged Classifying Gap
ƒ Chute inside the Grit Cone
ƒ Consequent Velocity
Increase
ƒ Grit Cone Extension

© by LOESCHE GmbH
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Loesche Retrofits
Classifier Type LDC (C/S- and Raw mills)

Main Targets:
Optimised mechanical properties
Optimised process
Optimised flow

ƒ After 14 successful years the LSKS willl be

replaced step-by-step by the LDC
ƒ Experience in operating large classifiers
was basis for new design

© by LOESCHE GmbH
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Loesche Retrofits
Classifier Type LDC (C/S- and Raw mills)

Flow profile with LSKS Flow profile with LDC

Results

© by LOESCHE GmbH
• Reduced pressure loss
• More homogenous filter pressuration
• Wear reduction

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 Loesche Retrofits
Classifier Type LDC (C/S- and Raw mills)

Improved velocity profile

v1 < v2
V&new = V&old ⋅ 85%
v2new = v2old (new geometry)

v2

Modified shape
v1

Results
• Reduced pressure drop across the mill
• lower gas volume
• Increase of classifying efficiency

© by LOESCHE GmbH
• Mill Reject can be controlled at10-15%

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Loesche Retrofits
Classifier Type LDC (C/S- and Raw mills)

Enlarged classifying zone

Results
• Enhanced classifier efficiency and less power
consumption of classifier
• Less fines in the grits

© by LOESCHE GmbH
• Better stability of grinding bed leads to better
grinding efficiency

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Loesche Retrofits
Classifier Type LDC (C/S- and Raw mills)

Rotor modular design:

ƒ Protected blades
ƒ Easy to assemble/maintain
ƒ Higher stiffness of rotor

© by LOESCHE GmbH
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Loesche Retrofits
Classifier Type LDC (C/S- and Raw mills)

ƒ Patented Vortex Rectifier

ƒ Air spins around with the rotor
ƒ Vortex kinetic energy recuperation
ƒ Restores a linear flow in the ductwork

© by LOESCHE GmbH
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Loesche Retrofits
Classifier Type LDC (C/S- and Raw mills)

Bearing Cartridge redesigned:

ƒ Load distribution into the frame via lower
fixed bearing
ƒ Temperature and Vibration Sensors

Bearing Cartridge

© by LOESCHE GmbH
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Loesche Retrofits
Classifier Type LDC (C/S- and Raw mills)

Grit cone + chute extension

• separate feed for raw material
• separate feed for grit return
• no mixing of wet and dry material
• caking can be prevented

© by LOESCHE GmbH
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Loesche Retrofits
A: Classifier Type LDC (C/S- and Raw mills)

ƒA 15% powersaving can be realized after Installation of a

complete new classifier type LDC

Advantage: High energy savings

Disadvantage: Additional height in plant is

needed
Material feed has to be adapted
Mill outlet duct has to be adapted
High erection costs

© by LOESCHE GmbH
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Loesche Retrofits
A: Classifier Type LDC (C/S- and Raw mills)

Check height for

bearing cartridge

© by LOESCHE GmbH
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Loesche Retrofits
B: Classifier Type LDC (C/S- and Raw mills)

ƒB 10% Energy saving can be realized after conversion of the

existing classifier to a classifier with Vortex Rectifier

Advantage: Classifier housing can be reused

so that feedpoint and outlet duct will be
unchanged
Erection costs are low compared to
erection costs of a complete LDC

Disadvantage: Efficiency lower then for a complete LDC

Full technical advantages cannot be
implemented due to limited space
Tailor made engineering for classifier is

© by LOESCHE GmbH
needed

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Loesche Retrofits
A+B : Classifier Type LDC (C/S- and Raw mills)

The price ratio between A and B will be appr. 2:1

due to the much higher costs of the erection of a
Complete LDC classifier compared to those of a
Modified LSKS classifier

© by LOESCHE GmbH
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Loesche Retrofits
C: Changing profile of M-tires (C/S- and Raw mills)
Welded
layer

Results
Optimized grinding efficiency through the whole
width of the tyre during operation

Actual condition Target state

© by LOESCHE GmbH
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Loesche Retrofits
C: Changing profile of M-tires (C/S- and Raw mills)

© by LOESCHE GmbH
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Loesche Retrofits
C: Changing profile of M-tires (C/S- and Raw mills)

ƒC Changing of profile of M Tyres

3% capacity increase

© by LOESCHE GmbH
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Loesche Retrofits
D: Exchange of S-roller tyre (C/S mills)

© by LOESCHE GmbH
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Loesche Retrofits
D: Exchange of S-roller tyre (C/S mills)

Investigations on particle trajectories

onto mill table:
influenced by:
- centrifugal force
- friction between particle and mill table
- friction between particle and particle
- size and shape of particles

© by LOESCHE GmbH
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Loesche Retrofits
D: Exchange of S-roller tyres (C/S mills)

ƒD Exchange of S-roller tyres

3 % capacity increase

© by LOESCHE GmbH
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Loesche Retrofits
E: Modified Classifier Type LSKS (raw mills)

ƒE 7% Energy saving by improved velocity profile of the

classifier LSKS

v1 < v2
V&new = V&old ⋅ 85%
v2

Modified shape v2

v2 new = v2old
v1

v1

© by LOESCHE GmbH
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Rocker Arm Sealing
F: False Air Entry

© by LOESCHE GmbH
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Rocker Arm Sealing
F: False Air Entry

ƒ Moving parts of the rocker

arm are sealed to the mill
body by a boot
ƒ Existing seal air prevents
deposit of ground material
inside boot
ƒ No additional seal air required

© by LOESCHE GmbH
Design of new sealing

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Rocker Arm Sealing
F: False Air Entry

Calculation basis (LM 48.4):

Energy savings related to operating hours
Electricity costs: 0,05 €/kWh

Reduction in kWh per year

Operating time: 8000 h/a
Volume flow: 690.500 m³/h
Fan power: 3500 KW
Power savings: 2.295.000
kWh/a
Additional profit: 115.000,- €/a
Benefits:
¾ reduces energy costs
Operational hours per year

© by LOESCHE GmbH
small investment = big savings

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Loesche Retrofits
G: Heat Utilization System

95°C
~35°C 20°C
Total heat loss:
Qv = [M1. cpw.+ (M2+M3) . cpL+ M4.cpV] x (35°C
(95°C - 20°C)

95°C 80°C

95°C

© by LOESCHE GmbH
20°C
80°C
20°C
80°C

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Design Example for Waste heat utilization system

© by LOESCHE GmbH
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Loesche Retrofits
G: Heat Utilization System
Plant Plant
without HE with HE

Mill Feed Slag, 90 t/h, Slag, 90 t/h,

Material moisture 8%, moisture 8%,
ambient 15°C ambient 15°C
total Exhaust air/ 76.394 Nm3/h 76.491 Nm3/h
temperature/ 104 °C 104°C
dew Point 55 °C 55 °C
Fresh Air/ 38.331 Nm3/h 39.850 Nm3/h
temperature 15 °C 84 °C
Exhaust air to HE, 76.491 Nm3/h
temp. behind HE 93,2 °C
Condensate 0,9 m3/h
Burning Gas 28,4 GJ/h 24,7 GJ/h

© by LOESCHE GmbH
energy savings 410.256 Euro/a* *Based on 14 Euro/GJ
(5,04 ct/kWh, 22h/d, 30
fuel/year ≈ 13 % d/month, 12months)
Estim. invest costs 600.000 Euro

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Loesche Retrofits
G: Heat Utilization System

ƒ ″Grinding Terminals″ which use hot gas generators

ƒ Feed materials with high moisture content
¾ The greater the moisture to be expelled, the more efficient the HUS

© by LOESCHE GmbH
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Loesche Retrofits
G: Heat Utilization System

ƒ Annual fuel cost savings of between 10% and 20%

ƒ Short Return On Investment
ƒ Partial or complete substitution of the return gas by preheated fresh air
ƒ Condensate can be used as mill injection water

© by LOESCHE GmbH
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Summary
ƒ List of selected raw mills:
Modification possibility
Mill type No Mill size Year Code name A B C D E F G
Raw mill 1 69.6 2007Bhatapara 2 India x x x x x
Raw mill 2 50.4 1992Tabfa 5 Thailand o x x x e
Raw mill 2 50.4 1998Tabfa 6 Thailand o x x x e
Raw mill 1 46.4 2005Settat Morocco x x x x x
Raw mill 1 46.4 1995Hon Chong Vietnam o x x x x
Raw mill 1 38.4 1978Almeria Spain o x x x e
Raw mill 1 38.3 1994Cartago Costa Rica o x x x e
Raw mill 1 32.4 1973Untervaz Switzerland o x x x e
Raw mill 1 32.5 1972Höver Germany o x x x e

A Classifier Type LDC (C/S mills and raw mills)

B Converted LSKS classifier to LDC (C/S mills and raw mills)

C Changed profile of M-tires (C/S mills) x possible

D Exchange of S-roller tyre (C/S mills) o to be checked

© by LOESCHE GmbH
E Modified classifier LSKS (raw mills) e complicated modification by mills without modular design

F False Air Entry

G Heat Utilisation System

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Summary

ƒList of selected C/S mills: Modification possibility

Mill type No Mill size Year Code name A B C D E F G
C/S mill 1 56.3+3 C 2007Kolar India x x x x x
C/S mill 1 56.3+3 C 2008Nalagarh India x x x x x
C/S mill 1 56.3+3 C 2007Dadri India x x x x x
C/S mill 1 56.3+3 C 2007Panipat India x x x x x
C/S mill 1 56.3+3 C 2007Bihar India o x x x x
C/S mill 1 56.3+3 S 2007Bellary India x x x x x x
C/S mill 1 56.3+3 S 2005St. Lawrence Slag Canada x x x x x
C/S mill 1 56.3+3 C 2005Settat Morocco x x x x x
C/S mill 1 56.2+2 S 2003Thi Vai Vietnam x x x x
C/S mill 2 56.2+2 C/S 1998Pacasmayo Peru x x x x
C/S mill 1 46.2+2 C/S 2002Carboneras Spain o x x x
C/S mill 1 46.2+2 S 2002Dunkerque France x x x x x
C/S mill 1 46.2+2 C 2002Ras el Ma Morocco x x x
C/S mill 2 46.2+2 C 1995Hon Chong Vietnam o x x x

A Classifier Type LDC (C/S mills and raw mills)

B Converted LSKS classifier to LDC (C/S mills and raw mills)

C Changed profile of M-tires (C/S mills) x possible

© by LOESCHE GmbH
D Exchange of S-roller tyre (C/S mills) o to be checked

E Modified classifier LSKS (raw mills) e complicated modification by mills without modular design

F False Air Entry

G Heat Utilisation System

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Many thanks
for
your
Attention!