khd separators april 2012

7/29/2019 Khd Separators April 2012

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VSK e Separator(e = extended version)

TheVSKe Separatorwill require significantly less mechanical conveyingcapacity. To accomplish this, theVSK is split into two parts. The staticV - part underneath the roller press and the dynamic SK- part above the

roller press are connected by a riser duct (e), over which all fines from theV- part are lifted by air flow to the VSK-part.

Focus on efficiencyKHD Separators

www.khd.com

VSK features:

Five jobs in one unit: Relieving the dynamic classifier of coarse material by pre-classifying. Mixing feed and recycled material before entering the roller press. Deglomeration of RP discharge by impact action of the cascade. Drying / cooling. High efficiency classifying.

Cut size between 25 and 150 m. Effective wear protection.

The benefits of the VSK

e are: Minimizing of bucket elevator capacity Higher feed rates can be processed

Reduction in building volume Lower capital investment.

VSK SeparatorTheVSK combines the sturdy design

of theV - Separatorwith the highperformance of the SEPMASTER.The cage wheel is arranged as anadd-on module to the V. With theV andVSK Separator, the needfor auxiliary equipment is greatly re-duced: no separate dryer, nodeglomerator. New ways of processdesign are now open to a widefield of applications for new plantand upgrade alike. Wear is minimi-zed, even when grinding

abrasive materials. These newsystems are not exclusively boundto the roller press, but can beapplied in grinding circuits with

tube mills and impact hammer mills.Tailor-made solutions by KHDHumboldt Wedag are available.

V + SK = VSK

KHD Humboldt Wedag GmbHColonia - Allee 351067 Cologne / GermanyPh.no: +49 221 6504 0

ZAB ZementanlagenbauGmbH DessauBrauereistrae 1306847 Dessau-Rolau / GermanyPh.no: +49 340 50 29-2 13

Humboldt Wedag India Private Ltd.Mehtab House, A - 36, MohanCo - op Estate, Mathura RoadNew Delhi - 110044 / IndiaPh.no: +91 11 4210 1100

OOO KHD Humboldt EngineeringMjasnizkaja ul., 24/7B. 1, Office 108101000 Moscow / RussiaPh.no: + 7 495 6 23 34 80

Humboldt Wedag, Inc.400 Technology ParkwayNorcross GA 30092 / USAPh.no: +1 770 810 7315

www.khd.com

KHD Humboldt Wedag MachineryEquipment (Beijing) Co. LtdCITIC Building, 25A19 Jianguomenwai StreetBeijing / China 100004Ph.no: +86 10 6500 4101

Humboldt Wedag GmbH,P.O. Box 380Jeddah 21411KINGDOM OF SAUDI ARABIATel: +966 2 671 7121

Humboldt Wedag GmbH MerkeziAlmanya Trkiye stanbul ubesiAyazaga Mah. Meydadan Sk. No: 1Beybi Giz Plaza K: 26&27Maslak 34396 stanbulTrkiye


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fine products suchas high qualitycement or filler.As a result ofthe excellentselectivity,grits returned

to the mill inthe grindingcircuit are wellcleaned of fine mate-rial. Because of this,more fresh material can be fedto the mill. The Tromp selectivitycurve is used to assess the selectivityperformance of separators.The KHD SEPMASTER achieves topmarks, as can be seen in the graph.

Setting the cutpoint:

Fineness of the finished product isquickly and accurately set by thecage speed.

Consistent qualityVariation in fineness and massflow of the feed material have little

effect on the fineness of the finished

product. The quality of the productremains constant.

Readily re-producible

separator

resultsThe desired

material fine-ness can be

quickly reproduced,a great advantage when

switching to a different product.

The SEPMASTERHigh-performance separators have a long tradition at KHD Humboldt Wedag.Our SEPMASTER provides excellent selectivity and fits into small space. Inaddition to installation in new mill circuits, the SEPMASTER is particularlywell suited for increasing the productivity of mills already in operation. Theinnovative rotor cage system enables the grinding of premium product qualities.The investment cost incurred by a change of separators is quickly recovered.Through its compact dimensions and low operating and maintenance cost theSEPMASTER significantly increases grinding plant efficiency.

Depending on size and application, the SEPMASTER separator is available in variousversions and with specifically tailored protection against wear and tear.

Efficiency of separation

Precise separation was previouslyonly possible on a laboratoryscale, but can now be achievedin large plants because of theSEPMASTER's high performance.Upgraded plants show savings ingrinding energy of 10 to 20 % onaverage and production increases

of 10 to 25 % for cement raw mealand normal cement. Significantlyhigher production increases of morethan 50 % have been achievedin the manufacture of extremely

SEPMASTERProcess and optionsFine material and coarse material are sepa-rated at the periphery of the rotor cage in avortex predetermined by air deflectors and therotation of the cage. The airstream, which is fedhorizontally, will drag the fine par ticles against thecentrifugal force to the inside of the cage wheel andfrom there to the fine material discharge. The coarsegrains are pushed away from the separator wheelby the centrifugal force and drop into thecoarse material discharge.

Rotor stability

The rotor shaft is supported at both ends. This concept avoidsvibration and ensures a smooth and safe running machine, evenwhen producing very fine products.

Why is the drive on the bottom?

For maintenance work on the separator, gearbox, motor and el ectriccables do not need to be moved. The drive is positioned away from

the heat and easily accessible.

The bearings are outside.

The support bearings are located outside the separator housing and canbe easily installed or removed, whilst the cage wheel remains in normal

position.

Resistance to wear and tear = lower costs.

Easily replaceable parts made of high quality materials such ascast basalt, ceramics, chromium carbide or chilled iron gua-

rantee long life.

Fits comfortably into small spaces.

The SEPMASTER is the perfect replacement for old se-parators. Compared to older generation separa-

tors, the SEPMASTER cage wheel separator is notonly more efficient but also significantly smal-

ler and l ighter.

10 100200

1.0

0.9

0.8

0.7

0.6

0.5

0.4

0.3

0.2

0.1

0.0 Grainsize,m

Degreeo

fseparation

1

Typical SEPMASTER selectivity curve according to Tromp.

Feed

Coarse

Fines

Replaceable cage bars makeeasy maintenance.

Feed

Fines

Coarse

Drive

Rotating

SKS-Z

4

3

2

1

4

3

2

1


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coarse separation t/h

150190240280350410480

560640770880980

fine separation t/h

230300370440550640750

8801,0001,2001,3701,530

SKS - Z and SKS - L

Rotor cage diameter (mm)

1,7502,0002,2502,5002,7503,0003,250

3,5003,7504,0004,3004,600

SKS - M

Separator Size

400550700850

1,0001,1501,350

1,550

fine separation t/h

491524344363

84

Feed material Feed material

coarse separation t/h

71525395772

104

141

SEPMASTER SKS - V:

For combination with the KHDV - SEPARATOR.

SEPMASTER SKS - Z:

The hundredfold proven separator for separating in the range from 20 to 250 m cut point.

SEPMASTER SKS - L:

For use on air-swept systems. Highly suitable for In-Process-Drying.SEPMASTER SKS - M:

For extremely fine products.

Important effect on downstreamperformance

Excellent product quality isachieved by accurate controlof oversize material. For rawmeal, low levels of super finematerial allows for good burn

and flow characteristics.

Fine material without "OSP's"(oversized particles)

The rotor seal, which is purgedwith fresh air, ensures fine pro-ducts without oversized particlesand higher protection againstwear. Quick-Lime producers inparticular enjoy the "OSP" freeoperation performance of theSEPMASTER. SEPMASTER SKS - V:The feed material is fines from theV - SEPARATOR.

Feed

Fines

Coarse

Coarse 1

Coarse 2

Secondary air

SKS - L SKS - M

Open-circuit mill (blue)and closed-circuit mill (blue and red)

Fresh material

Finished material

Coarse material

Waste gas

6

5

4

3

2

1

4

3

2

1

2

2

1

1

65

4

3

2 2

2

The SEPMASTER family

Although tube mills have higher energy consumptionthan more modern grinding systems, they do offer

a number of benefits which justify their use:

High availability Perfect cement characteristics Simple adjustment Easy maintenance Extreme resistance to abrasion

Our classic

For grinding cement or granulated slag, tube mills are inoperation either as open-circuit mill or as closed-circuitmill with the SEPMASTER high performance separator.These mills have a length to diameter ratio of more

than 3.0 and are supplied with one or two grin-ding chambers.

Optimum solutions for each grinding processGrinding with the tube mill

1

3

4 4


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Shape giving nameThe V - Separator

The V - SEPARATOR in operation

Originally developed to separate finematerial from a roller press circuit, the

V - SEPARATORhas, however, alsoproved its value in tough applications

with large mass flows and abrasivematerial of wide size range and high

levels of feed moisture.

How does it work?

Material is fed from above to the built-in step grate. From here, the fine ma-

terial is carried upwards with the airthrough the separating channels, the

coarse material falls down over the

step grate and is discharged at thebottom of the housing. The ratio of

material load to separating air can beup to three times higher than with an

airstream separator.

Virtually unlimited use

The required product fineness is achie-ved by adjusting the air speed in theseparating channels. Cut pointrange is from

approx. 80 mto 1.5 mm.

Limiting wearand tear

All internalparts are fixed

and havestraight and

level surfaces, as

does the housing.This ensures simple but

effective protection againstwear, eliminating the need for main-

tenance work for many years.

Grinding and drying, all in oneA short tube mill with or without drying

chamber (depending on feed material moi-sture) is used for drying and grinding of ce-

ment raw material. Theair-swept mill is advan-

tageous when the moi-sture level

is high, whereas the

closed-circuit mill is mostlyused for low moisture and high

fineness levels. Air-swept mills aregenerally used for grinding coal.

Team work is top!

The TANDEM grindingplant is a KHD Humboldt Wedag develop-

ment. An impact hammer mill (PHM) isconnected in series with a tube mill. Thesolution offers excellent drying performan-ce and handles feed sizes of up to 120

mm. Highly abrasive raw material can befed directly to the tube mill.

When the going gets hard

The center discharge mill is used for materialwhich is very difficult to grind. It has two

grinding chambers, both of which can befed with fresh material and grits. The

SEPMASTER SKS - L, which is fed bya gas stream from below and via

a bucket-elevator from above, isthe separator of choice for

this mill.

The benefit to you

TheV - SEPARATOR is an uncomplica-ted static separator without any mo-

ving parts. Since it carries outa whole range of pro-

cess functions,it considerably

extends the

range of ap-plications for

high pressurecomminution.

In additionto reduced in-

vestment for

machinery, theV - SEPARATOR also

results in energy savings.With the rising cost of energy, this will

become increasingly important.

The Allrounder.

Despite its si mple design, the V - SEPARATOR carries out a whole range of process-related tasks wit hin thegrinding circuit:

Separating fine material fromfresh material

Drying moisture from freshmaterial

Cooling hot fresh material

Deglomeration Mixing fresh material and grits Preventing formation of deposits

when grinding granulated slag bypositioning theV - SEPARATOR un-

derneath the roller press. Producing a finished material with

custom tailored grain size distribu-tion by combiningV - SEPARATOR

and cage wheel separator.

PHM impact dryer

V - SEPARATOR:

gas and material flow

Computerized-Fluid-Dynamic (CFD) Simulation

Center discharge mill

TANDEM grinding plant: Pneumatic transfer of groundmaterial from PHM and tube mill to the separator

Airswept grinding plant

(blue) and TANDEM

grinding plant (blue and red)

Fresh material

Finished material

Coarse materialHot gas

Waste gas

Return gas

Feed

Fines

Coarse

Air

Separating channels

6

5

43

2

1

5

4 4

33

2

1

6

6

5

44

3

2

15

4

3

2

1 4

5

2

3

1

m/sec

khd separators april 2012

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