Competence in cement - Gebr. Pfeiffer SE

GEBR. PFEIFFERProgress is our traditionGebr. Pfeiffer has a long andsuccessful history founded on highquality products, closeness to thecustomer and an international standing.Even in an environment undergoingfast changes, we remain loyal to thesestandards. This is how our companyand employees will shape the future.Since the company’s foundation in1864, we have always been significantlyinvolved in the development of modernprocess technologies for the sectorsgrinding, separating, drying, hydrating,and calcining.With more than 450 employees,our center of competence in Kaiserslauternas well as our subsidiaries inthe United States and India are activeall over the world, profiting from anextensive network of cooperationsand representations.The keys to our success are a wideproduct range, a modern test station,vast design and R&D capacities andinhouse workshops with a high verticalcapacity, all working with an extensivestore of experience especially in thecement, lime, gypsum, and ceramicsindustries.Our ultimate ambition is to developtailor made problem solutions meetingthe customer’s requirements. By establishinglong-lasting, reliable relationshipswith our customers to the benefitof high quality finished products, plantavailability, economic efficiency, andtechnical progress, we ensure a longservice life for our machines andplants.2 3

PFEIFFER MVR mill –the optimum machine forgrinding high throughput ratesThe solution to your problemIn the cement industry, MVR rollermills are used for grinding cement rawmaterial, cement clinker, granulatedblast-furnace slag, and pozzolana.Such bulk materials differ considerablyin terms of grindability and abrasiveness.The capacities of cement produc -tion lines vary within wide limits tosuit individual requirements. Due toits design, the MVR roller mill isspecially suited for high and veryhigh throughput rates.The working principleUp to six stationary grinding rollers rollon a rotating grinding track. Drawn inbetween the rollers and track, the feedmaterial is ground by pressure andshear. The compression forces requiredfor comminution are produced by aroller arm and pivot bearing along witha hydropneumatic tension system.The ground material is conveyed bycentrifugal forces towards the stationarynozzle ring. Gases (air or hot gas)flowing up through the nozzle ringcarry the ground and dried materialto the classifier where it is separatedinto grits and fines by the rotor. Thegrits fall back into the center of thegrinding area.The finished product leaves the classifierwith the gas flow for separation inthe downstream cyclones or filter.The advantagesMultiDrive ®The MultiDrive ® system consists of upto six identical drive modules ensuringactive redundancy of the drive system.The MultiDrive ® design allows anoptimum speed of the mill and thushighest flexibility.Active redundancy of thegrinding roller systemUp to six grinding rollers, which canbe swung out separately with theirspecial suspension system, and thegrinding plate form a grinding gapthat remains parallel in any operatingpoint, ensuring a uniform compactionof the material to be ground. Thisconcept creates an active redundancyas in the MultiDrive ® system.Low capital costMVR mills require few ancillaries,no or little building volume, theiroperation is dust free and theyhave a low noise level.Low electric power consumptionThe grinding principle and highefficiencyclassifier reduce electricpower consumption by up to 40 % ascompared with conventional ball mills.Optimum utilization of process heatMVR roller mills allow an optimumutilization of the thermal energy ofprocess gases.Maximum availabilityThanks to low specific wear rates, highquality wear materials, and modernrepair methods, the maintenancedowntime of MVR roller mills isreduced to a minimum.Favorable control behaviorHigh drying capacity, short retentiontime, and remote control of grindingpressure and rotor speed allow a fullyautomatic operation of the MVR rollermill even with varying raw materialqualities.4 5

Raw material grinding on thePfeiffer MVR roller millThe solution to your problemthroughput rates of up to 1,400 t/hdrive power of up to 12,000 kWtarget fineness60 - 100 mresidual moisture < 0.5%Combined grinding and drying of rawmaterials with moisture rates of morethan 20 %, all in one unit.Feed sizes of up to 100 mm, hence nosecondary crushing required.MVR roller millshort change-over time from directto compound operationmodular design, i.e. optimum combinationof housing cross-sectionsand geometry of grinding elementsoptimum, symmetric design ofwear parts and modern maintenanceconceptsgood partial load behaviorlow capital costlow electric energy consumptionhighest availabilityfavorable control behaviorcement raw materialmill typethroughput (t/h)MVR 6700 R-6MVR 6000 R-6MVR 6000 R-4MVR 5300 R-4MVR 5000 R-4MVR 4250 R-4installed power (kW)MVR 3750 R-41500 1200 900 600 300 0 0 2000 4000 6000 8000 10000 120000,10,20,5125101520253035404550556065707580grain size, µm10 20 30 40 50 100 200 300 400 500residue, %36,8raw material WOPCraw material OPC6 7

Grinding of granulated blastfurnaceslag and cement onthe Pfeiffer MVR roller millThe solution to your problemthroughput rates of up to 550 t/hdrive power of up to 12,000 kWtarget fineness 2000 - 6000 cm 2 /gCommon or separate grinding of maincement components.Combined grinding and drying of maincement components with moisture ratesof more than 20 %, all in one unit.Production of various cement qualitiesin one mill. Products in line with standardsand market requirements.MVR roller mill'0,10,52 1 5101520304050607075808590process and wear protectiondesigned to suit raw materialpractically no transitional productswhen changing overutilization of process heatoptimum, symmetric design ofwear parts and modern maintenanceconceptslow capital costlow electric energy consumptionhighest availabilityfavorable control behavior1 2 3 5 10residue, %36,8grain size, µm20 30 40 50 100 200PPCSmBlaine= 4350 cm²/ggranulated blast-furnace slagmill typethroughput (t/h)MVR 6700 S-6MVR 6300 S-6MVR 6000 S-6MVR 6000 S-4MVR 5300 S-4MVR 5000 S-4MVR 4250 S-4installed power (kW)MVR 3750 S-4400 350 300 250 200 150 100 50 0 0 2000 4000 6000 8000 10000 12000cementmill typethroughput (t/h)MVR 6700 C-6MVR 6300 C-6MVR 6000 C-6MVR 6000 C-4MVR 5300 C-4MVR 5000 C-4MVR 4250 C-4installed power (kW)MVR 3750 C-4600 500 400 300 200 100 0 0 2000 4000 6000 8000 10000 12000958 9

fine productfeed materialSLS high-efficiency classifierfor sharp separationoptimized freeflow areasentirely closedmill housingtorque supportfor pressure framemaintenance doorLift-and-SwingSystemliftable grinding rollershot gasexternal pull rodsreject materialmaintenance drive

PFEIFFER MPS mill –the proven system forcomminutionThe solution to your problemIn the cement industry, MPS roller millsare used for grinding cement raw ma -terial, coal, cement clinker, granulatedblast-furnace slag, and pozzolana. Suchbulk materials differ considerably interms of grindability and abrasiveness.The capacities of cement productionlines vary within wide limits to suit individualrequirements. Due to its design,the MPS roller mill is specially suitedfor small and medium throughput rates.The working principleThree stationary grinding rollers rollon a rotating grinding track. Drawn inbetween the rollers and track, the feedmaterial is ground by pressure andshear. The compression forces requiredfor comminution are produced by ahydropneumatic tension system.The finished product leaves the classi -fier with the gas flow for separationin the downstream cyclones or filter.The advantagesLow capital costMPS mills require few ancillaries, noor little building volume, their oper -ation is dust free and they have alow noise level.Optimum utilization of process heatMPS roller mills allow an optimumutilization of the thermal energy ofprocess gases.Maximum availabilityThanks to low specific wear rates, highquality wear materials, and modernrepair methods, the maintenancedowntime of MPS roller mills isreduced to a minimum.Favorable control behaviorHigh drying capacity, short retentiontime, and remote control of grindingpressure and rotor speed allow a fullyautomatic operation of the MPS rollermill even with varying raw materialqualities.The ground material is conveyed bycentrifugal forces towards the stationarynozzle ring. Gases (air or hot gas)flowing up through the nozzle ringcarry the ground and dried materialto the classifier where it is separatedinto grits and fines by the rotor. Thegrits fall back into the center of thegrinding area.Low electric power consumptionThe grinding principle and highefficiencyclassifier reduce electricpower consumption by up to 40 % ascompared with conventional ball mills.10 11

Raw material grinding on thePfeiffer MPS roller millThe solution to your problemthroughput rates50 - 650 t/htarget fineness60 - 100 mresidual moisture < 0.5%Combined grinding and drying of rawmaterials with moisture rates of morethan 20 %, all in one unit.Feed sizes of up to 120 mm, hence nosecondary crushing required.MPS roller millshort change-over time from directto compound operationmodular design, i.e. optimum com -bination of housing cross-sectionsand geometry of grinding elementsoptimum, symmetric design ofwear parts and modern maintenanceconceptsgood partial load behaviorlow capital costlow electric energy consumptionhighest availabilityfavorable control behaviorcement raw materialmill typethroughput (t/h)MPS 6000 BMPS 5600 BMPS 5300 BMPS 5000 BMPS 4750 BMPS 4500 BMPS 4250 BMPS 4000 BMPS 3750 BMPS 3550 BMPS 3350 BMPS 3070 BMPS 2800 Binstalled power (kW)MPS 2500 B700 600 500 400 300 200 100 0 0 1000 2000 3000 4000 5000 6000 70000,10,20,5125101520253035404550556065707580grain size, µm10 20 30 40 50 100 200 300 400 500residue, %36,8raw material WOPCraw material OPC12 13

Grinding of granulated blastfurnaceslag and cement onthe Pfeiffer MPS roller millThe solution to your problemthroughput rates10 - 300 t/htarget fineness 2000 - 6000 cm 2 /gCommon or separate grinding of maincement components.Combined grinding and drying of maincement components with moisture ratesof more than 20 %, all in one unit.Production of various cement qualitiesin one mill. Products in line with standardsand market requirements.MPS roller millprocess and wear protectiondesigned to suit raw materialpractically no transitional productswhen changing overutilization of process heatoptimum, symmetric design ofwear parts and modern maintenanceconceptslow capital costlow electric energy consumptionhighest availabilityfavorable control behaviorgranulated blast-furnace slagmill typeMPS 5600 BSMPS 5300 BSMPS 5000 BSMPS 4750 BSMPS 4500 BSMPS 4250 BSMPS 4000 BSMPS 3750 BSMPS 3550 BSMPS 3350 BSMPS 3070 BSthroughput (t/h)MPS 2800 BSinstalled power (kW)MPS 2500 BS175 150 125 100 75 50 25 0 0 1000 2000 3000 4000 5000 6000'0,10,52 1 5101520304050607075808590951 2 3 5 10residue, %36,8grain size, µm20 30 40 50 100 200PPCSmBlaine= 4350 cm²/gcementmill typethroughput (t/h)MPS 5600 BCMPS 5300 BCMPS 5000 BCMPS 4750 BCMPS 4500 BCMPS 4250 BCMPS 4000 BCMPS 3750 BCMPS 3550 BCMPS 3350 BCMPS 3070 BCMPS 2800 BCinstalled power (kW)MPS 2500 BC350 300 250 200 150 100 50 0 0 1000 2000 3000 4000 5000 600014 15

Coal grinding on thePfeiffer MPS roller millThe solution to your problemthroughput rates5 - 200 t/htarget fineness60 - 100 mresidual moisture < 1.0%Grinding of coal, lignite or pet coke.Combined grinding and drying of rawcoals with moisture rates of more than25 %, all in one unit.Feed sizes of up to 100 mm, hence nosecondary crushing required.MPS roller millutilization of process heatwear protection measures designedto suit raw materialoptimum, symmetric design ofwear parts and modern maintenanceconceptspressure shock proof machinehousingsproven safety conceptgood partial load behaviorlow capital costlow electric energy consumptionhighest availabilityfavorable control behaviorcoal, pet coke, lignitethroughput (t/h)mill typeMPS 4250 BKMPS 4000 BKMPS 3750 BKMPS 3550 BKMPS 3350 BKMPS 3070 BKMPS 2800 BKMPS 250 BKMPS 225 BKMPS 200 BKMPS 180 BKMPS 160 BKMPS 140 BKMPS 125 BKMPS 112 BKMPS 100 BKMPS 80 BKMPS 63 BKinstalled power (kW)200 160 120 80 40 0 0 400 800 1200 1600 20000,10,20,5125101520253035404550556065707580grain size, µm10 20 30 40 50 100 200 300 400 500residue, %pet coke36,8coallignite16 17

Wear protectionMaintenanceWear protectionDepending on the wear zones andabrasiveness of the material to beground, our roller mills are lined withdifferent wear materials. The grindingelements are mainly made of alloyedcast iron as per DIN 1695, hardfacedcast iron or composite materials withhigh-chromium inserts in ductile basematerials. The housing and other millcomponents exposed to jet wear areprotected by means of highly wearresistant steel plates or hardfacedcomposite steel plates. Componentsparticularly exposed to jet wear,e.g. gas outlet ducts, are fitted withceramic liners. Fast and easy replaceabilityis a major design feature.MVR roller swing-out systemAs with any roller mills, the wear partsof the grinding elements are exposedto the highest wear. On the MVR mill,it is very easy to replace or regeneratethese grinding elements. In fact theMVR mill has a hydraulic system thatallows to swing out the rollers in acontrolled way, using the newly conceivedroller suspension system, and toreplace the one-part wear parts easily.The wear parts of the grinding plate arereplaced with a lifting device and themaintenance drive.The grinding rollers can be swung outseparately, thus allowing the continuationof mill operation while doingmaintenance work (active redundancy).The regeneration of wear parts can bedone either inside or outside the mill.The advantagesactive redundancyshort downtimesafe and easy handling ofcomponentsonly one hydraulic system for bothmill operation and maintenance work

MPS Lift-and-Swing SystemAs with any roller mills, the wear partsof the grinding elements are exposedto the highest wear. Therefore it mustbe very easy to replace or regeneratethem. With the proven Lift-and-SwingSystem, the wear parts can be replacedrapidly, using one single maintenancedoor. For this purpose, the grindingrollers and grinding bowl segmentsare moved in front of the maintenancedoor, using the maintenance drive, andare swung out of the grinding zone.The advantagesshort downtimesafe and easy handlingonly one maintenance doorarranged for ease of accessreduced space requirement18 19

PFEIFFER SLV high-efficiencyseparator – the name forquality and economyPFEIFFER SLV high-efficiency separatorThe solution to your problemseparation ofbulk materialsfeed rates1 - 500 t/htarget fineness10 - 90 mThe working principleDispersed in the air stream, the materialto be separated is conveyed to theseparating zone where it is separatedinto fines and grits. The grits are evacuatedthrough a cone for any furtherpreparation. The fines are separatedin a downstream cyclone or filter.The advantagesSharp separationUniform material distribution in theseparating zone thanks to the centralmaterial feed.Pre-separation and post-separationdue to the optimum arrangement ofthe louver plates.Diverse applicationsSLV separators may be used forseparation in one pass or in circuitoperation with grinding plants.Long service lifeThe special linings we commend forwear protection are made of steel,rubber, synthetic or ceramic materialsdepending on the type and abrasivenessof the material to be separated.

PFEIFFER Triplex dryerThe solution to your problemDrying of bulk materialsproduction capacities 1 - 200 t/hfeed sizes up to150 mmany usual feed moistureresidual moisture up to 0.1%The working principleThe Triplex dryer type TRT operateson the co-current principle, i.e. materialand hot gases flow in the same direction,passing through the dryer tubesfrom inside to outside.Fed into the innermost tube of thedryer, the material passes through thedryer for being discharged throughdouble-pendulum flaps fitted to thedust jacket.The residual moisture of the productis controlled by setting the exhaustgas temperature and retention timein the dryer.The hot gases are generated in a combustionchamber that may be fired withsolid, fluid or gaseous fuels. Processexhaust gases may also be used.TRT Triplex dryer with hot gas generatorThe advantagesCareful material treatmentThanks to the co-current principle,the material cannot overheat.Low thermal energy consumptionMinimum heat loss by radiation dueto small dryer surface and co-currentprinciple.Reduced space requirementShort construction length due tothree-tube design, hence low capitalcost for building and foundations.Short starting and stopping timesTemperature resistant steel platedesign instead of ceramic lining.Dust collection of the dryer exhaustgases is performed in a filter.20 21

PFEIFFER services –you can always count on usTest stationAt our test station, raw materials aretested for their processing behavior.In our laboratories, we characterizethem, considering applicable specificationsand standards. The test station isequipped with pilot plants comprisingmachines from our production rangefor throughput rates from 0.5 to 10 t/h.The test results form the basis of ourselecting the process and rating themachinery.ConsultancyOur consultancy services comprise thedesign and planning of new plants andrebuilds, capacity increases and modernizationof existing plants, mainten -ance and repair schedules, selection ofappropriate wear materials as well asany process-related aspects.ManufactureOur own manufacturing facilitiescomprise mechanical workshops anda foundry. Every single manufacturingstep is thoroughly planned and qualityis supervised and documented systematicallyon the basis of the quality managementsystem as per DIN ISO 9001.Spare parts serviceOriginal spare parts guarantee thatyour plant will operate economicallyeven after many years after its installation.Our experienced specialists willbe pleased to give advice. The wearanalysis of the grinding elements,which is done electronically, recordstheir actual state, ensuring mainten -ance and procurement as neededfor the requirement.Erection and commissioningExperienced engineers and supervisorsare available for supervision of erectionand for commissioning as well as forthe training of your attendance andmaintenance personnel.22 23