中建材（合肥）粉体科技装备有限公司 HFC roller press Grinding technology …Hefei) English.pdf · 合肥水泥研究设计院 HEFEI CEMENT RESEARCH & DESIGN INSTITUTE

合肥水泥研究设计院 HEFEI CEMENT RESEARCH & DESIGN INSTITUTE

中建材（合肥）粉体科技装备有限公司

CNBM (Hefei) Powder Technology Equipment Co., Ltd.

Grinding Research Institute, HCRDI

Wang Xuemin 2013.11

HFC roller press Grinding technology intro



I. CNBM( Hefei) Powder Technology Equipment Co.,Ltd is a team which

integrates R&D, design, manufacture and service.

II. Core Technology----HFC Roller Press is at international advanced level

III. Systematic approach to solving grinding problem----Accomplishments of

grinding system

IV. HFC Roller Press Grinding System Applications in Cement Industry

V. Efforts to produce high-quality cement, reduce the cost and increase the

efficiency

Contents



Ⅰ. We are an team which integrates R&D, design, manufacture and service

History (64 Years)

Beijing Building Material Institute Grinding Task Group (1949) →Hefei Cement Research and Design Institute Grinding Research Office(1978) → Grinding Research Institute → Powder Engineering Company→CNBM(Hefei) Powder Technology Equipment Co.,Ltd. (2011)

Total employees are 212, including 21 professor senior engineers、25 senior engineers、51 Mid-level engineers and assistant engineers、about 100 after-sales service technicians. Majors are machinery, process and electric.

Our technology includes crushing, drying, grinding, classifying, grading, powder engineering micron process, separating in mill. All those advanced technology has already formed efficient drying system, roller press, high-efficient separator, ATT large sub-micron powder grading machines and other equipment. Many of them obtained Chinese Famous Brand, Anhui Famous Brand and Building Material Industry Famous Brand.

Occupy the Chief Position in cement grinding industry, enjoy a high reputation and receive many honors.



新型高细磨中国发明专利

新型高细磨中国发明专利

证书证书

高产磨美、英、日等国授

高产磨美、英、日等国授

权的发明专利

权的发明专利

2011-J-214-2-01-D01




Our company assumed and accomplished significant science and technology key project

with financial support under the state‘s sixth, seventh, eighth, ninth and eleventh five year plans, state’s ‘863 plan’ guidance project, state support plan project and state’s ‘spark plan’ project. We achieved over 40 science and technology key projects and fund projects and drafted a number of state (industry) criteria. We obtained 4 second prize and 1 third prize of state level science and technology progress, over 20 provincial level achievement awards and science and technology progress awards, 19 provincial level engineering design and consulting awards, 37 patents for state level invention, utility models and proprietary technology. In 2011, the first prize of state’s science and technology award for building material and machinery was vacancy, we were the No.1 of the second prize. Our chief engineer Mr.Bao Wei represented awarded project personal to meet and photograph with state leaders, Hu Jingtao and Wen Jiabao.

* We have many application achievements, most of cement enterprise in China use our technology and products.


合肥水泥研究设计院 HEFEI CEMENT RESEARCH & DESIGN INSTITUTE 第 6 页


Roller Press is our CORE TECHNOLOGY. It is the first brand in Chinese market. Nearly 10 years,

more than 100 sets per year has been produced, especially in 2009 and 2010, there were 170 sets. Total

No. of operating Roller Press is more than 1400 sets. In recent years, Chinese economic develop

rapidly and the domestic business is full, even though we are not actively explore for

international market, but there are still some overseas company which has been attracted to

build cooperation, which includes the company in Pakistan, Vietnam, Saudi Arabia,

Philippines, Indonesia, Bolivia, Ethiopia, Turkey, Mongolia and also Taiwan.

The output of HFCG

Roller Press is

1.12billions tons in

2012.




1. Overview: HFC Roller Press developed by key technology tackling topics research with the financial support of the state 7th 5-Year Plan, HCRDI launched the first domestic roller press which has been successfully applied to industrial productions in 1989. By continuous researches of the state 8th 5-Year Plan, 9th 5-Year Plan and 11th 5-Year Plan key technology tackling topics and combined with the experiences in applications over 20 years, III Generation HFCG series roller press with independent intellectual property right was launched in reasonable design, superior performance and high reliability. It has effectively solved a series of key technological difficulties such as the roller deflection, offset loading, horizontal vibration and driving system torsional vibration, which have strengthened the reliability of the equipment with the operating rate increased as over 90%. It has been awarded second prize of the state Science and Technological Progress Prize twice.

Ⅱ. Core Technology----HFC Roller Press is at international advanced level



In single particle grinding, all the particles in contact with the grinding equipment shall be grinded by direct pressure or shearing force. While in material layer grinding, only a few particles contact the grinding equipment and the material will be grinded by pressing each other.

Operating principle: broken the material level, soft operating with constant pressure




Roller press torque supporting device-roller press operates stably

High pressure and low impact hydraulic pressure system in high flexibility: 1. to increase the equipment operating rate by reducing the impact load and increasing the reliability of the equipment; 2. to ensure the continuity of the pressure on the material, i.e. to stabilize the output and the quality of the cement product.

Hydraulic system: Personality design, high reliability, whole set of Germany Bosch Rexroth product

3. Characteristics 1：




Roller-sleeve-type rollers-shaft+ roller sleeve. Different material and

heat treatment process can be selected as per the requirements on the axle and the sleeve to form the roller sleeve, which can guarantee the strength of the axle and improve the welding performance, completely eradicate the spalling of the roller surface wear layer and make repeated repairs possible.

Argyle pattern-with this pattern, the pressing effect can be guaranteed,

the wearability of the roller surface can be strengthened and the service life can be increased. Manually repair welding can be applied to the roller surface build-up welding instead of using a special welder. A special training is not necessary for the welders to carry out semi-automatic welding on site.

+ =

3: Character2:




Length to diameter ratio is determined for good integration of the equipment with the processes

Table 1: L/D Ratio of HFCG Roller Press

Diameter

(mm) 1200 1400 1600 1800 2000

Length

（mm）

500～

800

650～

800

1200～

1400

1400～

1600

1600～

1800

Installed

power (kw) 2×250 2×500

2×800～2×1120

2×1400～2×1600

2×1800～2×2240

4.Specification:




Ⅲ. Systematic approach to solving grinding problem

----Accomplishments of grinding system

1.The grinding system, comprised by the roller press as the key equipment, ball mill and separator, etc. It is used to grind the raw material into the finished cement product.



2.After research the raw material, choosing proper grinding proposals according to the physical properties differences and finished products produced upon different requirements. The material in high moisture shall be dried by the dryer and those in large grain size shall be pre-grinded by the crusher.

Fast Drying Technology: obtain 2 National Identification results, 2 National Inventions, 3 patents for utility models





Air classifier Vertical separating

classier

3 Various kinds of classifying equipment to form a closed circuit with the roller press

Air classifier

Breaking classifier

Breaking classifier





4.Ball Mill Technology: Obtained State

Science Progress Award twice; Four

National Research Identification Results;

Five National Invention Patents. It has

been applicated on thousands sets.

Water Spray System

Partition Plate and

Discharge Screen Format

Ball Mill Chamber、Length of Chamber and Form of liner

Grading of Grinding Media and Ball Load





5.Here are

various

kinds of

separators

which can

be used to

form a

closed

circuit with

the ball mill. Building material Industry Second

prize of science and technology

progress; Famous product of Anhui

province and China building materials

industry, 3 National invention patents,

dozen of utility model patents





Combined steady-flow weighing bin-the roller press operates stably

Uniform feeding device shall be applied to the air classifier- the output will be increased by 10% and the power consumption will be decreased by 5%.

6.Other Equipments related to the system





Ⅳ. HFC Roller Press Grinding System Applications in Cement Industry

1. Overview of Main Applications Cement Production Capacity from 50t/h to 400t/h; Raw Material

Production Capacity from 100t/h to 500t/h. New-build Cement Factory or Grinding Station Traditional ball mill system transformation, some of them add Roller

press in system, and others may completely replace the ball mill One Roller Press+One Ball Mill/ Multiple Ball Mills Two Roller Press+One Ball Mill



2. Technology Process Summary:

A. Combined Pressing Comminution System (Roller press, breaking classifier and open circuit mill)

B. Combined Pressing Comminution System (Roller press, breaking classifier and closed circuit mill)

C. Combined Pressing Comminution System (Roller press, air flow classifier and open circuit mill)

D. Combined Pressing Comminution System (Roller press, air flow classifier and closed circuit mill)

E. Combined Pressing Comminution System (Roller press, static state separator and open circuit mill)

F. Combined Pressing Comminution System (Roller press, static state separator and closed circuit mill)

G. Combined Pressing Comminution System with dryer, applicable to grinding high moisture material, like slag, steel slag

and cement raw meal.

H. Semi-finished grinding system (Roller press and ball mill), some products can be produced directly by roller press.

I. Roller press final grinding system, It is mainly used for cement raw meal.




3-1 Process A and B: Simple Flow sheet




3-2 Typical Case 1: Shanshui Cement Group Ltd. Qingdao Grinding Station designed and supplied by HCRDI was awarded First Prize for Excellent Design in 2005 by China Building Material Association. So far, this Grinding Station Project is the only one awarded First Prize in China.




3-2 Typical Case 2: At the end of 2008, China Resources Group purchased the 400,000 tpa Cement Grinding Station invested by Li Ka-shing, who is among the World’s Top 10 Billionaires. The grinding station takes an area of 30,000 m2 near Shantou Bay Bridge in Guangdong. HCRDI was delegated to upgrade this project to 2,000,000 tpa. The project was successfully put into production in Nov., 2009. It has been creating big profits for the company.




3-2 Typical Case 3: CNBM is the largest cement manufacturing Group in China. China United Cement Corp. (CUCC)Qingdao Jimo 2million tpa cement grinding station, CUCC Yidong grinding station and Xiangshui grinding station are the model grinding stations of CUCC , which is under CNBM. All these grinding stations are supplied by HCRDI.




3-2 Typical Case 4: Hefei Donghua Building Material

Company ltd. cement grinding station : in 2010, the first

grinding system was put into production, the average

output is 200t/h and the comprehensive power

consumption is lower than 30kwh/t; in Aug 2012, the

second grinding system was put into production and the

designed indexes are reached and exceeded in 10 days’

operation.

Main equipment configuration: HFC160-140 Roller

Press, Φ4.2x14.0m open-circuit mill 14.91kwh/t。

Raw material proportioning: Clinker 70%, limestone 8%,

fly ash 14%, gypsum 6%, clinker grindability 14.9kwh/t. ,

System output: 202t/h

Specific surface area of cement product: 362m2/kg

Power consumption of grinding system: 25.1kWh/t




3-3：

Advantages of process A and B

Good cement particle size distribution, particle well-shaped,

stable quality;

Flexible, convenient to change cement type

Simple process flow

Less equipment configuration;

Compact building, floor area 12*45㎡, building area 1272㎡;

★★★；

Lower investment;

Satisfactory energy-saving, power consumption of grinding section per ton of cement lower than 30 kwh/t;

★★★

Easy operation, less maintenance work, high operation rate, low operational cost.

Disadvantages: limited adaptations to raw materials.




4-1 Process C and D: Simple Flow Sheet

Roller press +Air Classifier closed-circuit combined grinding system




4-2 Typical Case 1: Huasheng Tianya Cement Co., Ltd. is the biggest cement producer in Hainan Province , China’s southernmost province. The production capacity is 13 million tons per year. Sanya and Haikou grinding stations are located in scenic area, neighboring a university and a golf course. Huasheng Tianya Cement Co., Ltd Sanya Grinding Station was awarded 2rd prize for Excellent Design in 2011 by China Building Material Association.


昌江熟料基地

Haikou

grinding plant

Sanya

grinding plant



4-2 Typical Case 2:Hainan Huasheng 9 sets -HFCG160-140 Roller Press combined with Φ4.2x13.0m closed circuit mill produces PO 42.5

with 85% of clinker in proportion. The specific surface area is 340m2/kg, output is above 210t/h and power consumption is below

30kwh/t.

品种

Type

产量

Output

(t/h)

比表面积 Specific

surface area

m2/kg

电耗

Power consumpti

on

kWh/t

PO42.5

230 340 26.41

PC32.5

270 370 24.83

品种

Type

熟料

Clinker

(%)

脱硫石膏

Desulfurated

gypsum(%)

火山灰

Pozzolana(%)

石灰石

Limestone(%)

PO42.5

85.0 5.0 6.0 4.0

PC32.5

68.0 4.0 13.0 15.0


recent operation situation of grinding systems

5 and 6 in Haikou grinding plant 230t/h

270t/h



4-2 Typical Case 3:

Yanan Shengwei Building Material Co., Ltd. 2,000,000 tons/year Cement Grinding Station




4-2 Typical Case 4: Tian Rui Group is the largest cement enterprise in Henan province.

It’s a private company. Annual production capacity is 40 million tons of cement.




4-2 Typical Case 5: Conch Cement is one of the top three cement producing companies, its annual

output is almost comes to 0.2 billion. The economical benefit is remarkable. It is a example in China

cement industry.




4-2 Typical Case 6-1 Chairman of Taiwan Yadong Cement Co.,Ltd said in the production start-up ceremony of

Huanggang Yadong Cement Production Line.

“The equipment has met EU standards,

the technology has reached European level. ”




4-2 Typical Case 6-2: Yadong Cement Co., Ltd. chooses the world famous equipment for all its production

lines and makes planned design based on its own using experience. It’s highly recognized in cement industry

for pursuing reliable, stable, reasonable, efficient and humanized production. The company represents the

internationally advanced technology and equipment.

The capacity and power consumption of all cement mill system which designed by HCRDI reach and even

better than the design value of contract.

HCRDI roller press cement grinding system reached all technical and economic indicators of to German KHD

roller press cement grinding system, and it has many advantages which includes easy operation, high

stability, less maintenance, low operating cost, etc.

Compare to LOESCHE vertical mill, HCRDI roller press cement grinding system easy to adjust varieties of

cement , less clinker consumption, no need of water spray and hot air supply, easy to operate and low

running cost.

HCRDI High-efficiency separator and large-scale cement mill dust collector also get high appraisal.




Time Supplier Grinding plan Project set Production time

Before 2008 German KHD Roller press Taiwan, China Several Sets 20 Years

German Loesche Vertical Mill Hubei China 1# 1

2008 China HFCG Roller press Huanggang Hubei China 1#&2# 2 2009

2009 China HFCG Roller press Hubei 5#,Jiangxi 5#, Yangzhou 3# 3 2010

2009 German Loesche Vertical Mill Hubei 3# China 1 2011

2010 China HFCG Roller press Sichuan 4# China 1 2011

2011 China HFCG Roller press Yangzhou 1#, Hubei Yaxin 3# 2 2011

2012 China HFCG Roller press Jiangxi 6#, 7#, 8# 3 2013

4-2 Typical Case 6-3: Yadong Cement Co., Ltd has used 11 sets of HCRDI Roller press cement grinding system




5-1. Process E and F: Simple flow sheet. This system is promoted rapidly. As for

the specification of Roller Press is relatively bigger than that of the Ball Mill, the

effect of energy conservation is more outstanding.

Raw meal

Separator Cyclone

Circulate fan

V type Separator

Roller press

Returned material

Ball mill

Cement




5-2 Typical Case1 : Jiande Songtao Cement Co., Ltd., the model cement company of

CNBM Southern Cement Company Limited, chooses HFCG150-100 Roller Press +

Φ3.2*13.0m open circuit mill. The production capacity is 110t/h for PO 42.5 and 156t/h

for PC 32.5. Power consumption per ton of cement is ≤ 26kwh/t . The operation cost of

equipment per ton of cement is ≤RMB 1.7per year.




5-2 Typical Case2: Guangdong Luofu Moutain Cement Group is private company which has great influence of scale and profit in Guangdong area. Annual cement output is more than 15 million tons. Baohu Cement Company and Huiyang Shuangxin Cement Company both adopt this process plan.




5-2 Typical Case3: The grinding system of Heilongjiang Huada Cement Company under Northern Cement of CNBM, is mainly used for grinding slag, and also cement.




5-3. The roller press equipped with dynamic & static classifier and ball mill has many advantages:

★★★The finished cement of this system has the advantage of closed and open type ball mill. The temperature is

low and there is no big particle. The gradation of the particle is good. The cement strength can develop well

at different period. It has less clinker consumption, less water, and good workability.

Raw material has good adaptability.

More extruding less grinding can develop the crushing advantage of roller press and the grinding advantage

of ball mill. And the material stay short time inside the mill. The possibility of material clustering and random

grinding is less. The grinding efficiency is higher. The power consumption of each ton of cement less than 30

kwh/t.

★★★ The operation is easy to control.

★★★ The abrasion of air system become less. The equipment and air pipes have more working life. There is less

maintenance work. It has high running efficiency and less running expense.




5-4 With dry process E&F, Typical Case 4-1,International advanced level steel slag grinding technology ——The steel slag grinding system of Maanshan Limin Xinhuo Metallurgy Slag Environment Protection Development Co.(800,000tpa) was put into production in Jan. 2011. The system power consumption has been less than 40kWh/t. —— The hard surfacing of the Roller Press is the most advanced at present. This thoroughly solves the wear problem during the steel slag crushing.




5-4 Typical Case 4-2:International advanced level steel slag grinding technology operation interface and flow chart

Maanshan Limin Xinghuo Company DCS control system




5-4 Typical Case 4-3:International advanced level steel slag grinding technology: currently promoted quickly

S.N. Applied Company Roller press Ball Mill Status

1 Maanshan Limin Xinghuo Metallurgy Slag Environmental Technology Company

HFCG140 φ3.2×13.0m 65t/h

2 Hasco Tai Steel Technology Co., Ltd HFCG150 φ3.2×13.0m 80t/h

3 Yuqingtang Xingye Interest Co., Ltd HFCG150 φ3.8×13.0m 80t/h

4 Wuhan Yaxin Cement Company Limited HFCG150 φ3.2×13.0m 70t/h

5 Xinyu Southen Building Material Company HFCG160 φ3.2×13.0m 90t/h

6 Maanshan Limin Xinghuo Metallurgy Slag Environmental Technology Company

HFCG140 φ3.2×13m 65t/h

7 Fujian Province Gangyuan Powder Material Co., ltd. HFCG160 φ4.6×14.5m Under commissioning

8 Wuhan Xinyuan Green Metallurgy Slag Technology Company HFCG160 φ3.2×13m 80t/h

9 Shanghai Baolong Building Material Company Limited HFCG140 φ3.48*9.36 Under commissioning

10 GuizhouGuixin Technical Enviroment Protection Company Limited HFCG140 φ3.2×13m Under designing




1、Open circuit ball mill improves the particle gradation;

2、Drying and grinding mill process leave out the drying system, simplify the process

routing, and reduce system investment.

3、Steel slag modifying process can adjust and improve the performance of steel slag

micro powder, based on the feature of the steel slag and the requirement of the building

material products.

4、Homogenizing regulation process can stabilize the product performance of the micro

powder and satisfy the requirement of building material user.

5、Metal loss and running cost come down; maintenance work become less; and system

runs in high efficiency.

5-4 Typical Case 4-3: International advanced level steel slag grinding

technical features




6-1 Process I simple flow sheet

Raw Meal

Separator

V Type Separator

Circulating Fan

Cyclone

To electric dust

collector

Final Product

Roller press

Material cake Returned Material




510t/h

6-1 Typical Case 1-1: First used for raw meal finish grinding system of CUCC

Shandong Yinan Cement ltd. Co. 5000t/d clinker product line




6-1 Typical Case1-2: The biggest Roller Press made in China Diameter mm 2000

Width mm 1800

Installed power kw 2*2000

Process capacity t/h 1500

Weight of equipment t 310

Design index

Actual running index

Output t/h 420t 500t

Fineness R0.2 ≤1.5% 0.50%

R0.08 14±2 16

Power consumption

kwh/t 13±1 11.6




Results of system evaluation

双辊压机系统工艺流程图

Cement Type PO42.5 PC32.5

System Capacity (TPH) 358.25 382.82

System Power Consumptions （kWh/t)

28.3 25.75

Ball Mill Installed Power,kW 3550 3550

Roller Press Power Consumption, kWh/t 11.65 8.93

Ball Mill Power Consumption, kWh/t

11.11 11.01

Auxiliary Equipment Power Consumption, kWh/t

5.53 5.56

Finish Product Blaine Value,m2/kg 358 364

7-1 Two Roller Press + One Ball Mill Typical Case1-1: Xinjiang Kezhou Qinsong Cement Grinding System




Xinjiang Kezhou Qinsong Cement Clinker Production Line (6000t/d) is EPC project of HCRDI, it put

into production on July 2012. Cement grinding system: Two sets of HFCG180- 160 roller press

+Φ4.6×14.5m Open circuit ball mill, using V-separator combine with Separator(Air from below) to

separate the product from roller press.

7-1 Two Roller Presses + One Ball Mill Typical Case 1-2: Xinjiang Kezhou Qinsong Cement Grinding System




7-1 2 sets roller press with one ball mill typical case 1-2: Xinjiang Kezhou Pine Cement grinding

operation system screenshot.




Avoiding many problems which includes spare parts, machinery processing, transportation, maintenance and

other issues of single large Roller Press

More crush power provided by Roller Press, it could reduce the ball mill power consumption and improve

efficiency

Two sets of Roller presses as an independent system respectively, easy to manage, adjust and control.

Change the proportions and variety of material of two sets, to achieve separated grinding function, then

through ball mill grinding to produce and homogenizing mixing, to ensure the product quality.

To achieve open circuit grinding process of large ball mill.

7-2 Advantages of Two Roller Press+ One Ball Mill




SN Applied Company Roller press Ball Mill Operation status

1 Zhejiang Xindu 2-HFCG120 φ3.2×13.0m PO42.5#，100t/h, in operation for two yeas

2 Guangxi Huahong 2- HFCG120 φ3.2×13.0m Under designing

3 Fujian chunchi 2- HFCG120 φ3.2×13.0m Under designing

4 Jinyun Hongshi 2- HFCG140 φ4.2×13.0m To be put into production

5 Shandong Aluminum 2- HFCG140 φ3.8×13.0m Under designing

6 Xinjiang qingsong 2-HFCG180 φ4.6×14.5m PO42.5#，358t/h

7 Xinjiang Hailuo Qingsong 2- HFCG180 φ4.6×14.5m Under designing

8 Longli Hongshi 2- HFCG180 φ4.6×14.5m Under designing

9 Nanyun hongshi 2- HFCG180 φ4.6×14.5m Under designing

10 Lanzhou Hongshi 2- HFCG180 φ4.6×14.5m Under designing

7-3 The combined grinding system with several sets of roller presses and one set of ball mill is specially suitable for upgrade of earlier roller press grinding mill system. And it popularizes quickly.




We are the research institute, the design institute, the equipment manufacture, and also the power technology service provider which provides grinding mill program to satisfy the grinding mill system index and long-time using effect. 1、Provide reasonable, reliable, and high process index grinding system for the customer and consult and design service which will guarantee the investment interests of the owner. 2、Provide advanced, high -efficiency, energy saving reliable quality roller press and grinding system equipment, and assist the owner and design company optimize system parameter and realize design target. 3、Train the technical and operation engineer for the owner, explain the working principle and structure, let them control the grinding system operation, decide and handle the general failure of the roller press. 4、Provide free site instruction for installation and commissioning of roller press, assist the owner to realize the designed capacity and standard of the grinding system; and also provide site instruction for equipment maintenance, like repair wielding for rolling face of roller press. 5、Provide periodically after-sale service, long-term spare parts and technical innovation consult in privilege. price.

Ⅴ. Efforts to produce high quality cement, reduce cost & increase efficiency






HCRDI will continue its research in grinding mill technology and equipment . Basically has the following three aspects:

including different kinds of new type grinding mill process system and the combination of different kinds of

equipments.

the research and development of new equipment, based on different type of new process.

different kinds of composite admixture based on optimize cement product performance.

We will try to design personalized cement factory, increase the use ratio of raw material and

performance of products, reduce the cost of cement product company and promote the technology

progress of cement industry in China.




Documents

中建材（合肥）粉体科技装备有限公司 HFC roller press Grinding technology …Hefei) English.pdf · 合肥水泥研究设计院 HEFEI CEMENT RESEARCH & DESIGN INSTITUTE