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Process Guidelines V3
October 2005
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Raw milling Raw milling
Preheater Preheater
Kiln Kiln
Cooler Cooler
Kiln and Cooler Filter Kiln and Cooler Filter
Kiln by-pass system Kiln By-pass system
Gas analyser Gas analyser
Coal mill Coal mill
Cement grinding Cement Gr
Weighing-dosing Weighing-dosing
05 10 05
Process guidelines - Contents -
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Process Guidelines V3 - October 2005
Best practice /
recommendation
To be written
Specifications These are the figures we give to suppliers in the tender ; this column should contain the same
figures as other documents.
Alternatives In this column we describe alternatives, which could be accepted for cost reason, but also are
necessary for process reasons. Example would be cement mill specification is vertical mill,
Alternative is ball mill and in case of a existing ball mill a roller press
Operating target Operating target is the range where we want to have an equipment operated; this is not to be
given to suppliers, but we will check offers accordingly. Important value for process evaluation of
existing equipment or to calculate operation cost.
Not advisable These are choices we dont accept. Important if suppliers send alternatives on their own
Comments
Raw milling
Best Practice /
Recommendation
Specifications Alternatives Operating target Not advisable Comments
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CHOICE OF MILL SYSTEM
Vertical Mill with cyclone and
fan with VFD
Vertical Mill with cyclone and
fan with VFD
2 compartments closed circuit
tube mills with drying
chambers (if moisture < 7-8%)
or
Tube mills in combination with
heated hammer crushers.
High efficiency separator
or
Roller Press with Ball Mill
Tube mills without drying
chamber, or without external
drying.
Autogenous Mills (only in case
of specific applications).
Roll Press in circuit with V or
VSK separator and/or dynamic
separator.
Pregrinding circuit with two-
compartments ball mill.
Air Swept mill
Central discharge mill
Modification of existing
grinding shop
Closed circuit mill
High efficiency separator
Closed circuit mill
High efficiency separator
Roll Press in circuit with V or
VSK separator and/or dynamic
separator.
Pregrinding with two-
compartments ball mill circuit.
Modification of 1st generation
separator
Addition of external drying
drum
New Equipment Ball Mill with drying chamber
Mill Circuit Closed circuit Partial feed to the separator Open circuit
Ball mill speed 75% critical speed 75 % critical speed <73% or >78% critical speed
Ventilation ball mill
Air velocity above ball
charge=1,5 to 2,2 m/s
inside the trunion: 22-25 m/s
inside partition:8-14 m/s
0,6 - 0,8 Nm3/kg raw mix
hood < 5m/s
drop out box < 2m/s
VFD fan
Air velocity above ball
charge=1,5 to 2,2 m/s
VFD fan
Mill L/D ratio
1,5 < L/D < 3,2
First compartment length = 35 -
45% of mill total length
Process guidelines - Raw Milling - Page 1 / 3 06/10/2005 - 10:58
Raw milling
Best Practice /
Recommendation
Specifications Alternatives Operating target Not advisable Comments
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Ball mill Liners
Moderate lifting liners for first
compartment, classifying liners
for second compartment
Classifying liners in second
compartment
Duo lift
Ripple liners
Without classifying liners keep
a maximum of 3 - 4 ball sizes
Intermediate Partition wall
Central opening adapted to
the filling degree. Slots placed
concentricly. - 8 to 12 mm slot
for central partition.
- open area > 50 % by central
opening
Diaphragms with material flow
control
Slots placed radially.
Outlet partition wall
Central opening adapted to
the filling degree. Slots placed
concentricly. Partition wall slot
size + 2mm (max slot = 0,5
min ball size)
Slots placed radially.
Ball charge
Volume Loading:
- for minimum kWh/t: 26-28%
in C1 and 28-30% in C2
- for max output: 32-34% in
C1 and 34-36% in C2
Separator Third Generation High
Efficiency
Dust load < 1kg/m3
Qf/Qa < 2.5
1st or 2nd generation
separators
Control
Fresh feed control to assure
constant feed to the separator.
Mill controled by LUCIE.
Weighing rejects (belt
weigher), measuring elevator
power, mill presure loss, mill
outlet temperature and
electronic ear.
Control mill fresh feed using
only one parameter (only
rejects flowrate or only
elevator power , for example)
Fresh feed control can be done
by different ways, using
different instruments or signals
(rejects flowrate, elevator
power, eletr. Ear, mill kW). It is
recommended to use them in
conjunction.
Feed
Feed size 95%< 50 mm
d80 feed < 20mm,
Precrushing, screening,
external drying
The finer, the better
Drying compartment Moisture inlet C1 < 1.5%
Specific drying capacity
<300kg/m3
Process guidelines - Raw Milling - Page 2 / 3 06/10/2005 - 10:58
Raw milling
Best Practice /
Recommendation
Specifications Alternatives Operating target Not advisable Comments
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Equipment VRM
Vertical Roller Mill Recirculation of gas to the mill.
Metal detector and extractor in
the feeding line (after reject's
return)
Gas flow measurement after
cyclone or filter
Water injection system
Central mill feed.
HE Separator
Material External Recirculation
System >30% Fresh Feed
Capacity Fan
with VFD
Bed depth sensor
Metal detector and extractor in
the feeding line (after reject's
return)
Bed depth sensor
Water injection max 25 kg/t
Material External Recirculation
System >30% Fresh Feed
Capacity
Fan with VFD
Water injection facilities in the
mill housing
Gas speeds:
Nozzle ring >30 m/s
Mill Body: 5 - 7 m/s
Separator: 3 - 5 m/s
Dust Load: 600 g/m3 at mill
outlet
Feed device with triple flap
gate or rotary air lock valve,
heated if wet or sticky raw
materials.
Fan max speed typical 700 rpm
and >80% efficiency
Control Constant mill exit T
Constant mill gas flow
Mill feed a to mill deltaP
Process guidelines - Raw Milling - Page 3 / 3 06/10/2005 - 10:58
Preheater
Best practice /
Recommendation
Specifications Alternatives Operating target Not advisable Comments
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Equipment
Cyclones
5 Stage Preheater - low
moisture < 5% raw materials
Low pressure drop
Bottom of cyclone
> 50 height
No horizonatal inlet ; no
horizontal surface
4 Stage Preheater - high
moisture >5% raw materials
For a 5 stage PH, 4.5 to 5.5
kPa (including kiln)
See priority study Preheater
Dip Tube Length relative to
cyclone inlet height
Top (stage 1): 100%
Stage 2/3: 75%min
Stage 4/5 : 50%min
Top (stage 1): 100%
Hurrivanes - depending on
geometry
Number in % of inlet height
Splash box
Lafarge design
cleaning devices. At least 55
to 80 between meal pipe and
splash box
2 m from flap, pipe without
elbow
60 for kiln feed to splash box.
>60
o
below C3 Splash plates See priority study Preheater
Pendulum flap External knife bearing
Precalciner
Vessel + Hot core preferred
Residence time > 6 sec
for petcoke, Low-Nox
Residence time > 6 sec Riser Duct plus hot core
Very specific to fuel and plant
conditions
Tertiary air duct
Downward split design
for in-line calciner
Damper control
Duct velocity 20 to 30 m/s
Process
Gas duct velocity at meal
entrance
Mini 12 m/s top stage
with 17 m/s bottom
(intermediate proportional)
Can install restriction
as alternative
Riser velocity 16 m/s minimum
Process guidelines - Preheater - Page 1 / 2 06/10/2005 - 10:58
Preheater
Best practice /
Recommendation
Specifications Alternatives Operating target Not advisable Comments
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Cyclones Top cyclone efficiency > 95% Top cyclone efficiency > 95%
Meal curtain
Considered if high volatile
cycles expected
Most common on N-1 stage
on kiln side
Lateral
Consider a splitter
Kiln inlet box
No dead zone
Smooth design (entrance in the
middle)
No turbulances
45- 50 slope of inlet
Downcomer
Cooling by water sprays
Minimum evaporation: 4 sec
(for target at 185C)
No bleed air is recommended,
except for start up
Water design target able to
provide 185 C. Take care
about moisture in gas to coal
mill take off above water
injection
ID fan preheater
VFD drive
Fresh air intake before
the fan (fan protection)
Fan Typical Max speed 990
rpm and efficiency >80%.
Design margin 5% volume and
1 kPa pressure
number of fans
3
ID fan, raw mill fan &
baghouse fan
Only 2 fans
Secondary Fuel
usage
Burner preferred for Calciner
Process guidelines - Preheater - Page 2 / 2 06/10/2005 - 10:58
Kiln
Best Practice /
Recommendation
Specifications Alternatives Operating target Not advisable Comments
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Equipment
Burner type and position Lafarge Burner
MAS burner in case of regular
solid fuel and alternative fuel ;
Position in center line of kiln
and aligned on kiln axis (only
if kiln is stable and burner
having sufficient impulse)
See Lafarge Burner Design
Spreadsheet
Fuel speed
Solid Fuel: 25 - 35 m/s in
burner ; >25m/s in conveying
line
Solid Fuel: 25 - 35 m/s in
burner ; >25m/s in conveying
line
Alternative Fuel: 25 - 40 m/s
in burner ; >25m/s in
conveying line
Total primary air <12% with coal / petcoke
< 15% primary air (as low as
possible when firing
alternative fuels)
Liquid (main fuel) > 25 cSt
Swirl Design: 0,15
Impulse Design: >2,2
Final design criteria to be
worked out.
Retaining rings
0,6 to 1 m from nosering as
single ring, triangulkar shape
Double flat bar
Maggoteaux system
Kiln slope 3 - 3,5 % 4%
L/D
>10,5 for preca (> 15 is
required when designing for
alternaitve fuels)
> 15 for preheater
Tertiary air
From kiln hood
Take off velocity 5-6 m/s
throat and tertiary air and 25
m/s in the duct
From kiln hood
Take off velocity 5-6 m/s
throat and tertiary air and 25
m/s in the duct
Settling chamber Heat shield IKN not proven
Shell cooling fans 12 to 18 m/s at shell Supplied
Fan should be below kiln so
that air flow comes up on
both sides.
Process guidelines - Kiln - Page 1 / 2 06/10/2005 - 10:58
Kiln
Best Practice /
Recommendation
Specifications Alternatives Operating target Not advisable Comments
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Process
Thermal load
< 5 MW/m (kiln cross
section)
< 5 MW/m < 6.5 MW/m
Limit for refractory.
Some wet and big kilns can
overpass the limit
Kiln hood velocity < 6 m/s
Kiln load <4,5 t/d/m
Production 24 m/s hearth velocity pc kiln <28 m/s
Clinker bypass
With > 0,025% of Cl input
(related to clinker) consider a
bypass
Clinker storage
For off specification clinker, 8
hour separate storage
considered
Process guidelines - Kiln - Page 2 / 2 06/10/2005 - 10:58
Cooler
Best practice /
Recommendation
Specifications Alternatives Operating target Not advisable Comments
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Equipment
Equipment Selection Cross Bar or Walking Floor
Design
Cross Bar or Walking Floor
Design
Grate load < 45 t/m d < 45 t/m d
Variable speed fans All on 1st grate Variable speed on all on 1st
grate fans. 2nd grate fans can
be with variable inlet vanes
dampers
Fan dampers (inlet radial) Flap max speed typical 1500 rpm,
Efficiency > 80%. Normally 20-
30% pressure reserve.
Fix inlet rows 5 to 8 (1.5 - 2.5 m)
Max 15 degree angle
Refractory Horseshoe
Air Cannons
Crusher Roller crusher intermediate
or at the end
Hammer
Crusher
Hammer crusher can be the
first choice if no need for very
effective cooling
Grate slope 0 3 maximum
Evacuation hoppers Simple gate and sensor level Double gate mechanically
activated
Process
Air flow design Not < 2,1 Nm3/kg > 2.1 Nm/kg ck
> 1.7 Nm/m/s on first fans, 2
Nm/m/s for KIDS
First fans pressure > 10 kPa (100 mbar) for KIDS
Optimal bed depth Lowest stroke permitted with
20% reserve on fans
(6-8 st/min for properly
designed cooler)
Air velocity above clinker 5 to 7 m/s
Clinker transport design Min. 1,5 x nominal capacity
steel conveyor
Min. 1,5 x nominal capacity
steel conveyor
Process guidelines - Cooler - Page 1 / 1 06/10/2005 - 10:59
Kiln filter
Best practice /
Recommendation
Specifications Alternatives Operating target Not advisable Comments
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Equipment
Equipment Selection
Low Pressure Pulse Jet Bag
Filter ( 2,5 bars)
Low Pressure Pulse Jet (LPPJ)
Bag Filter ( 2,5 bars)
High Pressure Pulse Jet (HPPJ)
Bag Filter (6bar/100psi),
Electrostatic precipitator
Max dP< allowed by fan
capacity at end of bag life.
Limit cleaning cycles to obtain
target bag life.
Off line cleaning is not
acceptable due to the
potential damage to the bags.
BH sizing must maintain
operating pressure drop within
the limits of the ID fan and the
pulse jet filter ability to clean
bag on line.
Equipment Sizing
Gross Air to clothe ratio:
1m/min average
1.3 m/min max (upset cond)
Gross Air to clothe ratio:
1m/min average
1.3 m/min max (upset cond)
Bag quality
Fabric with PTFE membrane
and fiberglass structure.
Known suppliers: Gore, BHA,
Tetratec working
at 180C- 230C max
Design temperature 230C
Peak temperature 260C
P84 bags of suitable
construction.
Adequate temperature control
to prevent teflon and SGT
evaporation and bag damage.
working at 180C- 230C max
Other bag materials that are
not proven.
If using P84 verify the risk of
hydrolysis.
Bag quality and workmanship
are critical. Bag to cage fit is
critical.
Airflow Distribution
Scale model to ensure good
airflow distribution and correct
fan sizing before purchase
Compressed Air Supply
Air coolers can be acceptable
for LPPJ.
Use air dryers (dessicant) for
HPPJ (-30deg C due point).
Prevent moisture condensation
in the bag during the
compressed air pulse.
No oil in cleaning air.
Exhaust Fan VFD VFD
Fan Typical Max speed 990
rpm and efficiency >80%.
Design margin 15% volume
False Air
Direct < 30% Preheater Gases
Compound < 50% Preheater
Gases
Process guidelines - Kiln and Cooler Filter - Page 1 / 2 06/10/2005 - 12:08
Kiln filter
Best practice /
Recommendation
Specifications Alternatives Operating target Not advisable Comments
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COOLER FILTER
Equipment Selection
Air to air heat exchanger to
get 130C at exit
Air to air heat exchanger to
get 130C at exit
Common baghouse for
RM/kiln and cooler
ESP when all cooler gas used
for raw materials drying
Exhaust system capacity to
handle normal operation and
to provide sufficient capacity
for push conditions for the full
length of the bag life.
Gas flow in BH hopper must
not cause abrasion of filter
bags due ro high velocities.
Exhaust gas flow from the
cooler straight entry and
oriented downwards through
heat exchanger
Gas velocity at heat
exchanger's inlet in normal
conditions: <10 m/s
Water injection in the exhaust
pipe
Cooling fan are VFD speed
Exhaust Fan VFD VFD
Fan Typical Max speed 990
rpm and efficiency >80%.
Design Margin 15% volume
System Sizing
Design upset conditions 450 C
exhaust gas temp. Design
flow 1.7 nm3/kg clinker
Design upset conditions 450 C
exhaust gas temp. Design
flow 1.7 nm3/kg clinker
Process guidelines - Kiln and Cooler Filter - Page 2 / 2 06/10/2005 - 12:08
Kiln By-pass system
Best practice /
Recommendation
Specifications Alternatives Operating target Not advisable Comments
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Equipment
Dedusting Bag filters (240C) ESP
Wet scrubber may be a
solution when cement Cl is a
limitation
Dust transport
As short as possible
Mechanical
Air transport if Cl < 10%
Storage
As small as possible,
with mechanical extraction
Direct dust addition to cooler
filter or heat exchanger
intermediate storage
Addition to cooler only if
clinker storage does not
promote segregation (quality -
dust separation in pile)
Process
Location take-off
On top of the smoke box, on
the kiln side
Distant from C3 discharge to
avoid dust mixing
Level of chlorine in dust
Dilution with kiln feed if >
10% Cl
Cl control using cyclone system
with bypass (Taiheyo)
Quenching
Air quenching as close as
possible to the take out, either
directly to 200C or at least to
400C
Air to air cooler as second
cooling step to minimize the
gas quantity
Exhaust air
To cooler fans to avoid
SO2/Dioxins
Raw mill or main stack if SO2 is
acceptable, dioxins still a
threat. Detached plume also a
potential issue if organics in
raw mix
Separate stack
Dust management
Cement (limiting factor forCl
as allowed by local standard)
Clinker (limiting factor for Cl)
Dust Washing with heavy
metal recovery, for low limit of
Cl in cement
Dust wasting
Target level of chlorine in kiln
back-end mat
1,00%
Higher concentration
acceptable if possible for build-
ups
Process guidelines - Kiln By-pass system - Page 1 / 1 06/10/2005 - 10:59
Gas analyser
Best practice /
Recommendation
Specifications Alternatives Operating target Not advisable Comments
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Kiln inlet
Kiln inlet
Probe
Probe long enough to enter
the kiln, retractable,
motorised
Dry probe required
Water cooled jacket
Same probe for all gases
Back flush (clean, dry air)
Oil cooled
In-situ
CO
Mandatory
Type: IR
Scale: 0-20000 ppm
NOx
Mandatory
Type IR
No NO2 converter needed
Scale: 0-20000 ppm
O2
Mandatory
Type: Paramagnetic
0-10%
SO2
Required if Total SO3 input >
1.2% on clinker basis or
S/A ratio > 1.2
Type UV
Quartz cells
0-20000ppm
IR (on separated line)
Gas treatment
Heated line (>180C)
2 cooler dryer 1 for SO2 and 1
for other gases
For other gases H2O2 injection
Suspension preheater kiln - no PC
Exit of preheater tower Mandatory for O2 and CO
Exit of Precalciner
Precalciner
Probe
Probe at Bottom cyclone exit
retractable,
Dry probe required
Water cooled jacket
Same probe for all gases
Back flush (clean, dry air)
Process guidelines - Gas analyser - Page 1 / 2 06/10/2005 - 11:02
Gas analyser
Best practice /
Recommendation
Specifications Alternatives Operating target Not advisable Comments
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CO
Mandatory
Type: IR
Scale: 0-20000 ppm
NOx
Mandatory
Type IR
No NO2 converter needed
Scale: 0-20000 ppm
O2
Mandatory
Type: Paramagnetic
0-10%
Gas treatment
Heated line (>180C)
2 cooler dryer 1 for SO2 and 1
for other gases
For other gases H2O2 injection
3 other in line O2 last
CEM (stack)
Location Follow local regulation
Dust Scattered light system
O2
In-situ system (Zircon)
0-10%
H2O
Optical in-situ system IR
0-10%
CO
Optical in-situ system IR
0-2000 mg/Nm3
Extractive with heated probe
and line (>180C) + FTIR
NOx
Optical in-situ system-UV
0-2000 mg/Nm3
Extractive with heated probe
and line (>180C) + FTIR
SO2
Optical in-situ system-UV
0-500 mg/Nm3
Extractive with heated probe
and line (>180C) + FTIR
HCl
Optical in-situ system-IR
0-100mg/Nm3
Extractive with heated probe
and line (>180C) + FTIR
COV
Extractive FID
0-200mg/Nm3
CO Protection with ESP
Precalciner Kiln
Use precalciner exit CO with
preheater exit CO as back up
Suspension preheater kiln
Use kiln exit CO with
preheater exit CO as back up
Process guidelines - Gas analyser - Page 2 / 2 06/10/2005 - 11:02
Coal Mill
Best practice /
Recommendation
Specifications Alternatives Operating target Not advisable Comments
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Equipment
Equipment Selection Vertical mill Vertical mill
Ball mill ,
Ring roller mills
Pendulum mills
Central discharge mills
"deep bowl" mills
Ball mills are better suited for
very hard fuels and certain
cokes. Also need to consider
turndown ratios if AF is
significant - need VFD or
something appropriate.
Process Gas
Hot gas from pre heater with
de dusting
Hot gas from pre heater with
de dusting
Direct or semi direct firing
Sensors
CO analysers:
- Raw Coal Bin
- Mill Filter Exit
- Each Pulverised Fuel Bin
O2 analysers:
- Preheater Exit
- Before Mill
- Mill Filter Exit
Temperature sensors
- Raw coal hopper/silo
- Before mill
- After mill
- Hot gas duct
- Filter bottom
- Coal dust after filter
- PF silo bottom ( In banks of
four around cone)
- Differential temperature
across filter
Differential temperature across
separator for ball mill
Load Cells
- Raw Coal Bin
- Pulverised Coal Bins
Pressure indication
- Before mill
- After mill
- Mill differential pressure
- Filter differential pressure
Dust monitor
- Coal bag filter main stack
Process guidelines - Coal mill - Page 1 / 2 06/10/2005 - 11:00
Coal Mill
Best practice /
Recommendation
Specifications Alternatives Operating target Not advisable Comments
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Safety for mill and feeding
system
See Safety Equipment in Model
Plant
See Safety Equipment in Model
Plant
Study fuel - need to have
temperature limit at mill inlet
and mill outlet appropriate for
fuel. Favor high gas volume so
it can be run cooler. High
volatile O2<12%. Moderate
volatile 21% O2 is OK if
temperature < 70C
Pet coke grinding
Install a dynamic 3rd
generation separator
According to Combustion BP
the fineness should be less 0.1
% rejects on 200
Open circuit
See Combustion manual for
fineness vs. volatile
Fire suppression system Bulk system C0
2
2Kg/m
3
of volume of the
system coal mill, filter, silos and
ducts and enough for 2
complete discharges (X3 for
remote locations)
Bottle CO
2
systems can be
considered if local conditions
or regulations do not allow
bulk or if delivery time is
excessive.
Process guidelines - Coal mill - Page 2 / 2 06/10/2005 - 11:00
Cement Grinding
Best practice /
Recommendation
Specifications Alternatives Operating target Not advisable Comments
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Equipment
Equipment Selection Vertical Mill Vertical Mill
Roller Press
Pregrinding circuit with two-
compartment ball mill
circuit.CKP with 2
compartment mill,
Ball mill
Ring roller mills,
central discharge mills
Ball Mill Circuit
Closed circuit mill with
separate filter for mill
ventilation and separator
Ball mill
Single compartment with
lifting and classifying liners*
2,8 < L / D <3,2
* 27% <Length first
Compartment< 35% mill
effective length.
1st comp: 8 - 10 kWh/t
Ball mill speed 75% of the critical speed 75% of the critical speed <73% Critical speed >78%
Separator
3rd generation high efficiency
separators,
de dusting by filters
Basket variable tip speed
10 to 30 m/s,
radial process air velocity 3 to
5 m/s,
Static separator for pregrinding
circuits,
fines to separator
1st generation separators, De
dusting by cyclones
By-pass 5 to 10 %
Imperfection < 0.30
Acuity <= 15 m
Rosin Rammler specification
value to be provided
Ventilation ball mill
Air velocity above ball
charge:1.4 - 2.2 m/s
Inside the trunion: < 22m/s
Inside partition:<12m/s
VFD fan
>1.5% moisture at mill
inlet(Pozzolanic materials
should be dried before
feeding)
Static separators for separation
of mill dust to final product for
open circuit mills and mills
with old dynamic separators
Process guidelines - Cement grinding - Page 1 / 2 06/10/2005 - 11:28
Cement Grinding
Best practice /
Recommendation
Specifications Alternatives Operating target Not advisable Comments
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Ventilation separator
Separator Qf/Qa:1.8 kg/m,
VFD fan for HES,
The circulating load 200%
Separator Qf/Qa:1.8 kg/m,
VFD fan for HES,
The circulating load 200%
Separator Qf/Qa range: 1.8-
2.5 kg/m3(200% C.L), Cement
temp 90-110 deg ,
VFD for fan
Final product load<0,8 kg/m3
Ball mill internals
Reverse step liners for first
compartment, classifying liners
for second compartment
Reverse step liners in first
compartment with lifting ht
range: 70-75mm. Classifying
liners in second compartment
Duo lift
Ripple liners
Intermediate Partition wall
central opening adapted to the
filling degree
*Material transport capacity
500t/m2/h
* 6 to 8 mm slot
* Central screen open area 60
% minimum
*Provision of Flow control
gates to regulate material
flow
Single plate, slots
on reverse side of diaphragm
liners
Outlet partition wall
central opening adapted to the
filling degree
*Material transport capacity
500t/m2/h
Intermediate partition wall slot
size+2mm,
Ball charge
Nominal ball charge loading
28-30% for both
compartments,
(installed power on 32%
filling)
>32% ball charge
Higher filling causes higher
specific energy, problems for
cooling. Ball charge with
pregrinder needs to be
modified
Process
Control
Pre requisites for Lucie - Fresh
feed variation through
weighing of separator rejects,
feed accuracy with in +/- 1%,
electronic ear to detect filling
of first compartment.
Belt weigher for rejects
Elevator power
Feed
Feed size passing on
100% <30mm,
95% < 25mm
Precrushing, drying of wet
additives
Temperature control
Cement temp range:
90-110 deg C
Cement cooler
Water injection from partition
wall if required
Process guidelines - Cement grinding - Page 2 / 2 06/10/2005 - 11:28
Weighing Dosing
Best Practice /
Recommendation
Specifications Alternatives Operating target Not advisable Comments
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Pulverised Coal
Equipment Selection
Small bins close to the burning
point <50 m
on cells for calibration
Schenck Coriolis,
Variation < 0,5 % (short term)
Small bins close to the burning
point <50 m
on cells for calibration
Schenck Coriolis,
Variation < 0,5 % (short term)
Pfister
New systems of Pfister and
Coriolis > 50 m
Old Pfister > 40 m. Actual limit
is back pressure. Long distance
means more backpressure but
can be compensated for by
proper design. Schenk Star
feeder with high pressure
transport line not
recommended (low tolerance).
Schenk Coriolis + Bremer
Screw + FK pump for long
distance is very good.
Velocity
Minimum number of elbows
velocity >= 25 m/s
Minimum number of elbows
velocity >= 25 m/s
Solid concentration 4-6 kg/nm3 4-6 kg/nm3 > 7 kg/nm3
Raw meal
Equipment Schenk Coriolis

Pfister
Weigh Feeder
Both still recommend level bin
ahead of scale to minimize silo
flushes. Using airlift pressure to
calculate flow can be
sufficiently accurate.
Effective weighing Variation < 0,5 % (short term) Variation < 0,5 % (short term) Accuracy < 0,5 % (short term)
Transport Elevator Elevator Air-lift
Process guidelines - Weighing-dosing - Page 1 / 1 06/10/2005 - 11:05