XP4 The New Generation Classifier H

XP4
the new generation classifier

1
introduction
slegten s.a. is a Magotteaux company - specialized in grinding and
separation processes - organized in 3 divisions.
R&D : liners, diaphragms, separators / lab tests / special contracts
Consulting : grinding process expertise, audit
Projects : engineering, separators, precrushers
"grinding optimization
our expertise"
2
why a new separator ?
Optimization of existing plant

compact solution easy to implement
HE separators designed in 80s and 90s

possible improvements in energy
"All in" concept
no cyclone !
no process filter !
direct fines recovery
compact design
3rd generation separator
efficiency
+
1st generation separator
compactness
5
cost effective solution

short erection shut down time
lower total project cost
20% to 30% lower pressure drop

lifetime substantial energy savings
Genesis
First idea 2000
CFD study 2002 - 2004

7
Design optimization 2002 - 2004
rejects
HE cyclone 1%
cage H/D ratio

fines chamber ratio H/D
vortex enhancer
fines chamber discharge
fines separator 99%
separation efficiency
pressure drop
fines recovery
8
standard arrangement
30
72.84
80.98
27.58
93.87
22.5
85.05
7.90
40
81.72
90.07
40.61
93.07
35
107.97
20.89
45
84.85
92.90
47.24
92.45
42.5
83.14
30.15
50
87.42
95.14
53.57
91.89
47.5
80.16
34.24
63
92.34
98.43
68.06
90.00
56.5
57.12
44.81
75
95.75
100.00
78.52
88.18
69
36.43
55.12
90
98.02
100.00
87.77
86.14
82.5
0.00
100.00
100
99.08
100.00
92.10
85.22
95
0.00
100.00
120
100.00
100.00
97.21
84.44
110
0.00
100.00
130
100.00
100.00
98.53
84.44
125
0.00
100.00
Blaine:
3910cm2/gr
Laboratory tests 2004

4490cm2/gr 1160cm2/gr
circulating load: 1.18
PLANT:
SEPARATOR:
SAMPLE:
DATE:
essai 3143A1
3500/500/1000/60
efficiency
0
29.03.04
dim.
feed
P.F.
rejects
dim
effic. (i)
%.P
%.P
%.P
Tromp
%
2.2
15.51
15.59
7.26
84.86
1.1
99.56
7.90
2.6
17.47
17.67
8.13
85.40
2.4
95.54
7.17
3.2
19.64
20.02
8.99
86.07
2.9
95.21
6.32
0.9972
vf= 0.844
vg= 0.156
99
98
97
96
95
90
85
80
32.46
33.93
11.77
88.26
5.6
97.88
3.55
15
49.88
54.07
15.07
91.53
11.5
96.94
2.93
30
72.84
80.98
27.58
93.87
22.5
85.05
7.90
40
81.72
90.07
40.61
93.07
35
107.97
20.89
50
45
84.85
92.90
47.24
92.45
42.5
83.14
30.15
40
50
87.42
95.14
53.57
91.89
47.5
80.16
34.24
30
63
92.34
98.43
68.06
90.00
56.5
57.12
44.81
75
95.75
100.00
78.52
88.18
69
36.43
55.12
20
90
98.02
100.00
87.77
86.14
82.5
0.00
100.00
15
100
99.08
100.00
92.10
85.22
95
0.00
100.00
10
120
100.00
100.00
97.21
84.44
110
0.00
100.00
130
100.00
100.00
98.53
84.44
125
0.00
100.00
Blaine:
correlation :
70
60
characteristics
d75..............: 60.43
d50..............: 48.84
d25..............: 39.48
Imperfection.....: 21.45 %
5
4
3
dl...............: 11.50
by-pass..........: 02.93 %
3910cm2/gr 4490cm2/gr 1160cm2/gr
correlation : 0.9972
vf= 0.844
vg= 0.156
10
100
1000
10
Not only a concept !
11
Cementi della Lucania 2005
Confidential agreement (patenting)
Scale up tests (separation efficiencies, fines recovery)
100% in 450 HB steel construction (wear monitoring)
12
13

PLANT:
SEPARATOR:
efficiency confirmed
99
98
97
96
95
90
85
80
70
60
50
40
30
20
characteristics
15
d75..............: 68.91
d50..............: 53.64
d25..............: 41.75
10
Imperfection.....: 25.32 %
5
4
3
SAMPLE:
DATE:
Cementi Della Lucania

XP 4/50
efficiency
10 h 00
24.11.05
dim.
feed
P.F.
rejects
dim
effic. (i)
Tromp
%.P
%.P
%.P
2.2
12.43
16.59
5.53
91.68
1.1
83.26
13.19
2.6
14.14
18.89
6.23
91.73
2.4
84.92
12.27
3.2
16.18
21.66
6.97
91.92
2.9
86.96
10.87
26.13
35.76
9.07
93.97
5.6
92.70
6.36
15
36.21
50.25
10.88
95.29
11.5
93.75
5.39
30
53.51
72.95
16.27
93.61
22.5
90.28
9.78
40
63.36
82.84
23.34
89.78
35
98.97
24.58
45
67.57
86.44
27.52
87.84
42.5
-3.93
34.65
50
71.50
89.52
32.23
85.97
47.5
37.52
41.13
55
74.96
91.93
36.99
84.21
52.5
38.43
47.40
63
79.93
94.96
44.75
81.58
59
36.03
53.86
75
86.13
98.07
55.76
78.19
69
30.55
61.79
90
91.39
99.49
67.94
74.75
82.5
17.38
79.61
100
94.05
100.00
74.25
73.01
95
12.08
84.94
105
95.07
100.00
77.05
72.22
102.5
0.00
100.00
dl...............: 11.50
Blaine:
by-pass..........: 05.23 %
2
1
10
100
1000
2530cm2/gr 4150cm2/gr
680cm2/gr
correlation : 0.9941
vf= 0.687
vg= 0.313
14
improvements

Mill
Cement
KVS 10 x 20
CEM IV/B 32.5R
800 kW installed
50% clinker - 45% pozzolana 5% gypsum
Scope
1st generation Sturtevant 16 replaced by XP4-50

New mill equipment and charge adaptation
Results
Before
After
Output
kW mill
kW separation
C.L.
%R90
kWh/t mill
kWh/t workshop
20 t/h
680 kW
50 kW
6.5
5%
34.0
36.5 kWh/t
24 t/h (+20%)
680 kW
15 + 50 = 65 kW
1.8
<1%
28.3 (-16.7%)
31.0 kWh/t (-15%)
15

one year operation mechanical assessment
technical design approved
16
XP4-80 arrangement side view
17
XP4-80 arrangement plan view
18
TANGENTIEL OUTLET
19
IMPLEMENTATION
20
basic segmentation
Conversion to closed circuit
Old separators substitution
Cement, raw, chemicals, etc
No cooling (but cement mix, clinker T, dedusting filter)

No airswept arrangement
No combustible nor explosive materials
21
pressure drop
Pressure drop (mmWG)

3rd gen sep (250) + filter (150) + ductings (50) = 450 (500 inst.)
3rd gen sep (250) +cyclone (125) + ductings (50) = 425 (475 inst.)
XP4 + ductings = 325 (350 installed)
in general 10% reserve on the installed fan
22
cycloning
Selection cage speed (fines recovery chamber inlet speed)

from 14 m/s (2755 fpm) for coarse finished product
to 36 m/s (7086 fpm) for fine finished product
compared to cyclone inlet speed which is around 18 m/s (3543 fpm)
23
project cost
Comparison WW22' >>> SD120 >>> XP4/120 (200.000 Am3/h)
Cement mill - 4,5 x 13,5 m - 4.100 kW 160 mtph
SD120 + filter
SD120 + cyclone
XP4/120
2.030.000 USD
1.050.000 USD
870.000 USD
+ shorter down time
+ lower energy
24
references
Cementi della Lucania (Italy)
2005 - 2006
XP4/50 cement
Costantinopoli (Italy)
2006 - 2007
XP4/80 cement
Costantinopoli (Italy)
2006 - 2007
XP4/70 cement
25
sizes and design airflow
XP4 size
50
60
Cage (m)
1,5 1,75
Airflow (000 m3/h)
42
75
58
70
80
90
100
2,25 2,5 2,75

95
118
110
120 130 140
3,25 3,5 3,75
142 169 199 231 265
26
XP4 innovative technology
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27
EVOLUTION
28
thank you
29

XP4 The New Generation Classifier H

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XP4 The New Generation Classifier H

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Copyright:

Available Formats

XP4

the new generation classifier

why a new separator ?

Optimization of existing plant

HE separators designed in 80s and 90s

"All in" concept

cost effective solution

20% to 30% lower pressure drop

First idea 2000

CFD study 2002 - 2004

Design optimization 2002 - 2004

cage H/D ratio

fines separator 99%

Laboratory tests 2004

circulating load: 1.18

3910cm2/gr 4490cm2/gr 1160cm2/gr

circulating load: 1.18

Not only a concept !

Cementi della Lucania 2005

Confidential agreement (patenting)

Scale up tests (separation efficiencies, fines recovery)

100% in 450 HB steel construction (wear monitoring)

Cementi della Lucania 2005

Cementi della Lucania 2005

Cementi Della Lucania

Cementi della Lucania 2005

1st generation Sturtevant 16 replaced by XP4-50

Cementi della Lucania 2006

XP4-80 arrangement side view

XP4-80 arrangement plan view

No cooling (but cement mix, clinker T, dedusting filter)

Pressure drop (mmWG)

Selection cage speed (fines recovery chamber inlet speed)

sizes and design airflow

Airflow (000 m3/h)

2,25 2,5 2,75

120 130 140

3,25 3,5 3,75

142 169 199 231 265

XP4 innovative technology

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