Grinding plant modernization
To get better performance from existing grinding installations, Fives offers modernization projects by implementing innovative and efficient process equipment. These modernization projects aim at increasing the capacity with limited capital cost while reducing operating costs. Considering these constraints, modernization of a cement grinding unit with implementation of a high efficiency classifier is a very profitable opportunity.
Increasing the mill output
Reduction of the bypass is the main way to boost the mill throughput when the modernization is limited to replacement of an old generation classifier.
Fives' 3rd generation classifier, the FCB TSV™ Classifier, drastically reduces the bypass flow. This avoids the return of fine particles to the mill, thus limiting overgrinding thanks to a sharp classification which allows an increased feed of fresh material to the ball mill. By reducing the classifier bypass, the efficiency of the mill is directly improved as the overgrinding and corresponding waste of energy are drastically reduced, to the benefit of fresh feed flow.
Installing a FCB TSV™ Classifier on existing grinding plant results in an increase of the mill output ranging from 15% to 50% upon application.
Enhancing the quality
The FCB TSV™ Classifier allows more accurate control of the particle size distribution so its installation provides the opportunity to target cement quality parameters and to set operating points with much tighter margins. Both result from the sharp classification of the patented turbine blade profile and from the proven air seal of the turbine preventing coarse particles from passing into the finished product.
The drastic reduction of coarse particles in the finished product plays a key role in the cement quality. This directly improves the homogeneity of the cement, thus leading to a higher final compressive strength.
Depending on the product, this quality enhancement enables two different options:
- A reduction in the Blaine fineness (i.e. decreasing the specific energy consumption) to enable an increase of the mill output
- A modification of the mix formulation to increase the cement/clinker ratio without changing the targeted fineness
Lowering the carbon footprint
The installation of the FCB TSV™ Classifier, by reducing the bypass and the corresponding overgrinding, enables a reduction in the specific electrical energy consumption. This has a direct positive effect on the carbon footprint.
Furthermore, the cement quality improvement enables either a reduction of Blaine fineness (thus reducing the specific grinding energy) or a reduction of the clinker ratio in cement (i.e. introducing more substitution material).
This results in significant CO2 abatement, high energy saving effects, and thus leading to an active contribution to environmental protection.
- Improve mill efficiency
- Increase cement mill output
- Enhance cement quality through grinding process
- Reduce energy consumption and contribute to environmental protection
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