To maintain state-of-the-art standards, Siniat GmbH has set up a new gypsum grinding-drying plant in their Hartershofen works in Germany in close cooperation with Gebr. Pfeiffer SE. As stipulated in the contract, the new roller mill of the type MPS 160 B had to be integrated into the existing gypsum works in a way that the latter could remain in full operation until 2 weeks before the planned switchover from old to new. This challenge meant a great amount of sophisticated coordination work, project management, and engineering that Gebr. Pfeiffer was able to meet within the very short time schedule of 8 months as requested by the customer who was fully satisfied with job.
Siniat GmbH, member of the Belgian Etex Group, isspecialized in dry construction materials and systemsolutions made of gypsum plaster and cement. Since1991 a vertical roller mill of the type MPS 125 A hasbeen operating in the Hartershofen works taken overby Siniat. This mill was used for grinding and processingnatural gypsum, flue gasdesulfurization gypsum, andrecycled material to obtain the basic material neededfor the production of plasterboard products
Siniat aimed at reducing capital expenditure for therebuild to a minimum and keeping the production stopas short as possible. The new mill of the size MPS 160B was to be set up next to the existing mill so that thelatter could stay in operation while construction workwas going on. The intention was to switch over fromthe old mill to the new one within 2 weeks during amaintenance stop.
This was quite an ambitious goal that Pfeiffer promisedto achieve in the contract concluded with Siniat GmbH.Further requirements had also to be met: observingthe tight time schedule of only 8 months betweenconcluding the contract and commissioning, ensuringplant reliability, and handing over the overall grindingplant on a turnkey basis with all components from onesource.
To ensure proper project handling, Gebr. Pfeiffer couldrely on its long-term experience with the design andconstruction of tailor-made grinding solutions: theplanning of the entire plant, the installation of allcomponents, and finally the commissioning of theplant should be carried out without putting the ongoingproduction at risk.
As is often the case with brownfield projects, the space available for setting up the new mill was very limited in the Hartershofen works. Moreover, various components of the existing plant should be used in the new plant after the switchover which was an additional challenge. Therefore, Pfeiffer started with a stock taking of the existing plant, using the millimeter precision of laser technology, and creating a 3D CAD model. With this method it was possible to do a precise layout planning of the new grinding-drying plant considering all interfaces and new components within the 3D CAD model.
Hence this model did not only show the new vertical roller mill of the type MPS 160 B along with its components rotary lock, classifier and hot gas generator, but also the entire ductwork and connections as needed for the envisaged switchover. Upon arrival on the site, the above components were set up next to the old mill while existing plant parts such as supply and removal equipment, metering devices, plant filter, plant fan, and plant silo remained in operation just like the old mill.
The decisive phase was reached when the new mill, structural steelwork, electrics, and control system had been completely set up. Now the old mill had to be stopped, all ductings connecting the new mill with the existing plant parts had to be laid and the plant silo had to be shortened at its lower end and provided with a proportioning belt scale. Thanks to the accurate planning work, the reconnection measures could be carried out within the 2 weeks as stipulated, without causing any major production loss, and the new plant was fully operational after only 8 months.
When laying the foundation, an unknown sewagepipe was discovered. It ran across the foundation andit would have been expensive for the customer torelocate it. Hence a solution was needed and foundrapidly: the foundation was modified together withthe structural engineer and the inspecting structuralengineer so that the sewage pipe could remain in place.
The rebuild with the new MPS vertical roller mill has turned the gypsum grinding-drying plant into a modernized system operating even more energy efficiently and reliably. Moreover, this rebuild was carried out while production was continuing, without any major production loss. The old mill had reliably operated for 25 years and the customer is convinced that his capital expenditure for the new MPS vertical roller mill will pay off for at least the same length of time.
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Henan Zhengzhou Mining Machinery Co., Ltd, was established in 1956 and located in Xingyang of Zhengzhou City of Henan Province, specially produces metallurgical machinery. It covers an area of more than 55000m2 and various building area of 28000 m2. It has the annual income of more than RMB180million in 2008 and now the fixed assets of over RMB80 million. In the plant, there are branches and workshops of cast iron, cast steel, forging, heavy machine tool processing, rivet welding and heat treatment etc. Its ...
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Gebr. Pfeiffer supplies innovative plant solutions for cement, coal, lime, gypsum and ceramics on which you can rely 100 %. We only give our word if we know we can keep it. And we keep what we have promised. Extremely reliable and with excellent results. For sustainable economic success. What can we do for you?
The contract was awarded not only because of the customers satisfaction with the first mill but also because of the Pfeiffer mill grinding the kaolin much more efficiently than its competitors mills.
The essential modules of all three MVR mills will have the same design and therefore be interchangeable; the advantages in terms of spare parts management and maintenance of the mills will be significant.
In addition to short specialist talks, the two-day event was an opportunity for knowledge transfer between mineral processing specialist Gebr. Pfeiffer and leading figures from various cement companies in India.
As part of the companys expansion strategy to spread grinding plants across the whole of India, Shree Cement will now equip a grinding plant near Pune in the state of Maharashtra with a Pfeiffer mill.
The contract includes the supply and installation from the top of the foundation up. It comprises the complete process equipment, electrical equipment and automation system as well as the complete building on EPC basis.
More than 50 attendees were welcomed, representing clients from all over the MENA region who were given the opportunity to profit from the Pfeiffer experts experiences and to use them for the Pfeiffer mills in operation at their works.
Even though our team is very much looking forward to meeting our business partners in person again, which due to the current situation is not possible, sales, service and all support functions are still available via e-mail, telephone and video chat. Our supervisors and commissioning engineers are also there for you as far as possible and if feasible.
At the end of March, we received an inquiry from the Kaiserslautern District Medical Association as to whether we could pass on protective equipment to doctors in private practice in Kaiserslautern to enable them to continue providing appropriate care for their patients. Of course, we were pleased to be able to do so.
BIGBOSS CEMENT Inc., (BBCI) with a plant located in the province of Pampanga, Philippines has recognized the advantages of this modular plant concept, comprising a 4-roller vertical roller mill, and is of the opinion that ready2grind meets the requirements and provides the highest plant availability.
In the crushing and grinding of metallics for beneficiation, the sizing is normally done to liberate the metals or sulphides for further processing to improve recoveries of the basic metals or minerals. The objective is to reduce the ore in size through various closely controlled stages to that degree of fineness which gives an economic liberation of valuable mineral, but which avoids as much as possible the production of sliming fractions. A different philosophy applies to the crushing and grinding of Gypsum.
Gypsum as a mineral (CaSO42H2O) is number 2 on the Mohs scale of hardness; only Talc is softer. This would lead one to believe that it should be easy, to crush, like coal for example, and our equipment was formerly designed on this basis. Within the past 20 years, however, equipment suppliers guaranteeing their equipment performance have had to beef-up the design. Gypsum just didnt crush like a soft rock. Despite being soft, Gypsum is tough, a factor which is of critical importance when developing equipment specifications.
To prevent excessive delays at this point, proper crusher feed and feeder design is not enough. Close cooperation with the drilling and blasting must be maintained. One of the easiest places for cost reductions is by decreasing the powder usage. Since the emphasis is always on minimum cost per ton, this is looked at closely. However, large rock can cause excessive crusher delays. We have placed the primary crushing in the mining cost center in our accounting. This gives the Mining Superintendents both authority and responsibility to coordinate both activities.
The rock size in our quarries and mines depend on numerous factors. Method of transport (conveyor belts versus trucks), method of loading equipment (shovels, Joy mine type cars, front end loaders, etc.) all of which directly effect the rock sizing to the primary crusher.
In new installations., a single roll, toothed crusher of the heavy-duty type is recommended. The reservation to this is proper engineering of the feed to the crusher. That is, the size crusher feed opening with respect to the size rock anticipated. We have presently in use Jaw, Gyratory, Cone and Single or Double Roll crushers. All of these will work, with the usual criteria for final selection being the mining method (as it effects the size of rock fed to the primary crushing plant); tons per hour required; amount of headroom available for the installation; type of secondary crushing to be employed; and the lowest,capital investment consistent with these requirements.
The most commonly used unit is a Roller Mill with an integrated air separator, a very effective fine grinding machine, but requiring high capital investment. We still use Buhr Stones in few places (flat, circular granite stones operating like, a disc grinder) and Entoleters, Rod Mills and Tube Mills might also be used.
Batch grinding tests of gypsum ore were performed using a ball mill.We have systematically investigated some important grinding parameters.The grinding operation was sensitive to the grinding parameters except for one.The final product had a particle size of d50=4.25m.PSD width calculations showed that their values increased with grinding time.
Gypsum is a crystalline form of hydrated calcium sulfate (CaSO42H20) generally used in cements and plasters in the construction industry, though also in paints, fertilizers, medicines, papers, and textiles. For use in these materials, gypsum must be ground finely (<100m), if not ultra-finely (<10m), for which ball mills are most effective. Despite gypsum's widespread use and the regular need to grind it, studies concerning the grinding of gypsum ore remain scarce. In response, in this study, we have systematically investigated how certain grinding parameters (i.e., mill speed, ball filling ratio, ball size distribution, powder filling ratio, grinding aid ratio, and grinding time) of conventional dry ball mills affect the grindability of gypsum ore. We determined the properties of the micronized gypsum products obtained in optimal grinding conditions, and the results showed that the dry ball mill grinding process can effectively produce ultra-fine gypsum products.
The hydration of an anhydrite of gypsum (CaSO4.II) in a ball mill was studied as a function of time and temperature. The amount of gypsum formed at different intervals of time was determined by weight loss method and powder X-ray diffraction technique. Specific surface area at different time intervals was determined by LASER granulometric method. The results showed that the maximum rate of formation of gypsum was at a longer time than the time for the development of maximum specific surface area. In the presence of activators, the time for maximum rate of gypsum formation and maximum specific surface area shifted towards lower hydration time. Morphological changes during the course of hydration have been studied by the scanning electron microscopic (SEM) technique. A mechanism of hydration has been proposed.