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ESTANDA KINETIC HPS SYSTEM INCREASES STAROCEMENTNY CEMENT PLANT CAPACITY BY 28%

THE CHALLENGE

THE SOLUTION

THE BENEFITS AND ADVANTAGES

The cement company STAROCEMENTNY was looking at ways of reducing the costs and increasing the tonnage in the forsterite* section of the plant. The plant was feeding a 0-30mm feed to the mill.

The common applications for ESTANDA KINETIC systems are as pre-grinders for raw materials and cement clinker. The system is typically placed in the final reduction stage to condition the feed before entering the mill. The ability of the KINETIC system to produce a product with a high proportion of fine material improves milling circuit perfor-mance by reducing energy requirement and increasing plant

To place a KINETIC HPS in closed circuit to condition the feed to a 0-2mm product before it entered the mill.After consulting with the customer on the benefits of installing a ESTANDA KINETIC system into their operation, the customer placed an order for a KINETIC HPS. To maximise the savings that could be obtained by putting a finer feed into the mill, both the mill configuration and the ball charge were re-sized to suit the finer feed.

The product obtained from the mill after the inclusion of the KINETIC HPS in the circuit has lead to both a 28% increase in the capacity of the mill, from 21tph to 27tph; and a 13% reduction in the energy consumption, from 42,8kwh/tn to 37kwh/tn.

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0/30mm 0/30mm0/2mm 0/2mm

30

40 50

PRODUCTION CAPACITY INCREASE WITH KINETIC HPS:

SPECIFIC ENERGY CONSUMPTION REDUCTION WITH KINETIC HPS:

Production Tonnes per hour

Energy consumption kilowatt-hours per tonne

Mill feed particle size distribution

Mill feed particle size distribution

After Kinetic After Kinetic

Before Kinetic Before Kinetic

+28%

21tph

42,8kwh/t 37

kwh/t

27tph

-13%

*Forsterite: a magnesium-rich variety of olivine

Design Concept

Installation Capabilities

VSI Technology

Outstanding Reliability

Increased Effi ciency

OPTIMISING THE GRINDING PROCESSES

ENGINEERING OF THE GRINDING PROCESSES

A SIMPLE CRUSHING PRINCIPLE

MAXIMUM RELIABILITY ADAPTED TO YOURREQUIREMENTS

INCREASED PRODUCTION

Horizontal PregrindingSystem

Vertical PregrindingSystem

UNBEATABLE EFFICIENCY EFFICIENCY IN NUMBERS

One innovation proven very efficient has been the introduc-tion of the ESTANDA KINETIC pregrinding system to the final crushing stage of the comminuting process prior to the raw material milling section.

Additional improvements can be realised with the introduc-tion of an additional ESTANDA KINETIC system prior to the cement mill.

By adding the ESTANDA KINETIC system to the comminution circuit, the fluctuations in mill feed grading will be greatly re-duced as the variances in feed parameters (e.g. rock hardness, grading and moisture) are smoothed.

Milling Process Diagnosis and Facility Auditing Services are carried out by our Cement Engineering Department in order to obtain a comprehensive diagnosis of the existing grinding circuits processes and facilities. Solution recommendations are always advised upon the audit report to increase grinding circuit capacity and reduce the specific energy consumption.

MINIMUM MAINTENANCE

SPECIFIC ENERGY CONSUMPTION

SUPERIOR CUBICAL SHAPE

PAYBACK OF INVESTMENT

100% 100%

18months

20%

MILL OUTPUT INCREASE

ROCK ON ROCKTECHNOLOGY

AUTOGENOUS CRUSHING PROCESS

INTEGRATED MONITORING, SAFETY AND CONTROL

DIAGNOSIS AND AUDITINGSERVICES

THE FUTURE OF CEMENT PLANTS GOES THROUGH HIGH QUALITY CRUSHED MATERIAL. ROCK ON ROCK TECHNOLOGY; AUTOGENOUS CRUSHING PROCESS; AND INTEGRATED MONITORING SYSTEMS ARE THE INNOVATIONS PROVED TO GUARANTEE BEST CRUSHED MATERIAL QUALITY.

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