Cement | Minerals

WCA Webinar
24th June 2020

Advanced grinding and

classifying technologies

Fives FCB
Didier BOURBON – VP Sales - Asia
Eric EDET – FCB Horomill® Product Manager
Philippe NIEL – Grinding Products Manager
SUMMARY

Fives in Cement & Minerals

FCB Horomill® advanced grinding plant
FCB TSV™ Classifier and drying applications in grinding plants
SUMMARY

Fives in Cement & Minerals

FCB Horomill® advanced grinding plant
FCB TSV™ Classifier and drying applications in grinding plants
 Fives Cement and Minerals business line

Within Fives’ Process Technologies main activity, An international organization

the Cement & Minerals business line is dedicated to design, and a worldwide network
supply and installation of core process equipment,
comprehensive systems and complete plants with the
highest performances.

For two end-markets :

CEMENT & MINERALS

 Cement industry
 Minerals grinding industry

85 years
in Cement industry
A renowned experience Sales offices in China, India, Brazil,
since 1933 Russia, USA, Canada & Mexico

Fives FCB – WCA Webinar – 24th June 2020 – Grinding by Fives 4

A complete range of innovative & sustainable technologies

To maximize product quality

and plant output Crushing systems Combustion systems
(FCB Rhodax® 4D, FCB VIF™ crusher) (Pillard NovaFlam®, Pillard
PrecaFlam®…)

To reduce environmental foot print

Grinding systems Pyroprocessing systems

To provide the best Total Cost of (FCB Horomill®, FCB B-mill, (Burning line, FCB Zero-NOx Preca,
Ownership FCB TSV™ Classifier…) FCB Preca-Max®…)

For smooth and reliable operations

Gas Treatment systems Control & optimization systems
(TGT® Filter, Sonair™ Filter…) (COSMA™, FCB Opti-Kiln™…)

Fives FCB – WCA Webinar – 24th June 2020 – Grinding by Fives 5

SUMMARY

Fives in Cement & Minerals

FCB Horomill® advanced grinding plant
FCB TSV™ Classifier and drying applications in grinding plants
FCB Horomill® grinding plant

All grinding, drying and

classifying functions within
a very compact workshop

Link to video

Fives FCB – WCA Webinar – 24th June 2020 – Grinding by Fives 7

 FCB Horomill® workshop: full FCB Aerodecantor flow-sheet

Bag
Classifying Feed and mill outlet to FCB Aerodecantor
function FCB TSV™ filter
Fan
Classifier
Feed Final
product
Perfect layout for separate grinding centers
or modular plants
Drying
function Adapted for high moisture content feed
product, clinker with high content of fines or
FCB Aerodecantor from various sources
Hot gases supply
Rejects Adapted for ultrafine grinding

Grinding function

FCB Horomill® Bucket elevator

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 Drying in FCB Horomill® + Aerodecantor + FCB TSV™ Classifier

Gas + Raw mill plant Cement plant

Fine particles to (Apazapan – Mexico) (Teresa – Philippines)
cyclones or filter

Mill outlet
+ Wet feed
(pozzolana, slag…)

Advantages Coarse
particles
to mill
Increase of drying capacity
Gas
pozzolana feed up to
Reduction of material load of the 80 mm coarse size
classifier and improvement of FCB Horomill® 3800+ADC+TSV™ 5500
selection performances and Feed with up to 6,5% moisture FCB Horomill® 3800+ADC+TSV™4500
Feed with up to 29% pozzolana
consecutive grinding efficiency with 25% moisture
Coarse particles to mill

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Aerodecantor drying for raw mix and cement grinding

Fives FCB – WCA Webinar – 24th June 2020 – Grinding by Fives 10

 FCB Horomill® - High flexibility

The same FCB Horomill® The identical machine for both

for various applications application within the same plant

Cements
Raw mix 1 line in Maryneal (1 raw meal / 1 cement)
1 line in Tula (1 raw meal / 2 cement)
1 line in Apazapan (1 raw meal / 2 cement)
2 lines in Cerritos (1 raw meal / 2 cement)
2 lines in Tepetzingo (1 raw meal / 1 cement)

Slags &
FCB Horomill® installed Minerals
base by applications

Same operations, same spare parts, same maintenance

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Large energy savings compared with ball mill

Energy consumptions in kWh/t @ same strength

67,9 6,3
CEM III/B - slag

39,4 vs 75,7 kWh/t

28,1 8,5 - 48%

46,2 4,1
CEM I

35,5 vs 51,4 kWh/t

26,1 6,7 - 31%

31,8 3,6
CEM IIA/P

19,9 vs 36,0 kWh/t

13,8 4,9 - 45% Mill Fan Others

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Large energy savings compared with vertical mill

Energy consumptions in kWh/t @ same strength

CEM II-A/P
19,1 8,1
same Strength

21,8 vs 29,2 kWh/t

16,1 3,9 - 25%

CEM II-A/P
17,0 8,1
same Blaine

21,8 vs 27 kWh/t
16,1 3,9 - 19%

7,9 8,2
Raw meal (12% R90µ)

12,3 vs 16,7 kWh/t

7,9 3,3 - 26% Mill Fan Others

Fives FCB – WCA Webinar – 24th June 2020 – Grinding by Fives 13

Energy savings compared with ball mill + roller press

Industrial average values remained consistent

other a whole year of production
Type of cement CEM I CEM II A-P
Ball mill with Roller press
Specific energy (kWh/t) 39,2 32,8 - 28%
FCB Horomill®
Specific Energy (kWh/t) 28,4 23,1 Energy consumption compared with
Energy savings 28% 30% ball mill + roller press on CEM I
Tepetzingo plant – Cementos Moctezuma (Mexico)
Operation figures
- 30%
Energy consumption compared with
ball mill + roller press on CEM II A-P

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 Energy consumption achieved results from industrial sites

Strength Blaine /
Cement / Product Sites HRM size Capacity FCB Horomill® Total plant
class Fineness
t/h kWh/t elec kWh/t elec
Raw meal N/A Tula 3800 300,0 11,8% R90 6,5 11,2
N/A Barroso 4400 438,0 11,2% R90 5,4 10,8
Type I 42,5 Çimentas 3800 76,0 2890 18,1 27,2
42,5
42,5
Tepetzingo
Ciskovice
3800
2800
103,0
58,7
3070
3050
18,7
16,0
24,6
10,8 kWh/t
Teresa 3800 86,2 3560 21,9 30,7
42,5 Karsdorf 3800 72,6 3860 24,5
Energy consumption
42,5 RCC 3600 92,0 3260 19,9
Type II / A-L 32,5 Karsdorf 3800 105,0 3850 17,4 for raw meal grinding
42,5 Darica 3600 100,0 3210 18,7 24,2 @ Barroso plant (Brazil)
Type II / A-M (P-L) Cerritos 3800 115,0 3580 15,6
Type II / A-P 32,5 Tepetzingo 3800 115,0 4100 16,1 21,9
Tula 3800 125,5 4430 13,8 21,4
Campha Twin 3800 242,0 2930 14,7 21,5
Campha Twin 3800 224,0 3200 15,3 23,2
32,5 Konya 3800 140,0 3100 15,4 21,2
Type IV / A-P (pouzz only 30%)
Type II / B-P 32,5
Trino
Çimentas
3800
3400
129,0
81,0
4920
4210
16,1
18,1
22,2
25,9
25,2 kWh/t
32,5 Çimentas 3400 88,6 3880 17,3 24,2
32,5 Denizli 3400 81,0 4210 17,0 22,1 Energy consumption
33,5 Denizli 3400 83,2 4220 16,0 21,7
Type II / A-S 42,5 HanZhong 3800 78,0 3330 20,5 for type IV cement
Type III / B 42,5 Karsdorf 3800 63,3 4170 28,4 @ Teresa plant (The Philippines)
Slag EKO Karsdorf 3800 55,0 4800 31,0
Thyssen Karsdorf 3800 57,0 4100 28,0
Thyssen Karsdorf 3800 66,0 3500 23,9
Type IV / B (1P – C/K 1,80) Teresa 3800 107,6 4380 16,3 25,2
(1P – C/K 1,84) Norzagaray 3800 108,7 4630 16,6 26,4
(1P – C/K 1,97) Norzagaray 3800 91,2 5220 19,6 31,8

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FCB Horomill® compact installation (raw meal grinding)

Raw meal grinding workshop

can be structurally combined
with preheater tower for even
more compact arrangement
37m (as in Maryneal plant, TX, USA)

26m 13m

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FCB Horomill® compact installation (cement grinding)

30m

14m 28m

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Quality of cement from FCB Horomill® vs cement from ball mill

ORDINARY PORTLAND CEMENT

COMPRESSION STRENGTH ON MORTAR
FCB Horomill® and Ball mill cement

Same resistance @ lower Blaine

FCB Horomill® cement at 3050 Blaine

Ball mill cement at 3400 Blaine

Same water demand

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FCB Horomill® cement quality achieved - Industrial results

High C/K ratios Grade 52,5 cements

Plants NORZAGARAY TERESA TULA Europe

Mill HRM HRM HRM Ball m ill HRM
National Standard PNS (equiv. ASTM) NMX (equiv. ASTM) EN
Type of cement 1P 1P OPC CPC 30 CEM I 52,5 CEM I 52,5 CEM III B
equivalent EN 197-1 CEM IV/B-P CEM IV/B-P CEM I CEM II/B-P "" "" ""
mai-16 mai-16 juil-15 juil-15 nov-17 nov-17 2012 oct-06 1999-2003
Composition Clinker % 54,3% 50,8% 55,6% 91,9% 68,6% 68,6% 91,4% ~ 91% 23,0%
C/K ratio 1,84 1,97 1,80 1,09 1,46 1,46 1,09 4,35
Quality cm²/g 4630 5220 4380 3560 4420 4730 4480 (*) 3780 (*) 4400 (*)
1D 7,3 9,0 6,0 17,2 19,6 19,0 23,1
2D 35,7 33,9
3D 17,3 18,1 18,6 30,7 31,7 31,0
7D 24,0 25,0 24,4 37,4 37,7 34,2 31,7
28D 36,4 35,8 36,5 45,8 43,4 43,9 60,2 56,4 48,2
(*)
from LASER analyser

Better resistance @ lower Blaine

(results expressed according to EN standards)

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Quality of cement from FCB Horomill® vs cement from vertical mill

Specific energy (kWh/t)

Strength at 28 D (MPa) Blaine (complete department)
32
41,2 43,1 5200 5000
28 27
34,9 35,3 4250 3950 25

CPC 30A
Cement CPC40 B
Cement Cement
CPC 30 A Cement
CPC40 B CPC 30A
Cement CPC40B
Cement

For the same strength, in comparison with VRM, FCB Horomill® allows for:

5 to 10% Blaine reduction (as BM)

10 to 15% electricity consumption reduction
No water (up to 3,0 % of water with the VRM for Cement A)
No grinding aids on Cement A (VRM: 1700g/t)

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FCB Horomill® main regulation loops in full automatic operation

CIRCULATING LOAD
TEMPERATURE Material feeding
FY
TIAS

GAS FLOW
TIAS FIC To Feed
PT
PDT
FIAS SP Recipe
weighfeeder
flows
TIC SP

From Feed
ZC
SP FYIC

Hot air Mill behavior is stable and

controlled

SC Full automatic operation for start-

up, stop and running sequences
including recipe change
ZC PI
PRESSURE PC

SP

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FCB Horomill® - High availability and reliability

More than 7600 hours/year Around 95%

average hours of operations on cement mills
average of availability of raw
and > 6200 hours/year on raw mills and cement grinding plants installed

Operation time Availability

(hours) (%)
Raw mill 1 6576 95,2 Long lifetime of wearing parts for reduced maintenance needs
Raw mill 2 6352 94,4
Year 1

Cement mill 1 7828 95,1 Single shoe

Titanium carbide roller sleeve with zigzag welding
Cement mill 3 7831 95,4
Chromium cast iron shell liners
Ball mill + Roller press 7038 93,3 Tungsten carbide reversible scrapers
50,000 hours
Year 2 (10 months)

Raw mill 1 5429 94,7

>
Raw mill 2 5809 96,2
Cement mill 1 6042 92,9 Shell liners
20,000 to 40,000 hours
Cement mill 3 6444 94,1
Roller sleeve
Ball mill + Roller press 5551 89,7
Tepetzingo plant - Cementos Moctezuma (Mexico) (figures observed for cement applications)

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FCB Horomill® worldwide grinding plants

3
1+1
16
2

2
2
2

2+4
3

27
1+2

2+2
2+2
2

21

Plants with both raw Raw grinding

and cement grinding
Slag or mineral grinding
Cement grinding
Twin slag grinding
Twin cement grinding
Not erected
Fives FCB - General presentation 23
FCB Horomill®: the best available and proven technology

Maximized production & quality Smooth & reliable operation

• Higher cement quality with less Blaine • High production flexibility
• High drying capacity • Fully automated operation
• No water injection • Smooth operation
• Capacity un-sensitive to wear • Low wear rate and high availability

Minimized operating costs Low environmental footprint

• Lowest electrical consumption • High energy efficiency
• Best overall thermal efficiency • Zero water consumption
• No need of grinding aid • Higher c/k ratio reducing CO2 levels
• Low wear rate and maintenance cost • Low noise emission

Fives FCB – WCA Webinar – 24th June 2020 – Grinding by Fives 24

SUMMARY

Fives in Cement & Minerals

FCB Horomill® advanced grinding plant
FCB TSV™ Classifier and drying applications in grinding plants
FCB TSV™ Classifier – range of applications

Large scale of grain size of products

From d50 = 2 µm (UHF type)
To d50 = 150 µm (TBF type)
From  1 m to  8 m

Various industrial applications

Coal, petcoke, raw mix, cement, slag, fly ash…

Combined with all types of mills

Ball mill, vertical mills, FCB Horomill®

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FCB TSV™ Classifier – range of applications

Distribution of FCB TSV™ Classifier sold by product

Slags and fly ash More than 250

Raw meal 12 references worldwide
28 for various applications
Cement
Minerals 87
21

Limestone
31

Coal & Petcoke

73

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FCB TSV™ Classifier – range of applications

Distribution of FCB TSV™ Classifier sold by cut size Typical applications

BF: mainly raw meal, minerals...
MF: mainly coal, petcoke...
90 - 500 µm TBF
HF: mainly cement
50 - 250 µm BF THF: blended cements, slag and minerals

30 - 180 µm MF HF BF
134 41
20 - 110 µm HF

10 - 60 µm THF

3 - 30 µm UHF
Cutting diameter (µm)
500 50 3

MF
THF 64
13

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 Typical Tromp curves of dynamic separators

Strong reduction of coarse particles

→ Better compressive strength

Steep slope of selection curve

→ Perfect quality control of cement grain size

Patented turbine blades shape

Lower by pass
→ Better grinding efficiency of the mill

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TSV™ Classifier single filter closed circuit – Capacity increase

Revamping of Chelm grinding plant (Cemex – RMC – Poland)

Ball mill n°9 – Ø4m*12m – 2750 kW AFTER MODIFICATION

Static separator cyclones Separator type FCB TSV™ HF 3200

Dynamic separator CV ϕ7100/6300 Separator motor 90 kW
Bucket elevator 75 kW Bucket elevator not changed
Filter type E.S.P Filter type pulse jet bag filter
Mill fan motor 40 kW Filter area 1805 m²
Separator motor 250 kW Fan design capacity 136 000 m3/h
Separator fan motor 40 kW Exhaust fan motor 360 kW
Installed power auxiliaries (fan + sep.): 310 kW

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Chelm grinding plant revamping – Results on Mill 9

UPGRADING with FCB TSV™ Classifier

Cement grinding mill n°9 CEM II B-V
66% ck + 6% gypsum + 26% fly ash + 2% slag Up to + 28%
Before After
Guaranteed Guaranteed Achieved Output increase
Cement Type A Type B (new)
Output (tph) 80 97 67 70,9
Fineness Blaine
Mill consumption (kWh/t)*
3700
31
3700
25
4500
36,2
4470
34,5
Up to 30 %
Main motors consumption: Mill +
Mill specific
40,2
TSV™ + Elevator + Fan (kWh/t)
power decrease
21% output increase guaranteed
21% output increase calculated & guaranteed

28% calculated output increase realized

* Mill consumption in kWh/t at electrical sub-station counter

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Chelm grinding plant revamping – Obtained Tromp curve

Selection
efficiency

Acuity = Sharpness Index

(Laser Reduced values)
d75 = 25.5 µm
= d25/d75 = 0.59

Selection curve obtained in

Chelm Cement type CEMI
4500 Blaine

d25 = 15 µm

cut size = d50 = 19.4 µm

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Chelm grinding plant revamping – Repeat orders

2002
Cement Mill 9

2007
Cement Mills 8 & 10

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FCB TSV™ Classifier performances - capacity increase examples

Industrial results obtained with:

• Conversion from 1st generation to FCB TSV™ Classifier
• Blended cements

At constant Blaine
CEM II AMP-Q Blaine 3600 +17%
CEM II AL Blaine 3520 +18%
At constant R45µm
CEM II AMP-Q R45µm 10% +21%
At constant Strength
CEM II AS Before = R32µm With TSV = R32µm
11.2% 6.5%
+26%
CEM II B-LL Blaine 5200 Blaine 4400
R32µm R32µm + 57%
14,1% 9.4%

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Examples of Sieve Grain Size Analysis with FCB TSV™ Classifier

0,1
C 0,5
u 1
m 5
u 10
l 15
20
a Rosin Rammler Diagram 25 High Rosin Rammler slope with the
30
t 35
i
40
45
complete elimination of the
50
v 55 coarsest particles:
60
e 65
70 → Better compressive strength
CEM I 52,5R 4740 Blaine - Chelm slope = 1,47 75
w
t
80 → Allows for lower Blaine target
CEM I 3000 Blaine - Jbel Oust slope = 1,30 85
% value for the same strength
r CEM II A-L 3500 Blaine - Jbel Oust slope = 1,15
90
91
92
values
93
e 94
t 95
96
a
97
i
n 98
e
d
99
10 µm 100 µm 1000 µm

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Improved compressive strength with FCB TSV™ Classifier

CEMENTIR TARANTO ITALY

Ball mill + First gen. dynamic separator : 4100 Blaine (R32µm = 11.5 % )
Production of CEMII AS 42.5 (15% slag)
Ball mill + FCB TSV™ : 3920 Blaine (R32µm = 4.9 % )
Before With FCB TSV™
Mill output (tonne/hour) 49 58 62
55
Mill consumption (kWh/t) 50 42.2 39.5
50
Blaine (cm²/g) 4100 3920
Compressive Strength (N/mm²)

45
R32µm sieve % 11.5 4.9 6-7
40
35 Compressive strength MPa 25 25.4
2 days
30
25
7 days 37.3 40.8
20 28 days 49.3 54.1
15
10
5

+ 27% Output increase

0
2 days 7 days 28 days

Fives FCB – WCA Webinar – 24th June 2020 – Grinding by Fives 36

 Flexible installation of FCB TSV™ Classifier

Volute Air Inlet

Bottom Feed Inlet In Vertical mill

Top and Bottom Feed Inlet Volute (Air + dust) Inlet

Fives FCB – WCA Webinar – 24th June 2020 – Grinding by Fives 37

SUMMARY

Fives in Cement & Minerals

FCB Horomill® advanced grinding plant
FCB TSV™ Classifier and drying applications in grinding plants
Ball mill by-pass flash dryer

Applicable for raw mix & cement

with wet additives grinding

Fives FCB mill by-pass flash dryer

Flap valve enables to optimize the ball mill circuit
operation with moist raw material

Hot gases
Feeding

By-pass
duct
Flash

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Ball mill by-pass flash dryer

Fives FCB – WCA Webinar – 24th June 2020 – Grinding by Fives 40

Ball mill by-pass flash dryer

106 kW

PGT results April 2018

Umm Bab 5,000 tpd plant
Raw grinding 101°C 2000 kW
Total dry
(QNCC – Qatar) RAWTotal dry
MILL FEED
RAW MILL FEED
450 ph tph
450
12 kW
@@8%8% moisture
moisture

Classifier TSVTM 7500

450450
tph tph
R90µm = 11,5%
R90µm
@ = 11,5%
0,6 % moisture
@ 0,6% moisture

112°C

Mill outlet pressure

- 30 mbar
348 °C Flash drier
120°C
Mill inlet pressure
- 4 mbar

5910 kW

FCB B Mill
HGG
Ø 5,6 m x (4 drier + 5 + 9) m
6600 kW From preheater

Fives FCB – WCA Webinar – 24th June 2020 – Grinding by Fives 41

Ball mill by-pass flash dryer

Umm Bab 5,000 tpd plant

Raw grinding
(QNCC – Qatar)

Common hypothesis:
Basic BM - FCB Index grindability: 12 kWh/t @ R90µm=12% (at mill axis)
- Hot gases available temperature: 300°C
- 440 tph mill Ø 5,6 m x (5+7,5 m) ; 25% filling ratio

Fives FCB – WCA Webinar – 24th June 2020 – Grinding by Fives 42

FCB Flash dryer - Venturi

Drying of fine & granular product (fly ash, bottom ash, pozzolana, GBFS, minerals)

In separate drying plant or associated with mill

Installed below TSV™
IF associated with mill
Low investment cost (static equipment)
Reduction of over-grinding of fines which are
Low footprint
already at the correct fineness
Decrease of specific electrical power
consumption
Reduction of the mill pressure loss and mill
internal wear

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FCB Flash dryer - Venturi

Example of FCB Flash dryer in Sacci Testi plant (Italy)

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FCB Flash dryer - Venturi

Example of FCB Flash dryer in Sacci Testi plant (Italy)

Type of cement CEM IV/B-M (54% clinker + 5% gypsum
+ 5% limestone + 26% Fly ash)
UPGRADING with FCB TSV™ Classifier
+ FCB Flash dryer
Before After
upgrade upgrade
Fly ash moisture Max 25 % Max 25 %

Total feed moisture ± 9.5 % Max 11.2 %

Plant capacity 85 t/h > 120 t/h

+ 17 % More than + 40 %
Moisture content
Capacity increase

Fives FCB – WCA Webinar – 24th June 2020 – Grinding by Fives 45

FCB Flash dryer - Extract of references for fly ash

Capacity Moisture TSV Mill Power Type of

Customer Site Country Material
[tph] [%] Classifier (1) [MW] fuel

Renevis Kamien Poland Fly ash 40 18-25 2000 BF - 7 Coal

SACCI Testi Italy Fly Ash 40 25 4000 HF B 11 Multiple
CDF - HBL Carling France Fly Ash 80 18-25 2800 MF - Gas
CDF Ingénierie ETR / Surschiste Hornaing France Fly Ash 40 18-25 - - 4 Gas
Surschiste France Coal schist 30 18-25 -

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FCB TSV™ Classifier + Flash dryer: Adequate and efficient solutions

Maximized production with wet feed Efficient operation

• Optimized grinding circuit with adapted • Low by pass of Tromp curve, better efficiency
solutions of mill.
• Boosting drying capacity. • Low wear rate due to lower moisture in the mill
• Debottlenecking of existing ball mill grinding • Lowest power consumption of TSV™ due to its
plant. anti vortex item.

Product quality improvements Environmental benefits

• Reduction of coarsest particles with
higher cement strength or raw mix and
solid fuels burnability
• Low by pass of Tromp curve, no over
grinding of fines.
• Valorization of industrial waste (fly ash, bottom
ash, slags)
• Integrated solutions in existing plants
• Minimizing electrical and thermal power
consumptions.

Fives FCB – WCA Webinar – 24th June 2020 – Grinding by Fives 47

Fives FCB

50, rue de Ticléni – BP 376

59666 Villeneuve d’Ascq Cedex – FRANCE

www.fivesgroup.com