1、.LV CLASSIFIERFORVERTICAL MILL & BALL MILLOCTOBER 2001CONTENT目录1. INTRODUCTION 简介2 NCEPT OF LV CLASSIFIER LV 选粉机的概念3 DESIGN PROCEDURE AND CONSTRUCTION 设计程序与构造4 MODIFICATION APPLYING LV CLASSIFIER FOR VERTICAL MILL LV 立磨选粉机的改造5 MODIFICATION APPLYING LV CLASSIFIER FOR BALL MILL LV 球磨机的改造6 NEW CONCEPT
2、CYCLONE 新概念的旋风筒APPENDIX附录1. ERECTION PROCEDURE AT SITE 安装步骤2 SCHEDULE OF ERECTION WORK AT SITE 安装工作的进度表3 REFERENCE DRAWINGS 参考图纸1. Introduction 简介LV Classifier is a new concept separator, which has been developed for vertical mill modification, to improve the gas and material flow in the vertical mi
3、ll.LV 选粉机是一种全新概念的物料分离设备，它能提高了立磨中的气流及物流速度，并且在立磨的改造中得到了广泛的应用。This Classifier is very unique equipping the special formed stator, LV Pocket. This makes possible to separate coarse material and fine material before the gas comes into Classifier rotor.这种选粉机具有一种独特结构的导风叶片LV 气室。它使粗颗粒物料与细颗粒物料在气体进入选粉机转子之前就有可能
4、分离。This conversion of vertical mills usually leads to: production rate increase 12-30% power saving 1.5 to5.0kwh/t(mill + IDF)by decreasing air volume remarkably vibration level decreasing cement strength increase by getting optimum product size distribution.通过这种改变可以得到如下结果： 产量增加 12-30%； 通过明显减少风量，磨机与
5、风机的电耗可节约 1.5-5 千瓦时/吨； 可以降低磨机振动； 水泥强度增加，产品粒径分布更加合理， 。Our reference is 87 sets already for vertical mills including for slag, clinker, coal, petro-coke, and totally 93 sets including ball mill modification (August 2001).这个结论是根据已经改造的 87 台粉磨矿渣、熟料、原煤、石油焦的立磨于 2001 年 8 月得到的，如果包括球磨改造在内总共有 93 台套。We applied t
6、his Classifier to the ball mill equipment today already mainly to increase the production rate LV Technology has reference for supplying LV Classifier for ball mills in total 6 sets and one of them is scheduled to start to operate this coming September.今天，我们应用该选粉机在球磨机上主要是为了增加产量。LV 技术对 6 台球磨机使用 LV 选粉
7、机提供了咨询，它们都在即将来临的九月开始运行。LV Technology has developed this time the new concept cyclone, called LVC, which is used for down stream of mill outlet gas with smaller pressure loss and higher collection efficiency. This can be applied for not only grinding equipment but also for suspension preheater and re
8、levant equipment. Shortly we can observe the actual operation.至今，LV 技术已开发出称为 LVC 的新型概念旋风筒，它用于磨机出口，以较小的压降获得较高的收集效果。这不仅应用于粉磨设备，而且能用于旋风预热器等相关设备。很快我们就能见到实际的运行。LV Technology can supply the total plant engineering including equipment supply and engineering applying these our high technology.LV 技术工程公司能够提供整
9、套的工程服务，包括设备的供应，以及实施这些高技术的工程施工。2. Concept of LV Classifier LV 选粉机的概念(1) Gas flow 气流方式Gas speed in mill body up to Classifier increases it speed up to the inlet of Stator of Classifier, named LV pocket, gradually in order to carry all the material which once goes up from mill table. It makes possible
10、to avoid the material circulation in mill body and separator, and it decreases the pressure loss in mill body and separator. Although higher gas speed in the mill body decreases remarkably by reducing the internal circulation of material. The common understanding is not applied for LV Classifier,“hi
11、gher gas speed makes higher pressure loss”.提高气体的磨内流速并在气体到达导风叶片时达到最大，即 LV 气室，目的是逐级地将一旦离开磨盘的所有物料带上来。尽量避免物料在磨体和选粉机之间的循环， 减少在磨体和选粉机间的压力损失。虽然在磨内风速要高于原有的磨内风速，但由于物料的内部循环减少，在磨机体内的压降随之显著减少。我们通常理解的：“气流速度越高，压力损失越大。 ” 对于带有LV 选粉机的立磨是不适用的。For this purpose, we apply the additional cone on funnel cone to get the op
12、timum gas speed in mill body and Classifier shell portion.However this cone is to be designed to have no interference with roller movement to taking outside of mill shell for roller maintenance.为此目的，我们在漏斗锥上增设一附加锥，使磨体内与选粉机壳体之间形成最佳流速。不过，该锥的设计不得干扰转子在检修时将它移至磨机壳体外面。Please refer to the gas speed distribut
13、ion for each stage of mill body and Classifier body, which is shown in Chapter 3.有关气流速度在磨体及选粉机体各阶段的分布请参照第三部分所示。(2) Special configuration of stator, LV pocket for coarse material separation 导风叶片的特殊结构， （用于粗料分离的 LV 气室）It is essential to separate the coarse material before the gas and material are intro
14、duced into Rotor.在气流和物料进入转子之前，最基本的要求是分离出粗料。LV Pocket is designed to separate coarse material by gravity force though pocket which is isolated from the effect of gas stream which is moving into rotor, because the LV pocket has material chute carrying the material to the point of Funnel Cone.LV 气室是根据粗
15、细颗粒在此处具有不同的动能这一原理设计的。在气流中的粗颗粒由于动能的作用被分离，被分离的物料在重力的作用下通过气室降至漏斗锥，通过溜子将物料送至漏斗锥顶。(3) Rotor 转子Rotor blades rotate almost same speed of with same circumference speed with injected gas speed from LV pocket.转子风叶的圆周线速度几乎与 LV 气室喷出的气体速度相同。It makes possible to reduce the material impact on rotor blades and this
16、 makes possible to reduce wear on rotor.这就可以降低物料对转子风叶上冲刷，从而减少了对转子的磨损。Usually we apply the harder material for LV pocket, such as Hardox 400 for longer life and free maintenance. However even for the slag grinding and clinker grinding, the wear on pocket and rotor blades are very small and negligible
17、 by observing the painting material on rotor blades remained after half years operation.我们通常在 LV 气室采用较硬材料，诸如哈氏 400，寿命既长又免维护。即使对于粉磨矿渣和熟料，气室导风叶片和转子风叶的磨损也很小，运转半年后，在转子风叶上的喷涂料都看不出有何变化。(4) Funnel cone with Chute 带溜管的漏斗锥It is important that the rejected coarse material coming down through LV pocket should
18、be feed directly without mixing with gas, which contains the fine material.最重要的是返回的粗料经过 LV 气室向下时不要再与含有细粉的气体混合。Chute, which is connected with the bottom of Funnel Cone, is designed to be as close as possible to the Mill Table.与漏斗锥底部连接的溜管要设计得与磨盘越近越好。Usually the distance between the Chute outlet and Ta
19、ble surface is only 500 mm for raw mill and 150mm for clinker grinding with special opening for the outlet of Chute in order to feed the material to the grinding point under Roller as much as possible.对于生料磨，溜管出口与磨盘表面的距离通常为 500mm，对于水泥磨此距离只有 150mm，在溜管出口带有一个专门的开孔，为了让料尽可能多的喂至辊子的辗磨点下。(5) Dam ring, armor
20、ring and louver ring 挡环、防护环和百叶环When we modify the existing mill applying LV Classifier, dam ring height, armour ring configuration / height and louver ring design, we plan the optimum design for modification and adjustment for modification work.Gas speed through louver ring and gas speed from the sp
21、ace between dam ring and armor ring are very important.当我们采用 LV 选粉机改造现有的磨机时，挡环高度、防护环的编排及高度和百叶环的设计，都要做设计修正及调整的优化工作。通过百叶环的气流速度，以及通过挡环及防护环之间空间的气流速度是很重要的。3. Design Procedure and Construction 设计步骤与结构(1) Gas speed for each level of mill body and classifierGas speed for each section is selected 6.5m/s(at t
22、he level of the roller top), 7.5 m/s(at the level of the top of mill body) and 8.5 m/s (at inlet of PV Pocket) for vertical mill for raw material grinding, as basic designed condition.In the case when the installation of Funnel Cone is not enough to increase the gas speed as shown above, then additi
23、onal cone is installed outside of Funnel Cone. This additional cone will be cylindrical sometimes.（1）在磨内不同截面和转子处的风速生料磨的基本设计条件：通常在磨辊上部的风速是 6.5m/s，在磨体的顶部的风速是 7.5m/s，在 LV 气室的入口的风速是 8.5m/s。在原有的锥体满足不了要求时，应该在加一个附加的锥体来提高风速，有时这个附加的锥体是一个圆柱体。(2) Rotor speed Rotor speed, which is defined by circumferential spe
24、ed, depends on Rotor diameter. For the Rotor diameter of about 2m, the speed is selected 16m/s.This speed will be adjusted by actual operation result, such gas volume or gas speed though rotor surface and fineness of product.Classifier outlet gas speed is about 10m/s.（2）转子的速度转子转速由转子的线速度及转子直径决定。当转子的直
25、径是 2m 时转子的线速度为 16m/s。可以通过实际情况，例如 根据通过转子截面风量，风速和成品的细度来校证转子的速度选粉机出口的风速一般为 10m/s.(3) Guide vane nozzle LV pocket designs guide vane nozzles, which locates between each LV pocket. The gas speed at Guide vane nozzle is almost same as rotor speed, and this shows that the relative speed between rotor speed
26、 and injected speed though nozzles is almost zero. Accordingly when the rotor speed is 16m/s, then the gas speed at nozzle is also about 16m/s. Based on this condition, number of nozzles and nozzle size are determined.(3) 导向风喷嘴LV 气室设计有喷嘴，它位于每个导向叶片（LV Pocket）之间。气流在喷嘴处的速度几乎与转子线速度相同，也就是说转子线速度与风环处气流速度的速
27、度差为零。根据以上关系当转子速度为 16m/s 在喷嘴处的风速也大约为 16m/s.在以上条件的基础上我们可以计算出喷咀的数量和大小。(4) Mill portion / dam ring + amour ring + louver ring It is necessary to adjust these parts to meet the optimum conditions after modification applying LV Classifier.The gas speed through louver ring is adjust about 60m/s, under the
28、condition of actual opening area of inclined nozzle plate, which has usually 60 degree from horizontal line.The dam ring height is depends on the configuration of each mill type. For the horizontal table, the optimum height is about 100-150mm.It is recommended to have amour ring height of 150-200mm
29、about the top of dam ring, and the inclination of the armor plate is to be 15-18 degree from vertical line.However these dimension are to be confirmed by actual operation and accordingly some adjustment is to be done during commissioning period at site.12mm thickness of normal steel plate will be se
30、lected for the first running and after confirmation of the performance of these parts, these parts will be exchanged to wear plate made expecting longer life.（4）磨机部分/挡料环，保护环，百叶环在使用了 LV 选粉机后，必须校正他们以达到最佳的使用条件。通过百叶环的气流速度为 60m/s 左右,百叶环通常与水平夹角为 60 度.挡料环的高度由磨机的类型决定,对于平磨盘挡料环的最佳高度为 100mm150mm.保护环位于挡料环的顶部我们推
31、荐的高度为 150mm200mm,并且与垂直方向夹角为 1518 度.所有这些尺寸都应在现场试运行,并进行校正后确定.在试机过程中可以使用 12mm 的普通钢板制作,当一切尺寸确定后再用耐磨钢板代替它们.4. Modification applying LV Classifier for Vertical MillL.V 选粉机在立磨上的应用(1) Mill performance before and after modification applying LV ClassifierPlease refer to the operation results showing before an
32、d after modification for vertical mills attached.请参看下列采用 LV 选粉机改造前后的生料立磨性能对照表。(2) Cement strength mixed with slag produced by using LV ClassifierThe Table shows the cement strength mixed with slag 50% produced by using LM8. All the strength shows higher than the conventional separator, LKS. This mea
33、ns that LV Classifier produces preferable product size distribution as shown in attached page.使用 LV 选粉机生产的矿渣水泥强度。表中所列为使用 LM8 生产的掺有 50%矿渣的水泥强度，所有的强度都表明比传统的选粉机 LKS 要高。这意味着 LV 选粉机生产的产品粒径分布更为有利，如相关的页数所示。Classifier Modification ResultsRaw mill LM63.4Item 项目 Unit 单位Operation result before Modification LSK
34、 Separator 改造前运行数据After ModificationLV Classifier LV 选粉机改造后数据Production 产量 t/h 617 709Power consumption Mill 磨机功率Kw 4870 4950IDF Kw 6350 5180Difference pressure of mill Mbar 85 75Gas flow rate m3/h 1,400,000 1,150,000Vibration mm/s 8 6Product finenessResidure 90micron % 10 12Residure 212micron % 1.0
35、 1.0Unit power consumptionMill kWh/t 7.9 7.0IDF kWh/t 10.3 7.3Total(Mill + IDF) kWh/t 18.2 14.3Extermal circulation t/h 30 15Increased Production % +15Energy saving % -21kWh/t -3.4Raw mill LM38.4Item Unit Operation ResultBefore Modification After ModificationLSKS Separator LV ClassifierProduction t/
36、h 236 281Power consumptionMill kw 1490 1751IDF kw 1792 1600Difference pressure of millMbar 82 87Gas flow rate m3/h 560,000 460,000Vibration mm/s 8-11 3-5Product finenessResidure 90micron % 13 12Residure 212micron % 1.3 0.8Unit power consumptionMill kWh/t 6.31 6.23IDF kWh/t 7.59 5.69Total(Mill + IDF)
37、 kWh/t 13.90 11.92Extermal circulation t/h 20 5Increased Production % +19Energy saving % -14kWh/t -1.9Coal Mill UBE LM18.2Item Unit Operation ResultBefore Modification After ModificationLSK Separator LV ClassifierProduction t/h 11.0 13-14Product finenessResidure 90micron % 30 27Increased Production
38、% +18-27Energy saving kWh/t -5.0Coal Mill UBE LM25.2Item Unit Operation ResultBefore Modification After ModificationLSK Separator LV ClassifierProduction t/h 26 28Product finenessResidure 90micron % 2 0.6Clinker grinding + slag grinding LM50.41Item Unit Operation ResultBefore Modification After Modi
39、ficationLSK Separator LV ClassifierProduction t/h 145/- 157 / 112Gas flow rate m3/h 340.000 340.000Product finenessBlaine 3600 / - 3348 / 4403Vibration Mm/s 8-11 3-5Residure 44micron % 6 6.2Unit power consumptionTotal(Mill + IDF) kWh/t - 29.9Increased Production % +8.2Cement Mill LM 46.2+2Item Unit
40、Operation ResultBefore Modification After ModificationLSKS Separator LV ClassifierProduction t/h 114 143Power consumptionMill Kw 2549 2805IDF Kw 1307 1183Difference pressure of mill Mbar 48 43-48Gas flow rate m3/h 385,000 325,000Vibration mm/s 3-5 3-5Product fineness Blaine 3624 3700Unit power consumptionMill kWh/t 22.3 19.7IDF kWh/t 11.5 8.3Total(Mill + IDF) kWh/t 33.87 27.95Extermal circulation t/hIncreased Production % +25.4Energy saving % -17.5kWh/t -5.92
