compaction with mit · material ˜ow to avoid damage to the roller press and the crusher. the...
TRANSCRIPT
Compaction with Roller Presses
KompaktierenmitWalzenpressen
Technische Änderungen vorbehalten. Subject to alterations serving technical advance© 2006 Maschinenfabrik Köppern GmbH & Co. KG.
MKV
KMA
KMS
KATKEG
KCH
Maschinenfabrik Köppern GmbH & Co. KG
Königsteiner Straße 245529 Hattingen/Ruhr
Tel.: +49/2324/207-0Fax: +49/2324/207-207
E-mail: [email protected]
Germany
Köppern Entwicklungs-GmbH
Königsteiner Straße 245529 Hattingen/Ruhr
Tel.: +49/2324/207-0Fax: +49/2324/207-301
E-mail: [email protected]
Germany
Köppern Aufbereitungstechnik GmbH & Co. KG
Agricolastr. 2409599 Freiberg
Tel.: +49/3731/2018-0Fax: +49/3731/2018-20
E-mail: [email protected]
Germany
Maquinarias Koeppern Venezuela C.A.
UD-321, Parcela 08-08, Edificio KoeppernZona Industrial Matanzas Sur
Apartado Postal 7668015-A Puerto Ordaz
Phone: +58/286/9941792Fax: +58/286/9941687
E-mail: [email protected]
Venezuela
Koppern Equipment, Inc.
2725 Water Ridge ParkwaySix Lake Pointe PlazaCharlotte NC 28217
Phone: +1/704/357-3322Fax: +1/704/357-3350
E-mail: [email protected]
USA
Koeppern Machinery Australia Pty. Ltd.
73 Pavers CirclePerth-Malaga, WA 6090Phone: +61/8/9248 4170
Fax: +61/8/9248 4176E-mail: [email protected]
Australia
Koppern Maco Services Pvt. Ltd.
Flat No. 6c, 6th Fl. Sukhsagar Apartments2/5 Sarat Bose Road
Kolkata 700 020Phone: +91/33/2476 1720
Fax: +91/33/2476 9052E-mail: [email protected]
India
Köppern China Holding GmbH
Office Beijing:Room 1201, Building B
No. 60 Anli Road (Runfeng Deshang)Chaoyang District, Beijing 100101
Phone: +86/10/6482-7348Fax: +86/10/6482-7341
E-mail: [email protected]
P. R. CHINA
32
Köppern Know-How– Compaction / Granulation
Köppern Know-How– die Pressgranulierung
Compaction testsin Köppern’s pilot plant
Kompaktierversuche inunserem Technikum
Partial list of materialscommonly granulatedby compaction:- ammonium sulphate- calcium cyanamide- ceramic materials- NPK fertilizers- potash- roasted pyrite- salts- sodium carbonate- sodium sulphate- thomas potash
Auswahl von Stoffen, die zu Pressgranulaten verarbeitet werden:- Ammoniumsulfat- Kali- Kalkstickstoff- Keramikmaterial- Kiesabbrände- Natriumsulfat- NPK-Dünger- Salze- Soda- Thomaskali
Premixed particulate material is compacted in a roller press into sheets (flakes), pre-crushed, granulated, and screened.
Das gemischte Feingut wird in einer Kompaktier-anlage zu Schülpen verpresst, vorzerkleinert, zu Granulat zerkleinert und klassiert..., .....
54
Roller press for compaction
Walzenpresse für die Kompaktierung
Köppern Roller Pressesare available
for all capacity ranges
Köppern-Walzenpressenfür alle Leistungsbereiche
Köppern Roller Presses– Designed for Top Performance
Köppern-Walzenpressen– Spitzenleistung bis ins Detail
capacity t/h Leistung t/h
max
. pre
ssin
g fo
rce
(kN
)m
ax. P
ress
kraf
t (k
N)
pre
ss t
ype
Pres
sen
typ
e
0 20 40 60 80 100 120
40 1600
52 2600
60 3750
72 5300
92 8650
500 10.400
Köppern Roller Pressescapacity ranges
Köppern-WalzenpressenLeistungsbereiche
3 376
KöppernPossesses Special Know-How
Including Plant Engineering
Köppern – Spezialkenntnisse
bis zum Anlagenbau
Köppern fertilizer compaction plant
Köppern Dünger-Kompaktieranlage
Screw feeder with transition piece Schnecke mit Übergangsstück Comparison planetary- / Vergleich Planeten- /double shaft drive Doppelwellenantrieb
Material feeder Materialzuteiler Planetary gears Planetengetriebe
Profiled roll tyre Profilierter Ring
Roller with hard facing Gepanzerte Walzenoberfläche
Köppern fertilizer compaction plant Köppern Dünger-Kompaktieranlage
So the advantages of the process are:
• Dry process, no additives
• No water, no drying
• Stable NPK distribution in the particles
• Utilization of low-price fines
• Quick change of NPK formulae
• Flexibility in raw material selection
Dry Granulation of Fertilizers
by Compaction
Fig. 2
Fig. 1
Fig. 3
Köppern is a medium size family owned company and for more than 100 years fully dedicated to the design of roller presses and process technology around the roller press. One major field for the application of roller presses (compactors) is the fertil-izer industry.
By compaction a fine grain material is com-pacted into the so called flake, a ribbon of defined thickness. The flake is crushed and screened to produce a course grain mate-rial (Figure 1). A typical use of compaction is the production of agricultural fertilizers. Fertilizer is granulated in order to avoid dust during dispersion onto the ground and for better (reduced) solubility.
When mined in large quantities potassium chloride (MOP) and other salts have particle sizes below 1 mm after concentration. With progressing mechanization and the use of
bulk blending techniques the agricultural industry is demanding coarser grain sizes between 1 and 4 mm, or 2 to 4 mm as of late.
NPK granules can also be produces by the compaction technology. A mixture of the nutrient carriers for nitrogen (N), phos-phate (P), and potassium (K) is compacted to a flake. Here as well the flake is crushed, and the desired fraction is screened out.
Because in contrast to conventional wet methods, the granulation of fertilizers by compaction is using dry feed materials from an almost unlimited number of sources and without special requirements on particle size or distribution, this technology is gain-ing increasing importance in the industry in particular with the raising energy costs (which is a major factor in wet granulation processes).
Although the principle of the compaction process is always the same (Figure 2), the development of each plant layout starts with the analysis of the customer’s indi-vidual requirements. That analysis covers the entire process from the arrival of the materials to packing and shipping. Planning a green field plant is a rare case. Most of our prospective customers are already en-gaged in some form of fertilizer production activity. Thus the planning exercise needs to take account of existing conditions. This may have an influence even on the design of buildings, depending on the choice of the material handlings system – either hori-zontal or vertical.
In a typical plant for approx. 25 t/h granular product, the blend of virgin materials is fed to the primary bin by belt conveyers and bucket elevator. The primary bin filling level is measured by means of level probes, and the measured values are transmitted to the compaction line’s programmable controller. The material blend for press granulation is volumetrically metered by a vibrating feed-er. In this way the material flow is precisely controlled, taking account of material re-cycled into the process.
A primary crusher fed by the vibrating feeder serves to homogenize materials of different hardness and/or particle size to a uniform fraction of < 1 mm. The virgin material and the recycled undersize mate-rial from the screening process are homog-enized in a twin-shaft mixer. A magnet separator arranged at the twin-shaft mixer inlet serves to remove tramp iron from the material flow to avoid damage to the roller press and the crusher.
The roller press (Figure 3) is fed by a trough chain conveyor. The material is guided to the roller press through an opening in the chain conveyor. At the end of the trough conveyor, there is a further overflow that makes sure that a sufficient flow of mate-rial is constantly supplied to the operating press. A flow meter provided in the overflow chute controls the flow of material supplied to the system that feeds the press.
Below the roller press there is a flake breaker which reduces the flake to an initial fraction of < 30 mm for handling purposes. The en-tire material from the flake breaker is con-veyed via belt conveyor and bucket elevator to a three-deck screen. The major portion of the material from the flake breaker is > 4
mm in size; this fraction is transferred to a bin for cur-ing. The 2-4 mm granules are transferred to the post treatment section and the < 2 mm undersize fraction goes to the recycle bin; from where it is added to the virgin material flow in dosed quantities.
After curing, the oversize material is reduced in a granulate crusher to a defined grain size. The crusher speed must be adjustable to ensure that the optimum size reduction for the specific raw material used can be obtained. The crusher oversize material is returned to the multiple-deck screen.
Description of an operating plant
Anyone involved with fertilizer compaction in general, and with potassium compac-tion in particular, is familiar with operat-ing conditions where vibrations and even hard blows occur in the press. Such phe-nomena are generally regarded as deaera-tion problems. From a mechanical point of view, however, they are direct exciters for resonant vibrations of the overall system. A continuous load of this type may lead to failures, mainly of components in the drive train. Damages can be avoided in most cas-es by compromising on press throughput, i.e. by reducing roll speed or feed rate to the press. Major factors contributing to vi-brations are feed material properties (main-ly fineness) and excessive roll speed.
With increasing press size the natural fre-quency is reduced. The risk to have the natural frequency within a critical range can be reduced by designing a stiffer sys-tem (instead of reducing the throughput). Stiffening/enlarging shafts and couplings, however, are limited with the commonly used twin shaft drive trains. A better way to achieve effective systems stiffening (press frame and drive train) is to use a different drive concept.
Since the late 1980ies Köppern has been manufacturing large roller presses for high pressure comminution. These presses are equipped with planetary gear reducers, which are mounted directly onto the roll shafts (Figure 4). It seemed to be appropri-ate to utilize this drive system also for large NPK/potash presses.
www.koeppern.com
Unique compactor design
Maschinenfabrik Köppern GmbH & Co. KG
Königsteiner Str. 2 phone + 49 (2324) 207 - 0D-45529 Hattingen fax + 49 (2324) 207 - 207Germany e-mail [email protected]
Fig. 6
Fig. 4
The granules from the compacting line are fed into an abrasion drum where sharp edges are rounded off. This operation is fol-lowed by a final screening step that serves to remove the separated fines. The gran-ules, after having been subjected to high loads in the drum, will undergo less abra-sion during shipment and handling at the
The power requirement for a MOP compaction line is in the range of 40-45 kWh/t while for NPK it again depends on the type of feed material and the necessary specific press force. So for NPK the power requirement is between 35 and 55 kWh/t.
customers. If necessary, the granules are coated with an anti-caking agent in a coat-ing drum to keep the grains from caking together during long storage times.
The product yield (2-4 mm) of a typical MOP circuit is 35-40% while for NPK it may be between 30 and 50% depending on the feed material mix.
The stiffening effect on the system can be explained best by the following comparison between the two concepts (Figure 5). It shows the traditional twin shaft drive and the individual roll drives with planetary gear reducers.
ConclusionBy the end of 1998 Köppern delivered the first large pot-ash compactor for a German potash mine for 130 tph flake capacity with the single shaft drive concept via plan-etary gears.
Since this first introduc-tion for a potash press the new technology has found worldwide recognition for NPK and MOP compaction. Clients in Canada (Figure 6), China, Brazil, Hungary, Italy,
Jordan and Serbia have since ordered roller presses for fertilizer compaction with the new drive concept.
Within less than 10 years there is a total number of more than 40 compactors supplied or on order with a combined flake capacity of 28 Million annual tons (as of November 2007). Along with the hinged frame design, a new feeder design and other developments like the pendulum piston Köppern has further devel-oped the performance and availability of large ferti-lizer compactors.
Fig.5
NPK Dry Granulation
Dry process, no additivesNo water, no dryingUse of low-price powdersQuick change of NPK formulationsFlexibility in raw materials
NPKTrockengranulierung
Trockener Prozess – keine ZusatzstoffeKein Wasser – keine TrocknungVerwendung günstiger EinsatzstoffeSchneller Wechsel der NPK FormulierungenFlexibilität bei Rohmaterialien
Flexible and economicalToday‘s intensive farming demands the use of single and multi-component
fertilizers. To improve application to the fields, several techniques have been
developed which produce uniform, dust-free, non-segregating granular
products from finely divided or powdered raw materials.
Because in contrast to conventional wet methods, the granulation of fertilizers
by compaction is using dry feed material from an almost unlimited number
of sources and without special requirements on particle size or distribution,
this technology is gaining increasing importance in the industry. No expensive
drying is necessary.
The fine premixed NPK fertilizer particles are
subjected to a sufficiently high pressure in a
roller press to squeeze them together and thus
freeze the desired formulation. Compaction
technology has been used for many years and,
in fact, millions of tonnes of granular potash
is produced each year in this manner.
We not only manufacture the press but also
take process responsibilities and supply key
equipments for the plant.
Flexibel und wirtschaftlich
Potash compactionCanada
Die heutige intensive Landwirtschaft erfordert den Einsatz von Ein- und
Mehrkomponenten-Düngern. Zur Verbesserung des Ausbringens auf
die Felder wurden verschiedene Techniken entwickelt, um ein einheitliches,
staubfreies und entmischungsfreies Granulat aus den fein verteilten
oder pulverförmigen Rohmaterialien zu erzielen.
Im Gegensatz zu der konventionellen Nassgranulierung kann man bei
der Kompaktierung eine Vielzahl von verschiedenen trockenen
Düngerkomponenten verwenden, ohne auf eine gleichmäßige
Kornverteilung zu achten. Daher gewinnt dieses Verfahren in der
Düngemittelindustrie mehr und mehr an Bedeutung, zumal keine teure
Trocknung erforderlich ist.
Die feinen und vorgemischten NPK Düngerpartikel werden in der
Walzenpresse einem ausreichend hohen Druck ausgesetzt, um sie
zusammenzupressen und so die gewünschte Formulierung zu fixieren.
Die Kompaktiertechnik wird seit vielen Jahren eingesetzt und es werden
jedes Jahr z.B. Millionen Tonnen Kaligranulat auf diese Weise hergestellt.
Wir fertigen nicht nur die Presse, sondern übernehmen auch Prozess-
verantwortung und liefern die Schlüsselkomponenten zur Anlage.
NPK-compactionHungary NPK-Kompaktierung
Ungarn
NPK-compactionSwitzerland
NPK-KompaktierungSchweiz
KalikompaktierungKanada
KPN
Press Presse
Mixer Mischer
Process FlowRaw material is metered from the surge bins and blended according to
the required nutrient ratio. The raw material might be of inexpensive
fines or they are crushed if necessary.
ProzessablaufAus Vorratsbunkern werden die
Rohstoffe nach der erforderlichen
Nährstoff-Rezeptur dosiert und
gemischt. Die Rohmaterialien können
als preiswertes Feingut vorliegen
oder werden bei Bedarf zerkleinert.
TSP / DAP / RPUR / AS / AC / DAP
Trace elements and filler may
be added as requested.
Spurenelemente und Füller
können nach Bedarf
zugegeben werden.
MOP / SOP / SPM
Crusher Brecher
Screen Sieb
Oversize fraction is
recycled to the crusher.
Überkorn wird zum
Brecher zurückgeführt.
Undersize material fromthe screen is recycled to
the compaction press afterbeing blended with fresh
feed.Unterkorn vom Sieb wirdmit Frischgut gemischtund vom Sieb zurKompaktierpressezurückgeführt.
The entire process comprises mechanical equipment,
which is easy to operate and maintain.
Der gesamte Prozess beinhaltet nur mechanische Ausrüstungen,
die leicht zu bedienen und zu warten sind.
15 – 15 – 15
0 – 10 – 28
8 – 21 – 21
12 – 6 – 18 – 2
15 – 8 – 8 – 3
18 – 20 – 0
13 – 13 – 26
23 – 8 – 6
An almost unlimited number of different
NPK's can be granulated.
In practice NPK compaction plants produce
5 to 50 different formulations depending
on market requirements, e.g.
Eine fast unbegrenzte Anzahl unterschied-
licher NPK-Dünger kann granuliert werden.
In Betriebsanlagen werden in Abhängigkeit
von der Marktsituation 5 - 50 verschiedene
Formulierungen produziert, z.B.
CVRDBrazil
PCSCanada
SQMChile
MINSALChile
Yantai Wuzhou ShidefuChina
Kali + SalzGermany
KohnenGermany
FerquiguaGuatemala
TVMHungary
Dead Sea WorksIsrael
KappaItaly
Arab PotashJordan
Atlas FertilizerPhilippines
URALKALIRussia
SILVINITRussia
FERTILSerbia
Chem. Fabrik UetikonSwitzerland
IGSASTurkey
Our services cover compaction tests, process layout, basic engineering,equipment supply, and start up support.
Unsere Leistungenbeinhalten:
Kompaktierversuche, Verfahrensauslegung,Basic Engineering, Komponentenlieferungen und Unterstützungbei derInbetriebnahme.
Selected references ofcompaction plants forMOP, SOP, NPK, PK.Some clients are operatingmore than 10 of our presses.
Auswahl von Kundenmit Kompaktieranlagenfür MOP, SOP, NPK, PK.Bei einigen Anlagen-betreibern sindmehr als10 unserer Pressenim Einsatz.
Königsteiner Str. 2 phone +49 (2324) 207 - 0D-45529 Hattingen fax +49 (2324) 207 - 207Germany e-mail [email protected]
Köppern Aufbereitungstechnik GmbH & Co. KG
Agricolastr. 24 phone +49 (3731) 2018 - 0D-09599 Freiberg fax +49 (3731) 2018 - 20Germany e-mail [email protected]
Köppern Entwicklungs-GmbH
Königsteiner Str. 2 phone +49 (2324) 207 - 0D-45529 Hattingen fax +49 (2324) 207 - 301Germany e-mail [email protected]
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w. k
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Main office / Stammhaus
Maschinenfabrik Köppern GmbH & Co. KG
Köppern unterhält Service-Stationen anstrategischen Standorten rund um den Globus.Die Versorgung mit Ersatzteilen von hoherQualität ist dadurch gewährleistet.
Gut ausgebildete Fachkräfte aus dem Stammhausin Deutschland oder von einer Niederlassungstehen dem Kunden immerzur Verfügung.
Köppern maintains service points at strategiclocations around the globe. This ensures fastsupply of high-quality spare parts. Well-trainedexperts from the parent company in Germanyor from a branch operation are availabe to
our customers at all times.
Koppern Maco Services Pvt. Ltd.
Flat No. 6c, 6th Floor Sukhsagar Apartments2/5 Sarat Bose RoadKolkata 700 020India
phone +91 (33) 24 761 720fax +91 (33) 24 769 052e-mail [email protected]
Koeppern China Holding
Office Beijing, Room 1201, Building BNo. 60 Anli Road (Runfeng Deshang)Chaoyang DistrictBeijing 100101P. R. China
phone 0086 (10) 64 82-73 48fax 0086 (10) 64 82-73 41e-mail [email protected]
Koeppern Machinery Australia Pty Ltd.
73 Pavers CirclePerth - Malaga WA 6090Australia
phone +61 (8) 92 484170fax +61 (8) 92 484176e-mail [email protected]
Koppern Equipment, Inc.
2725 Water Ridge ParkwaySix Lake Pointe PlazaCharlotte, NC 28217USA
phone +1 (704) 357 - 3322fax +1 (704) 357 - 3350e-mail [email protected]
Maquinarias Koeppern Venezuela C.A.
UD-321, Parcela 08-08, Edificio KoeppernZona Industrial Matanzas SurApartado Postal 7668015-A Puerto OrdazVenezuela
phone +58 (286) 99 41792fax +58 (286) 99 41687e-mail [email protected]
