150 18 255 2013 Anlagenoptimierung Homogenisierung

ThyssenKrupp Industrial Solutions
INVESTIGATION OF HOMOGENIZATION SILO

SHARRCEM SH.P.K, TITAN GROUP COMPANY
HANI I ELEZIT / KOSOVO
Untersuchungszeitraum: 18.09.2013 – 28.09.2013
Bearbeiter: Rüdiger Beyer TKRT, Abt. 150

Thomas Landmann TKRT, Abt. 150
Berichtsnummer: 150/18-255/2013
Verteiler: EB-SD, 010, 011, 150, 300, 600/630, 770, Customer
S:\Dept\A300all\360\AUFTRAG\SHARRCEM Titan Group\Dokumente\Berichte\150_18_255_2013_Anlagenoptimierung Homogenisierung.docx 1 / 26
Postal address: ThyssenKrupp Industrial Solutions GmbH, Business Unit Resource Technologies, Graf-Galen-Straße 17, 59269 Beckum, Germany
Phone: +49 2525 99-0 Telefax: +49 2525 99-2100 E-Mail: [email protected] Internet: www.thyssenkrupp-industrial-solutions.com
Business address: ThyssenKrupp Industrial Solutions GmbH, ThyssenKrupp Allee 1, 45143 Essen, Germany
Executive Board: Dr. Hans Christoph Atzpodien (Chairman), Martin Hilbig, Dr. Joachim F. Panek, Jörg Schönewolf
Registered office: Beckum Court of registration: Münster District Court HRB no. 7717 VAT ID no.: DE811152653
Table of Content
1 SUMMARY 3
2 TECHNICAL DATA 4
3 GENERAL PROCESS DESCRIPTION 5
3.1 Homo Silo ................................................................................. 7
3.2 Storage Silo .............................................................................. 8
4 FOTODOCUMENTATION 9
5 AUDIT (SERVICE PACK 1) 11
5.1 Audit Procedure ...................................................................... 11
5.2 Results for Silo 1 ..................................................................... 11
5.3 Results for Silo 2 ..................................................................... 14
5.4 Filter Dust Handling ................................................................ 17
6 RECOMMENDATIONS (SERVICE PACK 2) 18
7 APPENDIX 19
1 Summary
The Sharrcem cement plant, which was commissioned in 1974 by ZAB Dessau, is equipped with
a batch wise working raw meal silo, consisting of two homogenisation silos and two storage silos
and an overall storage capacity of 9.400 t raw meal.
The production capacity design is 1.500 t of clinker per day. Currently the plant produces approx.
1.500 t of clinker per day in compound operation. The aim for the future is a production increase
to an average of 1.650 t of clinker per day. Under that aspect and under the aspect to optimise
the current situation the audit was done.
During the audit of the raw meal silos the mixing efficiency of the homogenization silos was in-
vestigated as well as the influence of the storage silos. Additionally the installed transportation
systems were evaluated.
Due to the tight production capacity of the raw mill, compared to the required kiln feed mass flow;
the raw mill was operated in compound operation for approx. 95% of possible operation time.
The filter dust was fed continuously to the raw meal transport in compound operation as well as
in direct operation.
The results of the audit show, that the raw meal quality according chemical uniformity, delivered
by the raw mill, is already good. The standard deviation of the LSF after the raw mill was be-
tween 1,5 and 3. Both homogenisation silos improve that uniformity to a LSF standard deviation
between 0,4 up to 1,2. The LSF standard deviation of the kiln feed (after storage silo) showed a
slightly decline compared to the material after the homogenization silo. The values were between
0,9 and 1,4. But these values are still in a good range, compared to a general target standard
deviation for the kiln feed LSF of 1,2.
A reason for the current good chemical homogeneity was the used raw material, what is applied
to 95 % in the pre mix. If in the future other components should be used in the raw mix with high-
er percentages the raw meal silo should be evaluated again.
The development of the particle size distribution shows for both silos, that the uniformity of the
raw meal slightly decreases form homogenization silo inlet to storage silo outlet. The standard
deviation of the residue at 90 µm show for the material after the raw mill values between 1,1 and
1,6 and for the kiln feed 1,7 up to 2,7.
Currently the aeration air flow for the homogenization silo should be lifted to the recommended
level of 2 m³/m²•min and the aeration time should be revised. For the storage silos as well as the
homogenization silos the instrumentation, especially the pressure measurements, for the aera-
tion system should be reviewed. Additional for the storage silo the program logic of the aeration
cycle should be verified. All silos should be inspected inside to exclude damages of the aeration /
discharge systems.
Actual there are no points, at the raw meal silo, which could impair the production increase.
2 Technical Data
The Raw Meal Silo at the Titan – Group Sharrcem Plant consists in general of two Homogeniza-
tion Silos and two Storage Silos.
Technical Data
Capacity homogenization Silo 1 [t] : 1.500

Capacity homogenisation Silo 2 [t] : 1.500
Aerated sectors for Homogenization silo : 5
Capacity storage Silo 1 [t] : 3.200
Capacity storage Silo 2 [t] : 3.200
Aerated sector for storage silo : 12
Silo diameter [mm] : 15.000
Capacity of raw meal blower [m³/h] : 9.600
Capacity of kiln feed blower and storage Silo [m³/h] : 9.550
Deaeration capacity of silo filter [m³/h] : 18.000
Capacity of aeration blower Homo Silo [m³/h] : unknown
Capacity of each Pfister dosing system [t/h] : 80
3 General Process Description

The Raw Meal Silo in the Sharrcem cement plant is working batch wise.
The Raw Meal is transported via air slides from the raw mill building to the raw meal silos. On
that way the filter dust from the main bag house is added to the raw meal transportation air slide.
The filter dust is added to the meal during compound operation and during direct operation of the
kiln. There is no filter dust silo.
In a next step the raw meal together with the filter dust is transported pneumatically via a dense
phase into the first homogenization silo. According customer information the fill in for one batch
takes 6 h, what corresponds to approx. 660 t – 720 t of raw meal (without consideration of filter
dust. Including the filter dust the batch size is in the range of 740 t – 800 t.
During the time, when the raw meal is filled into the silo, the aeration system for the homogeniza-
tion silo is active continuously. After 6 h the raw meal feed is switched to the second homogeni-
zation silo, where the second batch is prepared for 6 h as well. The already filled homogenization
silo is aerated for 2 more hours. After that time the homogenized raw meal is released to the
storage silo. That takes additional 2 h. It is possible to release the raw meal into storage silo 1 as
well as storage silo 2. That means that it is feasible to blend the homogenized raw meal from silo
1 with that one from silo 2.
During the kiln feed system is in operation, the storage silo is aerated in a certain sequence. That
means that all 12 sectors are aerated in a certain order and for a specified time. After one cycle
is completed the next cycle starts automatically in the same order like that one before. The aera-
tion is working during the discharge as well as the time without discharge. During the time of the
plant audit the sequence wasn’t working proper. That means that always the same 5 aeration
valves were activated and the remaining 7 valves seem to be without function. That situation
could be verified at the silo itself.
After the storage silo the material is transported via air slides to two small bunkers. Each of these
bunkers is equipped with a Pfister dosing system, one dosing system for one calciner string. After
the dosing system the kiln feed is transported pneumatically to the preheater.
In the current arrangement it is possible to transport kiln feed material from each silo to both dos-
ing stations.
Fig. 1 Scheme of the Raw Meal Silo
Fig. 1 shows the general arrangement the the two homogenization silos and the two storage si-
los. Compared to the situation during the start up of the plant, nowadays there are two separate
Pfister dosing system, one for each precalciner string. These ones replaced the before installed
belt weigher systems.
3.1 Homo Silo
Fig. 2 Design of the Homogenization Silo Fig. 3 Top view Design Homogenization Silo bottom
In Fig. 2 a part of the original Homogenization Silo drawing is shown. According customer
informations, the silo is still in the shown configuration. During the audit it was not possible to
inspect the homogenization silos inside. The manometers for the aeration air pressure were not
working.
Each of the both homogenisation silo is equipped with an aerated bottom. That one is divided
into 5 segments. Each of these segment has its own air pipe. The two outer segments and that
one in the middle can be aerated together and the the two remaining segments can also be
aerated together.
Each homogenization silo is fitted with 2 discharge ports. Each of these ports is splited into two
ways, so that the material can be transported from both homogenization silos to both storage
silos. That means it is posssible to mix the raw meal from both homogenization silos together.
During the audit of the raw meal silo the complete material from one homogenization silos was
released only to the storage silo underneath.
According customer informations, all segments of the silo bottom are aerated at the same time
during the homogenisation cycle. One blower for the aeration of the homogenization silo wasn’t
equipped with a drive (see Fig. 7. For a better reliability of the silo the drive should be installed .
3.2 Storage Silo
Fig. 4 Design of the Storage Silo Fig. 5 Top view Design Storage Silo bottom
Each storage silo is equipped with 3 discharge ports. Just two of these discharge ports were in
operation during the audit.
From both storage silos, it is possible to supply kiln feed material to both Pfister dosing stations
and from each dosing station one calciner string can be supplied with feed. That means if there is
a problem, with one dosing or transport station, only one string of the pre calciner can be sup-
plied with kiln feed. That happened ones during the kiln audit.
The storage silo is equipped with 12 independently aerated sectors. During the audit only 5 of
these 12 sectors could be aerated. This might tend to segregation effects in the storage silo, be-
cause the material is extracted always from the same areas inside the silo.
During the audit period it was not possible to inspect the storage silo inside. The manometers for
the aeration air pressure were not working.
4 Fotodocumentation
Fig. 6 Air Distribution Homogenization Silo Fig. 7 Blower for Homogenization Silo aeration
Fig. 8 Blower for Raw Meal transport to silo
Fig. 9 Discharge port under Storage Silo Fig. 10 Air distribution for Storage Silo
Fig. 11 Blower for Storage Silo and Kiln Feed Fig. 12 Pfister dosing system for Kiln Feed
transport
Fig. 13 Kiln Feed transport station Fig. 14 Air distribution for Kin Feed transport
5 Audit (Service Pack 1)

5.1 Audit Procedure
The sampling for the Raw Meal silo audit was done by the customer.
The following sampling procedure was followed:

- Raw Meal for 2 batches (each 6 h) with an interval of 30 min (including the filter dust)
- Samples of material after both homogenization silo for 2 batches (each 2 h) with an inter-
val of 5 min
- Samples of kiln feed after both storage silos for 2 batches (each 6 h) with an interval of
30 min.
During the audit the material of homogenization silo 1 and homogenization Silo 2 wasn’t mixed
up.
5.2 Results for Silo 1

For these samples chemical and physical analyzes were done by the laboratory of the Sharrcem
plant. The main results are shown in Fig. 15 and Fig. 18.
Silo 1
Batch 1 Batch 2
MAX MIN AVG. STD. DEV. MAX MIN AVG. STD. DEV.
LSF - RM 107,14 98,65 102,49 3,06 103,46 99,32 102,27 1,69
LSF after Homog. 104,82 102,21 103,94 0,69 105,07 99,77 101,33 1,16
LSF Kiln Feed 104,03 99,59 101,66 1,39 106,02 101,61 103,33 1,25
Residue at 90 µm - RM 14,50 10,80 13,19 1,07 16,10 11,90 13,50 1,57
Residue at 90 µm - after Homog. 16,80 10,60 12,92 1,72 16,00 5,90 13,49 2,16
Residue at 90 µm - Kiln Feed 18,00 8,40 13,79 2,69 15,10 6,20 11,22 2,44
Residue at 200 µm - RM 4,80 3,50 3,88 0,44 6,30 3,20 4,20 1,27
Fig. 15 Results of the silo audit – silo 1
In Fig. 15 the results ot the silo audit of raw meal silo 1 are shown. The standard deviation (SD)
of the LSF at the homogenization silo inlet was between 1,69 and 3,06 with an average (AVG)
LSF of 102. These values are compared to other homogenization silos in a good range.
The Fig. 15 and Fig. 16 show the improvement of the LSF SD between homogenization silo inlet
and outlet. At the outlet the the SD was between 0,69 and 1,16. These values are, compared to
other plants, in a very good range.
The comparison of storage silo inlet and the kiln feed shows a decline of the SD for the LSF. The
value was between 1,25 and 1,39, what is still a good value for kiln feed (see Fig. 16). In general
the SD for the kiln feed should be < 1,2.
This change could be caused by the non proper working aeration cycle of the storage silo. That
means, that not all aeration valves worked properly.
Fig. 16 LSF results of laboratory analyzes of Silo 1
In Fig. 16 the development of the LSF from the Raw meal feed to the silo until the kiln feed for
both batches is diplayed.
The homogenization silo improved the uniformity of the LSF. This could be observed for both
batches. The storage silo influenced the uniformity of the material fed to the kiln in a slightly neg-
ative way. But the quality was still good.
Fig. 17 Residue results of laboratory analyzes of Silo 1
The results of the sieve analyzes for the samples of silo 2, are shown in Fig. 17. The average
residues at the 90 µm sieve as well as the 200 µm sieve stay within a tolerance but the standard
deviation decline from the homogenization silo inlet to the storage silo outlet. That shows, that in
the homogenization silo as well in the storage silo segregation effects occurred. These effects
influenced the uniformity of the particle size distribution negatively.
Reasons for that segregation effects could be:
- insufficient homogenization air flow, due to an unusable compressor

- to long aeration time
- a not proper working aeration cycle in the storage silo
- damaged aeration bottom inside the silos
5.3 Results for Silo 2

Silo 2
Batch 1 Batch 2
MAX MIN AVG. STD. DEV. MAX MIN AVG. STD. DEV.
LSF - RM 104,04 99,21 101,57 1,52 103,05 99,07 101,41 2,08
LSF after Homog. 103,31 97,21 102,44 1,21 102,22 100,49 101,59 0,40
LSF Kiln Feed 105,09 102,16 103,50 0,96 106,34 103,05 104,42 0,88
Residue at 90 µm - RM 14,50 10,40 12,67 1,13 14,20 12,00 13,07 1,10
Residue at 200 µm - RM 4,70 3,50 3,97 0,37 4,40 3,70 4,00 0,36
Fig. 18 Results of the silo audit – silo 2
Fig. 19 LSF results of laboratory analyzes of Silo 2
Fig. 18, Fig. 19 and Fig. 20 show the audit results for the raw meal silo 2. The SD for the LSF of
the homogenizatio silo inlet was between 1,52 and 2,08. That is, like it was for silo 1, a good
value. Over the homogenization silo 2 the uniformity of the LSF was improved, shown by a lower
SD between 0,4 and 1,21. The storage silo maintain the already good uniformity of the material
that show a SD of 0,88 and 0,96 for the two batches of kiln feed.
Fig. 20 Residue results of laboratory analyzes of Silo 2
Fig. 20 shows the development of the residues at 90 µm and 200 µm from the homogenization
silo inlet to the storage silo outlet.
The values for the sieve analyzes after the homogenization silo indicate a rise in the residue at
90 µm as well as at 200 µm for both batches. A change of the uniformity in the particle size dis-
tribution, between homogenization silo inlet and outlet, can’t be observed clearly.
But between the storage silo inlet and the storage silo outlet a drop of the residues at 90 µm and
at 200 µm can be observed as well as a raised standard deviation for both batches. These re-
sults are an indication for segregation appearances inside the storage silo 2.
A main reason for the good uniformity of the kiln feed is the used Marl, what is used in a percent-
age of approx. 95% in the raw mix. That Marl already shows a very good chemical uniformity.
This show the SD for the LSF in the pre mix, which was between 1,7 up to 3 for silo 1 and 1,5 up
to 2,1 for silo 2.
In Fig. 7 the aeration blowers for the homogenization silo are shown. One of these blowers
wasn’t working due to a missing motor. Therefore the specific aeration air flow, which should be
approx. 2 m³/min•m², was most probably to low (dedusting volume of the silo filter minus the air
flow of raw meal transportation blower) was around 0,9 m³/min•m².
Additionally the aeration time might be too long, what can cause segregation inside the homoge-
nization silo. According customer the aeration blower is working for 6 h during the fill in and addi-
tional two hours afterwards, for homogenization.
Normally the aeration time should be 45 min with the above mentioned specific air flow.
5.4 Filter Dust Handling

The filter dust of kiln line is always returned to the homogenising silo regardless whether the mill
is in operation (compound operation) or not (direct operation). This way of operation can influ-
ence the chemical composition of the kiln feed extremely.
For evaluation purposes of the dust influence to the Raw Meal quality POLYSIUS defined a so-
called Separation Factor. The LSF-Separation-Factor relates the lime saturation factor of the dust
to the lime saturation factor of the kiln feed:
LSFDust
SFLSF 
LSFKi ln Feed
Similarly to the previous mentioned factor there are additional the SM-Separation-Factor, which
relates the Silica Module of the dust to the Silica Module of the kiln feed:
SM Dust
SFSM 
SM Ki ln Feed
During the investigation period the following Moduli were determined:
Silo 1 Silo 2
Batch 1 Batch 2 Batch 1 Batch 2
LSF Dust 109,54 109,54 109,54 109,54
LSF Kiln Feed 101,66 103,33 103,5 104,42
SM Dust 2,08 2,08 2,08 2,08
SM Kiln Feed 2,15 2,16 2,15 2,15
SF LSF 1,08 1,06 1,06 1,05
SF SM 0,97 0,96 0,97 0,97
Fig. 21 esults of the separation factor calculation
The LSF-separation-factor for Silo 1 is calculated as 1,06 and 1,08, the SM-separation-factor as
0,96 and 0,97.
The LSF-separation-factor for Silo 2 is calculated as 1,05 and 1,06, the SM-separation-factor as
0,97.
The uncritical range is between 0.8 and 1.2.
From the chemical point of view major disturbances of the operation can not be expected. But it
needs to be considered, that dust accumulations during a longer stop
6 Recommendations (Service Pack 2)

- Install the drive for the second aeration blower for the homogenization silo
- Increase the specific aeration air flow in the homogenization silo to 2,0 m³/m²•h
- Reduce the homogenisation time
- Replace the manometer at the homogenization and at the storage silo aeration system
- Empty the homogenization silos and inspect the aeration floors for sediments or damages
- Empty the storage silos and inspect the aeration floors for sediments or damages
- Revise the aeration cycle for the storage silos, because only 5 of the 12 valves were in
operation
- Revise the aeration valves for the storage silo aeration
- If the raw mill capacity should be increased in the future, it might be possible to install a
separate filter dust hopper for the direct operation time of the kiln. As an alternative, a
dust recirculation to the kiln feed can be considered
7 Appendix
Daily Report: Test report From: 01-Oct-13 07:00:30
Package: Test report To: 17-Oct-13 10:06:31
Type: Daily First: 35531
Description: Test report Last: 36902
Non Passing %
SmpNo Smp Grp Time Comment SiO2 Al2O3 Fe2O3 CaO MgO Na2O K2O SO3 LSF SIM ALM HM 90µm 200µm
36310 Test 24.09.13 7.30 h 12,52 3,55 2,19 41,25 1,86 0,10 0,54 0,40 101,41 2,18 1,63 2,26 13,90 4,5
36343 Test 24.09.13 8.00 h 13,09 3,69 2,14 41,99 1,93 0,10 0,59 0,33 99,03 2,24 1,72 2,22 12,9 4,2
36311 Test 24.09.13 8.30 h 11,96 3,52 2,23 41,70 1,85 0,09 0,56 0,29 106,72 2,08 1,58 2,36 10,80 3,5
36345 Test 24.09.13 9.00 h 12,75 3,68 2,15 41,35 1,91 0,10 0,58 0,30 99,82 2,19 1,71 2,23 12,1 3,7
36346 Test 24.09.13 9:30 h 12,51 3,60 2,18 41,42 1,86 0,09 0,56 0,27 101,78 2,16 1,65 2,26 12,2 3,7
36312 Test 24.09.13 10.00 h 11,93 3,50 2,19 41,75 1,83 0,09 0,56 0,27 107,14 2,09 1,60 2,37 13,30 4,8
36350 Test 24.09.13 10.30 h 12,18 3,57 2,20 41,77 1,88 0,10 0,57 0,27 105,13 2,11 1,62 2,33 13,5 4
36313 Test 24.09.13 11.00 h 12,02 3,51 2,16 41,74 1,85 0,10 0,56 0,27 106,45 2,12 1,63 2,36 13,00 3,9
36357 Test 24.09.13 11.30 h 12,48 3,60 2,22 41,45 1,84 0,10 0,56 0,30 102,00 2,14 1,62 2,26 14,1 4,3
36211 Test 24.09.13 12:00 h 12,79 3,63 2,31 41,03 1,85 0,10 0,57 0,35 98,65 2,15 1,57 2,19 13,7 4,7
36358 Test 24.09.13 12.30 h 12,61 3,59 2,21 41,40 1,81 0,10 0,55 0,29 101,08 2,18 1,62 2,25 14,3 4,6
36361 Test 24.09.13 13.00 h 12,60 3,62 2,27 41,32 1,88 0,10 0,57 0,31 100,69 2,14 1,60 2,23 14,5 4,6
36172 Test 24.09.13 23:00 h 12,37 3,56 2,20 41,65 1,80 0,09 0,55 0,29 103,46 2,15 1,62 2,30 13,10 3,5
36171 Test 24.09.13 23:30 h 12,37 3,59 2,15 41,62 1,81 0,09 0,56 0,29 103,33 2,15 1,67 2,30 11,90 3,2
36158 Test 24.09.13 24:00 h 12,82 3,61 2,20 41,29 1,78 0,09 0,56 0,28 99,32 2,20 1,64 2,22 13,5 4,5
36174 Test 24.09.13 24:30 h 12,46 3,56 2,21 41,58 1,79 0,09 0,54 0,27 102,58 2,16 1,62 2,28 12,9 3,5
36169 Test 24.09.13 01:00 h 12,63 3,38 2,21 41,86 1,65 0,11 0,52 0,29 102,65 2,26 1,53 2,30 16,1 6,3
17 17 17 17 17 17 17 17 17 17 17 17
Mean: 12,48 3,57 2,20 41,54 1,83 0,10 0,56 0,30 102,42 2,16 1,62 2,28
Min: 11,93 3,38 2,14 41,03 1,65 0,09 0,52 0,27 98,65 2,08 1,53 2,19
Max: 13,09 3,69 2,31 41,99 1,93 0,11 0,59 0,40 107,14 2,26 1,72 2,37
S.dev: 0,32 0,07 0,04 0,25 0,06 0,01 0,02 0,03 2,68 0,05 0,05 0,05
R.Dev: 2,54 2,03 1,92 0,61 3,44 5,90 2,75 11,01 2,62 2,18 2,91 2,34
Sum:

Non Passing %
36828 Test 24.09.13 After Homo Silo #1 15:05 h 12,30 3,59 2,15 41,49 1,85 0,10 0,56 0,28 103,52 2,14 1,66 2,30 12,30 4,2
36889 Test 24.09.13 After Homo Silo #1 16.05 h 12,33 3,56 2,17 41,48 1,85 0,09 0,56 0,29 103,35 2,15 1,64 2,30 12,90 4,6
36888 Test 24.09.13 After Homo Silo #1 16.40 h 12,24 3,55 2,13 41,59 1,85 0,10 0,56 0,33 104,36 2,16 1,67 2,32 10,60 3
36450 Test 25.09.13 After Homo Silo #1 03.10 h 12,35 3,53 2,15 41,51 1,80 0,09 0,55 0,29 103,42 2,18 1,64 2,30 9,9 3
36467 Test 25.09.13 After Homo Silo #1 03.45 h 12,66 3,61 2,22 41,40 1,80 0,09 0,56 0,27 100,59 2,17 1,63 2,24 16 5
36515 Test 25.09.13 After Homo Silo #1 04;05 h 12,58 3,57 2,23 41,22 1,79 0,09 0,55 0,28 100,81 2,17 1,60 2,24 13,4 4,4
36525 Test 25.09.13 After Homo Silo #1 04:35 h 12,64 3,59 2,21 41,42 1,79 0,10 0,55 0,27 100,84 2,18 1,62 2,25 13,4 5
47 47 47 47 47 47 47 47 47 47 47 47
Mean: 12,57 3,58 2,21 41,41 1,80 0,09 0,55 0,28 101,33 2,17 1,62 2,26
Min: 12,21 12,21 12,21 12,21 12,21 12,21 12,21 12,21 12,21 12,21 12,21 12,21
Max: 12,73 12,73 12,73 12,73 12,73 12,73 12,73 12,73 12,73 12,73 12,73 12,73
S.dev: 0,18 0,18 0,18 0,18 0,18 0,18 0,18 0,18 0,18 0,18 0,18 0,18
R.Dev: 1,41 1,41 1,41 1,41 1,41 1,41 1,41 1,41 1,41 1,41 1,41 1,41
Sum:

Non Passing %
36586 Test 24.10.2013 After storage Silo #1 23.30 h 12,53 3,58 2,22 41,38 1,82 0,10 0,56 0,29 101,53 2,16 1,61 2,26 12,9 3,4
36589 Test 24.10.2013 After storage Silo #1 00.00 h 12,71 3,61 2,25 41,14 1,83 0,09 0,56 0,28 99,59 2,17 1,60 2,22 18 7,6
36999 Test 25.09.2013 After storage Silo #1 11:30 h 12,46 3,57 2,16 41,49 1,85 0,09 0,55 0,30 102,42 2,17 1,65 2,28 11,70 4
36998 Test 25.09.2013 After storage Silo #1 12:00 h 12,36 3,57 2,13 41,60 1,86 0,09 0,55 0,30 103,50 2,17 1,68 2,30 9,40 3,7
22 22 22 22 22 22 22 22 22 22 22 22
Mean: 12,35 3,57 2,15 41,52 1,86 0,09 0,55 0,30 103,33 2,16 1,66 2,30
Min: 12,05 3,52 2,08 41,14 1,80 0,09 0,54 0,28 99,59 2,13 1,54 2,22
Max: 12,72 3,61 2,30 41,66 1,88 0,10 0,56 0,32 106,02 2,17 1,70 2,36
S.dev: 0,15 0,02 0,06 0,14 0,02 0,00 0,01 0,01 1,55 0,01 0,04 0,04
R.Dev: 1,24 0,64 2,95 0,33 1,21 2,10 0,90 3,31 1,51 0,51 2,75 1,56
Sum:

Non Passing %
36162 Test 24.09.2013 Homo Silo #2 1:30 h 12,69 3,56 2,22 41,37 1,80 0,09 0,55 0,25 100,48 2,19 1,60 2,24 10,4 3,5
36206 Test 24.09.2013 Homo Silo #2 2:00 h 12,29 3,53 2,20 41,64 1,80 0,09 0,54 0,27 104,04 2,15 1,61 2,31 12,9 3,6
36173 Test 24.09.2013 Homo Silo #2 2:30 h 12,82 3,62 2,23 41,28 1,79 0,10 0,57 0,27 99,21 2,19 1,62 2,21 14,50 4,5
36205 Test 24.09.2013 Homo Silo #2 3:00 h 12,61 3,57 2,20 41,42 1,80 0,09 0,55 0,27 101,12 2,19 1,63 2,25 12,60 3,8
36175 Test 24.09.2013 Homo Silo #2 3:30 h 12,39 3,56 2,18 41,65 1,80 0,09 0,55 0,28 103,31 2,16 1,63 2,30 12,8 3,8
36201 Test 24.09.2013 Homo Silo #2 4:00 h 12,62 3,59 2,21 41,38 1,77 0,09 0,56 0,29 100,94 2,18 1,63 2,25 11,6 3,8
36203 Test 24.09.2013 Homo Silo #2 4:30 h 12,47 3,57 2,21 41,43 1,82 0,10 0,56 0,30 102,15 2,16 1,62 2,27 14,2 4,7
36200 Test 24.09.2013 Homo Silo #2 5:00 h 12,77 3,57 2,22 41,18 1,76 0,10 0,56 0,32 99,45 2,20 1,61 2,22 11,9 3,8
36204 Test 24.09.2013 Homo Silo #2 5:30 h 12,57 3,55 2,18 41,45 1,81 0,09 0,55 0,29 101,56 2,19 1,63 2,26 12,7 4,2
36159 Test 24.09.2013 Homo Silo #2 6;00 h 12,45 3,56 2,24 41,49 1,83 0,09 0,56 0,29 102,40 2,14 1,59 2,27 12,90 4
36161 Test 24.09.2013 Homo Silo #2 6:30 h 12,45 3,56 2,17 41,56 1,78 0,09 0,56 0,27 102,65 2,17 1,64 2,28 12,90 4
36210 Test 24.09.2013 Homo Silo #2 13.30h 12,36 3,53 2,23 41,45 1,82 0,09 0,56 0,29 103,05 2,14 1,59 2,29 14,2 4,4
36208 Test 24.09.2013 Homo Silo #2 14:00h 12,49 3,55 2,21 41,45 1,79 0,10 0,55 0,28 102,12 2,17 1,61 2,27 13 3,9
36209 Test 24.09.2013 Homo Silo #2 14.30h 12,77 3,64 2,26 41,14 1,86 0,09 0,56 0,32 99,07 2,17 1,61 2,20 12 3,7
14 14 14 14 14 14 14 14 14 14 14 14
Mean: 12,55 3,57 2,21 41,42 1,80 0,09 0,56 0,29 101,54 2,17 1,61 2,26
Min: 12,29 3,53 2,17 41,14 1,76 0,09 0,54 0,25 99,07 2,14 1,59 2,20
Max: 12,82 3,64 2,26 41,65 1,86 0,10 0,57 0,32 104,04 2,20 1,64 2,31
S.dev: 0,16 0,03 0,02 0,15 0,02 0,00 0,01 0,02 1,57 0,02 0,02 0,03
R.Dev: 1,31 0,83 1,11 0,36 1,38 2,43 1,21 6,42 1,54 0,90 1,01 1,43
Sum:

Non Passing %
36239 Test 25.09.2013 After Homo Silo #2 9:30 h 12,57 3,56 2,18 41,47 1,79 0,09 0,55 0,27 101,60 2,19 1,63 2,26 14 4,8
36268 Test 25.09.2013 After Homo Silo #2 10:20 h 12,68 3,60 2,22 41,40 1,79 0,10 0,55 0,28 100,49 2,18 1,62 2,24 15 6
48 48 48 48 48 48 48 48 48 48 48 48
Mean: 12,51 3,57 2,20 41,47 1,81 0,10 0,56 0,28 102,02 2,17 1,62 2,27
Min: 12,33 3,54 2,17 41,08 1,78 0,09 0,54 0,27 97,21 2,14 1,56 2,18
Max: 13,07 3,60 2,28 41,60 1,83 0,12 0,57 0,30 103,31 2,25 1,65 2,30
S.dev: 0,13 0,01 0,02 0,09 0,02 0,01 0,01 0,01 0,99 0,02 0,02 0,02
R.Dev: 1,03 0,37 1,09 0,21 1,01 6,00 1,05 3,44 0,97 0,91 1,09 0,86
Sum:

Non Passing %
36692 Test 24.09.2013 After storage Silo #2 19.00 h 12,42 3,60 2,17 41,45 1,87 0,09 0,55 0,29 102,49 2,15 1,65 2,28 14,50 5
36972 Test 25.09.2013 After storage Silo #2 5:00 h 12,29 3,58 2,17 41,50 1,87 0,09 0,55 0,29 103,63 2,14 1,65 2,30
36971 Test 25.09.2013 After storage Silo #2 7:00 h 12,05 3,53 2,04 41,73 1,89 0,09 0,54 0,31 106,34 2,16 1,73 2,37 7 1,3
24 24 24 24 24 24 24 24 24 24 24 24
Mean: 12,29 3,57 2,14 41,60 1,87 0,09 0,55 0,30 103,96 2,15 1,67 2,31
Min: 12,05 3,53 2,04 41,36 1,84 0,09 0,54 0,29 102,16 2,14 1,60 2,27
Max: 12,46 3,61 2,21 41,79 1,90 0,09 0,56 0,31 106,34 2,17 1,73 2,37
S.dev: 0,09 0,02 0,04 0,11 0,01 0,00 0,01 0,01 1,02 0,01 0,03 0,02
R.Dev: 0,77 0,58 1,80 0,27 0,75 2,25 1,00 2,38 0,98 0,34 1,58 1,02
Sum:

150 18 255 2013 Anlagenoptimierung Homogenisierung

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ThyssenKrupp Industrial Solutions

INVESTIGATION OF HOMOGENIZATION SILO

Untersuchungszeitraum: 18.09.2013 – 28.09.2013

Bearbeiter: Rüdiger Beyer TKRT, Abt. 150

Verteiler: EB-SD, 010, 011, 150, 300, 600/630, 770, Customer

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3 GENERAL PROCESS DESCRIPTION 5

3.1 Homo Silo ................................................................................. 7

3.2 Storage Silo .............................................................................. 8

5 AUDIT (SERVICE PACK 1) 11

5.1 Audit Procedure ...................................................................... 11

5.2 Results for Silo 1 ..................................................................... 11

5.3 Results for Silo 2 ..................................................................... 14

5.4 Filter Dust Handling ................................................................ 17

6 RECOMMENDATIONS (SERVICE PACK 2) 18

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Capacity homogenization Silo 1 [t] : 1.500

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3 General Process Description

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Fig. 1 Scheme of the Raw Meal Silo

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3.1 Homo Silo

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3.2 Storage Silo

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Fig. 8 Blower for Raw Meal transport to silo

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5 Audit (Service Pack 1)

The following sampling procedure was followed:

5.2 Results for Silo 1

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Fig. 16 LSF results of laboratory analyzes of Silo 1

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Fig. 17 Residue results of laboratory analyzes of Silo 1

Reasons for that segregation effects could be:

- insufficient homogenization air flow, due to an unusable compressor

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5.3 Results for Silo 2

Fig. 19 LSF results of laboratory analyzes of Silo 2

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Fig. 20 Residue results of laboratory analyzes of Silo 2

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5.4 Filter Dust Handling

During the investigation period the following Moduli were determined:

Fig. 21 esults of the separation factor calculation

The uncritical range is between 0.8 and 1.2.

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6 Recommendations (Service Pack 2)

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Daily Report: Test report From: 01-Oct-13 07:00:30

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Daily Report: Test report From: 01-Oct-13 07:00:30

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