Product Brochure Belt Weighfeeder Pfister BWF + Apron Weighfeeder Pfister AWF

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1 Product Brochure Belt Weighfeeder Pfister BWF + Apron Weighfeeder Pfister AWF The robust systems you can rely on Watch here how belt weighfeeder Pfister BWF works!

2 3 Dosing and feeding for industrial production Pfister feeding and dosing devices exemplary in the cement production process: Raw Mill Feeding Pfister TRW Pfister BWF Pfister AWF Coal Mill Feeding Pfister TRW-K Pulverised Fuel Feeding Pfister DRW Cement Blending Pfister FRW/Pfister URW Finish Mill Feeding Pfister URW Pfister BWF Pfister AWF Pfister TRW Bulk Material Pre-Loading Pfister VRW Kiln Feeding Pfister FRW Alternative Fuels Feeding Pfister TRW-S/D

3 4 Tradition & progress FLSmidth Pfister has almost 120 years of experience in manufacturing of industrial weighing equipment. It has been member stock quoted FLSmidth Group/Denmark since The patented rotor weighfeeder was invented by Pfister in 1984 to feed pulverised fuels for the cement burning process. This state-of-the-art dosing device has proved its properties in more than 2,500 installations worldwide. FLSmidth Pfister additionally supplies know-how for equipment, related to the coal feeding process in order to ensure problem-free material handling and optimal pneumatic transport of the coal. Pfister weighfeeders are - engineered - designed - assembled - tested with the experience of almost 120 years. Fuels have a wide variety of material characteristics. Thus, FLSmidth Pfister helps to design individual installation solutions. German Ludwig Pfister founded the company in 1894 Above: Historic scale

4 5 Functioning principle of belt weighfeeders Pfister BWF The picture below displays a belt weighfeeder Pfister BWF: Material is extracted out of the material silo and fed into the infeed hoppers. The conveyor belt transports the material over the weighing bridge where a controller regulates the speed of the belt inverse to the momentary load. From there the material is discharged into the further processes, for example cement mill feeding. rate and the measured bulk material mass to calculate the speed of the belt. Less material on the belt results in a higher speed, more material in a lower speed. With this pro-active principle, the prospective control ProsCon, belt weighfeeders Pfister BWF achieve highly stable short- and longterm accuracy. Belt weighfeeders Pfister BWF are controlled by controller Pfister idd. The control is mounted at the frame of belt weighfeeder Pfister BWF which makes an electrical control cabinet obsolete. Alternatively a cabinet solution with gravimetric dosing controller Pfister GDC is available. Prospective Control ProsCon : Advanced Weighing Electronics The electronic controller calculates the required speed of the motor for the time of the discharge. It uses the set feed

5 6 Customer benefits of belt weighfeeders Pfister BWF High flexibility - Modular design with a large variety in lengths and widths can be adapted optionally - Different types of inlet chutes guarantee excellent silo extraction for a variety of material properties - Feed rate adjustment (t/h) in a range of up to a turn down ratio - 1:10 High accuracy - Advanced belt tensioning by tension roller which supports highest feeding accuracy - Digital tachometer (incremental encoder). This results in accurate values for the controller to calculate the needed speed of the motor - Impressive feed rate accuracy Easy maintenance - Lifetime lubricated idler - Easy calibration and adjustment of zero point High reliability - Belt and pulley strippers ensure no dirt is sticking to the rollers or to any side of the belt - Spherical v-grooved machined pulleys for optimal belt guidance Dimensions of belt weighfeeder Pfister BWF (with exemplary V-infeed hopper): BB: belt width, AA: pulley center distance, EA: inlet to outlet distance, W: infeed hopper width, L: infeed hopper length EA L W optional hammer g ate AA BB

6 7 Structure of the dosing system: Gravimetric Dosing Controller Pfister GDC Pfister gravimetric dosing controller was especially developed to guarantee high dosing precision for gravimetric belt feeder Pfister BWF and Apron weighfeeder Pfister AWF The microprocessor-controlled Pfister gravimetric dosing controller works with a 16 bit processor and offers the following main features: variable frequency drive integrated multiple microprocessors, which allow true parallel processing Memory on EEPROM basis and a battery backup RAM with inbuilt real time clock (RTC) 16 digital inputs and 16 digital outputs as well as 3 analog inputs and 3 analog outputs Support of Modbus and Profibus protocols configurable functionality of inputs & outputs field-programmable logic controller can quickly implement features required on the field 7 touchscreen colour display HMI optional field interface module through CAN communication network for reduced cable cost Mill feeding control Pfister MUR

7 8 Belt weighfeeder Pfister BWF Highly accurate and reliable feeding For all kinds of continuously operated processes Belt weighfeeder Pfister BWF is especially suited for dosing nearly all kind of bulk materials. It proves its reliability and performance day by day. The modular design with its large variety in lengths and widths allows an adaption to nearly all applications. High Reliability: - Belt guiding devices make sure the belt runs in the middle of the rollers and idlers - Belt and pulley strippers make sure no dirt sticks to the rollers or to the belt - Spherical machined pulleys for optimal belt guidance - Compact controller with prospective control ProsCon mounted in a cabinet at the feeder s frame or as an onsite solution High Accuracy: - Advanced belt tensioning device guarantees stable tension of conveying belt - Digital tachometer measures the variable speed drive with a digital tachometer (incremental encoder). This results in accurate values for the controller to calculate the necessary motor speed - Monitoring of belt drift / belt slip by a proximity switch. This information is also used for calculation of the needed motor speed. - Very high feed rate accuracy

8 9 Technical facts of belt weighfeeder Pfister BWF Application fields: Material: Feeding capacity: Design example: Features: Dosing control: All continuously operated processes Bulk materials such as limestone, iron ore, clinker, sand, gypsum, raw coal, clay etc. from a few 100 kg/h up to 1,500 t/h (higher capacities on request) - Various infeed hoppers with shut-off devices - Belt weighfeeder Pfister BWF - Discharge hood - Spillage conveyor (optional) - Temperature resistant belts (optional) - Cold climate package (optional) - Stable material dosing - Outstanding reliability - High short- and longterm accuracy - Compact, robust machinery - Large variety in lengths and widths - Large feeding range - Easy to maintain - Gravimetric dosing controller Pfister GDC - Prospective control ProsCon - User oriented interfaces Certificates: ISO 9001

9 10 Raw mill feeding at a cement plant At this cement plant old belt weighfeeders (see picture to the right) were replaced by state-ofthe-art belt weighfeeders Pfister BWF to feed lime stone at a rate of 40 t/h (see picture below).

10 11 Cement mill feeding At this cement plant belt weighfeeders Pfister BWF handle the complete cement mill feeding with - clinker at a feed rate of 80 t/h - gypsum at a feed rate of 15 t/h and - additives at a feed rate of 5 t/h Old belt weighfeeders from the 1970ies (see picture on the right above) were replaced by three modern belt weighfeeders Pfister BWF.

11 12 Iron ore and coal feeding at a sinter plant After extraction from the vibrating hopper iron ore or coal is dosed by belt weighfeeders Pfister BWF onto a collecting belt to feed a sinter plant at a feed rate of 180 t/h. Coal feeding at a coke plant At these two coke plants coal is fed onto a collecting belt by belt weighfeeders Pfister BWF at a feed rate of 180 t/h (picture on the left) and at 350 t/h (picture on the right).

12 13 Application in minerals dosing These belt weighfeeders Pfister BWF were designed and assembled for application in a minerals plant. Dosed materials are petcoke, limestone and phosphate cake with feed rates up to 850 t/h.

13 14 Raw mill feeding At this cement plant belt weighfeeders Pfister BWF feed limestone into the raw mill at a feed rate of 120 t/h. An extra long infeed hopper and a belt length of 16 meters (see picture to the right) were realized. note: extra long belt with 16 meters! Belt weighfeeder Pfister BWF for iron ore with a vibrating chute

14 15 Assembly workshop for belt weighfeeders Pfister BWF in India Based on the more than a century long experience of the German engineers at the FLSmidth Pfister headquarters in Germany, gravimetric belt feeders Pfister GBF are engineered, designed and assembled at the brand new FLSmidth production facilities in Bawal/India. FLSmidth production facilities in Bawal/India

15 Assembly Workshop for belt weighfeeders Pfister BWF in India 16

16 17 Gravimetric belt feeder Pfister GBF: Highly accurate and reliable coal feeding in the Power Industry For dosing crushed coal to pulverizers in firing processes Gravimetric belt weighfeeder Pfister GBF is especially designed for feeding crushed coal to pulverizers in the boiler firing process in the power industry. Gravimetric belt weighfeeder Pfister GBF mainly replaces old volumetric feeders to improve a constant material feeding into the firing process. Due to its precise gravimetric dosing the coal fired boilers can be operated more stable, less access air is required and the efficiency of the boilers increased.

17 18 Functioning principle of gravimetric belt feeder Pfister GBF The picture below displays a gravimetric belt feeder Pfister GBF and its weighing and dosing principle: Crushed coal is extracted out of the material silo and fed into the infeed hoppers. The gravimetric belt feeder Pfister GBF consists of a conveyor belt with integrally moulded side skirting which is equipped with moulded V guide at the bottom of the carrying side ensuring no swaying of the belt, thus maintaining accuracy. A belt scraper scrapes coal off the top surface of the conveyor belt. Its blade is kept pressed against the surface of the belt by a counterweight. The weighing zone of gravimetric belt feeder Pfister GBF is defined by two rollers precisely located at a fixed distance. The weighing roller is at the center of these two rollers and suspended directly through load cells on both sides. The load on the weighing zone is measured by dual load cells which are barometrically insensitive and environmentally sealed. These load cells yield a very high linearity. The signal from the load cell is fed to a microprocessor-based gravimetric dosing controller Pfister GDC. Thus, the speed of the belt is controlled inverse to the momentary load. From there the crushed coal is discharged into the further processes. Gravimetric belt feeder Pfister GBF is auto calibrated by integrated calibration sensors. In case of load cell disrepancy an automatic change over switches to a volumetric weighing mode automatically. In the volumetric mode, the feeder runs based on historic density. It reverts automatically to gravimetric mode if load cell data show no more discrepany. Technical drawing of a gravimetric belt feeder Pfister GBF:

18 19 Technical facts of gravimetric belt feeder Pfister GBF Application fields: Material: Feeding capacity: Design example: Features: Dosing control: Feeding to pulverizers and mills Crushed coal, bituminous coal up to 150 t/h - Inlet collar - Head and tail pulley - Flat type idlers with mounting brackets - Discharge hoppers with shut-off devices - Gravimetric belt feeder Pfister GBF - Belt and scrapers - Drive unit with shaft mounted gearbox - Cleanout conveyor - Stable material dosing - Outstanding reliability - High short- and longterm accuracy - Compact, robust machinery - Custom-made lengths and widths - Large feeding range - Easy to maintain through 4 inspection doors - Pressure-proof design up to 3.5 bar as per NFPA 85 - Gravimetric dosing controller Pfister GDC - VFD drive - User oriented interfaces Certificates: ISO 9001

19 20 Applications with Pfister GBF: Oversize solutions Gravimetric belt feeders Pfister GBF can be built for extra sizes according to the customer s needs. The drawing below shows a solution for an oversize silo inlet with 3,500 x 1,000 mm in size and 8,525 mm in length.

20 21 Apron weighfeeder Pfister AWF and apron feeder Pfister AF Hghly accurate and reliable for continuous dosing of heavy bulk material The apron weighfeeder Pfister AWF is designed with a heavy, durable belt made of steel plates. With this heavy-duty design it helps to control the volume and weight of materials that are added to a process, and regulates the rate at which these materials are added. Apron weighfeeder Pfister AWF measures large, bulky materials like minerals or coal. To withstand the heavy weight of these types of materials, the belt portion of the apron feeder is made from thick steel trays. Chains along either end of the feeder help move the trays along the conveyor area. The apron feeder Pfister AF shows the same design and properties, but is used as a discharge feeder without a dosing function.

21 22 Technical facts of Apron weighfeeder Pfister AWF and Apron feeder Pfister AF Application fields: Material: Feeding capacity: Design example: Features: Dosing control: Feeding bulk materials Clay, raw mix, limestone, minerals, raw coal etc. up to 1,500 t/h (higher capacities on request) - Inlet hopper - Head and tail pulley - Flat type idlers with mounting brackets - Discharge hoppers with shut-off devices - Drive unit with shaft mounted gearbox - Cleanout conveyor - Stable material feeding - Outstanding reliability - High weighing accuracy (referring to apron weighfeeder Pfister AWF) - Compact, robust machinery - Custom-made lengths and widths - Large feeding range - Easy to maintain - Gravimetric dosing controller Pfister GDC - VFD drive - User oriented interfaces Certificates: ISO 9001

22 23 Applications with Apron weighfeeder Pfister AWF and Apron feeder Pfister AF: Mill feeding at a raw mill The picture on the right displays Apron weighfeeders Pfister AWF installed for mill feeding of clay and raw mix. The picture below shows Apron feeders Pfister AF utilised in a minerals process.

23 24 German design & assembly of Pfister rotor and belt weighfeeders FLSmidth Pfister weighfeeders are engineered, designed and assembled at FLSmidth Pfister s headquarters in Augsburg/Germany and at their workshop in India. An experienced team of engineers and technicians tests all equipment at their own test systems. In addition, Pfister spares and parts are kept in stock for immediate disposal. FLSmidth Pfister assembles all weighfeeders in Augsburg/Germany and in India

24 25 Pfister customer service & after sales support Thousands of FLSmidth Pfister systems are currently in operation worldwide and require global presence. Therefore FLSmidth Pfister operates sales and service offices in eight countries on four different continents. Experienced service technicians stand by your side and provide first-class service. A 24-hour hotline and online troubleshoo-ting provide worldwide support. Also available are telesupport packages. FLSmidth Pfister not only keeps a large number of spare parts in stock. Skilled spares specialists are looking forward to assist you in optimizing your own spare parts management. FLSmidth Pfister services are rounded up by service contracts, which can be adapted individually to the customer s needs. Customer training on-site or at FLSmidth Pfister training center ensures the best possible knowledge transfer. Pfister After Sales Support: - 24-hour Hotline - Telesupport - Modern Maintenance Management - Trainings and Seminars - Service Contracts Augsburg - Germany

25 Headquarters: FLSmidth Pfister GmbH Staetzlinger Str Augsburg, Germany T F Sales Department: sales@flsmidthpfister.com Technology Department: engineering@flsmidthpfister.com Service Department: service@flsmidthpfister.com Branch offices: FLSmidth USA, Inc. FLSmidth Pfister GmbH Pfister Operations 6, Rue de Bretagne 3235 Schoenersville Rd., Bethlehem, PA 18017, USA St. Quentin Fallavier, France p f p f pfister.usa@flsmidthpfister.com pnl@flsmidthpfister.com FLSmidth Pfister Ltda. FLSmidth Private Ltd. Rua José Dolles, Jardim Clarice II i-think Techno Campus, A-Wing, 6th Floor, Office No. 2 CEP Votorantim, S.P. Brazil Pokhran Road II, Thane West , India p f p f uwe.richter@flsmidthpfister.com twsales-in@flsmidthpfister.com FLSmidth Pfister GmbH Malaysian Branch FLSmidth Pfister China C-3A15, Centre Wing, Metropolitan Office Suite No. 8, Taisu Road, Metropolitan Square, Jalan PJU 8/1 Beiguan Industrial Park, Damansara Perdana, Petaling Jaya Jiaozhou City, Qingdao , P.R. China Selangor, Malaysia p f p f hour-hotline: sales@flsmidthpfister.com info-china@flsmidthpfister.com Copyright 2014 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth, Pfister, ProsCon and all other product names used herein are (registered) trademarks of FLSmidth A/S. This brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for general reference only and may change at any time. IB g-GB FLS-No. CM ENG