IM 23 PRAGUE 13-15 June 2016 Hosokawa Alpine Aktiengesellschaft, Augsburg, Germany Minerals & Metals Division Mr. Dietmar Alber 1
Topic & Discussion Processing developments: What are the innovations in mineral processing? What are the developments in producing finer products into the market? What part do quality and consistency play in technological advancements and market desires? What technological innovations are helping to increase efficiency and cut costs in processing? 2
HOSOKAWA MICRON Group > Formation of the Hosokawa Micron Corp., Osaka: 1916 > Shares are traded at the stock markets of Osaka und Tokyo > Production locations worldwide in 5 countries > 16 R&D and test centres worldwide at 11 locations > ca. 355 Mio. EUR consolidated turnover (Financial Year 2014/2015) > ca. 1500 employees worldwide HOSOKAWA MICRON Corporation, Osaka, Japan 3
HOSOKAWA ALPINE Augsburg, Germany > Formation of the Hosokawa Alpine, Augsburg: 1898 > Since 1987 part of Hosokawa Micron Group > Huge production facilities > Huge R&D and test centres with 65 pilot systems > ca. 152 Mio. EUR consolidated turnover (Financial Year 2014/2015) > ca. 650 employees in Augsburg, Germany HOSOKAWA Alpine, Augsburg, Germany 4
General Trends in the Industrial Mineral Filler Industry Strong trend towards finer products even into submicron range Dry processing of these fine powder down into the submicron rage Increase processing efficiency Reduce specific energy consumption contamination free processing for High End applications Apply wet processing for ultrafine products & products in submicron range Master tailored particle size distributions & shaping of particles Trend to much bigger sized production capacities Optimized investment and running cost 5
Definition Industrial Mineral Filler Industrial minerals are geological materials which are mined for their commercial value, which are not fuel, not sources of metals. They are used in their natural state or after benefication. Industrial Mineral Fillers are a variety of processed industrial minerals that may be irregular, fibrous or platy in shape and which are typically used in large volume in paper, plastic, paint and rubber industries. 6
High-Tech Mineral Powders For High-Tech Products 7
Typical Industrial Mineral Fillers > Calcium Carbonate > Talcum > Barite > Kaolin > Wollastonite > Bentonite > Diatomite > Aluminium oxide > Silica & Quarz > Zirconsilicates 8
Typical Industrial Mineral Fillers > Calcium Carbonate => > Talcum > Barite > Kaolin > Wollastonite > Bentonite > Diatomite Common Sizes of Industrial Mineral Fillers standard products: D97 = 20 160 µm ultrafine products: D97 = 5 20 µm superfine products: D97 < 5 µm => Dry Processed GCC at D97 < 2 10 µm 9
Energy Efficient Dry Processing of Ultrafine GCC fillers below D97 = 10 µm 10
History of Powder Processing classification anno 950 A.C. grinding 1500 B.C. 11
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VS ALPINE Super Orion Ball Mill SO-SF ALPINE Agitated Ball Mill ATR both working in closed circuit with High Efficient Ultrafine Classifiers and able to process ultrafine and superfine GCC fillers 13
Working Principals, Limits and Energy Considerations ALPINE Super Orion Ball Mill SO-SF ALPINE Agitated Ball Mill ATR 14
ALPINE Superfine Ball Mill Systems GCC dry grinding down to D97 = 3.2 µm on Superfine Ball Mill Systems 15
Processing Parameters of Dry running ball mills ball mill revolution (r.p.m.) L/D ratio of the ball mill drum selections of grinding media sizing of the grinding media number of grinding chambers selection of mill lining mill discharge system ball mill filling level 16
Screen-Shot 1000 TTD with SO-SF 270/660 Superfine Ball Mill 1000 TTD SO-SF 270/660 17
Typical values of Superfine Ball Mill Systems SO-SF Ball mill: Classifier: SO-SF 270/660, 710 kw Drive 1000 TTD Products: D97 = 3,5 µm, (70 % < 2.0 µm) 1,800 kg/h D97 = 10 µm, (D50 = 2.3 µm) 7,300 kg/h Fineness of 80 % < 2.0 µm possible 18
Innovation ALPINE TTD Classifier double flooded fine material outlet coarse material classifier with secondary classifying air inlet, coarse material reject outlet highly air dispersed feed material, targeting directly to the classifier wheel One Classfier for all finenesses 3 45 µm 19 19
ALPINE Agitated Ball Mill ATR Systems GCC dry grinding down to D50 = 0.8 µm (D97 = 2,2 µm) 20
Agitated Ball Mill Systems up to D50 = 0.8 µm 21
Energy-efficient Grinding Typical technical data: Mill diameter: 900 mm Mill height: 4.5 m Drive unit: 400 kw Grinding bin volume: 2 m 3 l Grinding media: ceramic 22
Advantages of Agitated Ball Mill Systems Designated for products D97 = 2.2 10 µm High fineness High capacity Compact design Iron-free grinding Low peripheral speed Low grinding media wear Low operation costs Optimum energy utilisation 23
Sine Qua Non Condition High Tech Ultrafine Classifier up to D97 = 2.5 µm Reaching very high fineness Highest possible output Very sharp top cut Excellent fines yield Ability of air dispersing Lowest energy consumption Reliability in daily rough operation in mineral industry 24
Calcite Processing 100,0 Calcite Processing with ATR (Analysed with Rhodos laser) 90,0 80,0 70,0 ATR- Product 60,0 Pass in % 50,0 40,0 30,0 20,0 10,0 0,0 0,1 1,0 10,0 Fines in Microns 25
Comparison Specific Energy Consumption SO-SF versus ATR system including classification kwh/t 1000 900 800 700 600 500 400 300 200 100 0 1 2 3 4 5 6 7 8 SO+TTD kwh/t ATR+ATP/NG kwh/t D97 = x µm 26
Comparison Specific Energy Consumption SO-SF versus ATR system including classification D97 µm SO+TTD kwh/t ATR+ATP/NG kwh/t 2,2 720 2,5 615 3 950 550 3,7 750 425 5 385 260 8 192 187 10 147 155 20 97 120 Calculation example for D97 = 5,0 µm: SO-SF system additional 120 kwh/t x 7200 h/a = 864.000 kwh/a at one ton of product per hour => 0,12 ct/kw => 103.680 /t = 259.200 /a for 2,5 t/h production capacity of a 900 ATR system 27
Comparison Specific Energy Consumption SO-SF versus ATR system including classification D97 µm SO+TTD kwh/t ATR+ATP/NG kwh/t 2,2 720 2,5 615 3 950 550 3,7 750 425 5 385 260 8 192 187 10 147 155 20 97 120 Calculation example for D97 = 3,0 µm: SO-SF system additional 400 kwh/t x 7200 h/a => 2.880.000 kwh/a at one ton of product per hour => 0,12 ct/kw => 345.600 /t = => 414.720 /a for 1,2 t/h production capacity of a 900 ATR system 28
ALPINE Pulvis PV Dry Agitated Classifier Mill for ultrafine and submicron powders 29 von 26
Working Range for PULVIS crushers impact crushers impact miulls Table roller mills classifier mills dry ball mills dry jet mills dry agitated classifier mills Pulvis wet pan mills wet ball mills agitated wet mills 1000 1 m 100 mm 10 10mm 1 1mm 100 0,1µm 10,01 µm 0,001 1 µm 100 0,0001 nm 0,00001 10 nm 10,000001 nm Particel size 30 von 26
Innovation Pulvis Dry Agitated Classifier Mill for ultrafine and submicron powders Key Points of Pulvis > Highest achievable fineness in dry processing > Low specific grinding energy > Compact desing and plant > Low contamination > For soft and hard minerals > Highly wear protected > Alternativ for Jet Mills solutions Fines Air Feed Classifier Mill 31 von 26
PULVIS PV Models PV-150 PV-800 Size PV-150 PV-250 PV-450 PV-600 PV-800 PV-1000 Mill Drive [kw] 0.75 2.2 11 18.5 37 75 Classifier Drive [kw] 1 1 3.7 7.5 15 30 32 von 26
Applications of PULVIS Products: > Soft and Hard Minerals > Ceramics > Batterie Raw Materials > Metall Oxide > Pigments, Graphit 33 von 26
Energy Efficient Wet Processing of Ultrafine GCC fillers below D97 = 10 µm 34
Alpine Wet Agitated Ball Mill Line ANR-CL The heart of your process 35
ALPINE Agitated Vertical Ball Mill ANR-CL Model Volume Grinding Drive Chamber 250 ANR-CL 70 ltr 15 kw 500 ANR-CL 550 ltr 110 kw 630 ANR-CL 1100 ltr 200 kw 710 ANR-CL 1570 ltr 315 kw 800 ANR-CL 2400 ltr 500 kw 900 ANR-CL 3200 ltr 630 kw 1000 ANR-CL 4400 ltr 1000 kw 36
Wet Grinding with the ANR-CL Typical production capacities for 710 ANR-CL (315 kw drive): - C60: 5,5 t/h @ 45 kwh/t* (grinding energy) - C75: 3,1 t/h @ 80 kwh/t* (grinding energy) - C90: 2,0 t/h @ 120 kwh/t* (grinding energy) - C95: 1,6 t/h @ 150 kwh/t* (grinding energy) - C98: 1,3 t/h @ 180 kwh/t* (grinding energy) * = medium hardness Typical solids contents: C60: 60 75 % C75 C98: max. 78 % 37
ANR-CL Advantages Advantages ANR-CL: steep particle size distribution 1-step grinding up to 90% < 2 µm 2-step grinding up to 99% < 2 µm 4 motor motor drive (water cooled at 1 gearbox low foot print less space 400 oder 690 V possible (no expensive high voltage!) start up by F/C variable stirrer speed for operation stirrer shaft direct connected to gear box no inlet screen no blockage classifier wheel on top keeps grinding beads back low cooling power quick and easy installation (plug and play) low maintenance cost 38
Dry Wet Coated - GCC Dry: AWM Wet: ANR-CL (s) Drying & Coating LGM 30mm D99 = 45 µm 60 to 98 % < 2 µm coated powder 39
Drying & Coating on Long Gap Mill; LGM Example LGM 20: Drying of 7,5 t/h GCC slurry C 90 Optional caoting simultan 40
Energy Efficient Wet Processing of Ultrafine Hard Minerals below D97 = 10 µm down to Nano Size 41
Wet grinding of Soft and Hard Minerals Alpine Hydromill 400 AHM 42
Circuit Grinding Process for Nano Size 43
From Laboratory Mill 90 AHM to 800 AHM (315 kw) Technical data 90 AHM: Grinding chamber volume : 90 AHM: 1.10 Liter 90/3 AHM: 0.50 Liter 90/1 AHM: 0.25 Liter Drive: 2.2 kw Max speed: 4200 rpm 44
PICO-Liq Agitated Wet Mill For processing of 1 gram of powder 45
100 Wet Milling of Nano-scaled Particles Analyzed by Dynamic Light Scattering 90 80 70 Q3 [%] 60 50 40 feed 5 kwh/kg 15 kwh/kg 25 kwh/kg 30 20 10 0 0,01 0,1 1 10 particle size [µm] 46
Wet Milling of Nano-scaled Particles Visualized by Transmission Electron Microscope 0 kwh/kg 15 kwh/kg 5 kwh/kg 25 kwh/kg 47
Left Topic Processing developments: What are the innovations in mineral processing? What are the developments in producing finer products into the market? What part do quality and consistency play in technological advancements and market desires? What technological innovations are helping to increase efficiency and cut costs in processing? 48
Quality and consistency: - Are a must and driver of technological advancements and is a market desire - Target quality of powders need top quality of processing equipment - Highest availability of processing equipment is a must and a precondition of mineral producers from their market/customers - Consistency includes quickest service, global service network and easy maintenance 49
Summarizing Trends in the Industrial Mineral Filler Industry Strong trend towards finer products even into submicron range Dry processing of these fine powder down into the submicron rage Increase processing efficiency Reduce specific energy consumption contamination free processing for High End applications Apply wet processing for ultrafine products & products in submicron range Master tailored particle size distributions & shaping of particles Trend to much bigger sized production capacities Optimized investment and running cost 50
Thank you very much for your attention!