Closed joint-stock company “Ural-Omega”
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Grinding Complexes KI

Complexes for fine and ultra-fine dry grinding of various materials (including highly abrasive ones) based on the centrifugal impact grinding principle with the productivity of up to 15 t/h.

General description

KI grinding complexes are the optimally assembled system of modular units that are easy to operate and service, require little space, and are notable for high performance and low power consumption.

Task of KI grinding complexes is fine and ultra-fine dry grinding, as well as disintegration of ore and non-ore materials of different density, solidity, and abrasive capacity.

Offered grinding stations make it possible to produce up to 15 t/h of several narrow fractions of the finished product within the required fineness range (-0.02 … -0.5 mm).

KI grinding complexes are successfully used in cement and micropowder production, etc. More than 50% of the total micro calcite amount is produced by KI grinding complexes manufactured by Ural-Omega Company.

KI grinding complex operation is based on the centrifugal impact dry grinding principle and dynamic classification of the raw product particles. Materials produced with the help of centrifugal impact grinding are characterized by the qualitative characteristics unreachable with the use of other grinding methods. Undeniable advantages of this method include: high specific surface and physicochemical activity of the particles, preset narrow grading.

Specific power consumption reduction and absence of overground classes is provided due to the iterative (uninterrupted) operation cycle of the KI complex: “grinding – separation – continuous discharge of the finished product from the grinding process”. In comparison with other grinding methods this one helps to reduce electric energy consumption by 12 to 56%!

High equipment use factor, absence of grinding bodies, ground product grading consistency, high reliability, low maintenance time, and long servicing intervals are the most important advantages of KI grinding complexes’ use.

KI grinding complexes comprise our Company’s unique patented solutions: design of accelerators and hammering elements, high accuracy of units and parts manufacturing, gasostatic support. Together with the many years’ experience of the Company these factors formed the basis of high technical characteristics of Ural-Omega equipment along with the low cost of its operation.

Fields of application

KI grinding complexes are applied for fine and ultra-fine dry grinding of materials, which require attention to their quality, homogeneity, and degree of fineness.

KI complex supports simultaneous production of several powder classes.
KI complex may produce:

  • preset grinding class product (monoproduct), D98: -500 .. - 40 μm.
  • monoproduct and aspiration unit product D98: 7 μm (Q=5-7%).
  • monoproduct, aspiration unit product, and additional preset class classification unit product (D98: -100 .. -20 μm).

KI complexes allow establishing efficient component mixing grinding. At that time, KI complex offers homogeneous preset grading of the final mix even when grinding the components with different characteristics: density, grindability, different initial feeding fineness.

Complex can be optionally equipped with automated feeding systems for liquid and solid surface-active agents or chemical additives. It helps to produce a whole range of products with the help of one and the same station, which requires using additional post-grinding processing technology in the classical configuration of the system.

Currently KI complexes are widely applied in different branches of industry connected with the production of high quality fine powders: dry building mixes components, weighting agents, refractory and abrasive masses, pharmaceutical and chemical agents.

Reference: As of the end of 2011, 50% of the Russian micro calcite market is produced at KI grinding complexes manufactured by Ural-Omega CJSC.

 

Today KI grinding complexes are successfully used in production and reprocessing of the following materials:

  • Gypsum
  • Graphite
  • Bentonite clays
  • Talc
  • Marble
  • Limestone
  • Calcite
  • Wollastanite
  • Dolomite
  • Mica
  • Brucite
  • Ammonium polyphosphate
  • Barite
  • Glass
  • Burnt kaolin
  • Schungite
  • Periclase
  • Clinker
  • Cement
  • Smelter slags
  • Fused corundum

Advantages

Product quality:

  • Consistency of grinding characteristics: product quality does not depend on the condition and degree of wear of the wear parts and equipment.
  • Narrow preset grading within the whole possible grinding coarseness range (from -0.01 to -0.5 mm).
  • Possibility of simultaneous production of several finished product fractions.
  • Minimum metal carry-over into the finished product.
  • Isometrical shape product output with the increased particle activity.

 

Economical efficiency:

  • No grinding bodies.
  • Low metal consumption.
  • Low power consumption. Reduction of energy expenditures for material grinding accounts for 12-56% in comparison with other methods.

 


Automation:автоматизация

  • Basic configuration of the KI complex includes a modern ACS on the basis of SCADA with the interactive control panel equipped with the system of operation analysis, logging, and statistics gathering, and the system of “for the parameter” operation, which takes account of variants and required parameters of the finished product.

 

Operational efficiency:

  • оперативность
  • Production with the use factor of > 0.9.
  • Low maintenance time, fast wear parts replacement. Execution of the complete list of maintenance works takes 4 man hours only.
  • Adjustment of the grinding fineness and product particle size distribution in the course of operation without any stops.

Infrastructure:

  • инфраструктура
  • Ease of servicing and accessibility.
  • Low spatial requirements.
  • Does not require an oil-pumping station or any addition infrastructure development.
  • Does not require any additional aspiration systems.
  • Integration into the operable processing lines.
  • Flexible siting of the complex in accordance with the individual premises infrastructure.

Operating principle

KI grinding complexes are the modular unit system. 

  • Iterative (ongoing) operating process of the grinding and separating complex helps to reduce the specific power consumption and avoid overground classes production due to the continuous discharge of the finished product from the grinding process.
  • Smooth material discharge speed adjustment and stepless adjustment of the cut points and classification finished material take off enables to produce narrow strictly set fraction of the finished product.
  • Feedback: main production equipment of the complex is mounted with the “for the parameter operation” feedback system, which provides the immediate ACS (automated) response for changes in the initial parameters of the material.
  • The whole processing chain of the complex operates in the rarefaction mode and does not produce dusting. Air consumption is optimized due to the reversal cyclic circuit of the air flow use. Air discharge and exhaust volume accounts for no more than 30% of the total air consumption necessary for traffic streams implementation and complex units operation.

 

KI grinding complex flow chart

The flow chart shows the variant of production of powders with different grinding fineness. This flow chart is not an exhaustive one. KI grinding complex may produce monoproduct as well. To complete each particular task, find out the optimal scheme and equipment configuration, ask our Company’s experts.

1- bin feeder; 2- centrifugal mill MC; 3- air classifier KC; 4- multicyclone arrangement CN; 5- filter; 6-transport fan; 7- aspiration fan; 8- ACS

 

Mill MC

Centrifugal impact mill MC can be used independently from other elements of the complex as a separate unit in processing lines. To decide upon the reasonability of this solution application, consult our manager.

Operating principle:

High pressure fan produces air pressure in order to create a “gas bearing” (air gap) between the rotor and the stator. Using the cardan drive, engine actuates the mill accelerator.

Raw grinding product is moved to the separating cone via the feed hopper, where it is distributed among the accelerator channels.

Having reached the required circumferential speed, the material is taken into the grinding chamber, where it is ground due to collision with the lining surfaces and particle intercollision.

Inside the grinding chamber the initial material air flow classification takes place: underground particles are separated to be returned into the mill. Ground product is carried by the air flow into the integrated mill air classifier, where fine separation of the material occurs: separated underground particles are returned into the grinding chamber. Particles corresponding to the preset fineness range are moved to the grinding complex flow chart for fractionation and final product deposition in the form of a dust air mixture formed in the process of grinding.

Additional classification unit

Additional classification unit is used to produce fine products with the fineness of less than 0.063 (0.04) mm. Depending on the operation modes and model, MC centrifugal mills offer 100% product yield with the fineness of less than 0.1, 0.063, 0.04 mm.

Grinding products of the MC mill are moved to the additional classification unit. This unit carries out separation of particles of the ground product according to the preset fineness cut point (10-50 μm). Large product (e.g. -0.063+0.02) is discharged and may be directed to regrinding. Product with the size of less than the preset cut point is directed to the multicyclone arrangement for deposition and discharge.

Depending on the base cut point and type and properties of the product, different types of classifying units may be used, which help to ensure high purity and efficiency of the particle segregation.


Product deposition mylticyclone arrangement

Multicyclone arrangements are used for deposition and discharge of the ground product. Grinding complexes are equipped with high performance cyclones, which help to separate up to 98% of the product from the dust air mixture. Next, purified air is directed to the complex filtration unit.

Filtration unit

Filtration unit of the complex is used to purify the used air before its discharge. Technological air discharge accounts for no more than 25-30% of the whole used air volume. In some cases the filter may be used as an additional unit for deposition / production of products with the fineness of less than 5 (10) μm. Filtration unit of the complex consists of bag-type purification filters with the automated accumulated product discharge and is a maintenance-free self-cleaning system.

 

Grinding characteristics

Grinding fineness range of KI grinding complexes for D98 class is [-500; -20] microns.

Fractional composition of the finished products is characterized by a high content of preset fineness particles with minor inclusions of plus and minus fractions.

This class distribution characteristic corresponds to any grinding fineness and is the basis of the high quality product.


Grinding comparative characteristics

The charts show the full grinding products composition with no class separation in the grinding complex process flow.

 Характеристика измельчения: шаровая мельница и МЦ

Grain shape

Powders of different grind methods are differ not only in grain composition, but also in particle shape. Microscopic examination reveals that centrifugal impact grinding particles has high defectiveness - sharp edges are observed similarly to that of jet grinding particles. Particles are more homogeneous in shape, which prevents formation of aggregates.

Particles with the size of 1-2 μm are located on the surface of ball grinding particles with the size of 30-80 μm. High aggregate content is observed. Differences in the shape of particles and aggregate content for powders of different grinding methods are explained by different comminuting actions caused by mills of different types. Material particles in a centrifugal impact mill are ground almost solely by free impact action, and in a tube mill constrained impact and abrasion are prevalent.


 

KI grinding complex (cement grains) Ball mill (cement grains)

 

Carry-over of metal into the finished product

KI grinding complexes provide the low yield of metal in the finished product. When milling one of the most abrasive and strong materials – white fused alumina – up to the fraction of 0-0.063 mm, the equipment-specific yield of iron in general for the whole grinding complex accounts for no more than 0.12%.

 

Fractional composition

Fractional composition of the finished products is characterized by a high content of preset fineness particles with minor inclusions of plus and minus fractions. This class distribution characteristic corresponds to any grinding fineness and is the basis of the high quality product.

Ground product possible fineness range

Диапазон крупности помола мельниц МЦ

Fractional composition of the grinding complex KI-0.63

(marble) without the recurrent scheme (products of the “classifier” are returned for regrinding).

Using the recurrent scheme it is possible to produce 100% of the product with the grinding fineness of less than 10 microns, however under a significant loss of performance.

Specifications

Currently there are more than 45 KI grinding complexes operating on the territory of the Russian Federation, Kazakhstan, Ukraine, Belarus, and other CIS countries, which are allocated to different tasks.

 

 

KI grinding complexes

1. Model 2. Productivity, t/h 3. Feeding fineness, mm 4. Ground product fineness, mm * 5. Installed capacity, kW 6. Dimensions, mm 7. Weight, t
L B H
KI-0.4

 

0.1-0.3

5

0.005-0.1

23

5700

2300

4000

2.5

KI-0.63

 

0.5-3

up to 10

0.005-0.1

155

10300

5400

8700

16.5

KI-1.0

 

1-5

up to 20

0.005-0.1

209

14300

6100

8500

24.7

KI-1.25

 

5-10

up to 30

0.005-0.1

315

15200

9150

9250

35

KI-1.6

 

8-15

up to 40

0.005-0.1

375

15100

9150

9250

38

 

Note:

(2) – Productivity depends on the material characteristics and the required grinding fineness;

(3) – Maximum feeding fineness is indicated. In most cases it is reasonable to reduce the feeding fineness up to 5-10 mm (affects complex's productivity and power consumption).

(4) – Interval of the upper cut point of the final product fineness (screen throughs - 98.5%).

(5) - Installed capacity index. Power consumption accounts for 60-80% of it and depends on the equipment operating modes.

(6),(7) – Weight and dimensions of the complex are given for reference only, the actual values may vary depending on the optional features and design variant or modification.


 

Configurations and options

KI grinding complex

Standard configuration

  • MC mill
  • bins and lock feeders of the complex
  • frame structures, ladders, servicing platforms
  • control panel and control box
  • security and control automation system
  • mill actuator smooth-start system
  • air flow control system
  • transport fan, air ducts
  • multicyclone arrangement for finished products deposition
  • aspiration system fan
  • aspiration system filter
  • SPTA, additional kit of wear parts
  • additional accelerator

 

Standard configuration depending on the modification and process task assignment

  • receiving bin with feeder
  • additional classification unit, KC classificatory assembly (incl. bin and shutter)
  • frame structures

 

Optional equipment

  • additional process monitoring system
  • interactive ACS
  • air compressor
  • material packaging electronic weighing unit
  • operator room (with control panel and control box)
  • frequency converter of the transport fan
  • frequency converter of the main mill actuator
  • frequency converter of the classification unit
  • raw material feed elevator

Special configuration / engineering

  • fire- and explosion proof construction of the complex and its components
  • individual unit arrangement
  • siting at the operating processing line 
Implemented projects
More than 267 mplemented projects for more than 200 clients
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