CPB Brochure Diaphragms en 2

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Mill Diaphragms

Innovations from
Christian Pfeiffer:
giving you the lead.
Improving industrial grinding processes with pioneering innovations
has been Christian Pfeiffers mission since its foundation in 1925.
Our companys unique developments include
the adjustable diaphragm
separator technology for
cement grinding.
From the research and development stage to production and installation, as an industry pioneer
we have the advantage of decades
of experience. We draw on cuttingedge knowledge and new findings
gained through close cooperation
with customers, research institutes and universities.
To optimally supply our international customers, we operate production facilities around the world
including one in
China. Our plants
all adhere to the
same high quality standards for
which Germany is
renowned.

Innovation and R&D

Greater efficiency:
all in the diaphragm.
By reducing energy consumption
and increasing efficiency, the
diaphragm is crucial to the profitability of your system. It is the
diaphragm that regulates the
material filling level and the heat
exchange in the compartments.
The more intelligent the design,
the more economically efficient
the energy-intensive processes
within your mill.

Adjustable material flow


control system, fully opened
(left), fully closed (right)

Installing a Pfeiffer-Monobloc guarantees many years of high grinding


plant availability and continuous finish material quality.
Mill diaphragm

The Monobloc:
globally unique.
The sturdy Monobloc is making
industry history. With its extremely long service life, this diaphragm
has proven itself to be the most
sophisticated solution for modern
ball mills for many decades.
Its design is the only one of its
kind in the world and is unbeaten
in stability. Comprising a self-supporting U-ring for axial fixation
on the mill tube, it supports
the mill cylinder and
prevents deformations.
Another special
feature is the
floating fixation
of the intermediate diaphragms,
guaranteeing
stress-free fastening
to the mill shells.
No other mill diaphragm offers
such outstanding qualities as the
Monobloc often imitated, never
matched.

Monobloc

Christian Pfeiffer Monobloc

Stability and reliability of mill tube using


different intermediate diaphragm designs

Conventional diaphragm design

Christian Pfeiffer Monobloc

Slotted plates:
unrivalled dimensional
stability.

Conical slot shape and plate hardness

Cast plates

CPB rolled steel plates

Hexagonal bolt
Wear zone

Tear-off-bolt
Wear
plate

20 mm

Wear zone
8 mm

Diaphragm
structure

50 HRC

60 HRC

Fastening System
Cast plates

CPB rolled steel plates

Hexagonal bolt
Wear zone
20 mm

Tear-off bolt
Wear
plate

Diaphragm
structure

Wear zone
8 mm

Your plants profitability will also


increase with the specially developed diaphragm plates from Christian Pfeiffer. The optimised design
includes innovative plate slots with
a small conical enlargement, ensuring that the material is only forwarded once it has been ground to
a sufficient degree. Constant conditions for material transfer are thus
guaranteed throughout the service
life and the plates do not clog!
Slotted plates from Christian
Pfeiffer are made from specially
treated, breakage resistant rolled
steel which is tempered up to 60
HRC. This process guarantees consistent hardness across the entire
slotted plate, producing an excellent material with an extremely
long lifetime.
An equally unique development is
the innovative fastening system
designed by our engineers. Bolts
with conical swages combined with
the special slotted plates from
Christian Pfeiffer allow efficient
plate use up to a residual thickness
of 8 mm. Thanks to this design, we
can achieve a utilisation level of
75 % compared to conventional
systems, which only manage 60 %
(20 mm).
Slotted plates

Separate outlet:
ground material below,
air at the top.

Air velocity through ball mill

Conventional mill diaphragms


send most of the material through
the air fl ow into the second grinding compartment in an
uncontrolled manner. The results
are energy loss and a high degree
of wear on the grinding media and
diaphragm plates. Large areas of
both compartments are left without grinding material.
Mill diaphragms from Christian
Pfeiffer are the intelligent solution
to this problem. In the first grinding compartment, the material
level is kept constant thanks to an
infi nitely adjustable ring, which
can be directly accessed and individually adjusted. In the second
grinding compartment, the
material falls down through separate openings underneath the
air fl ow, along the diaphragm and
directly into the ball charge.

Air ow

10 m/s

20 m/s

Material fl ow through intermediate diaphragm

Conventional design

Optimized CPB-Design

Increased air passage:


improved cooling,
shorter retention times.

Calculated air velocity above ball charge

v = 1.8 m/s

v = 1.8 m/s

Our engineers have succeeded in


increasing the air passage surface of the diaphragm without
compromising on stability. The result is 40% lower pressure loss
compared to conventional diaphragms.

[m/s]
13.06

23.30

15.53

7.76

This ingenuous design offers numerous benefits through better


cooling of your grinding material,
more effective fines discharge and
shorter retention times without
the risk of overgrinding.

0.00

Minimal pressure loss

Mechanical design and service life: Comparison of


conventional design to Christian Pfeiffer Monobloc
Basis: Closed circuit, ordinary cement production without pre-grinding system
Conventional design

Christian Pfeiffer Monobloc

Cast segments & individually bolted with a typical servicel life of 5 years

Welded free-standing steel


structure with servicel life in
excess of 10 years

Material

Cast

Machined & heat-treated


special alloyed rolled steel

Hardness

42-48 HRC

52-59 HRC

Thickness

50-60 mm

40-70 mm

Slot width

10-15 mm

4-6 mm

Service life

5,000-7,000 hours
8-18 months

15,000-20,000 hours
> 36 months

Slot shape

Peening over

Constant

Material level

No control

Adjustable

Ventilation

Restricted (higher p)

Maximized (lower p)

Structure

Slotted plates

Longer service life


Structure
1x
Wear plates
1x

2x
2-4 x

TCO Total Cost of Ownership

Price

Precision engineering &


process know-how: Basis
for design & fabrication
Our engineers primary goal is to
increase efficiency. Nowadays,
their comprehensive knowledge of
all details about the grinding process leads to a significant increase
in production of many grinding
plants but with a reduced power
consumption.
Moreover, reliability is enhanced,
non-operation periods are kept to
a minimum and repair and maintenance costs are reduced.

Efficiency
Energy
Quality
Useful life
Repairs
Maintenance
Carbon footprint

Total Cost of Ownership

Our experts:
specialists in all areas.
Since its early beginnings, our
company has been influencing the
industrial grinding of cement.
Our engineers and design experts
can accordingly draw on an extensive wealth of experience and
accumulated knowledge. State-ofthe art technology is also used
routinely in our work.
For complete planning reliability: all production processes are
CAD/CAM controlled.
For high precision: CNC machines
provide exact customization.
For long service life:
forces are structurally and
mathematically simulated using the FEM
(Finite Element
Method).

Engineering

Controlled quality:
in-house production.
For all of our supplies and services, our companys policy has
always been to implement and
strictly comply with our own high
quality standards as well as
national and international quality
standards and guidelines such as
DIN EN ISO 9001.
All product range components
that are directly relevant for
grinding and separation are
entirely manufactured by our own
production facilities. Theres a
good reason why we never procure parts from other manufacturers: we want to keep on providing you with a controlled level
of consistently high quality.

Production

Christian Pfeiffer worldwide

= Offices/Production facilities
= Agents/Representations

Christian Pfeiffer Maschinenfabrik GmbH


Sudhoferweg 110-112 59269 Beckum, Germany
Phone: +49 2521 849-00 Fax: +49 2521 849-123
Email: office@christianpfeiffer.de

www.christianpfeiffer.net

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