Roller Press for finish grinding of raw material,

cement and slag

Milano, June 6th 2018
Dr. York Reichardt
Agenda

1. Introduction
2. Maintenance
3. Raw Grinding
4. Cement And Slag Grinding
5. Cement Quality
6. Throughput Range Of KHD RP Series
7. GrindX® Modular Plant Concept

5/9/2018 | Slide 2
KHD Strategy In Grinding Solutions

Take market share from VRM by

» New roller press finish grinding circuits for raw material, cement and additives/slag
» Upgrading existing ball mills with roller press, impact hammer mill and/or separators
» New closed ball mill circuits

5/9/2018 | Slide 3
Maintenance

1 Feed Gate

2 Roller Casing

1 8 3 3 Drive

4 Cylindrical Roller Bearings

7

5 Hydraulic Cylinder
2
4

6
Hydraulic Pressing Device –
5
not pictured

7 Machine Frame

8 Service Platform

5/9/2018 | Slide 4
Roller Press Surface Comparison

Welded STUD-Lining

Wear-Resistant Complete Hard Facing + Cross Profiles Highly Wear-Resistand Tungsten-Carbide Studs

5/9/2018 | Slide 5
Stud-Lining – Lifetime Guarantees For Tyres

17,000 hours life time without refurbishment achieved and guaranteed for slag
40,000 hours life time guaranteed for clinker, raw material

moveable roller

wear rate
max 11.7 mm

wear rate
max 6.8 mm

fixed roller

5/9/2018 | Slide 6
Maintenance – KHD Roller Press With Studs vs. VRM

OPC Maintenance: Lifetime Of Tyres

RP stud lining VRM welding/ceramic wear parts
first re-welding after approx. 4.000 hours,
Lifetime
then re-welding each 8.000 hours
(cements 40.000 hours without
without refurbishment guaranteed
several 1000 kg to be welded each time,
slag)
min. 200 hours downtime per welding
five to six re-welding runs to reach 40.000
hours, breakage risk of tyres (approx. 33%)
lifetime of ceramic wear parts between
10.000 and 12.000 hours

three to four changes to reach 40.000 hours,

at least 36 up to 48 hours downtime per change

5/9/2018 | Slide 7
Maintenance – KHD Roller Press With Studs vs. Ball Mill: Cement

40.000 hours lifetime of

KHD roller press stud lining
before refurbishment is in
range with ball mill
internals!

15.000 h 25.000 h
15.000 h 30.000 h to
60.000 h

5/9/2018 | Slide 8
Maintenance

Slag Grinding: Ordered New Mills, excl. China (28 mills)

4
7 Other Western Suppliers:
KHD
AMCL, Cemengal, Cemtec, CPB,
Loesche DAL Teknik, Fives FCB, Intercem,
Koeppern, Promac, UBE, WIL
18 Other West
46 GPSE Other Chinese Suppliers:
Other Chinese CD Leejun, CITIC, Conch
Kawasaki, Great Wall Machinery,
Haijian, Pengfei, NHI, Tangshan,
Jidong, etc.

25

SOURCE: OneStone Research March 2016

5/9/2018 | Slide 9
Specific Energy Consumption Of Current Technologies

KHD for now takes VRM main

motor value as RP main
motors value

5/9/2018 | Slide 10
Raw Grinding

RP 60 mbar
VRM 95 mbar plus 2.5 to 3 kWh/t

No water spray also

means more heat for
cement mills or WHR

5/9/2018 | Slide 11
Raw Grinding

V-Separator
Functionality similar to nozzle ring in VRM:
» Deglomerating
» Mixing
» Drying

But no fluidized bed like nozzle ring

for feeding the rollers of VRM
» Roller press system has much lower
pressure loss in raw grinding!

5/9/2018 | Slide 12
Raw Grinding – Feed Moisture

Feed moisture <15%: Comflex® 50 m

Feed moisture <5%: V-Separator above roller press

(lower civil costs)

5/9/2018 | Slide 13
Holcim Jamul, India

ACC Jamul, India

Performance Guarantee Test Results For Raw Mill

Contract PG Test Results

Grand Total Running Hours 72 x 1 hours 72 hours

Avg. Production Rate 700 t/h 730 t/h

Avg. Product Residue
15.00 % 15,98 %
(90 µm)
Moisture 0,5 % 0,5 %
Specific Power
17,50 kWh/MT 18,40 kWh/MT
Consumption (Meters)

5/9/2018 | Slide 14
KHD Roller Press References For Raw Material Grinding

5/9/2018 | Slide 15
Cement And Slag Grinding – Feed Moisture

Feed moisture <3%: V-Seperator above roller press

(lower civil costs)

Feed moisture >3%: Comflex®

24 m

5/9/2018 | Slide 16
Cement And Slag Grinding: Ciminter, Ivory Coast

5/9/2018 | Slide 17
Ciminter, Ivory Coast - Slag Finish Grinding

5/9/2018 | Slide 18
Denizli, Turkey – OPC Finish Grinding

Cement Type CEM I 42,5 R

Limestone 4,9 %

Production 118,0 t/h

Blaine Value 3860 cm²/g

R 45 7%

Energy Consumption RP 22,5 kWh/t

Energy Consumption
26,7 kWh/t
(RP, Classifier, Fan)

5/9/2018 | Slide 19
Aslan Cement, Turkey – Cement Finish Grinding

5/9/2018 | Slide 20
Europe – Cement Finish Grinding

Cement Type CEM II A – LL 42,5 R CPF 40 Bag

Design Alas

Limestone 11,5 % 21 %

Production 69,0 t/h 94,0 t/h

Blaine Value 4210 cm²/g ---

R 45 7,5 % 8,5 %

Energy Consumption RP 14,4 kWh/t 17,4 kWh/t

Energy Consumption
19,3 kWh/t 23,9 kWh/t
(RP, Classifier, Fan)

5/9/2018 | Slide 21
Semi-Finish Grinding/Upgrading Of Ball Mill Circuit – Flow Sheet

finish product Typical is

doubling or tripling
the ball mill circuit
capacity

Energy effect by
removing transfer
wall and changing
ball charge

fresh preground finish product

feed product
(rejects)

5/9/2018 | Slide 22
Cement Finish Grinding – Quality

No water spray in KHD roller

press finish grinding of cement
with slag portion below 30 %

5/9/2018 | Slide 23
Denizli, Turkey – OPC Finish Grinding

Cement Type CEM I 42,5 R

2 days strength 32,9 MPa

7 days strength 46,1 MPa

28 days strength 58,0 MPa

Water demand 29,4 %

Initial setting 162 min.

Final setting 244 min.

Blaine Value 3610 cm²/g

R 45 7.3 %

5/9/2018 | Slide 24
Aslan, Turkey – Cement Finish Grinding

Cement Type CEM I 42,5 R CEM II A 42.5 R CEM V A 32.5

2 days strength 27,4 MPa 36,5 MPa 19,5 MPa

7 days strength 41,1 MPa 52,8 MPa 29,4 MPa

28 days strength 52,6 MPa 65,6 MPa 42.6 MPa

Water demand 27,5 % 30 % 36 %

Initial setting 165 min. 165 min. 195 min.

Final setting 210 min. 210 min 255 min.

Blaine Value 3400 cm²/g 4510 cm²/g 5520 cm²/g

5/9/2018 | Slide 25
Europe – Cement Finish Grinding

Cement Type CEM II A-LL 42,5 R

1 Day Strength 18,5 MPa

2 Day Strength 29,9 MPa

28 Day Strength 53,5 MPa

Water Demand 27,0 %

Initial Setting 100 min.

Final Setting 160 min.

Blaine Value 3210 cm²/g

R 45 7.5 %

5/9/2018 | Slide 26
Roller Press References For Cement & Slag Finish Grinding

5/9/2018 | Slide 27
KHD Roller Press Standard Series And Production Figures

RP Size Raw Meal OPC OPC Slag

Grinding 12 % R90µm
3200 cm²/g 4000 cm²/g 4200 cm²/g
Force (MN) (8 kWh/t at Shaft)
7 160 t/h 65 t/h 35 t/h 35 t/h
10 200 t/h 80 t/h 45 t/h 45 t/h
13 260 t/h 100 t/h 60 t/h 60 t/h
16 340 t/h 135 t/h 75 t/h 75 t/h
18 420 t/h 150 t/h 85 t/h 90 t/h
20 500 t/h 180 t/h 100 t/h 110 t/h
24 600 t/h 200 t/h 115 t/h 130 t/h
27 700 t/h 240 t/h 140 t/h 150 t/h
32 850 t/h 280 t/h 160 t/h 180 t/h

5/9/2018 | Slide 28
Modular Plant GrindX® RP7 170/90
Feed material: A) H20 diameter duct
1. clinker 95.0% 0.0% item NW
2. Gypsum 5.0% 5.0% 1 0
- 2 0
- 3 1250
- 4 1120
Moisture max.: 0.3% 5 1400
Feed size: max. 50 mm 6 1400
7 1400
8 1250
9 630

5111BI1 5111BI2

1 2

d: 100,000 m³/h
(90°C)
5111WF1 5111WF2 5115MS1 5115MD1 GrindX d: 20,000 m³/h
5312 SC 7-1750 (90°C)
5313BF1
5115BC1 5115DG1 rod sizer (STUDS: 50 mm)
5
d: 50 t/h
5115GR1
4 0
9
container (subjected to grindability test)

6 5316AS1 A) 40 t/h
d: 50 t/h
3800 cm²/g (BL)
5312SR1
5312FB1 8 OPC
(subjected to grindability test)
5312RP1 5315MS1
5312SR2
7

5315BC3 5313FN1
5315BC2 5315BC1
d: 560 t/h d: 560 t/h
a: 450 t/h a: 450 t/h 2 Hot gas generator
3
1382 MJ/h
a: actual For 20 deg C Clinker temperature
d: design 1
(subjected to grindability test)

5/9/2018 | Slide 29
Modular Plant GrindX® RP7 170/90

Clinker Gypsum Slag Limestone Blaine Capacity

% % % % cm²/g t/h

CEM I 95 5 3200 60

CEM I 95 5 4000 40

CEM II 75 5 20 4000 60

CEM III 35 5 60 4200 40

Slag 100 4200 40

5/9/2018 | Slide 30
Modular Plant GrindX® RP7 140/80

Clinker Gypsum Slag Limestone Blaine Capacity

% % % % cm²/g t/h

CEM I 95 5 3200 35

CEM I 95 5 4000 25

CEM II 75 5 20 4000 35

CEM III 35 5 60 4200 25

Slag 100 4200 25

5/9/2018 | Slide 31
Modular Plant GrindX® RP7 140/80

Structure shipped with maximum assembly

included equipment whenever possible

Structure engineered to be stacked

and bolted together without welding

5/9/2018 | Slide 32
Modular Plant GrindX® RP7 140/80

All modules fit standardized 20‘ ft or 40‘ ft containers

12100 12100

2500
2500
2500
12100 55000 12100

5/9/2018 | Slide 33
Modular Plant GrindX®

» Containerized compressor room

» Fully installed, inlet and outlet with quick connect fitting
» Containerized hot gas generator
» Containerized hydraulic room
» Fully installed, inlet and outlet with quick connect fitting
» Containerized electrical rooms
» Shipped pre-wired and fully installed

5/9/2018 | Slide 34
Modular Plant GrindX®

» Bolted cement silo

» Pre-coated silos for faster
and easier erection time
» Bolted connection, no welding,
blasting or coating on site required

5/9/2018 | Slide 35
THANKS FOR YOUR TIME!