Professional Documents
Culture Documents
1937 400 Loesche mills have already been sold for coal,
phosphate and cement raw material.
2
1971 Introduction of a modular system in mill construction:
creation of replacement groups of components such
as rollers, rocker arm and hydropneumatic spring for
constructing mills with 2, 3 and optionally 4 rollers of
the same size. The first LM 30.4 and LM 32.4 4-roller
mills are sold and have product throughputs of
178 t/h and 215 t/h.
1973
Sale of LM 36.4 und LM 43.4 mills with product
throughputs of 260 t/h and 425 t/h.
3
Benefits to customers and customer satisfaction
Quality and reliability right from the start are the globally Our competence is founded on the following key features:
recognised benefits to be derived from Loesche grinding plants.
As early as 1928, when the first Loesche mill came onto the • Tailor-made plant concepts from planning to commission-
market, the grinding principle of the vertical roller grinding ing, based on our own experience combined with customer
mill, with a driven grinding track and spring-loaded rollers was wishes
shown to be particularly energy-efficient and reduced the use
of natural resources. These advantages of Loesche mills will • Individual problem solutions through optimised process
become ever more important in the light of increasing plant technology
size and the obligation to make more careful use of primary
energy. • Rational solutions with simultaneous planning of cement
clinker/granulated blast furnace slag mills and raw meal
Moreover, the high product throughputs of Loesche mills mills through the use of exchangeable components for all
(up to 1,300 t/h for cement raw material and already 350 t/h models of mill, extending to the use of identical gear drives
for cement clinker and granulated blast furnace slag) result
in considerably reduced investment costs compared to two • Close cooperation with suppliers of rotary kilns in line with
smaller grinding plants. customer wishes
Loesche is a competent partner for its customers from the • Customer service: plant optimisation and advice in the
initial sale to customer service and from punctual project case of further technical developments
planning to the handing over of the plant. Our maxim is
“Every Loesche grinding mill must be a reference mill!” • Long-term delivery capability when supplying
spare parts
Loesche mill Type LM 60.4, Ras Al-Khaimah, United Arab Emirates, 2005
4
Grinding table of an LM 69 in the foundry
Assembly of the lower part of the mill Assembly of the grinding table Mill with classifier under construction
5
Working principle, construction and function
of Loesche mills
Working principle Construction
The material to be ground is crushed between the rotating The familiar basic principle of the modular system patented in
grinding track and the individually guided grinding rollers. 1970 is applied to Loesche mills with two, three, four and six
rollers. The rollers together with their lever systems, hydro-
Grinding is carried out primarily through the application of com- pneumatic springs and hydraulic control systems make up a
pressive force. A small amount of shear force supports the dis- functional unit. Large or small modules with a different number
placement of crystalline layers in the raw material. This effect of rollers (between two and six) can be deployed in the same
occurs through conical rollers whose axes are inclined at 15° mill sizes (grinding table diameter). This makes it possible to
compared to the horizontal grinding track. As already demon- customise the product to meet specific customer requirements.
strated through comparative studies in the 1930s, this permits
ideal fine grinding and at the same time ensures minimum wear. The following features characterise Loesche technology:
• The support and precise guiding of the rocker arm roller
A higher specific grinding pressure is applied compared to system with its roller bearings takes place in a pedestal with
coal grinding and a lower specific grinding pressure is applied integrated spring system.
compared to the fine grinding of clinker and granulated blast
furnace slag. • Hydropneumatic spring loading of the roller rocker arm unit
with integrated mechanism to lift the rollers serves as an aid
Hot gases are added in the dry-grinding process to evaporate for the mills when starting up with a filled grinding track.
material moisture. Use is predominantly made of the exhaust
gases from the rotary kilns, the heat exchanger or the cement • The rollers are connected in pairs to a common hydraulic
clinker cooler. If none of these sources are available or the unit (except in the case of 3-roller mills).
heat content of these exhaust gases is insufficient, Loesche’s
own hot gas generators are deployed. In the classifier above • An almost parallel grinding gap is maintained between the
the grinding chamber the ground product is separated from the grinding rollers and the grinding plates during the entire ser-
grit which then falls back onto the grinding track for renewed vice life of the grinding parts.
grinding.
6
Loesche mill Type LM 69.6, Idhan, United Arab Emirates, 2009
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8
Mill function 1 2 3 4 5 6 7 8 9
The cement raw material is fed via a rotary feeder 1 1 2 and 2 3 3 4 4The 5 5 6mill
6 7 is
7 8driven
8 9 9 by an electric
10 motor
1 11 2 12 313 4via
14 5a
15 flexible
616 717 8 coupling
18 919
falls via the chute 1 2 onto the centre of the grinding10bed
3 4 5 6 7 8 9 1 10 11 12 . 13 14 and
2 11 3 12 4 13 5 14 15 16the
6 15 7 16 17 mill
8 17 9 18
18 19 gearbox via an10output
19 20 21 11 12 flange
22 23 13 14 15 . 16
24 25 26 A segmental
27 28
17 18 19
2011 2112
222213 2323thrust
2424152525162626172727182828
Free ferrous foreign 10 11 objects
12 13 14 are15 separated
16 17 18 19 out from 10 the
20 21feed 14 bearing in19 the top of the20gearbox21 22 23absorbs 24 25 26 the27grinding
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20 21 22 23 24 25 26 27 28 20 21 22 23 24 25 26 27 28
material magnetically before reaching the rotary feeder 1 2 forces.
3 4 5 6 7 8 9
track towards the edge of the grinding table under the effect mill can then20 not 21 22 23 24 25 26 27 28
only be started empty but also par-
of centrifugal force and in this way passes under the hydro- tially filled with a low starting torque. Metallic
pneumatically spring-loaded grinding1 rollers 2 3 4 .The5 6 material
7 8 9 contact of grinding parts on an empty or loaded mill is pre-
that has been drawn in is ground in10the 11 material
12 13 14 bed 15 16 in 17 the18 19 vented by automatic lifting of rollers via a grinding bed depth
20 21 22 23 24 25 26 27 28
gap between the rollers and grinding track. The rollers 1 2 3 4 5 control.
6 7 8 9
are displaced upwards as they roll over the material 1 210 3bed
11 12
4 5 . 6
13 14 15
7 16
8 17
9 18 19
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As a result the functional unit consisting of 1 rocker
10
2 11 3 12 4arm 13
5 14 6 , 15 7 16 A8 so-called
9 18 19 “auxiliary drive” for starting up a filled mill at low
17
20 12 21 13 22 14 23 15 24 16 25 17 26 18 27 19 28
spring rod and pistons from the hydraulic cylinder 1 2 10 3 11 4 5 6 7 is
8 9 revolutions is not required!
20 21 22 23 24 25 26 27 28
moved. The piston displaces the hydraulic oil from the cylin- 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
der into the gas-filled bladder accumulator unit. Nitrogen-filled Servicing
rubber bladders in the accumulator units are compressed and
act as gas springs. The gas springs can be set to be harder or Worn grinding parts, roller tyres and grinding track segments
softer by selecting the gas pressure in relation to the hydraulic can be simply and quickly replaced. The rollers are retracted
operating pressure, depending on the fracture behaviour of the from the grinding chamber into a vertical position using a
material to be ground. retracting cylinder. Complete rollers, roller tyres and grinding
plates are then made accessible to hoisting devices.
The ground material is subjected to centrifugal force and
rotates outwards and over the edge of the grinding table. In When grinding cement raw material the metallic particles
the area of 1 the2 louvredam
3 4 5 6 ring
7 8 which
9 surrounds the grinding usually cause uniform wear throughout their entire service
table
1 2 the
3 1 10 5stream
4 2 11 3 12 7 5of
6 4 13 148 6hot
9 7 gas
15 16 8 17 9 18directed
19 upwards captures life so that the mill throughput only declines when mill parts
1210 20
the11mixture1311 21
of1222
1513 23
1614 24
ground 25
1816 26
material1917 2718
and2819
material as yet not com- 6are7 completely worn. Partial wear may occur if, for reasons
10 14 1715
1 2 3 4 5 8 9
20 21 2220 2321 2422 2523 2624 2725 2826 27 28
pletely ground and conveys this to the classifier 10 . 11 12 13 14 15of 16cement 17 18 19 chemistry, free quartz sand needs to be used
20 21 22 23 24 25as26concrete 27 28 aggregate. This can be offset by targeted hard
1 2 3 4 5 6 7 8 9
Depending on settings of the classifier 10 11 it rejects
12 131 14coarse2 153 16 4 17 5facing
186 197 in 8the 9 mill.
materials. This falls into the internal grit return cone 20 21 22 10 11 and
23 24 25 26 27 28
12 13 14 15 16 17 18 19
material.
10 11 12 13 14 15 16 17 18 1920 21 22 23 24 25 26 27 28
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2 3 4 5 6 7 8 9
0 11 12 13 Scrapers
14 151 162 17 3 connected
184 19 5 6 7to the
8 9grinding table transport foreign
0 21 22 23 matter
24 10 into
25 26 27the13reject
11 12 28 16 17 18 . 19
14 15hopper
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9
Mill selection sizing – models – dimensions – drives
• The identification is followed by a digit, separated by a full The modular construction principle of gearboxes permits further
stop. This specifies the number of rollers operated in the increases in performance in line with the current state of the art
mill. without the need to develop a new construction concept.
• The number and size of rollers is geared to the required The Loesche mill does not require a motor with increased start-
product throughput in conjunction with the “Loesche perfor- ing torque. Since the rollers are raised hydraulically, the break-
mance factor” as well as the product which is influenced by away torque for the filled mill only comprises 40% of the full
factors of grindability, moisture and fineness. The required load torque. This starting torque can be achieved by a “stand-
gas stream is decisive for the housing dimensioning of mill ard motor” without a problem.
and classifier.
The installed motor power is sized according to the energy
• The Loesche cement and raw meal mills are constructed in requirements of the mill. This is established in the test plant
a modular fashion. Modules are understood as units com- using a grinding test. The next suitable commercially available
prising rollers, rocker arms and roller-related spring compo- motor is selected and recommended to the customer.
nents with their pedestal. This is arranged from between 2
and 6 times around a grinding table as required.
Dimensions
• The coordinates of the grinding table diameter and number
of rollers can be read off from the following table. The
x-coordinate indicates which product throughputs can be
generated using the respective mills. The width of the fields
is a measurement of the output factor (see above).
10
LM for Raw Material and Minerals
Product rate [tph] as function of the LM size A H
[m] [m]
0 200 400 600 800 1000 1200 1400 1600 1800 2000
11
Raw materials for grinding
LIMESTONE CaO 60 – 69
SILICATE SiO2 18 – 24
12
According to Labahn & Kohlhaas the following terms are com- Cement raw materials require a CaCO3 content of between 74
mon for the raw materials used arranged with diminishing and 79 M %. The desired raw material composition is rarely
CaCO3 content: found in a natural raw material.
• Pure limestone > 95 M. – % CaCO3 For this reason materials containing SiO2 and ferric oxide as well
as fluorites must be used as correcting materials to precisely
• Marly limestone 85 – 95 M. – % CaCO3 adjust the required raw material compounds and to improve
sintering.
• Lime marl 70 – 85 M. – % CaCO3
Some of these grinding materials additives are highly abrasive
• Marl 30 – 70 M. – % CaCO3 and lead to the disproportionate wear of grinding parts, areas
of machines and in ducts through high speeds of gas-solid
• Argillaceous marl 15 – 30 M. – % CaCO3 mixtures. Loesche takes suitable protective measures against
wear when materials of this nature are used.
• Marly clay 5 – 15 M. – % CaCO3
13
The homogeneity and fineness of the cement raw meal also new construction projects, specified quantities of individual
plays an important role in the downstream sintering process in components are supplied and chemically analysed. Their mois-
addition to the correct chemical composition of the raw meal ture is measured and under some circumstances adjusted.
mixture. A quantity of feed material amounting to at least 1.5 t is pre-
pared from the supplied or manufactured raw material com-
There are high demands with respect to the permitted residual pound. If the supplied grain size is too coarse for the Loesche
moisture in the ground product. laboratory mill, the required feed material grain size is generat-
ed in the Loesche laboratory crusher in an intermediate stage
The residual moisture (max. 0.5 M %) must be just as homo before grinding. The raw material is then completely ground,
geneous as the distributed chemical components. dried and classified in the Loesche test plant mill in continuous
operation.
This also means that where water content varies, for example in
the case of limestone and clays, the residual moisture content The test grinding delivers the following representative results:
of each component of the finished material must be approxi- • Loesche grindability factor “MF“;
mately the same. The process control system of the Loesche • Loesche fineness factor “FF“;
mill guarantees this. • Moisture factor “WF” with water content of > 8 %;
• Specific energy consumption “e” [kWh / t] ;
• Wear factor “VP”.
CEMENT RAW MATERIAL The appropriate Loesche mill is determined using these param-
Tests on materials to be ground eters and standard charts.
The characteristics of the cement raw material must be known
in order to determine the size of the mill and classifier. The Notwithstanding these standardised methods, other decisive
material properties are examined in the Loesche test plant. variables flow into the dimensioning of the mill, the classifier
Ideally the customer supplies the test plant with a representa- and also the mill fan, such as extremely high grinding material
tive sample of the cement raw material compound as used in moisture or very high differences in the case of grindability fac-
his factory. If a quarry has not yet been opened in the case of tors of individual raw material components.
14
Complete grinding plants with components
Until the end of the 1950s Loesche mills were deployed in the specially adapted to the properties of the feed material. Thus
power station industry as coal direct firing mills for steam fur- oversized pieces, so-called “fish” or tree roots are used as
naces in model sizes up to LM 16. In the limestone and ferti- reference for the maximum filling level of the cells. The calculated
liser area mill sizes of up to LM 18 with product throughputs filling level of the chambers is less than 40 % of the pocket
of up to 40 t/h were common. Relatively few vertical mills are volume in order to prevent the rotor clogging. Both types of
still being used for grinding cement raw material in cement gate can be heated using process gas in the case of moist feed
works. Most can be found in cement works with shaft kilns. material.
The biggest mill in 1960 was an LM 20 with approx. 50 t/h Rotary and gate feeders are equipped with wear protection.
product throughput and drive power of 400 kW.
Grinding and classifying
The need for Loesche mills for grinding cement raw material The raw material is ground and dried in the mill. Mills with 2
skyrockets at the start of the 1960s. The reason for this trend rollers have one hot gas entry channel, while those with three
is the technological development in the cement manufacturing and four rollers have two and mills with six rolls have four. The
process which moves away from the energy-intensive wet pro- process gas is distributed from there uniformly by means of
cedure to the semi-dry process and ultimately to the dry pro- guide vanes into the grinding bed chamber. When it leaves the
cess with precalcination. As a result the kiln throughput grinding table the ground material together with the process
increased dramatically with simultaneous significant reduction gas, which has since been cooled by water evaporation to
in specific energy consumption. below 100°C, is fed to the classifier on the mill. The powdered
ground product leaves the classifier and is separated in a
From the beginning Loesche develops mill sizes that are downstream filter or a combination of cyclone battery with
adapted to the throughput of the cement rotary kiln. (smaller) filter. Separated grit falls back onto the grinding track
along with fresh material.
The mills launched onto the market satisfy the following
requirements:
• Mill capacities adapted to the raw meal requirements of the
rotary kilns and which permit parallel operation of the kiln
and mill.
• Mill sizes that permit the parallel operation of a kiln with a
mill, a concept that is specifically up to 30% more cost effec-
tive than the parallel operation of a rotary kiln with 2 roller
mills! This Loesche philosophy has been proven to be cor-
rect and is today generally accepted by customers.
• Mills which make ideal use of the exhaust gases of the
rotary kiln for dry grinding and for transportation of the
grinding materials with low specific energy consumption
[kWh/t].
• Grinding, drying, classifying in one machine unit through to
the ground product with the required grain distribution and
residual moisture.
• Grinding plants which can be quickly adjusted in line with
the operational requirements of the firing process.
15
Reject treatment Mill fan
The reject material passing through the louvre ring is automati- The mill fan requires no wear protection due to the high effi-
cally cleaned out and transported off via an airtight encapsu- ciency of the dust separator. It is generally equipped with an
lated conveyor and bucket elevator. The flow of feed material inlet vane control and / or a variable speed drive.
to the mill, which is the sum of the fresh material and reject
material, is maintained at a constant level by the proportioning
system.
16
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12 12 12 12 M 4
24 M M M M 21
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M
M 6
M
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M
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M
5
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Dynamic Loesche classifier LSKS
22
Loesche hot gas generator
Mode of operation
1 2 3 4 5 6 7
The process gas stream which enters the spiral 1 2housing
3 4 5 cools
6 7 8 9
12 13 14 15 16 17 18 20
19 21 22 23 24 25 26 27 28
interior of the combustion chamber through 1 the
2 annular
3 4 5 gap
6 7 8 9
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22 23 24 25 26 27 28
and holes in the perforated jacket, and mixes 10 11there
12 with
13 14the15 hot
16 17 18 19 Construction
20 21 22 23 24 25 26 27 28
flue gases from combustion. At the same time the flame and hot
flue gases are kept away from the perforated jacket. 1 Burner
2 3 4 5 6 7 8 9
1 10
2 Fuel
11
3 12
4 13 6 15
5 14 7 16
8 17
9 18 19
Heating media 1 10
2
20
11
3
21 13
12
4
22 14
5
23 15
6
24 16
Combustion 25 17
7 air
8
26
9
27 19
18 28
20 21 13
22 14
23 15
24 16
25 17
26 27 28
– Natural gas, bio gas, coke gas, blast furnace gas and other 1 10
2 11
3 4 Burner
12 5 6 7muffle
8 9 18 19
20 12
21 13
22 14
23 15
24 16
25 17
26 18
27 19
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low calorific value gases 1 10
2 11
3 4 5 Spiral
6 7 housing
8 9
20 21 13
22 14
23 15
24 16
25 17
26 18
27 1928
– Light and heavy oils, wood and lignite dust 1 10
2 11
3 12
4 5 6 Perforated
7 8 9 jacket
20 12
21 13
22 14
23 15
24 16
25 17
26 18
27 19
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1 10
2 11
3 4 5 6 7 Annular
8 9 gap
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21 13
22 14
23 15
24 16
25 17
26 18
27 19
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LOMA Hot Gas Generator units are constantly being developed 1 10
2 11
3 4 5 6 7 8 Protective
9 casing
20 12
21 13
22 14
23 15
24 16
25 17
26 18
27 19
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and conform to current technical standards. More than 600 hot 19 Temperature control
1 10
2 11
3 4 5 6 7 8 2 3 4 5 6 7 8 9
20 12
21 13
22 14
23 15
24 16
25 17
26 18
27 19
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gas generators of this type have been commissioned for a heat 10 11 10 Hot
11 12gas
13 outlet
14 15 16 17 18 19
20 21 22 23 24 25 26 27 20
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flow of between 100 kW and 64,000 kW. 21 22 23 24 25 26 27 28
23
Loesche rotary vane feeder
Material is fed continuously from above via the inlet hopper into
every vane pocket of the slowly rotating vane feeder. In order to
reduce wear from the abrasive feed stock the peripheral speed is
low and the filling level limited to 40%. Adjustable sealing strips
on the rotor prevent any large gaps between the wearing plate of
the housing and the rotor. The material is discharged downwards
into the feed chute of the mill.
Hot gas can be passed through the inside of the rotary feeder to
prevent material caking. It is easy to dismantle for maintenance
purposes.
24
25
The Loesche test facility for raw materials testing,
Research and Development
Calibrated standard grinding tests for mill sizing
Loesche has many years of experience in designing grinding
mills. The most important prerequisite for correctly designed
grinding mills is an exact knowledge of the physical properties
of the materials to be ground.
26
Loesche – worldwide presence
Loesche is an export-oriented company run by the owner, which was established in 1906 in Berlin.
Today the company is internationally active with subsidiaries, representatives and agencies world-
wide.
Our engineers are constantly developing new ideas and individual concepts for grinding
technologies and preparation processes for the benefit of our customers. Their competence is
mainly due to our worldwide information management.
This ensures that current knowledge and developments can also be used immediately for our own
projects.
The services of our subsidiaries and agencies are of key importance for analysis, processing and
solving specific project problems for our customers.
27
Quartz (SiO2) 50µm Calcite (CaCO3) 20µm Aluminum oxide (Al2O3) 5µm
Air-cooled blast furnace slag 1µm Iron oxide, Titanium 30µm Air-cooled blast 5µm
oxide and Orthoclase furnace slag