GRINDING TECHNOLOGY

I Turkish grinding systems

by Hans-Peter Kloeckner & KHD Humboldt Wedag has a long history of grinding expertise in the
Oral Türesay, KHD Humboldt cement industry. This knowledge and technology has been successfully
Wedag GmbH, Germany installed in cement plants all over the world and in this article the German
company details its successes in the Turkish market place. KHD has
worked with all the leading Turkish cement producers, optimising grinding
performance and equipping them with high capacity mills.

HGG
Recently completed roller
press projects in Turkey
grinding aid

Three of the recently installed KHD

1. Clinker
grinding systems in Turkey – at
Roller
Iskenderun Cimento, Mersin Cimento
2. Gypsum
Press
3. GBFS REC
4. Limestone
and Bolu Cimento – are equipped with
Separator
5. Pozzolana

Roller Press and V- Separator or VSK®-

3

VSK®
2
4
Separator Separator as main machines. These
projects are described below, followed
1

Products:
QPC
Slag meal
by details of Ünye Cimento where a new
Additive
Roller Press system is under construction.
metal metal

= new equipment 1. Iskenderun Cement plant

= existing equipment

to product
OYSA Iskenderun Cimento TAS,
Figure 1: flowsheet of Iskenderun subsidiary of OYAK and SABANCI
Cimento’s grinding plant Holding.

T
he first Roller Presses for high Figure 2: flowsheet of the Cimsa Cimento’s grinding plant
pressure comminution in producing
cement and raw meal had been 1. Clinker
2. Gypsum

sold to German cement producers. The 3. Slag

4. Limestone
5. Fly ash
first machine outside Germany was
5.

ordered by the client Baticim at its Bati 4.

3.

Anadolu cement plant in Izmir, Turkey. VSK® Products:

Separator (e.g.)
This Roller Press with a roller diameter OPC
PKQ
of 1150mm and a roller width of 2.
1.
Roller
1000mm and an installed motor rating Press

of 2 x 300kW was installed as pregrinder = excisting equipment

= new equipment

in front of the existing ball mills No 1

and No 3 for clinker grinding and was
put into operation in 1986, resulting in a Figure 3: flowsheet of Bolu Cimento ’s grinding plant
substantial increase in production capacity
of the finish mill and savings in specific
energy consumption.
In the following two years Baticim
ordered two additional machines, one for
clinker and one for raw material grinding. 1. Clinker
2. Gypsum 3,5 x 10 m

A total of 15 grinding systems with 3. Puzzolane M

4. Limestone

KHD Roller Presses in 11 various plants 1

2 VS
3. V-Separator
in Turkey for clinker-/additive-grinding,
Products:
4
PZC-B 32,5
Hot Gas

blast furnace slag-/pozzolana-grinding

SDC 32,5
from clinker cooler
PC 42,5

and for raw material grinding confirm Speed Variable

Drive
Roller
Press
the reputation of the high pressure
comminution equipment in general and
= excisting equipment

of the KHD Roller Press technology in

3,5 x 10 m
= new equipment

particular in the Turkish cement industry. new

MAY 2007 ICR XX

GRINDING TECHNOLOGY

Table 1: examples of grinding plants with KHD roller presses in Turkish cement production
plants – machine data

Cement producer OYSA Iskenderun Cimsa Mersin Cimento Bolu Cimento TAS
Cimento TAS TAS

Configuration of the New semi-finish New semi-finish (and New semi-finish grinding
grinding system grinding and finish) grinding and and drying circuit
drying circuit with drying circuit with with RP and V-separator,
RP and VSK® RP and VSK® separator, plus two existing closed
Separator, plus existing plus existing ball mill circuit ball mills with
ball mill in closed in closed circuit with separator
circuit with the the VSK® of the
VSK® of stage 1 stage before
or an existing Rec
separator

Main machines/parameters
Roller press/KHD RP 20-170/180 RP 20-170/180 RP 10-140/110
roller diameter 1700mm 1700mm 1400mm
roller length 1800mm 1800mm 1100mm
motor 2x1800kW 2x1800kW 2x800kW

Separator/KHD VSK® 112/24-3250 VSK® 112/28-4000 VS 80/20 (static)

Ball mill (existing) (existing) 2 x mills (existing)

diameter 4m 4m 3.5m
length 11.5m 12m 9.45m
motor 2640kW 3000kW 1650kW

Separator Rec 450 (existing) 2 x Sepol 200/4 (existing)

Table 2a: examples of grinding plants with KHD roller presses in Turkish cement production
plants – process and operating data

Cement producer OYSA Iskenderun Cimento TAS Cimsa Mersin Cimento TAS

Plant location Mediterranean region Mediterranean region

Feed material Clinker, additives/ Clinker, additives/
wet slag, pozzolana wet slag
Operating since 2006 2006

Production (tph) Before conversion After conversion Before conversion After conversion
Product 1 46 (QPC) 127 (QPC) 100 (OPC) 250 (OPC)

Product 2 30 (slag meal) 114 (slag meal) 130 (PKC 2) 315 (PKC 2)

Product fineness
Product 1 4500cm2/g 4715cm2/g 3100cm2/g 3100cm2/g
1.1%>45mm 0.7%>45mm 8.3%>45mm 8.45%>45mm

Product 2 5050cm2/g 5050cm2/g 3600cm2/g 3600cm2/g

0.6%>45mm 0.5%>45mm 4.7%>45mm 7.2%>45mm
Energy consumption
total (kWh/t
Product 1 61.2 48.5 34 32.5
Product 2 92.3 51.1 30 28

XX ICR MAY 2007

INTERNATIONAL REPORT

The cement grinding and packing plant

Table 2b: Bolu cement grinding plant with KHD roller press is located in Akdeniz region, near at the
– process and operating data coast of the Mediterranean.

Plant operator Bolu Cimento TAS 2. Mersin Cement plant

Plant location Black Sea region Cimsa Cimento TAS, subsidiary of
Feed material Clinker, pozzolana, additives SABANCI Holding.
Start-up 2007 The cement production plant is situated
in Mersin, on the Turkish south coast of
Production (tph) Before conversion Expected values Mediterranean.
(average of mill 1+2) (zero test) based on zero test
CEM I 47.5 167 3. Bolu Cement plant
Bolu Cimento TAS, wholly-owned
Product fineness subsidiary of OYAK.
CEM I 3300cm2/g 3300cm2/g Efficiency and reliability of Roller press
technology had been proven from the
Energy consumption very beginning mid-1986 up until today.
Total (kWh/t) Progress in machine design of the RP
CEM I 31.5 29.4 itself, improvement and development
of other components of the grinding
Figure 4: solid roller welded hard facing and staggered profiling systems, especially the classifiers and
(like Iskenderun and Bolu machine) flexibility in process flow sheets, tailored
to the specific application and the specific
conditions and requirements of the client
were the precondition of the advance
of Roller Presses in the cement industry,
including many installations in Turkey.
Special attention in machine design has
been paid to the rollers, its configuration
(solid roller or tyres), its materials
especially of the roller surface and the
shaping of the surface (hard facing or stud
lining-hard with inserted metal studs).
Additional attention in the grinding
process and in other grinding plant
components resulted in the development
of the VSK®separator. This high efficiency
classifier in closed circuit with a KHD
Figure 5: schematic diagram of VSK®
Roller Press combines five functions in one
unit:
• degglomeration of the typical Roller
feed recirculation Press product by the impact action of the
fines material air, fresh air or material cascade
and air hot gas • pre-classifying in the cascade part of
the VSK removing grossly oversized and
usually rough edged material
• mixing and spreading of both, fresh
feed- and recycled-material
• heat transfer for either drying or cooling
midlings • finish stage separation in the cage wheel
part of the VSK, adjustable to cover the
entire range of the final products.

Ünye Cement project

V-Separator A new KHD grinding system with Roller
Press, VSK®- and SKS-separator as the
main grinding equipment is currently
Rotor Cage Separator
under construction at Ünye’s cement
coarse
plant, Turkey.

XX ICR MAY 2007

INTERNATIONAL REPORT

Table 4: Ünye cement

grinding plant project with
KHD roller press – contract
data

Cement producer Ünye Cimento TAS

(OYAK Group)
Plant location eastern Black Sea
region
Feed material Clinker, additives/
wet slag, pozzolana
Start-up 2007

Figure 6: Ünye Cimento plant Production (tph)

Product 1 200 (CEM I 42.5)
Product 2 230 (CEM II A-M)
Table 3: Ünye cement grinding plant project with KHD roller Product 3 180- (CEM V/A)
press – machine data
Product fineness
Cement producer Ünye Cimento TAS (OYAK Group) Product 1 3750cm2/g
Product 2 3800cm2/g
Configuration of New semi-finish grinding and drying circuit with RP and VSK® Product 3 4300cm2/g
the grinding system separator plus existing ball mill No 3 in closed circuit with a
new Sepmaster® separator, type SKS Energy consumption total (kWh/t)
Product 1 29
Main machines/ Product 2 25
parameters Product 3 30
Roller press/KHD RP 20-170/180
roller diameter 1700mm
roller length 1800mm Ünye Cimento TAS is a wholly-owned
motor 2X1700kW subsidiary of OYAK Group. The cement
factory is located at the coast in eastern
Separator VSK® 96/20-3000 Black Sea region.
In 2002 KHD Humboldt Wedag
Ball mill (existing) successfully increased the clinker capacity
diamter 4.1m of Ünye’s kiln line from 1700tpd to
length 13.9m 4500tpd.
motor 3150kW In 2006 Ünye decided to contract KHD
for upgrading its cement mill No III. A
Separator Sepmaster® SKS-Z 2250 capacity increase of more than 100 per
cent for each of three different cement
qualities is one of the client’s objectives
Figure 7: flowsheet of Ünye Cimento’s grinding plant
associated with this investment.
The existing ball mill will be converted
to a semi-finish grinding system with
a Roller Press and a VSK® separator as
1. Clinker
2. Gypsum Products: pre-grinding system combined with the
3. Trass
4. Limestone
5. Slag
CEM I 42,5 R
CEM II A-M existing ball mill and a new dynamic
Sepmaster® separator, type SKS as closed-
CEM V / A
Roller
5
Press

circuit system.
4
3
2
Sepmaster®
1 SKS

Core components of the KHD design

VSK® for Ünye Cimento are:
Separator
• Roller Press RP 20 with Rolcox®
– system
• VSK® separator including cyclones and
fan
= new equipment
= excisting equipment

• Sepmaster®separator, type SKS including

cyclones and fans. __________________ I

XX ICR MAY 2007