The Horomill

HBM Process Conference, 10/97

By Sebastian Maibaum

Blue Circle Technical Centre

 The Horomill
• Time frame of “new” developments in
cement grinding
• Introduction of the horizontal roller mill
concept
• Comparison with other developments
• Operating data

Blue Circle Technical Centre

 Horomill - time frame
• FCB and Buzzi introduce Horomill on the
VDZ-conference 1993
• Horomill start up of 25 tph unit at Trino -
Italy in 1993
• High attention by the industry, e.g. Lafarge
buys Horomill for various plants
• Spring 1996 FLS introduces the Cemax
concept on the IEEE Conference in LA
Blue Circle Technical Centre
 Horomill - time frame
• Start up of different units in summer 1996
• No immediate press releases
• Rumours of mechanical problems
• Horomill = HorroRmill ???
• FCB describes mechanical improvements
• Scale up problems seem under control now
and operating data is available from FCB

Blue Circle Technical Centre

 Different developments
• Roller press gives good energy savings but
suffers of low mechanical reliability
• Few application without a ball mill
• VSM are successfully applied for raw meal
preparation, but few application in cement
• Higher acceptance of VSM for clinker
grinding in the Pacific region
• Ring-mill by Polysius
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 Horizontal roller mill objectives
• Reduce energy consumption by application
of material bed communition
• Independent grinding unit due to “proven”
closed circuit design
• Improve mechanical reliability
• Low energy cost for auxiliary equipment
since only low mill ventilation required

Blue Circle Technical Centre

 The Horomill
• Please refer to slides

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 Horomill - design features
• Pressure is medium pressure
• Material bed communition shows good
energy utilisation
♦ advantage: low ventilation necessary
♦ disadvantage: gypsum dehydration needs HGG?
• Possible to influence material retention time
♦ scraper system
♦ amount of mill feed

Blue Circle Technical Centre

 Horomill - design feature
• Ring and roller arrangement provides the
highest possible nib angle
• Gap between roller and shell 45 to 50 mm at
Horomill 3400
• Material discharge as known from ball mills
• No internals which tend to clock
♦ Drying can be done in separator circuit
♦ Gypsum dehydration by hot gases in sep-circuit
Blue Circle Technical Centre
 Horizontal Roller Mill Technology
Horomill Cemax
Feeding One side Both sides
Discharge Opposite side Both sides
Discharge type Gravity Air sweeping
Mill speed Hypercritical Sub-critical
Mat. transport Scraper system Scoops
Closed circuiting Bucket elevator Air sweeping
Drying Separation air Air sweeping
Dr

Blue Circle Technical Centre

 Influence of mill speed
• HOROMILL
♦ Mill is operating of
120 % of critical speed
♦ Constant material bed
thickness
♦ No sliding of material
♦ Low aeration within
the material bed
♦ Retention time can be
influenced by scraper
Blue Circle Technical Centre
• CEMAX
♦ Mill is operating at sub-
critical speed
♦ Scooping devices for
conveying + distribution
necessary
♦ Difficult to control
internal material transport
♦ Low recirculation load
 Horomill - operating data
• Horomill 2400 @ Trino/Italy
♦ Shell diameter: 2400 mm
♦ 25 tph CP 42.5 with characteristics such as
SD80
• Horomill 3400 Cimentas Izmir/Turkey
♦ PBC with 30% pozz. 3880 Blaine 17.3 kWh/t
closed circuit and 24.2 kWh/t total circuit
♦ Characteristics like closed circuit product

Blue Circle Technical Centre

 Horomill - operating data
• Material characteristics identical such as
closed circuit with high efficiency separator
♦ strength development
♦ water demand
♦ setting time
• Cement with 70 % slag produced and 12 %
moisture of the slag

Blue Circle Technical Centre

 Power consumption OPC
Specific power mill only grinding OPC • Aux. Equipment
100 OPC @ 3200 Bl
80
♦ Cemax
kWh/t - mill only

60
» ~ 8.5 kWh/t
40
♦ Horomill
20
» ~ 5.4 kWh/t
0
2000 2500 3000 3500 4000 4500 5000 5500 6000 ♦ CC Ball mill
SSA - Blaine » ~ 5 kWh/t
Ball Mill kWh/t Cemax kWh/t Horomill

Blue Circle Technical Centre

 Horomill - conclusion
• Experience of several years and half a dozen
installations
• Lower vent air system of the two systems
• Scale up problems are under control
• Development of material characteristic
• Benefit for Blue Circle of new developments
• Suitable for cubic meter per ton comparison

Blue Circle Technical Centre