06-flacher-holcim-vertical-roller-mills-for-clinker-grinding-with-holcim.pdf

Strength. Performance. Passion.

2014

Vertical Roller Mills for Clinker Grinding within HolcimHolcim Technology Ltd, D. Woldt, A. Flacher

Loesche Symposium 2014, 2014-08-24 2014

2014

Agenda

2. Loesche VRMs in the Holcim Group

4. Comparison of Cement Grinding Systems5. Performance of Loesche Cement Mills6. Holcim Approach to ensure high VRM Performance and Reliability 7. Focus of Holcim and Tasks for VRM Manufacturers

1. Holcim Requirements on Cement Grinding Systems

3. Grinding Systems and Cement Types

Loesche Symposium 2014, WOD, 2014-08-24 2

2014

Requirements on grinding system Achievement of required product quality Flexibility regarding changing market demands

(cement types) High reliability and net availability Energy efficient system (kWh/t) Low maintenance and wear parts cost Simple installation and operation

Trends in Holcim Large single VRMs with high flexibility

and capacity Roller press systems

(semi-finish and finish grinding)

Holcim Requirements on Cement Grinding Systems

Carboneras LM 46 2+2


2014

Agenda






2014

First VRMs for cement grinding within Holcim were two LM 46 2+2 in Hon Chong plant, Vietnam, commissioned 1998

Development of VRMs for Slag and Cement Grinding in the Holcim Group

0

5

10

15

20

25

30

35

1

9

9

7

1

9

9

8

1

9

9

9

2

0

0

0

2

0

0

1

2

0

0

2

2

0

0

3

2

0

0

4

2

0

0

5

2

0

0

6

2

0

0

7

2

0

0

8

2

0

0

9

2

0

1

0

2

0

1

1

2

0

1

2

2

0

1

3

2

0

1

4

2

0

1

5

N

u

m

b

e

r

o

f

V

e

r

t

i

c

a

l

R

o

l

l

e

r

M

i

l

l

s

Overall

Loesche

Hon Chong LM 46 2+2


2014

No CommissioningYear Country Plant Type/SizeMotor power

kWCement (C) /

Slag (S)1 1998 Vietnam Hon Chong LM 46 2+2 2'800 C2 1998 Vietnam Hon Chong LM 46 2+2 2'800 C3 2004 Morocco Fs LM 46 2+2 2'200 C4 2004 Vietnam Thi Vai LM 56 2+2 4'450 C5 2004 Spain Carboneras LM 46 2+2 2'400 S / C6 2005 France Dunkerque LM 46 2+2 2'400 S7 2006 Morocco Settat LM 56 3+3 5'000 C8 2007 Canada Mississauga LM 56 3+3 4'600 S9 2008 South Africa Roodeport LM 53 3+3 4'000 C

10 2009 India Kolar Thondebhavi LM 56 3+3 5'400 C11 2010 India Dadri LM 56 3+3 5'400 C12 2010 India Nalagarh LM 56 3+3 5'400 C13 2010 India Bellary Kudithini LM 56 3+3 5'400 C / S14 2011 Ecuador Guayaquil LM 56 3+3 5'100 C15 2011 India Chanda LM 56 3+3 5'600 C16 2013 Indonesia Tuban 1 LM 56 3+3 5'200 C17 2013* Philippines Mabini LM 46 2+2 3'400 C18 2015 Indonesia Tuban 2 LM 56 3+3 5'200 C19 2016 Nigeria Calabar LM 70 4+4 8800 C

Loesche Cement and Slag Mills in the Holcim Group

* since 2013 in operation in the Holcim GroupLoesche Symposium 2014, WOD, 2014-08-24 6

2014

Loesche Cement and Slag Mills within the Holcim Group

Latin America1 x LM 56 3+3

Europe2 x LM 46 2+2

Africa1 x LM 46 2+21 x LM 56 3+31 x LM 70 4+4

India 5 x LM 56 3+3

Southeast Asia 3 x LM 46 2+21 x LM 56 2+22 x LM 56 3+3

Status 2014

North America1 x LM 56 3+3


2014

Agenda






2014

54%

16%

1%29%

Ballmills

Ballmillswithpregrinding

Horomills

57%

32%

10%

1%

LoescheLM

PfeifferMPS

FLSmidthOK

Polysius DOROL

Mill Systems used for Cement and Slag Production

VerticalRollerMills

Based on produced volumes in the Holcim Group 2013


2014

43%

26%

16%

8%

7%Multipleblendcement

Pozzolancement

Flyashcement

Slagcement

Limestonecement

Cement Types and Slag produced with VRMs (Holcim 2013)

OPC(3600 5300cm2/g)

CompositeCement(3400 5700cm2/g)

Slag(3200 6200cm2/g)

24%

65%11%


2014

Agenda






2014

Comparison is based on production of same cement type on three representative grinding systems (yearly figures 2012)

Multiple blend cement:5000 cm2/g acc. to Blaine, 1.8 % R45 m, clinker 76 %

Grinding systems

VRM Performance compared to other Grinding Systems


Closed circuit ball mill (cage rotor separator)

Ball mill with roller press pre-grinder

Vertical roller mill

2014

The production rate index and overall equipment efficiency of the VRM system exceeds the performance of the other systems

Mean time between failures is similar to other grinding systems

Comparison of Key Performance Indicators


50

60

70

80

90

100

110

120

130

140

150

BM PG+BM VRM

N

A

I

,

P

R

I

a

n

d

O

E

E

i

n

%

NetavailabilityindexProductionrateindexNetoverallequipmentefficiency

150

160

170

180

190

200

210

220

BM PG+BM VRM

M

T

B

F

i

n

h

Meantimebetweenfailures

2014

VRM system is most efficient but shows highest energy consumption of mill fan (high air flow rate and pressure drop)

Specific Electrical Energy Consumption

0

5

10

15

20

25

30

35

40

45

50

55

60

BM PG+BM VRM

S

p

e

c

.

e

l

e

c

t

r

i

c

a

l

e

n

e

r

g

y

c

o

n

s

u

m

p

t

i

o

n

i

n

k

W

h

/

t

AuxiliariesSeparatorFanPregrinderMill

100% 101%

71%


Multiple blend cement: 5000 cm2/g, 1.8 % R45 m

2014

Cement quality of VRM system is comparable to the other systems

Comparison of Mortar Strength

0

5

10

15

20

25

30

35

40

45

50

55

BM PG+BM VRM

M

o

r

t

a

r

s

t

r

e

n

g

t

h

i

n

M

P

a

1d

3d

28d


Multiple blend cement: 5000 cm2/g, 1.8 % R45 m

2014

Long term comparison of maintenance cost from 2004 to 2010 including wear parts replacement CAPEX show benefit of Vertical Roller Mill

Maintenance Cost (7 Year Period)

0

20

40

60

80

100

120

BM PG+BM VRM

M

a

i

n

t

e

n

a

n

c

e

c

o

s

t

i

n

%


Dadri LM 56 3+3

2014

Agenda






2014

Comparison is based on performance of three representative mills in 2013

Loesche VRM Performance compared to other VRMs

Plant A Plant B Plant C

Mill manufacturer Loesche Competitor 1 Competitor 2

Mill type LM 56 3+3

Installed motor power kW 5'000 3'750 2'300

Cement data

Cement type Limestone Cem. Limestone Cem. Pozzolana Cem.

Product fineness cm2/g 4'250 5'650 4300

% R45 m 3.3 3.1 6.3

Clinker % 61.6 67.3 60.8


2014

All three VRM types show excellent performance at similar level Every mill type has particular advantages and disadvantages regarding process and

operation as well as reliability and maintenance


16,4 18,8 17,6

7,5

9,98,6

0,8

1,20,9

0

5

10

15

20

25

30

35

40

LM563+3 OK364 MPS4250BC

S

p

e

c

.

e

l

e

c

t

r

i

c

a

l

e

n

e

r

g

y

c

o

n

s

u

m

p

t

i

o

n

i

n

k

W

h

/

t

SeparatorFanMill

Limestonecement4250cm2/g,3.3%R45m

Limestonecement5650cm2/g,3.1%R45m

Puzzolana cement4300cm2/g,6.3%R45m

Competitor 1 Competitor 2

Loesche VRM Performance compared to other VRMs

2014

Agenda






2014

Feed uniformity and particle size distribution

In order to achieve a high performance of a VRM system following areas need particular attention:

Holcim Approach to ensure Vertical Roller Mill Performance


Reliably and effective metal detection and extraction system

Optimized mill process especially concerning air and material distribution

Mill operation and control

Automatic mill protection system

Preventive maintenance

Wear part strategy and managementDunkerque LM 46 2+2

2014

Holcim VRM Protection and Reliability Concept

Holcim strategy to improve the process and reliability of vertical roller mills and to avoid gearbox failures.

Started in 2006 with following main fields:

Regular process and maintenance trainings

Online monitoring system

Automatic protective actions *

High level mill control

New drive concepts for largemills (multiple drive concept)

* (WO2009087558) METHOD FOR PROTECTING MILL DRIVES ON VERTICAL ROLLER MILLS AND VERTICAL ROLLER MILLS

Interlocks / Stop of mill operationProtective Actions / Mill stabilizationControl loops / Normal operation


2014

The most common root causes for failures are: breakage due to foreign metal poor casting quality inadequate rewelding

The increase in specific electrical energy consumption with worn grinding tools is around 1 to 2 kWh/t.

Holcim Wear Part Experience


2014

Ceramic inserts for sold out markets to reduce production loss due to downtime

Holcim Wear Part Strategy


Rewelding in case grinding tool contoursignificantly impacts the production rate

2014

Agenda






2014

Process

Focus of Holcim and Tasks for VRM Manufacturers


Reduction of specific air flow rate

Reduction of pressure drop

Air flow & pressure drop

Operation at minimum water injection

Water

Operation at lowest specific electrical energy consumption

Energy

High level control to optimize production rate and operating costs

Auto mode

2014

Maintenance

Easy maintenance

Wear part strategy with best TCO

Gearbox reliability



2014



Design

High flexibility regarding cement types

Compact grinding system

Larger single units

06-flacher-holcim-vertical-roller-mills-for-clinker-grinding-with-holcim.pdf

Documents

systemscarboneras lm

3europe2 x lm

2africa1 x lm

cement grinding

india chanda lm

india dadri lm

india nalagarh lm

morocco settat lm