Comparison of Roller Press with VRM

for slag grinding

Dr. Stefan Seemann, Dr. York Reichardt

Humboldt Wedag GmbH
KHD Roller Press

1 Feed Gate
2 Roller Casing
3 Drive

1
4 Cylindrical Roller Bearings
8 3
5 Hydraulic Cylinder
6 Hydraulic Pressing Device –
not pictured
7
7 Machine Frame
8 Service Platform

2
4

5
KHD Comflex Circuit with Roller Press
KHD GrindX Circuit with Roller Press
VRM circuit
Roller Press / VRM Comparison: Grinding of slag

ENERGY
 Roller press circuit takes about minimum 3 to 5 kWh/t less electric energy than VRM circuit in slag
grinding at approx 4200 Blaine

 Same heat consumption, both need water spray with slag feed moisture below 8 to 10 %, no predrying to
be foreseen

MAINTENANCE
 > 25.000 h lifetime of Roller Press stud lining for slag with grinding the studs once

 Very easy metal extraction in RP circuit possible

 Accessibility of key components in RP circuit much easier

 For VRM tyres need to be hardfaced a minimum of 10 times of to reach 25000 h for slag

◦ 10 times downtime of several days each

◦ Costs of hardfacing, specialized people needed

◦ Risk of cracks in the tyres while welding

 Roller Press / VRM Comparison: Grinding of slag

Same plant-Same slag-Same time

Stud - Lining

17,000 hours USED

23,000 hours still AVAILABLE

Specific wear rate:

less than 0.5 grams per ton

11
Roller Press / VRM Comparison: Grinding of slag

START UP AND OPERATION

 Similar with same number and same skills of people.

CIVIL COSTS
 Civil costs for RP circuit approx. 10 to 15 % lower than VRM circuit

 VRM transfers vibrations into the foundation(s) which need to be isolated

Example 2017 project RP vs VRM

Concrete Steel Excavation Formworks Civil Price

Main (m3) Lean (m3) Reinforc. (t) Structure (t) (m3) (m3) (€)

VRM 3260 190 158 796 4000 4760 2,676,964

KHD RP 2250 120 170 702 2000 3520 2,362,232
 KHD Roller Press References for slag grinding
Roller press motor
Year of Capacity Type: OPC, CEM I, Fineness
Customer Country Roller Press type rated power
order [t/h] PPC, CEM II, RM, LS [Blaine]
[kW]
2016 Ultartec, Patliputra, Bihar India 7-170/90 2x600 kW 40 Slag 4200 cm²/g
2015 West Medinipur, JSW India 16-170/180 2x1450 kW 90 slag 4500 cm²/g
2015 West Medinipur, JSW India 16-170/180 2x1450 kW 90 slag 4500 cm²/g
2015 Vijaynagar 2, JSW India 16-170/180 2x1450 kW 90 slag 4500 cm²/g
2015 Vijaynagar 2, JSW India 16-170/180 2x1450 kW 90 slag 4500 cm²/g
2015 Vijaynagar 1, JSW India 16-170/180 2x1450 kW 90 slag 4500 cm²/g
2015 Vijaynagar 1, JSW India 16-170/180 2x1450 kW 90 slag 4500 cm²/g
2015 Dolvi 2, JSW India 16-170/180 2x1450 kW 90 slag 4500 cm²/g
2015 Dolvi 2, JSW India 16-170/180 2x1450 kW 90 slag 4500 cm²/g
2015 Dolvi 1, JSW India 16-170/180 2x1450 kW 90 slag 4500 cm²/g
2015 Dolvi 1, JSW India 16-170/180 2x1450 kW 90 slag 4500 cm²/g
2015 Moerdijk Netherland 7-170/90 2x700 kW 100 slag 4200 cm²/g
90 Slag 4200 cm²/g
2011 Ciminter Abidjan Ivory cost 18-200/180 2x1600kW
120 OPC 3200 cm²/g
2009 Birla Durgapur India 16-170/180 2x1600kW 95 Slag 4000 cm²/g
135 OPC 3400 cm²/g
2009 Dungsam Bhutan
100 PSC 3600 cm²/g
135 OPC 3400 cm²/g
2009 Dungsam Bhutan
100 PSC 3600 cm²/g
Wopfinger Stein- und Kalkwerke 21 Slag 4300 cm²/g
2007 Austria 7-140/80 2x470KW
Schmid & Co 69 LS
16-170/180 2x1400kW
2007 JSW Cement, Nandyal India 170 Slag 4500 cm²/g
16-170/180 2x1400kW
16-170/180 2x1400kW
2007 JSW Cement, Nandyal India 170 Slag 4500 cm²/g
16-170/180 2x1400kW
ENCI
2001 Netherland 16-170/140 2x1300 kW 104 Slag 3000 cm²/g
Ijmuiden Heidelberger Zement
S.A. Cimenteries CBR, Bruxelles, 125 3000cm²/g
2000 Belgium 16-170/140 2x1300 kW Slag
Gent Plant 50 5000cm²/g
Wopfinger Stein- und Kalkwerke 40 Slag 4000cm²/g
1998 Austria RP 7-140/80 2x470kW
Schmid & Co 40 CEM I 4900cm²/g
1995 Ssangyong Cement Singapore 16-170/140 2x1150KW 50 Slag 4500 cm²/g
KHD Roller Press References for slag grinding

Example: Netherlands

Finish grinding Guarantee Performance test

Composition 100% slag 100% slag

Feed moisture 13.0% 8.8%

Capacity 104 t/h,<0.5%H2O 110 t/h,0.1% H2O

Fineness (Blaine) 3400 cm²/g 3590 cm²/g

Spec. power consumption

Roller Press, VSK-drive, fan 22.8 kWh/t 19.6 kWh/t

Total with filter fan, bucket elevator --- 21.4 kWh/t

Heat consumption 60.3 GJ/h 41.9 GJ/h

Slag grindability (CC. ball mill) --- 57.8 kWh/t

KHD Roller Press References for slag grinding

Example: Netherlands

Roller Press RP16-170/140, 2x1200 kW

VSK Separator 96-24/2750, 220.000 m³/h
KHD Roller Press References for slag grinding - INDIA

S. No. Parameter Guaranteed figures Achieved figures

1 Production 95 tph ground slag 98 tph ground slag

2 Product fineness 4000 cm2/gm 4119 cm2/gm

Sp. power consumption

3 29.8 25.7
at meters**, kWh/t cement

Roller Press RP16-170/180,

2x1600 kW
SKS Separator 2750,
250.000 m³/h

** For RP, Sep., Sep. fan and

RP recirculation elevator
KHD Roller Press References for slag grinding – INDIA II

S. No. Parameter Guaranteed figures Achieved figures

1 Production 170 tph ground slag 194 tph ground slag

2 Product fineness 4500 cm2/gm 4560 cm2/gm

Sp. power consumption

3 35.8 34.86
at meters**, kWh/t cement

Roller Press RP16-170/180,

4x1400 kW
2 X SKS Separator 3000,
2 X 250.000 m³/h

** For RP, Sep., Sep. fan

Roller Press / VRM Comparison

SUMMARY
 Both Roller press and VRM are reliable technologies for grinding of raw material, cement and slag

 Roller press is the more advanced technology due to:

◦ Lower electric energy consumption of the circuit

◦ Easier maintenance and less downtime

◦ Lower civil costs and less impact of vibrations on the neighborhood

 KHD is offering much bigger roller presses from now on than in the past for grinding of cement raw
material, cement and slag

 KHD is market leader in slag grinding and roller presses (outside China)
KHD Roller Presses: KHD market

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

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

25

SOURCE: OneStone Research March 2016 Over 300

Roller Presses
sold worldwide
Special Slag application-JUGPK Novotroizk, Russia 2 x 3 000 t cli./day

Core Equipment – Raw

Material
 Blending Beds with Stacker and Reclaimer
 230 t/h COMFLEX® SR 13-72 Raw Grinding
(Static V-Separator, Rollerpress, Static LS-
Separator)
 Raw Meal Homogenization and Dosing
 Process Fan and De-Dusting

Core Equipment - Clinker

 5 Stage Cyclone Preheater WT 7950/5
Process Feature  PYROCLON® R Calciner with PYROTOP®
Up to 30% of raw material mix: Blast Furnace  2-Pier Rotary Kiln, PYRORAPID® Ø 4,4 x 52
Slag
Fe-corrective component: Siemens Martin Slag m
 PYROJET® Kiln Burner HPJ/270 G
Source  PYROFLOOR® Cooler PFC 533 w.
Slag dump (see picture above) from nearby Hammercrusher
steel works
 Process Fan and De-Dusting
Result
World Record Core Equipment - Cement
Specific Heat Consumption only ~ 600 kcal/kg
cli.  Clinker Silo, 35 000 t
 Gypsum Crusher
 Dosing
 155 t/h Ball Mill Ø 5,0 x 14,5 m, closed circuit
with Dynamic Separator, SEPMASTER®
SKS-Z 3250
 Process Fan and De-Dusting
 6-Chamber Cement Silo, 21 000 t
 Cement Dispatch (Bulk, Big Pack and Bags)

Core Equipment - Automation

 ROMIX® Raw Material Quality Management
KHD Roller Press  PRODUX® Processautomation
RP 13-170/140
for 230 t/h Raw Meal
600 kcal/kg cli.
A successful project as an
example of using Alternative Raw
Materials
Comparison of Roller Press with VRM
for slag grinding

Dr. Stefan Seemann, Dr. York Reichardt

Humboldt Wedag GmbH