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Stand-alone Grinding Plants

without Hot Gas Generator Results from India


Presented by
Dr. Daniel Strohmeyer
Loesche GmbH, Germany
loesche@loesche.de
www.loesche.com

Table of contents
1. Introduction
2. Loesche vertical roller mill for cement grinding
3. Ambuja Cements Dadri and Nalagarh projects
4. Projects Dadri and Nalagarh Realize It!
5. Dadri and Nalagarh Project Summary

Cemtech Dubai 2011

Introduction
- water and energy precious resources Water and energy are the basis for life and the world as we know
it today
water as well as energy are not available unlimited
both resources will become scarce and more expensive

Consequently saving energy and


water is essential for ecologically
and economically viable
production - also or in particular in
the cement industry

crude oil price development

Cemtech Dubai 2011

Introduction
- operational aspects of vertical roller mills Water injection on the grinding table is a common way of
stabilizing the grinding bed leading to a smooth and optimized
operation of the mill
Downsides of water injection
water needs to be evaporated thermal energy is required (e.g.
cooler gases, hot gas generator)
water may only be available in limited quantities or not at all

Resulting demands for stand alone grinding plants


reduced or zero water injection
no permanent utilization of hot gas generator no fuel costs

Cemtech Dubai 2011

Table of contents
1. Introduction
2. Loesche vertical roller mill for cement grinding
3. Ambuja Cements Dadri and Nalagarh projects
4. Projects Dadri and Nalagarh Realize It!
5. Dadri and Nalagarh Project Summary

Cemtech Dubai 2011

Loesche vertical roller mill for cement grinding


- material flow, feed materials, products -

Cemtech Dubai 2011

Loesche vertical roller mill for cement grinding


- cement grinding as part of the process -

quarry

CRM grinding

cement

kiln/cooler

cement grinding

Cemtech Dubai 2011

Loesche vertical roller mill for cement grinding


- working principle 1) Rotary feeder
2) Mill table with grinding track
3) Master roller
4) Support roller
5) Rocker arm
6) Hydro-pneumatic spring system
7) Bevel-planetary-gear box
8) Electric motor
9) Gas inlet
10) Ring duct
11) Louvre ring
12) Classifier
13) Grit cone
14) Outlet duct to dedusting system

Cemtech Dubai 2011

Loesche vertical roller mill for cement grinding


- grinding plant flow sheet -

Cemtech Dubai 2011

Table of contents
1. Introduction
2. Loesche vertical roller mill for cement grinding
3. Ambuja Cements Dadri and Nalagarh projects
4. Projects Dadri and Nalagarh Realize It!
5. Dadri and Nalagarh Project Summary

Cemtech Dubai 2011

Ambuja Cements Dadri and Nalagarh projects


- Location of grinding plants in India Nalagarh plant
Dadri plant

New grinding stations


each ~ 1.6 Mt/year of cement
each with 1 x Loesche mill and 250 t/h of
grinding capacity

Cemtech Dubai 2011

Ambuja Cements Dadri and Nalagarh projects


- feed materials dry Fly-Ash

All feed materials have different physical properties and


hence different grindabilities

Gypsum

Clinker

Cemtech Dubai 2011

Ambuja Cements Dadri and Nalagarh projects


- grinding test (1) Laboratory mill LM 3,6

Flow sheet LM 3,6

Cemtech Dubai 2011

Ambuja Cements Dadri and Nalagarh projects


- grinding test (2) -

LOESCHE Grindability Factors (MF, LF)


spec. energy consumption
wear factor (vp)

The factors are used to determine the right mill and gear box size as well
as a suitable material for the wear parts

Cemtech Dubai 2011

Ambuja Cements Dadri and Nalagarh projects

<== poor - grindability - good ==>

- cement grindability -

Dadri/ Nalagarh

15

25

35

45

power consumption - mill [kWh/t]

Cemtech Dubai 2011

Ambuja Cements Dadri and Nalagarh projects


- mill selection LM 56.3+3
(250 t/h PPC)

Cemtech Dubai 2011

Ambuja Cements Dadri and Nalagarh projects


- key data -

Capacity

250 t/h PPC

Gearbox power

5.400 kW (Flender)

Classifier

LSKS 102 CS; 560 kW

Fan motor power

3.000 kW

Mill diameter

13,5 m

Height H

20,0 m

Grinding table diameter

5.600 mm

Grinding table weigth

109 t

M Roller

3 * 2.450 mm

S Roller

3 * 1.600 mm

Cemtech Dubai 2011

Ambuja Cements Dadri and Nalagarh projects


- scope of supply and product Loesche scope of supply
Mill incl. classifier
Sampling station
Air slides for product transport

Product
PPC 4000 Blaine

250 t/h

30,75 kWh/t

PPC 60% clinker + 5% gypsum + 35% dry fly ash (2500 Blaine)

Cemtech Dubai 2011

Table of contents
1. Introduction
2. Loesche vertical roller mill for cement grinding
3. Ambuja Cements Dadri and Nalagarh projects
4. Projects Dadri and Nalagarh Realize It!
5. Dadri and Nalagarh Project Summary
6. Cement types produced in Loesche VRMs

Cemtech Dubai 2011

Projects Dadri and Nalagarh Realize It!


- mill base frame mill base frame

Cemtech Dubai 2011

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Projects Dadri and Nalagarh Realize It!


- pedestals and bearing blocks -

bearing block

~ 5,5 m

pedestal

Cemtech Dubai 2011

Projects Dadri and Nalagarh Realize It!


- erection of gear box -

gear box

gear box base plate

Chockfast

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Projects Dadri and Nalagarh Realize It!


- mill housing and classifier ground-assembly mill housing

classifier

Cemtech Dubai 2011

Projects Dadri and Nalagarh Realize It!


- mill with housing and erection of classifier mill housing

~ 16,5 m
~ 10 m

classifier

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Projects Dadri and Nalagarh Realize It!


- Loesche LM 56.3+3 -

~ 20 m

Loesche LM 56.3+3

Cemtech Dubai 2011

Projects Dadri and Nalagarh Realize It!


- dry fly-ash feeding system fly ash feeding

clinker/gypsum feeding
Cemtech Dubai 2011

13

Projects Dadri and Nalagarh Realize It!


- grinding plant (Nalagarh) -

filter
cement silo

mill

fan

Cemtech Dubai 2011

Table of contents
1. Introduction
2. Loesche vertical roller mill for cement grinding
3. Ambuja Cements Dadri and Nalagarh projects
4. Projects Dadri and Nalagarh Realize It!
5. Dadri and Nalagarh Project Summary

Cemtech Dubai 2011

14

Dadri and Nalagarh Project Summary


- schedule (Dadri) -

April 2007

Mill order

November 2008

Delivery (FOB)

December 2008

Start of Erection

December 2009

Start of Commissioning

February 2010

First feed

April 2010

250 t/h PPC reached

September 2010

Further optimization achieved:


zero water injection and no HGG

Cemtech Dubai 2011

Dadri and Nalagarh Project Summary


- performance data (Dadri) -

Dadri
LM 56.3+3

PPC
Guarantee

Achieved *

Mill through-put (t/h)

250

253

Fineness

4000

3920

Feed moisture (%)

1,1

Product moisture (%)

0,3

30,75

25,60

Spec. Power consumption:


(kWh/t)
(mill, fan, classifier, aux.)
* based upon 24 hours trial

Cemtech Dubai 2011

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Dadri and Nalagarh Project Summary


- zero water injection and no HGG -

Cemtech Dubai 2011

Stand-alone Grinding Plants


without Hot Gas Generator Results from India
Presented by
Dr. Daniel Strohmeyer
Loesche GmbH, Germany
loesche@loesche.de
www.loesche.com

Cemtech Dubai 2011

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