Vertical Roller Mills for Clinker Grinding within Holcim

Transcription

1 Strength. Performance. Passion. Vertical Roller Mills for Clinker Grinding within Holcim Holcim Technology Ltd, D. Woldt, A. Flacher Loesche Symposium 2014,

2 Agenda 1. Holcim Requirements on Cement Grinding Systems 2. Loesche VRMs in the Holcim Group 3. Grinding Systems and Cement Types 4. Comparison of Cement Grinding Systems 5. Performance of Loesche Cement Mills 6. Holcim Approach to ensure high VRM Performance and Reliability 7. Focus of Holcim and Tasks for VRM Manufacturers Loesche Symposium 2014, WOD,

3 Holcim Requirements on Cement Grinding Systems 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) Carboneras LM Loesche Symposium 2014, WOD,

4 Agenda 1. Holcim Requirements on Cement Grinding Systems 2. Loesche VRMs in the Holcim Group 3. Grinding Systems and Cement Types 4. Comparison of Cement Grinding Systems 5. Performance of Loesche Cement Mills 6. Holcim Approach to ensure high VRM Performance and Reliability 7. Focus of Holcim and Tasks for VRM Manufacturers Loesche Symposium 2014, WOD,

5 Development of VRMs for Slag and Cement Grinding in the Holcim Group First VRMs for cement grinding within Holcim were two LM in Hon Chong plant, Vietnam, commissioned Number of Vertical Roller Mills Overall Loesche Hon Chong LM Loesche Symposium 2014, WOD,

6 Loesche Cement and Slag Mills in the Holcim Group No Commissioning Year Country Plant Type/Size Motor power kw Cement (C) / Slag (S) Vietnam Hon Chong LM '800 C Vietnam Hon Chong LM '800 C Morocco Fès LM '200 C Vietnam Thi Vai LM '450 C Spain Carboneras LM '400 S / C France Dunkerque LM '400 S Morocco Settat LM '000 C Canada Mississauga LM '600 S South Africa Roodeport LM '000 C India Kolar Thondebhavi LM '400 C India Dadri LM '400 C India Nalagarh LM '400 C India Bellary Kudithini LM '400 C / S Ecuador Guayaquil LM '100 C India Chanda LM '600 C Indonesia Tuban 1 LM '200 C * Philippines Mabini LM '400 C Indonesia Tuban 2 LM '200 C Nigeria Calabar LM C * since 2013 in operation in the Holcim Group Loesche Symposium 2014, WOD,

7 Loesche Cement and Slag Mills within the Holcim Group North America 1 x LM Europe 2 x LM Africa 1 x LM x LM x LM Southeast Asia 3 x LM x LM x LM Latin America 1 x LM India 5 x LM Status 2014 Loesche Symposium 2014, WOD,

8 Agenda 1. Holcim Requirements on Cement Grinding Systems 2. Loesche VRMs in the Holcim Group 3. Grinding Systems and Cement Types 4. Comparison of Cement Grinding Systems 5. Performance of Loesche Cement Mills 6. Holcim Approach to ensure high VRM Performance and Reliability 7. Focus of Holcim and Tasks for VRM Manufacturers Loesche Symposium 2014, WOD,

9 Mill Systems used for Cement and Slag Production Based on produced volumes in the Holcim Group 2013 Ball mills Loesche LM FLSmidth OK 54% Vertical Roller Mills 32% 16% 57% 29% Ball mills with pre grinding 1% Horomills 10% Pfeiffer 1% MPS Polysius DOROL Loesche Symposium 2014, WOD,

10 Cement Types and Slag produced with VRMs (Holcim 2013) OPC ( cm 2 /g) 24% Fly ash cement Composite Cement ( cm 2 /g) 26% 16% Limestone cement 11% 65% 8% Slag cement Slag ( cm 2 /g) Multiple blend cement 43% 7% Pozzolan cement Loesche Symposium 2014, WOD,

11 Agenda 1. Holcim Requirements on Cement Grinding Systems 2. Loesche VRMs in the Holcim Group 3. Grinding Systems and Cement Types 4. Comparison of Cement Grinding Systems 5. Performance of Loesche Cement Mills 6. Holcim Approach to ensure high VRM Performance and Reliability 7. Focus of Holcim and Tasks for VRM Manufacturers Loesche Symposium 2014, WOD,

12 VRM Performance compared to other Grinding Systems Comparison is based on production of same cement type on three representative grinding systems (yearly figures 2012) Multiple blend cement: cm 2 /g acc. to Blaine, 1.8 % R45 µm, clinker 76 % Grinding systems Closed circuit ball mill (cage rotor separator) Ball mill with roller press pre-grinder Vertical roller mill Loesche Symposium 2014, WOD,

13 Comparison of Key Performance Indicators 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 NAI, PRI and OEE in % Net availability index Production rate index Net overall equipment efficiency MTBF in h Mean time between failures BM PG+BM VRM 150 BM PG+BM VRM Loesche Symposium 2014, WOD,

14 Specific Electrical Energy Consumption VRM system is most efficient but shows highest energy consumption of mill fan (high air flow rate and pressure drop) Spec. electrical energy consumption in kwh/t Multiple blend cement: cm 2 /g, 1.8 % R45 µm 100 % 101 % 71 % BM PG+BM VRM Auxiliaries Separator Fan Pre grinder Mill Loesche Symposium 2014, WOD,

15 Comparison of Mortar Strength Cement quality of VRM system is comparable to the other systems Mortar strength in MPa Multiple blend cement: cm 2 /g, 1.8 % R45 µm BM PG+BM VRM 1d 3d 28d Loesche Symposium 2014, WOD,

16 Maintenance Cost (7 Year Period) Long term comparison of maintenance cost from 2004 to 2010 including wear parts replacement CAPEX show benefit of Vertical Roller Mill Maintenance cost in % BM PG+BM VRM Dadri LM Loesche Symposium 2014, WOD,

17 Agenda 1. Holcim Requirements on Cement Grinding Systems 2. Loesche VRMs in the Holcim Group 3. Grinding Systems and Cement Types 4. Comparison of Cement Grinding Systems 5. Performance of Loesche Cement Mills 6. Holcim Approach to ensure high VRM Performance and Reliability 7. Focus of Holcim and Tasks for VRM Manufacturers Loesche Symposium 2014, WOD,

18 Loesche VRM Performance compared to other VRMs Comparison is based on performance of three representative mills in 2013 Plant A Plant B Plant C Mill manufacturer Loesche Competitor 1 Competitor 2 Mill type LM Installed motor power kw 5'000 3'750 2'300 Cement data Cement type Limestone Cem. Limestone Cem. Pozzolana Cem. Product fineness cm 2 /g 4'250 5' % R45 µm Clinker % Loesche Symposium 2014, WOD,

19 Loesche VRM Performance compared to other VRMs 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 Spec. electrical energy consumption in kwh/t Limestone cement cm 2 /g, 3.3 % R45 µm 0,8 7,5 16,4 Limestone cement cm 2 /g, 3.1 % R45 µm 1,2 9,9 Puzzolana cement cm 2 /g, 6.3 % R45 µm 0,9 8,6 18,8 17,6 Separator Fan Mill 0 LM Competitor OK MPS Competitor 4250 BC2 Loesche Symposium 2014, WOD,

20 Agenda 1. Holcim Requirements on Cement Grinding Systems 2. Loesche VRMs in the Holcim Group 3. Grinding Systems and Cement Types 4. Comparison of Cement Grinding Systems 5. Performance of Loesche Cement Mills 6. Holcim Approach to ensure high VRM Performance and Reliability 7. Focus of Holcim and Tasks for VRM Manufacturers Loesche Symposium 2014, WOD,

21 Holcim Approach to ensure Vertical Roller Mill Performance In order to achieve a high performance of a VRM system following areas need particular attention: Feed uniformity and particle size distribution 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 management Dunkerque LM Loesche Symposium 2014, WOD,

22 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 Interlocks / Stop of mill operation Protective Actions / Mill stabilization Control loops / Normal operation Online monitoring system Automatic protective actions * High level mill control New drive concepts for large mills (multiple drive concept) * (WO ) METHOD FOR PROTECTING MILL DRIVES ON VERTICAL ROLLER MILLS AND VERTICAL ROLLER MILLS Loesche Symposium 2014, WOD,

23 Holcim Wear Part Experience 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. Loesche Symposium 2014, WOD,

24 Holcim Wear Part Strategy Ceramic inserts for sold out markets to reduce production loss due to downtime Rewelding in case grinding tool contour significantly impacts the production rate Loesche Symposium 2014, WOD,

25 Agenda 1. Holcim Requirements on Cement Grinding Systems 2. Loesche VRMs in the Holcim Group 3. Grinding Systems and Cement Types 4. Comparison of Cement Grinding Systems 5. Performance of Loesche Cement Mills 6. Holcim Approach to ensure high VRM Performance and Reliability 7. Focus of Holcim and Tasks for VRM Manufacturers Loesche Symposium 2014, WOD,

26 Focus of Holcim and Tasks for VRM Manufacturers Process Reduction of specific air flow rate Air flow & pressure drop Reduction of pressure drop Operation at minimum water injection Operation at lowest specific electrical energy consumption High level control to optimize production rate and operating costs Auto mode Water Energy Loesche Symposium 2014, WOD,

27 Focus of Holcim and Tasks for VRM Manufacturers Maintenance Easy maintenance Wear part strategy with best TCO Gearbox reliability Loesche Symposium 2014, WOD,

28 Focus of Holcim and Tasks for VRM Manufacturers Design High flexibility regarding cement types Compact grinding system Larger single units Loesche Symposium 2014, WOD,

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