HRP - Hydraulic Roller Press

HRP - Hydraulic Roller Press

2 Increase energy efficiency and throughput Main features - Two types of wear lining are available welded hardfacing applied to a solid shaft or to a shrink fit sleeve - Roller design allows the use of rollers with either of the two types of wear lining - Bearing life is optimised by ample sizing and clean, con ditioned oil lubrication - Hinged frame allows easy roller removal High-pressure roller grinding of cement clinker and hard brittle materials is a modern and very energy-efficient process. During its relatively short history, roller press technology has undergone significant development from a pre-grinding process to a range of applications including semi-finish grinding and finish grinding. The HRP roller press developed by FLSmidth ranks among the most advanced and efficient units available. Its design incorporates the vast experience and expertise gained since roller press technology was first introduced. How it works In high-pressure roller press comminution the feed material is exposed to very high pressure for a short time. The high pressure causes formation of microcracks in the feed particles and generates a substantial amount of fine material. If the pressed material is fed directly to a ball mill, the power consumption required to produce finished cement will be much lower than that of a mill fed with unpressed material. This makes it possible to increase the throughput of a given size ball mill and reduce the specific power consumption of the whole mill system. A flexible solution The roller press is a flexible solution, highly suitable both for upgrades and for new installations. Upgrading may increase capacity by up to 100 percent, while the total specific energy consumption of new installations may be reduced by 20-30 percent compared with conventional grinding systems. The most typical process configurations are described in the following. Besides the cost-saving features already mentioned, the HRP roller press is characterised by: - long wear part life - low operational and maintenance costs - short shutdown for wear part replenishment

3 Process configuration As the grinding efficiency of a roller press is about twice that of a ball mill, considerable energy savings can be achieved by substitu t ing roller pressing for ball mill grinding. Basically, there are several different ways of incorporating a roller press in a grinding installation. Pregrinding system In the pregrinding system, the roller press is used for grinding fresh feed and a certain amount of recirculated pressed flakes. The roller-pressed material is finish ground in a conventional ball mill grinding circuit. Excessive flake recirculation may cause operational instability, so in practice the power consumption of the roller press is limited to approximately 5 kwh/t in the pregrinding mode. Semi-finish grinding system The semi-finish grinding system ensures better utilisation of the roller press. The roller press operates in closed circuit with two separators on top of each other a static separator making both disagglomerating and a coarse separation, and a dynamic separator. Fines from the roller press circuit are finish ground in a one-compartment ball mill to the required fineness. A very compact and energy-efficient semi-finish grinding installation can be attained by combining the roller press and the ball mill with a Sepax separator and our stabile RPGS separator. The roller press then operates in closed circuit with the static separator working as both disagglomerator and coarse separator, while the ball mill operates in closed circuit with the high-efficiency dynamic separator in the Sepax top module. As the separator air is used for both separation stages, the overall quantity of air and the fan power consumption remain at a very low level. Splitting the two circuits For some applications it may be necessary to split the two circuits, for instance if drying in the roller press circuit and cooling in the ball mill circuit are required, or if one roller press is to serve two or more ball mills. In that case the static separator is used as a stand-alone unit for the roller press circuit, and a standard high-efficiency Sepax is used for the ball mill circuit. Some types of feed material and some end products allow omitting the ball mill so that the roller press is used for finish grinding in a closed circuit with the dynamic Sepax separator on top of the static RPGS separator. When feasible, such a process configuration is very attractive in terms of operating and investment costs. Roller press pregrinding Roller press semi-finish grinding Two-stage Sepax Roller press finish grinding Mill air flow Seperator air flow Material flow

4 HRP - Hydraulic Roller Press 6 5 4 3 1 13 12

5 14 10 7 8 1 Grinding rollers with welded hardface wear lining 2 Oil-lubricated spherical roller bearing 2 3 Planetary reduction gear 4 Torque arm arrangement 11 5 Safety release coupling 6 Main motor 7 Hydraulic pressurising cylinders 9 8 Nitrogen-filled bladder accumulators 9 Bottom frame 10 Top frame 11 End section 12 Hinged L-shape end section 13 Elastomer shear pad 14 Feed control gate

6 Mechanical description Drive configuration The frame The frame is built up of parts fitted together by removable pins. The upper and lower frame, linked by vertical end sections, together form a horizontal U-frame. The U-frame is closed by an L-shape end section that is hinged to the lower frame and folds down for easy removal of the roller assemblies. This frame encloses and supports the bearing housings of the roller assemblies and carries the hydraulic cylinders of the pressurising device. The bearing housings slide on the lower frame. The upper frame supports a feed box and the dust casing, which encloses the two roller bodies. Rollers One roller is fixed while the other is horizontally movable and is pressed towards the former by four hydraulic cylinders. The position of the movable roller depends on the characteristics of the material fed to the press. Spacer shims between the roller bearing housings prevent the rollers from touching each other when pressurised without feed and permit adjustment of the minimum gap. Each of the two rollers has a separate drive. Each roller has a shaft mounted planetary reducer connected to the other reducer by a balanced torque arm system. The patented balanced torque arm system reduces foundation costs and complexity by taking the torque through the other reducer and not down to the foundation. Both drives include a safety release coupling between reducer and motor. The roller press is equipped with a hydraulic pressure system which ensures that the pressing force is kept practically even during the comminution process. In addition, it protects the press against overloading. Specific energy consumption, kwh/t 3500 Blaine Closed circuit Pregrinding Semi-finish Ball mill 37.5 28.0 17.1 Roller press 4.8 9.6 Separator 1.2 1.2 1.2 Grit separator 0.6 Separator fan 2.3 2.3 3.6 Mill fan 0.8 0.6 0.5 Aux. 1.2 1.6 1.8 Total kwh/t 43.0 38.5 34.5 Roller wear lining The rollers are normally supplied with a wear lining of welded hardfacing material. The hardfacing can be applied to either a solid shaft or a shrink fit sleeve bandage. Worn grinding surfaces are replenished by welding. Spot repairs or complete resurfacing can be performed with the rollers in situ, if desired.

7 Feed control gate To facilitate control of the choke feed press, FLS has introduced a motorised feed control gate located just above the roller surface. The feed control gate is only required for choke feed. The gate is used for smoothening the feed start and is suitable for trimming the press to optimum operation, for example when producing different cement types. It is also used for adjusting the throughput or power consumption of presses working with feed material of varying draw-in characteristics and/or friction characteristics. the roller gap or the roller press power consumption to maintain constant and optimum operating conditions at varying material characteristics. Local machine control The roller press has its own local control panel (PLC), similar to other complex machines. The panel is connected to the central control system. The panel is used for testing and running in the machine as well as for troubleshooting, independent of the central control system. The control panel includes a display that indicates status of the machine and has facilities for starting and stopping, making parameter changes, etc. The local control panel is delivered ready for use, thus saving engineering time during installation. Controlled feed by belt conveyor For roller presses used in semi-finish grinding systems, the controlled feed system greatly improves operational stability. The feeder ex traction rate may be controlled by Feed control gate

Characteristics, type range and typical data Roller Roller dimension speed Motor Press size D x W (peripheral) Capacity power A m 2 cm x cm m/sec t/h kw 0.60 117x51 1.60 198 2x230 0.90 136x66 1.60 297 2x350 1.25 148x85 1.60 412 2x485 1.60 160x100 1.60 528 2x615 2.00 174x115 1.60 660 2x770 2.50 192x130 1.60 825 2x960 3.00 212x141 1.60 990 2x1150 3.60 230x157 1.60 1188 2x1390 Dimensions Press size L1 L2 L3 H1 H2 B1 B2 B3 B4 m 2 mm mm mm mm mm mm mm mm mm 0.60 1775 4040 1170 1615 2065 1060 1260 2275 2330 0.90 2050 4615 1440 1985 2540 1220 1420 2460 2580 1.25 2320 5225 1640 2260 2890 1370 1570 3110 2800 1.60 2545 5665 1815 2480 3175 1475 1675 3450 2800 2.00 2830 6280 2060 2820 3575 1615 1815 4090 3190 2.50 3100 6860 2265 3130 4070 1800 2000 4270 3510 3.00 3480 7600 2605 3450 4410 1915 2115 4715 3510 3.60 4015 8740 2810 3900 5000 1985 2185 4910 3510 Copyright 2010 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth is a (registered) trademark of FLSmidth A/S. This brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for general reference only and may change at any time. www.flsmidth.com C 11-10 300-4-ENG Project Centre Denmark FLSmidth A/S Vigerslev Allé 77 DK-2500 Valby Copenhagen Tel: +45 3618 1000 Fax: +45 3630 1820 E-mail: info@flsmidth.com Project Centre USA FLSmidth Inc. 2040 Avenue C Bethlehem, PA 18017-2188 Tel: +1 610-264-6011 Fax: +1 610-264-6170 E-mail: info-us@flsmidth.com Project Centre India FLSmidth Private Limited FLSmidth House 34, Egatoor, Kelambakkam (Rajiv Gandhi Salai, Chennai) Tamil Nadu 603 103 Tel: +91-44-4748 1000 Fax: +91-44-2747 0301 E-mail: indiainfo@flsmidth.com