Strength. Performance. Passion. Vertical Roller Mills for Clinker Grinding within Holcim Holcim Technology Ltd, D. Woldt, A. Flacher Loesche Symposium 2014, 2014-08-24 2014
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, 2014-08-24 2014 2
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 46 2+2 Loesche Symposium 2014, WOD, 2014-08-24 2014 3
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, 2014-08-24 2014 4
Development of VRMs for Slag and Cement Grinding in the Holcim Group First VRMs for cement grinding within Holcim were two LM 46 2+2 in Hon Chong plant, Vietnam, commissioned 1998 35 Number of Vertical Roller Mills 30 25 20 15 10 5 Overall Loesche 0 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 Hon Chong LM 46 2+2 Loesche Symposium 2014, WOD, 2014-08-24 2014 5
Loesche Cement and Slag Mills in the Holcim Group No Commissioning Year Country Plant Type/Size Motor power kw Cement (C) / Slag (S) 1 1998 Vietnam Hon Chong LM 46 2+2 2'800 C 2 1998 Vietnam Hon Chong LM 46 2+2 2'800 C 3 2004 Morocco Fès LM 46 2+2 2'200 C 4 2004 Vietnam Thi Vai LM 56 2+2 4'450 C 5 2004 Spain Carboneras LM 46 2+2 2'400 S / C 6 2005 France Dunkerque LM 46 2+2 2'400 S 7 2006 Morocco Settat LM 56 3+3 5'000 C 8 2007 Canada Mississauga LM 56 3+3 4'600 S 9 2008 South Africa Roodeport LM 53 3+3 4'000 C 10 2009 India Kolar Thondebhavi LM 56 3+3 5'400 C 11 2010 India Dadri LM 56 3+3 5'400 C 12 2010 India Nalagarh LM 56 3+3 5'400 C 13 2010 India Bellary Kudithini LM 56 3+3 5'400 C / S 14 2011 Ecuador Guayaquil LM 56 3+3 5'100 C 15 2011 India Chanda LM 56 3+3 5'600 C 16 2013 Indonesia Tuban 1 LM 56 3+3 5'200 C 17 2013* Philippines Mabini LM 46 2+2 3'400 C 18 2015 Indonesia Tuban 2 LM 56 3+3 5'200 C 19 2016 Nigeria Calabar LM 70 4+4 8 800 C * since 2013 in operation in the Holcim Group Loesche Symposium 2014, WOD, 2014-08-24 2014 6
Loesche Cement and Slag Mills within the Holcim Group North America 1 x LM 56 3+3 Europe 2 x LM 46 2+2 Africa 1 x LM 46 2+2 1 x LM 56 3+3 1 x LM 70 4+4 Southeast Asia 3 x LM 46 2+2 1 x LM 56 2+2 2 x LM 56 3+3 Latin America 1 x LM 56 3+3 India 5 x LM 56 3+3 Status 2014 Loesche Symposium 2014, WOD, 2014-08-24 2014 7
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, 2014-08-24 2014 8
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, 2014-08-24 2014 9
Cement Types and Slag produced with VRMs (Holcim 2013) OPC (3 600 5 300 cm 2 /g) 24% Fly ash cement Composite Cement (3 400 5 700 cm 2 /g) 26% 16% Limestone cement 11% 65% 8% Slag cement Slag (3 200 6 200 cm 2 /g) Multiple blend cement 43% 7% Pozzolan cement Loesche Symposium 2014, WOD, 2014-08-24 2014 10
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, 2014-08-24 2014 11
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: 5 000 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, 2014-08-24 2014 12
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 % 150 140 130 120 110 100 90 80 Net availability index Production rate index Net overall equipment efficiency MTBF in h 220 210 200 190 180 170 Mean time between failures 70 60 160 50 BM PG+BM VRM 150 BM PG+BM VRM Loesche Symposium 2014, WOD, 2014-08-24 2014 13
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 60 55 50 45 40 35 30 25 20 15 10 5 0 Multiple blend cement: 5 000 cm 2 /g, 1.8 % R45 µm 100 % 101 % 71 % BM PG+BM VRM Auxiliaries Separator Fan Pre grinder Mill Loesche Symposium 2014, WOD, 2014-08-24 2014 14
Comparison of Mortar Strength Cement quality of VRM system is comparable to the other systems Mortar strength in MPa 55 50 45 40 35 30 25 20 15 10 5 0 Multiple blend cement: 5 000 cm 2 /g, 1.8 % R45 µm BM PG+BM VRM 1d 3d 28d Loesche Symposium 2014, WOD, 2014-08-24 2014 15
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 120 100 Maintenance cost in % 80 60 40 20 0 BM PG+BM VRM Dadri LM 56 3+3 Loesche Symposium 2014, WOD, 2014-08-24 2014 16
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, 2014-08-24 2014 17
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 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 cm 2 /g 4'250 5'650 4 300 % R45 µm 3.3 3.1 6.3 Clinker % 61.6 67.3 60.8 Loesche Symposium 2014, WOD, 2014-08-24 2014 18
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 40 35 30 25 20 15 10 5 Limestone cement 4 250 cm 2 /g, 3.3 % R45 µm 0,8 7,5 16,4 Limestone cement 5 650 cm 2 /g, 3.1 % R45 µm 1,2 9,9 Puzzolana cement 4 300 cm 2 /g, 6.3 % R45 µm 0,9 8,6 18,8 17,6 Separator Fan Mill 0 LM 56 3+3 Competitor OK 36 4 1 MPS Competitor 4250 BC2 Loesche Symposium 2014, WOD, 2014-08-24 2014 19
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, 2014-08-24 2014 20
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 46 2+2 Loesche Symposium 2014, WOD, 2014-08-24 2014 21
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) * (WO2009087558) METHOD FOR PROTECTING MILL DRIVES ON VERTICAL ROLLER MILLS AND VERTICAL ROLLER MILLS Loesche Symposium 2014, WOD, 2014-08-24 2014 22
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, 2014-08-24 2014 23
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, 2014-08-24 2014 24
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, 2014-08-24 2014 25
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, 2014-08-24 2014 26
Focus of Holcim and Tasks for VRM Manufacturers Maintenance Easy maintenance Wear part strategy with best TCO Gearbox reliability Loesche Symposium 2014, WOD, 2014-08-24 2014 27
Focus of Holcim and Tasks for VRM Manufacturers Design High flexibility regarding cement types Compact grinding system Larger single units Loesche Symposium 2014, WOD, 2014-08-24 2014 28