7 Cemtech Bangkok Operational experience with VRM for cement grinding (Citeureup - Port Kembla - Jhansi) J-M Reginster, HTC Indonesia Input —Citeureup_—_: Jack Gulikers Port Kembla : Manvinder Singh Jhansi + Anuj Jain / Sanjeev Gupta Heldelvergcement HEIDELBERG ora as we TECHNOLOGY CENTERM Agenda 1 Specificity of each installation 1.Mill characteristics table and drive 2.Mill characteristics separator - gas flow tonnages 3.Product types 4.Cement produced port Kembla - Janshi 5.Port Kembla Gbr Pfeiffer MVR 6000 C6 6.Janshi Loesche LM 53 3+3 7.Citeureup OK 42.4 8.Conclusions Heidelbergcement EIDELBE! e/as/is ne TECHNOLOGY CENTER1. Mill characteristics table and drive Data \VRM Cementgrinding 501+ vembia Jhansi Indocement P6C installes MotorPower 550 250 00 s.e00 ll tabledaneter 000 5300 600 5.600 Roller ameter/widhe 7205.60 ox 0 22801010 7505 7 number fllers ¢ 343 a 343 ill peed 2 222 22 23 wall oaietvolanel | #10000 S,008 3,008 0,008 wil inft tem 2 Ds 1 15 ispeed newer 2a so-e0 0-50 ra i ee Frid Tare De cate heating Tet 7 Tell deaningfor specs adative ca movable cutefor specs leaning Holdelbergcoment 6/25/15 Ne3 IDELBERG HEI TECHNOLOGY CENTERa 2. Mill characteristics separator - gas flow Heidelbergcement 6/25/18 Nr. \VRM Cementgrinding Port Kembla Iseparstortype rotor diancter zhi Installed ator? ower |Adiow dengan [ae7deth ratio ladiow Mtoe [Contrelgation eatzoureeor ving [Graranteecl capac Indocement PEC Isis 87S os. Ea 250 damper Wega Cinkereooler pupae Maix_|_P0e: 1.100 ‘0 _| = VSO Tat ge Ginkerooler P44, HGG standby pec_| ore 380 [50 ‘200 [40 et yet IDELBERG HEI TECHNOLOGY CENTERMI 3. Products types Raw Materials Port Kembla cem_| aces [Ginker 90% [Gypsum 3% we lumestone 3 slag IFy-ash Hrass [Moisture content additives [sypsum lumestone. sta llyash Tras lainkersource [Gnindability tested Gladstone/impors ‘adalnegcaae Pe Ossie nes max 10% Damioh Plank Indocement P6C Mix | Pcc 15% 1% 7% max % aX 8% max 12% max 20% Pe-P7-P8-PLL HEIDELBERG TECHNOLOGY CENTERMi 4. Cement produced Port Kembla and Jhansi Port Kembla Jhansi GM css cm oss aw rpc prc Actua cuarentece | _acvevedPcr Joperstion| | cuarantees |_achievedpor | actual operation vam [va [va [ vw [om vam [va [vem [ vem [om toh zoe_| 190 [220 [155 [191 mas] goase_| 657 | 2552 | i260 ewe nate tal nly ni [me [ a | = | s is [ee Dem) a [ es Separator as] 4 30] -si1_| ase naw Taira as mars [978 | 66 | 9730 | 977 fineness laine sa00 | e200 | anc0 | azon | 3900 zeo0 | 6s0 | 0608 | a580 | 3197 Fineness Rescue wetsieve mu a _| wm [toongh| ae | 58 3a | at Water consumption) VL [16 3 [compressive strength 14374 ae | uz acy Pa a ma [203 Ee aa st aaa | 286 rey 559 a wn | 82 Port Kembla: actual VRM data not representative. Residue 3.5 % achieved after first optimization. Jhansi : BM is with RP pre-grinder, VRM product has 3 % higher fly ash than BM. Heidelbergcement HEIDELBERG eyas/is nes TECHNOLOGY CENTERMi 5. Port Kembla - Gbr Pfeiffer multi drive 6 MVR vertical roller mill HEIDELBERG CENTER 6/25/15 Ne.7Mi 5. Port Kembla - Gbr Pfeiffer multi drive 7. | | sea ial lubrication unit| | | i i { Paaaem |e 1 | ot legac euenmttes eee: : ALG meee ae | & adie | ‘slide rails: “Anrrabientart a aa = C $4 gee Fundamentfei Getriebe _Getriebeplatte Manitellerlagerung —Mahltellerlagerung _Abtrigbsflansch feundatian part gearbox foundation plate of fable Mirus! bearing fable thrust Bearing output flange; Heideivergcement EIDELBERG Seas Ne TECHNOLOGY CENTERMi 5. Port Kembla - Gbr Pfeiffer multi drive 8 6/25/15 ro ‘HEIDELBERGCEMENTCMi 5. Port Kembla - Gbr Pfeiffer multi drive 9 » Multi drive is working smoothly no synchronization issue. » Hard facing technique is successful. 10-15 t/h (7%)lost after 30-35 mm wear. + Special gypsum preparation device. No major issue in cement quality but it took some efforts to adjust. It is a successful story. Holdelbergcoment HEIDELBERG S/35/48 Ne10 TECHNOLOGY CENTE!MI 6. Janshi Loesche mill 53 3+3 10 6/25/15 Neat HEIDELBERGCE MENTSMI 6. Janshi Loesche mill 53 3+3 11 + Classical Loesche solution working well. + Flyash introduce at the mill top in the separator. + Product quality has no issue. + No maintenance issue. Naldelbergcement HEIDELBERG S/is/As Nea TECHNOLOGY CENTERMI 7. Citeureup OK 42.4 mill 12 « Components and recipe Content % Moisture % Limestone 10 8 ‘Trass 20 24 Gypsum 5 9 + Humid component feeding is an issue Separate heated feeding system for wet components Rotary valve self cleaning with a scraper. Heidelbergcement HEIDELBERG meres TECHNOLOGY CENTERMi 7. Citeureup OK 42.4 mill Holdelbergcoment 6/25/15 Nraa Grinding roller Nozzle ring Grinding table Roller stopper Main hydraulic loading system 13 HEIDELBERG CENTERM7. Citeureup OK 42.4 mill 14 Movable chute for wet additive is a good design. Heldelbergcement HEIDELBERG 6/25/15 NraS TECHNOLOGY CENTERMi 7. Citeureup OK 42.4 mill 15 PCC Cement quality | esters seeseeastanel Value Suffix. w/otolerance Value Suffix with tolerance ar hes mu m rah 200 Min 278.2 1 * 281,0 x 05 Max 0.48 02 % 0.28 See Pernt) x 19 Max 79 1 x 169 EMSA mm/s 2 Max 13 02 mis ta nT serve 73 Max 16a 2 % 158 eres riers beurre 86 Max a8 2 x 36 Heidelbergcement HEIDELBERG TECHNOLOGY CENTERMI 8. Conclusion 16 Vertical mill - standard equipment Ball mill - Vertical mill Different operating philosophy 30 min / 1min Different maintenance approach years/month Vertical mill advantages a Compact (reduction of civil volume / one machine required) Easy to dry and grind together - ideal for composite cement Wide range product possible Easy to change product quality New drive large capacity possibility «Matured markets Heidelbergcement S/s/As NT Special caution - sensitivity to quality variation - expertise EIDELBE! TECHNOLOGY CENTERMI 8. Conclusion 17 + Special attention 4 Sensitive machine needs attention: process « Feed quality variation « Fast reaction « Sensitive to details « Grinding element profiles « Water spray and grinding aid « Accurate preventive maintenance required « Sealing ( false air) « Grinding element profiles maintenance « Hydraulic competence + For future project Vertical mill is the preferred option. Heidelbergcement EIDELBE! TECHNOLOGY CENTER SSSA Nee HEIDELBERG