NEW CEMENT

GRINDING PLANT
AT CEMMAC FACTORY,
HORNÉ SRNIE,
(SLOVAKIA)
§ Low energy consumption
§ High availability
§ Compact arrangement
§ Easy maintenance
 PSP Engineering completed another phase of
reconstruction at the cement plant CEMMAC,
Horné Srnie in Slovakia. After the successful
reconstruction of the kiln line in 2000 and
the total conversion of the plant from burning
in shaft kilns to burning in a rotary kiln, PSP
Engineering supplied a slag drum drier using
waste heat from the kiln line.
In June 2003 a new cement grinding plant
fitted with a ball mill 4.0 x 13.75 m seated on
hydrodynamic shoe-type bearings, working
in a closed mechanical circuit with a highly
efficient separator of the 3rd generation
PRESEP VTP 2700 and a pair of cyclones
ø 3200 separating subsequently the product
was commissioned.

TECHNICAL PARAMETERS AND DESCRIPTION OF MAIN SYSTEMS

Tube mill drum dia. 4.0 x 13.75 m
during dispatch.
The reconstruction of the buildings was
prepared for final connection of conveyors
and interconnection with the existing cement
grinding plant within 3 weeks, which was
fulfilled.

§ Two existing clinker silos were equipped § The grinding plant is sized for the
with new discharging mechanisms and belt production of cement CEM II/B – S 32,5
conveyors supplying clinker to the 200m3 and CEM I/A – 42,5 R at a guaranteed
feed bin of the grinding plant. capacity of 80 t/h.

§ Slag under 3-4% moisture is supplied to

the grinding plant building by a bypass in
a tube conveyor. If moisture is higher, the
slag is dried in a drum, stored in slag bins
and then conveyed to both the existing and
the new grinding plant. Bin volume is 80 m3 .

§ Gypsum is supplied to the grinding plant

together with slag by conveyors. The joint
conveying routes have a capacity of 60 t/h
of slag or gypsum. The 40m3 gypsum bin
has a discharging mechanism consisting
of an apron conveyor with enclosed pans.
The downstream weigh belt works with
variable speed.

Assembly of air separator

Up and down: Mill transport

Assembly of cyclones Assembly of the lower part of the air separator

 New cement grinding plant at CEMMAC factory
GRINDING SYSTEM DESCRIPTION
§ Mill
The ball mill has a size 4.0 x 13.75 m. It is
seated on shoe-type bearings with hydro-
dynamic lubrication. The mill is equipped with
an armored face wall, peripheral lifting shell
lining of the first compartment, adjustable
diaphragm, classifying shell lining of the
second compartment and discharge wall.
The 3100 kW mill drive is fitted with a Flender
gearbox DMGH type with two integrated pinions,
a PSP gear rim together with a rim cover. During
maintenance the mill can be rotated by an auxiliary
drive connected to the gearbox via a claw coupling.
Ball mill with drive
Mill inlet part
The recently developed shoe-type bearings
with four tilting segments seated on swinging
balance beams with hydrodynamic lubrication
adjust perfectly to the shape of the bearing
rings. The results are:
§ High reliability
§ Low operating costs
§ Easy maintenance
Shoe-type bearings have their own lubrication
Shoe-type bearing before placing
system. It automatically monitors pressures,
the mill drum
temperatures and flow rates.
Shoe-type bearing without a cover
Inside the 2nd compartment
Up and right: Mill drive assembly
§ Mill circuit

The mill operates with a mechanical
recirculation of material. A bucket elevator
followed by an air slide supplies the ground
material from the mill to an air separator
PRESEP VTP 2700. An indicator of metal
and non-ground particles integrated into
the air slide protects the separator against
mechanical damage. From the discharge of
the air slide the material is distributed into four
inlet chutes to the separator. The final product
is separated in the air separator. The fineness
required for the respective type of product is
controlled by the variable rotor speed.
A belt conveyor re-circulates the grit from the
separator to the feed bin of the mill, to which
the fresh components are supplied. The grit
is weighed on the belt conveyor and the fresh
components are dosed by means of weigh
belts.
Dust mixture is discharged to the separator
elevator.
The dosing of the fresh component is
controlled by a program, which adjusts the
fresh feed to the rate of re-circulated grit and The filter and the pair of separating cyclones
assures constant total mill feed.

Mill circuit scheme

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Discharge from the separator and

The final product is carried by air from the
separator to a pair of 3200 mm diameter
cyclones, which separate the air from the
product.
return grit conveyor belt
Dust mixture from the mill filter can be taken to
the separator elevator or to the final product.
Dust mixture from the dedusting filter of the
separator is taken to the final product.

A portion of the air from the cyclones is
returned to the separator while the rest goes to
a dedusting filter. The portion taken out of the
circuit corresponds with the fresh air intake,
which is controlled by a suction flap and the
required cooling of the product.
The final product from the separating cyclones
and the dust from the filters are lifted to a
higher floor of the building by a number of
screw conveyors and a bucket elevator.
From there a tube conveyor delivers the final
product to the storage and dispatch bins.

The mill has its own dedusting system

comprising another filter and mill fan.
Mill inlet and bucket elevator
§ Material transport

For low operating cost the transport of the
components of the cement production to the
grinding plant bin is mechanical.
As space is limited in the existing plant the
conveying system of the components from
different places is complicated. It comprises a
multitude of conveyor belts. The longest one is
the tube conveyor belt.
An identical tube belt conveys the final product
from the grinding plant to the top of the silos,
where the cement is distributed by a system of
air slides.
Belt bucket elevators provide all vertical
transports.

§ Filters
Final product supply from the grinding
The EFP filter cloth of the bag filters used for
plant
dedusting of the separating circuit and mill
reach a high degree of cleaning of the air. The
dust content of the inlet air reaches 150 g/m3
at an operating temperature of 98o C average.
The design temperature of filter sleeves is
150o C. During all operating conditions a dust
content of max. 10 mg/m3 is guaranteed for
the outlet air of the filters.

§ Performance parameters obtained

Product Fineness Electric energy Final product supply

Type of cement Capacity (t/h)
(Blaine) consumption (kWh/t)

CEM II/B-S 32,5 3500* 93 36

CEM I 42,5 3400 88 38

* including dust mixture from the preheater

During trial operation higher than guaranteed

capacities were attained.

The new design of the mill with the two-pinion

gearbox DMGH and shoe-type bearings met
the expected parameters PSP Engineering is
ready to supply mills of this design for higher
production capacities

Component and return grit dosing to

the mill
 www.pspengineering.cz

PSP Engineering a.s. is a leading

supplier of specialized products
and entire processing plants for
the building material and mineral
processing industries. PSP
Engineering has been involved in the
design and construction of cement
plants, lime works, quarry and
crushing plants, as well as gravel and
sand pits for more than 50 years.

PSP Engineering a.s.

Kojetínská 71, č.p.358
750 53 Přerov, Czech Republic
Tel. +420 581 232 604, +420 581 233 396
Fax +420 581 203 164
e-mail: info@pspeng.cz
www.pspengineering.cz

Grinding systems / New New cement grinding plant at Cemmac FACTORY EN 01/05

© 2005 PSP Engineering a.s.