„Stand-alone“ Grinding Plants without Hot Gas Generator Results from India Presented by Dr. Daniel Strohmeyer Loesche GmbH, Germany
[email protected] www.loesche.com
Table of contents 1. Introduction 2. Loesche vertical roller mill for cement grinding 3. Ambuja Cement´s “Dadri” and “Nalagarh” projects 4. Projects “Dadri” and “Nalagarh” – Realize It! 5. “Dadri” and “Nalagarh” – Project Summary
Cemtech Dubai 2011
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Introduction - water and energy – precious resources Water and energy are the basis for life and the world as we know it today water as well as energy are not available unlimited both resources will become scarce and more expensive
Consequently saving energy and water is essential for ecologically and economically viable production - also or in particular in the cement industry
crude oil price development
Cemtech Dubai 2011
Introduction - operational aspects of vertical roller mills Water injection on the grinding table is a common way of stabilizing the grinding bed leading to a smooth and optimized operation of the mill Downsides of water injection water needs to be evaporated – thermal energy is required (e.g. cooler gases, hot gas generator) water may only be available in limited quantities or not at all
Resulting demands for stand alone grinding plants reduced or zero water injection no permanent utilization of hot gas generator – no fuel costs
Cemtech Dubai 2011
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Table of contents 1. Introduction 2. Loesche vertical roller mill for cement grinding 3. Ambuja Cement´s “Dadri” and “Nalagarh” projects 4. Projects “Dadri” and “Nalagarh” – Realize It! 5. “Dadri” and “Nalagarh” – Project Summary
Cemtech Dubai 2011
Loesche vertical roller mill for cement grinding - material flow, feed materials, products -
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Loesche vertical roller mill for cement grinding - cement grinding as part of the process -
quarry
CRM grinding
cement
kiln/cooler
cement grinding
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Loesche vertical roller mill for cement grinding - working principle 1) Rotary feeder 2) Mill table with grinding track 3) Master roller 4) Support roller 5) Rocker arm 6) Hydro-pneumatic spring system 7) Bevel-planetary-gear box 8) Electric motor 9) Gas inlet 10) Ring duct 11) Louvre ring 12) Classifier 13) Grit cone 14) Outlet duct to dedusting system
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Loesche vertical roller mill for cement grinding - grinding plant flow sheet -
Cemtech Dubai 2011
Table of contents 1. Introduction 2. Loesche vertical roller mill for cement grinding 3. Ambuja Cement´s “Dadri” and “Nalagarh” projects 4. Projects “Dadri” and “Nalagarh” – Realize It! 5. “Dadri” and “Nalagarh” – Project Summary
Cemtech Dubai 2011
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Ambuja Cement´s “Dadri” and “Nalagarh” projects - Location of grinding plants in India Nalagarh plant Dadri plant
New grinding stations each ~ 1.6 Mt/year of cement each with 1 x Loesche mill and 250 t/h of grinding capacity
Cemtech Dubai 2011
Ambuja Cement´s “Dadri” and “Nalagarh” projects - feed materials dry Fly-Ash
All feed materials have different physical properties and hence different grindabilities
Gypsum
Clinker
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Ambuja Cement´s “Dadri” and “Nalagarh” projects - grinding test (1) Laboratory mill LM 3,6
Flow sheet LM 3,6
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Ambuja Cement´s “Dadri” and “Nalagarh” projects - grinding test (2) -
LOESCHE Grindability Factors (MF, LF) spec. energy consumption wear factor (vp)
The factors are used to determine the right mill and gear box size as well as a suitable material for the wear parts
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Ambuja Cement´s “Dadri” and “Nalagarh” projects
<== poor - grindability - good ==>
- cement grindability -
Dadri/ Nalagarh
5
15
25
35
45
power consumption - mill [kWh/t]
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Ambuja Cement´s “Dadri” and “Nalagarh” projects - mill selection LM 56.3+3 (250 t/h PPC)
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Ambuja Cement´s “Dadri” and “Nalagarh” projects - key data -
Capacity
250 t/h PPC
Gearbox power
5.400 kW (Flender)
Classifier
LSKS 102 CS; 560 kW
Fan motor power
3.000 kW
Mill diameter ∅
13,5 m
Height H
20,0 m
Grinding table diameter ∅
5.600 mm
Grinding table weigth
109 t
M – Roller
3 * ∅ 2.450 mm
S – Roller
3 * ∅ 1.600 mm
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Ambuja Cement´s “Dadri” and “Nalagarh” projects - scope of supply and product Loesche scope of supply Mill incl. classifier Sampling station Air slides for product transport
Product PPC – 4000 Blaine
250 t/h
30,75 kWh/t
PPC – 60% clinker + 5% gypsum + 35% dry fly ash (2500 Blaine)
Cemtech Dubai 2011
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Table of contents 1. Introduction 2. Loesche vertical roller mill for cement grinding 3. Ambuja Cement´s “Dadri” and “Nalagarh” projects 4. Projects “Dadri” and “Nalagarh” – Realize It! 5. “Dadri” and “Nalagarh” – Project Summary 6. Cement types produced in Loesche VRM´s
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Projects “Dadri” and “Nalagarh” – Realize It! - mill base frame mill base frame
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Projects “Dadri” and “Nalagarh” – Realize It! - pedestals and bearing blocks -
bearing block
~ 5,5 m
pedestal
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Projects “Dadri” and “Nalagarh” – Realize It! - erection of gear box -
gear box
gear box base plate
Chockfast
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Projects “Dadri” and “Nalagarh” – Realize It! - mill housing and classifier ground-assembly mill housing
classifier
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Projects “Dadri” and “Nalagarh” – Realize It! - mill with housing and erection of classifier mill housing
~ 16,5 m ~ 10 m
classifier
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Projects “Dadri” and “Nalagarh” – Realize It! - Loesche LM 56.3+3 -
~ 20 m
Loesche LM 56.3+3
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Projects “Dadri” and “Nalagarh” – Realize It! - dry fly-ash feeding system fly ash feeding
clinker/gypsum feeding Cemtech Dubai 2011
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Projects “Dadri” and “Nalagarh” – Realize It! - grinding plant (Nalagarh) -
filter cement silo
mill
fan
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Table of contents 1. Introduction 2. Loesche vertical roller mill for cement grinding 3. Ambuja Cement´s “Dadri” and “Nalagarh” projects 4. Projects “Dadri” and “Nalagarh” – Realize It! 5. “Dadri” and “Nalagarh” – Project Summary
Cemtech Dubai 2011
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“Dadri” and “Nalagarh” – Project Summary - schedule (Dadri) -
April 2007
Mill order
November 2008
Delivery (FOB)
December 2008
Start of Erection
December 2009
Start of Commissioning
February 2010
First feed
April 2010
250 t/h PPC reached
September 2010
Further optimization – achieved: zero water injection and no HGG
Cemtech Dubai 2011
“Dadri” and “Nalagarh” – Project Summary - performance data (Dadri) -
Dadri LM 56.3+3
PPC Guarantee
Achieved *
Mill through-put (t/h)
250
253
Fineness
4000
3920
Feed moisture (%)
-
1,1
Product moisture (%)
-
0,3
30,75
25,60
Spec. Power consumption: (kWh/t) (mill, fan, classifier, aux.) * based upon 24 hours trial
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“Dadri” and “Nalagarh” – Project Summary - zero water injection and no HGG -
Cemtech Dubai 2011
„Stand-alone“ Grinding Plants without Hot Gas Generator Results from India Presented by Dr. Daniel Strohmeyer Loesche GmbH, Germany
[email protected] www.loesche.com
Cemtech Dubai 2011
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