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of installed expertise
Innovative FLENDER vertical mill drives
for grinding coal, raw meal, slag and clinker.
siemens.com/verticalmilldrives
E20001-A370-P900-X-7600_EN.indd 1
03.04.13 11:25
5,000,000 kW
thats roughly equivalent to the gross power output of the most
important natural gas power plants in Germany. 5,000,000 kW
thats also the capacity of FLENDER vertical mill drives installed
internationally. For you, that means primarily three things: quality,
experience and versatility on the part of your drive technology
supplier.
FLENDER vertical mill drives are indispensable for those
who want the right solution for every vertical mill requirement, those who value sustainable, energy-efficient, optimized processes and those for whom drive availability and
safety have top priority in short, all those who want to
rely 100% on their drive technology.
In addition to first-class product quality and consultation
based on decades of experience and in-depth industry
expertise, we offer by far the most comprehensive portfolio of highly advanced, mature and proven drive solutions.
Whats more, we produce them ourselves from start to
finish.
With our global production concept and extensive expertise, thousands of references in all capacity classes and
partnerships with the worlds most significant OEMs
plus extraordinary, reliable customer service and the
entire might of the Siemens corporation we are the
right partner for all kinds of drives. We maintain good
customer relationships, treating both plant engineers and
end-users as peers and developing new solutions with
them, always with a view to the perfect result. This can
only be achieved with the outstanding technical expertise
of a leading innovator.
Product
Capacity range
Coal
Raw meal
KMP
Slag
Clinker
KMPS
KMPP
EMPP
MultipleDrive
4,000 kW
6,000 kW
8,000 kW
10,000 kW
12,000 kW
14,000 kW
16,000 kW
FLENDER KMP
Design
Capacity
Installation sizes
18
Transmission ratios
i = 15 to 45
Torque
25,000 to 700,000 Nm
(optimum application range: 25,000 to 500,000 Nm)
Axial bearings
Advantages
Tried and tested concept with approx. 4,000 references, global production
concept, international service locations, wide variety of options
FLENDER KMPS
Design
Capacity
Installation sizes
12
Transmission ratios
i = 30 to 55
Torque
600,000 to 2,500,000 Nm
(optimum application range: 600,000 to 1,800,000 Nm)
Axial bearings
Fully hydrostatic
Advantages
Tried and tested concept with approx. 400 references, global production
concept, international service locations, wide variety of options
High-capacity, wear-free
planetary gear unit: FLENDER KMPP
High-capacity
drives are often
used in cement
production.
Process stability
Process stability is not just an expression: it is a major
goal for the entire cement industry all around the world.
Stability and safety in grinding ensure plant availability
and are the pivotal requirements for every vertical mill
drive. Their relevance increases exponentially with increasing mill power input.
Variable speed in drive technology plays a critical role in
stabilizing processes. Driven by technological possibilities,
the idea that bigger is better is continuing to gain currency in the cement world. Against this backdrop, this
often conservative market has come to agreement on one
thing: speed variability, drive intelligence and, with increasing plant size, modular drive systems are the critical
parameters for plant efficiency and success in the face of
growing demands with regard to torque and plant
availability.
FLENDER KMPP
Design
Capacity
3,000 to 8,000 kW
Installation sizes
Transmission ratios
i = 35 to 55
Torque
1,300,000 to 3,500,000 Nm
Axial bearings
Fully hydrostatic
Advantages
The functioning
drive train
is now reality. Siemens has always been convinced that
the drive train must be seen and understood as a whole.
We are the only provider in the world that offers complete
industrial drive systems. In the context of our integrated
drive system concept, complete drive solutions have
proved their worth in many industries and have become
standards upon which todays industrial drives are based.
In the cement industry and power generation, our gear
units have been an integral part of customer solutions for
many years. The inherent frequencies of the drive change
depending on the moment of inertia of the mill and the
motor. The drive train as a whole is a logical, goaloriented development to meet the requirements of our
customers.
Variablespeed drive
train with
converter and
squirrelcage
motor
SINAMICS frequency
converter
SIMOTICS
squirrelcage motor
FLENDER coupling
Fixed-speed
drive train
with slip ring
motor
Slip ring motor
10
Service
Transformers
Frequency converters
Motors
C
ouplings (including electrically
insulated couplings)
Auxiliary gear units/auxiliary drives
Maintenance drives
Main gear units
Oil supply systems
Sensor technology
Condition monitoring
Drive controls (CEMAT)
Financing
For example, our logistics specialists make up a comprehensive, international network of certified service
centers, ensuring that spare parts are supplied quickly
and reliably.
Condition monitoring
The Siemens condition monitoring system SIPLUS
CMS 4000 gives you the option to track temperatures,
vibrations, torques and displacements in the gear unit
online and evaluate trends. The fundamental advantages of the condition monitoring system are obvious:
irregularities trigger an alarm and corresponding
recording activity. Increasing vibration levels are recognized early on and required maintenance work can
be planned accordingly. In this way, damage is prevented or recognized at an early stage.
Our condition monitoring system has a special, crucial
feature: it was developed and programmed by the
leading provider of industrial drive technology and
offers you secure communication paths to monitor
your drives from anywhere. For data analysis, we
can offer you a telediagnostics service provided by our
own experienced condition monitoring experts.
On request, condition monitoring can also be
expanded for use with the entire drive train.
11
FLENDER SmartSeries
is a product portfolio of drive solutions in which realtime controls enable the unit to react immediately to
external influences such as factors associated with the
production process. Under demands to produce larger and
larger plant layouts with maximum availability, operators
are well advised not to rely solely on conventional solutions for the medium term, but instead to take the right
step toward the future with FLENDER SmartSeries products. With the FLENDER EMPP, this step is now possible
for vertical mill drives.
Specialists in the largest geared motors
As a provider of innovative drive technology, we have
developed a drive concept that was specially designed to
significantly increase the efficiency and availability of
large vertical mills. In the FLENDER EMPP drive unit, which
features extremely high capacity, an integrated synchronous motor supplied by a frequency converter ensures the
required drive power and, because the bevel gear stage
is eliminated, it reduces the number of active components
in the gear unit. The brushless permanent magnet motor
is particularly robust and completely wear-free. Because
of its static seals it has a high protection class and an
extremely durable stator winding.
With the FLENDER EMPP, Siemens has developed a drive
concept that both prevents load impacts due to short
interruptions in the electrical power supply and optimizes
power transmission between the drive and the mill. That
increases plant availability and results in an expansion of
the capacity range up to 12 MW. The greatest strengths
of the innovative EMPP concept are found here in the
high capacity classes because the closed unit delivers
ultra-quiet running under full load. The converter control
also contributes to the ongoing protection of your plant
against overloading because torsional vibrations caused
by the grinding process can be actively dampened via the
drive. The active (electrical) damping of the drive train
and the mill behavior with situationally based torque control can be seen as the greatest innovation.
12
Components
Result
Benefit
visualizes
Operating situation
enables
Process optimization
shows
Machine state
leads to
Maintenance plan
evaluates
Load situation
influences
Control strategy
Motor
delivers
Controlled
machine dynamics
results in
Active protection
Sensor
technology
CMS
Monitoring
Control
Easy conversion
If you wish to switch over from an existing KMPP drive to
a new EMPP drive, conversion times are easily manageable. EMPP drives have the same housing dimensions and
require the same foundations and plant designs. The twopart housing makes transportation and assembly as well
as on-site service easier. The conversion does not require
any complicated modifications to the overall construction.
The plant is soon ready to start operating again.
FLENDER EMPP
Design
Capacity
3,000 to 12,000 kW
Installation sizes
Transmission ratios
i = 40
Torque
1,400,000 to 5,000,000 Nm
Axial bearings
Fully hydrostatic
Advantages
FLENDER MultipleDrive
14
Design
Capacity
Installation sizes
Transmission ratios
i = 50 to 120
Torque
1,200,000 to 8,000,000 Nm
(optimium application range: 2,500,000 Nm and up)
Axial bearings
Fully hydrostatic
Advantages
Other advantages
The lower overall height of the MultipleDrive in comparison with other vertical mill drives reduces factory and
operating costs because the material does not need to be
transported so far upward and the peripheral equipment
need not be so large. Of course, a suitable oil supply system directly on the drive is standard.
MultipleDrive also boasts optimum service options. The
simple, inexpensive stocking of small, standardized components can lead to invaluable advantages in plant
availability.
With the FLENDER MultipleDrive, we are offering a complete system with maximum availability and a modular
design from a single source. This modular system offers
the greatest possible flexibility in design and layout based
on customer needs.
Infinitely scalable:
the modular
FLENDER MultipleDrive
has endless possibilities
8 MW (4 x 2 MW)
15
Siemens AG
Industry Sector
Mechanical Drives
Alfred-Flender-Strae 77
46395 BOCHOLT
GERMANY