For Cement and Minerals: Complete Solutions

Complete Solutions
for Cement and Minerals
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Peter H. Sonderup
Department Manager Grinding Technology
FLSmidth
CEMENT GRINDING
SYSTEMS
Title The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. 23 April 2013 2
Agenda
Intro
Cement production in CIS region
Typical cement mill installation in Russia
Installed base
Increased production Upgrades
Open circuit Closed circuit
Installation of Roller Press
Increased production New Equipment
Ball Mill
Ball Mill and Roller Press
Vertical Roller Mill
Case stories from CIS region
Comparison of old and new grinding unit
Operational costs
Maintenance costs
End
CEMENT PRODUCTION IN CIS
REGION
Typical cement mill installation in Russia
Open circuit ball mills typically with three feeders

Clinker
Gypsum
Slag or other additive
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. 5
Installed base of Cement mills in Russia
The mills are very long L/D 5 (modern mill L/D 3.5)
INCREASED PRODUCTION
UPGRADES
Upgrade by installing a High Performance SEPAX Separator

Conversion from 3 compartments into 2 compartments
Install new linings, FLSmidth STANEX diaphragm and a new
outlet grade.
Example of upgrade of popular Cement mill

Ball mill 2.66 x 13 m
Open circuit Closed circuit Change

(Befor) (After)
Production 25 t/h 35 t/h +40%
Fineness in Blain 2900 cm2/g 3000-3200 cm2/g -
Specific Power Consumption ~ 40 kWh/t 30 kWh/t -25%
Cement temperatur 110 - 125 C 65 - 75 C - 50 C
Cement type produced OPC

Blaine 3000, 95% clinker, 5% gypsum
Upgrade by installing a Hydraulic
Roller Press
Impact
Attrition
Compression
Roller Press (pre-grinder)
Splitter gate:
To Ball Mill
Returns to HRP
Roller Press and a two stage separator
(Semi finish grinding)
Pre-grinding Semifinish grinding
Power saving [kWh/t] ~ 15% Up to 30%
Capacity increase [t/h] ~ 20% Up to 100%
Note: Compared to a close circuit ball mill installation
INCREASED PRODUCTION NEW
EQUIPMENT
Different machines and configurations
OK Vertical Roller Mill Ball Mill Dynamic Separator
Compact two stage

separators Roller Press
OK Roller Mill Closer look
Separator Separator drive
Grinding roller Mill outlet
Rocker arm Mill feed inlet
Gear box Grinding table
Mill stand Hydraulic system
Unique design developed specifically for cement and slag
grinding
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. 23 April 2013
Comparison of mill systems
Ball mill Roller press + Semi finish OK Mill

closed circuit Ball mill RP+BM
Mill 30.9 22.7 14.2 15.5
Roller Press - 4.4 9 -
Aux.+fan 4.1 4 6.7 7.6
Total 35.0 31.1 29.9 23.1
Specific energy consumption, kWh/t

Blaine 3600, 85% clinker, 5% gypsum, 10% limestone
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. 23-04-2013 17
COST OF OPERATION AND
MAINTENANCE
Cement Grinding
Different modern and viable alternatives today
Different machines
Different setups
Different cost
Operational
Maintenance
Control of and effect on

cement quality, benchmark
Energy Efficient Equipment
Typical dry process plant Plant Plant

with with
Calculated as kWh/t cement OPC ball roller
mills mills
Raw Material crushing, storage and 4 4
handling
Raw Meal production and storage 35 26
Clinker production 24 24
Cement Grinding 42 26
Cement storage and dispatch 4 4
Utilities, offices, lightning etc 6 6
Total kWh/t cement OPC 115 90
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
OK mill efficiency compared to ball mills
70
65
For OPC
60
Spec. Energy Cons.,Total, kWh/t
55 Ball mill
50
45
50 %
40
35 OK mill
30
33 %
25
20
2500 2700 2900 3100 3300 3500 3700 3900 4100 4300 4500
Blaine, cm2/g
Operational costs in EURO/ton
Electricity
0,80
0,70
0,70
0,60
0,60
0,50 0,46
/ton
0,40
0,30
0,20
0,10
0,00
Ball Mill Ball mill + Roller OK VRM
press
Based on an electricity price of 0,02 /kWh

Maintenance costs in EURO/ton
Actual plant data
0,80
0,70 0,67
0,60
0,50
0,42
/ton
0,40 0,36
0,30
0,20
0,10
0,00
Ball mill Ball mill + Roller OK VRM
press
Based on actual plant data from European plant operator

Total cost of operation
Different cement grinding systems
1,40
1,27
1,20
1,06
1,00
0,67 0,88
0,36
/ton
0,80
0,42
0,60
0,40 0,70
0,60
0,20 0,46
0,00
Ball Mill Ball mill + Roller OK mill
press
Operational costs + Maintenance costs

CEMENT QUALITY
Parameters influencing cement quality
Influencing factors from clinker production

Raw materials
Fuel
Burning zone condition
Clinker mineralogy, C2S, C3S, etc
Influencing factors from cement grinding

Gypsum de-hydration
Fineness (Blaine, residue)
Particle Size Distribution (PSD)
PSD impacts quality and
water demand in the cement paste
Flatter PSD curve, lower slope of PSD, gives:

Lower late strength compared to early strength
Lower water demand to cement paste normal consistency
Means of adjusting the PSD slope on the OK mill:
Decreased separator airflow and

decreased separator speed
Higher grinding pressure Lower PSD slope
Increased retention time in mill
Adjustment of quality and PSD in an FLSmidth OK mill
INDUSTRIAL CASE #1
Industrial Case Story #1
Adjustment of quality and PSD in an FLSmidth OK mill
Above mentioned means to control

the PSD and hereby the quality and
water demand in the cement has
been tried on an industrial OK mill
The conclusion is that it is quite

possible to control the quality, and Dam ring height
the parameter with the biggest
impact is retention time in the mill
controlled by the dam ring height
Cement PSD slope vs. dam ring height

1,1
1,05
RRSB slope
0,95
0,9
110 120 130 140 150 160 170
Dam ring heigth (mm)
Water demand to normal consistency vs. dam ring height

29,0
28,0
27,0
Water demand (%)
26,0
25,0
24,0
110 120 130 140 150 160 170
Dam ring height (mm)

Quality benchmark of cement from different grinding systems
INDUSTRIAL CASE #2
Plant located in CIS region:

Cement from ball mill and
Cement from OK mill
Industrial case #2A
Ball Mill cement and OK mill cement
Ball Mill OK Mill

Cement type PCII-400 PCII-400
Composition: Clinker 78% 78%
Gypsum 3% 5%
Slag 19% 12%
Limestone - 5%
Cement fineness 2810 3500 res <8
Mortar strength (MPa), 3d - 15

Mortar strength (MPa), 7d 33,73 39
Mortar strength (MPa), 28d 41,69 42
Mill (kWh/t) 41
Separator (kWh/t) - 28
Process fans (kWh/t) -
Customer stated:
Cement exclusively from vertical mill now demanded by main
customer because of improved cement quality
Final remarks
CONCLUSION
In conclusion
When looking at the different cement grinding options
It is possible to upgrade existing Ball mill installations
The different options come with different total cost of

operation including maintenance, where the OK vertical mill
has proven to have lowest cost of operation
Solutions including a Ball Mill has significantly higher total

cost of operation
Industrial cases have proven that the cement properties

and cement quality from the different grinding systems do
not differ in a benchmark analysis of:
Water demand
Setting times
Strength development
Thank you
for your attention
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. 23 April 2013 37

For Cement and Minerals: Complete Solutions

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Complete Solutions

for Cement and Minerals

Open circuit ball mills typically with three feeders

Upgrade by installing a High Performance SEPAX Separator

Example of upgrade of popular Cement mill

Open circuit Closed circuit Change

Fineness in Blain 2900 cm2/g 3000-3200 cm2/g -

Specific Power Consumption ~ 40 kWh/t 30 kWh/t -25%

Cement temperatur 110 - 125 C 65 - 75 C - 50 C

Cement type produced OPC

Pre-grinding Semifinish grinding

Power saving [kWh/t] ~ 15% Up to 30%

Capacity increase [t/h] ~ 20% Up to 100%

Note: Compared to a close circuit ball mill installation

Compact two stage

Separator Separator drive

Grinding roller Mill outlet

Rocker arm Mill feed inlet

Gear box Grinding table

Mill stand Hydraulic system

Ball mill Roller press + Semi finish OK Mill

Roller Press - 4.4 9 -

Aux.+fan 4.1 4 6.7 7.6

Total 35.0 31.1 29.9 23.1

Specific energy consumption, kWh/t

Control of and effect on

Typical dry process plant Plant Plant

Based on an electricity price of 0,02 /kWh

Based on actual plant data from European plant operator

Operational costs + Maintenance costs

Influencing factors from clinker production

Influencing factors from cement grinding

Flatter PSD curve, lower slope of PSD, gives:

Means of adjusting the PSD slope on the OK mill:

Decreased separator airflow and

Higher grinding pressure Lower PSD slope

Increased retention time in mill

Above mentioned means to control

The conclusion is that it is quite

Cement PSD slope vs. dam ring height

Water demand to normal consistency vs. dam ring height

Dam ring height (mm)

Plant located in CIS region:

Ball Mill OK Mill

Mortar strength (MPa), 3d - 15

It is possible to upgrade existing Ball mill installations

The different options come with different total cost of

Solutions including a Ball Mill has significantly higher total

Industrial cases have proven that the cement properties

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