High-Pressure Roller Press

In a high-pressure roller press, two rollers pressurize the material up to 3,500 bar, improving the grinding efficiency dramatically and significantly reducing energy consumption. High-pressure roller presses are most often used to expand the capacity of existing grinding mills, and are found especially in countries with high electricity costs or with poor power supply.

Chinese flag This technology is considered to be suitable for both for raw materials grinding and for finish grinding of cement, as well as ultrafine grinding of blast furnace slag. In China,the penetration rate of this technology was expected to reach 80% during the eleventh five-year development period – requiring an investment of 1 billion RMB and holding a potential to reduce energy consumption by 800 GWh (NDRC, 2008. p.49).

Development Status Products
Commercial
Cement

High-Pressure Roller PressCosts & Benefits

Parent Process: Finish Grinding
Energy Savings Potential

Power consumption can be reduced by 10 - 24 kWh/t-cement. 

Savings in the range of  7 - 15 kWh/t cement are reported from India. 

Chinese flag Energy consumption of a single-set high-pressure roller mill with 200 t/h capacity is reported to be less than 30 kWh/t-cement (NDRC, 2008. p. 48).

Chinese flag In China, a 5000t/d cement grinding plant reduced electricity consumption by more than 30% (approximately 8~ 10kWh/t cement) by using high-pressure roller mills, instead of ball mills (NDRC, 2008. p. 48)

Chinese flag In another plant with 2500t/d cement grinding capacity, switching over to high-pressure roller mills has reduced electricity consumption by more than 30% (approximately 8~ 10kWh/t cement) (NDRC, 2008. p. 48. )

CO2 Emission Reduction Potential

In the Chinese context, CO2 emissions can be reduced by 7.9 to 19 kg/t-cement with the use  of this technology.

In the Indian context, CO2 emissions can be reduced by 8.1 to 19.4 kg/t-cement with the use  of this technology.

Costs

Investment costs are estimated to be between US $2.5 - 8 /annual ton cement capacity, 

For India investments are reported to ranege between uS $10-15 million, or US $40-65 per ton of hourly capacity. 

Chinese flag For China investments are reported to range between 12~20 million RMB, and payback period may be between 3 and 4 years (NDRC, 2008. pp.48-49).

Parent Process:
Energy Savings Potential
CO2 Emission Reduction Potential

N/A

Costs
Parent Process:
Energy Savings Potential
CO2 Emission Reduction Potential

N/A

Costs

High-Pressure Roller PressSchematic

High-Pressure Roller Press Publications

Energy Efficiency Improvement Opportunities for the Cement Industry

The U.S. Environmental Protection Agency’s (EPA) energy guide, Energy Efficiency Improvement and Cost Saving Opportunities for Cement Making, discusses energy efficiency practices and technologies that can be implemented in cement manufacturing plants. This ENERGY STAR guide provides current real world examples of cement plants saving energy and reducing cost and carbon dioxide emissions.

Page Number: 

19-20

High-Pressure Roller Press Reference Documents

Page Number: 

48-49