High pressure roller press as pre-grinding to ball millCosts & Benefits
|Parent Process: Finish Grinding|
|Energy Savings Potential||
Specific power consumption decreases by about 10%.
Reductions in specific energy consumption in the range of 7-24 kWh/t-cement are reported (LBNL, 2008)
Power consumption per ton of cement can be reduced by 8 ~ 12 kWh, representing 15% to 30% saving over a traditional ball mill system. System output can be increased by more than 100%. Specific energy consumption is around 30 kWh/t-cement for grade 32.5 and around 33 kWh/t-cement for grade 42.5 (MIIT, 2012. p.25)
For a 5000 tpd plant, annual energy savings can reach 20 TWh (MIIT, 2012. p.25)
Hefei Donghua building materials Co., Ltd. installed a combined open-circuit roller press (HFCG160-140), SF650/140 dispersing classifier and a φ4.2 × 13.0m ball mill, and reached a capacity of 180t/h, with specific grinding power consumption of 27kWh/t-cement, and overall grinding station consumption of less than 32kWh/t-cement – saving 12kWh/t-cement as compared to a traditional ball mill system (MIIT, 2012. p. 25)
By installing a combined roller press and ball mill grinding system in a 2400tpd cement production line, Tianjin Zhenxing Cement Co, Ltd. reduced specific energy consumption by 7.0 kWh/t-cement. For an annual production of 900 000 tons, this provides a saving of around 6.3 TWh/y (MIIT, 2012. p.25).
|CO2 Emission Reduction Potential||
CO2 emissions can be reduced by 6 - 19 kg/t-cement.
For a 100 ton per hour mill in Japan, the installation costs are reported to be about US $2.7 million (1 US$=¥110), including auxiliary and construction.
For India installation costs are reported to be between $10 - 20 million, or between $55 000-$65 000 per tph system capacity.
For a 5000 tpd plant, annual electricity savings can amount to 10 million RMB (MIIIT, 2012. p.25).
By installing a combined roller press and ball mils system, Hefei Donghua building materials Co., Ltd. realized annual savings for more than 6 million RMB, due to reduced electricity consumption (MIIT, 2012. p.25)
By installing a combined roller press and ball mill grinding system for a 2400tpd cement production line, Tianjin Zhenxing Cement Co, Ltd. realized annual savings of more than 3 million RMB due to reduced power consumption (MIIT, 2012. p.25).
|Energy Savings Potential|
|CO2 Emission Reduction Potential||
High pressure roller press as pre-grinding to ball mill Publications
This Cement technologies booklet was compiled by the APP Cement Task Force (CTF) through one of its activities to help its member countries share information on all available energy efficient technologies generally used in the world’s cement industry. The document offers a comprehensive compilation of commercially-available energy efficient technologies used in 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.
Advanced and Applicable Technology Guide for Energy Saving and Emission Reduction in Building Materials Industry (first batch)
Published jointly by the Chinese Ministry of Industry and Information Technology, Ministry of Science and Technology, and Ministry of Finance, this guide describes information on currently available as well as developing technologies that can help reduce energy consumption and emissions in building materials industries. The guide aims to inform decision makers involved with designing new plants and/or implementing energy efficiency and emission reduction projects in existing plants.