High pressure roller press as pre-grinding to ball mill

High pressure roller press can be introduced as a pre-grinding step for the ball mill, in order to decrease specific power consumption in finish grinding and/or to increase the output of finish mill. Grinding capacity of finish mill increases by about 30%.

Indian flag Up to 100% capacity increases are reported in India with the use of this approach. 

Chinese flag In China this configuration is commonly installed in new plants using dry processes and during grinding system upgrades in existing plants. It can increase grinding output by more than 100%. Hourly outputs of more than  175 tons for grade 32.5 cement and more than 160 tons for grade 42.5 cement are reported. In addition, the technology requires less space (30% less as compared to having two ball mills) and allows for increased use of cement additives. The technology had a penetration rate of 20% in 2010 and this figure is expected to reach 50% during the twelfth five-year development period (MIIT, 2012. p. 25)

Development Status Products
Commercial
Cement

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)

Chinese flag 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)

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Chinese flag For a 5000 tpd plant, annual energy savings can reach 20 TWh (MIIT, 2012. p.25)

Chinese flag 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)

Chinese flag  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. 

Costs

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. 

Indian flag For India installation costs are reported to be between $10 - 20 million, or between  $55 000-$65 000 per tph system capacity. 

Chinese flag For a 5000 tpd plant, annual electricity savings can amount to 10 million RMB (MIIIT, 2012. p.25).

Chinese flag 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)

Chinese flag  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).

Parent Process:
Energy Savings Potential
CO2 Emission Reduction Potential

N/A

Costs

High pressure roller press as pre-grinding to ball mill Publications

Energy Efficiency and Resource Saving Technologies in Cement Industry

 

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.

Page Number: 

105

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: 

20

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.

Page Number: 

25