HRP Hydraulic Roller Press

s Large power savings s For new grinding plants s For upgrading of existing plants

Introduction

HRP HYDRAULIC ROLLER PRESS

MAIN FEATURES
Two types of wear lining welded hardfacing applied to a solid shaft or to a shrink fit sleeve are available Roller design allows the use of rollers with either of the two types of wear lining Bearing life is optimised by ample sizing and clean, conditioned oil lubrication Hinged frame allows easy roller removal

High-pressure roller grinding of cement clinker and hard brittle materials is a modern and very energy-efficient process. During its relatively short history, roller press technology has undergone significant development from a pre-grinding process to a range of applications including semi-finish grinding and finish grinding. The HRP roller press developed by F.L.Smidth ranks among the most advanced and efficient units available. Its design incorporates the vast experience and expertise gained since roller press technology was first introduced. In high-pressure roller press comminution the feed material is exposed to very high pressure for a short time. The high pressure causes formation of microcracks in the feed particles and generates a substantial amount of fine material. If the pressed material is fed directly to a ball mill, the power consumption required to produce finished cement will be much lower than that of a mill fed with unpressed material. This makes it possible to increase the throughput of a given size ball mill and reduce the specific power consumption of the whole mill system.

The roller press is a flexible solution, highly suitable both for upgrades and for new installations. Upgrading may increase capacity by up to 100 percent, while the total specific energy consumption of new installations may be reduced by 20-30 percent compared with conventional grinding systems. The most typical process configurations are described in the following. Besides the cost-saving features already mentioned the HRP roller press is characterised by: long wear part life low operational and maintenance costs short shutdown for wear part replenishment.

Process configuration
As the grinding efficiency of a roller press is about twice that of a ball mill, considerable energy savings can be achieved by substituting roller pressing for ball mill grinding. Basically, there are several different ways of incorporating a roller press in a grinding installation. In the pregrinding system, the roller press is used for grinding fresh feed and a certain amount of recirculated pressed flakes. The roller-pressed material is finish ground in a conventional ball mill grinding circuit. Excessive flake recirculation may cause operational instability, so in practice the power consumption of the roller press is limited to approximately 5 kWh/t in the pregrinding mode. The semi-finish grinding system ensures better utilisation of the roller press. The roller press operates in closed circuit with a disagglomerator and a dynamic separator. Fines from the roller press circuit are finish ground in a one-compartment ball mill to the required fineness. A very compact and energy efficient semifinish grinding installation can be attained by combining the roller press and the ball mill with a Sepax two-stage separator. The roller press then operates in closed circuit with the bottom part of the Sepax separator, comprising disagglomerator and dynamic grit separator, while the ball mill operates in closed circuit with the high-efficiency separator in the Sepax top module. As the separator air is used for both separation stages, the overall quantity of air and the fan power consumption remain at a very low level. For some applications it may be necessary to split the two circuits, for instance if drying in the roller press circuit and cooling in the ball mill circuit are required, or if one roller

Roller press pre-grinding

Roller press semi-finish grinding Two-stage Sepax

Roller press finish grinding

Material flow

Separator air flow

Mill air flow

HRP HYDRAULIC ROLLER PRESS

3 6 5

12 13 4

14

10 8

7 1 2 11

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Grinding rollers with welded hardface wear lining Oil-lubricated spherical roller bearing Planetary reduction gear Torque arm arrangement Safety release coupling Main motor Hydraulic pressurising cylinders Nitrogen-filled bladder accumulators Bottom frame Top frame End section Hinged L-shape end section Elastomer shear pad Feed control gate

Mechanical description
press is to serve two or more ball mills. In that case the bottom part Sepax separator with disagglomerator and grit separator is used as a stand-alone unit for the roller press circuit, and a standard high-efficiency Sepax is used for the ball mill circuit. Some types of feed material and some end products allow omitting the ball mill so that the roller press is used for finish grinding in a closed circuit with a two-stage separator. When feasible, such a process configuration is very attractive in terms of operating and investment costs. The frame is built up of parts fitted together by removable pins: The upper and lower frame, linked by vertical end sections, together form a horizontal U-frame. The U-frame is closed by an L-shape end section that is hinged to the lower frame and folds down for easy removal of the roller assemblies. This frame encloses and supports the bearing housings of the roller assemblies and carries the hydraulic cylinders of the pressurising device. The bearing housings slide on the lower frame. The upper frame supports a feed box and the dust casing, which encloses the two roller bodies. One roller is fixed while the other is horizontally movable and is pressed towards the former by four hydraulic cylinders. The position of the movable roller depends on the characteristics of the material fed to the press. Spacer shims between the roller bearing housings prevent the rollers from touching each other when pressurised without feed and permit adjustment of the minimum gap. Each of the two rollers has a separate drive. Each roller has a shaft mounted planetary reducer connected to the other reducer by a balanced torque arm system. The patented balanced torque arm system reduces foundation costs and complexity by taking the torque through the other reducer and not down to the foundation. Both drives include a safety release coupling between reducer and motor. The roller press is equipped with a hydraulic pressure system which ensures that the pressing force is kept practically even during the comminution process. In addition, it protects the press against overloading.

Specific energy consumption, kWh/t

Specific energy consumption Ball mill Roller press Separator Grit separator Separator fan Mill fan Aux. Total kWh/t 3500 Blaine Closed circuit 37.5 1.2 2.3 0.8 1.2 43.0 Pregrinding 28.0 4.8 1.2 2.3 0.6 1.6 38.5 Semi-finish 17.1 9.6 1.2 0.6 3.6 0.5 1.8 34.5

Drive configuration

Roller wear lining

The rollers are normally supplied with a wear lining of welded hardfacing material. The hardfacing can be applied to either a solid shaft or a shrink fit sleeve bandage. Worn grinding surfaces are replenished by welding. Spot repairs or complete resurfacing can be performed with the rollers in situ, if desired.

Feed control gate

To facilitate control of the "choke feed" press, FLS has introduced a motorised feed control gate located just above the roller surface. The feed control gate is only required for choke feed. The gate is used for smoothening the feed start, and is suitable for trimming the press to optimum operation, for example when producing different cement types, and for adjusting the throughput or power consumption of presses working with feed material of varying draw-in characteristics and/or friction characteristics.

Feed control gate

Local machine control

The roller press has its own local control panel (PLC), similar to other complex machines. The panel is connected to the central control system. The panel is used for testing and running in the machine as well as for troubleshooting, independent of the central control system. The control panel includes a display which indicates status of the machine and has facilities for starting and stopping, making parameter changes, etc. The local control panel is delivered ready for use, thus saving engineering time during installation.

Controlled feed by belt conveyor

For roller presses used in semi-finish grinding systems, the controlled feed system greatly improves operational stability. The feeder extraction rate may be controlled by the roller gap or the roller press power consumption to maintain constant and optimum operating conditions at varying material characteristics.

Characteristics
Type range and typical data
Press size A m2 0.60 0.90 1.25 1.60 2.00 2.50 3.00 3.60 Roller Roller Capacity dimension speed D x W (peripheral) cm x cm m/sec t/h 117x51 136x66 148x85 160x100 174x115 192x130 212x141 230x157 1.60 1.60 1.60 1.60 1.60 1.60 1.60 1.60 198 297 412 528 660 825 990 1188 Motor Power kw 2x230 2x350 2x485 2x615 2x770 2x960 2x1150 2x1390

Dimensions
Press size m2 0.60 0.90 1.25 1.60 2.00 2.50 3.00 3.60 L1 mm 1775 2050 2320 2545 2830 3100 3480 4015 L2 mm 4040 4615 5225 5665 6280 6860 7600 8740 L3 mm 1170 1440 1640 1815 2060 2265 2605 2810 H1 mm 1615 1985 2260 2480 2820 3130 3450 3900 H2 mm 2065 2540 2890 3175 3575 4070 4410 5000 B1 mm 1060 1220 1370 1475 1615 1800 1915 1985 B2 mm 1260 1420 1570 1675 1815 2000 2115 2185 B3 mm 2275 2460 3110 3450 4090 4270 4715 4910 B4 mm 2330 2580 2800 2800 3190 3510 3510 3510

Data in this brochure is intended for preliminary project planning only. Manufacturer reserves the right to modify equipment details and/or specifications without notice. XX-XX-XXX Bazement Grafisk Design ApS

DENMARK
www.flsmidth.com
Up-to-date addresses of worldwide subsidiaries and sales offices are available from our website

INDIA
Fuller India Limited Capital Towers 180, Kodambakkam High Road Nungambakkam Chennai 600 034 India Tel: +91 44-252 191234 Fax: +91 44-2827 9393/5214 4295 E-mail: fil@fullerindia.co.in

USA
F.L.Smidth Inc. 2040 Avenue C Bethlehem, PA 18017-2188 Tel: +1 610-264-6011 Tel: +1 800-523-9482 Fax: +1 610-264-6170 E-mail: info@flsmidth.com

F.L.Smidth A/S Vigerslev All 77 DK-2500 Valby Copenhagen Tel: +45 36 18 10 00 Fax: +45 36 30 18 20 E-mail: info@flsmidth.com