EXPERIENCE WITH ROLLER PRESS SYSTEMS AT SOUTHERN PROVINCE CEMENT COMPANY

Mohammed Najeeb Sukkar Works Manager Southern Province Cement Co. INTRODUCTION
In 1997, a greenfield cement plant commenced operations at the Bisha site in Saudi Arabia. The rated 3800 MTPD plant is operated by Southern Province Cement Company (SPCC). In the ensuing years, the original design production of the preheater and kiln was boosted through various enhancements until reaching the current production of over 5700 MTPD - an increase of more than 50%. A short-fall in cement grinding capacity eventually became apparent due to the growing market demand, and beginning in the year 2000, SPCC embarked on an upgrade project of the cement grinding systems at site to meet the increased need. The two original and identical cement ball mill systems were upgraded with pre-grinding hydraulic roller presses, but from two different suppliers, and therefore two different system designs and operational philosophies. The mill circuit #1 includes a roller press as shown in FIGURE 1 and utilizes the existing mill separator for the total product. The mill circuit #2 includes a roller press along with a static and dynamic combination separator which pre-classifies product-sized material away from the press and mill and directly to the final product stream. From the beginning of the proposal effort, the supplier of the press in circuit #1 was confident that the additional separation was not required and that the simpler layout would be more attractive in terms of both the equipment required and operational efficiency.
FIGURE 1: Circuit #1 roller press

By Kevin Happ Product Manager FLSmidth Inc.

Ahmed Shahid Senior Process Engineer Texas Industries Inc.

The circuit #1 system has now been in operation for close to two years, enabling a thorough review of the systems performance long after handover to the customer. This paper focuses on the layout, equipment features, and operational results of the upgraded circuit #1.

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BACKGROUND The original cement grinding area of the SPCC Bisha plant consisted of two identical closed2 circuit ball mill systems rated for 110 MTPH each at a Blaine of 3200 cm /g. Each circuit includes a 4.4 meter diameter by 13.0 meter long ball mill with 3500 kW motor and separator with 225 kW motor. The mill and separator are vented to separate dust collectors. The original layout is shown in FIGURE 2.

FIGURE 2: Original cement grinding circuit

The original circuits each ran with a total specific power consumption of about 40 kWh/mt at a 2 production of 105-110 mtph and Blaine of 3000 cm /g. The product 45 micron residue was 12-14%. Ordinary Portland cement consisting of 92% clinker, 4% gypsum, and 4% limestone is the normal product at the Bisha site. The pre-grinding upgrade solution was chosen by SPCC for many reasons. It enabled a fast and costeffective production increase of over 45%. The original mill and separator size could be maintained, and only a short tie-in period would be necessary for incorporating the new equipment. In the event of maintenance on the roller press, the fresh feed can be bypassed directly to the mill and continue to produce near the original capacity. While power is relatively inexpensive in Saudi Arabia, the power savings of 6 kWh/mt was nonetheless attractive.
FIGURE 3: Circuit #1 roller press addition to existing cement mill building

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LAYOUT DESCRIPTION. Circuit #1 Layout The layout of circuit #1 as upgraded is shown in FIGURE 4. Fresh clinker is diverted from the existing mill feed belt to a bucket elevator and transported to a 25 ton surge bin ahead of the roller press. A magnetic separator and metal detector located on the belt conveyor before the bin protect the roller press from tramp metal, with the latter triggering a diverter gate to momentarily send the contaminated material directly to the mill. The total feed to the roller press is regulated by a weigh feeder below the bin, with several controlling operational modes available. It is normally desired to operate in the starve mode, in which the feeder rate is optimized to provide maximum average roller press power or roller gap without a head of material above the rollers.

FIGURE 4: Circuit #1 upgraded grinding system

At the outlet of the roller press, a static overflow chute breaks up and divides the pressed material between recirculation and feed to the ball mill. The recirculated material combines together with the fresh clinker in the same bucket elevator. The rate of recirculation is controlled by a belt scale on the variable speed belt conveyor that feeds the roller press product to the mill. By maintaining a constant weight in the surge bin, the fresh clinker feed is automatically adjusted to account for any changes in the recycle rate. The gypsum and limestone are fed directly to the mill and adjusted according to the weight of clinker being fed to the mill from the roller press circuit. Circuit #2 Layout The layout of circuit #2 as upgraded is shown in FIGURE 5. Fresh clinker is deposited on the existing mill feed belt modified to run in reverse direction. A new belt adjacent to the original one sends the gypsum and limestone directly to the mill. Even though the option exists to pass the additives through the roller press system, this is not in practice at Bisha. Similar to circuit #1, the fresh clinker and recirculated press product combine and are transported in a single bucket elevator before the roller press. A magnetic separator and metal detector are also available to protect the roller press from foreign objects. The combined material is then fed to a new separator which is a combination static and dynamic rotor separator. Large material drops through the static portion to a small feed bin above the roller press. Airflow passing through the separator carries entrained material through the rotor. Rejects from the rotor are sent to the ball mill, while material of product size is collected in a bank of cyclones. The system fan of the

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combination separator is positioned after the cyclones and therefore operates in partially dustladen air. A majority of the air is recycled back to the separator. The product from the cyclones and separator filter are conveyed and ultimately combined with the rest of the product from the existing separator filter. A proportioning gate controls the passing of material from the feed bin through the roller press. The entire product from the roller press combines with the fresh clinker feed.

FIGURE 5: Circuit #2 upgraded grinding system

PROCESS DESIGN CONSIDERATIONS By passing the total upgraded production rate through the existing separator in the circuit #1 3 3 approach, the product loading of the separator became 1.07 kg/m at the nominal 2500 m /min 3 airflow, and higher than the typical design standard of 1.0 kg/m . On the other hand, the feed 3 loading would still remain well below the typical maximum of 2.5 kg/m . The issue then was whether the separator performance in circuit #1 would be affected by the higher loading. It is known that there are numerous installations throughout the world with this type of separator that 3 are operating at product loads over 1.0 kg/m without a significant degradation in efficiency. Post-modification separator efficiencies and Tromp curves will be given later in this paper. A finer charge was desired in the first compartment of the ball mill with the modification (maximum 70mm balls). This was to take advantage of the finer roller press product feed to the mill by maximizing the charge surface area and production potential from the mill. However, SPCC sought to maintain the flexibility of operation near the original rated production when the roller press was not in operation and the clinker was bypassed directly to the mill. The mill in circuit #1 has never had the finer charge and despite this, the system fulfilled all the contractual obligations.

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MECHANICAL FEATURES OF THE HYDRAULIC ROLLER PRESS The roller press of circuit #1, shown in FIGURE 6, is equipped with a frame with hinged gable end section which allows easy access for maintenance of the roller assemblies. The rollers are made of forged heat treated alloy steel with integral journals. The journals have tapered withdrawal sleeves to accommodate the installation of the tapered bore bearings. The roller surface is provided with a hard welded-on wear resistant coating. Both bearings of one shaft are axially fixed in their respective housings. Axial movement due to thermal expansion and thrust takes place between the floating bearing housing, frame, and cylinder block. Special flexible rubber shear pads are placed between the bearing housings, gable end pieces, and cylinder blocks to eliminate axial load on the bearings. The roller shaft bearings are lubricated by a circulating oil pump set complete with sump tank, filters, oil/water heat exchanger, heating facilities, flow switches and temperature monitors. This, along with an improved sealing arrangement, provides long service life for the bearings. The bearing housings are furnished with low friction slide ways to allow the bearing housings to slide during operation of the press. Lubrication of the slide ways is not required.

FIGURE 6: Circuit #1 roller press

TABLE 1 highlights some of the features of the circuit #1 roller press. FEATURES 1 Roller surface is a welded Chevron pattern Roller press frame is a hinged design Movable and fixed roller reducers are connected by a patented balance torque arm Both rollers are provided with safety coupling shear tubes to take extreme loads REMARKS Chevron pattern increases friction and increases roll gap Hinged design allows for easy removal of the rollers for maintenance Balanced torque arm reduces stress on drive components resulting in increased life Coupling shear tubes release for protection of drive and press components

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Variable roller motor speed (optional) Simple hydraulic system for pressurizing the rollers and roller seals are designed to accommodate gap differential between the end of the rollers

Variable speed motor gives flexibility when the clinker granulometry changes or operation requirement changes Capability to handle high roller gap differential prevents unnecessary system stoppages

TABLE 1: Features of circuit #1 roller press

ACTUAL PERFORMANCE OF CIRCUIT #1 The upgraded system was commissioned in July 2003 and within two weeks, the performance as guaranteed was officially accepted with the results shown in TABLE 2. Later optimization did enable operation at more than the rated capacity. GUARANTEED Cement production (mtph) Cement Blaine (cm /g) Specific power consumption (kWh/mt for mill and roller press only)
2

ACHIEVED 157.2 3200 27.9

160 (with 3% tolerance) 3200 28.5

TABLE 2: The performance test results of circuit #1

The minimal amount of roller wear on the circuit #1 roller press has been very promising. The moveable roller surface (FIGURE 6) and stationary roller surface (FIGURE 7) show nearly new condition after more than 4,000 hours of operation. Now with about 10,000 hours of operation, the roller surfaces are still in excellent condition and there have been no stoppages to repair the surfaces.

FIGURE 6: moveable roller surface

FIGURE 7: stationary roller surface

The original design of the upgraded circuit #1 returned nuisance dust back to the roller press recirculation material. This fine material in the system created some instability for the roller press and was a cause for early problems of releasing of the coupling safety shear tubes. The layout was modified to return the dust directly to the ball mill feed belt, and since that modification, the

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releasing of the safety shear tubes are virtually non-existent. Long-term Operational Results A review was made of the operating results of circuit #1 over the first 4 months of the year 2004 on days in which the press operated 24 hours. The data in TABLE 3 is a representative picture of day-to-day operation by SPCC with the system not being pushed to performance guarantee levels. The power indicated is of each complete grinding circuit, including auxiliary equipment. Cement production (mtph) Cement Blaine (cm /g) Specific power consumption (kWh/mt for total circuit)
TABLE 3: Circuit #1 operational data
2

156.4 3213 33.4

TABLE 4 below gives a more in depth analysis of the performance of the roller press in circuit #1. Based on roller physical dimensions, measured density of the material cake discharging from each of the presses, and actual operational data, a ball mill equivalent factor can be calculated. This factor is simply the fractional improvement in specific power consumption demonstrated by the press compared to the ball mill. The enhanced preparation of the material passing out of the press and through the mill becomes apparent by the fact that the existing separator speed is decreased by 15% when the press is in operation compared to mill only operation.
Roller diameter Roller width Grinding bed thickness Hydraulic pressure Density of pressed material Torque factor New feed to system Specific roller pressure Roller peripheral velocity Power consumption (net) Roller press capacity Specific power consumption at each pass Roller press circulation factor Specific power consumption at each pass (net) Mill power draw at shaft Specific mill power draw at shaft Theoretical mill power rqrd (based on FGI and Blaine) Power required by roller press Ball mill equivalent factor D W s B d m P Kt v N M E1 C E 1.6 0.78 0.042 138 m m m bar 3 2.52 t /m 0.086 158.5 tph 2 5956 KN/m m/s kW tph kWh/t kWh/t kW kWh/t kWh/t kWh/t

1.32 845 392 2.15 2.48 5.33 3151 19.88 28.02 8.14 1.53

TABLE 4: Operational performance of circuit #1 roller press

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Cement chemical properties Following the upgrades, composite samples of both circuit #1 and #2 products were analyzed for basic chemistry. The results in TABLE 5 show them to be virtually identical. CIRCUIT #1 SiO2 Al2O3 Fe2O3 CaO MgO K2O Na2O SO3 (total) LOI Free lime 19.10 4.61 4.07 60.01 4.79 0.46 0.49 2.87 2.77 0.20 CIRCUIT #2 19.08 4.64 4.07 60.04 4.76 0.46 0.51 2.81 2.82 0.16

TABLE 5: Comparison of cement chemistry for circuit #1 and #2 product

Cement physical properties The same composite samples of the two system products were also analyzed for particle size and other physical properties, with the results shown in TABLE 6 below. The 45 micron residue is marginally improved in circuit #2 at a lower Blaine. As expected, due to the slightly higher 45 micron residue from circuit #1, the water demand is also slightly lower. CIRCUIT #1 Cement Blaine 75 micron (200 mesh) residue 45 micron (325 mesh) residue 32 micron (450 mesh) residue Air content (ASTM C1851) Water demand (ASTM (C187) Time of setting (Vicat set - ASTM C191) Time of setting (Gillmore set - ASTM C266) 3133 cm /g 1.5 11.2 22.2 8.7% 23.0% Initial - 138 min Final - 195 min Initial - 120 min Final - 195 min
2

CIRCUIT #2 3002 cm /g 1.2 10.1 21.5 9.1% 23.5% Initial - 150 min Final - 210 min Initial - 120 min Final - 195 min
2

TABLE 6: Comparison of physical properties for circuit #1 and #2 product

Several samples over a month period were taken by SPCC to perform 3, 7, and 28-day compressive strength tests. The results are shown in TABLE 7 and indicate no significant difference between the strength results of the two circuits, despite the apparent difference in particle size distribution. In general, the strength levels have improved in the upgraded systems compared to the original operation. Comparison of long-term average compressive strength data

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over the complete year before the upgrades (2002) and the complete year after the upgrades (2004) reveals the significant improvements, as shown in TABLE 8. CIRCUIT #1 Cement Blaine (cm /g) Autoclave expansion (%) Compressive strength - 3 days (kg/cm ) Compressive strength - 7 days (kg/cm ) Compressive strength - 28 days (kg/cm )
2 2 2 2

CIRCUIT #2 3160 0.21 239 282 373

3195 0.24 228 286 361

TABLE 7: Comparison of compressive strengths for circuit #1 and #2 product

BEFORE UPGRADES Cement Blaine (cm /g) Compressive strength - 3 days (kg/cm ) Compressive strength - 7 days (kg/cm )
2 2 2

AFTER UPGRADES 3231 250 304

3028 213 275

TABLE 8: Comparison of compressive strengths before and after upgrades

Existing separator performance A thorough study was made of the existing separator performance after the upgrade. As previously mentioned, the separator in circuit #1 has a high product loading since all the feed material passes through it. The Tromp curve (incremental recovery towards coarser products) of this separators product is shown in FIGURE 8. The apparent bypass is shown to be 18%. For a high efficiency separator, less than 10% apparent bypass is normally achievable. With knowledge of the performance of the separator in circuit #2, the lower efficiency in #1 is not suspected to be related to the product loading. It is known that further optimization with the airflow could take place through the separator. There is also a problem with some of the aerated feed slides plugging due an accumulation of worn out and broken ball charge from the mill.

Incremental Recovery %

0 1

10

20

30

40

50

60

70

80

90

100

10

20

30

50

100

200

Particle Size (microns) P70/P30 = 2.35 P50 = 47um ABP = 18% E60um = 62% WACL = 71%

FIGURE 8: Tromp curve (existing separator in circuit #1)

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With one or two of the four feed points blocked off, the other feed points overload and create an imbalance of material feed into the separator rotor. Regardless, the product of circuit #1 is not being adversely affected by the existing separator performance, and the cement strengths are comparable to that found in circuit #2. SUMMARY The upgrade of the circuit #1 cement grinding system at the Southern Province Cement Company Bisha plant has proved to be a successful design of a clinker pre-grinding circuit. The simple layout has fulfilled expectations not only on the basis of production and product quality, but also on installed power and equipment cost, equipment selection, and operating and maintenance costs.

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