HRP - Hydraulic Roller Press

Increase energy efficiency and throughput

Main features
- Two types of wear lining are available welded hardfacing applied to a solid shaft or to a shrink fit sleeve - 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 FLSmidth 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. How it works 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. A flexible solution 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. Pregrinding system 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. Semi-finish grinding system The semi-finish grinding system ensures better utilisation of the roller press. The roller press operates in closed circuit with two separators on top of each other a static separator making both disagglomerating and a coarse separation, 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 semi-finish grinding installation can be attained by combining the roller press and the ball mill with a Sepax separa-

tor and our stabile RPGS separator. The roller press then operates in closed circuit with the static separator working as both disagglomerator and coarse separator, while the ball mill operates in closed circuit with the high-efficiency dynamic 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. Splitting the two circuits 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 press is to serve two or more ball mills. In that case the static 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 the dynamic Sepax separator on top of the static RPGS separator. When feasible, such a process configuration is very attractive in terms of operating and investment costs.

Roller press pregrinding

Roller press semi-finish grinding Two-stage Sepax

Roller press finish grinding

Mill air flow Seperator air flow Material flow

HRP - Hydraulic Roller Press

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10 8 1 7 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

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10 Top frame 11 End section 12 Hinged L-shape end section 13 Elastomer shear pad 14 Feed control gate

Mechanical description

The frame 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.

Rollers 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. 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.

Drive configuration

Specific energy consumption, kWh/t

3500 Blaine Closed circuit Ball mill Roller press Separator Grit separator Separator fan Mill fan Aux. Total kWh/t 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

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. It is also used for adjusting the throughput or power consumption of presses working with feed material of varying draw-in characteristics and/or friction characteristics. 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. 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 that 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.

Feed control gate

Characteristics, type range and typical data

Roller dimension Press size A m2 0.60 0.90 1.25 1.60 2.00 2.50 3.00 3.60 DxW cm x cm 117x51 136x66 148x85 160x100 174x115 192x130 212x141 230x157 Roller speed (peripheral) m/sec 1.60 1.60 1.60 1.60 1.60 1.60 1.60 1.60 Capacity t/h 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
C 11-10 300-4-ENG

Copyright 2010 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth is a (registered) trademark of FLSmidth A/S. This brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for general reference only and may change at any time.

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