Grinding

FLSmidth Roller Breaker

HRP Hydraulic roller press

The HRP lets you increase capacity without increasing power consumption – or just dramatically lower energy usage

  • The basics
  • Design & configuration
  • Maintenance

Key benefits

  • Highly energy efficient
  • Low operational and maintenance costs
  • Upgrades can increase capacity up to 100% as compound to traditional ball mill grinding
  • Suitable for variety of cement types
  • Two types of wear lining available – welded or bandage
  • Hinged frame for easy roller removal

 

Learn more

More in-depth information is available here
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How it works

The roller press grinds cement clinker and brittle material by subjecting it to immense pressure, producing micro-cracks in the material as well as a substantial amount of fine material.

For some types of feeds and end products, the roller press can function as a finish-grinder, replacing the ball mill and practically doubling grinding efficiency.

More commonly, however, the HRP works in conjunction with a ball mill, either pre-grinding or semi-finish grinding the material, significantly increasing throughput and reducing power consumption of the entire mill system. When pressed clinker is fed directly to a ball mill, for example, it greatly reduces the power consumption required to produce finished cement compared with clinker that has not gone through a roller press beforehand.

Built on innovative roller press technology, the HRP is one of FLSmidth’s most advanced and efficient units. A highly flexible solution, it is suitable for both new installations and upgrades.

As an upgrade, the HRP can increase capacity by up to 100%. As part of a new installation, it can reduce energy consumption by 20-30% compared with traditional ball mill grinding systems.

Wear lining

HRP rollers have a wear lining of welded hardfacing material that has two application possibilities: hardfacing applied either to a solid shaft or a shrink fit sleeve bandage.

Worn grinding surfaces are reconditioned by welding. Spot repairs or complete resurfacing can be performed with the rollers in situ, if desired.


Controlled feed system

To facilitate a choke feed press, the HRP has a motorized feed-control gate that smoothes the feed start and helps adjust the throughput or power consumption of the press. The feed-control gate is beneficial when processing a variety of material types, but is only required for choke feed.

Configuration options

There are several ways that a roller press can be incorporated into a grinding system:

  • As a pre-grinder, the roller press grinds fresh feed that is then finish ground in a ball mill grinding circuit.
  • As a semi-finish grinder, the HRP operates in closed circuit with a disagglomerator and a dynamic separator. Fines are finish ground in a one-compartment ball mill. In this configuration, the HRP can be made additionally compact and energy efficient by utilising a Sepax two-stage separator in conjunction with a ball mill.
  • For some types of feed material and some end products, the HRP can operate as a finish grinder without a ball mill. Here the HRP operates in a closed circuit with a two-stage separator. This configuration keeps operating and investment costs low.

Low maintenance costs

The highly durable wear parts of the HRP reduce maintenance and operating costs. Additionally, the roller press rollers do not need dismantling for hard facing repair or complete resurfacing, and shutdown for wear part replacement is brief.

Tips

  • Bearing life optimised by ample sizing and clean, conditioned oil lubrication
  • Hinged frame allows easy roller removal
  • Worn grinding surfaces reconditioned by welding – spot repair or complete resurfacing can be performed with rollers in situ

  • Main Office

    FLSmidth A/S
    Cement Technologies & Corporate Matters
    Vigerslev Allé 77
    2500 Valby
    DENMARK
    Tel: +45 36 18 10 00
    Fax: +45 36 44 11 46
    info@flsmidth.com
  • Main Office

    FLSmidth Inc.
    Cement Projects Americas
    2040 Avenue C
    Bethlehem, PA 18017
    USA
    Tel: +1 610 264 6011
    Fax: +1 610 264 6170
    info-us@flsmidth.com
  • Main Office

    FLSmidth Pvt. Ltd
    Cement and Minerals Projects India
    FLSmidth House, 34, Egatoor, Kelambakkam
    (Rajiv Gandhi Salai – Chennai)
    Tamil Nadu – 603 103
    INDIA
    Tel: +91 44 4748 1000 / 2741 1000
    Fax: + 91-44-2747 0301/0302
    indiainfo@flsmidth.com
  • Main Office

    FLSmidth Salt Lake City, Inc.
    Minerals Processing
    7158 S. FLSmidth Drive
    Midvale, UT 84047-5559
    USA
    Tel: +1 801 871 7000
    Fax: +1 801 871 7001
    info.slc@flsmidth.com
  • Main Office

    FLSmidth Wadgassen
    Material Handling Technologies
    Karl Koch Str. 1
    D-66787 Wadgassen
    GERMANY
    Tel: +49 6834 4700
    Fax: +49 6834 470-339
    wadgassen@flsmidth.com

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