The inauguration of the world’s largest vertical roller mill for cement grinding completes a smooth commissioning process at Shah Cement in Bangladesh.
With an 8.1-metre grinding table and six grinding rollers powered by an 11.6-megawatt gearbox, the FLSmidth OK™ 81-6 Mill has milled its first cement at Shah Cement’s Muktarpur Plant, Munshiganj, Bangladesh.
Shah Cement Industries Ltd. of the Abul Khair Group is one of Bangladesh’s largest cement producers. The FLSmidth vertical roller mill (VRM) was chosen to produce a full range of cement types at the Muktarpur Plant. Driven by two 5.8 MW FLSmidth MAAG Max Drive gear systems, the impressive mill is the biggest VRM ever to be installed in a cement plant in terms of dimension, operating capacity and installed power.
The world’s largest VRM was successfully put into operations in September 2018, and plant management at Shah Cement is extremely impressed with its outstanding performance. In just a few weeks, it has achieved a highly satisfactory production capacity with low energy consumption.
Hafiz Sikander, Director of Operations, Cement Division of Shah Cement Industries Ltd., says: “We are proud to have the world’s largest vertical roller mill as part of our operations. We selected the FLSmidth OK 81-6 Mill for its exceptional efficiency and reduced power consumption – and we are expecting it to deliver as promised. As the largest single-unit grinding mill in the industry, we expect it to meet our production requirements for many years.”
Supporting Shah Cement’s versatility in high quality cement production, the mill is designed to produce OPC, PPC, PSC and slag cement types. It is producing PPC at a capacity of 500 tonnes per hour @ 3500 Blaine with 15% slag.
Full equipment and service supply
In addition to the OK Mill, FLSmidth supplied the process and layout engineering, along with site advisory. The supporting equipment included FLSmidth Pfister weigh feeders, FLSmidth Airtech process bag filters, process fans and auxiliary equipment from raw material hopper discharge to process bag filter discharge.
Shah Cement management believes that FLSmidth was the best choice as partner for this significant project, a decision made in 2016. Mr. Hafiz Sikander comments: “We have worked with FLSmidth for many years, and we have always been able to rely on the high level of service at all stages.”
Designed for versatility
The FLSmidth OK 81-6 Mill installed at Shah Cement is designed to produce a full range of cement types.
|Feed mix||95% Clinker + 5% Gypsum
||65% Clinker + 5% Gypsum + 30% fly ash
||65% Clinker + 5% Gypsum + 30% Slag
|Capacity||540 TPH @ 3600 Blaine
||640 TPH @ 3800 Blaine
||450 TPH @ 3800 Blaine
||380 TPH @ 4000 Blaine
About Shah Cement
Located at Muktarpur, Munshigonj, Shah Cement Industries Ltd. is the largest cement producing plant in Bangladesh, with a capacity of 8.0 million metric tonnes per year. As one of the country’s leading cement brands, Shah Cement is the only cement company featuring in the list of Consumer Prestigious Brands of Bangladesh. The company is part of the Abul Khair Group, the largest business conglomerate in Bangladesh.
FLSmidth OK™ Mill highlights:
- Parts commonality for raw and cement applications
- Well-suited to changing cement production demands
- Flexibility to grind diverse materials and ability to accommodate changes to product type within minutes
- 5-10% less power consumption than other cement VRMs, saving millions of kilowatts annually
- Achieves 60-70% of nominal output, even with half of its rollers out of service