The limestone-rich belt of Karnataka in India is home to many cement plants, and the market for roller presses in the region is highly competitive. Given the numerous different options on the market, choosing the correct roller press solution and the equipment supplier can be daunting for plant owners. For Orient Cement, selecting the FLSmidth Hydraulic Roller Press (HRP) has proven to be a cost-effective solution.

HIGH-PERFORMANCE HRP

FLSmidth’s latest hydraulic roller press sets the bar with its efficient design and includes other noticeable improvements in performance:

  • Solid forged rollers (No hollow shaft)
  • Spherical roller bearing to accommodate angular misalignments
  • Oil for bearing lubrication, bearing cooling, and filtering of foreign media
  • Optimum roller Diameter to Width ratio
  • Hinged frame for easy roller removal


These features enable the HRP to achieve high energy efficiency and contribute to a low cost of ownership, largely due to its ease of operation and minimal maintenance costs.

Hydraulic roller press
The HRP is suitable for upgrades and new installations. In some cases, an upgrade can more than double the capacity while reducing energy consumption by 30%.

Finding the right solution


With a desire to optimise productivity, Orient Cement established selection criteria for evaluating a new roller press system for use in its 6,600 tonnes-per-day integrated greenfield plant. The three most critical objectives were high production performance, low power consumption, and grinding without adding water. Head of Projects at Orient Cement Shyam Asawa explains: “Hydraulic roller press systems are the best choice for the raw materials in our region as the materials are quite dry in nature and have high grindability. We also require a waterless operation, so the HRP system was the obvious solution for us.”

 

Performance at Orient Cement

Unit Guaranteed Achieved during Performance test
Guaranteed capacity TPH 250 266
Product fineness (Wet sieve redidue on 90μ) % 12 12
Product moisture (Indicative only) % 1.0 0.8
Specific power consumption, includes roller press drive, separator drive, separator fan, booster fan and auxiliaries Kwh/tonne@metre 16.8 14.6
Table 1: The grinding system's performance after the installation of two hydraulic roller presses.

 

Low power, no water


Shortly after the installation, it was evident that Orient Cement’s project objectives would be achieved, with all performance guarantees successfully delivered. As shown in table 1, actual production exceeded the intended capacity target by 6.5 percent – at a lower power consumption and with zero water consumption.

 

Today, the grinding system at the Karnataka plant is performing well. After the initial 10,000 hours, the conventional wear surface remains in good condition. No repair work has been required or performed thus far. This strong result is a testament to both the quality and durability of the equipment. “We chose FLSmidth to supply the HRP system for raw grinding based on its brand credibility and industry experience. FLSmidth has yet again proven itself and has clearly set a new standard with its superior performance and commendable results,” says Mr. Asawa.

 

“Hydraulic roller press systems are the best choice for the raw materials in our region as the materials are quite dry in nature and have high grindability. We also require a waterless operation, so the HRP system was the obvious solution for us.”

Shyam AsawaHead of Projects at Orient Cement
Since the successful installation of the HRP, Orient Cement has opened its plant doors to other cement producers to showcase the successful grinding solution and welcomed any discussion regarding its positive experiences.

Orient Cement's hydraulic roller press specifications

  • Raw material grindability: 12kWh/t at VRM shaft for product residue of 12% on 90μm sieve
  • Overall feed moisture: 4%
  • Unit type: Roller Press HRP 3.0
  • HRP dimension: 1920mm (diametre) × 1563mm (width)
  • Installed power: (1600kW *2)
  • HRP speed: 2m/s maximum
  • Grinding pressure limit: 5500kN/m2 (maximum)
  • Static separator size: RPGS – 3150
  • Dynamic separator size: RARL 40

 

HRP at Karnataka plant

When to consider an HRP system

  • In regions with a high price per kW/hr
  • In applications with an average feed moisture of less than 6%
  • If water is scarce
  • Where waste heat recovery power generation is important

Contact

Avanish Karrahe

Avanish Karrahe

Global Product Line Manager - HRP Systems
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