Hydraulic roller presses boost productivity at Orient Cement

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.

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.”

 

 

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.

 

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.