1Presented byDr. Daniel Strohmeyer

Loesche GmbH, Germany loesche@loesche.de

www.loesche.com

Stand-alone Grinding Plants without Hot Gas Generator -

Results from India

Cemtech Dubai 2011

Table of contents

1. Introduction2. Loesche vertical roller mill for cement grinding 3. Ambuja Cements Dadri and Nalagarh projects4. Projects Dadri and Nalagarh Realize It!5. Dadri and Nalagarh Project Summary

2Cemtech Dubai 2011

Introduction- water and energy precious resources -

Water and energy are the basis for life and the world as we know it today water as well as energy are not available unlimited both resources will become scarce and more expensive

crude oil price development Consequently saving energy and water is essential for ecologically and economically viable production - also or in particular in the cement industry

Cemtech Dubai 2011

Introduction- operational aspects of vertical roller mills -

Water injection on the grinding table is a common way of stabilizing the grinding bed leading to a smooth and optimized operation of the mill

Downsides of water injection water needs to be evaporated thermal energy is required (e.g.

cooler gases, hot gas generator) water may only be available in limited quantities or not at all

Resulting demands for stand alone grinding plants reduced or zero water injection no permanent utilization of hot gas generator no fuel costs

3Cemtech Dubai 2011

Table of contents

1. Introduction2. Loesche vertical roller mill for cement grinding 3. Ambuja Cements Dadri and Nalagarh projects4. Projects Dadri and Nalagarh Realize It!5. Dadri and Nalagarh Project Summary

Cemtech Dubai 2011

Loesche vertical roller mill for cement grinding- material flow, feed materials, products -

4Cemtech Dubai 2011

Loesche vertical roller mill for cement grinding - cement grinding as part of the process -

cement grinding

quarry CRM grinding kiln/cooler cement

Cemtech Dubai 2011

Loesche vertical roller mill for cement grinding- working principle -

1) Rotary feeder2) Mill table with grinding track3) Master roller4) Support roller5) Rocker arm6) Hydro-pneumatic spring system7) Bevel-planetary-gear box8) Electric motor9) Gas inlet10) Ring duct11) Louvre ring12) Classifier13) Grit cone14) Outlet duct to dedusting system

5Cemtech Dubai 2011

Loesche vertical roller mill for cement grinding- grinding plant flow sheet -

Cemtech Dubai 2011

Table of contents

1. Introduction2. Loesche vertical roller mill for cement grinding 3. Ambuja Cements Dadri and Nalagarh projects4. Projects Dadri and Nalagarh Realize It!5. Dadri and Nalagarh Project Summary

6Cemtech Dubai 2011

Ambuja Cements Dadri and Nalagarh projects - Location of grinding plants in India -

Nalagarh plant

New grinding stations

each ~ 1.6 Mt/year of cement

each with 1 x Loesche mill and 250 t/h of grinding capacity

Dadri plant

Cemtech Dubai 2011

Ambuja Cements Dadri and Nalagarh projects- feed materials -

dry Fly-Ash

ClinkerGypsum

All feed materials have different physical properties andhence different grindabilities

7Cemtech Dubai 2011

Laboratory mill LM 3,6 Flow sheet LM 3,6

Ambuja Cements Dadri and Nalagarh projects- grinding test (1) -

Cemtech Dubai 2011

LOESCHE Grindability Factors (MF, LF)

spec. energy consumption

wear factor (vp)

The factors are used to determine the right mill and gear box size as wellas a suitable material for the wear parts

Ambuja Cements Dadri and Nalagarh projects- grinding test (2) -

8Cemtech Dubai 2011

5 15 25 35 45

power consumption - mill [kWh/t]

Dadri/ Nalagarh

Ambuja Cements Dadri and Nalagarh projects- cement grindability -

Cemtech Dubai 2011

LM 56.3+3

(250 t/h PPC)

Ambuja Cements Dadri and Nalagarh projects- mill selection -

9Cemtech Dubai 2011

Capacity 250 t/h PPC Gearbox power 5.400 kW (Flender) Classifier LSKS 102 CS; 560 kW Fan motor power 3.000 kW Mill diameter 13,5 m Height H 20,0 m Grinding table diameter 5.600 mm Grinding table weigth 109 t M Roller 3 * 2.450 mm S Roller 3 * 1.600 mm

Ambuja Cements Dadri and Nalagarh projects- key data -

Cemtech Dubai 2011

PPC 60% clinker + 5% gypsum + 35% dry fly ash (2500 Blaine)

Product PPC 4000 Blaine 250 t/h 30,75 kWh/t

Ambuja Cements Dadri and Nalagarh projects- scope of supply and product -

Loesche scope of supply Mill incl. classifier Sampling station Air slides for product transport

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Cemtech Dubai 2011

Table of contents

1. Introduction2. Loesche vertical roller mill for cement grinding 3. Ambuja Cements Dadri and Nalagarh projects4. Projects Dadri and Nalagarh Realize It!5. Dadri and Nalagarh Project Summary6. Cement types produced in Loesche VRMs

Cemtech Dubai 2011

Projects Dadri and Nalagarh Realize It!- mill base frame -

mill base frame

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Cemtech Dubai 2011

Projects Dadri and Nalagarh Realize It!- pedestals and bearing blocks -

~ 5,5 m

pedestal

bearing block

Cemtech Dubai 2011

Projects Dadri and Nalagarh Realize It!- erection of gear box -

Chockfastgear box base plate

gear box

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Cemtech Dubai 2011

Projects Dadri and Nalagarh Realize It!- mill housing and classifier ground-assembly -

mill housing

classifier

Cemtech Dubai 2011

Projects Dadri and Nalagarh Realize It!- mill with housing and erection of classifier -

~ 10 m

mill housing

~ 16,5 m

classifier

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Cemtech Dubai 2011

Projects Dadri and Nalagarh Realize It!- Loesche LM 56.3+3 -

Loesche LM 56.3+3

~ 20 m

Cemtech Dubai 2011

Projects Dadri and Nalagarh Realize It!- dry fly-ash feeding system -

fly ash feeding

clinker/gypsum feeding

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Cemtech Dubai 2011

mill

Projects Dadri and Nalagarh Realize It!- grinding plant (Nalagarh) -

cement silo

fan

filter

Cemtech Dubai 2011

Table of contents

1. Introduction2. Loesche vertical roller mill for cement grinding 3. Ambuja Cements Dadri and Nalagarh projects4. Projects Dadri and Nalagarh Realize It!5. Dadri and Nalagarh Project Summary

15

Cemtech Dubai 2011

Dadri and Nalagarh Project Summary- schedule (Dadri) -

April 2007 Mill order November 2008 Delivery (FOB) December 2008 Start of Erection December 2009 Start of Commissioning February 2010 First feed April 2010 250 t/h PPC reached September 2010 Further optimization achieved:

zero water injection and no HGG

Cemtech Dubai 2011

Dadri PPC

LM 56.3+3 Guarantee Achieved *

Mill through-put (t/h) 250 253

Fineness 4000 3920

Feed moisture (%) - 1,1Product moisture (%) - 0,3Spec. Power consumption: (kWh/t)(mill, fan, classifier, aux.)

30,75 25,60

Dadri and Nalagarh Project Summary- performance data (Dadri) -

* based upon 24 hours trial

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Cemtech Dubai 2011

Dadri and Nalagarh Project Summary- zero water injection and no HGG -

Cemtech Dubai 2011

Presented byDr. Daniel Strohmeyer

Loesche GmbH, Germany loesche@loesche.de

www.loesche.com

Stand-alone Grinding Plants without Hot Gas Generator -

Results from India