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A new drive concept for large Loesche cement mills: Abdullah Bellafkih, Loesche (Germany)

Filmed at Cemtech MEA 2015, 8-11 February, Grand Hyatt Dubai, UAE

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The subject of my today's presentation is Loesche Cement Mills and New Drive Concept for Large Cement Mills. Well, my presentation is therefore has been structured in three parts. Well the first part will be the explanation of the reason, the reason why the decision was made in the favor of Loesche Vertical Roller Mills and then the second part of my presentations, we'll be introduce a new drive concept for the Loesche Cement Mills and then after about, around 20 minutes, I will finalize my presentation with a short conclusion.

Well, the cement can produce a much more energy efficiency in VRM system compared to the traditional boomer system, is a common knowledge and in general accepted by the cement producer worldwide. However, when I had the first model Loesche VRM was solved for the production of cement mill in 1993, the market was still hesitating and waiting for operation results but after the operation results of the first installation showing that the cement qualities are accepted to the market and that the major of the cement's producer changed their preference to Vertical Roller Mill system.

Whilst for the ball system, it had a market share of some 905 in the 2000 and has now been drastically reduced to the way below 15% and compensated by the more efficient and flexible Vertical Roller Mill system. Therefore, Loesche has currently solved nearly more than 320 vertical roller mill for cement grinding equipped with the parting design,

2+2, or 3+3 and 4+4 technology of which more than 200 mills are already in successful operation. By the way, when I say the cement grinding, it's like grinding is also included. Such number underline the fact that the market has acknowledged the improved the Loesche vertical roller mill technology for the cement grinding and the state of the art, market trend has also knowledge- enriched the region of Middle East.

All Loesche Mills are designed with flat grinding table, ensure the defined grind to get between the grinding roller, rollers in grinding plates during the entire service life of the grinding parts. Also, the welding, the welding can take place much easier than machines with groove grinding tracks. Grinding is carried out primarily to the application of compressive forces in the small amount of the share forces. The Loesche, type of grinding roller ideally fine grinding and at the same time ensure the minimum rare.

This is especially compared to the non tapered cylindrical rollers which is so far extremely rare. The grinding rollers of the Loesche Vertical Roller Mills are supported and guided by the individually in rocker arm system. Therefore, no intermediate frame and groove grinding trick is necessary in order to keep the grinding rollers in a position. Flexible hydro-pneumatic string loading system of the rocker arms ensure the correct grinding pressures for all circumstances.

It could mean different materials with different grandibility or different product finances and so on. It is also included in the integrated mechanism to lift the roller as an aid for the mill wind starting up for the grinding track. The wall grinding parts can be simply and quickly replaced. The grinding rollers for the example are retracted from the grinding chamber into the, into the vertical position using the hydraulic string. A complete, complete Rollers or roller tyres can be simply be maintained. Loesche mills are designed following modular design concept. This concept allows to use a proper paths for the cement raw materials,

coal and cement mills. Last but not least ladies and gentlemen, Loesche has developed a new type of separator offering numerous of mechanicals and process-related improvements. Coming back to the Loesche modular design concept. Loesche mills are equipped with assembly consistent of the grinding tyre and the grinding rollers [incomprehensible] in spring assembling unit necessary for the grinding process, this is assembly college module. As already explained ladies and gentlemen, the rollers has, the modules are independent from each other, and no contact to and no connecting and keeps in place via intermediary frame.

This enables Loesche VRM for them to increase the capacity for proving mill just by adding proof additional modules and possibly encroach other mill designs. Nowadays, only six modules for Loesche mills are in operation covering the production range from 80 ton power/hour to 1,400 ton per hour for the cement room materials, grinding and form 40 tons/hour about 2,550 tons/hour for the cement grinding.

The modules are used for the grinding table, diameter starting from 2.4 meters up to 7.5 meter. Well, in additional to that our customers in the Middle East region wanted to be ready for the change in the market required not only for simple OPC cement but also various types of additive cements with wide brand of the different product finances.

Loesche Vertical Roller Mill is ideally designed for such demand guarantee a quick and simple changing over from from one product to another and at the same time ensuring the energy efficiency, production for all cement types required. Those demands are easily fulfilled when the using a Loesche Vertical Roller Mill system for the cement grinding.

As you can see, nearly 60% of the installation have been reason for more than one product and about 30% of the machine population has been as in for three and more per products. Our customers is in the reason are convinced that Loesche Vertical Roller Mills are ensured quick change from production from simple OPC cement to composite cement, from low blaine value to high blaine values, and this is an impossible task for the traditional alternative grinding system. One of the reasons for the flexibility of Loesche Vertical Roller Mill for the cement grinding is that the parting roller pair design which is necessary for a very important persons.

Cement products are ground much finer than for example, cement raw materials, that the finer the finished product gets, the finer the total feed material on the grinding table. Hence, the more challenging is to operate a vertical roller mill stable without any change a de-aeration at higher productions of level. To the count for this, Loesche cement Mills are equipped with a patent roller path design, one roller, that's so call it soparge roller, prepares the grinding bed for the actually combination by grinding rollers.

In this case, proforation means the pre-compaction of the grind embed and the result in duration of sale due to the actual combination takes place a higher efficiency and without anyone unwanted de-aeration when then grinding to very high product finesses. With the parting system, Loesche Mills have produced Slag cement up to finesses of 7,600 blaine and an OPC type cement up to the product finesses about 5,900 blaine.

Well, ladies and gentlemen, Loesche is focusing also on the development. It is on the focus of Loesche and to offer the most available VRM drive system at the lowest possible total cost of the ownerships to the market. This has been achieved ladies and gentlemen, with innovation engineering of constant research and development activities. It has been now honored with an order from one of the biggest cement producers Holcim and Lafarge 70.4 4+4 with new drive concept.

Loesche in co-oporation with the Rank has been developing new drive, a new drive concept call it, COPE drive. COPE drive means ladies and gentlemen, it is the Compact Planetary Electric Drive. As we can see here, the 6 to 8 water jacket coolage, cage induction motors are driven at central ball gear. That ball gear is in linked to the planetary out stage.

The planetary stage is used since more than 15 years in VRM Drive System as well and Bolmin Drive up to the more than 5 millimeters of output track. The first parts have to set with the six to eight more offers experience has been high duration, at [incomprehensible] the mill's sped requirements.

With these two stage are enough to cover duration of required for the Loesche Mills, for the LM from starting for LM46 to LM75. The radiation bearing is ranged next to the mill table and to cover the radio routes to directly into the caging. The rating of the bearing loads, the operation of four and five for us mills with oath with one of the roller out of the service.

COPE Cup Drive Ladies and Gentlemen, open new horizon in the maintenance compact drives under various ends. In case of an availability of motor or drive sets, the operators has two options. Either the the ultimate quick drive disassembled or the drive set remains specifically in the gears and the gear just remove and dissemble it or complete remove by using of the transpire system.

As we can show here, we have just removed the motor 30 millimeters and it kept the mill or the system running. In both the cases, the gear is lift under the mill and can be continue the operation closed to the nominal load as one motor represents just 12.5% of its motors of the total installed power.

The truth is grinding table of the Loesche mills, the center [incomprehensible] and the coupling between the two stages are accessible. All the bearings which are not easily accessible are the slave for bearings with all the features lifetime. All the gears and couplings are designed in the way that they're are back flank and can become the load flank.

COPE is the first large size drive with the space built in. Well, as already mentioned, the COPE drive is designed for the availability if a motor is out of service, the motor can be quickly dissembled and operation can continue. As already mentioned before, we can keep it or you can check complete motor outside and via the monorail.

Well, Ladies and Gentlemen, I want to show you a video in mind to give you the overall about the new COPE drive system. Loesche Mills could easily assemble the motor sense in here, [incomprehensible] modules out of the service. Well, Ladies and Gentlemen, we're already at last subject of my today's presentation in which I would like to show you the Loesche situation at the present, short conclusion.

Well, Loesche is the first company to install the vertical raw mills in the Saudi Arabian, increase the total Loesche mills population to 16 mills in Saudi Arabia. We are convinced Ladies and Gentlemen that the sections will change the preference of the cement producer toward the flexibility and the energy efficiency, Loesche Vertical Roller Mills for the cement grinding in their region as well in Saudi Arabia.

Well as mentioned in the beginning, the total number of Loesche mills sold worldwide has reached more than now, nearly more than 320 machines which is underlies Loesche Mills clearly market leadership in the field of the cement grinding. Well, now I'm at the end of my presentation but I don't want to leave the stage without the the short conclusion.

Loesche is clearly a market leader in the field of the cement with the Vertical Roller Mills. This is who due to the energy efficiency of the Loesche mills also for the flexibility to the easily changed from simple OPC to the composite cement from low blaine value to the high blaine values and this ladies and gentlemen, is an unpossible task for traditional alternative grinding systems.

Well, in addition to that and the most important for the cement producer, the cement qualities produced in the Loesche Vertical Roller Mills do fully match the strict market demands. This has been achieved with innovation, engineering, and constant research and development activities and has now been honored with the first to installation in the Saudi Arabia.

Ladies and Gentlemen, thank you very much for your kind attention.

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