Cemtech Presentation

1
Overcoming challenges
of
HPGR Grinding
systems
Internal use only, not intended for further distribution or publication

2
» Producing greener cement and at the same time reducing input costs.
» Methods used are
» Clinker produced from alternative fuels.
» Use of low grade coal.
» Clinker from calcined clay, slag, etc.
» Use of higher percentage of alternative cement materials such as
slag, limestone, concrete waste, wet flyash, etc.
» Optimizing existing systems to decrease energy consumption.
Though low percentage reduction of CO2 for grinding circuits but
direct financial benefits.
Existing system should be capable of handling the challenges and
thereby upgrading.
Present challenges in the cement industry

3
» Faster
» Low investment
» Easy implementation
» Quicker ROI
Why to upgrade?
What could be upgraded?
» Rollers with HEXADUR®- zero maintenance wear
protection system.
» From closed loop hydraulic system to open loop
hydraulic system.
» Feeding system adaptable to different types of feed
materials.
» Combination separator to change from
pregrinding/flake recycling system to semi finish system
as the initial grinding plants supplied where HPGR was
used as pregrinder or flake recycle.
HEXADUR® roller surface
Gravity feeder
Koesep® Separator
Upgrading of Grinding systems

4
» founded in 1898 in Hattingen, Germany by Family
Köppern
» Production of roller presses and briquetting plants since
the early 20th century
» 1986: first High Pressure Grinding Roll (HPGR) for
cement comminution
» 1996: development of HEXADUR®-wear protection
» 2015: first full industrial operation of 2-Stage Koesep®
in Vils/Austria
» 2015: Upgraded Roller Press from another OEM in
Thailand with HEXADUR ®, Köppern feeding and
hydraulic system.
» 2020: Commissioning of first complete grinding Plant in
Vils/Austria with 2 Stage Koesep ® /HPGR/Ball Mill.
Steady development since 1898
Köppern at a glance

5
HEXADUR®
Unconditional
High
Performance

6
Implementation of HEXADUR® – Surface profiling
HEXADUR ® concept

7
HEXADUR ® Roller Surfaces
After 2,000 hours After 53,700 hours, wear rate 0.5 to 0.6 mm
per 10,000 hours of operation
After 12400 hours, wear rate 1.3 to 1.8 mm
After 33,600 hours, wear rate 1.0 to 1.3 mm

8
Country Material Roller size HPGR Operation Hexadur Start up
D x W Supplier Hours Installations Hexadur
[mm] [-] [h] [-] [Year]
Europe
Clinker 1.000 x 930 Köppern 75.000 1 1996
Slag (23% Slag) 1.000 x 500 Other > 46.000 1 1998
Clinker (35% Slag) 1.000 x 630 Other 43.000 1 2001
Clinker 1.400 x 1.200 Other 76.000 2 2001
Clinker 1.400 x 660 Other > 35.000 1 2003
Clinker 1.400 x 660 Other > 26.000 1 2006
Clinker 1.400 x 660 Other > 25.000 1 2007
Feldspat/Kaolin 532 x 400 Other 8.630 1 2008
Clinker 1.000 x 380 Other 37.300 1 2008
Clinker (35% Slag) 1.500 x 1.300 Köppern 24.464 1 2011
Clinker (75% Slag) 1.500 x 1.300 Köppern > 25.500 1 2012
Clinker 1.150 x 630 Other > 53.700 1 2012
Clinker 1.400 x 530 Other 14.000 1 2012
Clinker (56% Slag) 1.000 x 380 Other 25.600 1 2014
Clinker 1.400 x 800 Other 25.500 1 2016
Clinker (Slag 30%) 1.450 x 1.000 Other > 16.500 1 2020
Clinker (Slag 20%) 1.400 X 1.400 Other > 17.700 1 2020
Clinker 1.000 X 930 Köppern > Ordered 1 2022
North America
Clinker 1.150 x 1.000 Other > 39.000 1 2009
Clinker 1.400 x 800 Other > 27.000 1 2012
Limestone 1.000 x 380 Other 22.000 1 2012
Clinker 1.400 x 525 Other > 32.000 1 2013
Limestone 1.400 x 1.100 Other > 26.000 1 2016
Clinker 1.400 x 1.400 Other Ordered 1 2022
* Excerpt, dated Dec’2022
Reference List*

9
[mm] [-] [h] [-] [Year]
South America
Clinker 1.150 x 1.000 Other > 19.000 1 2013
Clinker 1.700 x 1.400 Other 39.000 1 2014
Clinker 1.400 x 1.400 Other > 29.900 1 2017
Clinker (14 % Riolito
Quarzporphyr)
1.740 x 1.000 Other > 15.500 1 2018
Limestone 1.200 x 630 Other > 7.500 1 2019
Asia
Clinker 1.200 x 1.200 Köppern 40.500 2 1999
Clinker (35% Slag) 1.200 x 1.200 Köppern 43.000 2 2002
Clinker 1.200 x 1.200 Köppern > 27.800 1 2003
Clinker 1.000 x 765 Köppern > 55.600 4 2011
Clinker 1.500 x 1.300 Köppern 33.973 3 2013
Clinker 1.500 x 800 Other 43.500 2 2014
Clinker 1.220 x 760 Other > 48.500 1 2015
Clinker 1.524 x 965 Other > 13.340 1 2015
Clinker 1.500 x 800 Other 42.000 1 2016
Clinker (Trass 23%) 1.500 x 1300 Köppern > 3.800 2 2020
Limestone 1.730 x 1500 Köppern > 4.500 1 2020
* Excerpt, dated Dec’ 2022
Reference List*

10
[mm] [-] [h] [-] [Year]
Asia
Clinker 1.524 x 965 Other > 8.500 1 2021
Clinker 1.400 x 1.100 Other > 2.800 1 2022
Clinker 1.350 x 1.100 Köppern Delivered 1 2021
Limestone 1.780 x 1.500 Köppern Ordered 1 2022
Clinker, wet flyash 2.050 x 1.500 Other Ordered 1 2022
* Excerpt, dated Dec’ 2022
Reference List*

11
» Customized tile composition
» Profiled surface for better nip
» Constant intake and throughput
» Production increase
» Constant grinding pressure
» Resistant against tramp metal
» Regular maintenances not required
» Yearly ultrasonic wear
measurement
Advantages of HEXADUR®

12
HPGR upgrades
Feeding system
Hardmetal cheek plates
Hydraulic system

14
Never Operate at Static Gap!
Working gap
Static gap
Fixed Roller Moving Roller

15
Throughput = Bed Pressure =

16
Feeding system
• Inlet shaft (1)
• Adjustable face walls (2)
• Regulating devices (3)
• Lateral cheek plates* (4)
• Thrust bolts* (5)
• Openings for inspection (6)
• Cover plates (7)
* - not part of the feeding system

17
Motorised feeding system
Minimum
Maximum
Arbitary

18
Feeding system
HPGR Throughput and Power Consumption vs. Gravity Feeder Opening

19
Feeding system- Advantages
à Flexibel adjustment of the gravity feeder opening according to process requirement
(Standard version: manually or motorised: automatically with geared motor).
à Optimizing of roller press throughput and power consumption.
à Easy adjustment and maintenance.
à Cheek plates with installed hard metal à lifetime > 5 years without maintenance.
à Position of cheek plates is fixed with spring loaded thrust bolts à possibility to
move out in case of back pressures from the rollers or material.
à Bottleneck of production or quality loss due to side-leakage through the cheek plate
area is very much reduced.

20
Köppern open loop Hydraulic system
Hydraulic Unit
Salient features
- Two pumps operating 24/7, 365 days to maintain the
pressure.
- Pressure is regulated with proportional valves which
are pressure dependent valves and maintains
pressure as being set.
- Effective and automatic skew control with individual
pumps and proportional valves.
- Online filteration and cooling unit. Filteration unit is
also used for oil filling therefore avoiding dirt in the
system.
- Operation logic can be implemented in customer‘s
DCS i.e. no requirement of separate black box.

21
Hydraulic System
S1 > S2
SP1 > SP2
S2
S1
S1 < S2
SP1 < SP2
S2
S1
SP1
SP2
SP1
SP2
case 1
case 2
skew

22
Hydraulic system
27 .
09 .
1999
09 :
58 :
40 09 :
58 :
50 09 :
59 :
00 09 :
59 :
10 09 :
59 :
20 09 :
59 :
30
K
N
M
2600
2275
1950
1625
1300
975
650
325
0
MM
55
50
45
40
35
30
25
M /
_
S
1 ,
8
1 ,
7
1 ,
6
1 ,
5
1 ,
4
1 ,
3
1 ,
2
1 ,
1
1 ,
0
A
1750
1500
1250
1000
750
500
250
0
0z3S peed -fi
xed -r
o l 1z4S peed -
m ove -r
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e 2z3C u rr
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que -
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01 .
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32 :
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5 16 :
32 :
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5 16 :
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00 ,
5 16 :
33 :
01 ,
5 16 :
33 :
02 ,
5 16 :
33 :
03 ,
5 16 :
33 :
04 ,
5
m *
H z
2 ,
00
1 ,
75
1 ,
50
1 ,
25
1 ,
00
k
N
m
800
750
700
650
600
550
500
450
400
0z3
S peed -fi
xed -r
o l 1z3
S peed -
m ove -r
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e 2z3
C u rr
en t-fi
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essur
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or
que-
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m ove-r
o ll 14z3Sa f
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y coup li
ng 15z3
M e t
a ll
de t
ec t
or
Conventional system (closed hydraulic) vs. Köppern system (open hydraulic)
Comparision of operation curves

23
Hydraulik block – Pendulum piston
Forces transmitted directly to the
cylinder body and then to the press
frame. No vertical loads through the
seals.

24
Hydraulic System
Major advantages to conventional systems (closed systems)
à More stability of grinding pressure, which could be changed during operation as
per the process requirement.
à Reduced torque fluctuations in drive train.
à Skew controller for stable grinding bed.
à Bigger Nitrogen accumulator serving as an oil reservoir in case of rapid roller
movement.
à Pendulum piston cylinders with improved design (no vertical loads).
à Easy adjustment and maintenance.
à Emergency operation with single pump and single valve possible.

25
Case Study -Customer‘s pain visa vis Köppern‘s
solutions
1. Severe problems with roller surface
maintenances due to chunk offs and
profile repairs.
2. HEXADUR® process audit indicated
following
§ Skew operation
§ Pressure fluctuation
§ Repeated seal failures and severe
leakages from the cylinders
§ Uneven pressure distribution.
§ Operation with very high bed
pressure resulting to problems with
roller surface, frequent damage of
shafts and bearings.
§ Repeated problem with gearbox
1. HEXADUR® roller was
commissioned in May‘2015.
2. Köppern open hydraulic system
was commissioned in 2016.
3. Köppern patented Gravity feeder
was commissioned in Sept‘2018.
Solutions

26
Before Upgradations
Old Hydraulic system Old Feeding system
solutions

27
Before Upgradations
Case Study Asia Cement -Customer‘s pain visa vis
Köppern‘s solutions

28
After Upgradations
Köppern Hydraulic
system
Köppern Feeding system
solutions

29
• Average increase of production from 118 tph to 128.5 tph which is approx. 9%
• Average reduction of power consumption from 43.66 kWh/t to 37.93 kWh/t
which is approx. 14 %
• Yearly saving of production cost approximately half a million euro i.e. till now 2
Million euros and still adding.
• Payback achieved within two years of operation.
• Higher lifetime of machine components therefore lower maintenance costs.
solutions - Results

30
Set-up and function:
1 – feed (product from HPGR)
2 – primary air inlet
3 – baffle plates
4 – guiding plates
5 – outer cone
6 – coarse discharge → back to HPGR
7 – guide vanes
8 – rotating cage
9 – motor
10 – inner cone
11 – middlings discharge
→ to ball mill
12 – feed (product from ball mill)
13 – product + air discharge
1
1
2
2
3
4
5
6
7
8
9
10
11
12 13
static
classifying
stage
dynamic
classifying
stage
Patented in Germany and Europe
The 2-Stage Koesep

31
Upgrade in Austria: HPGR in pre-grinding mode upgraded into semi-finish grinding
existing
Fresh Feed
Product
Product
Flake Recycle
① HPGR
② Dynamic Air Classifier
③ Ball Mill
④ Köppern 2-Stage Koesep
⑤ Cyclones
①
②
③
④ ⑤
» downtime during upgrade:
40 hours only
Case Study Schretter Cement, Upgradation with
Koesep®

32
Comparison of combined air classifiers
Construction height of air classifiers with a plant capacity of 41 t/h, like at the Austrian cement plant
scaled figures
» more than 40 % less construction
height with 2-Stage Koesep
compared to usual combination
17.8
m
10.7
m
static
air
classifier
dynamic
air
classifier
static
+
dynamic
air
classifier
3. The 2-Stage Koesep

33
Cement
Type
HPGR in pre-grinding mode
HPGR in semi-finish grinding mode with 2-Stage Koesep,
with former cement strength
Spec. surface
in cm2
/g
Capacity
in t/h
Spec. surface
in cm2
/g1)
Capacity
in t/h
Improvement
in %
A 5000 22 4900 26 18.2
B 4200 27 4100 32 18.5
C 4200 34 4000 40 17.6
D 4800 26 4700 32 23.1
1)
Specific surface could be decreased to achieve required 2-days- and 28-days-strength.
0
5
10
15
20
25
30
35
40
45
A B C D
Capacity
in
t/h
Cement Type
HPGR in pre-grinding mode with
conventional dynamic air classifier
HPGR in semi-finish grinding mode
with 2-Stage Koesep
capacity
+20 %
spec. energy
-13 %
Case Study Schretter Cement, Upgradation with
Koesep®

34
Why Köppern?
» Products and quality – Made in
Germany.
» Audits of existing grinding plants.
» Upgradation of existing grinding
circuit and Roller Press.
» Transfer of more than 30 years of
Grinding process Know – How.
» Supply of improvement parts for
other makes presses.
» On time delivery.
» Service support.

35
Thank you very much
for your patience
hearing.
Kaushik Ghosh
Phone: + 49 2324 207- 256
Mobile + 49 1784 207203
Email k.ghosh@koeppern.de
Internet: http://www.koeppern.com

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