Emami Cement orders five mills from Gebr. Pfeiffer


Updated Fri, 14 Mar 2014 00:00:00 GMT

Gebr. Pfeiffer SE and its Indian subsidary Gebr. Pfeiffer (India) Pvt. Ltd. have been awarded a contract by Kolkata-based Emami Cement Ltd. It includes four MVR mills of the latest design and an MPS mill for coal grinding.

Emami Cement Ltd is an enterprise of the private Emami Group of Companies and a newcomer in the cement industry. Its decision to set up a greenfield cement plant in Chhattisgarh and various grinding plants in the east of India was preceded by a detailed analysis of the market situation.

The order comprises an MVR 6000 R-6 roller mill with an installed drive power of 6700 kW for raw material grinding. This mill is designed to yield 610 tph of raw meal, with the difficult-to-grind material being ground to a fineness of 15% R 90 µm.

Three mills of the type MVR 6000 C-6, Gebr. Pfeiffer’s current top-seller, will be used for cement grinding. Each of these mills featuring an installed drive power of 6700 kW will be capable of producing 335 tph of Ordinary Portland Cement. The grinding plants will also be designed to allow flyash cement and granulated blastfurnace slag to be ground to a fineness of 3800 cm²/g according to Blaine and 4000 cm²/g according to Blaine, respectively.

The beneficial feature of the MVR 6000 C-6 and the MVR 6000 R-6 is their six rollers representing an innovative concept of an actively redundant system. In the case of an unplanned outage of one grinding roller, this innovation allows the mill to continue in operation with four rollers during maintenance on the swung-out roller outside the roller mill. In particular, when it comes to cement grinding, where regular and planned maintenance works are scheduled for the regeneration of the grinding elements, this concept offers the customer the option to carry out maintenance works on two rollers outside the mill while at the same time cement can continue to be produced, albeit at a reduced capacity.

Thanks to the modular design of MVR mills, the essential components, such as bearings, seals of the grinding rollers and the tension system as well as the gearbox of the mill main drive, are identical in design. This feature enables the customer to manage with a small pool of strategic spare parts, which can be used with all the MVR mills.

This order brings the number of MVR mills sold to the Indian market to 10, increasing the number of MVR mills ordered worldwide to 16.

For the grinding of the fuel to be used for the cement rotary kiln the customer opted for an MPS 3350 BK vertical roller mill, which will produce 80 tph of hard coal ground to a fineness of 15% R 90 µm. The MPS mill, with its proven pressure-shock-proof design, competed successfully against mills of Indian manufacture because the customer favours Gebr. Pfeiffer’s technologically advanced machine.

As the customer is new to the cement sector, advice was sought from the New-Delhi-based Cemtech India and the Guargon-headquarted Holtec. In particular, the extremely positive experience that these consultants have been able to accumulate with mills from Gebr. Pfeiffer in nearly 20 years, contributed to the customer’s decision to purchase Pfeiffer mills.

While Gebr. Pfeiffer SE will supply the core components of the mills and the gear units from Europe, its Indian subsidiary, Gebr. Pfeiffer (India) Pvt. Ltd., will provide components such as housing of the mills and classifiers, the steel foundation parts as well as the interior parts of the classifiers. In addition, the Indian subsidiary will design the plant layout and advise the customer on the equipment to be procured.