The Fives FCB Horomill® workshop
Case study for grinding plants in the Philippines
CemTech Asia 2014, Kuala Lumpur
Main project environment
Ú The Philippines market growth is strong and the Teresa plant was sold out in its existing state, grinding
systems used were two small ball mills and one RP/ ball mill combi grinding unit (without Vseparator). All
of these systems were lacking significant drying capabilities and were therefore unsuitable for new cement
types production with higher additive content, limitation being humidity in mills 1st chamber and/or
circulation elevators.
Ú The main expectation was to increase c/k ratio from existing 1.38 (original production target 2013) to
expected 1.8
Ú To do that, key issue was to enable 1P grade cement (55% clinker only, 5% gypsum, 5%limestone, 6%
flay ash, and 29% pouzzolan) production by adding a new grinding plant, the available pouzzolan having
good reactivity, but a high moisture up to 25%.
Ú The market response to the cement quality produced in another Lafarge plant in Bulacan (with existing
Horomill® size 3600) was already very good
Ú The solution selected was therefore:
› Co grinding of the 1P cement with additional possibility to produce the other types produced
in Teresa plant (OPC cement and masonry cement) by a new Horomill® size 3800 based plant.
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Horomill® plant key advantages
" Horomill®: many key competitive advantages
" Lowest energy consumption
" No water added (lower heat
consumption, better product quality &
lower wear)
" High and stable product quality
" Full automatic operation including start/
stop or change of recipe and
Adaptability to raw material variations
" Easy switch of recipe in 5 to 10 minutes
e.g. switch OPC / 1P / masonry cement
" Same nominal capacity during the
whole lifetime of wear parts
" Low wear rate and low maintenance
cost of grinding parts
" Low noise level
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Key project parameters
1) Key design decisions to address the requirements
• In order to optimize 1P cement production conditions, the drying function is fully integrated into the grinding plant, i.e. an
aerodecanter dryer arrangement is used with 100% of the pouzzolan fed separately at the dryer.
• By using co-grinding, the systems also benefits from hot clinker remaining heat, which would otherwise be wasted in
separate grinding (approx. 1MW heat power is saved depending on clinker temperature).
• The plant design has been optimized regarding fineness targets, in order to meet quality requirements of the 1P cement
(main production)
Blaine 4000 4400
Output 125 tph 106 tph
All plant equipment is designed for the production of finer cement at a fineness up to 4900 Blaine.
2) Material feed and main process arrangement
The grinding circuit as designed is capable of producing the three main products of the Teresa plant i.e.
OPC cement, 1P cement and masonry cement. With its design the plant is able to dry/grind a wide range
of additives combination due to the following feed features:
- main feed for clinker, gypsum and limestone (generally clinker + dry / coarse additives)
- feed to dryer for pouzzolan (wet additives) Note: can be used also for GBS.
- pneumatic feed below separator for fly ash (fine / dry additives)
- a by pass with remote control allows to divert part or whole of the circulating load from the main elevator outlet to
either top of classifier or aerodecantor (this design feature allows optimization of the process for fine grinding).
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Horomill® flow sheet for Teresa plant
Bypass
Application case Bag filter
Fan
for fine and wet additives
blended cement
Final
product
Pouzzolan feed up to 25% moisture
Secondary feed point
Main feed: clinker, Aerodecanter Fly ash pneumatic feed
gypsum, dryer
limestone
Feed Reject
Pulverized coal HGG 12 MW
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ITEMS FLOW SHEET
GRINDING PLANT
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PROCESS FLOW SHEET 1/2
1P Cement 4400 Blaine
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PROCESS FLOW SHEET 2/2
OPC Cement 3500 Blaine
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MAIN GRINDING PROCESS EQUIPMENT
Horomill, TSV, Aerodecanter dryer
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Horomill® main regulation loops
Air flow
Flow,
T°
Temperature
Feeding control
Main feed Constant reject flow
Mill underpressure
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Operation benefits
• The power consumption as shown in the attached table is very low compared to other systems (mill
system proper and limited material handling)
• 1P production 106t/h @ 4400 Blaine total plant consumption excluding cement transport inferior to
30kWh/ton.
• OPC production 85 t/h @ 3500 Blaine total plant consumption excluding cement transport inferior to
36 kWh/ton.
• No water injection is necessary, stability of the mill is controlled automatically by the process automation
software and cooling in case of OPC cement can be effected by fresh air in the classifier gas loop, cement
quality (i.e. mostly 28d compressive strength) is obtained with lower fineness (minus 200-300 Blaine vs.
ball mill or combi grinding unit).
• Wear inside the mill due to water content of the feed is avoided with the aerodecantor drying arrangement.
• Mill capacity is not sensitive to wear of the roller sleeve, no need to oversize the mill.
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Integration in the existing plant
Layout
• Interference with the existing equipment is limited to the minimum in order to avoid production disturbance
during construction and erection. Plant truck circulation scheme is only slightly affected.
• Clinker is fed directly from the plant existing clinker storage transport system, other components are
delivered by dump trucks or tankers (for fly ash)
• Fine dried pouzzolan separate transport in the plant is avoided, limiting dust emission
• Product dispatch is linked to the existing silos and packing systems for maximal production flexibility
• Pulverized coal for HGG is taken from existing coal mill outlet and transported pneumatically to the
pulverized coal bin for HGG feed.
Electrical
• Mill is starting empty, therefore peak load stress to the plant grid while starting is minimized.
• The plant is designed to operate in full automatic mode and provision is foreseen in the control software to
be able to program several additional cement recipes to cover also eventual future grades.
• Power feed arrangement has been especially designed to preserve load balance on the existing plant grid
and transformers. (i.e. two main feeders, one for mill main motor, the other for other equipment)
• System control will be from the existing control room with a new operator station.
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GENERAL VIEW OF THE PLANT
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CEMENT GRINDING WORKSHOP
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3D views of grinding plant 1/2
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3D views of grinding plant 2/2
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Key selection factors
" The key factors of the selection of Horomill® for this project were:
§ Best energy savings available compared to any other system: 15 to 35% savings
§ Excellent and proven product quality: 1st grade 1P cement is reliably produced on the existing Horomill.
§ Cement 1P is produced with 55% clinker content only. Efficiency of the external drying with Aerodecanter
dryer, allowing use of hot clinker to reduce thermal consumption of the plant, while maintaining finish
product temperature at ca. 85°C, in case of OPC production temperature control is achieved without water
injection.
§ Ease of operation with fully automated control system
§ Ease of maintenance with no critical maintenance operations, mill availability allows for high operating
hours ( more than 7500 h/y average achieved in Mexico), availability of existing size 3600 Horomill® 97%
in 2nd half of 2013.
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Repeat order in Norzagaray plant
HOROMILL® REFERENCE LIST
YEAR
Nb OF CUSTOMER SITE COUNTRY Nb TYPE PRODUCT OUTPUT
ORDER
58 2014 Lafarge Rebublic Inc. Norzagaray Philippines 1 3800 Cement 106 t/h
57 2014 Buzzi Unicem Maryneal USA 1 3800 Raw meal 280 t/h
56 2013 Lafarge Republic Inc. Teresa Philippines 1 3800 Cement 106 t/h
55 2011 Holcim Barroso Brazil 1 4400 Raw meal 420 t/h
54 2009 Jingye Xinyu P.R. China 1 3800 Steel slag 48 t/h
53 2009 Jingye JiuJiang P.R. China 1 3800 Steel slag 48 t/h
52 2008 Buzzi Unicem Maryneal USA 1 3800 Cement 105 t/h
51 2008 Holcim Apasco Hermosillo Mexico 3 3800 Cement 100 t/h
48 2007 Cementos Moctezuma SA de CV Apazapan Mexico 2 3800 Cement 105 t/h
46 2007 Cementos Moctezuma SA de CV Apazapan Mexico 1 3800 Raw meal 225 t/h
45 2007 Rizhao Jinghua Rizhao P.R. China 2 Twin 3800 Steel slag 200 t/h
41 2006 Lalitha Cement Andhra Pradesh India 2 3800 Raw meal 235 t/h
39 2006 Cemex Panama Cem. Bayano Panama 1 3800 Cement 120 t/h
38 2005 Konya Cimento Konya Turkey 1 3800 Cement 115 t/h
37 2005 Vinaincon Thai Nguyen Vietnam 1 Twin 3800 Pouzzolana cement 240 t/h
35 2004 Vinaconex Cam Pha Vietnam 1 Twin 3800 Pouzzolana cement 240 t/h
33 2004 Confidential U.K. 1 2000 Limestone 10-50 t/h
32 2003 Cementos Moctezuma Cerritos Mexico 2 3800 Cement 105 t/h
30 2003 Cementos Moctezuma Cerritos Mexico 1 3800 Raw meal 225 t/h
29 2002 Holcim Costa Rica Hidalgo Costa Rica 1 3800 Cement 110 t/h
28 2002 Hanzhong Cement Shaanxi P.R.China 1 3800 Slag cement 3200 Blaine 82 t/h
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Location of the Horomill® grinding plants
2
1+1 2
2
3
2+4 3
1+2 2
2+2
Plants with both raw
and cement grinding
Cement grinding Slag or mineral grinding
Twin cement grinding Twin slag grinding
" 58 HOROMILL® Raw grinding Not erected
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CONCLUSION
Ú In a tense market with strong demand, the Fives FCB solution with Horomill® was selected as giving
maximal flexibility and competitive edge on power consumption and product quality, as well as being
ready for additional blended cement recipes.
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Five FCB - Horomill® workshop for slag grinding 21
