Grinding equipment for the Indian market

In 2007, Gebr. Pfeiffer SE received contracts to supply 20 MPS mills to the Indian cement industry (see picture). By April 2008, another 14 MPS mills alone were ordered from India.

Early in 2007, Jaykaycem Ltd., a subsidiary of the Indian cement manufacturer J. K. Cement Ltd., ordered an MPS 5600 BC with a grinding capacity of 160 t/h of granulated blastfurnace slag cement from Gebr. Pfeiffer SE and its Indian subsidiary Gebr. Pfeiffer (India) Pvt. Ltd. Jaykaycement Ltd. intends to use the mill not only for grinding granulated blastfurnace slag cement but also for OPC or pure granulated blastfurnace slag. The grinding plant will also be capable of producing fly ash cement, in which case dry fly ash will be fed into the classifier separately. With an installed capacity of 5400 kW, the gearbox for this mill will be one of the largest gearboxes operating in India.

Gebr. Pfeiffer SE has been awarded a contract by Deccan Cement Ltd. for the supply of an MPS 3750 B – one of Pfeiffer’s best-selling MPS models in India. Hyderabad-based Deccan Cement Ltd. decided to buy the raw meal grinding plant for the Bhavanipuram works from Gebr. Pfeiffer SE and its Indian subsidiary. The grinding equipment will have a capacity of 260 t/h of raw meal ground to a product fineness of 15 % R 90 ?m. This latest contract follows orders for MPS 3750 B mills received from other Indian cement manufacturers: Shree Cement bought 5 MPS 3750 B mills for its lines RAS I – RAS V, and one was sold to My Home Cement.

New Delhi-based cement manufacturer Dalmia Cement (Bharat) Ltd. ordered six grinding units for two new cement production lines. An MPS 5000 B for cement raw material grinding, an MPS 2800 BK for coal and an MPS 5600 C for fly ash cement (PPC) will be supplied to the 4500 t/d Kadapa cement factory in Nawabpet, Andhra Pradesh. In response to the strong demand for cements with added fly ash, Dalmia Cement (Bharat) Ltd. decided to produce 300 t/h of fly ash cement with a Blaine fineness of 3600 cm2/g. Featuring an installed power of 5400 kW, the MPS 5600 BC mill is one of the largest MPS mills in the world. Furthermore, the new Ariyalur works, located in Tamil Nadu, will be equipped with the same mill models, which are an MPS 5000 B, an MPS 2800 BK and an MPS 5600 BC. While identical fly ash cement and coal will be processed at Ariyalur and Kadapa, the properties of the raw material to be ground differ considerably: Though very easy to grind, the raw material at Ariyalur can include as much as 12 % of feed moisture. The mill selected for this application will have a capacity of 400 t/h. Gebr. Pfeiffer AG was faced with the task of having to enable the moist material to be dried in the mill and the integrated classifier, while ensuring the use of as many components identical with the ones in Kadapa as possible.

In February 2007, Gebr. Pfeiffer SE and its subsidiary Gebr. Pfeiffer (India) Pvt. Ltd. received a follow-up order from Gujarat Anjan Cement Ltd. for expansion projects in the Sardar works in Gujarat. Gujarat Anjan Cement Ltd. is also planning an expansion of its Wanakbori works. To this end, the Jaypee Group-owned company ordered a further grinding plant for fly ash cement (PPC) from Gebr. Pfeiffer AG and its subsidiary Gebr. Pfeiffer (India) Pvt. Ltd. in February 2007. An MPS 4750 BC mill will be used for the production of 180 t/h of PPC with a Blaine fineness of 3500. Fly ash can be fed into the mill either in dry or wet form. Suitable for combined grinding, drying and separation, MPS vertical roller mills offer distinct advantages over other grinding systems, especially when used for drying wet extenders added to cement clinker. Just as in the case of the previous order for the first line at Wanakbori works, the scope of supply comprises not only the actual mill but also the conveying equipment, the plant filter, process fans and the entire planning of the plant. In April 2007, Gebr. Pfeiffer AG and its Indian subsidiary were awarded a contract to supply two vertical roller mills for Jaiprakash Associates Ltd.’s new HP-II works located in Himachal Pradesh.

Gebr. Pfeiffer SE and its Indian subsidiary Gebr. Pfeiffer (India) Pvt. Ltd. received orders from two Indian cement manufacturers held by Holcim India. Ambuja Cement in Mumbai selected an MPS 5600 B with an installed drive of 5600 kW for its Rauri works in Himachal Pradesh. ACC Ltd., which is also headquartered in Mumbai, plans to expand its Wadi plant and has ordered the same MPS model. The raw material to be processed at this facility being even more difficult to grind, the mill for ACC Ltd. is guaranteed to produce 560 t/h of finished product. The latest news is that ACC Ltd. has placed an order for a further MPS 5600 B roller mill to produce up to 560 t/h of cement raw material for the Chanda works. In terms of their finished product capacity or installed drive power, these three mills will be the largest MPS mills for cement raw material grinding. The performance of an MPS 5600 B with the same gearbox that has been running at Ambuja Cement’s Maratha Cement works for over seven years was surely a key factor in these customers’ choices. Four MPS mills are currently running at the Indian based ACC works, grinding raw material and coal. An MPS 5600 BC for granulated blastfurnace slag is under erection.

Orient Cement ordered an MPS 2800 BK for its new cement plant in Devapur, Andhra Pradesh. The coal mill will grind 40 t/h of coal to a fineness of 14 % R 90 ?m. The nominal moisture content of the coal is 7 %, although it can reach a level of 12 %. The coal will be ground and dried in the MPS, using inert gases from a cement rotary kiln, and classified by an integrated state-of-the-art high efficiency classifier.