Wonder Cement belongs to a family company based in Udaipur/India, which – apart from other businesses – is active in the cement industry.
As Gebr. Pfeiffer already supplied four mills of the type MPS for raw material and pet coke grinding, the customer has now decided to use a vertical roller mill also for cement grinding.
Until now, the customer has used combined grinding plants of another supplier for grinding cement. Besides the lower specific energy consumption of the MVR mill, the fact that it can be used for grinding and simultaneously drying moist feed materials played a key role in his buying decision.
In India a trend towards the use of stored fly ash replacing more and more dry fly ash from coal power plants as a cement constituent can be identified. This type of fly ash, stored in the open, has a very high moisture content and – if processed in a grinding system different from the MVR mill – would have to be dried separately.
The customer’s engineering team called in Holtec, a consultant based in Gurgaon, close to New Delhi. Its good experience with Pfeiffer MVR mills which are in operation in other Indian cement works has led the consultant to suggest changing the grinding system and switching to a Pfeiffer MVR mill.
Gebr. Pfeiffer SE, Kaiserslautern/Germany, will supply a mill of the type MVR 6000 C-6 with a 5280 kW drive that will be set up in Nardana, in the state of Maharashtra. It will produce mixed cements with finenesses of up to 5 % R 45 µm.
The customer was particularly keen on grinding relatively hot clinker in the mill, while, at the same time, the cement outlet temperature is reduced. Added to this was the fact, that the concept offered the possibility of using cold clinker from stockpiles.
The offered MVR mill, which is currently experiencing a high demand around the world, is equipped with six actively redundant grinding rollers. This means that all six grinding rollers take part in the grinding process. When it comes to scheduled maintenance works, two opposite grinding rollers can be swung out and the mill can continue production with the four remaining rollers.
Even in the case of an unplanned outage of one of the grinding rollers, the mill can continue in operation while the roller under service is being worked on outside the mill.
The core components of the mill, such as tension system and grinding rollers, will be supplied by Gebr. Pfeiffer, Germany. The grinding bowl and the gearboxes for mill and classifier will also be supplied from Europe.
The parts for housing and foundation, the supports for the grinding rollers and most of the parts of the integrated high-efficiency classifier of the type SLS 5600 BC will be provided by Gebr. Pfeiffer (India) Pvt. Ltd., Pfeiffer’s wholly-owned subsidiary in Noida.
It will also supply most of the equipment required to complete the grinding plant, including plant fan. For all components which will be procured by the customer, he will receive the corresponding specifications. Delivery is scheduled to be effected before the end of this year.