Headquarters
KHD Humboldt Wedag
International AG
Von-der-Wettern-Straße 4a
51149 Cologne
Germany
Pressure and gap. Or more precisely: contact pressure and the consistency of the gap between the rollers. These two factors determine the quality and efficiency of grinding in a roller press. As the company that introduced the roller press to the cement industry, we understand these details better than anyone. And we provide that expert know-how to you in the Rolcox® roller press monitoring and control system: your smart assistant when it comes to achieving optimum roller press performance.
Product Features
Monitor, control and analyze roller press operation for optimum grinding
Product Features
Monitor, control and analyze roller press operation
The dynamic conditions inside a roller press provide a significant challenge to any control system. To maintain optimal grinding performance, Rolcox® must monitor not only contact pressure but understand this as a function of the real-time position of the rollers – which in turn is determined by the material load going through the press at any particular time.
Ideally, material flow is a homogenous mix of coarse and fine material, evenly distributed across the roller. An uneven load or inhomogeneous feed (when a greater amount of coarse material is present on one side of the roller) results in asymmetrical weight distribution across the rollers and will cause the moveable roller to skew.
Rolcox® continuously fights against this. The system automatically detects changes in roller position and intelligently adjusts the pressure on the moveable roller to bring the gap back to parallel. In this way, Rolcox® adapts roller press operation to real-word conditions to maintain consistent grinding performance, while also protecting the press against potential damage.
Rolcox® will also control start-up of the roller mill to efficiently establish stable operation. In short, it takes the complexity out of roller press operation, so you can sit back and enjoy the benefits that rollers presses bring.
Product Features
The service box
The Service Box allows remote access to Rolcox® for local and online support. Remote services are available for commissioning and operational support, including access to all critical components, parameters and configurations. Software updates are also provided over the internet.
Historical operating data from the roller press is also collected and stored locally in a Service Box. In the event of fault or failure, this data can be sent to our experts, who are able to analyse it, helping to figure out what happened – and to prevent similar failures in future. The data can also be used to create trends or input for analyses by third-party expert systems.
We are currently working on a Cloud-based system that will allow remote access to historical data as the basis for advanced process analysis and control solutions, such as predictive maintenance.
Product Features
Better human-machine interface
The latest Rolcox® 3.0 update features a new human-machine interface (HMI). Taking advantage of the capabilities of WinCC Faceplate, all instruments can be visualized and controlled from the control panel, according to the authorization level of the user. The HMI also allows the modification of most internal parameters, allowing commissioning to take place without the need to access the software code via a programming device.
The local touch panel can be viewed remotely via the web using a standard internet browser, without the need to install additional software.
Product Features
Common KHD programming library
A modern library of PLC-datatypes, function blocks, and faceplates has been developed to be the core of all KHD PLC-based automation solution, including the Rolcox® 3.0 system. This allows PCS-like level of automation, such as the auto-generation of alarms and event. This core library also unifies the look, feel, and behavior of all KHD automation products.
Key Benefits
Grinding is an energy-intensive process. Getting best performance from your roller press will therefore positively influence energy consumption, process efficiency and product quality. Which is where Rolcox® comes in.
Key Benefits
Optimal grinding performance
Rolcox® provides our unparalleled expertise in roller press technology, which goes back to the first introduction of the technology in the cement industry in 1989, to your plant – full time. It’s your smart assistant, ensuring your roller press runs at the best possible levels of performance, right from start-up.
Key Benefits
Extend the life of your rollers
The nature of its job means your roller press is exposed to wear-intensive conditions. Protecting your roller press from excessive wear is another benefit that Rolcox® provides. By ensuring proper contact pressure and automatically correcting the roller gap and any skewing of the moveable roller, Rolcox® is able to control wear rates and therefore extend the intervals between maintenance.
Key Benefits
Cut commissioning and maintenance times
The Rolcox® advantage starts even before your roller press is commissioned. With its local control panel offering access to perform a wide range of tasks, commissioning periods can be reduced and costs lowered. It’s also useful when undertaking maintenance of the roller press, shortening downtime and therefore improving availability. Local control also helps to ensure the safety of personnel during maintenance operations
System Architecture
Communication (Profinet, Profibus or client specification)
Hardwired
References
| Project | Country | Year | Roller Press | Rolcox Version |
| UTCL-7 Kharagpur | India | 2024 | RP 17-170/180 | ROLCOX 3.0 |
| UTCL-6 Bhagalpur | India | 2024 | RP 17-170/180 | ROLCOX 3.0 |
| UTCL-5 Vizag | India | 2024 | RP 17-170/180 | ROLCOX 3.0 |
| UTCL-8 Nathdwara 3 | India | 2024 | RP 20-170/180 II | ROLCOX 3.0 |
| UTCL-7 Kharagpur | India | 2024 | RP 20-170/180 II | ROLCOX 3.0 |
| UTCL-6 Bhagalpur | India | 2024 | RP 20-170/180 II | ROLCOX 3.0 |
| UTCL-5 Vizag | India | 2024 | RP 20-170/180 II | ROLCOX 3.0 |
| UTCL-4 Hotgi 3 | India | 2024 | RP 20-170/180 II | ROLCOX 3.0 |
| UTCL-3 Aligarh 2 | India | 2024 | RP 20-170/180 II | ROLCOX 3.0 |
| UTCL-2 Tadipatri | India | 2024 | RP 20-170/180 II | ROLCOX 3.0 |
| UTCL-1 Petnikota | India | 2024 | RP 20-170/180 II | ROLCOX 3.0 |
| Deccan Cement | India | 2024 | RP 20-170/180 II | ROLCOX 3.0 |
| Dalmia Umrangshu | India | 2024 | RP 16-170/180 II | ROLCOX 3.0 |
| Dalmia Umrangshu | India | 2024 | RP 16-170/180 II | ROLCOX 3.0 |
| Dalmia Rajgangpur | India | 2024 | RP 7-170/90 II | ROLCOX 3.0 |
| UTCL Karur | India | 2024 | RP 17-170/180 | ROLCOX 3.0 |
| UTCL Sonar Bangla | India | 2024 | RP 17-170/180 | ROLCOX 3.0 |
| UTCL Durgapur | India | 2024 | RP 17-170/180 | ROLCOX 3.0 |
| UTCL Kukurdih | India | 2024 | RP 17-170/180 | ROLCOX 3.0 |
| UTCL Burnpur | India | 2023 | RP 7-170/90 II | ROLCOX 3.0 |
| UTCL Burnpur | India | 2023 | RP 20-170/180 II | ROLCOX 3.0 |
| UTCL Shahjahanpur | India | 2023 | RP 20-170/180 II | ROLCOX 3.0 |
| UTCL Kukurdih | India | 2023 | RP 20-170/180 II | ROLCOX 3.0 |
| UTCL Maihar | India | 2023 | RP 20-170/180 II | ROLCOX 3.0 |
| UTCL Maihar | India | 2023 | RP 20-170/180 II | ROLCOX 3.0 |
| UTCL Karur | India | 2023 | RP 20-170/180 II | ROLCOX 3.0 |
| UTCL Rajpura | India | 2023 | RP 20-170/180 II | ROLCOX 3.0 |
| UTCL Kotputli | India | 2023 | RP 20-170/180 II | ROLCOX 3.0 |
| UTCL Arakkonam | India | 2023 | RP 20-170/180 II | ROLCOX 3.0 |
| UTCL Roorkee | India | 2023 | RP 20-170/180 II | ROLCOX 3.0 |
| PK 3800 | Iran | 2023 | RPS 16-170/180 II | ROLCOX 3.0 |
| PK 3800 | Iran | 2023 | RPS 16-170/180 II | ROLCOX 3.0 |
| My Home Cement CM | India | 2023 | RP 20-220/180 | ROLCOX 2.4 |
| Dalmia Calcom | India | 2022 | RP 16 - 170/180 | ROLCOX 2.4 |
| My Home Cement 2 | India | 2022 | RP 20 - 220/180 | ROLCOX 2.4 |