Automation

ROLCOX®

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.

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
Dalmia Calcom India 2022 RP 16 - 170/180 ROLCOX 2.4
My Home Cement 2 India 2022 RP 20 - 220/180 ROLCOX 2.4
UTCL Hirmi RawGrinding RP1 India 2021 RP 20 - 220/180 ROLCOX 2.4
UTCL Hirmi RawGrinding RP2 India 2021 RP 20 - 220/180 ROLCOX 2.4
UTCL Hirmi Cement  India 2021 RP 20 - 170/180 ROLCOX 2.4
UTCL Jharsuguda  India 2021 RP 20 - 170/180 ROLCOX 2.4
UTCL Sonar Bangla  India 2021 RP 20 - 170/180 ROLCOX 2.4
UTCL Neem Ka Thana  India 2021 RP 20 - 170/180 ROLCOX 2.4
UTCL Magdalla India 2021 RP 20 - 170/180 ROLCOX 2.4
Deccan India 2021 RP 13 - 170/140 ROLCOX 2.4
UTCL Maihar India 2021 RP 16 - 170/180 ROLCOX 2.4
Gauri Shankar India 2021 RP 10 - 170/110 ROLCOX 2.4
My Home Cement India 2021 RP 20 - 220/180 ROLCOX 2.4
ACC Ametha RP1 India 2020 RP 16 - 170/180 ROLCOX 2.4
ACC Ametha RP2 India 2020 RP 16 - 170/180 ROLCOX 2.4
Schäfer Kalk (Upgrade) Germany 2019 RP 5 - 100/90 II ROLCOX 2.4
Satguru RP1 (Clinker Grinding) India 2019 RP 13 - 170/140 II ROLCOX 2.4
Satguru RP2 (Raw Grinding) India 2019 RP 13 - 170/140 II ROLCOX 2.4
Mitsubishi Cement USA 2019 RP 7 - 120/63 ROLCOX 2.4
KJS Cement India 2019 RP 16 - 170/180 II ROLCOX 2.4
JSW Salem India 2019 RP 16 - 170/180 II ROLCOX 2.4
UTCL Patliputra India 2019 RP 17 - 170/180 ROLCOX 2.4
Samrat Nepal Nepal 2019 RP 16 - 170/180 ROLCOX 2.4
UTCL Dankuni India 2019 RP 17 - 170/180 ROLCOX 2.4
CRH Iligan Philippines 2018 RPZ 20 - 170/180 ROLCOX 2.3
Basundhara Bangladesh 2018 RPZM 18 - 200/180 B ROLCOX 2.3
Zagros White Iran 2018 RPS 7 - 170/90 B ROLCOX 2.3
Rai Cement Kenya 2018 RP 7 - 170/90 ROLCOX 2.3
Samrat Nepal 2018 RPZM 16 - 170/180 ROLCOX 2.3
thomas zement Germany 2018 RPS 7 - 170/90 B ROLCOX 2.4

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