Simply put, the roller press is the most energy-efficient grinding machine on the market. Since its commercial introduction into the cement industry by KHD in the 1980s, hundreds of them have been installed in the cement and minerals industries, in both finish and semi-finish applications. And with the lowest specific energy consumption among comparable comminution technologies, including ball and vertical roller mills, it’s not difficult to understand why.
Grind cement raw materials, clinker, and slag, as well as minerals, with a roller press from the technical leader.
The machine frame – open or closed?
We offer both open and closed frame layouts. But what’s the difference? Open frames benefit from quicker erection and easier roller exchange. Rollers are removed sideways, rather than lifted out from above, eliminating the need to dismantle the top frame, bin and feeding equipment. Closed frame, however, offers lower initial machine costs.
Not sure which is going to work best for you? You can rely on our experts to guide you through the decision-making process and ensure your roller-press best meets your requirements.
Wear protection of the roller surface
Wear is a fact of life. But if not properly monitored and controlled, it can end up degrading grinding performance, lowering production rates, and significantly extending maintenance downtime of your machine and production. Deciding the best wear protection for your process is therefore an important task – and one where an expert opinion can help make sure of the best results. Which is where we can help.
Our engineers will take all relevant factors into consideration to suggest the type of wear protection most suited to your application choosing from three different technologies:
- Hi-Chrome – long, worry-free operation
KHD’s newest surface option is a special compound casting bandage with a wear-resistant top layer made of high-chrome. This surface combines robustness with ease of use because the material does not need to be rewelded. In comparison to competitor solutions, KHD’s profile application method is also advanced. Because we grind the profile into the surface instead of welding extra material on it, we prevent tiny surface cracks, that can lead to major follow-up problems during regular operation. Another special feature is that the profile is designed to prevent material embedding.
- Hardfacing – the cost-competitive option
Rollers with hardfacing are ideal for low investment cases and grinding plants that conduct intermediate rewelding. Such maintenance jobs can be executed during regular daily stoppages thanks to intelligent service solutions such as KHD’s in-situ roller grinding.
- Stud Lining – best-in-class wear resistance
Rollers with stud lining comprise a special pattern of extremely wear resistant tungsten carbide studs which are inserted into the roller surface. The stud arrangement is designed to also form an autogenous wear protection layer from ground material. Thus, stud lining rollers achieve highest lifetimes without any need for regular surface maintenance in grinding applications that do not contain oversized feed material.
Interested in learning more about wear protection options as they relate to your specific application? Contact us today. Our team is here to help. You can also check out our roller press maintenance services, including our innovative Roller Press Scanner. This detects potential problems with your roller surfaces early to help planning of your maintenance schedules and reduce downtime.
A unique bearing arrangement
Our unique four-line cylindrical roller bearing arrangement allows a compact machine design, as well as needing only one hydraulic cylinder per side, instead of the two required by roller presses with spherical bearings. And because skewing of the moveable roller is facilitated by a separate rubber thrust bearing and pivoting cylinder, our cylindrical bearings are simpler to seal. This improves the reliability of the lubrication, a key factor in prolonging service life.
Flexible skewing and even load distribution
Skewing of the moveable roller is made possible via a combination of rubber thrust bearing and flat pivoting cylinder. These are mounted between the hydraulic cylinder and the roller bearing housings. The patented rubber thrust bearings also ensure even load distribution across the bearings for longer service life.
A low-energy, reliable, flexible grinding option backed by unparalleled know-how and long years of experience.
Low energy consumption
We said it before. But it’s worth repeating. When compared with other grinding options, such as ball mills and vertical roller mills, the roller press is the most energy-efficient grinding system on the market. Which means lower energy bills for you. So, your production costs will be more competitive and sustainable, both today and into the future.
High availability and reliability
With its unique bearing system, long-life roller surface protection and ease of roller exchange (when opting for the open frame design), our roller presses are designed to provide the highest levels of reliability and availability. They just keep grinding… and grinding… and grinding. And therefore, keep your production flowing, stress-free. Looking for uninterrupted and long uptime? A roller press is the way to go.
Flexible grinding options
Our roller presses are able to grind various feed materials, giving you the option of producing a range of cements at one site. For example, with the appropriate grinding circuit and drive train arrangements, you can switch quickly and easily between clinker and slag grinding.
Going with the experts
As we mentioned in the introduction, we were the first company to install a roller press in the cement industry. And we’ve done so successfully many times since. You might say that makes us the experts – whether it’s for new, greenfield installations or for brownfield upgrades (e.g., adding a roller press to a ball mill circuit to raise production rates and improve energy efficiency). And when you know the experts, why go anywhere else?
Is the roller press the equipment for you? Check out the performance data below. Or contact us to talk to an expert.
1700 mm up to 2200 mm
900 mm to 1800 mm
7000 kN up to 20000 kN
Feed Options (Materials):
Raw Materials, Cement, Minerals, Slag
|Dalmia Calcom||India||2022||RP 16 - 170/180|
|My Home Cement 2||India||2022||RP 20 - 220/180|
|UTCL Hirmi RawGrinding RP1||India||2021||RP 20 - 220/180|
|UTCL Hirmi RawGrinding RP2||India||2021||RP 20 - 220/180|
|UTCL Hirmi Cement||India||2021||RP 20 - 170/180|
|UTCL Jharsuguda||India||2021||RP 20 - 170/180|
|UTCL Sonar Bangla||India||2021||RP 20 - 170/180|
|UTCL Neem Ka Thana||India||2021||RP 20 - 170/180|
|UTCL Magdalla||India||2021||RP 20 - 170/180|
|Deccan||India||2021||RP 13 - 170/140|
|UTCL Maihar||India||2021||RP 16 - 170/180|
|Gauri Shankar||India||2021||RP 10 - 170/110|
|My Home Cement||India||2021||RP 20 - 220/180|
|ACC Ametha RP1||India||2020||RP 16 - 170/180|
|ACC Ametha RP2||India||2020||RP 16 - 170/180|
|Schäfer Kalk (Upgrade)||Germany||2019||RP 5 - 100/90 II|
|Satguru RP1 (Clinker Grinding)||India||2019||RP 13 - 170/140 II|
|Satguru RP2 (Raw Grinding)||India||2019||RP 13 - 170/140 II|
|Mitsubishi Cement||USA||2019||RP 7 - 120/63|
|KJS Cement||India||2019||RP 16 - 170/180 II|
|JSW Salem||India||2019||RP 16 - 170/180 II|
|UTCL Patliputra||India||2019||RP 17 - 170/180|
|Samrat Nepal||Nepal||2019||RP 16 - 170/180|
|UTCL Dankuni||India||2019||RP 17 - 170/180|
|CRH Iligan||Philippines||2018||RPZ 20 - 170/180|
|Basundhara||Bangladesh||2018||RPZM 18 - 200/180 B|
|Zagros White||Iran||2018||RPS 7 - 170/90 B|
|Rai Cement||Kenya||2018||RP 7 - 170/90|
|Samrat||Nepal||2018||RPZM 16 - 170/180|
|thomas zement||Germany||2018||RPS 7 - 170/90 B|