Grinding

Roller Press

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.

Feeding Device

Cylindrical Roller Bearing Units

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Rubber Thrust Bearing

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Hydraulic Cylinder

Drive

Machine Frame

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Gearbox Removing Device

Roller Removing Device

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Roller Transport Vehicle

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Product Features

Grind cement raw materials, clinker, and slag, as well as minerals, with a roller press from the technical leader.

Product Features

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.

Product Features

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. That might be a welded complete hardfacing (CHF) of the rollers, a cost-competitive option. Or it could be our long-lasting stud lining.

The stud lining comprises extremely wear-resistant tungsten carbide studs that are inserted into the roller surface. The arrangement of the studs on the roller surface is also designed to create an autogenous wear protection layer between the studs, providing an extra level of protection for longest-possible wear life.

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.

New high-chrome wear protection

Our latest development is a high-chrome bandage (HCB) made from a compound casting. HCB combines lower maintenance requirements with a convincing extra-long service life. The new surface option has already run successfully for over two years in real-world conditions. Plus two more installations are in operation since the beginning of 2022.

The specialty of our HCB is the mechanical insertion of the profiling. Instead of welding the profile, which causes tiny surface cracks that can lead to problems, we mechanically grind the profile into the surface. This makes the surface also more reliable and longer lasting in direct comparison to other compound castings available in the market. Quite ingenious, right?

Interested in learning more about this promising new development? Let us know and we’ll arrange a call with one of our experts.

Product Features

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.

Compact design = low civil cost

An additional benefit of our unique four-line cylindrical roller bearings – and resulting compact frame design – is a lower-weight construction for lowest civils cost.

Product Features

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.

Key Benefits

A low-energy, reliable, flexible grinding option backed by unparalleled know-how and long years of experience.

Key Benefits

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.

Key Benefits

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.

Key Benefits

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.

Key Benefits

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?

Performance Data

Is the roller press the equipment for you? Check out the performance data below. Or contact us to talk to an expert.

Roller Diameter:

1700 mm up to 2200 mm

Roller Width:

900 mm to 1800 mm

Pressing Force:

7000 kN up to 20000 kN

Feed Options (Materials):

Raw Materials, Cement, Minerals, Slag

References

Project Country Year Roller Press
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

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