MVR vertical roller mills for grinding cement and cement raw material

The customer will realize a second kiln line at the Kallur plant. This will require 600 t/h of cement raw material, which will be ground with an MVR 5600 R-6 mill. The order is the first realization of an MVR 5600 mill with 6 rollers.

In Nepal, an MVR 5600 R-4 with 4 rollers has been in operation for several years and produces approx. 525 t/h. Due to the latest design, the mill at Chettinad Cement will have a significantly higher production rate. Because of the well-known redundancy concept of Pfeiffer MVR mills, a 4-roller mill can continue to operate with 2 rolls at approx. 55% nominal capacity in case of planned or unplanned work on one roll. In such a case, a 6-roller mill can continue to be operated with 4 rollers at more than 70% nominal capacity.

It is pleasing for Gebr. Pfeiffer that Chettinad Cement has used other grinding systems in the past, such as high-pressure grinding rolls for raw meal grinding, and is now convinced of the advantages of MVR mills also in this area. It is a confirmation of the path taken by Gebr. Pfeiffer to contribute to energy reduction and more sustainable cement production with the revised process concept of the MVR vertical roller mill system.

Furthermore, the customer has also ordered an MVR 5300 C-6 for grinding composite cements. Due to the increased power density of the latest design of MVR mills, the production rate of 300 t/h of cement can be realized by a mill with a 5.3 m grinding bowl diameter. Previously, a grinding bowl of approx. 6 m diameter was the standard for this purpose. Competitive systems require a significantly larger grinding bowl and thus also significantly larger mill housing. As a result of the more compact design and high power density of the MVR mills, a more effective flow of process gases and more efficient operation can be realized. This is reflected in lower energy consumption and a more positive CO2 balance.

With an upfront delivery of an MVR 6000 C-6 for granulated blastfurnace slag and slag cement grinding in 2020, Gebr. Pfeiffer was able to demonstrate the customer that the system of Pfeiffer MVR mills has clear advantages in operating behavior and operating costs compared to competitive systems. This was one of the reasons for the customer and its technical consultant Virinchi Engineering Pvt. Ltd. to opt for the MVR mill again, for cement grinding as well as for raw meal grinding.

The core components of the MVR mills as well as the 5810 kW gearbox will be supplied by Gebr. Pfeiffer SE from Europe. Foundation parts, housings and other components will be manufactured in India and delivered to the customer under responsibility of Gebr. Pfeiffer (India) Pvt. Ltd., a 100 % subsidiary.

The office of Gebr. Pfeiffer (India) Pvt. Ltd. in Noida, near New Delhi, will also support the end customer in plant design, procure most of the grinding plant machinery such as filters, fans, hot gas generators, the fly ash handling and conveying aggregates, and will be on site with skilled personnel for quality control of the customer's site fabrication as well as supervision of erection and commissioning.