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5,000,000 kilowatts of installed expertiseInnovative FLENDER vertical mill drives for grinding coal, raw meal, slag and clinker.

E20001-A370-P900-X-7600_EN.indd 1 03.04.13 11:25

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5,000,000 kW …

FLENDER vertical mill drives are indispensable for those who want the right solution for every vertical mill require-ment, those who value sustainable, energy-efficient, opti-mized processes and those for whom drive availability and safety have top priority – in short, all those who want to rely 100% on their drive technology.

In addition to first-class product quality and consultation based on decades of experience and in-depth industry expertise, we offer by far the most comprehensive portfo-lio of highly advanced, mature and proven drive solutions. What’s more, we produce them ourselves from start to finish.

With our global production concept and extensive exper-tise, thousands of references in all capacity classes and partnerships with the world’s most significant OEMs – plus extraordinary, reliable customer service and the entire might of the Siemens corporation – we are the right partner for all kinds of drives. We maintain good customer relationships, treating both plant engineers and end-users as peers and developing new solutions with them, always with a view to the perfect result. This can only be achieved with the outstanding technical expertise of a leading innovator.

As the only system provider with expertise throughout the entire drive train, we offer you investment security on one hand and rapid response times on the other. Our global setup and virtually seamless international service net-work, our formidable supply capacity and short delivery times, our guarantee for complete systems and, last but not least, our extraordinary price/performance ratio are unrivalled the world over.

Because requirements in the vertical mill sector differ by target product, we offer you special solutions and installa-tion sizes for every application.

… that’s roughly equivalent to the gross power output of the most important natural gas power plants in Germany. 5,000,000 kW – that’s also the capacity of FLENDER® vertical mill drives installed internationally. For you, that means primarily three things: quality, experience and versatility on the part of your drive technology supplier.

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ProductCapacity range

Coal Raw meal Slag Clinker

KMPOptimum application range: 100 to 1,500 kW

KMPSOptimum application range: 1,500 to 4,000 kW

KMPPOptimum application range: 3,000 to 8,000 kW

EMPPOptimum application range: 4,000 to 8,000 kW

Multiple-Drive Optimum application range: 6,000 kW and up

16,000 kW14,000 kW12,000 kW10,000 kW8,000 kW6,000 kW4,000 kW2,000 kW

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Costs are crucial …… not only in decisions regarding the procurement of the gear unit, but also throughout the entire process and in the availability of your plant. Efficiency and life cycle costs play a critical role here, so it’s good to know that you can depend on Siemens with regard to price, concept and quality.

With over 4,000 tried and tested standard and special solutions, we continue to prove that the highly advanced, completely mature KMP gear units have set benchmarks for grinding coal. As well as offering the right solution for every available type of mill in the world, we will adapt your gear unit to the mill design on request. To do this, we rely on standards and design modules in order to guar-antee a great deal of flexibility and quick realization. All of our KMP gear units are ATEX 95 compliant and virtually fault-free, based on statistics.

Accommodating process forces

For all vertical mill drives, we use maintenance-free tilt- ing pad thrust bearings to accommodate the high axial loads which arise during the grinding process due to material hardness, mechanical process influences, and mill technology and design. These bearings are available with hydrodynamic or hydrostatic lubrication (fully hy- drostatic) or with starting aids (partially hydrostatic).

While hydrodynamic thrust bearings are standard in the KMP gear units used primarily for grinding coal due to the low dynamics, fully hydrostatic lubrication is used in our solutions for cement applications.

The pads are coated with babbitt, and their trapezoidal shape allows optimum use of the gear unit installation space. The resulting low surface pressure allows a thick oil film to be generated along with good damping character-istics – the uncontested advantages of this tried and tested design. A continuous supply of fresh oil guarantees optimum bearing cooling and dissipates the heat from the mill. Extremely high-quality oil supply systems are used here. These were developed specially by Siemens, are produced at our own plant and are available in standard versions. Built-in sensors monitor the temperature.

Hydrodynamic and hydrostatic lubrication

In hydrodynamic lubrication, oil is introduced into the bearing by the rotation of the output flange. The bearings tilt slightly toward the oil feed side and a wedge-shaped, hydrodynamic oil film is formed. Due to the trapezoidal pad design, the side flow is minimal and a stable, thick oil film remains at the outlet, which supports the flange and, in turn, the grinding plate.

To prevent friction loss and increased wear upon start-up, hydrostatic starting aids are available. On request, fully hydrostatic solutions can even be supplied for KMP. In this case, the oil is forced into the bearing under high pres-sure. Each pad has its own connection and is always sup-plied with exactly the same amount of oil, regardless of the load.

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Coal grinding takes place in power plants, but also in cement plants, where it is mostly used for heat production.

FLENDER KMP

Design Bevel gear stage, planetary gear stage

Capacity 100 to 2,000 kW (optimum application range: 100 to 1,500 kW)

Installation sizes 18

Transmission ratios i = 15 to 45

Torque 25,000 to 700,000 Nm (optimum application range: 25,000 to 500,000 Nm)

Axial bearings Hydrodynamic, opt. starting aid, opt. fully hydrostatic

Advantages Tried and tested concept with approx. 4,000 references, global production concept, international service locations, wide variety of options

In addition, the hydrodynamic effect occurs here and oil is drawn in on the inlet side. In this case, the oil film is about twice as thick as with hydrodynamic lubrication. High-pressure radial piston pumps are used to supply the oil, and they ensure a consistent volume flow into the bearing.

Our gear units are also very well suited for use with high dynamic axial forces. The oil film on the tilting pad thrust bearings is always thick enough because the actual inter-val of the dynamic forces is in fact too short to influence the lubrication effect of the oil film in any critical way. In practice, it takes just a fraction of a second.

The best in its class: FLENDER KMP

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FLENDER gear units …

… that comply with Siemens quality standards are avail-able all over the world. Siemens solutions are particularly impressive in the mass market in capacity ranges up to 1,500 kW, not only because of their good energy balance, but also due to their optional measuring sensor technol-ogy. This is another crucial factor for efficient processes right from day one of production.

The Siemens material specification includes special steels for these applications. The associated requirements have been developed in thousands of reference projects and demand even more specific characteristics than the inter-national norm. This increases service life and reduces life cycle costs.

The ribbed or corrugated form of the special housing – either steel welded or made of spheroidal graphite cast iron – also ensures that axial forces are introduced evenly into the foundation through the housing. Not all housings are created equal. Only those who have been casting for decades understand the fine details and their great rele-vance in housing production. This is another particular strength of Siemens gear units.

Thanks to their high-quality design and manufacture, outstanding bearings, first-class gear tooth geometry and extraordinary housing stiffness, our gear units perform excellently with respect to noise emissions.

In addition to all of these arguments, the process is al- ways the decisive factor for mill plants. All over the world, the continual pursuit of efficiency and productivity is not only leading to evolution in mill design and layout – it is also raising awareness of variable-speed drive systems.

Medium capacity range

In recent years, drive technology has been confronted with the challenge of output speeds falling as capacity requirements increase, causing a disproportionate increase in torques. But this has not been accompanied by more installation space for gear units. To deal with the problem of increasing transmission and power density at the same time, gear unit technology has evolved from three to four planetary gears in the output stage up to five or six.

The grinding of raw meal, clinker and slag is in the medium to high power range. The right drive solu-tions: KMPS or KMPP.

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FLENDER KMPS

Design Bevel gear stage, helical gear stage, planetary gear stage

Capacity 1,500 to 5,500 kW (optimum application range: 1,500 to 4,000 kW)

Installation sizes 12

Transmission ratios i = 30 to 55

Torque 600,000 to 2,500,000 Nm (optimum application range: 600,000 to 1,800,000 Nm)

Axial bearings Fully hydrostatic

Advantages Tried and tested concept with approx. 400 references, global production concept, international service locations, wide variety of options

Planetary gear unit with helical gear stage: FLENDER KMPS

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Those who make decisions ...

… should be allowed to doubt, but not have to. It doesn’t matter whether you make your choice based on capacity requirements or experience, based on the available instal-lation space or simply based on personal bearing prefer-ence – every time you choose a FLENDER gear unit, you are making the right choice. But we want to make the decision easier and provide you with the right arguments for selecting the world’s leading drive technology.

In the low to medium capacity range for pre-grinding, KMPS gear units are most often used, which combine a helical gear stage supported by a rolling bearing with a planetary gear stage also supported by a rolling bearing. Due to the high degree of plant individualization, the gear units are available in hundreds of versions. Our global production concept keeps high production and assembly capacity available for KMPS so that large quantities can be realized.

In the medium to high capacity range for clinker and slag grinding, KMPP gear units are primarily used. Their high power density is achieved by using two planetary gear stages. The gear units in the KMPP series are entirely sup-ported by sliding bearings. The advantage of sliding bear-ings is that they are better able to accommodate dynamic loads which are generated in the process by various mate-rials and hardnesses. Sliding bearings provide a robust, durable solution in this scenario. The option of choosing between sliding and rolling bearings for the gear units caters for different customer preferences.

The patented corrugated shape of our housings and their extremely effective, stable ribs are typical for larger FLENDER vertical mill gear units. They offer greater flexi-bility for optimizing the sliding bearing arrangement and enable the same housing to be used with different mill connection geometries. Moreover, the modular structure makes it possible to equip mills with the same dimensions but different power requirements. The casting quality of our housings alone should convince you. It provides out-standing damping characteristics.

The high demand for KMPS and KMPP gear units resulting from retrofitting clearly demonstrates the high degree of satisfaction in the market. So whatever your motivation is to buy whichever FLENDER gear unit, you can be confi-dent that you are making the right decision.

High-capacity, wear-free planetary gear unit: FLENDER KMPP

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Process stability

Process stability is not just an expression: it is a major goal for the entire cement industry all around the world. Stability and safety in grinding ensure plant availability and are the pivotal requirements for every vertical mill drive. Their relevance increases exponentially with in- creasing mill power input.

Variable speed in drive technology plays a critical role in stabilizing processes. Driven by technological possibilities, the idea that “bigger is better” is continuing to gain cur-rency in the cement world. Against this backdrop, this often conservative market has come to agreement on one thing: speed variability, drive intelligence and, with in- creasing plant size, modular drive systems are the critical parameters for plant efficiency and success in the face of growing demands with regard to torque and plant availability.

High-capacity drives are often used in cement production.

FLENDER KMPP

Design Bevel gear stage, 2 planetary gear stages

Capacity 3,000 to 8,000 kW

Installation sizes 9

Transmission ratios i = 35 to 55

Torque 1,300,000 to 3,500,000 Nm

Axial bearings Fully hydrostatic

Advantages Tried and tested concept with approx. 200 references, wear-free, high power density, standardized components

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The functioning drive train …

… is now reality. Siemens has always been convinced that the drive train must be seen and understood as a whole. We are the only provider in the world that offers complete industrial drive systems. In the context of our integrated drive system concept, complete drive solutions have proved their worth in many industries and have become standards upon which today’s industrial drives are based.

In the cement industry and power generation, our gear units have been an integral part of customer solutions for many years. The inherent frequencies of the drive change depending on the moment of inertia of the mill and the motor. The drive train as a whole is a logical, goal- oriented development to meet the requirements of our customers.

For this reason, as well as providing a comprehensive range of top-quality drive train components, Siemens ensures that they are perfectly dovetailed with one another from the initial concept to the functioning plant.

Siemens Integrated Drive Systems turn simple drive com-ponents into real systems. Drive technology based on IDS guarantees maximum productivity, energy efficiency and reliability in every area of automation and throughout the entire life cycle.

Prevent risks at interfaces and opt for a system partner-ship with Siemens, supported by our tried and tested con-trol technology.

SIMOTICS squirrelcage motor

Slip ring motor

FLENDER coupling FLENDER vertical mill gear unit

FLENDER oil supply system

SINAMICS frequency converter

Variable-speed drive train with converter and squirrelcage motor

Fixed-speed drive train with slip ring motor

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Our component range includes:

◾ Transformers

◾ Frequency converters

◾ Motors

◾ Couplings (including electrically insulated couplings)

◾ Auxiliary gear units/auxiliary drives

◾ Maintenance drives

◾ Main gear units

◾ Oil supply systems

◾ Sensor technology

◾ Condition monitoring

◾ Drive controls (CEMAT)

◾ Financing

Service

Our global network of experts proactively and reliably contributes comprehensive technology and product knowledge to every project. This enables you to benefit from the wide-ranging experience and in-depth technological knowledge of our service experts – on-site in 190 countries, 24/7.

For example, our logistics specialists make up a com-prehensive, international network of certified service centers, ensuring that spare parts are supplied quickly and reliably.

Condition monitoring

The Siemens condition monitoring system SIPLUS CMS 4000 gives you the option to track temperatures, vibrations, torques and displacements in the gear unit online and evaluate trends. The fundamental advan-tages of the condition monitoring system are obvious: irregularities trigger an alarm and corresponding recording activity. Increasing vibration levels are rec-ognized early on and required maintenance work can be planned accordingly. In this way, damage is pre-vented or recognized at an early stage.

Our condition monitoring system has a special, crucial feature: it was developed and programmed by the leading provider of industrial drive technology and offers you secure communication paths to monitor your drives from anywhere. For data analysis, we can offer you a telediagnostics service provided by our own experienced condition monitoring experts.

On request, condition monitoring can also be expanded for use with the entire drive train.

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FLENDER SmartSeries …… is a product portfolio of drive solutions in which real-time controls enable the unit to react immediately to external influences such as factors associated with the production process. Under demands to produce larger and larger plant layouts with maximum availability, operators are well advised not to rely solely on conventional solu-tions for the medium term, but instead to take the right step toward the future with FLENDER SmartSeries® prod-ucts. With the FLENDER EMPP, this step is now possible for vertical mill drives.

Specialists in the largest geared motors

As a provider of innovative drive technology, we have developed a drive concept that was specially designed to significantly increase the efficiency and availability of large vertical mills. In the FLENDER EMPP drive unit, which features extremely high capacity, an integrated synchro-nous motor supplied by a frequency converter ensures the required drive power and, because the bevel gear stage is eliminated, it reduces the number of active components in the gear unit. The brushless permanent magnet motor is particularly robust and completely wear-free. Because of its static seals it has a high protection class and an extremely durable stator winding.

With the FLENDER EMPP, Siemens has developed a drive concept that both prevents load impacts due to short interruptions in the electrical power supply and optimizes power transmission between the drive and the mill. That increases plant availability and results in an expansion of the capacity range up to 12 MW. The greatest strengths of the innovative EMPP concept are found here – in the high capacity classes – because the closed unit delivers ultra-quiet running under full load. The converter control also contributes to the ongoing protection of your plant against overloading because torsional vibrations caused by the grinding process can be actively dampened via the drive. The active (electrical) damping of the drive train and the mill behavior with situationally based torque con-trol can be seen as the greatest innovation.

Electronic Application Control

The drives in the FLENDER SmartSeries are equipped with electronic application control (EAC), which offers the operator active protection for the plant against overload-ing as well as comprehensive options for process optimization.

At the heart of the EAC is situation recognition that func-tions in real time. In just fractions of a second, the loading situation is evaluated and a control strategy adapted and applied. The machine dynamics can be controlled directly by the motor, and undesirable conditions (e.g. strong vibrations) can be prevented. This generates active pro-tection for the drive and plant against overloading as well as continuous, stable running with far fewer interruptions due to unanticipated events in the grinding process. The visualization of the recognized operating situation in the process control system enables operators to optimize the process and extend their process expertise. Moreover, an optional condition monitoring system (CMS) allows the machine’s state to be diagnosed and enables the creation of a maintenance plan.

Tested success-fully in the field: FLENDER EMPP

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Electronic application control offers intelligent, real-time situation recognition and uses the control strategy to realize long-term protection of the drive train and the plant.

Especially with changes in the materials to be ground and various starting materials, active vibration damping and an adjustable grinding plate speed guarantee the greatest degree of smooth running. This significantly optimizes the grinding process and considerably improves grinding results by dramatically increasing throughput, lowering power consumption per ton or reducing the water spray-ing required, for example.

Easy conversion

If you wish to switch over from an existing KMPP drive to a new EMPP drive, conversion times are easily manage-able. EMPP drives have the same housing dimensions and require the same foundations and plant designs. The two-part housing makes transportation and assembly as well as on-site service easier. The conversion does not require any complicated modifications to the overall construction. The plant is soon ready to start operating again.

Components

Process control system

Real-time situation recognition and frequency converter

Result Benefit

Operating situation Process optimizationvisualizes enables

shows leads toMachine stateSensor technology CMS Maintenance plan

evaluates influencesLoad situation Control strategy

delivers results inControlled

machine dynamics Active protectionMotor

Monitoring Control

FLENDER EMPP

Design Built-in synchronous motor, 2 planetary gear stages

Capacity 3,000 to 12,000 kW

Installation sizes 5

Transmission ratios i = 40

Torque 1,400,000 to 5,000,000 Nm

Axial bearings Fully hydrostatic

AdvantagesActive damping with situationally based torque control, highest degree of availability with variable speed, greatest power density with high degree of efficiency, wear-free, same dimensions

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Really large mills …

… need a unique drive concept. Siemens meets the grow-ing need for extremely powerful, high-availability produc-tion plants with the FLENDER MultipleDrive®. This drive indisputably places us in the topmost segment for vertical mill drives, where Siemens is currently the only provider. Key considerations here are maximum output, minimum downtime and the lowest possible life cycle costs. The result: a concept that guarantees long-term availability with the modularity of a multi-stage drive. Theoretically, there are no limits to power input for this system. De- pending on equipment, the concept currently provides for an output capacity of 16.5 MW.

The MultipleDrive principle

A common girth gear is driven by two, three, four, five or even six autonomous drive units. The synchronization of the individual drives, each positioned on a carrier, is performed by frequency converters that also enable the speed to be adjusted to suit the various product qualities. If one of the installed MultipleDrive units has to be ser-viced, it can simply be disengaged. The other units con-tinue to drive the girth gear, preventing a complete pro-duction stoppage. The pre-arrangement of the drive units on a carrier also makes it easier to replace the units quickly. Moreover, the FLENDER MultipleDrive is not sensitive to static radial forces, so it gives you greater freedom, e.g. when servicing individual rollers.

The high control dynamics of the MultipleDrive with the corresponding load distribution among the individual drive units guarantees quiet running. In turn, this feature and the adjustment of the speed to the grinding process for various materials ensure optimum operating condi-tions for the drive system and, at the same time, an out-standing grinding result.

FLENDER MultipleDrive

Design Squirrelcage motor, gear unit (bevel gear stage/helical gear stage), grinding plate bearing (girth gear)

Capacity 4,000 to 16,500 kW (optimum application range: 6,000 kW and up)

Installation sizes 4

Transmission ratios i = 50 to 120

Torque 1,200,000 to 8,000,000 Nm (optimium application range: 2,500,000 Nm and up)

Axial bearings Fully hydrostatic

AdvantagesHighest capacity class, maximum availability with variable speed, standard components with simple stocking, low overall height, not sensitive to static radial forces

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Other advantages

The lower overall height of the MultipleDrive in compari-son with other vertical mill drives reduces factory and operating costs because the material does not need to be transported so far upward and the peripheral equipment need not be so large. Of course, a suitable oil supply sys-tem directly on the drive is standard.

MultipleDrive also boasts optimum service options. The simple, inexpensive stocking of small, standardized com-ponents can lead to invaluable advantages in plant availability.

With the FLENDER MultipleDrive, we are offering a com-plete system with maximum availability and a modular design from a single source. This modular system offers the greatest possible flexibility in design and layout based on customer needs.

The high capacity range of the FLENDER MultipleDrive enables two plants to be replaced by one plant with significantly greater throughput, keeping the necessary construction work to a minimum.

Infinitely scalable: the modular FLENDER MultipleDrive has endless possibilities

The innovative concept of the FLENDER MultipleDrive and its low overall height

4.5 MW (3 x 1.5 MW)

8 MW (4 x 2 MW)

16.5 MW (6 x 2.75 MW)

Further information about gear units: www.siemens.com/flenderapplications www.siemens.com/empp www.siemens.com/multipledrive www.siemens.com/gearunits

Further information about couplings: www.siemens.com/flendercouplings

Siemens partners near you: www.siemens.com/drives-contact

The information provided in this brochure contains merely general descriptions or characteristics of performance which in case of actual use do not always apply as described orwhich may change as a result of further development of the products. An obligation to provide the respective character-istics shall only exist if expressly agreed in the terms of con-tract. All product designations may be trademarks or product names of Siemens AG or supplier companies whose use by third parties for their own purposes could violate the rights of the owners.

Siemens AG Industry Sector Mechanical Drives Alfred-Flender-Straße 77 46395 BOCHOLT GERMANY

Subject to change without prior notice 04/13 Order-Nr.: E20001-A370-P900-X-7600 DISPO 27904 GD.MD.AP.XXXX.52.3.02 WS 04131.0Printed in Germany© Siemens AG 2013