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ThyssenKrupp�Resource�Technologies�
Quadropol QMC-RD
World’s first vertical roller mill with driven rollers
Dr. Thomas Schmitz
7th International VDZ Congress, 26 September 2013
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Quadropol RD – World’s first VRM with driven rollers
26 September 2013
VDZ Congress 2013 – Dr. Thomas Schmitz
2 ThyssenKrupp�Resource�Technologies
InnovativedriveconceptfortheQuadropolcementmillInnovativedriveconceptfortheQuadropolcementmillInnovativedriveconceptfortheQuadropolcementmillInnovativedriveconceptfortheQuadropolcementmill
Roller-driveconcept
fordemanding
operatingconditions,due
tohighcementfineness
andhighthroughput
Traditionaltabledrive Innovativerollerdrive
Table-driveconceptfor
conventionaloperating
conditionsataverage
cementfineness
Themarketdemands:
• Evergreaterunits
• Unitsthatcangrindeverfinercements
• Unitsthatcangrindgreatvarietyofcementtypes
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Quadropol RD – World’s first VRM with driven rollers
26 September 2013
VDZ Congress 2013 – Dr. Thomas Schmitz
3 ThyssenKrupp�Resource�Technologies
Bettermaterialpull-incapabilityoftheroller-driveconcept
Tabledrive Rollerdrive
Roller
Material
layer
Velocityprofile
Table
� Therollerspeedisalwayslowerthan
thetablespeed
� Materialispushedinto thegrinding
gapbythemovementofthetable
�Therollerisspeedalwayshigherthan
thetablespeed
�Materialisdrawninto thegrindinggap
bythemovementofroller
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Quadropol RD – World’s first VRM with driven rollers
26 September 2013
VDZ Congress 2013 – Dr. Thomas Schmitz
4 ThyssenKrupp�Resource�Technologies
Lowerpowerandtorqueofgearunits
nroller≈
2xntable
Powerloweredaccordingtothenumberofdrives
Speedincreasedaccordingtodiameteroftableandroller
Torqueloweredaccordingtochangedpowerandspeed
PmotorRD ≈
xPmotorTD1
3
TRD ≈
xTTD16
ExampleonaRDmillwith3rollers:
► Standard gear unit sizes can be applied.►Gear units very similar to the ones well proven in Polycom applications.
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Quadropol RD – World’s first VRM with driven rollers
26 September 2013
VDZ Congress 2013 – Dr. Thomas Schmitz
5 ThyssenKrupp�Resource�Technologies
Lowerpowerandtorqueofgearunits
P motor
[kW]
n table
[rpm]
Torque
[kNm]
4500 21.6 1989
7200 19.2 3575
10200 18.7 5216
P motor
[kW]
n roller
[rpm]
Torque
[kNm]
3x1500 37.2 385
4x1800 35.3 487
6x1700 42.0 388
Table-driven Roller-driven
QMC51/25
- 3
QMC64/30
- 4
QMC68/27
- 6
► RD concept assures low drive torques even at high capacities.
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Quadropol RD – World’s first VRM with driven rollers
26 September 2013
VDZ Congress 2013 – Dr. Thomas Schmitz
6 ThyssenKrupp�Resource�Technologies
►Maintenance on mill drive possible at continued production.
Operationstillpossiblewith
onepassiveroller
(atreducedthroughput)
Dismounted gear
unit and coupling
Highoperationalreliability
Millswith4or6rollers:
Operationstillpossiblewithtwo
opposingrollersliftedorremoved
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Quadropol RD – World’s first VRM with driven rollers
26 September 2013
VDZ Congress 2013 – Dr. Thomas Schmitz
7 ThyssenKrupp�Resource�Technologies
DesignofRDrollerunits
Cardan shaft
Motor
Hydraulic cylinder
Torque sensor
Drive shaft
Planetary and bevel gear
Grinding roller
SafeSet
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Quadropol RD – World’s first VRM with driven rollers
26 September 2013
VDZ Congress 2013 – Dr. Thomas Schmitz
8 ThyssenKrupp�Resource�Technologies
DesignoftheQuadropolRD
Separator
Grit cone
Roller unit
Feed chute
Mill housing
Gas inlet
Foundation
Motor
Grinding table
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Quadropol RD – World’s first VRM with driven rollers
26 September 2013
VDZ Congress 2013 – Dr. Thomas Schmitz
9 ThyssenKrupp�Resource�Technologies
Smoothoperationbydamping– TransmissionofForces
Rollerunit
FoundationTable bearing/
Gear unit
Grindingtable
► Smooth and low-vibration operation.
• Fulldampingofrollerunitsby
foundation
• Millhousingcompletelyfree
ofgrindingforces
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Quadropol RD – World’s first VRM with driven rollers
26 September 2013
VDZ Congress 2013 – Dr. Thomas Schmitz
10 ThyssenKrupp�Resource�Technologies
Smoothoperationbydamping– TransmissionofForces– RoughRunning
Rollerunit
Foundation
Grindingtable
Zerogap
~10mm
Tablebearing/
Gearunit
• Fulldamping
ofrollerunits
byfoundation
• Millhousingcompletelyfree
ofgrindingforces
► No contact between roller and table – Table bearing protected.
• If,foranyreason,the
grindingbedisdestroyed,all
forcesaredirectlyfedviaa
stopperintothefoundationof
therollerunit.
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Quadropol RD – World’s first VRM with driven rollers
26 September 2013
VDZ Congress 2013 – Dr. Thomas Schmitz
11 ThyssenKrupp�Resource�Technologies
Scale-up:Fromlaboratoryteststomarketintroductionin2steps
Tablediameter:0.6m
Installeddrivepower:60kW
Conceptdevelopment
atR&Dlaboratory
2008-2010 2011 2012
• Newdriveconceptwastested
• Considerablysmootherrunningdemonstrated
• Increasedgrindingefficiency
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Quadropol RD – World’s first VRM with driven rollers
26 September 2013
VDZ Congress 2013 – Dr. Thomas Schmitz
12 ThyssenKrupp�Resource�Technologies
Scale-up:Fromlaboratoryteststomarketintroductionin2steps
Tablediameter:0.6m
Installeddrivepower:60kW
Tablediameter:3.2m
Installeddrivepower:1000kW
Conceptdevelopment
atR&Dlaboratory
Industrialtests
ofsinglecomponents
2008-2010 2011 2012
Confirmationof
• Mechanicalfunctionality
• Resultsoflabresults
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Quadropol RD – World’s first VRM with driven rollers
26 September 2013
VDZ Congress 2013 – Dr. Thomas Schmitz
13 ThyssenKrupp�Resource�Technologies
Scale-up:Fromlaboratoryteststomarketintroductionin2steps
Tablediameter:0.6m
Installeddrivepower:60kW
Tablediameter:3.2m
Installeddrivepower:1000kW
Tablediameter:5.1m
Installeddrivepower:4500kW
Conceptdevelopment
atR&Dlaboratory
Industrialtests
ofsinglecomponents
Introductiontomarket,
1stindustrialplant
2008-2010 2011 2012
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Quadropol RD – World’s first VRM with driven rollers
26 September 2013
VDZ Congress 2013 – Dr. Thomas Schmitz
14 ThyssenKrupp�Resource�Technologies
QuadropolQMC51/25-3RD– Firstindustrialplant– Lagunas
Lagunas,
Mexico
ProductspecificationCPC-30RS
Clinker: 75%
Gypsum: 5%
Pozzolana: 10%
Limestone: 10%
Productfineness: <3%R0.045mm
(~450m²/kg)
CooperativaLaCruzAzulS.C.L.
Lagunas,Mexico
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Quadropol RD – World’s first VRM with driven rollers
26 September 2013
VDZ Congress 2013 – Dr. Thomas Schmitz
15 ThyssenKrupp�Resource�Technologies
Millperformance
(designdata)
Throughput:
175tph
Specificpower
consumption:@counter,maindrives
mill,fan,separator
28kWh/t
QuadropolQMC51/25-3RD– Firstindustrialplant– Lagunas
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Quadropol RD – World’s first VRM with driven rollers
26 September 2013
VDZ Congress 2013 – Dr. Thomas Schmitz
16 ThyssenKrupp�Resource�Technologies
QuadropolQMC51/25-3RD– Firstindustrialplant– Lagunas
Tablediameter: 5100mm Rollerdiameter: 2500mm
InstalledPower: 3x1500kW Typeofdrive: VVVFdrive
Mainequipmentdata:
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Quadropol RD – World’s first VRM with driven rollers
26 September 2013
VDZ Congress 2013 – Dr. Thomas Schmitz
17 ThyssenKrupp�Resource�Technologies
Guarantee
175 t/h
< 3%
28.0 kWh/t
Mill throughput
Residue 45µm
Specific power consumption
4500 cm²/gProduct fineness
YesGrinding aid
10/2012
Performancetest
178 t/h
2.6%
26.9 kWh/t
4560 cm²/g
No
12/2012
6weeksfromfirststartuntil
successfulfinishof
performanceguaranteetest
27.9 kWh/t
August2013
204 t/h
2.4%
4630 cm²/g
No
08/2013
Furtherprocessoptimisation
QuadropolQMC51/25-3RD– Firstindustrialplant– LagunasFast-trackcommissioningforprototypeinstallation
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Quadropol RD – World’s first VRM with driven rollers
26 September 2013
VDZ Congress 2013 – Dr. Thomas Schmitz
18 ThyssenKrupp�Resource�Technologies
Mill throughput:
175 t/h ►11 min
after start-up
Mill throughput:
190 t/h ►25 min
after start-up
Grinding pressure:
max.►5 min
after start-up
Vibration at roller
units < 1.5 mm/s
Vibration at table
bearing < 0.5 mm/s
QuadropolQMC51/25-3RD– Firstindustrialplant– LagunasFastandextremelysmoothautomaticstart-upoftheQuadropol-RD
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Quadropol RD – World’s first VRM with driven rollers
26 September 2013
VDZ Congress 2013 – Dr. Thomas Schmitz
19 ThyssenKrupp�Resource�Technologies
Productportfolio:
CEMI52.5N
Productfineness: 440m²/kg
HolcimFrance
LaRochelle,France
Startofcommissioning:
10/2013
LaRochelle,
France
GGBF
Productfineness: 450m²/kg
CEMI52.5N
Productfineness: 520m²/kg
QuadropolQMC48/24-3RD– Secondindustrialplant– LaRochelle
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Quadropol RD – World’s first VRM with driven rollers
26 September 2013
VDZ Congress 2013 – Dr. Thomas Schmitz
20 ThyssenKrupp�Resource�Technologies
Throughput:
75– 110tph
QuadropolQMC48/24-3RD– Secondindustrialplant– LaRochelle
Tablediameter: 4800mm
Rollerdiameter: 2400mm
InstalledPower: 3x1300kW Typeofdrive: VVVFdrive
Mainequipmentdata:
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Quadropol RD – World’s first VRM with driven rollers
26 September 2013
VDZ Congress 2013 – Dr. Thomas Schmitz
21 ThyssenKrupp�Resource�Technologies
QuadropolQMC64/30-4RD– Thirdindustrialplant– PalmardelBravo
PalmardelBravo,
MexicoProductspecificationCPC-30RS
Clinker: 75%
Gypsum: 4%
Pozzolana: 13%
Limestone: 8%
Productfineness: <3%R0.045mm
(~420m²/kg)
CycnadeOriente,S.A.deC.V.
PalmardelBravo,Mexico
Startofcommissioninginsummer2015
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Quadropol RD – World’s first VRM with driven rollers
26 September 2013
VDZ Congress 2013 – Dr. Thomas Schmitz
22 ThyssenKrupp�Resource�Technologies
Throughput:265–320tph
QuadropolQMC64/30-4RD– Thirdindustrialplant– PalmardelBravo
Tablediameter: 6400mm
Rollerdiameter: 3000mm
Installedpower: 4x1800kW Typeofdrive: VVVFdrive
Mainequipmentdata:
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Quadropol RD – World’s first VRM with driven rollers
26 September 2013
VDZ Congress 2013 – Dr. Thomas Schmitz
23 ThyssenKrupp�Resource�Technologies
Conclusion
• Thyssenkrupp ResourceTechnologiesoffersaninnovativedriveconcept
thatallowsthereliableoperationoflargeverticalmills.
• TheRDconceptprovidesadvantagesintermsofplantavailability
• TheRDconceptshowsprocess-technologicaladvantagesandallowsa
highlyefficientcomminution process
• ThefirstRDinoperationproveditsutilisability andoperationalreliability
robustly.