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World’s largest roller mill underway at Shah Cement

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World Cement,

The inauguration of the world’s largest vertical roller mill (VRM) for cement grinding completes a smooth commissioning process at Shah Cement in Bangladesh.

The FLSmidth OKTM 81-6 mill has milled its first cement at Shah Cement’s Muktarpur plant, in Munshigani, Bangladesh. The mill has an 8.1 m grinding table and six grinding rollers, and is powered by an 11.6 MW gearbox.

Shah Cement is part of the Abul Khair Group and is one of the largest cement producers in Bangladesh. The company’s VRM was chosen to produce a full range of cement types at the Muktarpur plant. The mill is driven by two 5.8 MW FLSmidth MAAG® Max Drive gear systems and is the biggest VRM ever to be installed in a cement plant in terms of dimension, operating capacity, and installed power.

The machine was successfully put into operation earlier this year, with Shah Cement’s plant management impressed with its performance. In a few weeks, it has achieved highly satisfactory production capacity, with low energy consumption.

The mill is designed to produce ordinary portland cement, portland pozzolana cement, portland slag cement, and slag cement types. It is producing portland pozzolana cement at a capacity of 500 tph at 3500 Blaine, with 15% slag.

In addition to the OK mill, the company has also supplied process and layout engineering, as well as site advisory. Supporting equipment included FLSmidth Pfister weigh feeders, FLSmidth Airtech process bag filters, process fans, and auxiliary equipment from raw material hopper discharge to process bag filter discharge.

The mill is designed for versatility. It produces ordinary portland cement with a feed mix of 95% clinker and 5% gypsum and a capacity of 540 tph at 3600 Blaine; portland pozzolana cement with a feed mix of 65% clinker, 5% gypsum, and 30% flyash, at a capacity of 640 tph at 3800 Blaine; portland slag cement with a feed mix of 65% clinker, 5% gypsum, and 30% slag, at a capacity of 450 tph at 3800 Blaine; and slag with a feed mix of 100% slag and a capacity of 380 tph at 4000 Blaine.

The mill is well-suited to changing cement production demands, has the flexibility to grind diverse materials, and the ability to accommodate changes to product type within minutes. It uses between 5% and 10% less power consumption that other cement VRMs, saving millions of kilowatts each year. It also achieves between 60% and 70% of nominal output, even with half of its rollers out of service.

“We are proud to have the world’s largest VRM as part of our operations,” said Hafiz Sikander, Director of Operations for the cement division of Shah Cement. “We selected the FLSmidth OK 81-6 mill for its exceptional efficiency and reduced power consumption – and we are expecting it to deliver as promised. As the largest single-unit grinding mill in the industry, we expect it to meet our production requirements for many years. We have worked with FLSmidth for many years and we have always been able to rely on the high level of service at all stages.”

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FLSmidth news Cement news 2018