Olaf Michelswirth, Intercem Engineering, explores the advantages of modular grinding plants over larger cement production units.
In industrialised countries, large cement production units are dominant. However, many regions in the world do not have easy access to construction materials and for this reason, prices tend to be very high. Therefore, smaller grinding units are becoming a more attractive option, especially from a logistical point of view. The reduction of transport costs for raw materials as well as for cement and other final products has a positive effect on cement prices.
Modular plants can be implemented within approximately 12 months. Their advantage is the reduction of transport costs for raw materials and final products as they do not require as much space as big stationary plants and can therefore be located closer to the relevant infrastructure. Moreover, their impact on the environment is considerably lower than that of cement plants.
Regional demand for cement is the basis for the development of local modular grinding plants. The availability of the necessary raw materials, local companies with expertise in parts production and assembly, and sufficiently rained personnel are secondary preconditions. Furthermore, reliable energy supply and transport routes are essential. Potential investors will also consider the political context and stability as an incentive to start activities.
Intercem has developed a modular grinding system with production capacities between 20 – 50 tph, called InterMod. This is a complete grinding station, supplied mainly in a 40 in. container size.
Within 6 – 8 weeks, it can be mounted and commissioned on site, using only tried and tested aggregates. This contributes to the economic efficiency of the plant and its high availability. Moreover, handling and service are easy.
In the same short period of time the modular plants can be disassembled and stored or rebuilt in another location. This enables operators to respond flexibly to economic, cultural, political or environmental changes.
The three main modules
Separation
In terms of separation, the inhouse-development InterSep ICS – a high efficiency separator with tangentially-fed airflow – is recommended.
Grinding
In terms of grinding, vertical roller mills (VRM) can be used as an alternative to ball mills for modular cement grinding plants. VRMs allow higher capacities than ball mills, depending on their size. New ball mills are of course the other recommended option and can also be installed in semi-modular systems. The possibility to also integrate used and refurbished second hand ball mills is a further opportunity to save costs and to act in a sustainable way.
Enjoyed what you've read so far? Read the full article and the rest of the August issue of World Cement by registering today for free!