Innovation In Indonesia

The cement industry continually seeks innovative solutions to enhance efficiency, reduce costs, and improve sustainability and safety. Vertical roller mills (VRMs) are at the heart of cement grinding operations, where wear parts play a critical role in maintaining plant performance. Magotteaux's Expand solution was responsible for a recent success story at PT Semen Padang, Indonesia, demonstrating the impact of the Expand wear parts, not only in extending the lifespan of grinding components but also in optimising energy efficiency and reducing total cost of ownership (TCO).

PT Semen Padang is Indonesia’s oldest cement manufacturer, established in 1910. As a subsidiary of Semen Indonesia Group, it plays a vital role in the country’s infrastructure development. With a commitment to innovation and sustainability, PT Semen Padang continuously seeks advanced solutions to optimise production efficiency and to reduce the plant’s CO2 emissions.

The challenge: frequent replacements and high maintenance costs

At PT Semen Padang, the OK54.6 vertical mill processes raw materials for cement production. Before 2019, PT Semen Padang relied on high-chrome (HiCr) rollers with periodic resurfacing. The grinding operation required hard facing every 4 – 8 months, resulting in frequent mill stoppages, high maintenance costs, and inefficient energy consumption. Each roller required approximately 2 t of welding material, with a cost of US$15/kg, translating into a significant financial burden for the cement plant.

Hard facing challenge

Cracking

There is a certain risk of roller cracks occurring during or shortly after welding. Welding introduces inevitable microcracks into the support structure and causes stress due to uneven heating. It is impossible to predict when cracking will occur or how many welding sessions it will take to appear. There is generally no early warning, which can lead to unexpected mill stops due to roller breakage, potentially affecting the entire plant.

Mill availability

Hard facing operations require the mill to be stopped for 7 – 10 days each time, reducing mill availability and increasing maintenance costs.

Lethal fumes

Welding emits hazardous fumes, especially when done inside the mill (i.e., in a confined space).

Recognising these inefficiencies, PT Semen Padang sought a solution that would extend the operational life of its grinding components, reduce the frequency of maintenance, and ultimately lower total cost of ownership.

Transition

Magotteaux was chosen as the first priority supplier for metal matrix composite (MMC) solutions. The initial installation of MMC rollers, without altering the original equipment manufacturer (OEM) design, marked the beginning of a new era for PT Semen Padang. During this period, it was observed that the first wear zone started on the edge of the casting, impacting the ceramic grain faster than the mid-zone.

Based on wear pattern analysis, Magotteaux applied its Expand solution, which includes a long-lasting metal-matrix composite material. This further enhances the hardness of the grinding elements while maintaining ductility and mechanical reliability. The solution also features a customised design tailored to the wear profile, ensuring uniform surface wear and maintaining the proper pressure on the material in the mill.

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Read the article online at: https://www.worldcement.com/special-reports/14072025/innovation-in-indonesia/