The limestone-rich belt of Karnataka in India is home to many cement plants, and the market for roller presses in the region is highly competitive. Given the numerous different options on the market, choosing the correct roller press solution and the equipment supplier can be daunting for plant owners. For Orient Cement, selecting the Fuller Hydraulic Roller Press (HRP) has proven to be a cost-effective solution.
With a desire to optimise productivity, Orient Cement established selection criteria for evaluating a new roller press system for use in its 6,600 tonnes-per-day integrated greenfield plant. The three most critical objectives were high production performance, low power consumption, and grinding without adding water.
SHYAM ASAWA - Head of Projects at Orient Cement
TABLE 1: The grinding system’s performance after the installation of two hydraulic roller presses.
Shortly after the installation, it was evident that Orient Cement’s project objectives would be achieved, with all performance guarantees successfully delivered. As shown in table 1, actual production exceeded the intended capacity target by 6.5 percent – at a lower power consumption and with zero water consumption.
Fuller's latest hydraulic roller press sets the bar with its efficient design and includes other noticeable improvements in performance:
These features enable the HRP to achieve high energy efficiency and contribute to a low total cost of ownership, largely due to its ease of operation and minimal maintenance costs.
Today, the grinding system at the Karnataka plant is performing well. After the initial 10,000 hours, the conventional wear surface remains in good condition. No repair work has been required or performed thus far. This strong result is a testament to both the quality and durability of the equipment.
The HRP is suitable for upgrades and new installations. In some cases, an upgrade can more than double the capacity while reducing energy consumption by 30%
MR. ASAWA - Head of Projects at Orient Cement
The Fuller Hydraulic Roller Press installed at the Karnataka plant
Orient Cement's Hydraulic Roller Press - Raw Grinding Circuit
Since the successful installation of the HRP, Orient Cement has opened its plant doors to other cement producers to showcase the successful grinding solution and welcomed any discussion regarding its positive experiences.
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