FLENDER Vertical Mill Drives

8/10/2019 FLENDER Vertical Mill Drives

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5,000,000 kW

FLENDER vertical mill drives are indispensable for thosewho want the right solution for every vertical mill require-ment, those who value sustainable, energy-efficient, opti-mized processes and those for whom drive availability andsafety have top priority in short, all those who want torely 100% on their drive technology.

In addition to first-class product quality and consultationbased on decades of experience and in-depth industryexpertise, we offer by far the most comprehensive portfo-lio of highly advanced, mature and proven drive solutions.

Whats more, we produce them ourselves from start tofinish.

With our global production concept and extensive exper-tise, thousands of references in all capacity classes andpartnerships with the worlds most significant OEMs plus extraordinary, reliable customer service and theentire might of the Siemens corporation we are theright partner for all kinds of drives. We maintain goodcustomer relationships, treating both plant engineers andend-users as peers and developing new solutions withthem, always with a view to the perfect result. This canonly be achieved with the outstanding technical expertiseof a leading innovator.

As the only system provider with expertise throughout theentire drive train, we offer you investment security on onehand and rapid response times on the other. Our globalsetup and virtually seamless international service net-work, our formidable supply capacity and short deliverytimes, our guarantee for complete systems and, last butnot least, our extraordinary price/performance ratio areunrivalled the world over.

Because requirements in the vertical mill sector differ bytarget product, we offer you special solutions and installa-

tion sizes for every application.

thats roughly equivalent to the gross power output of the mostimportant natural gas power plants in Germany. 5,000,000 kW thats also the capacity of FLENDER vertical mill drives installedinternationally. For you, that means primarily three things: quality,experience and versatility on the part of your drive technologysupplier.


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ProductCapacity range

Coal Raw meal Slag Clinker

KMPOptimum application range: 100 to 1,500 kW

KMPSOptimum application range: 1,500 to 4,000 kW

KMPPOptimum application range: 3,000 to 8,000 kW

EMPPOptimum application range: 4,000 to 8,000 kW

Multiple-Drive Optimum application range: 6,000 kW and up

16,000 kW14,000 kW12,000 kW10,000 kW8,000 kW6,000 kW4,000 kW2,000 kW


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Costs are crucial not only in decisions regarding the procurement of thegear unit, but also throughout the entire process and inthe availability of your plant. Efficiency and life cycle costsplay a critical role here, so its good to know that you candepend on Siemens with regard to price, concept andquality.

With over 4,000 tried and tested standard and specialsolutions, we continue to prove that the highly advanced,completely mature KMP gear units have set benchmarksfor grinding coal. As well as offering the right solutionfor every available type of mill in the world, we will adaptyour gear unit to the mill design on request. To do this,

we rely on standards and design modules in order to guar-antee a great deal of flexibility and quick realization. Allof our KMP gear units are ATEX 95 compliant and virtuallyfault-free, based on statistics.

Accommodating process forces

For all vertical mill drives, we use maintenance-free tilt-ing pad thrust bearings to accommodate the high axialloads which arise during the grinding process due tomaterial hardness, mechanical process influences, andmill technology and design. These bearings are availablewith hydrodynamic or hydrostatic lubrication (fully hy-

drostatic) or with starting aids (partially hydrostatic).

While hydrodynamic thrust bearings are standard in theKMP gear units used primarily for grinding coal due to thelow dynamics, fully hydrostatic lubrication is used in oursolutions for cement applications.

The pads are coated with babbitt, and their trapezoidalshape allows optimum use of the gear unit installationspace. The resulting low surface pressure allows a thick oilfilm to be generated along with good damping character-istics the uncontested advantages of this tried andtested design. A continuous supply of fresh oil guaranteesoptimum bearing cooling and dissipates the heat from themill. Extremely high-quality oil supply systems are usedhere. These were developed specially by Siemens, are

produced at our own plant and are available in standardversions. Built-in sensors monitor the temperature.

Hydrodynamic and hydrostatic lubrication

In hydrodynamic lubrication, oil is introduced into thebearing by the rotation of the output flange. The bearingstilt slightly toward the oil feed side and a wedge-shaped,hydrodynamic oil film is formed. Due to the trapezoidalpad design, the side flow is minimal and a stable, thick oilfilm remains at the outlet, which supports the flange and,in turn, the grinding plate.

To prevent friction loss and increased wear upon start-up,hydrostatic starting aids are available. On request, fullyhydrostatic solutions can even be supplied for KMP. In thiscase, the oil is forced into the bearing under high pres-sure. Each pad has its own connection and is always sup-plied with exactly the same amount of oil, regardless ofthe load.


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Coal grinding takes place inpower plants, but also in cementplants, where it is mostly usedfor heat production.

FLENDER KMP

Design Bevel gear stage, planetary gear stage

Capacity 100 to 2,000 kW (optimum application range: 100 to 1,500 kW)

Installation sizes 18

Transmission ratios i = 15 to 45

Torque 25,000 to 700,000 Nm(optimum application range: 25,000 to 500,000 Nm)

Axial bearings Hydrodynamic, opt. starting aid, opt. fully hydrostatic

Advantages Tried and tested concept with approx. 4,000 references, global productionconcept, international service locations, wide variety of options

In addition, the hydrodynamic effect occurs here and oil isdrawn in on the inlet side. In this case, the oil film isabout twice as thick as with hydrodynamic lubrication.High-pressure radial piston pumps are used to supply theoil, and they ensure a consistent volume flow into thebearing.

Our gear units are also very well suited for use with highdynamic axial forces. The oil film on the tilting pad thrustbearings is always thick enough because the actual inter-val of the dynamic forces is in fact too short to influencethe lubrication effect of the oil film in any critical way. Inpractice, it takes just a fraction of a second.

The best in its class:

FLENDER KMP


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FLENDER gear units that comply with Siemens quality standards are avail-able all over the world. Siemens solutions are particularlyimpressive in the mass market in capacity ranges up to1,500 kW, not only because of their good energy balance,but also due to their optional measuring sensor technol-ogy. This is another crucial factor for efficient processesright from day one of production.

The Siemens material specification includes special steelsfor these applications. The associated requirements havebeen developed in thousands of reference projects anddemand even more specific characteristics than the inter-national norm. This increases service life and reduces lifecycle costs.

The ribbed or corrugated form of the special housing either steel welded or made of spheroidal graphite castiron also ensures that axial forces are introduced evenlyinto the foundation through the housing. Not all housingsare created equal. Only those who have been casting fordecades understand the fine details and their great rele-vance in housing production. This is another particularstrength of Siemens gear units.

Thanks to their high-quality design and manufacture,outstanding bearings, first-class gear tooth geometry andextraordinary housing stiffness, our gear units performexcellently with respect to noise emissions.

In addition to all of these arguments, the process is al-ways the decisive factor for mill plants. All over the world,the continual pursuit of efficiency and productivity is notonly leading to evolution in mill design and layout it

is also raising awareness of variable-speed drive systems.

Medium capacity range

In recent years, drive technology has been confrontedwith the challenge of output speeds falling as capacityrequirements increase, causing a disproportionateincrease in torques. But this has not been accompanied bymore installation space for gear units. To deal with theproblem of increasing transmission and power density atthe same time, gear unit technology has evolved fromthree to four planetary gears in the output stage up to fiveor six.

The grinding of raw meal, clinkerand slag is in the medium to highpower range. The right drive solu-tions: KMPS or KMPP.


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FLENDER KMPS

Design Bevel gear stage, helical gear stage, planetary gear stage

Capacity 1,500 to 5,500 kW (optimum application range: 1,500 to 4,000 kW)



Torque 600,000 to 2,500,000 Nm(optimum application range: 600,000 to 1,800,000 Nm)

Axial bearings Fully hydrostatic

Advantages Tried and tested concept with approx. 400 references, global productionconcept, international service locations, wide variety of options

Planetary gear unit withhelical gear stage: FLENDER KMPS


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Those who make decisions ... should be allowed to doubt, but not have to. It doesntmatter whether you make your choice based on capacityrequirements or experience, based on the available instal-lation space or simply based on personal bearing prefer-ence every time you choose a FLENDER gear unit, youare making the right choice. But we want to make thedecision easier and provide you with the right argumentsfor selecting the worlds leading drive technology.

In the low to medium capacity range for pre-grinding,KMPS gear units are most often used, which combine ahelical gear stage supported by a rolling bearing witha planetary gear stage also supported by a rolling bearing.Due to the high degree of plant individualization, the gearunits are available in hundreds of versions. Our globalproduction concept keeps high production and assemblycapacity available for KMPS so that large quantities canbe realized.

In the medium to high capacity range for clinker and slaggrinding, KMPP gear units are primarily used. Their highpower density is achieved by using two planetary gearstages. The gear units in the KMPP series are entirely sup-ported by sliding bearings. The advantage of sliding bear-ings is that they are better able to accommodate dynamicloads which are generated in the process by various mate-rials and hardnesses. Sliding bearings provide a robust,durable solution in this scenario. The option of choosingbetween sliding and rolling bearings for the gear unitscaters for different customer preferences.

The patented corrugated shape of our housings and theirextremely effective, stable ribs are typical for largerFLENDER vertical mill gear units. They offer greater flexi-bility for optimizing the sliding bearing arrangement andenable the same housing to be used with different millconnection geometries. Moreover, the modular structuremakes it possible to equip mills with the same dimensions

but different power requirements. The casting quality ofour housings alone should convince you. It provides out-standing damping characteristics.

The high demand for KMPS and KMPP gear units resultingfrom retrofitting clearly demonstrates the high degreeof satisfaction in the market. So whatever your motivationis to buy whichever FLENDER gear unit, you can be confi-dent that you are making the right decision.

High-capacity, wear-freeplanetary gear unit: FLENDER KMPP


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Process stability

Process stability is not just an expression: it is a majorgoal for the entire cement industry all around the world.Stability and safety in grinding ensure plant availabilityand are the pivotal requirements for every vertical mill

drive. Their relevance increases exponentially with in-creasing mill power input.

Variable speed in drive technology plays a critical role instabilizing processes. Driven by technological possibilities,the idea that bigger is better is continuing to gain cur-rency in the cement world. Against this backdrop, thisoften conservative market has come to agreement on onething: speed variability, drive intelligence and, with in-creasing plant size, modular drive systems are the criticalparameters for plant efficiency and success in the face ofgrowing demands with regard to torque and plantavailability.

High-capacitydrives are oftenused in cement

production.

FLENDER KMPP

Design Bevel gear stage, 2 planetary gear stages

Capacity 3,000 to 8,000 kW



Torque 1,300,000 to 3,500,000 Nm


Advantages Tried and tested concept with approx. 200 references, wear-free,high power density, standardized components


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The functioning

drive train is now reality. Siemens has always been convinced thatthe drive train must be seen and understood as a whole.We are the only provider in the world that offers completeindustrial drive systems. In the context of our integrateddrive system concept, complete drive solutions haveproved their worth in many industries and have becomestandards upon which todays industrial drives are based.

In the cement industry and power generation, our gearunits have been an integral part of customer solutions formany years. The inherent frequencies of the drive changedepending on the moment of inertia of the mill and themotor. The drive train as a whole is a logical, goal-oriented development to meet the requirements of ourcustomers.

For this reason, as well as providing a comprehensiverange of top-quality drive train components, Siemensensures that they are perfectly dovetailed with oneanother from the initial concept to the functioning plant.

Siemens Integrated Drive Systems turn simple drive com-ponents into real systems. Drive technology based on IDSguarantees maximum productivity, energy efficiency andreliability in every area of automation and throughout the

entire life cycle.Prevent risks at interfaces and opt for a system partner-ship with Siemens, supported by our tried and tested con-trol technology.

SIMOTICSsquirrelcage motor

Slip ring motor

FLENDER coupling FLENDER vertical millgear unit

FLENDER oil supplysystem

SINAMICS frequencyconverter

Variable-speed drivetrain withconverter andsquirrelcagemotor

Fixed-speeddrive trainwith slip ringmotor


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Our component range includes:

Transformers

Frequency converters

Motors

Couplings (including electricallyinsulated couplings)

Auxiliary gear units/auxiliary drives Maintenance drives

Main gear units

Oil supply systems

Sensor technology

Condition monitoring

Drive controls (CEMAT)

Financing

Service

Our global network of experts proactively and reliablycontributes comprehensive technology and productknowledge to every project. This enables you tobenefit from the wide-ranging experience and in-depth technological knowledge of our service experts on-site in 190 countries, 24/7.

For example, our logistics specialists make up a com-prehensive, international network of certified servicecenters, ensuring that spare parts are supplied quicklyand reliably.

Condition monitoring

The Siemens condition monitoring system SIPLUSCMS 4000 gives you the option to track temperatures,vibrations, torques and displacements in the gear unitonline and evaluate trends. The fundamental advan-tages of the condition monitoring system are obvious:irregularities trigger an alarm and correspondingrecording activity. Increasing vibration levels are rec-ognized early on and required maintenance work canbe planned accordingly. In this way, damage is pre-vented or recognized at an early stage.

Our condition monitoring system has a special, crucialfeature: it was developed and programmed by theleading provider of industrial drive technology andoffers you secure communication paths to monitoryour drives from anywhere. For data analysis, wecan offer you a telediagnostics service provided by ourown experienced condition monitoring experts.

On request, condition monitoring can also beexpanded for use with the entire drive train.


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Electronic application control offers intelligent, real-time situation recognitionand uses the control strategy to realize long-term protection of the drive train and the plant.

Especially with changes in the materials to be ground andvarious starting materials, active vibration damping andan adjustable grinding plate speed guarantee the greatestdegree of smooth running. This significantly optimizes thegrinding process and considerably improves grindingresults by dramatically increasing throughput, loweringpower consumption per ton or reducing the water spray-ing required, for example.

Easy conversion

If you wish to switch over from an existing KMPP drive toa new EMPP drive, conversion times are easily manage-able. EMPP drives have the same housing dimensions andrequire the same foundations and plant designs. The two-part housing makes transportation and assembly as wellas on-site service easier. The conversion does not requireany complicated modifications to the overall construction.The plant is soon ready to start operating again.

Components

Process control system

Real-time situation recognitionand frequency converter

Result Benefit

Operating situation Process optimizationvisualizes enables

shows leads toMachine stateSensortechnology

CMS Maintenance plan

evaluates influencesLoad situation Control strategy

delivers results inControlled

machine dynamicsActive protectionMotor

Monitoring Control

FLENDER EMPP

Design Built-in synchronous motor, 2 planetary gear stages

Capacity 3,000 to 12,000 kW


Transmission ratios i = 40

Torque 1,400,000 to 5,000,000 Nm


AdvantagesActive damping with situationally based torque control, highest degreeof availability with variable speed, greatest power density with high degreeof efficiency, wear-free, same dimensions


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Other advantages

The lower overall height of the MultipleDrive in compari-son with other vertical mill drives reduces factory andoperating costs because the material does not need to betransported so far upward and the peripheral equipmentneed not be so large. Of course, a suitable oil supply sys-tem directly on the drive is standard.

MultipleDrive also boasts optimum service options. Thesimple, inexpensive stocking of small, standardized com-ponents can lead to invaluable advantages in plantavailability.

With the FLENDER MultipleDrive, we are offering a com-plete system with maximum availability and a modulardesign from a single source. This modular system offersthe greatest possible flexibility in design and layout basedon customer needs.

The high capacity range of the FLENDER MultipleDriveenables two plants to be replaced by one plant withsignificantly greater throughput, keeping the necessaryconstruction work to a minimum.

Infinitely scalable:the modularFLENDER MultipleDrivehas endless possibilities

The innovative concept of the FLENDERMultipleDrive and its low overall height

4.5 MW (3 x 1.5 MW)

8 MW (4 x 2 MW)

16.5 MW (6 x 2.75 MW)


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Further information about gear units:www.siemens.com/flenderapplicationswww.siemens.com/emppwww.siemens.com/multipledrivewww.siemens.com/gearunits

Further information about couplings:www.siemens.com/flendercouplings

Siemens partners near you:www.siemens.com/drives-contact

The information provided in this brochure contains merelygeneral descriptions or characteristics of performance whichin case of actual use do not always apply as described orwhich may change as a result of further development of theproducts. An obligation to provide the respective character-istics shall only exist if expressly agreed in the terms of con-tract.

All product designations may be trademarks or productnames of Siemens AG or supplier companies whose u se bythird parties for their own purposes coul d violate the rightsof the owners.

Siemens AGIndustry SectorMechanical DrivesAlfred-Flender-Strae 7746395 BOCHOLTGERMANY

Subject to change without prior notice 04/13Order-Nr.: E20001-A370-P900-X-7600DISPO 27904GD.MD.AP.XXXX.52.3.02 WS 04131.0Printed in Germany Siemens AG 2013

FLENDER Vertical Mill Drives

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