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CRUSHING TECHNOLOGY
Down to size
PT Cemindo Gemilang, part of the Ganda group and relative newcomer to the cement
business, has recently constructed a 10,000tpd integrated cement works on Java, Indonesia.
The crushing plant for the new facility, supplied by HAZEMAG & EPR, has the capacity to handle
2500tph and benefits from a roller screen and impact crusher combination.
n by Daniela Ulbrich, HAZEMAG & EPR GmbH, Germany
P
T Cemindo Gemilang has been
marketing its cement in Indonesia since
2011 under the Semen Merah Putih (SMP)
brand name. The company’s recentlyconstructed greenfield 10,000tpd cement
plant in Indonesia, is located in Bayah,
Banten province on the main island of
Java. Situated near the coast, the plant
has its own jetty to transport materials
and final product, as well as its own power
station.
The order for the clinker line was
awarded to Sinoma International
Engineering (China) which in turn selected
Hazemag & EPR (Germany) to supply the
2500tph crushing plant for the new facility.
Design data of the crushing plant
Before selecting the crushing system,
Hazemag conducted sample tests at its
laboratory in Germany to determine the
materials’ properties, crushability and
wear characteristics. The raw materials
to be crushed are limestone and up to 20
Figure 1: layout of the primary crushing plant for
PT Cemindo Gemilang’s cement works in Bayah, Indonesia
per cent of clay (ie, mainly grey clay and
partly brown clay). The limestone has an
average moisture content of 2-4 per cent
(with a maximum of 10 per cent) and an
average uniaxial compressive strength of
90MPa. The moisture content of the grey
and brown clay mixture can be up to 25
per cent.
It is the task of the crushing plant to
reduce the limestone and clay from the
run-of-mine (ROM) size down to a suitable
feed size for the vertical raw mill. The raw
mill requires a particle size of 95 per cent
passing at 80mm.
Technical solution
The crushing system designed and
supplied by Hazemag comprises two apron
feeders to discharge the limestone and
clay each from separate hoppers. The
smaller apron feeder for clay (supplied by
Sinoma) is arranged crosswise to the main
apron feeder.
Figure 2: at the core of the crushing plant is the HAZEMAG HPI 2530 primary impact
crusher with hydraulically adjustable impact aprons and grinding path
INTERNATIONAL CEMENT REVIEW JANUARY 2016
Figure 3: scrapers underneath the rollers
ensure a clean operation
©Copyright Tradeship Publications Ltd 2016
CRUSHING TECHNOLOGY
75
allow for the easy and safe turning and
changing of the six blow bars.
The contract also included extensive
customer training by Hazemag personnel
both in Germany as well as on site to
ensure the crushing plant is operated
and maintained correctly. The scope of
supply further included engineering of the
crushing system, as well as supervision of
erection services and commissioning.
Figure 4: there are three roller screen levels
each equipped with a separate drive unit
Figure 5: one of two drive units for the
heavy-duty apron feeder
Figure 6: view into the crusher at an
opened-hinged section
Figure 7: patented GSK rotor design with
rugged cast steel discs
From the main apron feeder the
limestone and clay are fed to a roller
screen. The roller screen separates
the material at 80mm and removes
approximately one-third of the total feed
before it reaches the crusher. The roller
screen overflow is fed to an impact crusher.
Key features of installation
Apron feeder and spillage conveyor
The limestone/clay apron feeder is
2500mm wide and has a centre distance
length of 14,200mm. The apron feeder is
driven by a double-side electromechanical
drive with an installed power of 2 x 75kW.
A spillage conveyor is mounted
underneath the apron feeder to ensure a
clean operation.
Roller screen
The roller screen comprises 16 shafts
arranged on three levels. With this
arrangement the screen has two steps.
The steps have a loosening and turning
effect on the material, allowing for more
efficient screening. Of the 16 shafts one
shaft on each level is driven and the power
is transferred to the neighbouring shafts
by chains. The purpose of installing a roller
screen is to take out the fine materials
that are already <80mm, ie the required
A combined effort
size. The fine materials mainly comprise
clay and finer limestone particles with a
relatively high moisture content. The total
feed capacity to the crusher is therefore
reduced and, especially during the rainy
season, sticky material is separated before
it reaches the crusher. Scrapers installed
beneath the rollers keep them clean.
Both the apron feeder and roller screen
are fully encased to ensure effective
dedusting.
Impact crusher
The Hazemag HPI 2530 impact crusher
selected for the project is the largest of
its type available. It has a rotor diameter
between the blow bar tips of 2500mm, a
rotor width of 3000mm and a total weight
of 168t, excluding the drive unit. The
installed motor power of 2700kW enables
smooth handling of the crusher’s 2250tph
design capacity.
At the heart of the crusher is the
patented GSK rotor, a welded construction
comprising rugged steel discs. The front
and rear impact apron as well as the
grinding path are hydraulically controlled.
The crusher is also equipped with a
centralised lubrication system.
Additional accessories, such as blow bar
changing and hydraulic extracting devices,
©Copyright Tradeship Publications Ltd 2016
The combined benefits of a roller screen
and impact crusher have been proven at a
number of successful installations across
the world. PT Cemindo Gemilang selected
this crushing system due to the following
benefits:
•low operating costs through the reduced
need for crushing and therefore less wear
and power consumption of the impact
crusher
•less sensitivity to tramp metal compared
to other crusher types
•ability to handle sticky materials by
the screening out of fines with a higher
moisture content
• reduced wear costs through the
increased utilisation of blow bars
•less maintenance downtime as there are
only six crushing tools (ie, blow bars).
Further crushing and screening
contracts awarded in Indonesia
PT Cemindo Gemilang’s crushing plant
has been successfully assembled and
commissioned.
This order is one of many Hazemag &
EPR has been awarded for Indonesian
projects, including a semi-mobile
secondary crushing system in East Java
with a capacity of 1400tph of limestone.
The system, which includes apron feeders,
roller screen and impact crusher, is built on
steel structure units which are moved by
self-propelled modular transporters as and
when the need arises.
Elsewhere on the archipelago, Hazemag
supplied two sizers, each with a width of
3000mm for clay crushing to newly-built
plants in Indarung Padang (West Sumatra)
and Rembang (Central Java).
The company has also supplied
a screening unit comprising a large
screen drum for very difficult to handle
contaminated limestone to Indonesia’s
second-largest cement producer. Thanks
to the screening unit, valuable raw
materials are gained from previouslyunused materials which otherwise would
have been stockpiled for years. n
JANUARY 2016 INTERNATIONAL CEMENT REVIEW