Roller Press Refurbishmentoptimize your business

• flexible, work can be performed inside the machine - no dismantling required

• reliable• reduce downtime

your partner in roller refurbishment

• fast roller refurbishment• re-weld two rollers at the same time• on-site

Keeping your rollers in good condition is critical to longer rol-ler life as well as for high machine availability and throughput. For years, KHD has provided Roller Press Refurbishing (RPR) services at our workshops in Cologne and Delhi. Now, with the development of our mobile re-welding equipment, we are able to bring that same quality and performance to your plant site. With our new mobile RPR service, not only do we bring the refurbishing process to you but we further minimi-ze downtime with our ability to refurbish both rollers at the same time, without removing them from the machine.

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KHD’s group vision and mission are based on achieving the highest quality with the highest levels of qualification for our employees. With a large installed base of Roller Presses and over 155 years of experience in the cement industry, KHD is a global leader in Roller Press (RP) equip-ment and services. Our RP experts are available to help you plan for your service, follow-up after your service, and guide you towards increased roller life and longer CHF surface life.

Defining the right moment to reweld is key to reducing downtime, costs, and increasing the lifetime of the roller. In addition to our on-site rewelding service, we can offer an optional pre-service machine audit to help you plan efficiently for our service. During this audit we will help plan exactly when to weld and how best to prepare to reduce the machine downtime. Ask your RP Specialist about our optional audits.

expertise

NEW ROLLER

COMPLETE REFURBISHMENT

PROFILING

ROLLER LIFECYCLE

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after 1 lifecycle +1 lifecycle

RPRSERVICE

Two rollers can besimultaneously re-profiled, maximizing the life of the hard-face layers.

REFURBISHEDROLLERSURFACE

ROLLER SURFACE

WORNROLLERSURFACE

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unique workflow

TRANSPORT TO SITE

NEW

All welding tools andequipment fit in two 20ftcontainers.

CLEANING

Vacuum sandblastingsystem allows work to continue around themachine.

MEASURING

Measurement and in-spection of the rollerensures the best andmost efficient process for refurbishing.

We have optimized the refurbishing process and established cutting-edge welding practices to provide you with the highest quality product that offers the best in performance and availability. From transport to the final welding, each step in our workflow has been designed to provide reliable, high quality refurbishment with minimal disruption to the site. Using our KHD repair pro-cedures and cutting-edge technology, your KHD technician will guide you towards increased rol-ler life and longer CHF surface life.

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LEVELING PREHEATINGGRINDING PLASMA

NEW NEW

KHD Induction pre- heating provides safe and quick heating of the rollers.

WELDING FOLLOW UP

Both rollers can besimultaneously weldedwhile inside the machine,allowing work to continuearound the machineand welding at twice the speed.

To monitor wear andhelp guide you towardsincreased roller life, KHD experts provide regular follow ups after the service.

Fully automated plasma leveling or grinding with industrialbelt grinders ensure the fastest possible leveling.

unique workflow

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COLOGNE

transport to siteKHD welding tools and equipment are transported to site in two 20ft containers where they can easily be unloaded using either a large forklift or crane. The containers should be stored as close to the welding location as possible and can be unloaded manually.

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It’s very important to start work on a clean roller, this reduces the likelihood of impurities entering the weld, which may lead to quality issues with the finished roller. We use a vacuum sandblasting system that ensures the maximum safety of the user and allows other work to continue around the machine, therefore causing minimum disruption.

cleaning

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measuring for informed decisionsBefore welding it is important to evaluate the current condition of the roller. This helps to establish the best and most efficient pro-cesses required to prepare the roller for refurbishing.

Depending on the measurements, we can decide if it is best to simply grind the roller in the traditional way or to use our plasma cutting process to remove the old hardface areas. This way we can ensure that we start welding on a level, cylindrical roller, which will give us the best possible result.

1–3 mm

TRADI- TIONAL

GRINDING

> 3 mm

NEW

PLASMA LEVELING

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With our plasma cutting process we can level the surface of the roller without the use of carbon electrodes. This gives us a level roller surface which can be directly welded on, depending on the initial condition of the roller and the crack development in the roller ground material.

Unlike traditional carbon electrodes this process is fully automated, making it much faster and easier to carry out. It also helps reduce the consumables used during the removal of the remaining hardfacing.

automated plasma leveling

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If the roller has worn reasonably level and is in good condition, but the hardface is worn out, then it is not necessary to plasma cut the roller. The normal method of roller grinding can be applied. For this we provide industrial belt grinding machines that are capable of removing large quantities of material in a relatively short amount of time, when compared to grinding wheels. This, combined with the greater width provided by the grinding belt, ensures the fastest possible grinding method for the rollers.

grinding

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Preheating is completed by our specially built induction units and coils. It is possible to heat the complete roller at 30˚C/hour to reach the required welding temperature within a single shift. KHD induction units can simply be plugged in, eliminating the dangers of working with gas bottles and hoses. The cables and induction coils never become hot, eliminating the dan-ger of burning and reducing hot air flow to the bearings, thus minimizing the risk of damage to the bearing during the welding process.

unrivaled preheating

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Welding on site can be carried out using different processes, according to your requirements. The preferred method is to use open arc welding wire as it is more efficient, but gas shielded wires can also be used. In order to increase the speed of welding, we use two independent welding heads. This gives us the option to continue welding in the event that one machine has a breakdown. When both machines are running we can weld at double the speed. We can also weld with oscillation and do fully automated profile welding.

welding

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With a large installed base of Roller Presses and over 155 years of experience in the cement industry, KHD is a global leader in Roller Press (RP) equipment and services. To monitor the wear of your rollers and guide you towards increased roller life and longer CHF surface life, our RP experts provide regular follow up after rewelding.

follow up

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CEMENTING A STRONGER FUTURE

CSC Asia Pacific

KHD Humboldt Wedag MachineryEquipment (Beijing) Co. LtdThe North Star Times Tower, Suite 1301-13038 East Beichen Road,Beijing, China 100101Tel: +86 10 6500 4101

CSC India / Sub-Sahara AfricaService Point South Africa

Humboldt Wedag GmbH31 Isando RoadIsando, JohannesburgSouth AfricaTel: +27 119 292911

For more information on KHD Roller Press Refurbishing and related audits, please contact your local Customer Service Center (CSC).

CSC Americas

Humboldt Wedag Inc.400 Technology ParkwayNorcross, Georgia 30092, USATel: +1 770 810 7300

CSC Asia PacificService Point Malaysia

Humboldt Wedag Malaysia Sdn, Bhd.Etiqa Twins,Suite 25, Level 25, Tower 2,No.11, Jalan Pinang, 50450,Kuala LumpurMalaysiaTel: +60 3 2726 9902

CSC Russia/CISService Point Russia

OOO KHD Humboldt EngineeringMjasnizkaja ul., 24/7, Office 108Moscow 101000, RussiaTel: +7 495 623 3480

CSC Russia/CIS

ZAB Zementanlagenbau GmbHBrauereistr. 1306847 Dessau-RosslauTel: +49 340 5029 0

CSC India / Sub-Sahara Africa

Humboldt Wedag India Pvt. LtdA – 36, Mehtab HouseMohan Co-operative Industrial EstateMathura Road New Delhi, 110044, IndiaTel: + 91 11 4210 1100

CSC AmericasService Point Brazil

Humboldt Wedag do Brasil Servicos Technicos Ltda.Av Sao Joao 2375Sala # 1102Sao Jose dos Campos - SP12242-000 - Brasil Tel: +55 (31) 3658

Service Point Saudi Arabia

Humboldt Wedag GmbHP.O. Box 380Jeddah 21411Kingdom of Saudi ArabiaTel: +966 2 671 7121

Group Support Center KHD Humboldt Wedag International AGColonia-Allee 351067 CologneGermanyTel: +49 221 6504 0info@khd.com

Service Point Turkey

Humboldt Wedag GmbH TurkeyWindowest TowerEski Büyükdere Cad. No: 26Kat. 6 Ofis No: 614, Maslak, Istanbul, TurkeyTel: +90 212 999 37 82