Cement Energy & Environment

32 Roller press technology by KHD From conventional to green: upgrading existing plants for the future Ashok Kumar Dembla ,Venkatesh Vanam, Prakash Patil Humboldt Wedag India Private Limited, India ABSTRACT Energy saving is one of the foremost global priorities of the 21st century. In cement plants, grinding operations consume over two-thirds of the total electrical energy required to produce one ton of cement, making it both an ecological and economic challenge. The combination of Roller Press with advanced separator technology— offered through KHD’s Comflex® and GrindC® Grinding Systems—delivers the lowest specific energy consumptionper ton of product, positioning it as one of the most efficient solutions available. With nearly 400 successful Roller Press installations across raw material, clinker, and slag grinding, KHD brings extensive expertise to new projects as well as upgrades. The technology has proven effective in pre-grinder, semi-finish, and finish modes. Increasingly stringent carbon reduction targets are driving cement producers to adopt greener technologies in new plants, while older plants need transformation from traditional ball mills to energy-efficient Roller Press systems. Such upgrades not only lower specific power consumption but also increase production capacity. This paper outlines the technological options for both new installations and retrofit projects, supported by a detailed case study. 1.0 INTRODUCTION The concept of high-pressure grinding was first patented in 1977 by Prof. Klaus Schoenert. In the 1980s, KHD Humboldt Wedag pioneered its industrial application with the first Roller Press for slag pre-grinding. The subsequent invention of the V-Separator further accelerated global adoption of Roller Press technology as a standalone grinding solution. Over the decades, Roller Press systems have become a key element in cement