New and innovative developments in the latest Plug&Grind® models
Since its presentation to the world in Ghana in 2011, Plug&Grind® has introduced new features in its development of its new modular and portable grinding stations.
First introduced was the Plug&Grind® Classic, with a production capacity of 90,000 t/y, with a ball mill Ø 2,2 x 9,5 m and 500kW. The first unit was sold in Kenya for Mombasa Cement.
A year later, Cemengal’s Plug&Grind® XL made its appearance. A cement grinding plant with a production capacity of 230,000 t/y: ball mill Ø 3,0 x 9,5 m and 1100 kW; bag filter for 50,000 m³/h. The “big brother” of the Classic model, it comprises eight containers and four special modules, delivered only in eight and a half months FOB.
As a result of the R&D department’s continuing investigations and modifications, the Plug&Grind® Fuels emerged late in 2014. This is a petcoke and coal-fuelled grinding plant with a production capacity of 130,000 t/y and a ball mill Ø 3,0 x 9,5 m and 1100kW. This is the fuels grinding station for which most cement players have been waiting. Eight containers and four special modules are delivered in eight and a half months FOB.
Spring 2015 saw the arrival of the Plug&Grind®XP4. This cement grinding plant is an XL model equipped with the new Magotteaux Classifier XP4®.
Magotteaux, as a historic partner of Cemengal, collaborated on the concept for the process sizing and tube mill internals as well as for the classifier.
The current development of its original classifier XP4® comes after 30 years of experience with the third-generation SD Sturtevant classifier, and the new XP4® is fully aligned with the growing success of Cemengal’s Plug&Grind® – a no less original concept.
This XP4®I classifier integrates the three functions in one unique body: the particle classification, the fan and the cyclone
The main advantages of this classifier are:
•Its compact design, which aligns perfectly with the full compact plug and grind concept. No ducting to one external fan, no external fan and a drastic reduction of the filter capacity and sizing as only 10% of the air classifier throughput (5000 m³/h) has to be utilised on top of the main mill process filter for dedusting
•Its own efficiency, which is fully comparable to latest classifier generation
•Its lower energy consumption due to the lower pressure drop also linked to the compact design, using the air rotation movements after the classifier cage for the integrated cycloning function
The production capacity is 230,000 t/y. It has a ball mill of Ø 3,0 x 9,5 m and 1100kW.
During this past summer, the very latest model of Plug&Grind® was launched to the market – the VP&G® Cement and Slag grinding station which has a production capacity of 17 t/h for GGBFS and 23 t/h for cement.
This new product will meet customers’ needs for energy savings and includes the latest technology in vertical mill products.
Any of the above models would provide the solution for investing in new markets, isolated markets, or just for major short-term projects.
Plug&Grind’s® short time to market after contract signature, as well as the modularity and portability of these grinding stations, makes the Plug&Grind® the ideal solution for most grinding projects in Africa.
In addition to all the above advantages, the Plug&Grind® is the only modular and portable grinding solution which has units already sold, operating and proven. To date, more than 20 units in three different continents are working for all kind of clients producing cement and slags.
In Africa we have sold two units in Uganda, two in Kenya, two in Mauritannia and two more units in two other African countries.
In summary, the main advantges of all Plug&Grind® models are:
Modular design: the Plug&Grind® Classic fits in just nine standard containers, and the Plug&Grind® Xl fits into eight standard containers and four special modules
Short time to market: delivery in under eight months
Preassembled in Spain: small and easy work on site
Easy to transport, erection and commissioning
Simple civil works
Simple operation and maintenance
Low staff numbers required to operate the Plug&Grind®
Strategic for penetration into new and/or small, niche markets.
For all the above reasons, we firmly believe Plug&Grind is the solution for an increasing number of markets worldwide.