5,000,000 kilowatts

of installed expertise
Innovative FLENDER vertical mill drives
for grinding coal, raw meal, slag and clinker.
siemens.com/verticalmilldrives

Answers for industry.

E20001-A370-P900-X-7600_EN.indd 1

03.04.13 11:25

5,000,000 kW
thats roughly equivalent to the gross power output of the most
important natural gas power plants in Germany. 5,000,000 kW
thats also the capacity of FLENDER vertical mill drives installed
internationally. For you, that means primarily three things: quality,
experience and versatility on the part of your drive technology
supplier.
FLENDER vertical mill drives are indispensable for those
who want the right solution for every vertical mill requirement, those who value sustainable, energy-efficient, optimized processes and those for whom drive availability and
safety have top priority in short, all those who want to
rely 100% on their drive technology.
In addition to first-class product quality and consultation
based on decades of experience and in-depth industry
expertise, we offer by far the most comprehensive portfolio of highly advanced, mature and proven drive solutions.
Whats more, we produce them ourselves from start to
finish.
With our global production concept and extensive expertise, thousands of references in all capacity classes and
partnerships with the worlds most significant OEMs
plus extraordinary, reliable customer service and the
entire might of the Siemens corporation we are the
right partner for all kinds of drives. We maintain good
customer relationships, treating both plant engineers and
end-users as peers and developing new solutions with
them, always with a view to the perfect result. This can
only be achieved with the outstanding technical expertise
of a leading innovator.

As the only system provider with expertise throughout the

entire drive train, we offer you investment security on one
hand and rapid response times on the other. Our global
setup and virtually seamless international service network, our formidable supply capacity and short delivery
times, our guarantee for complete systems and, last but
not least, our extraordinary price/performance ratio are
unrivalled the world over.
Because requirements in the vertical mill sector differ by
target product, we offer you special solutions and installation sizes for every application.

Product

Capacity range
Coal

Raw meal

KMP

Slag

Clinker

Optimum application range: 100 to 1,500 kW

KMPS

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

KMPP

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

EMPP

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

MultipleDrive

Optimum application range: 6,000 kW and up

2,000 kW

4,000 kW

6,000 kW

8,000 kW

10,000 kW

12,000 kW

14,000 kW

16,000 kW

Costs are crucial

not only in decisions regarding the procurement of the
gear unit, but also throughout the entire process and in
the availability of your plant. Efficiency and life cycle costs
play a critical role here, so its good to know that you can
depend on Siemens with regard to price, concept and
quality.
With over 4,000 tried and tested standard and special
solutions, we continue to prove that the highly advanced,
completely mature KMP gear units have set benchmarks
for grinding coal. As well as offering the right solution
for every available type of mill in the world, we will adapt
your gear unit to the mill design on request. To do this,
we rely on standards and design modules in order to guarantee a great deal of flexibility and quick realization. All
of our KMP gear units are ATEX 95 compliant and virtually
fault-free, based on statistics.
Accommodating process forces
For all vertical mill drives, we use maintenance-free tilting pad thrust bearings to accommodate the high axial
loads which arise during the grinding process due to
material hardness, mechanical process influences, and
mill technology and design. These bearings are available
with hydrodynamic or hydrostatic lubrication (fully hydrostatic) or with starting aids (partially hydrostatic).

While hydrodynamic thrust bearings are standard in the

KMP gear units used primarily for grinding coal due to the
low dynamics, fully hydrostatic lubrication is used in our
solutions for cement applications.
The pads are coated with babbitt, and their trapezoidal
shape allows optimum use of the gear unit installation
space. The resulting low surface pressure allows a thick oil
film to be generated along with good damping characteristics the uncontested advantages of this tried and
tested design. A continuous supply of fresh oil guarantees
optimum bearing cooling and dissipates the heat from the
mill. Extremely high-quality oil supply systems are used
here. These were developed specially by Siemens, are
produced at our own plant and are available in standard
versions. Built-in sensors monitor the temperature.
Hydrodynamic and hydrostatic lubrication
In hydrodynamic lubrication, oil is introduced into the
bearing by the rotation of the output flange. The bearings
tilt slightly toward the oil feed side and a wedge-shaped,
hydrodynamic oil film is formed. Due to the trapezoidal
pad design, the side flow is minimal and a stable, thick oil
film 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, fully
hydrostatic solutions can even be supplied for KMP. In this
case, the oil is forced into the bearing under high pressure. Each pad has its own connection and is always supplied with exactly the same amount of oil, regardless of
the load.

Coal grinding takes place in

power plants, but also in cement
plants, where it is mostly used
for heat production.

In addition, the hydrodynamic effect occurs here and oil is

drawn in on the inlet side. In this case, the oil film is
about twice as thick as with hydrodynamic lubrication.
High-pressure radial piston pumps are used to supply the
oil, and they ensure a consistent volume flow into the
bearing.
Our gear units are also very well suited for use with high
dynamic axial forces. The oil film on the tilting pad thrust
bearings is always thick enough because the actual interval of the dynamic forces is in fact too short to influence
the lubrication effect of the oil film in any critical way. In
practice, it takes just a fraction of a second.
The best in its class:
FLENDER KMP

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 production
concept, international service locations, wide variety of options

FLENDER gear units

that comply with Siemens quality standards are available all over the world. Siemens solutions are particularly
impressive in the mass market in capacity ranges up to
1,500 kW, not only because of their good energy balance,
but also due to their optional measuring sensor technology. This is another crucial factor for efficient processes
right from day one of production.
The Siemens material specification includes special steels
for these applications. The associated requirements have
been developed in thousands of reference projects and
demand even more specific characteristics than the international norm. This increases service life and reduces life
cycle costs.
The ribbed or corrugated form of the special housing
either steel welded or made of spheroidal graphite cast
iron also ensures that axial forces are introduced evenly
into the foundation through the housing. Not all housings
are created equal. Only those who have been casting for
decades understand the fine details and their great relevance in housing production. This is another particular
strength of Siemens gear units.

The grinding of raw meal, clinker

and slag is in the medium to high
power range. The right drive solutions: KMPS or KMPP.

Thanks to their high-quality design and manufacture,

outstanding bearings, first-class gear tooth geometry and
extraordinary housing stiffness, our gear units perform
excellently with respect to noise emissions.
In addition to all of these arguments, the process is always the decisive factor for mill plants. All over the world,
the continual pursuit of efficiency and productivity is not
only 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 confronted
with the challenge of output speeds falling as capacity
requirements increase, causing a disproportionate
increase in torques. But this has not been accompanied by
more installation space for gear units. To deal with the
problem of increasing transmission and power density at
the same time, gear unit technology has evolved from
three to four planetary gears in the output stage up to five
or six.

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)

Installation sizes

12

Transmission ratios

i = 30 to 55

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 production
concept, international service locations, wide variety of options

Planetary gear unit with

helical gear stage: FLENDER KMPS
7

Those who make decisions ...

should be allowed to doubt, but not have to. It doesnt
matter whether you make your choice based on capacity
requirements or experience, based on the available installation space or simply based on personal bearing preference every time you choose a FLENDER gear unit, you
are making the right choice. But we want to make the
decision easier and provide you with the right arguments
for 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 a
helical gear stage supported by a rolling bearing with
a planetary gear stage also supported by a rolling bearing.
Due to the high degree of plant individualization, the gear
units are available in hundreds of versions. Our global
production concept keeps high production and assembly
capacity available for KMPS so that large quantities can
be realized.

In the medium to high capacity range for clinker and slag

grinding, KMPP gear units are primarily used. Their high
power density is achieved by using two planetary gear
stages. The gear units in the KMPP series are entirely supported by sliding bearings. The advantage of sliding bearings is that they are better able to accommodate dynamic
loads which are generated in the process by various materials and hardnesses. Sliding bearings provide a robust,
durable solution in this scenario. The option of choosing
between sliding and rolling bearings for the gear units
caters for different customer preferences.
The patented corrugated shape of our housings and their
extremely effective, stable ribs are typical for larger
FLENDER vertical mill gear units. They offer greater flexibility for optimizing the sliding bearing arrangement and
enable the same housing to be used with different mill
connection geometries. Moreover, the modular structure
makes it possible to equip mills with the same dimensions
but different power requirements. The casting quality of
our housings alone should convince you. It provides outstanding damping characteristics.
The high demand for KMPS and KMPP gear units resulting
from retrofitting clearly demonstrates the high degree
of satisfaction in the market. So whatever your motivation
is to buy whichever FLENDER gear unit, you can be confident that you are making the right decision.

High-capacity, wear-free
planetary gear unit: FLENDER KMPP

High-capacity
drives are often
used in cement
production.

Process stability
Process stability is not just an expression: it is a major
goal for the entire cement industry all around the world.
Stability and safety in grinding ensure plant availability
and are the pivotal requirements for every vertical mill
drive. Their relevance increases exponentially with increasing mill power input.
Variable speed in drive technology plays a critical role in
stabilizing processes. Driven by technological possibilities,
the idea that bigger is better is continuing to gain currency in the cement world. Against this backdrop, this
often conservative market has come to agreement on one
thing: speed variability, drive intelligence and, with increasing plant size, modular drive systems are the critical
parameters for plant efficiency and success in the face of
growing demands with regard to torque and plant
availability.

FLENDER KMPP
Design

Bevel gear stage, 2 planetary gear stages

Capacity

3,000 to 8,000 kW

Installation sizes

Transmission ratios

i = 35 to 55

Torque

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

Axial bearings

Fully hydrostatic

Advantages

Tried and tested concept with approx. 200 references, wear-free,

high power density, standardized components
9

The functioning
drive train
is now reality. Siemens has always been convinced that
the drive train must be seen and understood as a whole.
We are the only provider in the world that offers complete
industrial drive systems. In the context of our integrated
drive system concept, complete drive solutions have
proved their worth in many industries and have become
standards upon which todays industrial drives are based.
In the cement industry and power generation, our gear
units have been an integral part of customer solutions for
many years. The inherent frequencies of the drive change
depending on the moment of inertia of the mill and the
motor. The drive train as a whole is a logical, goaloriented development to meet the requirements of our
customers.

For this reason, as well as providing a comprehensive

range of top-quality drive train components, Siemens
ensures that they are perfectly dovetailed with one
another from the initial concept to the functioning plant.
Siemens Integrated Drive Systems turn simple drive components into real systems. Drive technology based on IDS
guarantees maximum productivity, energy efficiency and
reliability in every area of automation and throughout the
entire life cycle.
Prevent risks at interfaces and opt for a system partnership with Siemens, supported by our tried and tested control technology.

Variablespeed drive
train with
converter and
squirrelcage
motor
SINAMICS frequency
converter

SIMOTICS
squirrelcage motor

FLENDER coupling

Fixed-speed
drive train
with slip ring
motor
Slip ring motor

10

FLENDER vertical mill

gear unit

FLENDER oil supply

system

Our component range includes:

Service

Transformers

Our global network of experts proactively and reliably

contributes comprehensive technology and product
knowledge to every project. This enables you to
benefit from the wide-ranging experience and indepth technological knowledge of our service experts
on-site in 190 countries, 24/7.

Frequency converters
Motors
C
 ouplings (including electrically
insulated couplings)
Auxiliary gear units/auxiliary drives
Maintenance drives
Main gear units
Oil supply systems
Sensor technology
Condition monitoring
Drive controls (CEMAT)
Financing

For example, our logistics specialists make up a comprehensive, international network of certified service
centers, ensuring that spare parts are supplied quickly
and reliably.
Condition monitoring
The Siemens condition monitoring system SIPLUS
CMS 4000 gives you the option to track temperatures,
vibrations, torques and displacements in the gear unit
online and evaluate trends. The fundamental advantages of the condition monitoring system are obvious:
irregularities trigger an alarm and corresponding
recording activity. Increasing vibration levels are recognized early on and required maintenance work can
be planned accordingly. In this way, damage is prevented or recognized at an early stage.
Our condition monitoring system has a special, crucial
feature: it was developed and programmed by the
leading provider of industrial drive technology and
offers you secure communication paths to monitor
your drives from anywhere. For data analysis, we
can offer you a telediagnostics service provided by our
own experienced condition monitoring experts.
On request, condition monitoring can also be
expanded for use with the entire drive train.

11

FLENDER SmartSeries
is a product portfolio of drive solutions in which realtime controls enable the unit to react immediately to
external influences such as factors associated with the
production process. Under demands to produce larger and
larger plant layouts with maximum availability, operators
are well advised not to rely solely on conventional solutions for the medium term, but instead to take the right
step toward the future with FLENDER SmartSeries products. With the FLENDER EMPP, this step is now possible
for vertical mill drives.
Specialists in the largest geared motors
As a provider of innovative drive technology, we have
developed a drive concept that was specially designed to
significantly increase the efficiency and availability of
large vertical mills. In the FLENDER EMPP drive unit, which
features extremely high capacity, an integrated synchronous motor supplied by a frequency converter ensures the
required drive power and, because the bevel gear stage
is eliminated, it reduces the number of active components
in the gear unit. The brushless permanent magnet motor
is particularly robust and completely wear-free. Because
of its static seals it has a high protection class and an
extremely durable stator winding.
With the FLENDER EMPP, Siemens has developed a drive
concept that both prevents load impacts due to short
interruptions in the electrical power supply and optimizes
power transmission between the drive and the mill. That
increases plant availability and results in an expansion of
the capacity range up to 12 MW. The greatest strengths
of the innovative EMPP concept are found here in the
high capacity classes because the closed unit delivers
ultra-quiet running under full load. The converter control
also contributes to the ongoing protection of your plant
against overloading because torsional vibrations caused
by the grinding process can be actively dampened via the
drive. The active (electrical) damping of the drive train
and the mill behavior with situationally based torque control can be seen as the greatest innovation.

12

Electronic Application Control

The drives in the FLENDER SmartSeries are equipped with
electronic application control (EAC), which offers the
operator active protection for the plant against overloading as well as comprehensive options for process
optimization.
At the heart of the EAC is situation recognition that functions in real time. In just fractions of a second, the loading
situation is evaluated and a control strategy adapted and
applied. The machine dynamics can be controlled directly
by the motor, and undesirable conditions (e.g. strong
vibrations) can be prevented. This generates active protection for the drive and plant against overloading as well
as continuous, stable running with far fewer interruptions
due to unanticipated events in the grinding process. The
visualization of the recognized operating situation in the
process control system enables operators to optimize the
process and extend their process expertise. Moreover, an
optional condition monitoring system (CMS) allows the
machines state to be diagnosed and enables the creation
of a maintenance plan.

Tested successfully in the field:

FLENDER EMPP

Electronic application control offers intelligent, real-time situation recognition

and uses the control strategy to realize long-term protection of the drive train and the plant.

Components

Result

Process control system

Benefit

visualizes

Operating situation

enables

Process optimization

shows

Machine state

leads to

Maintenance plan

Real-time situation recognition

and frequency converter

evaluates

Load situation

influences

Control strategy

Motor

delivers

Controlled
machine dynamics

results in

Active protection

Sensor
technology

CMS

Monitoring

Control

Especially with changes in the materials to be ground and

various starting materials, active vibration damping and
an adjustable grinding plate speed guarantee the greatest
degree of smooth running. This significantly optimizes the
grinding process and considerably improves grinding
results by dramatically increasing throughput, lowering
power consumption per ton or reducing the water spraying required, for example.

Easy conversion
If you wish to switch over from an existing KMPP drive to
a new EMPP drive, conversion times are easily manageable. EMPP drives have the same housing dimensions and
require the same foundations and plant designs. The twopart housing makes transportation and assembly as well
as on-site service easier. The conversion does not require
any complicated modifications to the overall construction.
The plant is soon ready to start operating again.

FLENDER EMPP
Design

Built-in synchronous motor, 2 planetary gear stages

Capacity

3,000 to 12,000 kW

Installation sizes

Transmission ratios

i = 40

Torque

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

Axial bearings

Fully hydrostatic

Advantages

Active damping with situationally based torque control, highest degree

of availability with variable speed, greatest power density with high degree
of efficiency, wear-free, same dimensions
13

Really large mills

need a unique drive concept. Siemens meets the growing need for extremely powerful, high-availability production plants with the FLENDER MultipleDrive. This drive
indisputably places us in the topmost segment for vertical
mill drives, where Siemens is currently the only provider.
Key considerations here are maximum output, minimum
downtime and the lowest possible life cycle costs. The
result: a concept that guarantees long-term availability
with the modularity of a multi-stage drive. Theoretically,
there are no limits to power input for this system. Depending on equipment, the concept currently provides for
an output capacity of 16.5 MW.

The MultipleDrive principle

A common girth gear is driven by two, three, four, five
or even six autonomous drive units. The synchronization
of the individual drives, each positioned on a carrier, is
performed by frequency converters that also enable the
speed to be adjusted to suit the various product qualities.
If one of the installed MultipleDrive units has to be serviced, it can simply be disengaged. The other units continue to drive the girth gear, preventing a complete production stoppage. The pre-arrangement of the drive units
on a carrier also makes it easier to replace the units
quickly. Moreover, the FLENDER MultipleDrive is not
sensitive to static radial forces, so it gives you greater
freedom, e.g. when servicing individual rollers.
The high control dynamics of the MultipleDrive with the
corresponding load distribution among the individual
drive units guarantees quiet running. In turn, this feature
and the adjustment of the speed to the grinding process
for various materials ensure optimum operating conditions for the drive system and, at the same time, an outstanding grinding result.

FLENDER MultipleDrive

14

Design

Squirrelcage motor, gear unit (bevel gear stage/helical gear stage),

grinding plate bearing (girth gear)

Capacity

4,000 to 16,500 kW (optimum application range: 6,000 kW and up)

Installation sizes

Transmission ratios

i = 50 to 120

Torque

1,200,000 to 8,000,000 Nm
(optimium application range: 2,500,000 Nm and up)

Axial bearings

Fully hydrostatic

Advantages

Highest capacity class, maximum availability with variable speed,

standard components with simple stocking, low overall height, not sensitive
to static radial forces

Other advantages
The lower overall height of the MultipleDrive in comparison with other vertical mill drives reduces factory and
operating costs because the material does not need to be
transported so far upward and the peripheral equipment
need not be so large. Of course, a suitable oil supply system directly on the drive is standard.
MultipleDrive also boasts optimum service options. The
simple, inexpensive stocking of small, standardized components can lead to invaluable advantages in plant
availability.
With the FLENDER MultipleDrive, we are offering a complete system with maximum availability and a modular
design from a single source. This modular system offers
the greatest possible flexibility in design and layout based
on customer needs.

Infinitely scalable:
the modular
FLENDER MultipleDrive
has endless possibilities

4.5 MW (3 x 1.5 MW)

8 MW (4 x 2 MW)

The high capacity range of the FLENDER MultipleDrive

enables two plants to be replaced by one plant with
significantly greater throughput, keeping the necessary
construction work to a minimum.

16.5 MW (6 x 2.75 MW)

The innovative concept of the FLENDER

MultipleDrive and its low overall height

15

Further information about gear units:

www.siemens.com/flenderapplications
www.siemens.com/empp
www.siemens.com/multipledrive
www.siemens.com/gearunits
Further information about couplings:
www.siemens.com/flendercouplings
Siemens partners near you:
www.siemens.com/drives-contact

Siemens AG
Industry Sector
Mechanical Drives
Alfred-Flender-Strae 77
46395 BOCHOLT
GERMANY

Subject to change without prior notice 04/13

Order-Nr.: E20001-A370-P900-X-7600
DISPO 27904
GD.MD.AP.XXXX.52.3.02 WS 04131.0
Printed in Germany
Siemens AG 2013

The information provided in this brochure contains merely

general descriptions or characteristics of performance which
in case of actual use do not always apply as described or
which may change as a result of further development of the
products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract.
All product designations may be trademarks or product
names of Siemens AG or supplier companies whose use by
third parties for their own purposes could violate the rights
of the owners.