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 …
… that’s roughly equivalent to the gross power output of the most
important natural gas power plants in Germany. 5,000,000 kW –
that’s 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 As the only system provider with expertise throughout the
who want the right solution for every vertical mill require- entire drive train, we offer you investment security on one
ment, those who value sustainable, energy-efficient, opti- hand and rapid response times on the other. Our global
mized processes and those for whom drive availability and setup and virtually seamless international service net-
safety have top priority – in short, all those who want to work, our formidable supply capacity and short delivery
rely 100% on their drive technology. times, our guarantee for complete systems and, last but
not least, our extraordinary price/performance ratio are
In addition to first-class product quality and consultation
unrivalled the world over.
based on decades of experience and in-depth industry
expertise, we offer by far the most comprehensive portfo- Because requirements in the vertical mill sector differ by
lio of highly advanced, mature and proven drive solutions. target product, we offer you special solutions and installa-
What’s more, we produce them ourselves from start to tion sizes for every application.
finish.
With our global production concept and extensive exper-
tise, thousands of references in all capacity classes and
partnerships with the world’s 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.

2
 Capacity range
Product
Coal Raw meal Slag Clinker

KMP
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

Multiple-
Drive 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

3
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 it’s 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 guar-
antee 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 tilt-
ing 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 hy-
drostatic) or with starting aids (partially hydrostatic).
4
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 character-
istics – 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 pres-
sure. Each pad has its own connection and is always sup-
plied 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 inter-
val 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

25,000 to 700,000 Nm
Torque
(optimum application range: 25,000 to 500,000 Nm)

Axial bearings Hydrodynamic, opt. starting aid, opt. fully hydrostatic

Tried and tested concept with approx. 4,000 references, global production
Advantages
concept, international service locations, wide variety of options

5
FLENDER gear units …
… that comply with Siemens quality standards are avail- Thanks to their high-quality design and manufacture,
able all over the world. Siemens solutions are particularly outstanding bearings, first-class gear tooth geometry and
impressive in the mass market in capacity ranges up to extraordinary housing stiffness, our gear units perform
1,500 kW, not only because of their good energy balance, excellently with respect to noise emissions.
but also due to their optional measuring sensor technol-
In addition to all of these arguments, the process is al-
ogy. This is another crucial factor for efficient processes
ways the decisive factor for mill plants. All over the world,
right from day one of production.
the continual pursuit of efficiency and productivity is not
only leading to evolution in mill design and layout – it
The Siemens material specification includes special steels is also raising awareness of variable-speed drive systems.
for these applications. The associated requirements have
been developed in thousands of reference projects and
Medium capacity range
demand even more specific characteristics than the inter-
national norm. This increases service life and reduces life In recent years, drive technology has been confronted
cycle costs. with the challenge of output speeds falling as capacity
requirements increase, causing a disproportionate
The ribbed or corrugated form of the special housing –
increase in torques. But this has not been accompanied by
either steel welded or made of spheroidal graphite cast
more installation space for gear units. To deal with the
iron – also ensures that axial forces are introduced evenly
problem of increasing transmission and power density at
into the foundation through the housing. Not all housings
the same time, gear unit technology has evolved from
are created equal. Only those who have been casting for
three to four planetary gears in the output stage up to five
decades understand the fine details and their great rele-
or six.
vance 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 solu-
tions: KMPS or KMPP.

6
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

600,000 to 2,500,000 Nm
Torque
(optimum application range: 600,000 to 1,800,000 Nm)

Axial bearings Fully hydrostatic

Tried and tested concept with approx. 400 references, global production
Advantages
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 doesn’t
matter whether you make your choice based on capacity
requirements or experience, based on the available instal-
lation space or simply based on personal bearing prefer-
ence – 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 world’s 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.
8
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 sup-
ported by sliding bearings. The advantage of sliding bear-
ings is that they are better able to accommodate dynamic
loads which are generated in the process by various mate-
rials 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 flexi-
bility 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 out-
standing 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 confi-
dent 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 in-
creasing 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 cur-
rency in the cement world. Against this backdrop, this
often conservative market has come to agreement on one
thing: speed variability, drive intelligence and, with in-
creasing 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 9

Transmission ratios i = 35 to 55

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

Axial bearings Fully hydrostatic

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

Advantages
high power density, standardized components

9
The functioning
drive train …
… is now reality. Siemens has always been convinced that For this reason, as well as providing a comprehensive
the drive train must be seen and understood as a whole. range of top-quality drive train components, Siemens
We are the only provider in the world that offers complete ensures that they are perfectly dovetailed with one
industrial drive systems. In the context of our integrated another from the initial concept to the functioning plant.
drive system concept, complete drive solutions have
Siemens Integrated Drive Systems turn simple drive com-
proved their worth in many industries and have become
ponents into real systems. Drive technology based on IDS
standards upon which today’s industrial drives are based.
guarantees maximum productivity, energy efficiency and
reliability in every area of automation and throughout the
In the cement industry and power generation, our gear entire life cycle.
units have been an integral part of customer solutions for
Prevent risks at interfaces and opt for a system partner-
many years. The inherent frequencies of the drive change
ship with Siemens, supported by our tried and tested con-
depending on the moment of inertia of the mill and the
trol technology.
motor. The drive train as a whole is a logical, goal-
oriented development to meet the requirements of our
customers.

Variable-
speed drive
train with
converter and
squirrelcage
motor
SINAMICS frequency SIMOTICS
converter squirrelcage motor

FLENDER vertical mill FLENDER oil supply

FLENDER coupling
gear unit system
Fixed-speed
drive train
with slip ring
motor

Slip ring motor

10
Our component range includes:
◾◾ Transformers
◾◾ 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
Service
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 in-
depth technological knowledge of our service experts
– on-site in 190 countries, 24/7.
For example, our logistics specialists make up a com-
prehensive, 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 advan-
tages of the condition monitoring system are obvious:
irregularities trigger an alarm and corresponding
recording activity. Increasing vibration levels are rec-
ognized early on and required maintenance work can
be planned accordingly. In this way, damage is pre-
vented 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 real- Electronic Application Control
time controls enable the unit to react immediately to
The drives in the FLENDER SmartSeries are equipped with
external influences such as factors associated with the
electronic application control (EAC), which offers the
production process. Under demands to produce larger and
operator active protection for the plant against overload-
larger plant layouts with maximum availability, operators
ing as well as comprehensive options for process
are well advised not to rely solely on conventional solu-
optimization.
tions for the medium term, but instead to take the right
step toward the future with FLENDER SmartSeries® prod- At the heart of the EAC is situation recognition that func-
ucts. With the FLENDER EMPP, this step is now possible tions in real time. In just fractions of a second, the loading
for vertical mill drives. 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
Specialists in the largest geared motors
vibrations) can be prevented. This generates active pro-
As a provider of innovative drive technology, we have tection for the drive and plant against overloading as well
developed a drive concept that was specially designed to as continuous, stable running with far fewer interruptions
significantly increase the efficiency and availability of due to unanticipated events in the grinding process. The
large vertical mills. In the FLENDER EMPP drive unit, which visualization of the recognized operating situation in the
features extremely high capacity, an integrated synchro- process control system enables operators to optimize the
nous motor supplied by a frequency converter ensures the process and extend their process expertise. Moreover, an
required drive power and, because the bevel gear stage optional condition monitoring system (CMS) allows the
is eliminated, it reduces the number of active components machine’s state to be diagnosed and enables the creation
in the gear unit. The brushless permanent magnet motor of a maintenance plan.
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 Tested success-
high capacity classes – because the closed unit delivers fully in the field:
ultra-quiet running under full load. The converter control FLENDER EMPP
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 con-
trol can be seen as the greatest innovation.

12
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 Benefit

Process control system visualizes Operating situation enables Process optimization

Sensor
CMS shows Machine state leads to Maintenance plan
technology

Real-time situation recognition evaluates Load situation influences Control strategy

and frequency converter

Controlled
Motor delivers results in Active protection
machine dynamics

Monitoring Control

Especially with changes in the materials to be ground and Easy conversion

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 spray-
ing required, for example.
If you wish to switch over from an existing KMPP drive to
a new EMPP drive, conversion times are easily manage-
able. EMPP drives have the same housing dimensions and
require the same foundations and plant designs. The two-
part 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 5

Transmission ratios i = 40

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

Axial bearings Fully hydrostatic

Active damping with situationally based torque control, highest degree

Advantages 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 grow-
ing need for extremely powerful, high-availability produc-
tion 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. De-
pending 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 ser-
viced, it can simply be disengaged. The other units con-
tinue to drive the girth gear, preventing a complete pro-
duction 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 condi-
tions for the drive system and, at the same time, an out-
standing grinding result.

FLENDER MultipleDrive

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

Design
grinding plate bearing (girth gear)

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

Installation sizes 4

Transmission ratios i = 50 to 120

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

Axial bearings Fully hydrostatic

Highest capacity class, maximum availability with variable speed,

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

14
 Infinitely scalable:
Other advantages
the modular
The lower overall height of the MultipleDrive in compari- FLENDER MultipleDrive
son with other vertical mill drives reduces factory and has endless possibilities
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 sys-
tem directly on the drive is standard.
4.5 MW (3 x 1.5 MW)
MultipleDrive also boasts optimum service options. The
simple, inexpensive stocking of small, standardized com-
ponents can lead to invaluable advantages in plant
availability.
With the FLENDER MultipleDrive, we are offering a com-
plete 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. 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 Subject to change without prior notice 04/13 The information provided in this brochure contains merely
Industry Sector Order-Nr.: E20001-A370-P900-X-7600 general descriptions or characteristics of performance which
in case of actual use do not always apply as described or
Mechanical Drives DISPO 27904
which may change as a result of further development of the
Alfred-Flender-Straße 77 GD.MD.AP.XXXX.52.3.02 WS 04131.0 products. An obligation to provide the respective character-
46395 BOCHOLT Printed in Germany istics shall only exist if expressly agreed in the terms of con-
GERMANY © Siemens AG 2013 tract.

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.