WNCC Line I

Daily Plant Report

Wednesday, July 15, 2020 From : 0

Crusher Raw Mill Kiln Cement Mill

Packing Power Condition Monitor Stack emission

Total run Avarage

Summary Totals
hours t/h

Crusher 0.00 0.00

Raw Mill 0.00 0.00 #DIV/0!
Kiln 0.00 0.00 0
Cement 24.00 6658.25 277
Coal Mill 0.00 0.00 #DIV/0!
Packer Machine 1 14.06 1484.65 105.61
Packer Machine 2 10.60 1138.60 107.42
Packer Machine 3 7.53 700.95 93.05
Cement Bags Dispatch 3324.20 306
Cement BLK Sales 2575.40
 Main
Crusher Area
Date : 7/15/2020
Production Process Details
Description Unit Value Description Unit Value
Crusher Feed Total Tons Air Receiver, Pressure Bar
Crusher Feed Avg T/H
Crusher Weight Cell Avg T/H
Mix Production Tons 0
HG Production Tons

Utilisation % of Raw Materials

Description Unit Value
Lime Stone %
Clay %

Power Consumption
Description Unit Value
Hammer Crusher Energy kWH

Incoming Power Avg kW 32.71 Stoppage Detail

Incoming Power Tot kWH 785.01 Description Unit Value
Belt conveyor BC100 kWH 0 Total Crusher Run Time "A.Feeder" Hrs 0.0
LS AF Power kWH 0 Total Crusher Stop Time Hrs 24.0
Clay AF Power kWH 0.02 % Utilisation of Crusher % 0.0
Specific Power/Ton Feed Total kWh/T No of Stoppages of L.S. A.Feeder No. 0

Belt Conveyer Operation

Belt Unit Value
111BC200 Belt Conveyer Hrs 0.00
111BC210 Belt Conveyer Hrs 0.00
121BC100 Belt Conveyer Hrs 0.00
Crusher Motor Running Hrs 0.00
CAN Running Hrs 0.00

Laboratory Analysis
Crusher Analysis Lim. Max Max
LSF N/A 3410.18 3410.18
SM N/A 8.75 8.75
AM N/A -0.90 -0.90
CL 0.07-0.24 0.20 0.20
SO3 0.40-0.60 0.18 0.18

Crsh
Production Vs Specific Power Production.
1.00 Specific Power

0.90
0.80
0.70
0.60
0.50
0.40
0.30
0.20
 Main
Raw Grinding Area
Date : 7/15/2020
Production Process Details
Description Unit Value Description Unit
Mill Feed - Avg T/H #DIV/0! Mill Inlet Draft mbar
Mill Production on Wet Basis T/D 0 Mill Inlet temperature Deg C
Mill Production on Dry Basis T/D 0 Mill Outlet temperature Deg C
Raw Mix Consumption (wet) T/D Mill Diffrential Pressure mbar
HG Limestone Consumption (wet) T/D Mill Main Drive Load KW
SandConsumption (wet) T/D Mill Fan Load KW
Iron Ore Consumption (wet) T/D Pre Heater / Filter Fan Load KW
Clinker Factor % Roller Hydraulic Pressure bar

Utilisation % of Raw Materials Reject Bucket Elevator Load %

Description Unit Value Silo Bucket Elevator Load %

Raw Mix Usage % Table Bed Thickness Avg mm
HG Limestone Usage % Mill Vibration mm/Sec
Sand / Kaolin Usage % Mill Separator Speed rpm
Iron Ore Usage % CF Silo Level %

Fuel consumption in HGG Mill Motor Vibration mm/Sec

Description Unit Value Water consumption (spray) m3/day

Gas - Avg. Nm3/H 0.0 CT Inlet Teprature Deg C
Gas- Tot. Nm3 0 EP Inlet Teprature Deg C

Oil -Avg. Kg/H 0.0 Stoppage Detail

Oi- Tot. T 0 Description Unit
Total Mill Run Time Hrs

Power Consumption Total Mill Stop Time Hrs

Description Unit Value % Utilisation of Mill %

Mill Main Drive Power KW/D No of Stoppages of Mills No

Mill Fan Power KW/D No of feed cut No

Mill Separator Drive Power KW/D
BC600 Power KW/D
BC620 Power KW/D
Mill Total Power KW/D 0
Mill Specific Power/Ton Feed KWh/T

Raw Mill Analysis Lim. Avg Max

LSF 96.0 - 106.0
SM 2.24 - 2.3
AM 1.35 - 1.45
SO3/ALK Ratio 0.4 - 1.8

Laboratory Analysis
Raw Mill Product Analysis Lim. Avg Max
Residue - 200 um (Dry) 1.0 - 3.5
Residue - 90 um (Dry) 9.0 - 15.0
Moisture H2O 0.40 - 0.75
SO3 0.40 - 0.60
CL 0.80 - 0.26

sand
Production Vs Specific Power Total Feed HG
HG
1
Specific Power ,sand
1 and Residue 90um Res9
1 1 0
1 1
1 1
1 1
1 1
0 0
0 0
0 0
0 0
0 0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
0

Value

88.49

Value
0.0
24.0
0.0
0.0
1 22 23
 Main
Kiln Area

Production
Description Unit Value
Kiln Feed - Avg T/H
Kiln Feed Tot T/D
Clinker Production Avg T/H
Clinker Production Tot T/D 0
Clinker Factor %

Fuel Consumption
Description Unit Value
Gas at main Burner - Avg Nm3/H 0.0
Gas at main Burner - Tot Nm3 0.0
Gas at Calciner Burner - Avg Nm3/H 0.0
Gas at Calciner Burner - Tot Nm3 0.0
Oil at main Burner- Avg. Kg/H 0.0
Oil at main Burner- Tot t 0.0
Oil at Calciner Burner- Avg. Kg/H 0.0
Oil at Calciner Burner- Tot t 0.0
Coal at main Burner- Avg. T/H 0.0
Coal at main Burner- Tot t 0.0
Coal at CalcinerBurner-Avg. T/H 0.0
Coal at CalcinerBurner- Tot t 0.0
Total Coal Consumed t 0.0
Total Oil Consumed t 0.0
Total Gas Consumed Nm3 0.0
Total Gas Consumed at 6:00 AM (burners+ RM HGG) Nm3 0
Total Heat Consumption Kcal 0.0
Kiln Specfic heat consumption Kcal/KgCL #DIV/0!
Power Consumption
Description Unit Value
ID Fan Power Kwh
Cooler Fans + Excess air Fan Kwh 0
Cooler Drives Kwh
Cooler Crusher Kwh
Kiln Drives Kwh 0.0
Main EP Fan Kwh 0
Total Power Kwh 0.00
Specific Power Kwh/t #DIV/0!
Laboratory Analysis
Kiln Feed Analysis Lim. Avg Max
SiO2 N/A
Al2O3 N/A
Fe2O3 N/A
CaO N/A
LSF 96.0 - 106.0
SM 2.24 - 2.32
AM 1.35 - 1.45
Residue -200 um 1.0 - 3.5
S/Alk Ratio 0.4 - 1.8
SO3 0.40 - 0.60
Cl 0.26 - 0.80
Clinker Analysis Lim. Avg Max
C3S 42.0 - 65.0
C2S 10.0 - 35.0
C3A 5.5 - 8.0
 Date : 7/15/2020
Process Details
Description Unit Value
Liquid Phase %
Calciner Temperature Deg C
Kiln Torque Nm
NOX ppm
Kiln Speed Rpm

Degree of Filling %

By Pass dust rate %

Tertiary Air Temperature Deg C
Secondary Air Temperature Deg C
ID Fan Inlet Temperature Deg C
ID Fan Power KW
ID Fan Speed %
Kiln Inlet O2 %
Kiln Inlet CO %
PreHeater Exit O2 %
PreHeater Exit CO %
By Pass CT inlet temp. Deg C

By Pass CT outlet temp. Deg C

By Pass Ctfan speed Rpm #VALUE!

Stoppage Detail
Description Unit Value
Kiln Total Run Time Hrs 0.0
Kiln Total Stop Time Hrs 24.0
% Utilisation of Kiln % 0.0
No of Stoppages No 0.0

Kiln Specfic
Kiln ENERGY & Kiln Specfic heat consumption
heat
0 consumption

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19ENERGY
20 21 22 23 24
0

KF
Kiln Feed Vs Specific Power Specific
1 Power

1
1
1
1
1
0
0
0
0
0
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
 Main
Cement Grinding Area
Date : 7/15/2020
Production Process Details
Description Unit Value Description Unit
Mill Feed - Avg T/H 277 Mill Inlet Draft mbar
Mill Production T/D 6658 Mill Inlet temperature Deg C
Mill Feed - Avg (Set Point) T/H 273 Mill Outlet temperature Deg C
Clinker Consumption T/D 5737 Mill Diffrential Pressure mbar
Gypum Consumption T/D 574 Mill Main Drive Load KW
Additives Consumption T/D 347 Mill Fan Load KW
Roller Hydraulic Pressure bar
Bucket Elevator Load %

Utilisation % of Raw Materials Table Bed Thickness mm

Description Unit Value Mill Vibration mm/Sec

Clinker Usage % 87.68% Mill Separator Speed %
Gypum Usage % 8.77% Cement Silo1 Level %
Addatives Usage % 3.54% Cement Silo2 Level %

Fuel Consumptionin HGG

Description Unit Value
Gas- Avg Nm3/H N/A
Gas-Tot Nm3 N/A Stoppage Detail
Oil- Avg Kg/H N/A Description Unit
Oil-Tot t N/A Total Mill Run Time Hrs

Power Consumption Total Mill Stop Time Hrs

Description Unit Value Grinding Aid Run Time Hrs

Mill Main Drive Power KW/D 119375 % Utilisation of Mill %
Mill Fan Power KW/D 62828 No of Stoppages of Mills No
Mill Separator Drive Power KW/D 501.27 No of feed cut No

Mill Total Power KW/D 182704

Mill Specific Power/Ton Feed KWh/T 27.44
Laboratory Analysis
Cement Mill Lim. Avg Max
Residue - 45 um (Dry) 10.0 - 16.0 18.96 21.20
Residue - 90 um (Dry) 0.6 - 2.0 1.80 2.20
Blaine 2800 - 3150 2830.17 2923.00

Cement Mill Lim. Avg Max

SO3 2.0 - 2.8 3.16 3.83
Cl 0.02 - 0.10 0.08 0.09
Temperature 100 - 120 100.23 103.50

Production Vs Specific Power Total Feed

Blaine
Specific Power CM_BLAINE
7700 2950

7600 2900

7500 2850

2800
7400
2750
7300
2700
7200
2650
7100
2600
7000 2550
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
0

Value
3.26
89.75
100.08
35.79
5005.77
2287.24
132.84
37.68
20.77
0.72
62.59
50.84
51.33

Value
24.0
0.0
24.00
100.0
0.0
0.0
22 23
 Main
Coal Mill Area
Date : 7/15/2020
Production Process Details
Description Unit Value Description Unit Value
Mill Feed - Avg T/H #DIV/0! Mill Inlet Draft mbar
Mill Production T/D 0.0 Mill Inlet temperature Deg C
Mill Feed - Avg (Set Point) T/H Mill Outlet temperature Deg C
Raw Coal Consumption T/D Mill Diffrential Pressure mbar
Pet Coke Consumption T/D Mill Main Drive Load KW
Coal Feeder Calciner T/D Mill Fan Load KW
Coal Feeder Main Burner T/D Table Bed Thickness Avg mm
Total Material Fed to Raw Coal Bin T/D Roller Hydraulic Pressure bar
Total Material Fed to Pet Coke Bin T/D 4.5 Screw Pump Load %
Mill Vibration mm/Sec

Utilisation % of Raw Materials Mill Separator Speed %

Description Unit Value Raw Coal Bin Level % 0.01

Raw Coal Usage % Pet Coke Bin Level % 0.02
Pet Coke Usage % Main Burner Coal Meal Bin Weight t 1.43
Calciner Burner Coal Meal Bin Weight t 2.32

Power Consumption
Description Unit Value Stoppage Detail
Mill Main Drive Power KW/D Description Unit Value
Mill Fan Power KW/D Total Mill Run Time Hrs 0.0
Mill Separator Drive Power KW/D Total Mill Stop Time Hrs 24.0
Mill Total Power KW/D 0 % Utilisation of Mill % 0.0
Mill Specific Power/Ton Feed KWh/T No of Stoppages of Mills No 0.0
No of feed cut No 0.0
Coal Feeder Calciner Run Time Hrs 0.0
Coal Feeder Main Burner Run Time Hrs 0.0
 Main
Condition Monitor
Date : 7/15/2020
Kiln Data Vibration
Support Bearing Temperature Others ID Fan Main EP Fan Excess Fan RM Fan RM
Axial Mig. Mig. Mig. GB
Hour T1-B1 T1-B2 T1-B3 T1-B4 T2-B1 T2-B2 T2-B3 T2-B4 T3-B1 T3-B2 T3-B3 T3-B4 pres. pos. T1 T2 T3 NDE DE NDE DE NDE DE NDE DE Base
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23

Avg. Point not found

Max. Point not found
 Main
Power
Date : Date : 7/15/2020
Raw Mill Kiln

Specific Cooler Fans, Cooler Cooler Main EP Specific

Hour Mill Motor Fan Motor Seperator Feed ID Fan Kiln Drive Clinker
Power Excess air Fan drives Crusher Fan Power

0 0.00 0.0 -0.4 0.0 0.0 0.00

1 0.00 0.0 -0.4 0.0 0.0 0.00
2 0.00 0.0 -0.4 0.0 0.0 0.00
3 0.00 0.0 -0.4 0.0 0.0 0.00
4 0.00 0.0 -0.4 0.0 0.0 0.00
5 0.00 0.0 -0.4 0.0 0.0 0.00
6 0.00 0.0 -0.4 0.0 0.0 0.00
7 0.00 0.0 -0.4 0.0 0.0 0.00
8 0.00 0.0 -0.4 0.0 0.0 0.00
9 0.00 0.0 -0.4 0.0 0.0 0.00
10 0.00 0.0 -0.4 0.0 0.0 0.00
11 0.00 0.0 -0.4 0.0 0.0 0.00
12 0.00 0.0 -0.4 0.0 0.0 0.00
13 0.00 0.0 -0.4 0.0 0.0 0.00
14 0.00 0.0 -0.4 0.0 0.0 0.00
15 0.00 0.0 -0.4 0.0 0.0 0.00
16 0.00 0.0 -0.4 0.0 0.0 0.00
17 0.00 0.0 -0.4 0.0 0.0 0.00
18 0.00 0.0 -0.4 0.0 0.0 0.00
19 0.00 0.0 -0.4 0.0 0.0 0.00
20 0.00 0.0 -0.4 0.0 0.0 0.00
21 0.00 0.0 -0.4 0.0 0.0 0.00
22 0.00 0.0 -0.4 0.0 0.0 0.00
23 0.00 0.0 -0.4 0.0 0.0 0.00

Avg. 0.0 0.0 -0.4 0.0 0.0 0.0

Total 0.0 0.0 0.0 0.0 N.A. 0.0 0.0 0.0 -9.2 0.0 0.0 0.0 N.A
 Main

Dust Main EP
1
Main EP Cooler Cement Coal
Hour 0.9
Mg\m3 Mg\m3 Mg\m3 Mg\m3 0.8
0.7
7 0.00 0.00 16.64 0.00
0.6
8 0.00 0.00 8.55 0.00 0.5

9 0.00 0.00 8.21 0.00 0.4

0.3
10 0.00 0.00 8.17 0.00 0.2
11 0.00 0.00 16.11 0.00 0.1
0
12 0.00 0.00 7.28 0.00
7 8 9 10 11 12 13 14 15 16 17 18
13 0.00 0.00 7.18 0.00
14 0.00 0.00 7.99 0.00
15 0.00 0.00 16.57 0.00
Dust Cooler
16 0.00 0.00 8.53 0.00 1.00
17 0.00 0.00 8.21 0.00 0.90
0.80
18 0.00 0.00 8.99 0.00 0.70
19 0.00 0.00 16.80 0.00 0.60
0.50
20 0.00 0.00 8.46 0.00
0.40
21 0.00 0.00 7.72 0.00 0.30

22 0.00 0.00 8.09 0.00 0.20

0.10
23 0.00 0.00 17.12 0.00 0.00
0 0.00 0.00 9.29 0.00 7 8 9 10 11 12 13 14 15 16 17 1

1 0.00 0.00 9.66 0.00

2 0.00 0.00 10.04 0.00
3 0.00 0.00 17.39 0.00
Dust BY Pass
4 0.00 0.00 8.27 0.00
1.00
5 0.00 0.00 7.46 0.00 0.90

6 0.00 0.00 7.01 0.00 0.80

0.70
0.60
Avg. 0.00 0.00 10.41 0.00 0.50
Max. 0.00 0.00 250.11 0.00 0.40
0.30
Time more than 23:59 0:00 23:59 23:59 0.20
100 Mg\m3 0.10
0.00
7 8 9 10 11 12 13 14 15 16 17
 STACK DUST EMISSION

11 12 13 14 15 16 17 18 19 20 21 22 23 0 1 2 3 4 5 6

11 12 13 14 15 16 17 18 19 20 21 22 23 0 1 2 3 4 5 6

Coal
Mg\m3

0 11 12 13 14 15 16 17 18 19 20 21 22 23 0 1 2 3 4 5 6
 Daily brief
Wednesday, July 15, 2020

Production
Summary Hrs Production tons Stock
Kiln/Clinker 0.00 0.00 162288.48
Mill/Cement 23.99 6658.25 16479.90
 Sales & dispatch
Sales\Dispatch Cement Bags Cement BLK Total
Yesterday 3020.08 2390.13 5410.21
Total up to date

162289.36
15231.86
Clinker
0.00
 Main

CEMS1_COCEMS1_SO CEMS1_NOCEMS1_O2851AM850A0851AM850A851AM850A
Main Stack Coal Stack

Hour CO SO2 NO O2 CO SO2 NO

7 0.00 0.00 16.42 23.11 0.00 0.00 0.00

8 0.00 0.00 16.43 23.11 0.00 0.00 0.00
9 0.00 0.00 16.37 23.11 0.00 0.00 0.00
10 0.00 0.00 16.35 23.10 0.00 0.00 0.00
11 0.00 0.00 16.27 23.10 0.00 0.00 0.00
12 0.00 0.00 16.29 23.10 0.00 0.00 0.00
13 0.00 0.00 16.22 23.10 0.00 0.00 0.00
14 0.00 0.00 16.33 23.09 0.00 0.00 0.00
15 0.00 0.00 16.57 23.11 0.00 0.00 0.00
16 0.00 0.00 16.65 23.12 0.00 0.00 0.00
17 0.00 0.00 16.99 23.13 0.00 0.00 0.00
18 0.00 0.00 17.09 23.14 0.00 0.00 0.00
19 0.00 0.00 17.13 23.15 0.00 0.00 0.00
20 0.00 0.00 17.27 23.16 0.00 0.00 0.00
21 0.00 0.00 17.16 23.16 0.00 0.00 0.00
22 0.00 0.00 17.16 23.16 0.00 0.00 0.00
23 0.00 0.00 17.10 23.16 0.00 0.00 0.00
0 0.00 0.00 17.09 23.16 0.00 0.00 0.00
1 0.00 0.00 17.07 23.17 0.00 0.00 0.00
2 0.00 0.00 16.82 23.17 0.00 0.00 0.00
3 0.00 0.00 16.65 23.15 0.00 0.00 0.00
4 0.00 0.00 16.40 23.14 0.00 0.00 0.00
5 0.00 0.00 15.96 23.12 0.00 0.00 0.00
6 0.00 0.00 15.72 23.11 0.00 0.00 0.00
7
Avg. 0.00 0.00 16.65 23.13 0.00 0.00 0.00
Max. 0.00 0.00 22.07 23.20 0.00 0.00 0.00
 851AM850A01A01
ack

O2

21.22
21.21
21.21
21.20
21.20
21.20
21.19
21.20
21.22
21.24
21.24
21.24
21.24
21.23
21.22
21.23
21.23
21.23
21.23
21.24
21.24
21.23
21.21
21.21

21.22
21.29
 Main
Gypsum Crusher Area
Date : 7/15/2020
Production Stoppage Detail
Description Unit Value Description Unit Value
Crusher Feed Total Tons 921 Total Crusher Run Time "A.Feeder" Hrs 8.9
Crusher Feed Avg T/H 104 Total Crusher Stop Time Hrs 15.1
Gypsum Tons 574 % Utilisation of Crusher % 37.0
Additives Tons 347 No of Stoppages of Crusher No. 7.0

Power Consumption Belt Conveyer Operation

Description Unit Value Belt Unit Value
Hammer Crusher Energy kWH 4678 BC200 Belt Conveyer Hrs 22.42
Incoming Power Avg kW -567.8289 BC320 Belt Conveyer Hrs 22.76
Incoming Power Tot kWH -5406.98 BC340 Belt Conveyer Hrs 0.00
Crusher Motor Running Hrs 9.52
Specific Power/Ton Feed kWh/T -9.42
 Main
Cement Packing Area
Date : 7/15/2020
Production Process Details
Description Unit Value Description Unit Value
Total Cement Bags Dispatched Ton 3324 PC 1 bags counter Bags 29693
Packing Machine 1 dispatch rate average T/H 105.61 PC 2 bags counter Bags 22772
Packing Machine 2 dispatch rate average T/H 107.42 PC 3 bags counter Bags 14019
Packing Machine 3dispatch rate average T/H 93.05 Total Bags consummption Bags 66484
Bulk Cement dipatched Ton 0.00 cement silo gates running status
Total Cement Dispatched Ton 3324

Stoppage Detail
Description Unit Value
Total packing machine 1 running hours Hrs 14.1
Total packing machine 2 running hours Hrs 10.6
Total packing machine 3 running hours Hrs 7.5
Total packing machines running hours Hrs 32.2
Packing machine 1 utilization % % 58.6
Packing machine 2 utilization % % 44.2
Packing machine 3 utilization % % 31.4
Bulk cement 1 utilization % %

Bulk cement 2 utilization % %

Power Consumption
Description Unit Value
Total Power cons. KW/D 8270
Specific Power consumpution KW/t 2
General Configuration
Input Ref date 7/15/2020 44028
Input FirstDayOfWeek 1
Input Report hour 0

Output Period: Day d

Output Period: Week w
Output Period: Month m
Output Period: Year y
Output SpotInterval: 10Sec 10Sec
Output SpotInterval: 20Sec 20Sec
Output SpotInterval: 30Sec 30Sec
Output SpotInterval: 1Min 1Min
Output SpotInterval: 5Min 5Min
Output SpotInterval: 6Min 6Min
Output SpotInterval: 10Min 10Min
Output SpotInterval: 15Min 15Min
Output SpotInterval: 30Min 30Min
Output Week no. of date 29
Output Start date of week 7/12/2020
Output End date of week 7/18/2020
Output Start date of Month 7/1/2020
Output End date of Month 7/31/2020
Output Days in month 31
Output Hours in month 744
Output Weekday number 4
Output Weekday name Sun
Output Day number 15
Output Month number 7
Output Month name Jul
Output Year number 2020
Output General date 15 July 2020

Input Start time 7/15/2020 0:00

Input End time 7/15/2020 23:00
 Main
Totalizer
Date : 7/15/2020
Crusher Raw Mill
Description Unit Value Last 24H Description Unit Value

Limestone Tons 15723926.000 Dosimat Mix Feeder Tons 21507442.000

0.000 Lime

Clay Tons 9723263.000 Dosimat limestone Feeder Tons 1533522.000

0.000 Clay

Mix Tons 26763002.000 dosax sand feeder Tons 319844.000

0.000 111

dosax iron ore feeder Tons 248113.000

Tons 23608920.000
raw mill total feed
112271.727
RM MWH MWH
216934.078
Raw mill fan MAH MWH

Seprator KWh KWh

0.000
Power cons. KW\ton

Raw mill Oprating hours 52752.930

with KW >500KW H
Value

0.000

0.000

0.000

0.000

0.000

0.000

0.000

0.000

0.000