Anilkumar C.

M
Green Cementech 2010 Customer Service Projects - India
Up Grade Possibilities in Ce ment P lants
SUCESS STORIES
OF CEMENT PLANT RETROFITS
IN INDIA

KEERTI CEMENT S GRASIM CEMENTS - RAI PUR

Production increased from 900 TPD to 1600 TPD Production increased from 4275 TPD to 5328 TPD

MODIFICATIONS DONE MODIFICATIONS DONE

§ New ILC tower installed with 6-stage cyclones § New ILC tower installed with 6-stage cyclone

§ New PH fan § New PH Fan for ILC tower

§ Modification in TAD with hoisting damper § Kiln feed system for ILC tower

§ New CFG Cooler § New TAD for ILC calciner

ADVANTAGES ADVANTAGES

§ Specific heat consumption reduced by 100 kcal/kg cl § Specific heat consumption reduced by 8.0 kcal/kg cl

§ Specific power consumption for PH fan reduced by 5 kw hr/MT cl § Specific power consumption reduced by 7.8 kw hr/MT cl

AMBUJA CEMENT EASTERN LTD- RABRIYAWAS ACC - WADI

Production increased from 4200 TPD to 6230 TPD Production increased from 7300 TPD to 13000 TPD

MODIFICATIONS DONE MODIFICATIONS DONE

§ New SLC tower installed with 6-stage cyclone § New ILC twin tower

§ New PH fan for SLC tower § New SF 6x8 Cooler

§ New TAD for SLC Calciner § New Duoflex Burner

§ Modification in cooler CFG and RFT plates § Modification in kiln drive

ADVANTAGES ADVANTAGES
§ Specific heat consumption reduced by 12 kcal/kg cl § Specific heat consumption reduced by ~18 kcal/kg cl

§Specific power consumption for ph fan reduced by 5 kw hr/MT cl § Specific power consumption 16.4 kw hr/MT cl
 Reference List for Plant Upgrades
Examples …

Existing SLC + New ILC Existing ILC + New SLC

Grasim Raipur GACL Rabriyawas

ILC – In Lin e Calci ner

Imp rovement s I n Py ro Pro cess ing

Special advanta ges SLC-D - Separa te Li ne Cal ciner - Do wn draft

§ High material and gas retention time in calciner due to its large
volume and moderate swirl.

§ Regulation range of up to 60% bypass of kiln gas using ILC-I

version.

§ Well-suited for low-grade fuels

§ Long refractory life due to low thermal kiln load and stable kiln
coating

§ Lowest NOx emission among traditional calciner kiln systems

§ Higher fuel substitution rates

 SF Cro ss Ba r Coole r
Special advantages
Simple to Operate
§ High material and gas retention times § Mechanical Air-Flow Control
Simple to Maintain
§ Very well-suited for all fuel types, especially low-volatile fuels § No moving Grates
Higher Thermal Efficiency
§ Low NOx operation is possible.
§ Optimized air distribution
§ Smallest possible tower dimensions, as the calciner can be Modular Design
installed separately from the cyclone tower. § Reduced installation time and costs

§ Especially well-suited for retrofits of existing SP or ILC pre SF Cooler installed in India
heaters due to very short down time. 43
SF Cooler installed World wide
180
SF Cooler retrofits in India
5

Constan t Air Flow to Each G rate P late ABC (Air Blast Controlled) Inlet Coolers

Cast grates on
Internal sloped profile
check
valve

MFR’s
Flexible control of
• Blasting area

Air blaster • Blasting frequency

manifold • Blasting intensity
and pipes

Solution for Better Recuperation and removal of Snowman

AIR BEAM MFR 2n d N ew Tech & Equi pment for Cement Producti on 25 Sept 200 8

Heavy Duty Roll Breake r - MF

§ A combination of transport and crushing rolls in series
§ Permits fines to pass through predetermined gaps

§ Coarse is transported to the crushing rolls

§ Over-size material is broken into the required size by two heavy crushing rolls

Ball M ill Up Grade

Using High Ef ficiency Separators

 O-SEPA Se parator
SEPAX Separator
§ Compact separator to
facilitate easy installation
§ High efficiency separation with cage type rotor
§ High efficiency separation
§ Separator weight less due to self supporting
structure with cage type rotor

§ Dispersion in air stream simplifies transport to § Oil lubricated bearings for

separator and functions as nip trap maximum endurance

§ Ample wear protection § Cost efficient wear

protection by selection of
best fitted materials to the
individual components

R TK M Se parator

§ High efficiency separation with cage

type rotor enables economic and
very fine grinding of e.g. Petcoke

§ Design eliminates deposits of coal

dust, hence self ignition VRM –UPG RADE WITH H RP

§ Air stream transport simplifies lay

out

§ Ample wear protection

RAR Separator

§ High efficiency separation with cage

type rotor enclosed by guide vanes

VRM w ith § Fines are not returned to the mill

HRP C ircuit
§ Vibrations are not triggered even at
very high production rates

§ Selection of wear protection, for best

balance between cost and endurance

Ti t l e 5/19/2 01 0 23
 CLOSED CI RCUIT G RINDING SYSTEM WITH
RO LL P RESS AS PREG RINDE R

Imp rovement s in Ce ment G rinding Capacity

CLOSED CI RCUIT G RINDING SYSTEM WITH FLS - HRP

RO LL P RESS IN FINISH M ODE

ASC feed gate for roller press

By this new developed feed gate the roller
press skewing can be regulated back to
parallel service by adding relative more feed
in the side of rollers where the distance is
smallest thus resulting in more stable
condition for the roller press

Air + fi ne s ou tlet Fee d I nle t Air int et

§ NO MOVING PARTS

§ MAINTENANCE FREE
OPERATION FOR YEARS

§ CARRIES OUT 4 JOBS:

Ø SEPARATION OF FINES

Ø DEGLOMERATING
Sup por t
Ø DRYING OR COOLING
ALTE RN ATI VE FUE L SO LUTIO NS F ROM F LSMIDTH

Ø MIXING OF BOTH
FRESH FEED & REJECTS

Roller P ress G rit Sepa rato r

Rejec t ou tle t
 FLSmidth Key Products for Alternative fuels

FLSmidth calciner sol utions for Alternative Fuels 21 ins tallatio ns

5 ins tallatio ns

1. The HOTDISC solution

2. ILC calciner adapted for alternative fuel
3. SLC-D calciner with duoflex burner
4. Retrofits & other calciner types
N ew produc t
1 ins tallatio n

5 ins tallatio ns

150 ins tallati ons

68 ins tallatio ns 63 ins tallatio ns 37 ins tallatio ns

Inline calciner system

with a HOTDISC

Waste Hea t Recovery Syste m With F LS mid th

COLD RAW
MEAL BIN

RAW MEAL TO CALCINER

CALCINER AND
HOTDISC

TRIPLE FLAP TERTIARY AIR

SLUICE

HOTDISC

Why WHRS requir ed?

Typical Co-ge neration circuit
CDM Benefits

Clean & Green

Effective utilizatio n
of energy Env ironment

Waste H eat
step to energy Minimizing the
Recov er y
conservation utilization of CPP

Reduction in Carbon More independence from

Emission rising energy prices
L ower operation costs
by own power

Wast e Heat Recovery Syst em 35

Why FLSmidth for WHR Projects?
s
1) Better integration of Cement process to boiler system Wish you all the very best in your Green Initiatives
2) Continuous R&D to boost up heat to generate higher power with a
combustion chamber using alternative fuels
3) Combo package of alternative fuels and waste heat recovery
system to reduced production cost of cement.
4) FLSmidth Automation for WHRPP (Referen ce JK Lakh smi Cemen t s)
5) FLSmidth Electrical, Automation and Civil Design

6) Higher level of customer satisfaction.