Lucky cement limited.

PEZU plant
[DETAIL TRAINING REPORT ON LINE TRACING
Main Indus Highway
KPK
& PROCESS UNDERSTANDING ON LINE 1]

[Type the author name]

[Type the author name]
The report is composed of the visits and detail information which is gathered &
compiled by Hamza Younas during the initial training about line tracing &
process understanding on Line 1. The various areas were visited under
supervision of Engr. Muhammad ALI PERVAIZ (Manager production Line1) and
the assistance of Engr. MATEEN Farooq (DM-Pyro kiln), Engr. INAAM (DM-Raw
Mill) & ENGR.AURANGZAIB(S.AM-Raw Mill) and all shift engineers.
DESIGNATION UNIT VALUE
Machine type - LM 69.6

Table nominal diameter Dm 69 dm= 69/10=6.9m or 6900mm

Number of grinding rollers - 6

Main Motor power Kw 5860

Voltage KV 6

speed rpm 995r/min

Table speed Rpm ≤21

Heater power for gearbox oil Kw 2

heating

Auxiliary motor Kw 5.5

Height m 29.4

Width m 22.7

Depth m 19.9

Throughput t/h 600

Product grain size %R 90µm Residue≤12%

Product moisture % H2O ≤0.5%

Rollers weight with slew Ton 35(25+10)

Rollers + slew+ rocker arm’s Ton 60

weight
Dam ring height mm 120

LOESCHE RAW MILL

 Process description
(TECHNICAL DATA)
The Loesch vertical roller mill for the grinding of raw mix primarily consist of;

1. The feed chut

2. The mill
3. The classifier
4. The mill gearbox with coupling and drive motor.
5. Hydraulic and lubrication control cabinets for the rollers

Via an Airlock the grinding stock is dropped in the feeding chute of the vertical roller mill. The material
comes at the Centre of table and begins to grind. Any pulverized stock that has not reached its final
grain size is rejected by the classifier according to its setting. The return material falls back into the
internal classifier with the hot gas flow to the dust precipitator.

A vertical roller mill is equipment used in both raw material & cement grinding. It consists of a rotating,
circular grinding table that turns around by a mechanical shaft, rollers which are pressed on the surface
of the table. A stream of gas flows upward around the table. Feed material enters at the center of the
table and travels by centrifugal force & passes under the roller. Where it is grinded and lifted by the
gases. Vertical mill performs four basic functions.

1. Grinding of material
2. Drying of material by hot gases
3. Separation of material & gas by separator
4. Material transport
The pros & corns of vertical mill are following
Advantages Disadvantages
Very compact workshop Investment cost

Larger feed size Prone to high Vibrations

Better grinding & low power consumption Need a good maintenance mastery
Can accept moisture up to 20 %
Vertical roller mills can be divided into two main types
1. Track guided (Polysius, Pfeiffer, Babcock, Claudius, Peters)
2. Lever Mounted (Lausche, Kawasaki, Raymond, etc.)
 Vertical Roller Mill Design

Some inside view of Raw Mill

 Raw mill feeding area
Equipment # Description
216BC14 Main feeding belt conveyor
216MS15 Magnetic separator
21683 Belt conveyor
216MY84 Metal detector
216MW85 chute
216RA86 Main rotary airlock

Raw mill reject area

216HO66 Reject bin
216NG67 Needle gate
216BC68 Belt conveyor
216MY69 Metal detector
216MW70 Divertor
216BE71 Bucket elevator
216BF (72+73) Bag filter
216BC74 Mill reject belt conveyor
 Mill grinding area
216SP45 Classifier
216DR46 Main drive of raw mill
216LU (47+48) Main reducer lubrication unit
216HU (49+92+93) Roller hydraulic unit
216LU52 Raw mill grease unit
216LU (50+99+AO) Roller lubrication unit
216LU95 Classifier gearbox lubrication unit
216LU96 Classifier grease unit

Raw meal transport area

216SG (56,57,58,59) Manual screw gate
216RA (60,61,62,63) Cyclone rotary airlock
216FU (92 & 93) Double flap
216FA64 Raw mill system fan
314FA03 Raw mill bag house fan motor
218AS01 Main air slide

Bag house transport sequence

314BH02CV03 Drag chain
314BH02CV04 Drag chain
314CV04 Main Drag chain
218BE03 Bucket elevator
314RA (15,16,17,18,19 & 20) Rotary airlock

Silo distribution system

218BE14 Beumer Bucket elevator
218AC15 Silo top main air slide
218D123 Distributor
218AS (25,26,27,28,29 & 30) Distribution air slides

Raw mill motors data

Description KW
Raw mill main feeding belt motor 216BC14 160
Raw mill main feeding belt motor brake 0.33

Raw mill main feeding belt bucket elevator motor 55

Raw mill feeding bucket elevator auxiliary motor 5.5

Raw mill main feeding belt motor BC83 30

Raw mill main feeding belt motor BC83 brake 200 W
Raw mill main feeding magnetic separator motor 2.2
Raw mill feeding building bag filter fan motor 18.5
Bag filter rotary 1.5
Raw mill main rotary motor 18.5
Raw mill cleaning fan 10.12
Raw mill feeding belt BC68 motor 7.5
Raw mill feeding belt BC74 motor 15
Raw mill auxiliary motor 5.5
Raw mill classifier motor 450
Raw mill classifier cooling fan motor 2.2
Raw mill classifier oil pump motor 1.3
Classifier grease motor 0.17
Raw mill lubrication low pressure oil pump motor 69
Raw mill lubrication high pressure pump 5.1
motor#1,2,3,4,5,6
HSLM (1-2-3) hydraulic station pressure 17
pump#1,2
HSMS PUMP 1.01
Reducer lubrication station bypass cleaning pump 10.1
Water spray pump motor
Raw mill classifier water spray pump motor#1,2 0.37
Raw mill cyclone rotary motor#1,2,3,4 5.5
Raw mill system fan motor 6700
Raw mill air slide fan motor#1,2,3 7.5
Raw mill conveying area bucket elevator motor 11
BE03M01
Raw mill conveying area bucket elevator motor 1.5
BE03M02
Raw mill conveying area bag filter fan motor BF10 15
Raw mill conveying area bag filter rotary motor 1.5
BF10
BF12 18.5
BF12 rotary 1.5
Raw mill sampler motor 0.18
Electric push rod#01,02 1.5
Raw mill silo bucket elevator auxiliary motor 18.5
 Raw mill Silo main bucket elevator motor 250
Silo top blower motor #01 30
Silo top blower motor #02 5.5
Silo top blower motor #03 7.5
Silo top blower motor #04 7.5
Silo top blower motor 11
Raw mill hot gas generator blaster motor 75
Hot gas generator lubrication pump motor
Raw mill cyclone top rotary motor #1,2 1.5
Divertor motor #1,2 1.5
Compressor house motor #1,2,3,4,5,6 132
Rheostat motor 0.55

216BC14
Raw material feed coming from Dosing/proportioning area to 216 BC83 via belt named as 216BC14.

Motor power, current, voltage

Item no Technical specification
216BC14 Capacity=790 t/h 160kw,285 A, 380V,50Hz
Raw material feed coming from Dosing/proportioning area to 216 BC83 via belt named as 216BC14.
Bucket elevator-216BE71
At the top Bucket elevator ’s motor also present beside the 216BC14 belt’s motor speed is 64.8m/min.

Motor specification
Power 55 KW
Voltage 380 V
Current 104 A
Frequency 50 HZ
speed 1485 RPM
Drive type Single drive right chain type
capacity 350 t/h
Height 31.9 m
Auxiliary drive motor 3 KW
Charge level indicator 1
Speed sensor 1
At the bottom, Bucket elevator takes up both chutes coming from mill reject’s belt BC74 and reject bin

Belt BC68 and drops on, At a top belt name BC83.

 216BC83
Material is coming from 216BC14 to 216BC83.Here is 2 chutes are dropping, One from 216BC14 Other
from Bucket elevator which is coming from the bottom (say reject bean & mill reject material)

Here, speed sensor, magnetic separator, metal detector(speed=1.25m/s), pull chord V-liner and belt
deviation switch are present.

Motor specification
Power 30 KW
Voltage 380 V
Frequency 50 HZ
Current 58.1 A
speed 1450 RPM
Belt capacity 950 t/h (max.1090 t/h)
Size B 1.400*12.700 m
Speed 1.2 m/s
 Divertor (216MW85)
Material from 216BC83 is coming in a chute, here it can divert either towards rotary or in reject bean. A
pneumatic 2-WAY VALVE is used for this purpose.

Size 800 X 800 mm

Pneumatic actuator 1
Solenoid valve (proximate switch) 1
power 0.85 KW
 REJECT Bin-216HO66
IF we don’t want to send material in raw mill than pneumatic 2-way valve(216MW85) operates and
material goes towards reject bin.

Sometimes a metal piece in a feed belt 216BC83 comes than it will recognize by metal detector, a two-
way valve operates and feed divert to reject bin.

Reject bean capacity is 120t.

Level transmitter used in reject bin for level indication. A needle valve (216NG67) is use at the bottom of
bin to adjust the flow from bin to reject belt 216BC68.
 Reject bin belt-216BC68
Size B 0.8 X 6.372 m
capacity 15-150 t/h
Speed 1.6 m/s
Inclination 0
VFD 5.5 KW
Voltage 380 V
Belt deviation switch 2
Pull chord 2
Speed sensor 1
Metal detector (216 MY69) 1 (B 0.8 m, speed=1.6 m/s)
Main Rotary Airlock-216RA86
Capacity 900 t/h
Rotor speed 0-6.7 RPM
Geared motor Power 15 KW
current 13.89 A, 610 Ton feed
ROTARY VALVE
Rotary valve is a valve which control the flow of feed at raw mill and helps in maintaining the pressure in
the mill.

Purpose of RA:
“To avoid the false air”

Note: if material drops from direct chute (diverter) instead of rotary than system fan works more and
suction pressure drops and more current will be consumed.
 Reject Mill Belt-216BC74
An extra raw material from the table passes through the nozzle rings comes down than with the help of
scrapper, material goes to 216BC74 via reject chute.

Size B 0.8 X 13.55 m

Capacity 300 t/h
Speed 1.25 m/s
Inclination 13.050
Power 15 KW
Current 29 A
Voltage 380 V
Frequency 50 HZ
The rejected material from the mill after passing through the reject belt 216BC74 is entre in a bottom of
Bucket elevator.218BS87 Belt scale and magnetic separator 216MS75 Is present here.
 Bag filter-216BF72
Gas flow 9000 m3/h
Gas temp <1200
Inlet consistency <200 g/Nm3
Outlet dust content ≤20 mg/Nm3
Compressed air 0.4 Nm3/min
Total Pulse valve 10

Bag filter fan-216FA73

Rotating direction Clockwise 450⸋
Gas flow 9639 m3/h
Pressure 3802 PA
power 18.5 KW
voltage 400 V
current 35.5 A
speed 1450 r/min
There is 3 suction point:
1. Hood of the bucket elevator at the top.
2. From 216BC83, where raw mix is fallings from 216BC14.
3. From the reject BIN.
 SeillngFan-216FA53
Power 10.12 KW
Voltage 380 V
Speed 1450 RPM
pressure 19 mbar
It is use for the cleaning the dust of rotary and rollers of raw mill.
 Classifier-216SP45
 Classifier type= LDC655RM
 Rotor diameter=6500 mm or 6.5 m
 Rotor speed range= 30-74, Rotor speed= 1500 rpm
 Gas flow= 130800 m^3/h
 VFD Motor (with reducer) =450 KW, Voltage= 6.3 KV
 Water pump for cooling of classifier’s gearbox lubrication=2 no
 Separators
Separator is used for the separation the required size particles and the rejected particles. Fine or
required size particles are collected through dust collectors while the rejected material is sent back to
the mill for further grinding.

Air separation usually involve most of the following components

 Feed inlet
 Air inlet
 Material dispersion
 Classifying mechanism
 Recovery of products from air
 Rejects collection

Raw and finish grinding are very energy intensive processes that accounts for a significant amount of
production cost of cement. Therefore, even small changes in efficiency of grinding process will be
worthwhile in reducing production cost.

Types of separators
There are different designs of air separator but they can be roughly grouped into five different types:

 Static separator
 Turbo separator
  Cyclone separator
 Cage type separator
 V separator

Static separator
The static separator is sometimes used to separate materials in the mill vent into two size fractions. The
finer material, which is already product size, is separated so it can be transported directly into the
storage without being fed into the main separator. It is usually located directly after the grinding system.
The air enters into the inner cone through a series of adjustable vanes that impart a swirling motion and
due to this swirling motion separation of course and fine materials take place. The coarse particles fall
by gravity and they are directed back to the grinding area for further processing. The parameter for
controlling the cut size of the separator is the length of the central tube/dip tube. Lengthening the tube
will give finer products. Except for the adjustable guide vanes, this unit has no moving parts, and is very
simple to operate. The inner cone is subjected to high abrasion and therefore must be protected with
wear resistant liners.

Static separator

Turbo separator
This type of separator was the first generation of dynamic separators to be widely used in the cement
industry. It is similar to the static separator except it has an internal mechanism that controls the
separation. Recently, turbo separators have also been called conventional separators to distinguish
them from the newer designs. They were, however, the standard of the industry for many years and
many are still in operation.
 Turbo Separator

Cyclone Separator
The cyclone separator uses most of the same operating principles as the turbo separator but has
external cyclones to recover the fines from the classifying air. The separator consists of the inner
housing with the classifying area, selector blades, dispersion plate, and rejects cone. The classifying air
leaves the separator via tangential outlets that help swirl the air and then goes to a series of cyclones
located around the separator. After the cyclones the air is combined by a manifold and then goes to a
conventional fan.

Therefore, the fan that moves the air in this type of separator is a more efficient design and has a
considerably reduced dust loading compared to the turbo design. The fan is now located downstream of
the area where most of the fines are removed from the air. Also, the cyclones are more efficient in

classifying efficiency compared to the turbo separator. It also reduces wear on the separator internals.
The cyclone separator is shown in figure below.
 Cyclone Separator

Cage Type Separator

This type is often referred to as the high efficiency separator and is distinguished by a cage-type rotor.
The rotor in most cases is cylindrical and has many blades spaced evenly around the periphery. The
blades are typically radial, fairly small, and closely spaced. Around the rotor are stationary guide vanes
angled to aid the swirl of air. Between the rotor blades and the guide vanes is the classifying zone. The
air enters the separator housing through one or more inlets. The separator housing serves as a manifold
to distribute the air to the guide vanes. The highest air velocity in the separator is through the guide
vanes.

The pressure drop created by the guide vanes helps to distribute the air evenly around and vertically
into the rotor area. After being swirled by the guide vanes, the air travels through the classifying zone,
picking up the fine material, and exits from the center of the rotor. The exit duct consists of an elbow
that can take the air and fines out either the top or the bottom of the separator, depending on the
design. In this type of separator the fines are removed from the airflow in a separate device.
 Cage type Separator

V separator
The V-separator as shown in Figure was developed in the 1990s specifically for use with roller presses. In
a grinding circuit including a roller press and a closed-circuit ball mill, it is essential that the roller press
throughput be dis-agglomerated and as many fines as possible removed. This is particularly true when
there is a high degree of recirculation around the roller press. The fines from the V-separator are then
fed to the closed-circuit ball mill, while the remaining coarse material is recycled to the press. The
reduction in fines in the recycled material will greatly enhance the consistency of the feed to the press,
and contribute significantly to minimizing the process-related vibrations in the roller press. Feed is
introduced to the V-separator near the top and showers down a series of inclined plates. Air is induced
into the separator and sweeps the fines from the cascading material. The classifying zone is the area
between the plates and a series of baffles. Typically, the specific feed loading in the air stream is
significantly higher than cage-type separators, at about 4 kg/m3. Also, the cut size is much coarser than
the cage-type separator, at between 0.1 and 3 mm. This type of separator does not serve the same
function as the cage- type separator and is normally followed in the circuit by a cage-type separator.

The cut size of the V-separator is controlled solely by the airflow quantity. If ambient air is used, a
significant amount of cooling is possible. Conversely, if hot air were to be used, substantial drying of the
separator feed would be possible. The airflow that is used for the V-separator can be taken directly into
the circuit’s cage type separator and induced by the main separator fan. By using the same airflow as a
separating medium in both separators, the size of dust collection in the circuit is not increased even
though there are two separations at different cut sizes taking place. A further refinement to this type of
separator is to combine it into a single separator with a cage-type rotor.

V- Separator
Gear box Lubrication unit-216LU95
For thrust pad lubrication lines= 17, mill gear lubrication line= 3 small+2 large lines as shown below
High pressure pump for MGL

Flender system
HSLM
It is a lubrication system for the roller’s hydraulic jeck.

There is total 3 cabinet.

HSLM-1, HSLM-2, HSLM-3

HSLM-1 for rollers 1 & 4

HSLM-2 for rollers 2 & 5

HSLM-3 for rollers 3 & 6

Tank volume 1400 l/m

Delivery rate 54 l/m
Total cabinet 3
Total pump 6
Solenoid valve per cabinet 3
Heaters for tank heating per cabinet 3
Above pitcher there is 3 manual valves

5.2= for grinding pressure

5.5 = for counter

5.4 = for extra safety of counter pressure for rollers while working during maintenance

Accumulator
Accumulators are generally classified by means of the use of energy storage. Accumulators are classified
as,

1. Weight loaded accumulators

2. Spring-loaded accumulators 
3. Gas loaded accumulators

Gas loaded accumulators are further divided as the non-separator type and separator type.

Separator type gas loaded accumulators consist of

 Bladder type
 Diaphragm type
 Piston type.
Bladder Accumulator
Bladder accumulators are used extensively to hold pressure in a system They maintain system pressure
when all valving is closed.it act as shocks absorber.

Total no. of bladder accumulator per 8

roller(numbers)
Pressure(bar) 40
Gas type Nitrogen
Valve type Puppet valve (spring type)
A bladder accumulator is the most commonly used hydro-pneumatic accumulator. The bladder is filled
with nitrogen and fitted in a welded or forged steel pressure vessel. The bladder is made of an elastic
material (elastomer), e. g. rubber. The gas pre-charge pressure can be adapted via the gas inlet/outlet
valve on top of the bladder accumulator.

If the bladder accumulator is mounted vertically or at an angle, the gas side must always be on top.
When the pressure drops, the compressed gas in the bladder expands and pushes the stored fluid into
the hydraulic circuit. At zero pressure, the bladder may be pushed out of the pressure vessel. To prevent
this, a spring-loaded valve is provided on the fluid side.

Application
ENERGY & PUMP MAINTENANCE SAVINGS

SURGE CONTROL & SHOCK ABSORBERS

ELIMINATE SUDDEN PRESSURE DROPS

THERMAL EXPANSION:
Piston cylinder
An accumulator contains a free-floating piston with liquid on one side of the piston and precharged air
or nitrogen on the other side.

An increase of liquid volume decreases the gas volume and increases gas pressure, which provides a
work potential when the liquid is allowed to discharge.

It is use for counter pressure.

Total number of piston cylinder per roller 4

Gas type Nitrogen
Cylinder’s pressure 8 bar
Valve type Piston
Maintenance:
Before removing an accumulator for repairs, relieve the internal pressure: in a spring-loaded type,
relieve the spring tension; in a piston or bag type, relieve the gas or liquid pressure.
HSMS
It is a Hydraulic system for the roller’s internal lubrication.

Tank volume 850 l/m

Pump capacity of pressure pump 6 l/m
Pump capacity of suction pump 10 l/m
No. of pump per cabinet 4 (2-suction,2-delivery)
There is total 3 cabinet.

HSMS-1, HSMS-2, HSMS-3

HSMS-1 for rollers 1 & 4

HSMS-2 for rollers 2 & 5

HSMS-3 for rollers 3 & 6

Air breather:
Air breather filters ensure that there is no dangerous buildup of pressure or vacuum due to temperature
or volume changes.
Damper # Description

LD01 ID fan louver damper towards Coal mill side

LD03 ID fan Inlet damper

LD04 ID fan Inlet damper

LD79 System fan damper towards bag house

BD14 Bag house butterfly fresh air damper

LD06 ID fan Bypass damper

BD91 Hot gas generator damper at coal mil

BD88 Fresh air hot gas generator damper

BD90 Hot gas generator damper at raw mill

LD78 Circulation damper

LD81 Circulation damper

BD82 Fresh air damper

BD89 Fresh air damper

LD80 Mill main inlet damper

Total dampers at Raw mill area

 I.D FAN (313FA07)
I.D fan or induce Draft fan is the fan which provides hot air to the VRM from the preheater. It also
produces negative pressure in the kiln and preheater.

Technical specification
Gas flow 1050000 m3/h
Static pressure -6900pa
Gas temp 270 0C (400 0C)
Power 3150 KW
Voltage 6.3 KV
Auxiliary drive 11 KW
Voltage 380 V
SYSTEM FAN (216FA64)
System fan is also an I.D fan but it is used for the suction of air from the VRM through the cyclones. It
sucks the hot air from the VRM and send it to Bag house. It also works for maintaining the negative
pressure into the VRM.

Technical specification
Gas flow 1510000 m3/h
Static pressure -11600 pa
Speed 980 r/min
Gas temp 90 0C (Max. 130 0C)
Cooling water consumption 1.2 m3/h
Power 6700 KW
Voltage 6.3 KV
Speed 980 r/min
Traveling of hot air along with product:
In the plant area or VRM area the hot Air flows from one place to another through the Ducts. Ducts are
pipe lines of very big diameter which are used for transportation purpose.

CYCLONE (216CN55)
Capacity 1380000 m3/h
Gas temp 90~110 0C
Efficiency >94%
Pressure loss ≤1200 Pa
Rotary airlock (60,61,62,63) capacity 170 m3/h
Power 4 KW
Voltage 380 V
Total Speed sensor at each cyclone rotary 4 (1+1+1+1)
A cyclone is a conical vessel into which a dust-bearing gas-stream is passed tangentially. This produces
vortex within the vessel. The gas leaves the vessel through a co-axial "vortex-finder". The solids are
thrown to the outside edge of the vessel by centrifugal action, and leave through a valve in the vertex of
the cone. Cyclones were originally used to clean up the dust-laden gases leaving simple dry process
kilns.

In lucky cement plant 4 cyclones are used in the VRM area which purify the hot gas which is coming
from VRM.
AIR SLIDE (218AS03)
Air Slides is a mean of transportation in the cement plant it can convey the material from one place to
another with the help of air. Canvas cloth and blowers are used in air slides. Air slides are normally used
at the bottom of cyclones.

Air slide Capacity 700 t/h

Slope 80
Air slide fan(218FA02/05/06) 3
Gas flow 2844 m3/h
Pressure 5517 Pa
Speed 2900 r/min
Motor power 7.5 KW
Voltage 380
 Bucket elevator (218BE03)
Material coming from bag house through drag chain into the elevator.

Drive type Single drive type

Conveyor type Chain type
Capacity 600 t/h (max. 750 t/h)
Height 14.890 m
Speed 75.7 m/min
Motor power 75 KW
Voltage 380 V
Speed 1480 r/min
Main reducer ratio i=56
Auxiliary motor 3 KW
Voltage 380 V
Speed ratio i=28
Charge level indicator 1
Speed sensor 1
Belt deviation switch 1

Bag filter (218BF10)

Gas flow 6700 m3/h
Gas temp <120 0C
Total filtering area 98 m2
Bag filter rotary sensor 1
Pulse valve 10
Pressure loss ≤1700 Pa
1 qty
216Fan11
Gas flow 7388 m3/h
pressure 3237 Pa
power 15 KW
Voltage 380 V
 Bag filter (218BF12)
Gas flow 9000 m3/h
Total filtering area 129 m2
Gas temp <120 0C
Pressure loss <1700 Pa
Pulse valve 10
Rotary airlock 1
Speed sensor 1

218FA13
Rotating direction Anti-clockwise 45
Gas flow 9639 m3/h
Pressure 3802 Pa
power 18.5 KW
Voltage 380 V
speed 1450 r/min
Bypass air slide (218AS04) capacity 750 t/h and (slope = 80)
 Silo elevator (218BE14)
Drive type Single drive right
Conveyor type Belt type
capacity 660t/h (max. 750t/h)
Height 72.200 m
Material Fine raw meal
Bulk density 0.8 t/m3
speed 114 m/min
Motor power 250 KW
Voltage 380 V
Speed 1485 r/min
Main reducer Ratio i=45
Auxiliary drive 7.5 KW
Ratio i=39
Voltage 380 V
Hydraulic coupling 1
Charge level indicator 1
Speed sensor 1
Belt deviation switch 1
 Bag house sequence (314)
A baghouse, also known as a baghouse filter, bag filter, or fabric filter is an air pollution control device
and dust collector that removes particulates or gas released from commercial processes out of the air.

Equipment name power

Raw mill bag house rotary 2.2
motor#01,02,03,04,05,06
Drag chain motor #1,2 7.5
Raw mill bag house drag chain main motor 18.5
Raw mill bag house fan motor 1250 (current=157 A)
Cooling fan for raw mill bag house fan motor 11

314BH02 Bag filter Gas flow 991000 m3/h

Total number of chambers= 12

1 chamber= 2 compartment

Per chamber bags= 12x16= (192)2= 384

Total bags in bag house=384x12= 4608

BAG HOUSE FAN (314FA03)

Gas flow 1073000 m3/h
Gas temp 200 0C (Max.260 0C)
Inlet consistency 20 mg/Nm3
Static pressure -2800 Pa
Bag house fan is a suction fan which helps the bag house in filtering the hot air from cyclones. If it does
not work properly then there is a need to shut down the plant because it also helps in producing the
negative pressure and prevention of atmosphere from pollution.

The bag house removes fine raw mix particles from the hot air then remaining extra gases containing
Sox, NOx, CO and CO2 released in the atmosphere.
 Types of bag filter
Mechanical shakers
In mechanical-shaker baghouses, tubular filter bags are fastened onto a cell plate at the bottom of the
baghouse and suspended from horizontal beams at the top. Dirty gas enters the bottom of the baghouse
and passes through the filter, and the dust collects on the inside surface of the bags.

Cleaning a mechanical-shaker baghouse is accomplished by shaking the top horizontal bar from which
the bags are suspended. Vibration produced by a motor-driven shaft and cam creates waves in the bags
to shake off the dust cake.

Reverse air
In reverse-air baghouses, the bags are fastened onto a cell plate at the bottom of the baghouse and
suspended from an adjustable hanger frame at the top. Dirty gas flow normally enters the baghouse and
passes through the bag from the inside, and the dust collects on the inside of the bags.

Reverse-air baghouses are compartmentalized to allow continuous operation. Before a cleaning cycle
begins, filtration is stopped in the compartment to be cleaned. Bags are cleaned by injecting clean air
into the dust collector in a reverse direction, which pressurizes the compartment. The pressure makes
the bags collapse partially, causing the dust cake to crack and fall into the hopper below. At the end of
the cleaning cycle, reverse airflow is discontinued, and the compartment is returned to the main stream.
Pulse jet
In reverse pulse-jet baghouses, individual bags are supported by a metal cage (filter cage), which is
fastened onto a cell plate at the top of the baghouse. Dirty gas enters from the bottom of the
baghouse and flows from outside to inside the bags. The metal cage prevents collapse of the bag.
Bags are cleaned by a short burst of compressed air injected through a common manifold over a row
of bags. The compressed air is accelerated by a venturi nozzle mounted at the reverse-jet baghouse
top of the bag. Since the duration of the compressed-air burst is short (about 0.1 seconds), it acts as
a rapidly moving air bubble, traveling through the entire length of the bag and causing the bag
surfaces to flex. This flexing of the bags breaks the dust cake, and the dislodged dust falls into a
storage hopper below.
STORAGE OF POWDER GRINDED RAW MATERIAL TO THE SILO
Raw material in required ratio is grinded by the Vertical Raw mill is separated by the cyclones is sent to
the 65m silo having capacity 25000 tons with the help of air slides, screw conveyers and bucket
elevators. This silo is also used to give feed to the pre-heater

HOMOGENIZATION OF GRINDED RAW MATERIAL

As the raw mix is stored in the silo that’s why its need to homogenize it for this purpose heavy blowers
are used which through's air from the downward due to which a continuous motion occurs in the
material and Homogenization of grinded raw material takes place.

Item name Technical specification

Silo size (311) ɸ22x64m
Bulk density 1.3 t/m3
capacity 25000 ton
Total aeration unit (311AE09) 7
Silo aeration point 7x7=49
Total air slides at silo bottom 7 (A+B+C+D+E+F+G)
Total pneumatic shut off valve 7
Pneumatic actuator 7 (capacity=200t/h)
Motorized proportion gate 7
Total roots blowers for silo aeration 6 (49+50+51+52+53+54)
Roots blowers for silo aeration 50,51,52,53
Roots blower 49 For feed bin
Roots blower 54 Standby
 Hot gas generator-216HG39
ITEM CODE TECHNICAL SPECIFICATION
Fuel type Diesel oil
Gas temperature 300~600 0C
OIL PUMP-216PU40 3 m3/h
Oil pump power 3KW
Voltage 380 V
Speed 1450 r/min
Oil tank-216TN41 Capacity 5 m3
FAN-216FA42 Gas flow 27905 m3/h
Pressure 5309 Pa
Fan motor power 75 KW
Motorized shut-off Damper-216SG43 Power 0.02 KW
Torque 2500 Nm
Voltage 380 V
Interlocks, Sequence & limits
Interlocks are the setting of conditions for the smooth operation of equipment. Interlocks can be
electrical or mechanical in nature.

There are different types of interlocks which are very important for the smooth run of equipment & to
avoid major failures. Some important interlocks are:

a. Start interlock
It is the interlocking which must be fulfilled before the machine operation can be started.

b. Safety interlock
These are very important interlocks for the safety of both personal and machinery. Safety interlock are
generated by the conditions outside the machinery itself Evens where safety interlock fails.

c. Protection interlock
It is important for the safety of machinery especially when operating on manual conditions. These
interlocks can never be cancelled. Protection interlocking is always generated by a condition inside
machine itself. When protection interlock fails the machine will start an alarm.

d. Operation interlock
This interlock are necessary for the normal operation of machinery. For local test of machine
interlocking can be surplus without further risk for the man and machine.

e. Special interlock
When it is necessary to follow a fix sequence of operation special interlock can be used. During startup
and shut down interlocks are included to prevent operations from departing the required sequence.

Startup and shutdown sequences or groups are created for the smooth start and stop. These are
important to generate in order to facilitate the operator and to avoid personal errors due to negligence
of plant operator during operation.

There are different limits which are generated as an alarm to the operator. These limits may be

i. Extreme high (HH)

ii. high (H)

iii. low (L)

iv. Extreme low (LL)

The extreme high and extreme low is the maximum and the minimum limits. When the process value
approaches these limits the machine will automatically trip/stop due to safety and protection interlocks.
The high and low limits indicate the operator to be conscious and prepare himself to take certain actions
immediately.

There are 5 groups which are shown below:

Equipment Code
Operating H HH
216BC14(A) 155(575t/h feed),
160(605t/h feed)
175 220
216BE71(A) 39
90 100
216BC74 50-70
(Belt scale limit
300 300
capacity t/h)
216BE14(A) 300
396 440
218BE03(A) 9.3
15 21
Main Rotary(A) 13.8
90 95
Mill water sprinkle 9
pump(A)
50 50
Reject bin level(m) -
4 4.50
216BC68(A) -
30 30

Raw mill main motor

H HH
Power
- -
Current(A)
650 1000
Mill vibration (A)
20 25
Mill DP (mbar)
92 250
Classifier rotor speed (RPM)
100 100
Classifier’s bearing temp(0C)
55 70

SEILING FAN-FA53 H HH
0
Phase winding temp( C)
100 130
Rotor drive end temp(0C)
67 100
Rotor non drive end temp(0C)
52 80
System Fan-216FA64
H HH
Phase winding temp(0C)
95 130
Current (A)
702 780
Rheostat temp(0C)
90 130
Bearing temp rotor drive
end(0C) 57 100
Motor vibration(mm/s)
6 8
Mill outlet temp(0C) 150 180

ITEM NAME H HH
Limestone (ton)
16 17.5
Laterite(ton)
280 300
Sand (ton)
280 340
Clay (ton)
265 300
Silo level(m)
52 52
ID FAN(RPM)
1100 1100
 vertical roller mill
(operation parameters)

For a stable grinding procedure, the following parameters are important;

 The vibration of grinding table

 The delta p of grinding system
 The height of the grinding bed
 The pressure of grinding rollers
 The speed of the grinding table

What is grinding bed?

“Grinding bed is the material layer between the roller and table”

It must be 90-103 mm

R1=90.5mm R4=95.7 mm

R2=97 mm R5= 95.5mm

R3=92.5mm R6=102.8 mm

Speed=48-50 rpm

Raw mill process measured and manipulated variables

Process measured variables Manipulated variables

 Fineness(blain) or residue  Classifier speed
 Mill motor speed  Mill fan speed
 Mill air flow  Water injection
 Mill DP  Hot gas
 Temp after the mill  Fresh air
 Product transport volume
 Mill vibrations

How to control mill vibration

 Known the vibration limit and optimum grinding bed thickness for the mill
 Adjust the mill dam ring height to compensate for table wear
 Apply stable water spray to the control bed
VRM Reaction Results
 High mill motor current
If grinding pressure High  Thrust bearing pressure increase
 Lower mill DP
 Lower internal circulating load
 Low mill motor current
If grinding pressure low  Low capacity for a given air flow and
DP.
 Increase rejects level.
 Higher DP across nozzle ring and
classifier.
 High mill motor current
Bed height too high  Low mill DP
 Low mill motor current
Bed height too low  High mill DP
 High rejects level
 Low mill output
 High vibration than normal
 High exit temp
Feed material too dry  Lower material friction on grinding
table
 Low drive power
 Low DP across mill
 Low exit gas temp
Feed material too wet  Material agglomeration on the
grinding bed
 High drive power
 High DP across mill
 High vibration than normal
 High DP
High internal circulating  Product fineness too high
load  Classifier choked
 Low grinding pressure
 Low air flow
VRM Problems Reasons/causes
 Inconsistent feed size
High vibration 

Grinding pressure too low
Dam ring height not uniform
 Low material feed with high grinding
pressure
 High DP across mill

 Low grinding pressure

High mill DP 

Feed rate too high
Dam ring height too low
 High internal circulation load
 Product too fine
 Feed size too course
Low output 

Grinding pressure too low
Dam ring height too low
 Worn out liners
 Product too fine
 High system pressure drop
 Low separator speed
Product too coarse  High air flow through the mill
 Air velocity at nozzle ring is too high

Quality control Department Line-1

Raw mill for the month of jan-21

Raw mix Average

SiO2% 12.95
Al2O3% 2.91
Fe2O3% 2.51
CaO% 42.37
MgO% 1.74
SO3% 0.23
Na2O% 0.20
K2O% 0.55
SM% 2.39
AM% 1.16
LSF% 102.43
Thankyou