Industrial Load Management in Smart Grid: A Case Study

of Cement Industry

History of Askari Cement Limited

Askari cement limited is the part of Fauji Foundation, one is the largest business
conglomerate in Pakistan. With its two plants at Wah and Nizampur, have a total
production capacity 825 tons per day and only Asakri Cement Wah capacity is 3750
tons per day. Besides having major share in Pakistan market, Asakri Cement is being
export to Afghanistan, Central Asian Republics, India and South Africa.

Askari Cement Limited has a credit of being first in cement industry to acquire ISO 9001
certification. It also now stands as the first to acquire the ISO 14001 Environment
friendly standards certification in Pakistan.
Its established in 1921, is the successor of Associated Cement Company, the first
cement plant the territory now constituting Pakistan. The plant the famous Bombay
based Indian company in 1921, with a rate capacity of 120 tons per day. The plant
acquire by Army Welfare Trust in 1996.
After acquisition AWT changed the name of brand to Askari Cement. The plant installed
1994 was 3000 tons per day single production line design by FL Smidth of Denmark.
The capacity of plant enhance 750 tons per day in 2006.
On 30yh July 2013, shares a Askari Cement Limited were purchased by Faufi
Foundation.

Cement Manufacturing Process

Production of cement complete after passing of raw materials from the flowing seven
stages. There is;
Raw material extraction / Quarry
Grinding, proportioning and blending
Pre-heater phase
Kiln phase
Cooling of Clinker
Final grinding at Cement Mill
Packing and Loading

Stage 1- Raw Material Extraction

Cement users raw materials that cover calcium, silicon, iron and aluminium. Such raw
material are limestone, clay and sand. Limestone is for calcium, it is combined with
much smaller proportions of sand and clay. Sand and clay fulfill the need of silicon, iron
and aluminium. Generally cement plants are fixed where the quarry of limestone is
nearby. This save the extra fuel cost and makes cement somehow economical. Raw
materials are extracted from the quarry and by means of conveyor belt material is
transported to the cement plant.
There are also various other materials used for cement manufacturing. For example
shale, fly ash, mill scale and bauxite. These raw materials are directly brought from
other sources because of small requirements.
Before transportation of raw materials to the cement plant, large size rocks are crushed
into smaller size rocks with he help of crusher at quarry. Crusher reduced the size of
large rocks to the size of gravels.

Stage 2: Proportioning, blending and Grinding

The raw materials from quarry are now routed in plant laboratory where, they are
analyze and proper proportioning of limestone and clay are making possible before
beginning of grinding. Generally limestone is 80% and remaining 20% is the clay.

Now cement plant grinding the raw mix with the help of heavy wheel types other rollers
and rotating table at raw mill. Rotating table rotates continuously under the roller
bringing the raw mix in contact with the roller. Roller crushes the material to a fine
powder and finishes the job. Raw mix the stored in a silo ready to be fed to pre heater
cyclones.

Stage 3: Pre-Heating Raw Material

After grinding of raw mix by raw mill, the material is ready to face the pre-heating
chamber. Pre-heating chamber consists of series of vertical cyclone from where the raw
material passes before entering the kiln. Pre-heater utilized the emitting hot gases from
kiln. Pre-heater of the material save the energy and make plant environment friendly.

Stage 4: Kiln Stage

Kiln is huge rotating furnace also called as the heart of cement making process. Here,
raw material is heated up to 1250 c. in this process, carbon dioxide released the
material. Kiln is heated up from the exit side by the use of Furnace oil, natural gas and
coal.

Stage 5: Cooling of Clinker

After passing out from the kiln, clinker are cooled by mean of forced air, Clinker release
the absorb heat and cool down at lower temperature. After cooling the clinker ready for
fed in cement mill for final grinding.
Stage 6: Final Grinding at Cement Mill

Final grinding of clinker takes place in cement mill. A typical cement mill consists of Ball
mill. A horizontal ball mill is filled by steel balls i.e grinding media. Here, the steel balls
crush the clinker into very final powder. During grinding gypsum is also added at 5%.
After grinding at cement mill, the cement transported to cement storage silos at packing
plant.

Stage 7: Packing and Loading of cement

Using extraction gates fed to packing plant for package of cement bags usually 50 kg or
1 ton or in bulk. Cement are loaded to transportation vehicles ready for transportation to
the market.

System Model of Askari Cement Limitted

There are different kinds of loads in cement industry. Each types of load has different

type of appliances. These load types are Shift able load, Non shift able load, auxiliary

load and seasonal load etc.

Equipment
Code Shop Equipment Description Equipment Type Installed HP Installed kW
111.AF060 Limestone Crushing Apron Feeder Apron Feeder 250 186.50
111.BC210 Limestone Crushing Belt Conveyor # 1 Belt Conveyor 75 55.95
111.BC220 Limestone Crushing Belt Conveyor # 2 Belt Conveyor 150.00
111.CR100 Limestone Crushing Primary Crusher Crusher 500 373.00
111.CR150 Limestone Crushing Secondary Crusher Rotor #1 Crusher 350 261.10
111.CR150 Limestone Crushing Secondary Crusher Rotor #2 Crusher 350 261.10
111.FN312 Limestone Crushing Crusher Bag Filter Fan Fan 30.00
111.LQ065 Limestone Crushing Crusher Lube Pump Pump 0.33 0.25
111.MS222 Limestone Crushing Magnetic Separator - Motor Magnet 5 3.73
111.RF311 Limestone Crushing Baghouse Rotary Feeder Rotary Feeder 0.5 0.37

Area Number of Motors Installed kW Percent of Total kW

Materials Receiving 11 162.6 1.1%
Raw Materials Handling 37 533.4 3.6%
Raw Milling 41 3,115.3 21.2%
Main Baghouse 13 744.5 5.1%
Coal Milling 28 746.7 5.1%
Precalciner 20 1,932.1 13.1%
Kiln 16 540.1 3.7%
Cooler 42 1,368.9 9.3%
Cooler Vent 10 677.4 4.6%
Clinker Handling 7 171.6 1.2%
Gypsum Receiving 11 132.8 0.9%
Finish Grinding 71 4,139.6 28.2%
Cement Storage & Ship 42 437.2 3.0%

Equipment Type and their Typical Power Consumption

Mechanical Conveying 50%

Small Fans 60%
Large Fans 70%
Crushers 70%
Bucket Elevators 75%
Blowers 80%
Compressors 90%
Mills 95%

Sub-Shop Estimated kW Production tons /hr Sub-Shop kWh/t-shop Shop(kWh/t)

Operated Hours Clinker(kWh/t-clk) Clinker(kWh/t Shop)

Primary Crusher 1,316 851.7 1.55 32.4% 0.50

Secondary Crusher 1,528 851.7 1.79 32.4% 0.58 3.34 Crushing 1.08
Raw Mill Feed 325.3 236 0.72 84.8% 0.61
Raw Mill 10,457 325.3 32.14 84.8% 27.25 32.87 Raw Mill 27.87
Preheater 3,237 178.3 18.16 100.0% 18.16
Kiln 1,165 178.3 6.54 100.0% 6.54
Cooler 1,275 178.3 7.15 100.0% 7.15
Heat Exchanger 178.3 64 0.36 100.0% 0.36
Clinker Transport 178.3 358 2.01 100.0% 2.01
Coal Mill Feed 178.3 65 0.36 100.0% 0.36
Coal Mill 2,150 178.3 12.06 100.0% 12.06 46.64 Pyro 46.64
Clinker 75.59