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Process Description
Crusher Drives
Compressor Drives
Waste Gas Fan Drives
Rotary Kiln Drives
Cement Mill Drives
Cement Making
The raw materials for producing cement contain lime and silica as main
components and ferric oxide as fluxing components.
The limestone mixed from the quarries is crushed and transported to the
plant by dumper wagons.
The crushed limestone together with the required amounts of corrective
additives like clay bauxite, iron ore etc. is ground in grinding mills.
The fine dry powder coming out is homogenized by passage of air from
bottom and through the medium.
It is then fed into the kiln for producing cement clinker at high
temperatures.
The clinker coming out of the kiln is air cooled in special types of coolers
and then transported to the storage.
After aging in storage for atleast three days the clinker, mixed with the
right amounts of gypsum is fed to the cement grinding mills and ground
to required fineness.
The cement is stored in silos, drawn for packing in gunny bags and
dispatched by wagons to the dealers.
Block Diagram – Dry Process
Drives Used
The driving motors used in the cement industry can be broadly classified as
follows:
Cement Mill drives
Kiln drives
Crusher drives
Waste Gas Fan drives
Compressor drives
Crusher Drives
Crusher Drives
Function:
Mining – blasting limestone and clay. Rock fragments transported. Cement is
typically produced from limestone, clay, sand and iron ore. Before the raw
material is ground, high-powered stationary or mobile crushers reduce the
material to a processable size. The drive systems used not only have to handle
the significant mass moment of inertia of the crusher rotor during startup, but
also be able to withstand continuously high torque peaks.
Crusher chunks obtained this way are approximately 1.5 inches in size.
Requirements of crusher motors:
The starting torque should be limited to 160% of the full load torque.
Breakdown torque should be 200 to 250% of full load torque.
Overload capacity of 15% for 15s and 20% for 10s taking into
consideration the adverse loading conditions encountered in practice.
The rotor should be able to withstand locked rotor current, without any
external resistance, for one minute. (Important as entrapped boulders may
jam the crushers.)
The drive system used keeping in mind the above requirements are:
1. 3 phase slip-ring induction motors of 6.6 kV; though salient pole
synchronous motor can also be employed.
2. Liquid resistance starters are employed to start the motor and bring it
upto full speed.
3. Gear boxes are also attached in order to get the desired mill speed of about
15 rpm.
4. In order to improve the power factor of the line current drawn, high
voltage capacitors of adequate reliability and automatic capacitor control
switchgear and circuit breakers are used.
TWIN Drives: Due to large ratings (above 300 kW) required for the
drive and due to the limitations of the availability of large size gear boxes
and motors, twin drives are employed. The two motors have identical
capacity as also their liquid resistance starters.
GEARLESS Drives: The rotor is shrunk onto the mill and the air gap
between the rotor and the overlapping stator is maintained by levitation
using sophisticated electronic closed loop control. Variable frequency drives
are obtained by the use of cycloconverters and/or dc link converters. This
arrangement completely dispenses with the gearbox which is generally the
source of maintenance problems.
3. Separator:
A converter-fed dc motor/variable speed slip ring induction motor can be
employed. The speed is controlled between 150-300 rpm to adjust the
fineness of the cement product. The speed range is 1:10 by armature voltage
control at constant torque.
4. Blower Drive:
Squirrel cage induction motors with start/stop push buttons, overload relay,
fuses and contactors are used for all blower drives.
5. Cyclone:
The drive used is usually a slip-ring induction motor.
Thank You!