Cement, Energy and Environment

By focusing on these factors, we aim to stabilize both the Hot Air Generator and coal mill operations, ultimately improving energy efficiency. This initiative underscores our commitment to continuous improvement and sustainable growth in cement manufacturing. Issues Resolution and Process Optimization Dump Slag Management and Moisture Control The use of dump slag, containing 18% moisture, posed significant operational challenges, including frequent chute jamming and rotary feeder tripping due to the build-up of slag coatings on vanes, leading to high mill vibration and subsequent shutdowns. This caused an increase in the number of start-stop cycles, contributing to increased idle running hours, auxiliary drive power consumption, and overall inefficiency. Furthermore, the higher moisture content in the slag significantly reduced mill output, which in turn increased specific heat consumption as additional energy was required to evaporate moisture during the grinding process. After a comprehensive analysis, the team implemented a slag stacking strategy—mixing dump slag with fresh slag in a "pile by pile" manner to reduce the average moisture content. This approach not only minimized chute jamming and reduced the number of equipment stoppages but also led to smoother mill operations, less idle running, and lower fuel consumption. The optimization of this mixing process also helped balance mill throughput, ensuring that specific heat consumption was brought back to target levels. Actions Reference - figure 1.1 & 1.2 Figure 1.1 Figure 1.2 Fine coal bin modification. Mitigating HAG coating dislodges and burning zone temperature fluctuations. Fine coal bin modification 16