Cement and Energy

PLANT'S KILN & ENERGY PERFORMANCE T he maximum record production from the kiln reached at 3451 tonnes/day with specific kiln output of 6.22 tonnes/day m3 in the month of January, 1997 which should be one of the best figures in the world achieved till date. Based on 24 hours of kiln running during the month of January, 1997 for 20 days the average output rate of the kiln has been clocked at 3309 tonnes clinker/day which is equivalent to average Specific output of kiln at 5.9 tonnes/day m3. As a consequence of the above efforts the specific electrical energy consumption has decreased from 118.65 - 114.65 Kwh/t of cement during the years 1985 - 1988- 89 and further to 86.2 Kwh/t of cement in the month of January 1997. A comparison of specific electrical energy consumption in the various sections of the plant before taking steps of modernisation and after initiation of modernisation and productivity optimisation step is given in Table-2. Table-l : PLANT'S ELECTRICAL ENERGY PERFORMANCE BEFORE AND AFTER MODERNISATION EFFORTS Section Specific Electric Energyconsumption (Kwh/t cmt.) 1985 to 1988-8989 After initiation ofmodernisation/ Before initiating productivity optimisation Steps modernisation steps 1989-90 Apr. 1996 Jan. to to 1997 1995-96 Dec. 1996 Crusher 2.47-2.18 1.91-1.52 2.09 2.14 and Ropeway Raw Mill 29.20-23.95 26.05-19.58 18.58 18.72 Kiln, Coal 44.92-44.05 44.70-33.11 34.63 33.05 Mill and Cooler Cement Mill 44.89-38.50 39.29-33.95 34.10 30.71 Packing Plant 2.88-2.13 2.26- 1.38 1.59 1.64 TOTAL 18.65- 114.55 113.88-92.23 90.99 86.26 There has been considerable increase in output rate of raw mill , kiln and cement mill as can be seen from Table-3. Table-3 Equipment Raw mill vrm atox 37.5 1600KW Kiln3.95 M DIA, 56 MLong Cement Mill4.4M DIA, 13.4 MLong 3939KW open circuit INCREASE IN THROUGH PUT RATE OF GRINDING AND PYRO PROCESSING EQUIPMENT BEFORE AND AITERUPGRADATION OF THE SAME Output rate Installed rated Achieved before Best achieved output (May-85) upgradation upto till date in 1988-89 Jan., 97 after upgradation 175 tph for 220 tph at product 230-245 tph at grinding materials size 18-18.5% + product size 18- having 8% 90 microne and 20% + 90 moisture and 2.2-2.5% + 212 micron and 4.0- -90mmfeed size micron 5.0%+212 mircon 75 tph c1 inker 107-1 10 tph 136 tph clinker clinker (average) 120 tph (OPC) 130-135 tph 140-145 tph (OPC at 2600 to (OPC at 2700- 2700 blaine 2900 blaine cement) 135-140 cement) 150- tph (PPC at3500- 170 tph (PPC at 2550 blaine 3300-3500 cement) blaine cement) In accordance with upgradation offacilities in kiln section and optimisation measures taken for control– ling process and operating parameters the spe– cific heat consumption reduced from 820 to 780 Kcal/kg of clinker. "· tt. ~ ....r:, ' . . - ., .; '