Cement and Energy

Th e fo l low ing modifi ca ti ons were carri ed out i n the different ections with the effects shown against them : O' Sepa N-2000 separator installed Result : Capacity increased from 85 TPH to I IOTPH i) Increase in prcheater fan motor power Volume Pressure Before 5500 m 3 / min 600 mm WG Motor power 970 kW RPM 990 After 6600 m3/min 900 mm WG 1350 kW 990 ii) Increase in ESP fan motor power Before Volume 5430 m 3 / min Pressure 150 mm WG Motor power 350 kW RPM 580 iii) Modifications in top Q clone After 6600 m 1 / min 250 mm WG 465 kW 980 Immersion tube length increased from 2200 mm to 2800 mm Immersion tube diameter increased from 1750 mm to 2000 mm Cyclone inlet width increased: 1200 mm iv) Modifications in cement mill Conversion from open-circuit to closed circuit Conversion from three chambers to two chambers 0\erall Consequent on these modifications. the capacity of the unit increased from 1500 TPD to 1800 T PD in 1988-90, and power consumption decreased from 11 6.8 to L J 4.3 kWh/ tonne of cement. Unit II - Phases I & II The unit compri ses the following plant equipment: Phase I Phase U Commissioned Commissioned 1995 1996 Crusher, Impact-hammer 1IOOTPH Raw mill, Vertical roller 225 TPH 225 TPH Kiln 2500 TPD 2800 TPD Preheater 6-stage 6-stage Precalciner SLC 'S' SLC ·s' Coal miU 35 TPH Unit l coal mi.ll shifted Cement miU, Two- JSOTPH Unit I raw mill (ball) chambered with roller converted 50 TPH press ·~· After stabilisation of both the units. the performance fi gures stood ar : Power consumption Specific heat consumption 11 J kWh/t cement 750 kcal/kg cl inker The problems faced in th i ~ Unit. the remedial actions taken and the resu lt.~ achieved arc tabulated below : I Vertical roller mill Problem Action taken Result a. Unsteady mill operation a. Improved reed size b. Accumulation of dust in b. Installed screw conveyor in hori zontal duct hori zontal duct Specific power reduced c. High specific power c. Modification in Loesche Residue under control cyclone d. Guide vanes installed e. Increased louvre area 2