Cement, Energy and Environment

Special operational features vi. Replacement of multi-channel Shakti Burner by Pillard Burner to improve the The plant has introduced a number of measures burner efficiency and fuel economy. to overcome certain opera tional problems. Following among them are noteworthy. Electrical The poor and fluctuating quality of coal received from collieries, when used in rotary kilns, normally causes kiln upsets. Hence, such coal is used exclusively in the thermal power plant. This has enabled to maintain the kiln/ flash calciner coal quality steady and run the ESP's with the bare minimumCO tripp ing. The two boilers in the power plant are fluidized-bed combustion type and can burn high-ash, low calorific value coal. Also as the burning temperature is 880-900° C the generation of toxic oxides is minimal. 1. Conversion from pneumatic to mechanical conveying of raw meal and cement. Energy conservation Landscaped greenery adjoining the administrative block. Side by side with environmental care, the plant has taken a wide range of measures for reducing specific energy consumption, both thermal and electrical. Important among them are: Thermal i. Kiln production upgraded from 3400 TPD to4200TPD. 11. IKN Kids system incorporated in the clinker grate cooler. m. Low -pressure cyclones introduced in the kiln preheater. iv. Rice husk and bamboo dust used as fuel in the boilers of power plant. (see Table 7 for details) v. Segmental thimbles were incorporated in p reheater stages 2 and 3. n. Variable frequency drives incorporated in various fans and VRM air separators. 111. Roller-press circuit installed as an additional unit for finish grinding. iv. A number of fans like cooler ESP fan, raw mills' ESP fans, Sepal fan, etc, replaced with high efficiency ones. v. Modifications to blending silo system. vi. Switch-over to cluster-type nozzles in the water spray system of gas conditioning tower (GCT) which is expected to reduce the temperature in GCT's from 175°C to 135°C and to reduce the preheater fan load. vu. Modification of the preheater fan, coal mill fan and coal mill bag house fan and booster fan by high efficiency fans.