Cement Energy and Environment

Sl. Problem/Deficiency Modification Condition No. Before After modification modification Ill Preheater - Unit I 7. High pressure drop in Deflector plates provided at gas Pressure drop of 5th cyclone in preheater top cyclones duct entry points for 4th and 5th stage cyclones to guide the gases 140 mm WG 103 mm WG and material into the cyclone for better circling motion and hence Pressure drop of4th cyclone better heat transfer (see Fig.2 for details). 85 mm WG 70 mm WG ,K Preheater outlet gas temp 370° ( 360° ( Preheater outlet draught 650 mm WG 600 mm WG Preheater fan speed 820 rpm 790 rpm Preheater outlet gas vol 1.9 Nm3/ kg I .65 Nm 3 /kg. clinker clinker IV Vertical roller mill (VRM) - Unit II 8. Un-smooth mill Water spray in VRM optimised Un-smooth Smooth operation operation, energy loss with pump. Mill drive control operation with energy through variable speed frequency. saving v Kiln feed bucket elevator - Unit I 9. Fugitive dust Additional screw conveyor Dust nuisance Absence of dust, provided for transportation of and polluted clean working GCf dust to kiln feed bucket working environment. elevator. environment. VI GCT dust transport to kiln feed bucket elevator - Unit II 10. Dust nuisance Additional screw conveyor Excessive dust Clean working introduced environment. VII Cement mill circuit - Unit U 11. Disagglomerator in the Disagglomerator bypassed and Dust nuisance Clean working Polycom circuit found direct pipe provided from bucket Power environment redundant, i.e. Polycom elevator discharge to consumption by Power saving output was already in disagglomerator collecting hopper disagglomerator from by- passing powder form. Dust (see Fig. 3 for details). of disagglomerator. nuisance and avoidable energy consumption. 12. Fugitive emission, wear Stepped type chutes constructed. Fugitive dust. Clean working and tear, dust spillage Wear and tear, environment. around chutes. dust spillage No wear and around chutes. tear nor dust spillage. 13. Fugitive emission at belt Special design water spray nozzles Fugitive dust Clean working conveyor transfer points. installed. environment. 16