Cement Energy and Environment

Compa r Item Unit 1. Plant Capadty (TPD) TPD (Year of Installation) (90) No. of Kiln (I) 2a. Capacity MTPA lb. Production ( 1998-99) MTPA 3. Quarrying + Crushing Method 4. Raw Meal Grinding Ball Mill (BM) Sa. Klln/ PC Stages. types Cooler type and character V1 Sb. Temp. of Air PH exit CoolerVent Coal Mill (Ball Mill - BM) Type Fuel Type & Cal. Value K.Cai/ Kg. Material K.Cai/Kg. of Clinker Range. or each kiln Cement Mill (Ball Mill- BM) Power Consumption KwH/t Cement Captive Power Special Accreditions ISO etc. Waste Heat Recovery MW (WHR) Special Measures Energy Consumption (KWH/t material) Tr - Transport BM - Ball Mil s and Energy C- -- Table-1 ption Cnaracte Taiwan Plant I Plant 2 3250 ( 1975) - ( 1) No. 1,2 Closed 4200 ( 1980) - (2) 2200 (3) ( 1968/86) 4800/5100 ( 1992) - (3) 3300 (4) ( 1979) 6000 (Planned) 3300 (5) ( 1979) 5000 (6) ( 1992) 4.37 4.83 4.50 3.50 Driii+Biast. Semi Mobile Roller Driii+Blast. Ropeway Crusher. Belt conveyor (9 Km) trucks ( 15 km) Gyratory Crusher Ball Mill ( I &.2) 190 & 290 TPH VRM. BM (2) Roller Press+Ball Mill (450 TPH) 375TPH. 130/ ISOTPH 4 stage SP, Pyroclon (2). 4 Stage SP. 5 Stage & Pyrorapid (3) Separate line Calciner (6) 3 stage CP Coller (2.3) 3 stage CPG Cooler 2.2-2.4 Nm 3 / Kg of diker 2.6-2.8Nm 3 65 to 68% 60 to62% 350"C 312"C 352"C 350"C BM( I ). VRM (3). 44 tph. 35 tph VRM .17.25.27 tph Coal, 6500 K.Cal. From Coal, 6800 K. Cal., 12-16% South Africa, Australia ash, China/ Australia 15-20%ash 780( 1.2). 730(3) 850(3). 830(5), 750-780(6) (Latest 730) BM+Roll Press ( 1.2.3) Tube Mill (6) + Roll Press VRM(4).TPH-190+208+ I00:305 35,35.1OS, I 05. 1IS. 125TPH For OPC of 3400 blaine I05-1 I 0 (3,5) 85-90(6) (66-68) + 32 Cogen- 98- I00 (Taiwan I I0-1 IS KwH/t) 25 MW from Waste Heat I 5 MW from Wast Heat 9002(95). 1400I (96) 9002(93), 1400 I (98). CNLA (97) TQM(98) WHR- 25 MW 25% ofTotal. 15 MW from Kilns I , 2, 3. 32 KwH/t of clinker Aforestation of Natural park. Aforestation Zero waste Measure 5.88 Mining+Transp.+Crushing 8.37 Mining+Transp+Crushing 20.67- Raw Mill 19.40 Raw Mill 31.45 - Kiln+Cooler+Coal Mill 31.28- Kiln+cooler+Coal Mill 40.00 Cement Mill 40.43 Cement Mill of Six Select Sou -L1 · 1\ 1 n Cement Plants Korean Republic Plant 3 Plant4 1950(55) ( 1) 1-0.5 MTPA 1800 (65) (2) 2-0.5 MTPA 4500 (90) (3) 3- 1.4MTPA each (57) (4. 5) 4500 (90) (4) 4.5 - Same (65-80) 6- I .4 MTPA (81) 4.00 7.00 3.09 5.00 Driii+Biast. Impact Crusher Drill+Blast. Impact crusher Belt Conveyor (6 Km.) Belt conveyor (4 Km.) BM( I ). Roller Mill (2.3) Ball Mill. VRM 2x200: I x370 + I x I 70 280TPH: 320TPH 4 Stage ( 1.2). 5 Stage (3.4) 5 Stage PC in all IKN Grate cooler 2. I 5-2.3 Nm 3 62 to64% 363"C 325"C 199"C 220"C VRM.2x20+ l x24 tph BM (2), VRM (2). 2x25:2x40 tph 90% Coal + I0 % Petcoke 90"h Coai+ S- 1 0% Petcoke South Africa (6800/ 8500 K.cal) 6400 K.Cai./Kg. 740 K.Cal./l<g. 710 to 780 ( 1.2) (Korea AV 750 K.Cal.) 710 to 720 (3.4.5,6) (Tyres used) BM( I -4 ,5). 6.7 (Roller Press) BM ( I TO 4 & 6). VRM (5. 7 to 9) 4x33+ 1x73:2x i30TPH 40x4+85xl:200x3+ 130x1TPH I 03 (target I00) 98-99 KwH/t Nil Nil - IS09001 (%) Not installed Not installed All cement types produced Tyre use as fuel 4.85 Mining+Transp+Crushing 3.55 (Mining + Tr) 21.58 - Raw Mill 15. I I - Raw Mill 32.55 - Kiln+Cooler+Coal Mill 28 .00 · Kiln + Cooler 43.00 - Coal Mill 37- BM } Cement 35.00- Cement Mill 29VRM Mill