Cement Energy and Environment

Table-2 Comparative Features and Energy Consumption Characteristics of Six Select South-East Asian Cement Plants Item Unit Thailand India Plant 5 Plant 6 Plant 7 Plant 8 Plant 9 Western India Central India North India I. l'lant Capacity (TPD) TPD 300-500 TPD ( 1-4) (46-60) 1&.2 (500) 6000 (95) (I) 3300 (1995) I I) 2200 ( 1985 ( I) (Year of Installation) (90) 5000 - Operating (5) (81) 3- 1250 6000 (97) (2) 3750 ( 1997) (l) 3700 ( 1997 (2) No. of Kiln ( I ) 5000 - Operating (6) (82) 4 -3000 (9 1) 5-5500 (97) 6- 7500(99) la. Capacity MTPA 3.20 6.00 4.00 2.33 I 95 lb. Production (1998-99) MTPA 2.90 4.20 2.23 I 93 1.97 3. Quarrying + Crushing Method Driii+Biast. Impact crusher. Driii+Biast. Impact crusher Driii+Biast. in-pit Crushing Drill+blast, in-pit crushing by Drill · Blast. in-pit crushing ropeway/belt (17 Km.) Beit(2 Km.) by gyratory. belt conveyor Impactor and double rotor Ropeway and belt transport (2 Km.) swing hammer; Truck .,. (5 Km) Ropeway (4.5 and 13.5 Km) 4. Raw Meal Grinding Ball Mill Ball Mill only VRM (4 5. 6). BM ( 1.2.3) VRM (2 Nos.). lx 450 TPH Close circuit Ball Mills VRM with Dynamic 2x2SOTPII 600TPH 2 x ~OOTPH (2 Nos.l 225 &. 300 TPH Sa. Kiln/ PC Stages. 4 Stage SP + rc 5 Stage (4. 5. 6). 6 stage SP. twin string SP"s: 5 stage. twin string. 4 st.1ge with top LP ( I). 6 stage types Separate line 4 stage ( 1.2.3) with SLC calciner DDF calciner ( I ): 6 stage. double string LP &. double string. LP &. separate line calclner (2) separate line calciner (2) Cooler type and character Pendulum grate cooler FLS CFG Cooler (both) Conventional grate( I ). Foolax Grate. IKN Kid system (I). (IKN) 65% Efficiency Control Flow 12) 2.66 and Grate Pyrostep (2) 2.05 2.44 Nm3/kg. for (I) &. (2) 1.9 Nm'/Kg for ( I ) &. (2) 62.% (I) and 68% (2.) 68-70% I I ) and 65·68''-b (2.) 5b. Temp. of Air PH exit 350 c 340"C 2.85 320 c 385-395"'( I) ' 2.90 C (2) Cooler Vent 360"C 200'C 2.80 300 c 2.50-2.80 C( I ) . 2.50 C (2.) Coal Mill (Ball Mill • BM) Type VRM. 5x2.0 tph VRM (50 tph) VRM . 2. x56 TPH E-Mili ix2.1 TPH. VRM VRM with Dyn. Sep( I). I x 40TPH VRM (2.) 2.5 8.. 35 TPH Fuel Type 8.. Cal. Value K.Cai/Kg. Lignite+ Coal 6700 K.cal/ kg. Petcoke (50%) 8500 K.Cai Importer coal of I 5 to 16% ash Domestic coal of 4000 K.Cal/kg Imported coal of 6000-6280 Material (Indonesia) + Petcoke. Coal (801t>J 6400 K.Cal. and 62.00 to 6500 K.Cai/Kg. and 3()'1< ash K.Cai/Kg. with 13 to 15% ash ash 12- 18% 12.-18% ash K.Cai/Kg. of Cllnl<er Range. or 800 (Type-1 Cement) 780 (4). 740 (5) 690 706 72.8.5 (Av): 757 to 700 each kiln 850 (Type-11 Cement) 72.0 K.Cai./ Kg. (6) Cement Mill (Ball Mill - BM) BM (9Nos.) BM+Roll Press BM·CC with sepax separator BM·OC( 1-5). BM-CC (No.6) BM-CC with Sepax separator (I). 6x20+3x 120 TPH 2.60TPH e<lch (3xl33 TPH) lx31 TPH Roll Press with V-scparator &. Roll Press+BM with Sepax 5x20 TPH (OC): BM(2.). 300 TPH each separator- Ix 161 TPH also OC Ix54 TPH. IX56 TPH Power Consumption KwH/ t 120 KwH/t 103 KwH/ t 81.02-81. 19 105.5 80 (Av): 8S to 75 Cement Captive Power 0.52MW Emergency 52MW 25 MW and 17 MW C<lp<lCity 2.5MVA llOO KVA Special Accreditions ISO etc. 9002.. 1400I . ISO 25.TQM 9002 (1995) ISO 9000. IS0- 14000 IS09002.: ISO 14000 &. TPM ISO 9002. ISO 14000 TQM (1998) Waste Heat Recovery (WHR) MW Not installed Not found feasible Not Installed Not Installed Installed 2 MW on trail basis Special Measures Lignite+ Petcoke use Petcoke use Flyash and cinder used in Raw Mill HDPE bag rejects used in Precal. Energy Consumption I0.00 (Mining -+ Transp) 1.5 (Mining TrdSp) 20.40 Raw Mill 0.9- 1.87 Mining •Crushing 1.96-1.57 : Crushing&. Transport (KWH/ t material) 30.00 • Raw M ill 26.00 - Raw Mill (VRM) 2.5.4( I). 25.71 (2) - Kiln•Cooler 25- Raw Mill 14.89- 16. I I Raw Mill Tr Transport 16.00 - Kiln (6) + Cooler 31 .00-26.00 Cement Mill 4.8-6.6 Coal Mill I 8.. 2 33.76 24.5 Kilns I &. 2 BM · Ball M il 40.00 - Kiln+Cooler-+ Coal Mill 40 - Coal Mill 2.00 l'lant 34.4 - Cement Mill 3 23 3 55 Cooler 18..2 40.00 - Cement Mill 40.00 Cement (BM) 33.9 24 7 -Cement Mill 27.3 - Roller Press+ Bail Mill I .99- Packing 3.0 ESP