Cement Energy and Environment

S.No. Modification/measure introduced Cement Mill I. Replacement of pneumatic transport of cement from mill to silo by mechanical transportation system t II. Installation of boltless liners in the first compartment iii. Providing polymer liners in storage hopper of gypsum to ensure uninte1rupted supply of gypsum to the mill, thereby cutting down the mill idling duration Kiln and Coal Mill I. Modification in kiln chain system II. Installation of positive-displacement type blower in place of high-pressure fan for transportation of fine coal to kiln. ... Operation of ESP on semi-pulse mode Ill. IV. Reduction in false entry into ESP by attending to its casmg V. Reduction in false air entry into ki ln by improving ki ln outlet seal design vi. lnstallation of fluid coupling on circulating air fan VII. Installation of improved-design liners in coal mill Compressors I. Optimisation of compressed air use in sluny/sludgc agitation ii . Shifting of dedicated compressor for packing plant operation from central location to avoid idle. running of compressor arising from lack of intradepartmental co-ordination Others I. Replacement of under loaded motor~ II. Installation of flapper and proxy an·angement to avoid idle running of belt conveyors '·· Installation of energy efficient pumps for slurry/ 111. sludge transportation iv. Installation of energy efficient water pumps Total Electrical Energy Saving Approx. reduction in specific power consumption kWh/ton of cement 4.0 1.0 0.5 1.0 1.0 1.0 0.5 0.2 1.8 5.0 0.2 1.5 0.2 0.5 0.5 27.3 Remarks Cement mill throughput increased from 37TPH in 1991-92 to 43 TPH in 1998-99 as a result of these modifications and continuous monitoring of mill performance Power saving due to higher production rate Enabled operate the fan on lower rated motor Only 2875 m 3 /hr compressed air is being used against the installed capacity of 9392 m 3 /hr 5