Cement, Energy and Environment

GREEN FIELD PLANTS & EXPANSION CEMENT INDUSTRY'S NOTABLE EXPANSIONS AND NEW KILN CAPACITY PROJECTS IN INDIA ABB has won an order for the first gearless mill drive (GMO) system ever to be installed in an Indian manufacturing plant. The order was placed at the end of October 2009, by Lalitha Cement Ltd (LCL), located in Hyderabad, the capital of Andhra Pradesh. The GMD system will power a 4.8 MW, 15ft cement mill at Lalitha's greenfield plant, which will have a clinker capacity of 1Mta. Once the mill is in operation, it will deliver a cement output of 3600 tpd . ABB's supply includes a complete GMD system with a 4.8 MW ringmotor, a cycloconverter, a converter transformer as well as an excitation converter. Equipment will be delivered by the end of 2010 and start-up of the GMD system is scheduled for March 2011. FL Smidth has received an order for Madras Cement's Ariyalur Line 2 4200tpd brownfield plant which includes supply of an ATOX 42.5 raw mill, an ATOX 25.0 coal mill, and a pyroprocessing line complete with coal dosing, firing, 04.15m x 64 m kiln, five-stage ILC preheater and 3 x 6F SF Cross-Bar Cooler with hammer crusher. The 1300 tpd kiln upgrade with SF Cross-Bar 2x3 cooler at Line 2 at Madras Cements' R R Nagar plant started operation in August 2009. The order for this upgrade was received during 2007. Madras Cements, RR Nagar Line 1, Tamil Nadu, has successfully commissioned a 1600tpd kiln , 3.3 m x 45 m with a 2 x 3 SF Cross-bar cooler, a five-stage ILC Low-NOx preheater/calciner and a OUOFLEX burner. Clinker production started in November 2009. The main fuel for the system is a mix of 50 per cent petcoke and 50 per cent imported coal, but the system is designed to handle 100 per cent imported coal or petcoke. For its 4200tpd cement plant, Madras Cements has ordered a complete package of air pollution control equipment from FLSmidth. This includes a reverse air baghouse, a coal mill filter, an electrostatic precipitator for the cooler and a hot electrostatic precipitator. Chettinad Cement, Tamil Nadu state, has placed an order with FLSmidth for its brownfield Karikkali plant. The producer plans to expand production to 4000tpd. FLSmidth implemented two earlier projects at the company's Ariyalur site in 2006-07. The second line at Ariyalur, with a capacity of 4000 tpd started production in September 2009. The main equipment supplied includes FL Smidth supplies of an ATOX 42.5 raw mill with high efficiency separator RAR-LVT 47.5, an ATOX 22.5 coal mill with high efficiency separator RAKM 25.0, a CF Silo and a 4.15 x 64 kiln with 5-stage ILC Low NOx preheater/ calciner, a 3 x 5 SF Cross-Bar cooler and a OUOFLEX burner designed for multiple fuels. The first line of this plant with identical equipment was commissioned in November 2008. FL Smidth has received an order HeidelbergCement India for supplies of equipment that will increase capacity at several plants. The contract includes a new 5000tpd pyroporcessing line at Narsingarth (Oamoh), Madhya Pradesh, a new clinker grinding system at lmlai (Damoh), Madhya Pradesh, and a material handling system for a grinding unit in Jhansi, Uttar Pradesh. The equipment to be supplied includes coal and additive crushers, limestone, add itive and coal stores, an ATOX raw mill and ATOX coal mill, a complete pyroline including SF Cross-Bar cooler, a UMS cement mill and CF silo, air pollution control equipment, mill gear units, and electrical and control equipment. In addition, the contract for civil/structural engineering for this project is also included in FL Smidth scope of supply. Commissioning is expected to take place around late-2011 . JK Cement, in collaboration with FL Smidth, has successfully put into operation another blended cement plant with a capacity of 2.5-3Mta. Located at Mudhol, Karnataka, the greenfield plant was commissioned in September 2009 and achieved its rated output. Core equipment supplies include stacker reclaimer for limestone and coal, an ATOX 52.5 raw mill, an ATOX 25 coal mill a CF Silo, a 04.75m x 74m kiln, a 4 x 6 SF Cross-Bar cooler, a six-stage two-string ILC firing low volatile fuels, ~ DUOFLEX burner, two UMS 0 4.6m x 16m cement mills and process filters. The plant 21