Cement, Energy and Environment

A detail study revels that retention time in calciner is only 2.5 sec which is well below the norms for petcoke firing & it be will further reduced at increased production level which will create reducing condition in calciner resulted into incomplete combustion. It has been decided to increase the length of calciner to the maximum extent, which is only way to increase retention time because it was not feasible to increase the diameter in existing layout. T A duct has also been commissioned during the running of plant. At increased clinker production , kiln main drive Was bottle-neck because less installed power. Two Solutions emerged out after lot of discussions. Either we should go for high rating motor or upgrade the single drive system to twin drive system & we have upgraded main drive with twin– drive which is one of the unique concepts in cement industry and cost viable but at the same time it was a challenge for us to operate with twin drive, but we accepted this challenge . We are happy to say that we have synchronized both drives in a single command. In-house study has been carried out for Selection of high efficient fan at new operating Parameters at increased clinker production . the overall cost for this modification, it was decided that going with a renowned supplier would be an expensive proposition, thereby looking for suppliers who are relatively new in this field and can offer at 60-70% of price was the aim of team, but this was really a challenge to install and commission it successfully. A team of JKLC, successfully commissioned Boilers & there is increase in power generation by 47362 units/day Results • • • Production-: Increased by 1500 TPD Heat Consumption-: Reduced by 18 kcall kg clinker Increase in WHR Power generation-: 47362 units/day A. From hot air Recirculation-: 8169 units/day B. With addition of one new boiler-: 39193 units/day Cost Benefit Analysis 1. Total Project Cost-: Rs. 102 crore 2 . Gain-: A. In terms of Clinker production-: Rs. 34.65 Crore B. In Terms of Coal-: Rs. 2.34 crore c. In terms of Green power-: Rs 7.03 crore D. Total-: Rs. 44.02 crore Apart from increasing production, we have also focused on more power generation through Waste heat recovery system. A detail study showed that more heat will be available at increased production by the installation of new cooler, but existing Boiler was not capable to 3. Pay Back Period-: 2.3 Years handle such amount of heat. Thus , it was decided that we will go for one additional boiler. To reduce Annexure-1 Kiln-1 Pressure profile Basis - WHR & 24 hr Running Parameter Unit Feed TPD Calciner Cyc 6 0 /L Cyc 5 0 /L Cyc 4 0 /L Cyc 3 0 /L Cyc 2 0 /L Cyc 1 0 /L PH 0 /L PH Fan 1/L Before Up Gradation 3000 Pressure (mmWg) -114 -172 -225 -274 -340 -400 -456 -466 -697 ~Pressure (mmWg) 58 53 49 66 60 56 10 231 After Up Gradation (Modification of Cy~2. 3, 4, 5 & 6) Pressure (mmWg) -268 -351 -440 -525 -654 -684 -866 4500 ~Pressure (mmWg) 61 81 84 89 85 130 30 182