Cement, Energy and Environment

Mill is vented separately through a dedicated jet pulse bag filter when the mill is in operation and excess kiln gases will be vented by the existing kiln hybrid ESP. f'll(ll lm The air flow required at mill 1/L is maintained by pre heater gases and by hot air generator. The product collected in mill bag filter would be conveyed through air slide and new belt bucket elevator to the existing blending silo. ,,.,,. ,./fit, Ia( - !k):l nml• '"' ""'"' IIO lPH H ....... IHJ rPN ~w(D !r.11 Nl!I I j l15UD rJ ,.. ; ~- ! IJl6l KIJ/In' i / / ) !~U. N.It! ./' =·It> / =lO a•ftk. -u amwg. / 6 .... ~.::;· ,/ -··--r-·--··-··---rT~- ------ ../ :Or1JP M1 /tf, 11X!5J1R FU :r~ m'fMr. ' i ~/ ~~j;., : :v' ! : ~;/; IJ+Jlto/.1 I L__--------- ·----··- ··-__/ 0 ! ~ A.•tn.liM"..:~~ : Mrttl'it-.,..sn : fall. ll)- lc.r.. W1 : f';.. /li M- 11; : - ,,. 151 , . f'n~ fliii''IIU : 13 I K011 Dnl Fig - 2 Design Process Flow Sheet Commissioning With Hot Air-: The mill was started with hot air duct and mill was stabilized at 140-150 TPH. But still we were far behind the targeted production of 180TPH. Upon thorough analysis and after series of brain storming session it was observed following problems had to be attended a ) Short circuiting of hot air to bag house from bypass dampers SD-3 and LD-6. b) Mill DP which was high due to high velocity across the nozzle ring area . To overcome these problems following activities were carried out, a) Optimized the nozzle ring area from 1.62m2 to 1.82m2. b) Proper sealing was done across SD-3 and LD- 6 dampers. c) Relocation of dampers LD-6 and LD-4 To reduce table speed (34 .87 to 30.64), Main motor speed was reduced from 990rpm to 870 rpm to help bed formation as it was analyzed and found to be more than standard norms. To achieve this one external resistance was installed in Main Motor Circuit. After doing this VRM was stable at 180 TPH. But this was not the end of the journey; we had to further sweat out the assets . For this we had to enhance the production by optimizing the mill operation that ultimately reduces the specific power consumption of mill. As production cost was high due to high specific power consumption of mill section. it was necessary to further optimize the process. Optimization Up to 200 TPH We have increased flow through mill to further enhance productivity of mill that helped us to increase feed from 180 to 190 tph but at the same