Cement Energy Environment

53 MCW manufacture the cement product range - OPC 43 & 53 grade, PPC, PPC HD+ and marketing in India and abroad under the brand name of “MAHA CEMENT” through a wide network of over 2000 dealers spread across South India, Eastern India and Maharashtra. Since last couple of years MCW is exporting its clinker and cement to Bangladesh. MCW is having three cement lines, two captive power plants, an alternative fuel plant and railway siding for wagon handling &Waste Heat Recovery (WHR) Power Plant. The Three kilns are set-up with state of the art technology from M/s Walchand Industries - India, M/s KHD - Germany and M/s FLSmidth - Denmark, the world’s leading suppliers of cement manufacturing equipment. The Organization has Established, Implemented the Quality , Environment, Occupational Health & Safety Management and Energy management Systems and certified in accordance to the requirements of ISO 9001:2015 , ISO 14001:2015 ,ISO 45001:2018 & ISO 50001:2018, Greenco Gold rating and continuing to comply with the requirements. My Home is also an active member of Cement Sustainability Initiatives (CSI) making its humble contribution towards sustainable business model including Energy Conservation. • Cooler optimization by modification of MFR hole size in line-1 FLS Cross bar Cooler to improve the cooler efficiency • Enlargement of all major process fans inlet box to reduce the power consumption • Replaced existing kiln burners with Low Nox KHD Pyro jet burners in all three kilns for thermal efficiency improvement As indicated Kiln is one of the major sources of thermal energy utilization in cement industry and the energy saving measures in kiln will result in significant thermal energy savings. Clinker generated in the kiln has very high temperature of about 1400®C. Effective and appropriate cooling of clinker can be done with the latest generation cooler and the heat released thereof can be used for fuel burning in the kiln and calciner and preheating of raw materials. Cooler efficiency places major role in cement plant The Significant Energy Efficient Projects completed at MCW are Cooler optimization by modification of MFR hole size in line-1 FLS Cross bar Cooler to improve the cooler efficiency to reduce thermal and power consumption. At MCW, the Cooler efficiency of unit-1 is about 66 %. During the measurements carried out at the Cooler , it was observed that the cooler discharge temperature is high at 180 Deg C. The high temperature was attributed to the low cooler efficiency. An energy saving proposal was made by in-house energy team to increase the Cooler MFR hole size and to increase the cooler efficiency .Based on the suggestion and the proposal the cooler MFR hole size were modified.