Cement Manufacturers Association (CMA)

30 Achieving 500 Days Of Kiln Refractory Life & Kiln Run Days By Optimization Of Plant Operations In Unit- 3 Kiln At My Home Industries Private Limited Mellacheruvu Cement Works Shri N.S. Rao President (Works) & Unit Head Introduction M/s My Home Industries Pvt. Limited. is located at Mellacheruvu, Suryapet District in Telangana State. At this location we have four Integrated Units for Cement Manufacturing with an installed capacity of total 5.25 MTPA of clinker. The plant is certified with ISO 9001:2015,ISO 18001:2015, ISO 45001:2018 & ISO 50001:2018.The Cement Industry is highly energy intensive with energy cost as high as 50- 70% comprising of both thermal and electrical energy of total cost of production. In the present scenario it is most challenging to optimize the fuel and power during the continuous operation of the cement plant without hampering production loss Hence, we focused on existing units to optimize the plant operations by identifying the key areas and minimizing the operation parameters variations to enhance the optimum clinker production. Our Unit-3 kiln capacity is 3500 TPD kiln with Single String ILC 6th stage preheater with Cemprotech grate cooler and Low NOX pyro jet burner Objective To improve the Unit-3 kiln running days by attending various jobs and maintenance activities to enhance the plant performance. The following jobs implemented to increase the refractory life in kiln-3: 1. PC coal firing change form single point to double point 2. Kiln Burning zone coating profile monitoring regularly 3. Fresh feed arrangement from kiln feed to PC 4. Installation of additional Nose ring fan for kiln outlet tip casting plates 5. Online monitoring logics improved for Major equipments (PID and online heat balance) 6. Maximize the equipment efficiency by maintenance activities 1. PC coal firing change from single point to double point PC coal single point coal firing create heavy coating in one side of riser duct area. This hindered the kiln operating performance and productivity performance. The kiln availability also hampered. The decision was taken for changing the coal firing pattern from single point firing to double point. Kiln riser duct PC coal firing point area brick refractory replaced with castable to avoid coating tendency.