Cement Manufacturers Association (CMA)

32 3. Fresh feed arrangement from kiln feed to PC Fresh feed Injection system installed from kiln feed bucket elevator to kiln inlet riser duct where PC coal firing takes place. A separate path is arranged from the kiln feed bucket elevator to the kiln inlet riser. The system consists of separate air slide conveyor, manual gate and RAL. VFD provided for RAL to control the fresh feed to PC. This Fresh feed system is utilized during usage of high ash coal in kiln system to eliminate the high coating formation at kiln riser duct area . With this modification, we reduced the kiln breakdowns due to heavy coating formation at kiln inlet riser duct and also reduced NOx emission at RABH stack. Figure 4: Fresh feed arrangement from Kiln feed Bucket elevator to Kiln inlet Figure 5: New Nose ring fan for Kiln outlet tip casting plates 4. Installation of additional Nose ring fan at kiln outlet tip casting plates A new additional nose ring fan installed for kiln outlet tip casting plates cooling to enhance the life of the tip castable. Arranged new pressure transmitter for kiln outlet nose ring fan duct and its feedback indication provided at CCR with Alarm to avoid the kiln shell tip casting damages by monitoring the fan pressure and immediate identification of Fan coupling failures. 5. Online monitoring logic improved for Major equipment’s PID and online heat balance • Installed RTD sensors for 8 No’s of cooler Fans to monitor DE & NDE bearing temperatures online values at CCR and alert system provided at CCR for immediate action to predict the Fan bearing temperature tolerance limit • Provided additional Zero speed Sensors for Cooler grate movement Drives for immediate identification of decoupled conditions • Provided RTDs for both cooler drive-1&2 shaft bearings housings for continuous monitoring of bearing temperatures for immediate rectification and hence improved the performance. • Arranged additional pressure signal for 6th cyclone feed pipeline and signal is provided at CCR for online monitoring to predict the feed pipe jamming conditions 6. Maximize the equipment efficiency by maintenance activities • M/s. ABB makes 690VAC VFD panel cooling blowers replaced with RABH fan to maintain the drive temperatures within tolerance limits. Hence avoided the failures of VFD trips • Thermograph of all MCC feeders and Motors regularly and rectification during opportunity of intermittent stoppages. • Dedicated cables laid for HT Breakers DC supply to avoid nuisance tripping. • Modified the cooler drives shear pins metallurgy has been changed and resulted in pin failures becoming zero and hence, drive performance improved. • Replaced pin & bush coupling in place of spring coupling for cooler fans because of bearing temperatures operating on the higher side that resulted in lubrication failure inside the coupling. Conclusion By various modifications and continuous monitoring of major equipment performance, we achieved liquid AFL TSR% increase from 5.32% to 6.83% and Sp. refractory consumption reduced to 0.18 kg/Ton Clinker. Achieved kiln refractory life and run days of more than 500 days. The team will strive to achieve further many more records.