Cement, Energy and Environment

43 2. Plant Layout While the plant layout will depend on the shape, size and topography of the available land , the best shape of plant layout is considered to be rectangular and typical optimal land requirement for an integrated three million ton / annum cement plant will be 1000m x 800m i.e. 800,000sq.m equivalent to 80 hectares for plant and its building including central control room , load centres , main substation and utilities. The layout will essentially house following  Main Sub Station.  Limestone Pre blending Circular Stockpile.  Fuel (coal/pet coke) Pre blending Circular Stockpile.  Stacker Reclaimer Load Centre.  Additive pre blending stock pile.  Additive Crusher and conveying.  Additive / Corrective storage.  Raw Material Proportioning and Conveying.  Raw Mill Building.  Raw Mill Cyclone Building.  Raw Mill Bag House.  Raw Mill Bag House Load Centre.  SP Boiler.  Preheater Building.  Continuous Blending Silo  Coal Mill Building.  H.A.G. for Coal Mill.  Rotary Kiln.  Cooler.  AQC Boiler.  Kiln ,Cooler and Coal Mill Load Centre.  Cooler ESP.  Clinker Silo .  Reject Clinker Silo.  Clinker Bulk Loading facility.  Coal Storage shed.  Coal Dump Hopper.  Water Circulation Pump for Clinker Line.  Water Circulation Pump House for Turbine.  Chemical Water Treatment Plant for Turbine.  Turbine House.  Air Compressor Station.  Oil Supply Pump Station.  Central Control Room Building.  Electrical and Mechanical Workshop.  Weigh Bridges.  Cement Mill Hopper Building.  Cement Grinding Building.  Cement Silo (3 x 5000tons).  Packing Plant (3 x 120TPH).  Truck Loading Bay.  Wagon Loading Bay. 3. Technology & Equipment Selection Plant Capacity 6500 / 7500 TPD clinker 12MW WHRPP 10,000 TPD PPC Cement Grinding VRM  As far as practicable, Limestone Crusher should be installed in quarry itself which will avoid long haulage of the Heavy Earth Moving Equipment , improving its availability with maintenance workshop in quarry and reduced operation cost. Single Rotor Impact Crusher of 1100 TPH is recommended for two shift operation.  Circular Storage for Limestone and Coal is preferred to save space, better blending efficiency, fast construction, ease in maintenance and all climate protection. Limestone Blending storage of 45000 tons and Coal / Pet coke of 20000 tons capacity is recommended.  Raw Material grinding - Vertical Raw Mill is preferred if moisture content in the limestone & corrective material is above 6% and for lower moisture content Roller Press Technology is equally good. However, from the maintenance point of view and consistency in product fineness, VRM has an edge over Roller Press grinding for raw materials. However, some suppliers claim roller press better than VRM. Raw Mill capacity of 550TPH and Vertical Coal Mill Capacity of 50 TPH is recommended.  Pyro-processing - 5-stage Preheater with Precalciner is preferred over 6-stage for specific reason to have integrated Waste Heat Recovery Power Plant (WHRPP). Comparing operational cost of 5-stage with WHRPP and 6-stage without WHRPP it may be that the benefit of power cost with WHRPP gets compensated by benefit of thermal energy savings depending upon power and fuel cost , however, WHRPP gives better IRR as sensitivity to fuel cost variation is reduced. Calciner volume of