Cement, Energy and Environment

CASE STUDY ON INSTALLATION OF KILN DISPLACEMENT MEASUREMENT EQUIPMENT AT JK WHITE CEMENT WORKS, GOTAN INTRODUCTION JK White Cement is the first White Cement factory in India , which manufactured White Cement through dry process technology. The Gotan plant was commissioned in 1984 with an ini al produc on capacity of 50,000 tons. It uses technical exper se from F. L. Smidth & Co. of Denmark and state-of-the-art technology with con nuous on- line quality control by microprocessors and X-rays, ensuring the purest white cement. Over the years, con nuous process improvements and modifica ons have increased the plant's produc on capacity to 6, 18, 000 tons per annum . Problem areas necessitated the plant to introduce innova on: A rotary kiln migrates on zero axis up or down on its own. It is the property inten onally allo ed to kiln otherwise it will form groves in tyre and roller. To avoid extra migra on of kiln upward or downward a hydraulic thrust drive is provided at kiln first tyre. The purpose of this thrust drive is to take the kiln to its zero posi on by applying pressure of 30-35 bar and when kiln goes above zero ,the relief valve releases the pressure so that kiln comes down on its own due to downward thrust. Ini ally M/s FL Smidth had provided four posi on (+5mm, - 5mm, +/-15mm) feedback based kiln displacement migra on device. The device has following problem areas: · Range limita ons of measuring displacement up to 15mm in either direc ons. · Con nuous kiln posi on feedback was not shown in CCR Only digital indica on was shown on the system of CCR Opera on · Operator gets only posi on based alarms at above men oned four posi ons with no analog values. 1. Methodology adopted: The team had sessions, discussions and departmental mee ngs with department head Figure 1: Fishbone diagram for iden fying the root cause of kiln displacement migra on device 95 Diwakar Bishnoi & Rahul Dwivedi JK White Cement Works, Gotan (A division of JK Cement Ltd)