Green Solutions –FLSmidth Contribution...High material and gas retention time in calciner due to its large volume and moderate swirl. Regulation range of up to 60% bypass of kiln

The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.

Green Solutions – FLSmidth Contribution

by R.S.Mani


FLSmidth is in 130th year…

� Supplying Cement Plants world wide from 300 TPD to 13000 TPD

� Upgrading the Cement Plant to improve the Productivity, Power Consumption, Fuel Consumption, Emission and Quality

� Supplying the most modern equipments, which are the result of their substantial investment in R&D, to meet the various demands of the customers

� Close contact with customer to solve their problem through Customer Service - A dedicated group to focus on customer needs

� Initiatives for Greener tomorrow, focusing more on the reduction in the emission

� Approximately 2.5% of turnover is spent on R&D for various green initiatives


FLSmidth initiatives for Greener tomorrow

In last few years, few of the major sectors being focused are

Pyro Section1) Reduction in Specific fuel consumption2) Reduction in Specific power consumption3) Solution for Alternative fuels4) WHR power generation5) Reduction in emission levels

Grinding, Filters and Automation

1) Adapting vertical mills for Raw and Coal Grinding2) Adapting vertical mills and HRP for Cement Grinding3) Highly efficient pollution control equipment4) Fuzzy logic system


Pyro Section

� High efficient and low pressure drop cyclones

� Best utilization of the gases coming from Kiln

� Lowest specific gas volume there by reducing

Hot gases being vented out to atmosphere

� Low pressure drop and result in Low power consumption

Result:Saving in Fuel and Power Consumption


ILC CalcinerILC Calciner

Result: Saving in Fuel and Power consumption

�High material and gas retention time in calciner due to its large volume and moderate swirl.

� Regulation range of up to 60% bypass of kiln gas using ILC-I version.

� Well-suited for low-grade fuels.

� Long refractory life due to low thermal kiln load and stable kiln coating.

� Lowest NOx emission among traditional calciner kiln systems


COOL TECHNOLOGYFLSmidth Cross-Bar™ Cooler – “The best got better”


Pyro Section

High efficient Cross bar coolers to recuperate maximum heat with ABC inlet

� Horizontal design with optimized transport method

� Separate clinker conveying and cooling systems

� Stationary, sealed grate line and Self-adjusting mechanical flow regulators

� Modular concept

Savings in SFC up to 50 Kcal/Kg.clk


Duoflex Burner


A Duoflex for burning liquid waste and coal A Duoflex for burning rice husk and a gas burner in addition

Duoflex Burner Features


Oil Gun for Liquid AF

� Solution to Alternative liquid

fuels

� High momentum burners with

Provision for alternative fuels

� Oil Burner atomized for firing

hazardous liquid fuels


Hot Disc

Solution to Alternative fuels

HOTDISC – To burn Anything and Everything


EmissionsEmissions

Disc

Reactor

Disc

Reactor

Kiln BurnerKiln Burner CoolerCooler

FilterFilter

Solid Waste Fuel

Receiving

Solid Waste Fuel

Receiving

Pneumatic

Conveying

Pneumatic

Conveying

Solid Fuel

Processing

Solid Fuel

Processing

DosingDosing

StorageStorage

LWDF

Receiving

LWDF

Receiving

StorageStorage

Kiln

Bypass

Kiln

Bypass

EmissionsEmissions

Overall aspects:

• Control/regulation

• Clinker production

• Heat consumption

• Availability

• Chemistry

• Emissions

Overall aspects:

• Control/regulation

• Clinker production

• Heat consumption

• Availability

• Chemistry

• Emissions

PumpPump

Preheater/

Calciner

Preheater/

Calciner

An integrated Alternative fuel solution


13

Pipe ConveyorPipe Conveyor

Pfister RotoscalesPfister Rotoscales

HOTDISCHOTDISC

OBA Burner SetOBA Burner Set

DUOFLEX BurnerDUOFLEX Burner

FLSmidth Key products for Alternative fuels

HopperHopper

COMBUSTION EQUIPMENTS

COMBUSTION EQUIPMENTS

HANDLING EQUIPMENTS

HANDLING EQUIPMENTS

DOSINGEQUIPMENT

DOSINGEQUIPMENT



Why WHRS required?

step to energy

conservation

Reduction in Carbon

Emission

Effective utilization

of energy

More independence from

rising energy prices

Minimizing the

utilization of CPP

Clean & Green

Environment

Waste Heat Recovery

CDM Benefits

Lower operation costs

by own power


Why with FLSmidth?..

Continuous Innovation

Process & Plant

Design Expertise

Complete integrated

Plant Supply

Extended focus on customer

satisfaction

One Source

Extensive experience in cement

Low

est C

ost o

f ove

rall

owne

rshi

p


Did you know WHR on a 5000 t/d cement plant can…?

Waste Heat Recovery


Available potential in Indian Cement plant

Installed Cement Capacity in India : ~ 280 MTPA

Average Gas emission in preheater : 2.0 to 2.4 Kg/kgcl at 280-340°C

Average Gas emission in cooler vent : 1.4 to 1.6 Kg/kgcl at 260-320°C

Average power Generation Possible : 25 to 35 KWH/MT


Heat recovery power cycles-

FLSmidth can offer


Steam Rankine cycle


Limitations with Steam Rankine cycle

� Single component system

� Power generated is low at Low temperatures

� Steam in a turbine can only expand until it reaches a temperature of ~100C, when it condenses at atmospheric pressure. This limits the efficiency of a system


Kalina Cycle Areas of Application

What are the areas of applications?

HighTemp.

LowTemp.

Waste Heat Recovery in Industries

� Gas compressor stations

� Iron + Steel Industry

� Cement Industry

� Chemical Industry

� Incineration Plants

� Diesel Plants

Hot Brine Heat Recuperation

� Geothermal Plants100°C

500°C

Primary

Source

Steel Plant (Japan)

Waste Incineration (Japan)

Geothermal Plant (Iceland)


Kalina-Cycle Heat Acquisition Advantage

Closer temperature profile means improved efficiency

IMPROVED HEAT TRANSFER FROM HOT TO COLD STREAMS

“Hot”-Side (Flue Gas or Vapor)

NH3-H2OSteam

Temperature

Heat Transferred

Mixture

isothermal boiling

saturated liquid- pinch points

Key: mixture boils at a variable temperature

saturated vapor


Kalina Cycle Conceptual Flow Diagram for Cement Applications

25

53

52

54

26

30

31

38

16

17

18

1

2

8

7 3

415 10

11

12 19

56

13

14

21

22

60 '

62 "

64 65

61 '

6343

44

45

23

58 5924

1

2 3

5 6

7 8

HRVG’s

Turbine

Cooler Gases

Preheater Gases� Unique ammonia/water process invented in

1980’s

� Ammonia and water mixture is controlled in a patented manner to achieve improved heat transfer and higher efficiency

� “Improved” Rankine cycle, not complete different cycle

� Based on proven principles as used in refrigeration plants for over 100 years, now applied to a power cycle

� Ammonia is environmentally stable with proven safety record


Pyro Section – Waste Heat Recovery system

Projects under execution by FLSmidth

Plant Start-upYear

Clinker capacity

Size of power plant

System type

D.G.KhanPakistan

Q4 2012 6700 t/d 8.6 MWdT PH – 95 Deg CdT Cooler–250 Deg C

Kalina(PH+Cooler

end tap)

Vicat SagarIndia

Q4 2012 6600 t/d 8.4 MWdT PH – 124 Deg C dT Cooler–312 Deg C

Steam(PH+Cooler

mid tap)

Star Cement, Dubai*Aditya Birla Group

Q1 2013 7500 t/d 4.75MW Kalina(Cooler vent only)

* Concept to Commissioning in 15 months


Mills and Auxiliaries


Vertical Mills

� Adapting vertical mills for raw, coal and cement grinding


Classifiers for the Mills

� Installing High efficiency Classifier to reduce the SPC forVertical Mills and Ball Mills


Mills and Pollution Control Equipments

In bag filter

Introduced long bag technology with 10 mtr long bagsUnique gas distribution arrangement for enhanced bag life

and minimum emissionsHybrid (ESP+FF) solution for lesser pressure drop and lesser downtime

ESP

Heavy duty tumbling hammer with Spheroidal tip for longer life & effective rapping

Unique Gas Distribution Screen (throttle plate with guide

vanes) for proper distribution, effective use of collection area and to prevent re-entrainment


ECS/Process Expert

A Complete Process Optimizer


ECS/Process Expert is a high-level Advanced Process Control and Optimization solution for complex and critical processes

FLSmidth’s international team of professional experts designed solutions specifically for various process applications. With more than 40 years of plant automation experience, FLSmidth has installed over 700 control systems and 450 laboratory systems – and so understands the needs of today’s plants.

Neural Networks

Robust - MPCs

Adaptive Controllers

Smart PIDs

MultiVariable Controls Estimators

Fuzzy Controllers

MatlabDeployment of Advanced Process Control Technologies….like

Process Optimisation...one of the many “Green Initiatives”

Help optimising the production process for a low carbon foot print


Kiln and Cooler Processes

Vertical Roller Mills ( Raw , Coal , Cement)

Ball Mills with/without Pre-Grinders

FLSmidth’s ECS/Process Expert EXACTLY

address optimisation needs...

2-8% Produc

tion Benefit

s

1-5% Power /

Fuel Savings

20-30% Qu

ality Impro

vements

Proven Technology with Typical Benefits



Payback for WHRS Kalina Vs Steam

Parameter Kalina Cycle design Steam design (same conditions)

Production (tpd) 7500 7500

Cooler ventGas volume (Nm3/hr)Temperature (°C)

340,000320 to 94

340,000320 to 190*

Steam/vapourQuantity (t/h)Temperature (°C)

42.5301

20.2300

Gross power(MWH) 4.75 3.9

Difference +22%

Annual revenue MINR 338.6 278

Installation Cost 850 615

Payback 2.5years 2.2years


Typical Cooler Upgrade Investment & Pay Back

� Cooler Capacity : 4000 TPD

� Cooler upgrade investment : 130 MINR*

� Expected fuel saving ~ 45 Kcal /Kg Clinker

� Guaranteed Clinker temperature = 65 + Amb Deg C

� Savings via fuel = 45*4000*330*5000 / 4500= 66 MINR / Annum

� Pay back in years = 130/ 66 = 1.9 years

100 % trouble free operation and planned maintenance

(*- Inclusive of Cooler , MF-HRB,E & I, Civil, Erection and Supervision)


Cement mill Upgrade with HRP in Semi-finish Mode

Existing Capacity : 120 TPH

Capacity Increment : 100 TPH

Savings in Sp. Power consumption : ~ 5 kWh/t

Benefit by capacity increment : 100 x 20 x 1000 x 330 = 660 MINR

Savings of power savings : 220 x 5 x 4.5 x 20 x 330 = 32.6 MINR

Total savings : = 660 + 32.6 = 693 MINR

Investment –

Mechanical : ~ 330 MINR

E&I : ~ 55 MINR

Civil : ~ 80 MINR

Misc : ~ 10 MINR

TOTAL : ~ 475 MINR

Payback : 475 / 693 ~ 9 months


Vertical Raw Mill Upgrade with HRP Kit



Savings of capacity increment : 55 x 20 x 1000 x 330/1.6

= 227 MINR

Investments

Mechanical : ~ 120 MINR

E& I : ~ 15 MINR

Civil : ~ 50 MINR

TOTAL : ~ 185 MINR

Payback : 185 / 227 ~10 months


Vertical Raw Mill Upgrade with HRP Kit / Ball Mill Kit



Savings of capacity increment : 55 x 20 x 1000 x 330/1.6

= 227 MINR

Investment With HRP With Ball Mill

Mechanical ~ 120 MINR ~ 60 MINR

E& I ~ 15 MINR ~ 10 MINR

Civil ~ 50 MINR ~ 30 MINR

TOTAL ~ 185 MINR ~ 100 MINR

Payback 185 / 227 ~10 months 100 / 227 ~ 5 months


Let us contribute towards a clean and green environment by Improving the Cement Plant

Performance


How do we do it…

Let us keep our plant Clean & Green

One Source One Partner


Contacts for Upgradation, AF, WHRS

Upgradation projects

� Mr.Anil Kumar – 9940110576 – [email protected]

� Mr.Logesh baskaran – 9566110327 – [email protected]� Mr.Rishi Kumar - 9500037491 – [email protected]� Mr.Sachin Chinchore -9500075942 – [email protected]� Mr.Jayaram Sudhakar -9500046285 - [email protected]

Alternative fuels

� Mr.Avanish karrahe - 967090223 – [email protected]� Mr.Venkatesh Seshadri – 9500075947 – [email protected]

Waste Heat Recovery System

� Mr.Avanish karrahe - 967090223 – [email protected]� Mr.Vaideesh Narayanan - 9500075947 – [email protected]


THANK YOU

Documents

Green Solutions –FLSmidth Contribution...High material and gas retention time in calciner due to its large volume and moderate swirl. Regulation range of up to 60% bypass of kiln