Up Grade Possibilities in Cement Plants

Green Cementech 2010Anilkumar C.M

Customer Service Projects - India

SUCESS STORIES SUCESS STORIES

OF CEMENT PLANT RETROFITSOF CEMENT PLANT RETROFITS

IN INDIAIN INDIA

KEERTI CEMENTS

§ New ILC tower installed with 6-stage cyclones

§ New PH fan

§ Modification in TAD with hoisting damper

§ New CFG Cooler

MODIFICATIONS DONEMODIFICATIONS DONE

§ Specific heat consumption reduced by 100 kcal/kg cl

§ Specific power consumption for PH fan reduced by 5 kw hr/MT cl

ADVANTAGESADVANTAGES

Production increased from 900 TPDto1600 TPD

GRASIM CEMENTS - RAIPUR

§ New ILC tower installed with 6-stage cyclone

§ New PH Fan for ILC tower

§ Kiln feed system for ILC tower

§ New TAD for ILC calciner

MODIFICATIONS DONEMODIFICATIONS DONE

§ Specific heat consumption reduced by 8.0 kcal/kg cl

§ Specific power consumption reduced by 7.8 kw hr/MT cl

ADVANTAGESADVANTAGES

Production increased from 4275 TPDto5328 TPD

AMBUJA CEMENT EASTERN LTD- RABRIYAWAS

§ New SLC tower installed with 6-stage cyclone

§ New PH fan for SLC tower

§ New TAD for SLC Calciner

§ Modification in cooler CFG and RFT plates

MODIFICATIONS DONEMODIFICATIONS DONE

§ Specific heat consumption reduced by 12 kcal/kg cl

§Specific power consumption for ph fan reduced by 5 kw hr/MT cl

ADVANTAGESADVANTAGES

Production increased from 4200 TPDto6230 TPD

ACC - WADI

§ New ILC twin tower

§ New SF 6x8 Cooler

§ New Duoflex Burner

§ Modification in kiln drive

MODIFICATIONS DONEMODIFICATIONS DONE

§ Specific heat consumption reduced by ~18 kcal/kg cl

§ Specific power consumption 16.4 kw hr/MT cl

ADVANTAGESADVANTAGES

Production increased from 7300 TPDto13000 TPD

Examples…

Existing SLC + New ILC GrasimRaipur

Existing ILC + New SLC GACL Rabriyawas

Reference List for Plant Upgrades

Improvements In Py ro Processing

ILC – In Line Calci ner

Special advantages

§ 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

§ Higher fuel substitution rates

SLC-D - Separa te Li ne Cal ciner - Downdraft

Special advantages

§ High material and gas retention times

§ Very well-suited for all fuel types, especially low-volatile fuels

§ Low NOx operation is possible.

§ Smallest possible tower dimensions, as the calciner can be installed separately from the cyclone tower.

§ Especially well-suited for retrofits of existing SP or ILC pre heaters due to very short down time.

SF Cro ss Ba r Coole r

Simple to Operate§ Mechanical Air-Flow ControlSimple to Maintain§ No moving GratesHigher Thermal Efficiency§ Optimized air distributionModular Design§ Reduced installation time and costs

SF Cooler installed in India43

SF Cooler installed World wide180

SF Cooler retrofits in India5

Constant Air Flow to Each G rate Plate

AIR BEAM MFR25 Sept 200 82n d New Tech & Equipment for Cement Production

Cast grates on sloped profileInternal

check valve

MFR’s

ABC (Air Blast Controlled) Inlet Coolers

Air blaster manifold and pipes

Flexible control of

• Blasting area

• Blasting frequency

• Blasting intensity

Solution for Better Recuperation and removal of Snowman

Heavy Duty Roll Breake r - MF§ A combination of transport and crushing rolls in series

§Permits fines to pass through predetermined gaps

§Coarse is transported to the crushing rolls

§Over-size material is broken into the required size by two heavy crushing rolls

Ball M ill Up Grade

Using High Efficiency Separators

SEPAX Separator

§ High efficiency separation with cage type rotor

§ Separator weight less due to self supporting structure

§ Dispersion in air stream simplifies transport to separator and functions as nip trap

§ Ample wear protection

O-SEPA Se parator

§ Compact separator to facilitate easy installation

§ High efficiency separation with cage type rotor

§ Oil lubricated bearings for maximum endurance

§ Cost efficient wear protection by selection of best fitted materials to the individual components

RTKM Se parator

§ High efficiency separation with cage type rotor enables economic and very fine grinding of e.g. Petcoke

§ Design eliminates deposits of coal dust, hence self ignition

§ Air stream transport simplifies lay out

§ Ample wear protection

VRM –UPG RADE WITH HRP

5/19/2 01 0 23Ti t l e

VRM with HRP Circuit

RAR Separator

§ High efficiency separation with cage type rotor enclosed by guide vanes

§ Fines are not returned to the mill

§ Vibrations are not triggered even at very high production rates

§ Selection of wear protection, for best balance between cost and endurance

Improvements in Ce ment G rinding Capacity

CLOSED CIRCUIT G RINDING SYSTEM WITHROLL PRESS AS PREG RINDE R

CLOSED CIRCUIT G RINDING SYSTEM WITHROLL PRESS IN FINISH M ODE

By this new developed feed gate the roller press skewing can be regulated back to parallel service by adding relative more feed in the side of rollers where the distance is smallest thus resulting in more stable condition for the roller press

ASC feed gate for roller press

FLS - HRP

Roller Press G rit Sepa rato r

§ NO MOVING PARTS

§ MAINTENANCE FREE OPERATION FOR YEARS

§ CARRIES OUT 4 JOBS:

Ø SEPARATION OF FINES

Ø DEGLOMERATING

Ø DRYING OR COOLING

Ø MIXING OF BOTH FRESH FEED & REJECTS

Air int etFee d I nle tAir + fi ne s ou tlet

Rejec t ou tle t

Support ALTERNATIVE FUE L SOLUTIONS F ROM F LSMIDTH

FLSmidth calciner solutions for Alternative Fuels

1. The HOTDISC solution2. ILC calciner adapted for alternative fuel3. SLC-D calciner with duoflex burner4. Retrofits & other calciner types

FLSmidth Key Products for Alternative fuels

37 installatio ns68 installatio ns

150 installati ons

5 installatio ns

5 installatio ns

21 installatio ns

63 installatio ns

New produc t 1 installatio n

Inline calciner systemwith a HOTDISC

CALCINER

COLD RAW MEAL BIN

TERTIARY AIR

RAW MEAL TO CALCINER AND HOTDISC

TRIPLE FLAP SLUICE

HOTDISC

Waste Hea t Recovery Syste m With F LSmidth

Waste Heat Recovery System 35

Why WHRS required?

step to energy

conservation

Reduction in Carbon

Emission

Effective utilizationof energy

More independence from

rising energy prices

Minimizing the

utilization of CPP

Clean & GreenEnvironment

Waste Heat Recovery

CDM Benefits

Lower operation costs by own power

Typical Co-generation circuit

sWhy FLSmidthfor WHR Projects?

1) Better integration of Cement process to boiler system

2) Continuous R&D to boost up heat to generate higher power with a

combustion chamber using alternative fuels

3) Combo package of alternative fuels and waste heat recovery

system to reduced production cost of cement.

4) FLSmidth Automation for WHRPP (Reference JK Lakhsmi Cements)

5) FLSmidth Electrical, Automation and Civil Design

6) Higher level of customer satisfaction.

Wish you all the very best in your Green Initiatives