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PLANT ARASMETA CEMENT PLANT, INDIA
LINE
DESIGN DATA MILL1 MILL2
COAL MILL TYPE Ball Mill Vertical Mill
COAL MILL DESIGN CAPACITY 15 25 tph product
POWER CONSUMPTION DESIGN (MILL ONLY) 2!"5 #$h%tFUEL ANALYSIS - AS PER DESIGN
CV NA !&'' #cal%#( )et ad*
ASH NA &2"+ ad*
TOTAL MOISTURE NA 2'-.a/0 ar
INHERENT MOISTURE NA & ar
VM NA 25"5 ad*
S NA '"! ad*
Cl NA NA ad*
HGI NA 5'
PRODUCT RESIDUE 90 um 12 12
COAL MILL MOTOR POWER INSTALLED !'5 &5 #$
COAL MILL GEARO! POWER NA NA #$TALE DIAMETER 2 .
ALL MILL DIAMETER & .
ALL MILL DRYING CHAMER LENGTH 2"3 .
ALL MILL GRINDING CHAMER LENGTH !"! .
SEPARATOR SUPPLIER 4LS%LT LNVT
SEPARATOR TYPE Static LVT t6pe
MILL FILTER AREA TOTAL &!'"&! 1''' .2
MILL FILTER AREA ACTIVE (OFFLINE CLEANING) .2
MILL FAN DESIGN VOLUME 2!'' 3!''' .&%hr
"#l$ %&'l $* +,m %'.'%#,+ 1! tph
C'l%#$/ %&'l $* +,m %'.'%#,+ 2' tphNote7
ad* air dried *ai
ar a recei8ed
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PLANT ARASMETA CEMENT PLANT, INDIA
LINE
CURRENT OPERATION
RAW MEAL
Cl&/# '"'12'"'2
"FUI & to !
CLIN"ER CHEMISTRY
S SO '" '"3
N'2O '"25 '"&
"2O 1"5 1"
Cl&/# '"'2' '"'25
COAL MILL PERFORMANCE MILL 1 MILL 2
PRODUCTION 15 2+ tph product Actual 9or
PRODUCT RESIDUE 90 UM 15"3 25"2
PRODUCT RESIDUE 200 UM 1":2 2"5
MILL POWER ASORED &+1 2+ #$
POWER CONSUMPTION &"' 2"' #$h%t
PRODUCT MOISTURE 1"35 1"1! FUEL 1 PROPORTION 1'' 1'' total CV i)put
FUEL 2 PROPORTION ' ' total CV i)put
FUEL ANALYSIS - CURRENT FUEL 1 FUEL 2
CV !333 !53 #cal%#( )et ad*
ASH &'"& &!"' ad*
TOTAL MOISTURE ar
INHERENT MOISTURE 1"35 1"1! ar
VM 2"1 2!"++ ad*
S '"& '"& ad*
Cl '"'15 '"'15 ad*
HGI 3 :
ALTERNATIVE FUEL NOT THRU MILLS c8 replace.e)t"ILN FEEDRATE VARIATION &"' tph
COAL FEED RATE VARIATIONS "ILN ;% 1' tph
COAL FEED RATE VARIATIONS PC ;% tph
URNER MOMENTUM &"3 Nh%
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2''2
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COAL MILL E!PLOSION PROTECTION4 FIRE SUPPRESSION
1 PREHEATER E!IT
Preheater gas analysis
Preheater e/it (a a)al6er i)talled -6%)0
@2 .eaured -6%)0
C@ .eaured -6%)0
Ser8ice 9actor o9 a)al6er :5 -6%)0
2 COAL MILL
Coal .ill dei() preure
DCS 6te. i)talled i9 )ot ?hat t6pe o9 co)trol 6te.
i)( hot (a 9ro. cooler,preheater or hot (a (e)erator
coal mill temperature monitoring
coal .ill e/it ther.ocouple i)talled -6%)0Nor.al operati)( e/it te.perature
Alar. co)9i(ured 9or e/it te.perature
4irt alar. le8el 9or coal .ill e/it te.perature
Seco)d alar. le8el 9or coal .ill e/it te.perature
i)let ther.ocouple i)talled -6%)0
Nor.al operati)( I)let Te.perature
Alar. co)9i(ured 9or i)let te.perature
4irt alar. le8el 9or .ill i)let te.perature
Seco)d alar. le8el 9or coal .ill i)let te.perature
Te.perature co)trolled *6 Recirculatio) da.per -6%)0
Auto.ated hutdo?) 9or hi(h hi(h coal .ill e/it te.perature -6%)0
@>
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Ba( 9ilter dei() preure
Bag filter temperature monitoring
I)let ther.ocouple 9itted -6%)0
@utlet ther.ocouple 9itted -6%)0
Di99ere)tial te.perature .o)itored a)d dipla6ed -6%)0
Poitio) o9 pro*e -e"(" i) 9ilter or duct0
T6pical di99ere)tial te.perature
4irt alar. le8el o9 di99ere)tial te.perature
Seco)d alar. le8el o9 di99ere)tial te.perature
Doe eco)d alar. tri((er auto.atic hutdo?) -6%)0
Te.perature .eaured i) *a( 9ilter *otto. -6%)0
Material dichar(e te.perature o9 *a( 9ilter .eaured -6%)0
Bag filter Gas monitoring
Ba( 9ilter (a e/it a)al6er i)talled -6%)0
Poitio) i)ide 9ilter or i) e/it duct
C@ .eaured -6%)0
@2 .eaured -6%)0
Nor.al operati)( le8el o9 C@ pp.
Nor.al operati)( le8el o9 @2
4irt alar. le8el -@2 0
Seco)d alar. le8el -@204irt alar. le8el -C@ pp.0
Seco)d alar. le8el -C@ pp.0
Do the eco)d alar. 9or C@ or @2 tri((er a) auto.atic hutdo?)
Bag filter level devices
A)6 le8el de8ice i)talled i) *a( 9ilter -6%)0
poitio) o9 le8el de8ice
A)6 *loc#a(e de8ice 9itted to 9ilter dichar(e -6%)0
Bag filter isolation4at acti)( iolatio) da.per i)talled outlet a)d i)let o9 9ilter -6%)0
Bag filter Explosion protection
E/ploio) relie9 i)talled o) *a( 9ilter -6%)0
T6pe o9 protectio) -el9 cloi)( door rupture pa)el etc0
Area o9 e/ploio) door, pa)el -.20
Li9ti)(% *rea#i)( preure o9 9lap , pa)el
Nu.*er o9 e/ploio) door pa)el etc
Poitio) o9 door pa)el -ide 8e)ti)( etc0
5 PULVERI6ED FUEL STORAGE4uel tora(e dei() preure
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Pulverized fuel Storage silo gas monitoring
Nu.*er o9 tora(e ilo
Capacit6 o9 ilo % -t0
C@ a)al6er i)talled o) i)di8idual ilo% -6%)0
Pulverized fuel Storage silo temperature monitoring
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Ther.ocouple i)talled i) ilo% -6%)0
Nu.*er o9 .eauri)( poi)t
Poitio) o9 poi)t - ilo *otto., *od6, top etc0
4irt alar. le8el
Seco)d alar. le8el
A)6 other te.perature .o)itori)( de8ice i)talled -decri*e0
pulverized fuel storage silo/s explosion protection
E/ploio) relie9 i)talled o) ilo -6%)0
T6pe o9 protectio) -el9 cloi)( door rupture pa)el etc0
Nu.*er o9 e/ploio) door pa)el etc
Area o9 e/ploio) 9lap, pa)el -.20
Li9ti)(% *rea#i)( preure o9 9lap , pa)el7 RAW COAL STORAGE HOPPER IF INSTALLED (PRIOR TO MILL)
4ire uppreio) 6te. i)talled -6%)0Te.perature .o)itori)( 9or hopper
E/ploio) 8e)t i)talled -6%)0
C@ .o)itori)( i)talled -6%)0
8 OPERATOR TRAINING
Fa8e operator had trai)i)( o) 9ire uppreio) tech)iHue
DOCUMENTATION
I there a ?ritte) procedure i) cae o9 9ire or upected 9ire o) the coal .ill 6te.
Are there a)6 ?ritte) procedure co8eri)( (e)eral houe #eepi)( i) coal (ri)di)( area
A)6 9or.al trai)i)( atte)d -?ith upplier Atc etc0
: SYSTEM GENERAL
I there a clea)i)( chedule 9or the coal pla)t area -6%)0
Fa8e earthi)( trap *ee) i)talled a)d teted o) all co)8e6i)( pipe -6%)0
I there a)6 horiJo)tal ducti)( i) the 6te.
9 FIRE SUPPRESSION SYSTEM
Date i)talled
Ma)u9acturer
T6pe o9 uppreio) ued
CO2 (gas)
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CO2 (liquid & gas)
N2
Stora(e capacit6
Stora(e i) *ul# or *ottle
Re9ill deli8er6 ti.e 9ro. ti.e o9 order -hr0
Deli8er capacit6 -M&%hr0
A8aila*le dichar(e area -coal .ill, 9ilter, ilo other etc0
A)6 alter)ati8e or eco)dar6 6te. ued
Auto.atic ra? .eal *la)#et 6te. i)talled
A)6 e/ploio) uppreio) 6te. 9itted - dr6 po?der or other0
$hat area ha8e e/ploio) the uppreio) 6te. i)talled
10
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COAL MILL E!PLOSION PROTECTION4 FIRE SUPPRESSION
1 PREHEATER E!IT
Preheater gas analysis
Preheater e/it (a a)al6er i)talled -6%)0
@2 .eaured -6%)0
C@ .eaured -6%)0
Ser8ice 9actor o9 a)al6er :5 -6%)0
2 COAL MILL
Coal .ill dei() preure -*ar0
DCS 6te. i)talled i9 )ot ?hat t6pe o9 co)trol 6te.
i)( hot (a 9ro. cooler,preheater or hot (a (e)erator
coal mill temperature monitoring
coal .ill e/it ther.ocouple i)talled -6%)0
Nor.al operati)( e/it te.perature Alar. co)9i(ured 9or e/it te.perature
4irt alar. le8el 9or coal .ill e/it te.perature
Seco)d alar. le8el 9or coal .ill e/it te.perature
i)let ther.ocouple i)talled -6%)0
Nor.al operati)( I)let Te.perature
Alar. co)9i(ured 9or i)let te.perature
4irt alar. le8el 9or .ill i)let te.perature
Seco)d alar. le8el 9or coal .ill e/it te.perature
Te.perature co)trolled *6 Recirculatio) da.per -6%)0Auto.ated hutdo?) 9or hi(h hi(h coal .ill e/it te.perature -6%)0
@>
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Area o9 e/ploio) 9lap, pa)el -.20
Li9ti)(% *rea#i)( preure o9 9lap , pa)el
Ma)u9acturer o9 e/ploio) relie9
E/tra Ve)ti)( 9itted o) duct 9ro. coal .ill to 9ilter -6%)0
Ve)ti)( directio) i)ide or outide *uildi)(
COAL MILL AG FILTER
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Ba( 9ilter dei() preure
Bag filter temperature monitoring
I)let ther.ocouple 9itted -6%)0
@utlet ther.ocouple 9itted -6%)0
Di99ere)tial te.perature .o)itored a)d dipla6ed -6%)0
Poitio) o9 pro*e -e"(" i) 9ilter or duct0
T6pical di99ere)tial te.perature
4irt alar. le8el o9 di99ere)tial te.perature
Seco)d alar. le8el o9 di99ere)tial te.perature
Doe eco)d alar. tri((er auto.atic hutdo?) -6%)0
Te.perature .eaured i) *a( 9ilter *otto. -6%)0
Material dichar(e te.perature o9 *a( 9ilter .eaured -6%)0
Bag filter Gas monitoring
Ba( 9ilter (a e/it a)al6er i)talled -6%)0
Poitio) i)ide 9ilter or i) e/it duct
C@ .eaured -6%)0
@2 .eaured -6%)0
Nor.al operati)( le8el o9 C@ pp.
Nor.al operati)( le8el o9 @2
4irt alar. le8el -@2 0
Seco)d alar. le8el -@204irt alar. le8el -C@ pp.0
Seco)d alar. le8el -C@ pp.0
Do the eco)d alar. 9or C@ or @2 tri((er a) auto.atic hutdo?)
Bag filter level devices
A)6 le8el de8ice i)talled i) *a( 9ilter -6%)0
poitio) o9 le8el de8ice
A)6 *loc#a(e de8ice 9itted to 9ilter dichar(e -6%)0
Bag filter isolation4at acti)( iolatio) da.per i)talled outlet a)d i)let o9 9ilter -6%)0
Bag filter Explosion protection
E/ploio) relie9 i)talled o) *a( 9ilter -6%)0
T6pe o9 protectio) -el9 cloi)( door rupture pa)el etc0
Area o9 e/ploio) door, pa)el -.20
Li9ti)(% *rea#i)( preure o9 9lap , pa)el
Nu.*er o9 e/ploio) door pa)el etc
Poitio) o9 door pa)el -ide 8e)ti)( etc0
5 PULVERI6ED FUEL STORAGE4uel tora(e dei() preure
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Pulverized fuel Storage silo gas monitoring
Nu.*er o9 tora(e ilo
Capacit6 o9 ilo % -t0
C@ a)al6er i)talled o) i)di8idual ilo% -6%)0
Pulverized fuel Storage silo temperature monitoring
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Ther.ocouple i)talled i) ilo% -6%)0
Nu.*er o9 .eauri)( poi)t
Poitio) o9 poi)t - ilo *otto., *od6, top etc0
4irt alar. le8el
Seco)d alar. le8el
A)6 other te.perature .o)itori)( de8ice i)talled -decri*e0
pulverized fuel storage silo/s explosion protection
E/ploio) relie9 i)talled o) ilo -6%)0
T6pe o9 protectio) -el9 cloi)( door rupture pa)el etc0
Nu.*er o9 e/ploio) door pa)el etc
Area o9 e/ploio) 9lap, pa)el -.20
Li9ti)(% *rea#i)( preure o9 9lap , pa)el7 RAW COAL STORAGE HOPPER IF INSTALLED (PRIOR TO MILL)
4ire uppreio) 6te. i)talled -6%)0Te.perature .o)itori)( 9or hopper
E/ploio) 8e)t i)talled -6%)0
C@ .o)itori)( i)talled -6%)0
8 OPERATOR TRAINING
Fa8e operator had trai)i)( o) 9ire uppreio) tech)iHue
DOCUMENTATION
I there a ?ritte) procedure i) cae o9 9ire or upected 9ire o) the coal .ill 6te.
Are there a)6 ?ritte) procedure co8eri)( (e)eral houe #eepi)( i) coal (ri)di)( area
A)6 9or.al trai)i)( atte)d -?ith upplier Atc etc0
: SYSTEM GENERAL
I there a clea)i)( chedule 9or the coal pla)t area -6%)0
Fa8e earthi)( trap *ee) i)talled a)d teted o) all co)8e6i)( pipe -6%)0
I there a)6 horiJo)tal ducti)( i) the 6te.
9 FIRE SUPPRESSION SYSTEM
Date i)talled
Ma)u9acturer
T6pe o9 uppreio) ued
CO2 (gas)
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CO2 (liquid & gas)
N2
Stora(e capacit6 #(
Stora(e i) *ul# or *ottle
Re9ill deli8er6 ti.e 9ro. ti.e o9 order -hr0
Deli8er capacit6 -M&%hr0
A8aila*le dichar(e area -coal .ill, 9ilter, ilo other etc0
A)6 alter)ati8e or eco)dar6 6te. ued
Auto.atic ra? .eal *la)#et 6te. i)talled
A)6 e/ploio) uppreio) 6te. 9itted - dr6 po?der or other0
$hat area ha8e e/ploio) the uppreio) 6te. i)talled
10