PLANT EQUIPMENT DETAILS

ILC type PC kiln , four stage PH , LP cyclones at top

stage, grate cooler upgraded with stationary inlet grate Twin roller mills for raw material grinding , 2 fan system Vertical roller mill for coal grinding Two open circuit ball mills for cement grinding

ENERGY CONSUMPTION (reported)

Power consumption

S.No.
1 2 3 4 5 6 7

Section
Crusher + ropeway Raw mills Kiln Coal mill Cement mills Packing Miscellaneous

kWh/t of cement 2.34 32.29 21.07 6.98 29.45 1.77 4.62 98.52
750 Kcal/kg cl

TOTAL
Heat consumption through fuel :

To coal mill

To GCT followed by PH fan

A - calciner B - kiln C - cooler D - cooler ESP E - cooler ID fan F - cooler chimney

Sl No

Location

Temp o C

St. pr mmWG

O2 %

COppm

Volume m3/hr

1 2 3 4 5 6 7

Cyclone IA outlet Cyclone IB outlet Cyclone IV outlet Kiln inlet Cooler takeoff Clinker discharge Tertiary air

425 412 855 1030 300-450 138 727

-765 -735 -265 -25 -45 -50

1.6 1.7 0.2 0.0 -

2280 1300 1080 15000 -

382699 358935 626455 -

Measurements in Kiln section (before repairs)

HEAT BALANCE ON KILN (before repairs)

Base Temperature Clinker production 20 C 165.33 tph

HEAT INPUT
Coal combustion Sensible heat Coal Air Kiln Feed

Kcal/ kg cl
853.4 2.8 12.8 19.2

HEAT OUTPUT
Heat of reaction PH exist gases I A PH exit gases I B Dust in PH exit gases Clinker leaving cooler Cooler vent air Evaporation of moisture Incomplete combustion Radiation and convection losses

Kcal/ kg cl
406.7 119.4 110.5 20.5 22.5 156.4 1.6 8.6 42.0

TOTAL

888.2

TOTAL

888.2

KILN
ABNORMAL OPERATING CONDITIONS

Preheater exhaust temperature of 425OC and 412OC at cyclone IA and IB respectively. High CO levels at kiln inlet, bottom cyclone outlet and top cyclone outlet Cooler exhaust air quantity of 1.77 Nm3/kg cl at a temperature of 300-450OC Clinker discharge temperature of 138OC

KILN
REASONS FOR EXCESS HEAT LOSSES Oxygen deficient conditions in kiln-precalcinerpreheater circuit leading to prolonged combustion of coal and consequently high temperature of preheater exhaust gases. Leakages in the system particularly in the tertiary air line resulting in insufficient combustion air drawn into the kiln and precalciner & abnormal quantity and temperature of cooler exhaust air

To coal mill

To GCT followed by PH fan

A - calciner B - kiln C - cooler D - cooler ESP E - cooler ID fan F - cooler chimney

Sl No

Location

Temp o C

St. pr mmWG

O2 %

COppm

Volume m3/hr

1 2 3 4 5 6 7

Cyclone IA outlet Cyclone IB outlet Cyclone IV outlet Kiln inlet Cooler takeoff Clinkerdischarge Tertiary air

389 395 890 1080 277 128 804

-775 -810 -350 -30 -30 -120

2.0 2.0 0.8 1.6 -

560 520 260 -

344437 345810 472511 -

Measurements in Kiln section (after repairs)

HEAT BALANCE ON KILN (after repairs)

Base Temperature Clinker production 20 C 172.0 tph

HEAT INPUT
Coal combustion Sensible heat Coal Air Kiln Feed

Kcal/ kg cl 763.6 2.5 4.1 19.4

HEAT OUTPUT
Heat of reaction PH exist gases I A PH exit gases I B Dust in PH exit gases Clinker leaving cooler Cooler vent air Evaporation of moisture Incomplete combustion Radiation and convection losses

Kcal/ kg cl 408.1 98.2 99.1 18.6 20.5 108.0 1.6 2.4 33.1 789.6

TOTAL

789.6

TOTAL

ENERGY SAVINGS
Potential thermal energy saving Repair of tertiary air duct and thereby Arrest leakages in tertiary air duct Draw required combustion air from cooler into kiln and calciner Reduce cooler exhaust air Optimisation of cooling air distribution in the different compartments of cooler to improve cooler thermal efficiency Kcal/kg cl

100

20

Total
Achieved thermal energy saving

120 105
(32475 t coal / annum)

2
Damper 100 % closed

A - from PH fan B1 - VRM 1 B2 VRM 2 C1 ESP 1 C2 ESP 2 D1 ESP fan 1 D2 ESP fan 2 E - chimney

Sl No 1 2 3 4 5 6 7 8

Location Mill 1 inlet Mill 2 inlet Mill 1 outlet Mill 2 outlet ESP fan 1 inlet ESP fan 2 inlet ESP fan 1 outlet ESP fan 2 outlet

Temp o C 188 192 90 95 94 97 107 103

St. pr mmWG -25 - 40 - 875 - 935 - 865 - 940 - 30 - 30

O2 % 4.4 5.1 10.7 8.8 11.1 11.4 11.0 11.7

Volume m3/hr 341352 336960 -

Measurements in raw mill section

A Booster fan B VRM C Cyclone 1 C2 Cyclone 2 D Mill fan E1 BF 1 (old) E2 BF 2 ( new) F1 BF fan(old) F2 - BF fan(new)

No 1 2 3 4 5 6 7 8 9 10 11

Location Booster fan inlet Booster fan outlet Mill inlet Mill outlet Cyclone outlet C1 Cyclone outlet C2 Mill fan outlet Bag filter fan (old) inlet Bag filter fan(old) outlet Bag filter fan (new) inlet Recirculation

Temp o C

St pr mmWG

O2 %

Vo m3/hr

396 371 287 72 71 71 82 80 71 83

-845 30 - 120 - 770 - 875 - 865 - 20 - 250 - 280 15

1.9 4.8 5.6 9.0 9.9 10.2 10.7 10.7 11.2 12.4 10.1

104580 84168 55908 16992 -

Measurements in coal mill section

MILLS
REASONS FOR EXCESS POWER CONSUMPTION

Leakages Mill 1 inlet to ESP fan 1 outlet Mill 2 inlet to ESP fan 2 outlet Mill inlet to mill fan outlet Across booster fan : : : : 66 % 71 % 49.5 % 17.9 %

Inadequate gas quantity through raw mills Worn out liners in coal mill

FAN EFFICIENCIES

S.No.
1 2 3 4 5 6 7 8

Fan location
Raw mill 1 fan Raw mill 2 fan Preheater fan Cooler ID fan Cooler fans Compartment 1 Compartment 2 Compartment 3 Compartment 4

Efficiency %
68.4 76.1 64.5 61.30 77.5 47.3 71.7 73.00

FAN EFFICIENCIES S.No.

9 10 11 12 13 14 15 16 17 18 19

Fan location
Compartment 5 Compartment 6 Compartment 7 Compartment 8 Compartment 9 Compartment 10 Coal mill booster fan Coal mill fan Coal mill bag filter 1 (old) Coal mill bag filter 2 (new) Cement mill fan

Efficiency %
56.9 79.2 69.5 78.0 36.6 67.8 61.1 57.8 78.4 64.9 30.4

REASONS FOR ENERGY LOSSES IN COMPRESSORS AND BLOWERS

LOW VOLUMETRIC EFFICIENCY LEAKAGES IMPROPER SIZE AND PIPELINE ROUTING IMPROPER DISTRIBUTION OF COMPRESSED AIR FOR DUST COLLECTORS

ENERGY SAVINGS
Potential electrical energy saving
Reduction in ESP-1 fan power consumption by arresting leakages in raw mill 1 circuit Reduction in ESP-2 fan power consumption by arresting leakages in raw mill 2 circuit Retrofitting raw mill 1 fan with high efficiency impeller Replacement of preheater fan with high efficiency fan Reduction in cooler ID fan power consumption due to reduction in vent air from 1.77 to 1.32 Nm3/kg cl Installation of variable frequency drives for cooling fans 2 & 9 Reduction of leakages in coal mill circuit Replacement of coal mill fan with high efficiency fan Optimisation of compressed air utilisation Reshuffling of motors and replacement of under loaded motors

Kwh/tonne material
0.75 0.82 0.39 1.50 0.32 0.17 4.52 2.00

Kwh/tonne cement
1.05 1.15 0.55 1.44 0.31 0.17 0.81 0.36 0.70 0.20

TOTAL Achieved electrical energy saving

6.74 3.00