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"Best Practices in Energy

Efficiency in Cement Sector"


under KEP initiative CEMENT
Presentation by,
JSW Cement Ltd, Nandyal Works

@ My Home Industries
7th & 8th July 2016
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Management Systems

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JSW CEMENT, NANDYAL WORKS

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INTRODUCTION

• JSW entered the cement market in 2009 with a vision to ensure a sustainable future for
the country by producing eco-friendly cement, using industrial by-products such as slag

• JSW Cement produces three varieties of products: Portland Slag Cement (PSC),
Ordinary Portland Cement (OPC), and Ground Granulated Blast Furnace Slag (GGBFS).

• Not only does JSW Cement manufacture one of the most eco-friendly cements in India,
but it also engineers its products for superior strength and durability.

Product Portfolio and • The plant has a capacity is to produce Clinker ~ 2.50 million ton per annum (mtpa) and
Production Capacity Cement ~ 4.80 mtpa

• It’s a state-of-the-art technology cement production unit at Bilakalaguduru village near


Kurnool District, Andhra Pradesh.

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Two Major Encon Projects of FY 2015-16

Operation of
Pyro Floor Cement
Cooler Grinding Roller
Optimization Press in Finish
Mode

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PYROFLOOR COOLER
OPTIMIZATION

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Objectives of the project

To Avoid Increase
snowman Reduce Sp.
cooler
formation Heat Cons.
efficiency

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Design Specification

• Pyro floor cooler type PFC 757A with roll


Model crusher

• 6000 TPD clinker production


Capacity

Clinker • 65 degC + ambient


Temp

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Driving Forces for the Idea

• Frequent snowman formation


Snowman

• High specific heat consumption due to poor cooler


Sp. Heat recuperation efficiency
cons.

• High clinker temperature which impacts on cement mill


Clinker operation
Temp

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Modifications done to increase
cooler efficiency

 Cooler static grate horse shoe modification


 Horse shoe base area reduced and static grate
area increased by 5%
 First four cooler fans upgraded
 Calibration of cooler bed height sonar
 Cooler inter compartment leakage arrested
 Installation of new shock blowers

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Cooler Horse Shoe Modification

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Cooler fans upgradation

PARAMETER Unit FAN-1 FAN-2 FAN-3 FAN-4

Flow m3/s 22.5 to 29.7 18.33 to 23.33 16.25 to 18.9 16.83 to 20.0

Motor Kw kW 400 to 520 315 to 400 250 250

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Installation of shock blowers

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Inter compartment leakage arrest

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Key Performance Indicators

PROCESS PARAMETER UOM Before After

Clinker Production tpd 6600 6600

SAT DegC 1000-1050 1050-1100

TAD DegC 850-875 925-950

Cooler Vent DegC 350-375 300-330

Clinker Temp DegC 180 120

Recuperation Efficiency % 57 66

Kcal/kg
Sp. Heat consumption 740 709
clinker

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Report on Savings

• Sp. heat cons. reduced from 740 to 709 kcal/kgclinker


• Cooler recuperation efficiency increased from 57 % to
Energy 66%

• No snow man formation after modification


Snowman • Clinker temperature reduced from 180 to 120 degC
& Clinker
temp
• Total annual savings of 3.60 crores/annum
Cost • Stable kiln operation and improved clinker quality

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Operation of Cement Mill
RP in Finish Mode

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Objectives of the project

Reduce Eliminate Setting


Sp. Benchmark
Water for Future
Power spray Projects

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Evolution of Roller Press
Grinding by RP –
8 COMFLEX SYSTEM

7 Grinding by RP & VSK “W ”

6 Slag Grinding by RP & VSK

Cement grinding by RP & BM with VSK


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4 Semi-Finish Grinding by RP with VSK

Semi-Finish-Grinding by RP with VS
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Semi-Finish-Grinding by RP
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Pre-Grinding by RP
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Design Specification

• 350 tph @ 320 m2/kg Blaine


Capacity

• KHD Roller Press with Ball Mill


Technology • Comflex Technology

Sp.
• 26.00 Kwh/ton of OPC @ 320 m2/kg Blaine
Power

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Implementation Strategy

Test run in finish grinding mode without


Ball mill

Identification of main constraints

Brain storming and task force selection

Modifications

Process optimisation

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Challenges Faced on Finish Mode

 Roller Press Skewing Problem


 High recirculation of fine material
 Uneven feed distribution to two roller presses
 Material flushing from RP prebin
 Heavy roller press vibration
 Frequent shear pin cut problem
 Difficult in handling separator reject material

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Modifications done to overcome
challenges
MAJOR CONSTRAINTS SOLUTIONS
High vibration levels in roller press due to high Homogenised feed to roller press by fines and
fine material re-circulation and material coarse mixing
segregation in pre-bin

Material flushing from RP pre-bin and unstable Maintain consistent pre-bin level by roller
operation press feed chute modification

Material flushing from V-separator discharge


V-separator discharge chute modification
and belts overloaded leads to stoppage

Not able to achieve the required fineness of Improve the V-separator and dynamic
350 kg/cm2 separator efficiency

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Not able to achieve the required production Process optimisation
Roller Press Feed Chute Modification

TARGET: To achieve consistent material flow to


roller press by maintaining stable pre-bin level

 Due to more gap between feed chute discharge


to roller surface, material column sliding and
pre-bin flushing which leads to heavy vibrations Gap reduced from
130mm to 70 mm
and unstable operation

Roller press feed chute height and width reduced


 Feed chute gap reduced from 130 mm to 70
mm,chute width reduced from 500 mm to 400
mm
400 mm
 Material flushing reduced and consistent
material flow increased roller press grinding
efficiency
RP Prebin Feed Chute Modification
 Material segregating inside pre-bin and passing through
roller press resulting high pressure and gap differences
leads to poor grinding efficiency.
 Mixing box installed by reducing the chute width to mix
coarse and fines to give homogenous feed to roller press
and improve the grinding efficiency.

Before After

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SKS rejects feeding to V-sep Discharge

Installation of two pipe chutes with


dosing gates from dynamic separator
reject bin to V-separator discharge belt
which results:

Reduced RP vibrations due to well


homogenization of separator rejects
with fresh feed

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V-Separator Gas Flow Optimization
 From the gas flow measurements difference was found between RP1 & RP2 V- separator efficiency
due to blockage of V-separator feed inlet chute.

After blockage removal equal gas flow distribution was achieved and process efficiency increased.

BEFORE AFTER
V-separator inlet V-separator inlet
Parameter unit SKS fan unit SKS fan
RP1 RP2 RP1 RP2
Static pressure mm Wg - 450 -10 -30 mm Wg - 465 -12 -13
Velocity m/sec 17.8 14.38 19.84 m/sec 17.35 17.86 17.68
m3/hr 499243 150971 248423 m3/hr 486872 192801 196696
Flow
Nm3/hr 324005 97979 161225 Nm3/hr 312864 123894 126397

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Further Improvements for Stable
Operation
Mixing box installation in intermediate feed bin to achieve homogenised fresh feed

Roller press de-dusting system modification for better venting to reduce vibrations

SKS reject bin inlet chute modification and de-dusting system provided for better
distribution

All the belt conveyor and bucket elevator discharge chutes were re-designed by
reducing the opening to avoid material flushing and overloading

Installation of cake breaker beam at roller press discharge to improve separation


efficiency

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Key Performance Indicators

PROCESS PARAMETER UOM SEMI-FINISHED FINISHED-MODE

Feed tph 293 240

Fineness m2/kg 330 350

Roller press power KW 5510 5520

Hydraulic pressure bar 140 142

Separator drive load KW 175 140

Process fan power KW 1100 910

Ball mill drive power KW 2000 0

Ball mill water spray Litre/t 5.5 0

Specific power Kwh/t 29.48 27.38


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Quality Parameters Comparison

Compressive strength
Parameters Semi-finish Finish
Blaine 330 330 70
Water demand 28.6 28.4 60
Setting time 50
215/290 200/270
initial/final RP+BM
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1 day 23.7 25.2 RP
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3 days 36.6 40.9
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7 days 47.2 52.1
10
28 days 62.1 66.4
0
1 day 3 days 7 days 28 days
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Report on Savings

• Sp. Power Savings of 2.10 kwh/ton of OPC with


Energy superior quality of product

• Water savings of 5.50 liters/ton of OPC


Water

• Total annual savings of 1.23 crores/annum


Cost • Reduction in capital cost for future projects

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