Learning During RM2 pressure drop study

Santanu Pachhal Shashikant Vala

Anil Chordia
Yashpal Fauzdar
Chandan Shrivastava S
P Gautam
Manish Ranjan
© LafargeHolcim Ltd 2015 Rajesh L Kathiriya
Content
• Specific Electrical Energy Consumption (SEEC) reduction
• Raw mill (RM 1 and RM 2) power comparison with design.
• Feed size – RM 1 and RM 2
• RM 1 and RM 2 process parameters
• RM 2 fan high pressure drop analysis
• RM 2 internal inspection findings
• RM 1 findings
• Analysis of Quality data

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Mill Performance comparison of Raw Mills ( RM)

Design equivalent
Parameter Design @current residue Operation (Feb 19)

RM1(Atox RM2(Atox
Mill Type RM-1 RM-2 RM-1 RM2
-40) -37.5)
Production (t/h) 340 260 318 223 304 201
% Residue on 90 15% - 13.16 13.16 13.21
µm/212 µm - 2.5% 1.35 1.35 1.34
Power
a) Mill main Drive (kW) - 5.2 6.35 8.02

b) Mill Fan (kW) - - 6.94 8.08

c) Mill Dept (kW) - - 15.11 19.12

• Kiln Bag house dust is added to RM 1 bucket elevator, which improves RM

1 performance by ~ 5%.
• Raw mill 2 consumes ~ 3 kWh/t higher than raw mill 1.
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Feed Size

• Feed Size: Too coarse

> 100 mm size limestone
coming to mill is avg 5%
against target of 0% on
100mm.

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Reduction of Mill Feed Size

•Wobbler Current
Setting: 80
mm gap between two
• Recommend New
Setting -50 mm

• New setting
will
implemented
in next
shutdown .

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Process parameters comparison for both raw mill

Parameter Unit VRM 1 VRM 2 • Fan inlet pressure of both raw

mills are same.
Mill inelt pressure mbar -9.3 -11.5
Mill outlet pressure mbar -85.2 -75 • RM 2 running with low dust
Mill Differential pressure mbar 75.9 63.5 loading at mill outlet.
CCRDP( inlet - casing) mbar 58 40
DPacrossseparator mbar 17.9 23.5 • High SEEC of RM fan is due to
Fain inlet mbar -92 -91 high flow (0.5 kWh/t) and low
efficiency of fan (0.5 kWh/t) (
Mill Inlet Temp DegC 225 165 high cone gap.)
Mill Outlet Temp DegC 92 86
Production t/h 330 200 • High mill differential pressure of
Fan flow m3/hr 680970 495830 RM 1 compared to RM 2 due to
Dust Loading gm/m3 485 403 high nozzle velocity in RM 1
(Vvertical ~ 48 m/s)
Fan Power kW 2028 1650
Fan Efficiency % 90 75

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Pressure Profile RM 2 inlet duct.

Junction
-35 mmwg

35 mmwg

Damper 2 I/L
-70 mmwg
Damper 2 0/L 09 mmwg
-79 mmwg

Damper 3 I/L
-83 mmwg 17 mmwg
Damper 3 O/L
-100 mmwg
12 mmwg
Mill I/L
-112 mmwg
~30 mmwg extra pressure drop due to unwanted dampers
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Higher pressure drop across RM 2 Cyclone

• High pressure drop across cyclone 100

mmwg.
• Cyclone inlet velocity is high ~19.7 m/s.
Normal design is 16 m/s (~ 40 mmwg
extra pressure drop in cyclone)
• Cyclone inlet duct pressure loss is 50
mmwg (~ 40 mmwg extra)

Saving potential of 0.5 kWh/t

material i.e. ~ 2.2 mio ₹/a

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RM 2 Mill internal condition
• Nozzle plates are worn out and
repaired during visit.
.• Mill fan: High wear of fan inlet cone.
Gap increased up to 40 mm.
• All bottom vane in Separator rotor
are worn out.
• Wear of static guide vanes at
specific location- Mill outlet duct
side.
• Water spray nozzle installed in roller
no 3 during visit .
• Roller no 2 nozzle height is 600 mm
creating material coating on roller
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Recommendations RM # 2
• Reduce dam ring height of RM 2 by 20 mm. Adjustment of
dam ring height needs to be done on regular basis once table
liner worn out
• Reduce inlet pressure of RM 2 by removing obstacle in duct (
unwanted dampers -1 nos) .
• Take down the nozzle of water spray by 100 mm in roller no.2.
• Feasibility study to reduce pressure drop across cyclone
through CFD.
• Repair separator rotor.
• Repair fan inlet worn parts.
• Reduce fan inlet cone gap as per design.
Potential to reduce 1 kWh/t material in main drive power
and 1 kWh/t material in fan power
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 Recommendations

• Reduce mill feed size < 100 mm

• d95 <= 3 % DR for hard material
In case of RB d95 <= 72 mm. d

• Repair separator static guide vanes

of RM 1.
• Increase nozzle area of RM 1 by
installing current nozzle plate blind at
elevated position as shown in
picture.

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Recommendation

• Check design gap

between two roller
segments. It should
be 3 mm with new
segments for both
raw MIll.
• Discuss with supplier
about dimensions.

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Thanks

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