PRODUCTIVITY IMPROVEMENT AND ITS RELEVANCE IN INDIAN CEMENT INDUSTRY- CASE STUDIES

Rabindra Singh *, Ramachandra Rao* AK Mishra * S Kumar**, Dr SC Aluwalia**, NKM Sudhakar*** * National Council for Cement and Building Materials ** OCL India Ltd, Rajgangpur *** Dalmia (Bharat) Cement Ltd, Kadapa

Indian cement Industry has resorted to a number of measures like technology upgradation, process optimization, use of captive power plant, use of energy efficient equipment etc. to reach the present level of productivity. However, there still exists a significant Potential for improving productivity in a number of cement plants. Case studies have been cited to emphasize the role of kiln optimization leading to reduction in energy consumption to meet Pat targets. Pro-active approach of cement plant can result in timely action giving immense benefits in terms of increased production, improved quality with moderate to significant reduction in energy consumption thus improving the overall productivity of cement plant. This is demonstrated by NCB in a million tonne kiln in Eastern part of India and a 1.5 Million tonne kiln in the Southern part of India. The paper highlights the efforts of NCB towards process optimization leading to improved production, quality and energy efficiency to prepare the plants achieve Pat targets of energy consumption besides abating the effect of global warming. The result of the optimization has been spectacular for both the kilns in terms of improvement in productivity and quality. For the million tonne kiln the production increased from 2800tpd to 3200 tpd with significant reduction in heat consumption to the tune of 80 kCal/kg clinker besides improvement in clinker quality in terms of free lime. For 1.5 million tonne kiln the production increased from the existing level of 5000tpd to 5500tpd and above with significant improvement in clinker quality.

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CASE STUDY-1: Problem Discussion The 3.8 m ID x 56 m long kiln (3000 TPD clinker) was having the problem

of high free lime in clinker and coating formation in burning zone resulting in reduction of output besides high preheater exit gas temperature and high heat consumption of 913 kCal/kg clinker. 1.2 Observations NCB team visited carried out process measurements and observed reducing condition in the kiln resulting in formation of CO at kiln inlet and increase in PH exit temperature. NCB team also observed that the flame momentum of the burner is low of around 1275% m/sec, high variations in the kiln feed LSF from 110-119 high degree of calcination at 98 -99 % at kiln inlet and heat consumption was high at 913 kCal/kg clinker. 1.3 Suggestions and Recommendations Based on the above observations, NCB team provided suggestions for changes in operating parameters in the areas of blending in silo, flame momentum, operation of cooling fans to improve the productivity of the kiln. Implementation of suggested NCB recommendations by the plant resulted in increased production from the level of 2850 to 3200 tpd and reduction in thermal energy consumption from 913 kCal/kg cl to around 830 kCal/kg cl. 2.0 2.1 CASE STUDY-2 Problem Discussion: The kiln equipped with 6 stage preheater and precalciner supplied by FLS is 4.35 m ID x 67 m long with rated capacity of 4500 TPD clinker and produces around 5000 TPD clinker as against the maximum production achieved to the tune of 5800tpd. The plant has been experiencing the problem of high free lime in clinker, coating formation in burning zone, yellow core formation in the clinker and feed flush to kiln leading to fluctuating kiln feed rate and dusty kiln conditions.

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Observation: NCB team visited the plant site and carried out process measurements

and observed that the Degree of calcinations was found to be 98.08 % which is high and Kiln feed LSF variation was high in the range of 0.88-0.97 which could be one of the reasons for high free lime in clinker. Silo filling maintained by the plant was 50-60 %. Filling of silo was through two gates with silo filling period of 7 minutes from a single gate which is on the higher side. Feed extraction was from a pair of opposite gates with extraction from consecutive segments as against alternate segments. The heat recuperation efficiency of S.F. Crossbar cooler which is equipped with latest MFR technology was around 65% against expected level of 75-80% at cooler loading of 42.8 TPD/M2 indicating a further potential savings of 30-35 kcal/kg cl after MFR correction and making the kiln one of the best in terms of heat consumption at around 650 kcal/kg cl. 2.3 Suggestions and Recommendations Implementation of NCB recommendations such as changes in silo filling and silo extraction pattern, flame adjustment etc. for M/s Dalmia Cement (Bharat) at Kadappa in A.P. resulted in increased clinker production to the tune of 5500 TPD from the existing level of 5000 TPD with simultaneous improvement in clinker quality besides reduced heat consumption without any capital expenditure. 3.0 CONCLUSION Kiln optimization is a potential tool and can be exploited effectively by Indian cement Industry in achieving its PAT targets. This is amply demonstrated through the above case studies. Technical expertise of NCB is available for cement plants interested in meeting the PAT targets and improving the plant productivity.