Green Cem entech 2 010

Anilku mar C.M Customer Service Projects - India

Up Grade Possibilities in Ce ment P lants

SUCESS STORIES OF CEMENT PLANT RETROFITS IN INDIA

KEERTI CEMENT S Production increased from 900 TPD to 1600 TPD MOD IFICATIONS D E ON New ILC tower installed wit 6-stage cyclones h New PH fan Modification in TAD with hoisting damper New CF Cooler G ADVANTA GES Specific heat consumption reduced by 100 kcal/kg cl Specific power consumpt ion for PH fan reduced by 5 kw hr/MT cl

GRASIM CEMENTS - RAI PUR Production increased from 427 TPD to 5328 TPD 5 MOD IFICATIONS D E ON New ILC tower installed wit 6-stage cyclone h New PH Fan for ILC t ower Kiln feed system for ILC t ower New TAD for ILC calciner ADVANTA GES Specific heat consumption reduced by 8.0 kcal/kg cl Specific power consumpt reduced by 7.8 kw hr/MT cl ion

AMBUJA CEMENT EASTERN LTD- RABRIYAWAS Production increased from 420 TPD to 6230 TPD 0 MOD IFICATIONS D E ON New SL tower inst C alled with 6-st age cyclone New PH fan for SLC tower New TAD for SLC Calciner Modification in cooler CFG and RF plates T ADVANTA GES Specific heat consumption reduced by 12 kcal/kg cl Specific power consumpt ion for ph fan reduced by 5 kw h r/MT cl

ACC - WADI Production increased from 730 TPD to 13000 TPD 0 MOD IFICATIONS D E ON New ILC twin t ower New SF 6x8 Cooler New Duoflex Burner Modification in kiln drive ADVANTA GES Specific heat consumption reduced by ~1 kcal/kg cl 8 Specific power consumpt ion 16.4 kw h r/MT cl

Reference List for Plant Upgrades

Examples

Existing SLC + New ILC Grasim Raipur

Existing ILC + New SLC GACL Rabriyawas

ILC In Lin e Calci ner

Imp rovement s I n Py ro Pro cess ing

Special advanta ges High material and gas retention time in calciner due to its large volume and moderate swirl. Regulation range of up to 60% bypass of kiln gas using ILC-I version. Well-suited for low-grade fuels Long refractory life due to low thermal kiln load and stable kiln coating Lowest NOx emission among traditional calciner kiln systems Higher fuel substitution rates

SLC-D - Separa te Li ne Cal ciner - Do wn draft

SF Cro ss Ba r Coole r
Special advan tages High material and gas retention times Very well-suited for all fuel types, especially low-volatile fuels Low NOx operation is possible. Smallest possible tower dimensions, as the calciner can be installed separately from the cyclone tower. Especially well-suited for retrofits of existing SP or ILC pre heaters due to very short down time. Simple to Operate Mechanical Air-Flow Control Simple to Main tain No moving Grates Higher Thermal Efficien cy Optimized air distribution Modular Design Reduced installation time and costs SF C ooler installed in India

43
SF C ooler installed World wide

180
SF C ooler retr ofits in India

Constan t Air Flow to Each G rate P late

ABC (Air Blast Controlled) Inlet Coolers Cast grates on sloped profile

Intern al check valve

MFRs

Flexible control of Blasting area

Air blaster manifold and pipes

Blasting frequency Blasting intensity

AIR BEAM

MFR

Solution f Better Recuperation and removal of Snowman or

n 2 d N ew Tech & Equ pmen for C i t emen P t rodu on cti

2 S 5 ept 2 0 8 0

Heavy Duty Roll Breake r - MF

A combination of transport and crushing rolls in series
Permits fines to pass through predetermined gaps Coarse is transported to the cru shing rolls Over-size material is broken into the required size by two heavy crushing rolls

Ball M ill Up Grade

Using High Ef ficiency Separators

O-SEPA Se parator
SEPAX Separator High efficiency separation with cage type rotor Separator weight less due to self supporting structure Dispersion in air stream simplifies transport to separator and functions as nip trap Ample wear protection Compact separator to facilitate easy installation High efficiency separation with cage type rotor Oil lubricated bearings for maximum endurance Cost efficient wear protection by selection of best fitted materials to the individual components

R TK M Se parator
High efficiency separation with cage type rotor enables economic and very fine grinding of e.g. Petcoke Design eliminates deposits of coal dust, hence self ignition Air stream transport simplifies lay out Ample wear protection

VRM UPG RADE WITH H RP

RAR Separator High efficiency separation with cage type rotor enclosed by guide vanes

VRM w ith HRP C ircuit

Fines are not returned to the mill Vibrations are not triggered even at very high production rates Selection of wear protection, for best balance between cost and endurance

Ti t l e

5/19/2 01 0

23

CLOSED CI RCUIT G RINDING SYSTEM WITH RO LL P RESS AS PREG RINDE R

Imp rovement s in Ce ment G rinding Capacity

CLOSED CI RCUIT G RINDING SYSTEM WITH RO LL P RESS IN FINISH M ODE

FLS - HRP

ASC fee gate for r d oller press

By this new developed feed gate th roller e press skewing can be regulated back to parallel service by adding relative more feed in the side of rollers where the distance is smallest thus resulting in more stable condition for the roller press

Air + fi ne s ou tlet

Fee d I nle t

Air int et

NO MOVING PARTS MAINTENANCE FREE OPERATION FOR YEARS CARRIES OUT 4 JOBS:
Sup por t

SEPARATION OF FINES DEGLOMERATING DRYING OR COOLING MIXING OF BOTH FRESH FEED & REJECTS

ALTE RN ATI VE FUE L SO LUTIO NS F ROM F LSMIDTH

Rejec t ou tle t

Roller P ress G rit Sepa rato r

FLSmidth Key Produc for Alternative fuels ts

FLSmidth calciner sol utions for Alternative Fuels

5 ins tallatio ns

21 ins tallatio ns

1. 2. 3. 4.

The HOTDISC solution ILC calciner adapted for alternative fuel SLC-D calciner with duoflex burner Retrofits & other calciner types
N ew produc t 1 ins tallatio n 5 ins tallatio ns 150 ins tallati ons

68 ins tallatio ns

63 ins tallatio ns

37 ins tallatio ns

Inline calciner system with a HOTDISC

COLD RAW MEAL BIN

Waste Hea t Recovery Syste m With F LS mid th

RAW MEAL TO CALCINER AND HOTDISC TRIPLE FLAP SLUICE HOTDISC

CALCINER

TERTIARY AIR

Why WHRS requir ed? Typical Co-ge neration circuit

CDM Benefits Clean & Green Env ir onm ent

Effective utilizati n o of en gy er

step t en gy o er conser vation

Waste H eat Recov er y

Minimizing th e utilization of CP P

Reduction in C arbon Emission L ower operation costs by own pow er

Mor independenc fr e e om rising en ergy prices

Wast e Heat Recovery Syst em

35

Why FLS midth for WHR Projects? s 1) 2) 3) 4) 5) 6) Better int egrat of Cement process to boiler system ion Cont inuous R& t boost up heat to generate higher power wit a D o h combustion chamber using alternative fuels Combo package of alternat ive fuels and wast heat recovery e syst em t reduced production cost of cement. o FLSmidth Automation for WHRPP (Referen ce JK Lakh smi Ceme t s) n FLSmidth Electrical, Aut omation and Civil Design Higher level of customer satisfact ion.

Wish you all the very best in your Green Initiatives