TUNNEL VIEW

CLINKERING LINE CAPACITY

S S Kothari and A N Unnikrishnan

Cemtech Consultant Pvt Ltd. lndia

SUMIV1ARY
Rccent derelopments in cement indust4r' have witnessed the emergence of a number of ven' large clpacitr plants of the tune of 7500-10000 tonnes per dal'. Most of thcse. dunng the last decadc. hare been installcd in the south east Asian region. The first phase of such mega plants came into e.ristence in Japan in lhe clrlr crghties b1 u'a1 of rehabilitation of the old large rvet/long dn' kiln plants into precalcination kiln units rvith suspcnsion prc-heaters. This paper trics to naluate the technical concepts and the economic considerations of
thcsc mega uruts and compare the same tith other medium size units. Data collccted shou's that inrestmcnt. cost do txrt donn rrhcrc unit size goes up. Several plants hare multiple units in other unit operation defeating thc purpose of large singlc lincs. Thc rate of reduction of lanable costs follo*s a as]'rnptotic cun'e. Ven large dia

mctcr kilns have problcms of high oralititt' migration. loading conditions & results in lower utilization. Theplants studicd in Thailand & lndoncsia shol a lnel of production lorrcr than thcir potential compared to plants in lndia.

I.

INTRODTICTION

ctllrcpriuctil

so'cral ol- the ducloping countries. an ulrvtrs lltccd rr,rth a dilcrnnra rbout the sizc of a single clirftering linc as ucll as other major unit opcrlltir)n\ c r, crushrtt;i. grrndrng & scpirnlron. storagc ctc to be adoptcd. With plant sizcs ranging from singlc
ts

lri tltr; cottlcrt of rlpid grolth ol'Ccnrcnt lndustn in

r x

llrrcol'r50()'l(xXX)t/da\ ittAscancountrics.55()(,UdavinJapan. lolersizcsinEuropc.USA&l.atiuAmcrican colrtltrrcs (c\ccpt in lt le'rr cases) and rcn small sizcs in Chrna in opcmtion. rrhat future holds for tndia in this rcspcrl t: lr srrb.jcct oI nruch intcrcst.

I
u

r *
t t'
la

'

rlllottitlizalion of opcration. influcncc on product nrir. risk

'l'ltis papcr clrrclls on \anolls lspccts of

sclc-ction critcria. e.g. operating & inrcstmcnt cost. ancl costs of scale up ol machincr-\ ctc.

E {,

2.

\\'HY VERY LARGE PLANTS ?

I F
7:

Basrc considcratiort rrhich pronlpts installatiolr of nrcga singlc lines can be traccd to

[:
tl, [.
',t.

- \/cn llrrgc dcposits of ratr rnaterial - Hrgh progrcssion o[dcntand

'

,
.;

- l-orrcr olrcr;ltln.rl cosls - \lil\ ahcitd rn a ficrcclr - Rclr;tblc ittlr.stnrcture

l.orrcr irrrcslnrcnl

costS

/t corlpctitite rnarket

'

ro susrnn high dcnsitr supplr & nacuation channels. and Conlidcncc of cquipnrcnt suppticr to Inect thc dutr condition

\otnc ol'tltcsc rrill bc dcalt in dctail rrhich nmv senc

as basis

fbr nrakinq a matris for decision

II-46

sEvE rrH NcB INTERNAnoNAL sElt wAR oN IEMENT AND BUtLDtNc MATERIALI

3.

DEMAND FORECAST

Reason'ably conect forecast of demand of ccment is very difficult to come by. It is authors' view that several of these studies are zubjective' having been by equipment supplien, shijping companies etc. -compiled Semi-Government bodies, Corporate Entities lren independent agencies such as Govern-ment & Trade Organizations. Funding Agencies e.g. Banks, Muhral Funds and other advising bodies have at times faulte4 special\' in del'eloping countries. It rnould be prudent to base demand forecast on a conservative estimate while sizing a plant.

Prtscnt Status

regard to mega capacities

have

& India).

countries, i'e', Indonesi4 Thailand, Japan & India. comparative figures of single lines in these three countries as well as Japan is tabulated in table below. Plant wise derails grnlo in tables 3,4 &5 (For ruilan4 Indonesia

A few countries have been identified here for making assessment of plant / equipment sizes with and their experience on operating & iniesrment costs. very large size of single lines been built earlier in Japan and later in Indonesi4 rhailand & Korea. comparison is made taking data of 4

TABLE - T

Thailand
Indonesia
Japan

India

Authon have considered only prants above 5500 uday for comparison.

I Includes mini -acement & white cement TECHNOLOGICAL CONCEPTS

plant

Review ofthe sizes ofabove 33 clinkering plants indicates:

ClinkeringPlant
Precalciner Kilns

Only Preheater Kiln

3 (In Japan only)

stage stage 6 stage

.$

l0 Nos.
12 Nos.

5 Nos. 4 Nos.

Rotary Kiln Size -

below 5 m. between 54 to 5.5 m. diameter between 5.5 to 6.0 m. diameter

diameter

- 14 Nos. - 15 Nos.

SEVENTH NCB INTERNATIONAL SEM//NAR ON CEMENT AND BIJILDING

MATERIALS

II-47

Rarr Grinding Plant

- All mills are vertical roller mills - One mill - one kiln configuration - 19 Nos. - Trro mills - one kiln configuration - l4 Nos. - 6800 mm dia. table and 5000 kW polver - Larplest size
With wide lariance in grindabiliry properties of rarv material (10-20 kwh/t) and at times nith higher lnoisture. the size selection is frought n,ith risk. It is also obsen'ed that several vcrtical roller mills have been
rctrolittcd b1
rva,v

of alteration in separation s-vstem indicating sub-optimal performance.

Grate Cooler

It is in this section that we hnd verl lide ranation in sizing bascd on grate loads. The fact that cral nor large plants have opted for load of 38 llm'\z/d demonstrate the grel area. High heat rccuperation and iryrrlabilin of coolcrlorksatcrosspurposes. Manl havebcenrecentl.vrctrofitted. Thelargestcooleris of 262
ser

nr"2 gratc area sith

a nidth of {.80

m.

Clinker Grinding Plants

It is obsencd that all most all plants hare 2/3 clinker grinding mills and several of these are rvith high prcssurc grinding rolls for pregrinding. sincc lhroughput rcquirements are at the rang,c of 2(X) t/h and abor e. It is lirrthcr found that po*cr sharing bct*een mill & roll prcss are still highlf incompatible. The entire technologl' ol this grinding $stem as lell as dcsign aspccts of roll press machine is under going changes. not u'ithstanding thc tirct thal first gcneration plants ucre built almost l5 lears back.
Coal

Grinding Mills

All coal grinding mills are vcrtical rollcr mills and corporatcd as under :Onc
Onc

kiln - onc mill kiln - tuo or more mills

Packing & Despatch

-' 23 Nos.

l0 Nos.

Vcn huge multiple packing facilitics hare been built in Thailand & Indoncsia around small m/c of ll()0.15(X) bags / hr. In the absencc ofadcquatc rail nct. rcn'high pcrccntage is moved by road. Largc tttor.cnrcnt of bulk cemcnt is not sccn. As against this. largc nnchines & substaintial investrnent arc madc in loldirrq br rail in India.

PERFORMANCE LEVELS

Pcrlbrmancc level of large plants in Thailand & Indonesia could not bc obtained c\ccpt for couplc o[ plltttts. This is morc so in thc background of major dosn turn in ccmcnt dcmand in these countrics as ccononric rttclt-dorrn startcd hcrc in -3 r'ears back.

With capacities in thc range of {5--17 million Va and donrcstic consumption of onlr 25.-30 nrillion t.ta. thcsc conlpanrcs in Thailand & lndonesia had no option but to c\port large quantit\ al vcn'lon ratcs. It uill bc -.cr cr;rl rcars bcforc donrcstrc production & capacitl match.

It

has bccn possiblc to collcct orcrall capacitl utilization for.1 couutrics undcr

rcvicl uhich

is as urrdcr

II-48

IEuENTH NcB INTERNAqINAL SEMINAR oN IEMENT AND BU,LDING MATER;ALS

TABLE.2
All fipurc in miltion Ue

tInstalld I

1995

1996
27.3 40.0 96.25 24.64 37.65 69.9
25.43

tggt
33.6 42.0

l99t
45.07

Indonesia

; 1
Production

Thailand
rndia

24.3 37,50

K.76
23.t2
33.37
64.53

48.60

10t.92
27.50 76.74 27.44 73.0s

47.(l N.A
I 19.10

I16.56
22.34
87.91

Indonesia

Thailand India
Consumption - lndonesia

23.92 100.45

Thailand India

24.0s 33.30 60.43

37.65 67.36

t9.07
79.76

18.8
92.0s

very low

*ffiT*f,ff;:two

7500 t/dav kilns in Indonesia also indicted a row throughp.t

rates

as

*rn

as

6.

EMPERICAL CONSIDERATION

We have, based on data of operating plants as well as well estabilished crercrio rmdea,r ^'a -*:^r: kiln size' Here also' in diffLrence in tength to diameter ,"uo ln"ryiog from LrD = l l to l5), its influence 'iewof is also projected' Though two support kilns with rJD nteof lo has been advocated for quite some time, actual plants in operation are still nery iet". 'lhe reason for this will also *oto no* be found in tne ract that it has low throughput potential, not withsranding good the.o,al

orthrougbput,tui;"',ffiff

;:f ;ilij;ff"?:.l:tr#:l';:*Tlfl#Tffi ,Hh1;THfr [:;

etrci;;;;i*.,
*o.

Thrurghput
Based on actual performanct. following emperical relationship can ghe a fairly accurate assessment of production for a given geometrical size.

a) Thermal load in kiln : 20x10^3 kcal / m^3. m. dia. h b) Tfuoughput :6tlm^3.day

Both are on effective diameter of kiln.
Operating data from various sources reveal:

i) ii) iii) ir')

For kilns of diameter < 4m, thermar road is the limiting factor. For larger kilns rvith diameter > 4nr, lolumetric loading rimits th output potential.

:}fitlrT

*to 12000 to 13000 tpd can be achieved

from a single kitn of diameter upto 6 m and an r-lD

For same diameter, potential of kilns wirh higher r,lD ratio is larger than that with lower L/D ratio. Performance characteristics of plants with kilns of 3.g0 m. dia. to 6 m. dia. is detarred in tabre -6. Capacities atIJD rarios 15 and I I grn*

i;*.h

case.

SEVENTHNCB

MATERiALS CEMENT AND BIJILDING TIONALSEI"'VAR ON

'A'TER'VA

Fucl ConsumPtion
on number of factors like' consumption of fuel is depended installation an1 For

- Plant sizc - no,ufa of rau material - troe of fuel uscd - ;Jilt of stages in Preheater' - iw or clinker cooler used'

and

levels for comaprision' folloning lalues at various capacitv consumption fuel theoretical at To arrire

have been considered: basic paramcters

a) Hcat of

b)

.i

stagcs ^' ^rint"'r Ti?eolclinkercooler 'n'rler d)

I..Io.
-L^^.^? or Preheater -tddAc

Fuel

used

clinkerisation , #":#t : '.

: )

kcavkg oal of calorific varue 5000

grate q'pc with beam aerated

:) /q Reciprocating : r(ssrPrr
:

fired

grates at inlet'

It is obsencd that in the radiation loss'

MajorvariationinsPecifrcfuelconsumption.aseridentfromthetableisonaccountofthevariation
srz-e

ir ii)

drmrnishes as plant Rate of decrease in fuel consumption

increascs'

lf

plotted' the cun'e takes an

aslmptotic nature' from Dccrease in fuel consumption

3000 tpd to 5000 tpd 50(X) tpd to 751,0 tpd 75tX) tPd to l(XXl0 tPd

ll Kcal/kg . 7 Kcul/kg and . I Kcal/kg

onl" for plants abor c 75tx) tpd ts nontinal Thus. decrcasc in fuel consttmption

rii) rr)

whcn k*ns

loucr l-lD ratio' fttcl consumption is highcr lbr

\\,hctr contparistttl
t,.;

*ith

saure diamctcr. but of diffcrcnt

optirnunr potcntial' L/D ratios are crlrulprctl. rr thcir

lerc|s. litcl consttntptrorr is |orrcr donc rrith sante rhrottglrprtt

lt

|orrcr.L/D rittto

is rlrcndr higlt' flrisnlcans.toachicrcsllncpotcntialrhroughpul.dtantctcrotkilnsl,.ith|orrcrL/Drlrtioshotr|dbc nrcga pr,urt*. rrrrcrc kiln cliamctcr .,,i.',rr ,:rtio'in'tr.,. t-ro hrrlhcr o[ ruar lcarJ to poor ktln lrrg'cr co'rpurcd lo rlurt rcquirc rp.a,,ri-,ir,antlou. ils trrrs thc'bor; of o'acco.rt rirrthcr i'crcasc rn drirurctcr lr lilatrrlrlr br 2()Kcal,,'k'g and rcducc dorrn thc litcl consuntptlon st|ll
brrng lltslltllatrort ol.a ('-Stegc prchcillcr clttr clinkcr' Kcal''!tg t'75 to lcrcl tltc tuttttntttnt consuntption

Ptlncr ConsumPtion
on ltctors likc' \1xe rlic L1o\\cr constllttptiott in a ccttlcnt planr is largclr dcpcndctl

- ttuth'rr.r[ !hltftlctcrlstlc - l\l)e ol recltrtologr ttsr.'d lbr srzc rctlttctiort and prro-proccsslll!l - llt\li1").luttlotl illld colltrol pltilcrscpln cttlplolcd
lts ptrtnt c'tpltcit) ";;.,a;.' .\t lilrrcr plirnt t::tpltcitr lcrcls. spccr!rc po\\,.r noil,..llr dccr':lscs .^4. tn111t; itltplcttrcittltlro' .f .rrrrc .f rrtih.rrtro. optrnl,u.r trr ridrr..(r .lccrrullrrul rosscs. this is ll9 nlorC prcciscI c.p,rcrttcs ltborc itU"t-Ct"""pO' 11s11.1s11,-,qr ttlorr :rnd co.lrol tcchtllqtlcs l'-tx

lllcrcllscs oll ilccortlll

ft50

ON CEITENT AND BU'I-D'NG ilATER'ALS SEVENTH NCB INTERNAT'ONALSEI'''VAR

the unit operations, 9...ry applicable, as in this case most of characteristic is unaltered with capacity' capacities ana innuence of material

pyro{toTs$n& are in multiple lines of smaller

Thu$

comparable grnding sections of a 10'000 tpd plant wiu b specific power in raw grrnding and clinker to unit weisht or clinker also is armosr unaltered as it is proportional

SfffJ"Hrlffi:#iil: cooler.
at varYing caPacities

.variationexpectedmainlyisinthepowerconsumptionofprelreaterfan.
Prhaterfanpowerisdependedonfactonlike,leakageair,systemprssuredrwadtype&calorific powers to workout comparative prehater fan are, therefore, value of fuel use. Following basic ,rorllrp,ion, 'oid"
:

a) b, c) i) ii)

Orygenlevelinpreheaterexhausgas
pteleater sysempressure
Fuer

drorp

used
:

: 450 mm wg' : pulverised-coal

ltlo/o'

of calorificval'e 5000 Kcar/kg.

Salient features noted are

in porvr If plotted the curve takes an asymptotic natue. Saving

Difrerence in spocific power consumptionbetween

decreases as plant size becomes larger'

3ooo@-

5oootpd 5000S- 7500tpd 7500 tpd - 10000 tpd

= o'l2kwh/tonne = 006 = 0'03

narrorvs down to negligible levels' Thus. at higher plant capacities. thc adlanlage

AVAILABILITY . CAPACITY UTILIZATION

in projects of high

plant availability / capacity utilization is a very important ear-anqter' especially of the r"1't J.louerv related to this' Availability investrnenr and bonowing, as rhe p."iltilit utilization de,pended on ilrmerous factors like'

capacity

- machinery rePairs - refractory rePlacement - Powr scenario - market flucturations etc'

the plans in this regar4 some basic factors that inlluence In the absence of performance data of maga are : y of pl-ants in general demand the attention The'y operational

i) ii)

"u"itruili comminution' pyro-processing' heat recuperation scaling up of machineries for operations like
constnrclion as well as operation' separation etc ha\ presented probluns during Large diameter kilns exhibit high shell ovalitY
:

- higher migration (rolling between tyre & shell) - t q"it"..it of higher section of tyre to control ovality - higher specrfic refraclory brick loading rrL
- thicker and unerven coatings & build

drhe' for rrr. power r^r -^^-- --.,-uf requiring high motor

Xit-

SEVENTH NCB INTERNANONAL SEi"'VAR ON CEMENT AND BII//LDING

MATER'ALS

II.5I

Improlement in kiln oomponent design eg. splined F"res, 2 support kilns. self aligining bearings. through support roller station etc. are the aspects that require serious'attention for better capaciS' drir-es direct
utilization.

iii)

Large plants employ s'ide cooler of above 4.8 m rvidth. The-v are difftcult to operate at high level of rccuperation due to t'ariation in granulometry. liquid phase and distribution. This can. in the long run.
lead to higher maintenance cost. lower recuperation and larger pon'er consumption.

INVESTI{ENT SCENARIO

Based on published data by various agencies it is revealed that investment cost per ton of annual insralled capacitv is uidely varying. lnspite of the fact that large portion of equipment is manufactured indigcnouslr. project cost in Thailand & Indonesia is in the range of US$ 120 -150 per ton. As against these. project cost in lndia has been as low as US$ 80 -100 per ton. Our anallsis shorv cost of equipment in these countrics is hrgher. Hence the perception that investment reduces as size ofsingle clinkering line increases. is not srftstantiated bv published information. Very large size plants hal'e left the operating companies in huge foreign loan shich are diffrcult to senice. In India. eren norv. it nill be possible to build 2 million t/a single line in US$
E-5-9() per

ton rvithout pos'er plant.

POTENTTAL OF EXISTING

PII\NT

Several operating plants are now looking to the possibility

of

exploiting .the potential of existing

plants. In last 5-7 I'ears, considerable experience has been gained in this area and capacity increase upto 20-30o/t) has been possible from existing clinkering lines by uay of:

inslalhtion of stateof-the-art d1'namic cage rotor separator in lertical roller mills for raw
grinding.
retrofrt of prehater & precalciner S'stem cnlargement of inlet section of the kiln Installation ofstatic grate at inlet ofcooler u'ith beam areated plates in recuperation zone. and installation ofhigh pressure roll press as pregrinder in clinker grinding plant.

&

coal

A bricf account of some ol the upratings done in India is gir.en in rablc - 7. Bascd cn cxperiencc rre gained in such uprating c{fort. it is pro.jcctcd that the additional invesLnrcnt inrolrcd in this uill be US $ 3(t-.10 per ton of annual capaciS'.

IO

CI,AIRVOYANCE

A strttplc <lccision rnatrix for sire of plant is ven dilhcult to o'olve as contributing factors arc *idclv diffcrcnt \\'c consitlcr that to cnsure good return on rnvestrncnt rn thc conlcNt of espcricnce gained. follorring Sutdc lirtcs rrrrn '*- forrnd uscful for dcciding thc sizc of a plant :

I tt ' 't . \
:f

Srnglt chnkcring linc of 6(xn-7(XX) Lidar. linrrting the kiln sizc to 5 mctcr & singlc line of rarr ntill. e orrl nrrll. blcnding silo and other m:rjor facililics. Strllctcrll cushlorl in rarr & coal enidrng phrnts. as porcntial of krllr is rncreasing npidlr \ltxltrlrtr conslntction of phnts.- io, c.rprns,nn to rcducc caprtal cosl as scll irs crccution time fralnc. trrlil capacilr of clinkcr grinding pllnt ro a lcrel lo cnsurc oprrmum polcr shanng bctlecn mill 1:"llll & llPRt'lhiqh prcssurc rtllcr frcss; ritrcn targc chpacitr plants are cnris.rged. l)cslgrr clinkc-r *nndrng plants for qr:rck changc ovcr ro various product qualities" rrhich nrar rn lorr r olurrrc gir c highcr r alti,: additrons.

;'!

F
t\)

TALE. o
Countn

Indo g9!B (Plan!:!s001 t/dev nnd nbove)

rtaul

--T -..__lr

D'f Canan flmilr

I

Tuban-l
FLS 7500

(rrnnlior / f)ecipn Clikerins caoacitv

_+
rDd

Trbat{ _T_FLS 7500 510

P-T.Scmen

T.Semen P.T.Scmen

P.T.Semen

P.T.Semen P.T.Semen

P.T.lndo
9emen!:_
r

f;

Tubrn-Itr Tones&-W Nusrntara

FLS 7800 600

CDtoolg_
Narugong

Cibinong

cilrceD-u
FI.JLLER
7E00

_!e!ev!-f hlglodccq.
lvlSrOS
I

I
o = @ 2

ul|tsl;sr FLS

FLS 7800 570

FLS 7500 2x330

FI.JLLER

FIJLLER

FLS

;i T

7E00
700

Ra* mill

tnh

s70 LM 59.42 2x20000

LM 59.42
2x20000
5.6 x 84

LM59.42
2x20000
5.6 x E4

LM4l.4
2x20000 5.5 x 87

LM59.42
2x20000
5.6 x 84

LNI59,42
2x20000 5.6 x 84

700 Llotr59.42 2x20000 5.6 x

8.1

Rlendins silo

t
,li
r,tD lno

--_l
-t

t-usrfizT _tM{u I -EwirsZXJ+UUU

500

)/u .-- -------!

_J

I i
q

ot,

o
F

5.6 x 84

l5

l5
4 2

l5
4
2

l5.E
4
2

l5
4
2

l5

t5

5x80 ----+
l6
5

--r1

5.5 x 87

$ 3 T o z
c)

ln
m = =

_P.qLq41!g:_&_lte93l,

:ltq.olstages__ :Ng.-g|$rtttg!--(itqlc

o =
CFG

16102 cFG 16102 CFC 16132 with 16102 cFC

16102 cFG

16102 cFG

1490 CFG

CFG FI.JLLER FI.JLLER

FULLER

FULLER

FI,JLLER

FI,JLLER

FI.JLLER

FI.JLLER

FULLER

o = o

- Area / Size

sq.q
rph
55 55 55

l7l.l

sa.m

il I
o

52

50

VRM
mill f,titl
| - Separator
1---

VRM
2x215 4.8 xl3

IVRM
550 4.E xl3

LM26.3
2x20O

LM-26.30

50 LM-26.30

50

45

50

LM-26.30
2x210 4.8 xl3

LM-26.30
550

FLS-32/lE

tph

mdiaxm
I -Press/ VRM
- Siz

-Mrkc

5x17.5 nill-2 ball mill-2 ball nill-2 ball mi[-2 ball miU-2 ball mill-2 ball mi[-2 bdl N-5000 & N-3200 N-5000 & N-5000 & N-5000 & uvP30.40 HRC LI\1P30.40 60.38 HRC 60.3E HRC 60.38 HRC 60.3E (\/RM.I.JBE) (VRM-LJBE) 2 noa. 2 nos. 2 noe. 2 nos. 2nos. 2nos, 2m0ktt 2000kw 2000 kw

2x215 4.8 xl3

2x2l0 4.t x13

2x22O
ball mill

1x210
4.7 x L4

5x15
ball mill N-5000
2.08 HRP

ball

nill

uvP30.40
(\/RM-I.JBE)
2nos.

TABLE - {

l(

ounlr.r Siam C ment Public

I'lant

Limlted

Thailand (Plants - 5500 Udav & aboye Shm Arlr Ce ment

TPI Polene Public

KaengKhoi Lampang Thung Song Thttng SonglKhro W

Lhcl
FLS FLS 5500

Line-2

Llne-l

LtE-3
KP
8500

Supplicr

I.'I,S ,
rN
rph

K}II)
5t00
440

KT{D
5500 440

KTID

UBE
10000

FLS

KP 7500

KP
7500

o rT fi
= a o o = il T
b = T

hkcnng capaclt\'
Ii-aw

5500 2x220
LM 1x25000

7500 I
T

2xl00O0
4x400

7500

mill

60t)

3E.40

LM 50.4

LM 50.4
1x25000

LM 53.4

2x4U)

2x240
LM 38.440
1x30000

2x350
LM 48.4
1x40000 5.5 x E7
15.8

2x280
VRM

2x280
VRM

2x280
VRM

LM 50.42
2x25000

LM 50.4

srlo

k-iln
'rc-heatcr

m diaxm lng.

Ln)
&
Prccalcrncr txrler

I 1x25000 5xE0 : 52x61 16 ll7

5stg. ,
5stg,

1x25000

r
, I

5.2 x 6l I 1.7
5 stg

5.6x82
t4.6

| exlo5
17.5

6x96

5 xtO

l6
5 stage 3 strings

t6
5 stg

I
6

) slg.
2

5stg
3 strings

4/5

an

2-strng

2-stnng

3stq.(;C'

3sts..GC'

3 stc,.GC

3stc,.Gc
IKN 5o-vRM

4stc.Gc
CPAG
4x1644 3x30

4 stace GC

GC

3 stq.GG

CPAG.I2
ral

CPAG-l2l
35 -

CPAG 3tt/m^2/dav
4x45

Fuller 2 x28

CPAG1644
38t/m^2/dav

3 stac.e 4830

3 strace

4830
KP(195m^21

KP

= o = o s
E
D

mill

tph

x35+l x22 A1'OX

I

45-VRM
L.M 28.3
3 5

VRM LM 23.2

2x40
LM 26.30

LM 28.3 2x26O
5

LM25.2
1x220
4.8x

ATOX
27.5 3x300 2x2E0

LM 21.20

cnrcnt
Sizc

mill

tnh m dra xrn

.l6r l-l
ballmill Sepax &
RP

185

r I4.5 ball mill &

SKS 2IO
seDarator
3 nos

xl50

2xl2O
.1.6

13.5

14.5

l4

2x t70 4.4 x 13
ball mill-2

2x270 5x12
ball mill-2

2x24Q
ball mill-2

3x240
ball mill-3

2 x 218

S
ball mill-2

o = o

ball mill-2

ball mill-2

ball mill-3
Osepa& I-IRC

ball mill-5
RP

sKs 210
separator
2 nos

SKS&
R.P

&
HRC

&
KP 850/20
2650 kw

&
R.P.

&
R.P.

o o
D

I.VRM

il I
(t

IL51

SEVENTH NCB //NnERNANONAL SET''YAR ON CENENT AND BUII-DING NATER'ALS

TABLE.S Cuntry
Plant

Indir (Ptrntr - 55{n Udey end rbove)

Flnem[6i1
Fullcr

Prirm
FLS 6600

L&TAndhrr
FLS 6500

SengDi

L&T Guirnl
FLM.&,T
6000

Srmlir/D6irn
qinecdng C@itv RnYMill

Fuller
750/J

bd
bh
mdia x 6Inc-

5000 / 6500

"

450

2x275

2x275

LM 46.4 Kiln
4.75x75
5

ATOX42.5
4.75{75
6 $asc
2

ATOX 50
4.75x75
6 stacc 2 stinr

t'Jt''59.42 5.6x&{
5 stase 2 slring

ATOX45
4.75x75
5 stasE 2 stdnc

Pre.Hcr& Prccahiu
Coolcr

shs

2 sEitrr

strinr

Coolax 14102

Coolu

14102

l4lm2
C@lMill
tph
40
50

l4l

m2

cFG 16102 152m2

50

I
TNT26.3
2 NG. Tbbc mills

50

LM26.3 CelndMilt

kTctx27.5

xroxz?.5
2x160
Tubc nill 4.2 x 2 Nos Rollcr

ATOX27.s

bh

6xt0
Tbbenilt 3.8 x 12.5

2x16o Tubo mill 4.2 x ll

2 NosRollcr

ll

atvaios
locaions

NcRoller
Prsg

hesr

Prss

TABLE-6
PERTONilTANC-I CIARACTER$ITICS Kiln dianrcter
Capacity (Kiln LrD

Or CLN{KENtrIG L[{ES WITE KILN

4.4

SI'ZES
5.75
6

3.8

4.7:
465( 550(
7500
39

5.2:

5.5

=ll)

tDd

215(
290(

270(;
360C

3650 497A
45

ffi
E75(

7330
10000
35

850(

9750

CapacitvGilnL1D =15)
Radiation loss(kilnI./t) = Radiation loss(kilnt /D

bd

63ft

l160(
3

l33m

ll)

kcaUke

5i
5(
72E
721

5l
5C

4l
4C

3i
35

3l
3C

=I5)

kcal,ftg

14

38

34

32

Fuel consumption(kiln IJD =

ll)

kcalftg

721
720

7t4 7t2
6.9{

709
70E

7U 70:
6.8t

7U
702
6.E6

702

699
69E

69

nuel censunpionftiln UD =15) kcaVke

Power oonsumption for

701
6.EJ

69(
6.81

P.l[

fan

kWVt

7.05

6.9t

6.83

SEVENTHA'CA "VTER'{A

T'ONALSEM''VAR ON CEMENT AND BIJILDING

MATERIALS II-55

TABLE.

PLANT UPRATEID BY RETROFITS

Companl

Kiln

Size

(ndiarml&)
3.8 x 50

Capacity (tPd) Uprated Original t500

2.100

Maior Retrofits

2nd string of Preheater. rpgradation ofcooler. rollpress in raw mill.

Znd string of Preheater. Step grate for cooler

Vikram - I

?Rr5o

1500

2+00

Vikram'Il l

3.E x lU

t500

2,100

2nd string of preheater. Steo grate for cooler

Shree Cement -

2400

3600

Modification in

clonlrecalciner & fan : step glate in cooler :0'namic seP.for

P.H.c1

Atox mills (R.M.&CLM)

-t.75 x 75
.1.'r5

L&T Piparar'-

5000 5500

6000
6(X)0

lL&T Piparar' - II

75

?I Iuiirat Ambuia - I

-t.0 x 60

2600

4000

Enlargement of inlet sgctlg!

of kiln. New P.H.-Precalciner

&

--f
-_J

retrofit of cooler I R.M. / C.M. New Cement Mill

8
9

lGujarat Ambuja -

ll

.1.0 x 60

2800
5500

4000 6500

doRetrofit ofcooler.

Himachal Ambuja*

,1.75

x 75