"Best Practices in Energy Efficiency in Cement Sector"

under KEP initiative

Presentation by,

JSW Cement Ltd, Nandyal Works

1

CEMENT

@ My Home Industries

7th & 8th July 2016

2

Management Systems

3

JSW CEMENT, NANDYAL WORKS

4

Product Portfolio and Production Capacity

• 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.

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

• It’s a state-of-the-art technology cement production unit at Bilakalaguduru village near Kurnool District, Andhra Pradesh.

INTRODUCTION

5

Pyro Floor Cooler

Optimization

Operation of Cement

Grinding Roller Press in Finish

Mode

Two Major Encon Projects of FY 2015-16

6

PYROFLOOR COOLER OPTIMIZATION

7

To Avoid snowman formation

Increase cooler

efficiency

Reduce Sp. Heat Cons.

Objectives of the project

8

Model

• Pyro floor cooler type PFC 757A with roll crusher

Capacity• 6000 TPD clinker production

Clinker Temp

• 65 degC + ambient

Design Specification

9

Snowman• Frequent snowman formation

Sp. Heat cons.

• High specific heat consumption due to poor cooler recuperation efficiency

Clinker Temp

• High clinker temperature which impacts on cement mill operation

Driving Forces for the Idea

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

10

Modifications done to increase cooler efficiency

11

Cooler Horse Shoe Modification

12

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

13

Installation of shock blowers

14

Inter compartment leakage arrest

15

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

Sp. Heat consumptionKcal/kg

clinker740 709

Key Performance Indicators

16

Energy

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

• Cooler recuperation efficiency increased from 57 % to 66%

Snowman& Clinker

temp

• No snow man formation after modification

• Clinker temperature reduced from 180 to 120 degC

Cost

• Total annual savings of 3.60 crores/annum

• Stable kiln operation and improved clinker quality

Report on Savings

17

Operation of Cement Mill RP in Finish Mode

18

Reduce Sp.

Power

Eliminate Water spray

Setting Benchmark for Future Projects

Objectives of the project

19

1 Pre-Grinding by RP

2 Semi-Finish-Grinding by RP

3 Semi-Finish-Grinding by RP with VS

4 Semi-Finish Grinding by RP with VSK

5 Cement grinding by RP & BM with VSK

6 Slag Grinding by RP & VSK

7 Grinding by RP & VSK “W ”

8Grinding by RP –

COMFLEX SYSTEM

Evolution of Roller Press

20

Capacity• 350 tph @ 320 m2/kg Blaine

Technology

• KHD Roller Press with Ball Mill

• Comflex Technology

Sp. Power

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

Design Specification

21

Test run in finish grinding mode without Ball mill

Identification of main constraints

Brain storming and task force selection

Modifications

Process optimisation

Implementation Strategy

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

22

23

Modifications done to overcome challenges

MAJOR CONSTRAINTS SOLUTIONS

High vibration levels in roller press due to high fine material re-circulation and material segregation in pre-bin

Homogenised feed to roller press by fines and coarse mixing

Material flushing from RP pre-bin and unstable operation

Maintain consistent pre-bin level by roller press feed chute modification

Material flushing from V-separator discharge and belts overloaded leads to stoppage

V-separator discharge chute modification

Not able to achieve the required fineness of 350 kg/cm2

Improve the V-separator and dynamic separator efficiency

Not able to achieve the required production Process optimisation

Gap reduced from

130mm to 70 mm

Roller press feed chute height and width reduced

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 and unstable operation

Feed chute gap reduced from 130 mm to 70 mm,chute width reduced from 500 mm to 400 mm

Material flushing reduced and consistent material flow increased roller press grinding efficiency

400 mm

25

Before After

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.

RP Prebin Feed Chute Modification

26

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

SKS rejects feeding to V-sep Discharge

27

Parameter unit SKS fanV-separator inlet

RP1 RP2

Static pressure mm Wg - 450 -10 -30

Velocity m/sec 17.8 14.38 19.84

Flowm3/hr 499243 150971 248423

Nm3/hr 324005 97979 161225

unit SKS fanV-separator inlet

RP1 RP2

mm Wg - 465 -12 -13

m/sec 17.35 17.86 17.68

m3/hr 486872 192801 196696

Nm3/hr 312864 123894 126397

BEFORE AFTER

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.

V-Separator Gas Flow Optimization

28

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

Further Improvements for Stable Operation

29

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

Key Performance Indicators

30

Parameters Semi-finish Finish

Blaine 330 330

Water demand 28.6 28.4

Setting time initial/final

215/290 200/270

1 day 23.7 25.2

3 days 36.6 40.9

7 days 47.2 52.1

28 days 62.1 66.40

10

20

30

40

50

60

70

1 day 3 days 7 days 28 days

RP+BM

RP

Compressive strength

Quality Parameters Comparison

31

Energy

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

Water• Water savings of 5.50 liters/ton of OPC

Cost

• Total annual savings of 1.23 crores/annum

• Reduction in capital cost for future projects

Report on Savings

32