roshan dhaker report
TRANSCRIPT
A
PRACTICAL TRAINING REPORT
ON
J.K.CEMENT PVT.LTD.
NIMBAHERA
(RAJ.)
Submitted In partial fulfillment of the requirement for award of the Degree of
BACHELOR OF TECHNOLOGY
IN
Electrical Engineering
From Rajasthan Technical University, Kota
Session 2016-17
Submitted to Submitted byMr. K.C MODI ROSHAN LAL DHAKER(HOD OF EE) IVth Year (13EMTEE043)Mr. HAMENT KUMAR Electrical Engineering(SEMINAR INCHARGE)
DEPARTMENT OF ELECTRICAL ENGINEERING MAHARISHI ARVIND INSTT.OF ENGG. & TECH.MANSAROVAR, JAIPUR (RAJ.)
RAJASTHAN TECHNICAL UNIVERSIT
PREFACE
As per the requirement of B.tech course J K Cement WORKS has been kind enough to permit
me to complete my project on “cement manufacturing process and energy optimization
in cement manufacturing ”.
This report prepared during the practical training. Which is student’s first and greatest treasure as
it is full of experience, observation and knowledge.
The summer training was very interesting and gainful as it is close to real what have been studied
is all the years through was seen implemented in a modified and practical form.
The only fault was that the time available was short and there was much to learn, yet the
things learned shall never be oblivion and are of great aid in the near future.
The student wishing that gorgeous private sector undertaking success so that is may flourish and
serve the nation which has reached significant years of its independence and has to achieve many
goals
ACKNOWLEDGEMENT
It gives to me tremendous pleasure in acknowledge the invaluable assistance to me by various
personalities. In successful completion of this report.
I express my gratitude towards Mr. S K Rathore, Unit Head, and the entire management of J.
K. Cement Works for giving me a chance to work as a vocational trainee in their esteemed
organization.
I wish to acknowledge my profound gratitude towards Mr M S Shekhawat, Asst. Vice President
– HR, ER & RTC for giving me opportunity in this field.
I also wish to acknowledge my profound gratitude towards Mr. N K Vaishnav, Sr. Officer -
RTC for incessantly guiding me in-depth training on “Cement Manufacturing Process”, they
support me in every aspect of my report and encouraging me at every step.
I would be a thankless child if I don’t mention the name of my continuous source of energy and
inspiration i.e. that is my parents who always encourage and support me at every right step in my
life.
1. OVERVIEW OF J K CEMENT LTD.
1.1 The Company
J.K. Cement Ltd is an affiliate of the multi-disciplinary industrial conglomerate J.K. Organisation which was founded by Lala Kamlapat Singhania. For over four decades, J.K. Cement has partnered India's multi-sectoral infrastructure needs on the strength of its product excellence, customer orientation and technology leadership The Company has over four decades of experience in cement manufacturing. Our operations commenced with commercial production at our first grey cement plant at Nimbahera in the state of Rajasthan in May 1975. Subsequently the Company also set up 2 more units in Rajasthan at Mangrol and Gotan. In the year 2009 the Company extended its footprint by setting up a green-field unit in Muddapur, Karnataka giving it access to the markets of south-west India. In the year 2014, the company further expanded its capacity in the north with brownfield expansion of 1.5 MTPA integrated unit at Mangrol and split grinding unit of 1.5 MTPA at Jhajjar. Today J.K. Cement has an installed grey cement capacity of 10.5 MTPA making it one of the leading manufacturers in the country.
Kamla Tower, Kanpur
The Company is the second largest manufacturer of white cement in India, with an annual capacity of 600,000 tonnes in India. We are also the second largest producer of Wall putty in the country with an annual installed capacity of 5,00,000 tonnes.
J.K. Cement was the first Company to install a captive power plant in the year 1987 at Bamania, Rajasthan. J.K Cement is also the first cement Company to install a waste heat recovery power plant to take care of the need of green power. Today at its different locations, the Company has
captive power generation capacity of over 140.MWs which include 23 MW of waste heat recovery power plants.
The Company has made its first international foray with the setting up of a green-field dual process white cement-cum-grey cement plant in the free trade zone at Fujairah, U.A.E to cater to the GCC and African markets. The plant at Fujairah has a capacity of 0.6 million tonnes per annum for White Cement with a flexibility to change over its operation to produce upto 1 million tonnes per annum of Grey Cement.The commercial production from Fujairah Plant started from Sep'2014.With this, J.K Cement Ltd has become the second largest White Cement Producer in the World.
As a part of its new initiatives, the Company plans to increase the production capacity of Wall Putty to keep pace with the rising demand .In this direction, the company plans to put up 6 lac tonnes capacity at Katni in M.P.The first phase of 2 lacs tonnes will be taken up by the end of Fiscal 16.
Backed by state-of-the-art technology, access to the best quality raw materials and highly skilled manpower against the backdrop of India's infrastructural growth in an overdrive, we are upbeat about the future. Superior products and a strong Brand name, an extensive marketing and distribution network and the technical know-how represent the Company's abiding strengths.
1.2 About J K Cement
J.K Cement has three decades of experience in cement manufacturing. From modest beginning in the year 1974 with a capacity of 0.3 million tonnes at Nimbahera in Rajasthan, today J.K Cement has 6 kilns of different capacities with a combined annual capacity of 7.5 million tonnes. The three cement units having aggregate capacity of 4.5 million tonnes are located in Rajasthan at Nimbahera (capacity 3.25 million TPA), Mangrol (capacity 0.75 million TPA) and Gotan (capacity 0.47 million TPA) and one unit in Karnataka at Muddapur with capacity of 3 million TPA. The Company is the second largest manufacturer of White Cement in India, with an annual capacity of 400,000 tonnes and value-added building products such as Wall Putty.
The Company also has a fully automated plant of White Cement based Wall Putty having a production capacity of 3 lac tonnes per annum. J.K. White Cement's plants are accredited with ISO - 9001 and 14001 Certified Company by LRQA. Further, the plant is also OHSAS 18001 (For safety and environmental upkeep) accredited.
1.3 Grey Cement Plants and Production CapacityWe manufacture grey cement in two facilities located at Nimbahera and Mangrol in the state of Rajasthan in Northern India. Our plants have obtained many accolades and recognition, the most noteworthy being IMS Comprising of : ISO-9001:2008 for QMS and ISO-14001:2004 for EMS for the grey cement facility at Nimbahera and Mangrol.
The following tables shows : PRESENT CAPACITY AND PERFORMANCE
CLINKER PRODUCTION – Nimbahera and Mangrol Plant
Plant Capacity ( Tonnes / day)
J K Plant, Nimbahera
I. Kiln 1200 II. Kiln 1650 III. Kiln 4700 TPD7550
Unit 1 at Mangrol 2100
Unit 2 at Mangrol 5000
Total Capacity 14650 TPD
PRODUCTION ANALYSIS TABLE: IN TONS – Nimbahera and Mangrol Plant
Year Clinker Cement
2012 - 13 2955814 3567226
2013 – 14 3008736 3523527
2014 – 15 1961430 2378020
FINANCIAL ANALYSIS: IN Million – J K Cement Ltd.
J.K. Cement Works, Nimbahera
Commenced commercial production in 1975 with an initial capacity of 0.3 MnTPA. In the year 1979, a second production line was added to enhance the production capacity to 0.72 MnTPA. 1982 witnessed the incorporation of another production line taking the production capacity to 1.14 MnTPA. In 1988 a pre-calciner was installed and the production capacity touched 1.54 MnTPA. Constant modernization and up-gradation was instrumental in bringing the plant to its present capacity of 3.25 MnTPA. Major modification to reduce the electrical energy cost & to utilize the waste heat at maximum, Waste Heat Recovery System of
Nimbahera
Year Turnover PBT
2012 - 13 3342.58 337.54
2013 – 14 3201.72 114.18
2014 – 15 3859.40 144.10
13.2 MW was installed in the year 2007-2008.
Recognition : IMS comprising of ISO-9001:2008 for QMS and ISO-14001:2004 for EMS.
J.K. Cement Works, Mangrol
Commenced commercial production in Dec'2001 with a capacity of 0.75 MnTPA. It is situated close to
Nimbahera plant (10kms away) - offers it significant synergy benefits like assistance from technical &
commercial staff of Nimbahera Complex. The current capacity is 1.0 MnTPA. We are also starting
work on a brown field expansion at Mangrol having a capacity of 3 MnTPA, integrated plant with 1.5
Mn. TPA cement grinding capacity, 25 MW Captive power plant and 10 MW Waste Heat Recovery
plant.
J.K. Cement Works, Muddapur
It is situated near Muddapur village of taluka - Mudhol, District - Bagalkot (Karnataka) and has the latest state of art technology to manufacture 3.0 Million tonnes of cement per annum. The commercial production at Muddapur started in September, 2009 and the despatch commenced in October, 2009. The plant has the latest and the most modern dry process pre-calcination technology with sophisticated state of the art technology and control system from Internationally renowned firms like FL Smidth, Tahio Engineering Corporation, Japan and others for manufacturing cement with robotic technology and to ensure top quality cement consistently. The best equipments available in the global market have found their way into the plant making it the most modern plant. The plant has a 6500 TPD kiln. The cement production capacity of the plant is upto 3.0 Milliontons per annum based on the quantum of OPC, PPC and Slag Cement.
J.K. White Cement Works, Gotan
Our pioneering foray into white cement 25 years ago created a new chapter in the history of J.K. Cement and the J.K. White Cement Plant is an integral part of the same.
We were the first White Cement facility in India, which was limestone based, and manufactured Cement through the dry process. The White Cement plant was commissioned in 1984 at Gotan, Rajasthan, with an initial production capacity of 50,000 tons. The White Cement plant uses technical expertise from F.L. Smidth & Co. from Denmark and state of the art technology with continuous on-line quality control by micro processors and X-rays ensure that only the purest White Cement is produced. Over the years, continuous process improvements & modifications have increased the plant's production capacity to 400,000 tons per annum.
J.K. Cement Works, Fujairah
Foundation Stone Laying Ceremony of J.K. Cement Works, Fujairah - The Foundation Stone being laid by H.H. Sheikh Mohammed Bin Hamad Al Sharqi - Crown Prince of Fujairah along with Shri Yadupati Singhania - MD & CEO, J.K. Cement Ltd. and Shri Raghavpat Singhania - Special Executive.
J.K. Cement Ltd. has added yet another feather to its cap with the announcement of its maiden overseas plant at Fujairah, UAE which has a capital outlay of US $ 150 million. The plant's foundation stone laying ceremony was held on November 14th, 2011in the presence of His Highness H.H. Sheikh Mohammed Bin Hamad Al Sharqi - Crown Prince of Fujairah. Also gracing the occasion were Shri Yadupati Singhania – MD & CEO, J.K. Cement Ltd., Shri Raghavpat Singhania – Special Executive, Mr. A.K. Saraogi – CFO & President (CA), Mr. N. Gowrishankar – Unit Head (J.K. Cement Works, Fujairah) and Mr. D. Ravisankar – President, J.K. Cement Works, Nimbahera.
The capacity of the Grey cum White cement plant is slated to be at 1,750 tonnes per day (tpd) for White Cement clinker and 2,800 tonnes per day (tpd) Grey cement clinker.
The Commercial production from the plant started from Sep'14.
The plant at Fujairah has a capacity of 0.6 million tonnes per annum for White Cement with a flexibility to change over its operation to produce upto 1 million tonnes per annum of Grey Cement. The plant shall have the flexibility to have 100% white cement, a mix both of white cement and grey cement or 100% grey cement, depending upon the market demand. Thus, the Company plans to cater to the demand in the region as well as to the neighbouring countries through this manufacturing facility.
As has been a ritual with J.K. Cement Ltd., in this venture as well, we will continually strive to uphold the quality consciousness, customer experience and best ethical practices that J.K. Cement Ltd. is known for.
1.4 Power Plants
All our plants have captive power facilities except grinding unit at Jhajjar. Infact, J.K. Cement was the first Company to install captive power plant in the year 1987. J.K Cement is also the first cement Company to install a waste heat recovery power plant to take care of the need of green power. Today at
its different locations, the Company has captive power generation facilities of over 140.7 MWs including Waste Heat Recovery of 23.2 M.W.
2. MANAGEMENT SET- UP
2.1 Corporate Level- Kanpur
Chairman & Managing Director - Shri Y P Singhania
Special Executives - Shri Raghavpat Singhania
Shri Madhavkrishna Singhania
Business Head - Shri Rajnish Kapur
2.2 Heads:
Project
President Project Shri D Ravishankar
Units
Unit Head Shri S K RathoreJ K Cement, Nimbahera and Mangrol, Distt: Chittaurgarh, Rajasthan
Unit Head Shri A K JainJK Cement Works, Muddapur,Distt: Bagalkot, Karnataka
President - Works Shri B K AroraJ K Cement- White and Grey Plants at Gotan, Distt: Nagaur, Rajasthan
3. ORGANISATIONAL CHART
J K Cement Ltd.
Production & Location
J K Cement Works, Mangrol (Raj.)
Unit 1 & 2
Grey Cement–
7100 TPD
J K Thermal Power, Bamania (Raj.)
CPP – 15 MW
J K Cement, Mudhol, Karnataka
Grey Cement –
9000 TPD
J K Cement, Gotan (Raj.)
White Cement
–1000 TPD
Grey Cement –
1200 TPD
J K Cement Works, Nimbahera (Raj.)
Grey Cement–
7550 TPD
ABROAD:
JK Cement Fuzairah, UAE
White and Grey Cement
J K Organization
4. Regional Training Centre : Nimbahera
The Regional Training Centre - North is a premier training centre of India promoted with assistance from World Bank, DANIDA and Govt. of India as a unique HRD project in Cement Industry. It is equipped with modern training aids and caters to the skill enhancement and competency developmental needs of more than 20 cement and other plants. It has trained over 13000 technical and managerial personnel during the last 21 years.
The centre has conducted many tailor-made in-house programs for cement and other industries in India and abroad including for Oman Cement, Oman and Star Cement, Dubai and Hama Cement, Syria / EHDASSE Sanat Corp.Iran and NCC Yemen.RTC has specialized packages / modules in Mining, Process, Maintenance disciplines like Operation & Maintenance of HEMM / Gear-boxes / Pumps / Compressors / Electrical & Electronics Equipments / Energy Conservation /Environment Management and Machinery Alignment, etc. designed and developed by renowned International / National agencies like FLS Denmark, NCCBM, TATA Interactive Systems, VEC, NITTTR, etc. More than 100 senior line mangers from ten plants have been trained at Denmark, NITTTR, Bhopal and Chennai, who act as resource persons. Besides OEM's and management experts of national repute are invited to make these programs effective and gainful experience for the participants.
RTC VISION Be a premier centre of excellence in competency development of human resources in cement,mining and other industries for meeting the techno-economic challenges under globalized environment.
RTC MISSION RTC seeks to develop ordinary manpower to produce extra ordinary results by providing the best inputs of learning to help industry generate surpluses with sensitivity towards environment, quality and cost.
RTC OBJECTIVE 1. To prepare the employees of Cement and other industries by developing desired competencies for meeting the requirements of present and future roles.
2. To develop and maintain a pool of competent technocrats and managers to meet the emerging challenges of competition & growth.
3. To help people strive for innovative solutions and create a passion for quality, energy, Environment conservation and optimization of resources.
5. CORPORATE SOCIAL RESPONSIBILITY
J K Cement has contributed significantly to the development of various services in and around its offices and plants. Some of such activities can be enumerated as under :
Education Schools and University:
1. Dr Gaur Hari Singhania Institute of Management & Research, Kanpur
2. Sir Padampat Singhania Technical University at Bhatewar, Udaipur.
3. J K Institute of Technology – JKIT at Nimbahera
4. Padam Vidya Vihar – Primary School at Nimbahera
5. Kailash Vidya Vihar – Sr Secondary School at Nimbahera
6. Sr Secondary School, Gotan
Educational services:
1. Construction of rooms in Govt. College at Nimbahera.
2. Running JK Institute of Technology, ITI in five trades affiliated to NCVT.
3. Running 10+2 CBSE affiliated school
4. Running Regional Training Centre for Cement technocrat’s aided by WorldBank & DANIDA.
5. Various constructions in nearby Govt. Schools of Chittorgarh district.
6. We are involved in girls school (under construction) and committed reasonable financial contribution for above
Medical services
1. Rs. 36 lacks contribution for the construction of govt. Hospital at Nimbahera.
2. Ambulance to govt. Hospital.
3. Free facility of pathological laboratory for the persons of surrounding area.
4. Financial contribution to various NGOS for medical camps in the district.
5. Financial contribution for construction of dispensary & health centre in nearby villages.
6. Free Homeopathic consultancy/medicines for the patients of nearby area.
Religious services
1. Radhakrishna temple at colony premises.
2. prayer hall in hanuman temple in Nimbahera.
3. Bheemkeshwar temple in staff colony.
4. Dharmashala at Bhanwarmata (tourist/ religious place).
5. 8 rooms for Dharamshala at Pashupati Nath temple in Mandsaur (M.P.).
6. Various temples in number of nearby villages.
Sports services
7. Sports infrastructure like wooden badminton court, table tennis court, billiard room, and cricket ground, volleyball ground in colony campus.
8. Sponsoring all India youth football, volley ball and badminton tournaments.
9. Sponsoring inter-district tournaments.
10. Arranging summer camps for various sports.
Other social services
11. Construction of approach roads in and around villages of mining area.
12. Digging of tube wells.
13. Supply of tube well pumps.
14. Construction of water tanks.
15. Supply of drinking water in tankers in nearby needy places during summer.
16. Regular plantation in plant, colony and nearby villages.
17. Direct and indirect employment to thousands of persons of surrounding area.
18. Financial helps to NGOS.
19. Financial aid to organize religious festivals by municipal board.
6. Manufacturing Process - White Cement
At J.K. White Cement Works, Gotan we use technical expertise from F.L. Smidth & Co. from Denmark and state of the art technology with continuous on-line quality control by micro processors and X-rays to ensure that only the purest White Cement is produced. We manufacture White Portland Cement through
these 5 significant stages - Crushing, raw meal grinding, clinkerisation, cement grinding and packing for dispatch.
1. At raw mill, crushed limestone, clays and feldspar of desired chemical compositions are fed through electronic weigh feeders.
2. Clinkerisation is the heart of cement manufacturing process, where the raw material is fed to pre-heater at controlled rate through electronic weigh feeder. The feed enters the kiln through cyclones and fuel is fired at the kiln outlet end.
3. Clinker and gypsum are fed to the cement mills through electronic weigh feeders at controlled rate and ground in ball mills. The classifier (high efficiency separator) controls the fineness of white cement. The finished product of desired chemical composition and physical properties is transported to Cement Silos for storage.
4. White cement is drawn from cement silos, for packing in bags by electronic rotary packer and in small pouches by Fill, Form and Seal machines..
Step 1 (Mining) Step 2 (Crushing) Step 3 (Grinding) Step 4 (Fuel Preparation)
Step 5 (Kiln Operations) Step 6 (Cement Grinding) Step 7 (Packing Process) Step 8 (Loading Process)
7. Manufacturing Process - Grey Cement
The production process for cement consists of drying, grinding and mixing limestone and additives like bauxite and iron ore into a powder known as "raw meal". The raw meal is then heated and burned in a pre-heater and kiln and then cooled in an air cooling system to form a semi-finished product, known as a clinker. Clinker (95%) is cooled by air and subsequently ground with gypsum (5%) to form Ordinary Portland Cement ("OPC"). Other forms of cement require increased blending with other raw materials. Blending of clinker with other materials helps impart key characteristics to cement, which eventually govern its end use.
All J.K. Cement plants are dry process plants. Limestone is crushed to a uniform and usable size, blended with certain additives (such as iron ore and bauxite) and discharged to a vertical roller mill/Ball Mill, where the raw materials are ground to fine powder. An electrostatic precipitator dedusts the raw mill gases and collects the raw meal for a series of further stages of blending. The homogenized raw meal thus extracted is pumped to the top of a preheater by mechanical transport /FK pumps. In the preheaters the material is heated to 750ºC. Subsequently, the raw meal undergoes a process of calcination in a precalcinator (in which the carbonates present are reduced to oxides) and is then fed to the kiln. The remaining calcination and clinkerization reactions are completed in the kiln where the temperature is raised to between 1,450ºC and 1,500ºC. The clinker formed is cooled and conveyed to the clinker silo from where it is extracted and transported to the cement mills for producing cement. For producing OPC, clinker and gypsum are used , for producing Portland [Pozzolana] Cement ("PPC"), clinker, gypsum and fly ash are used and for producing Portland Slag Cement (PSC), cement uses clinker , gypsum and slag.
The JK Cement has adopted the latest technology of manufacture of cement by dry process with suspension pre heater and pre calcination. The unit has selected the dry process for the manufacturing of cement because the fuel consumption in dry process of cement manufacture is less; compared to wet process, The coal consumption ratio of wet and dry process is about 1.3: 1. However, in the case of dry process power consumption is higher. The present worldwide trend in cement industry is to put up all plants with dry process mainly because of the overall economy and lesser need of water resources.
RAW MATERIALS USED
1. Lime Stone 2. Gypsum3. Laterite
4. Alumina5. Coal6. Fly Ash
STAGES OF MANUFACTURING PROCESS
STAGE I - MINING
Maliakhera, Karoonda and Tilakhera are the mines feeding the plants. Open cast mining technique is
used. The limestone is transported to the crusher hopper through conveyor belts and dumpers.
STAGE II - CRUSHER
The limestone is crushed to the standard size for feeding the Raw Mill.
STAGE III - STACKER RECLAIMER
The stacker is used to make huge stockpiles of crushed raw material while the reclaimer picks up the
required quantity of raw material from the stockpiles and feed them into the Raw Mill through a belt
conveyor.
STAGE IV - RAW MEAL HOPPER
There are different hoppers for storing crushed Limestone, Alumina, Laterite & Gypsum, before being fed
into the Raw Mill.
STAGE V - RAW MILL
All these components of raw mix are put through grinding mills and then properly homogenized and
stored in silos.
STAGE VI - KILN
The materials from the silos are fed to the kiln through automatic weigh feeders. The hot flue gases from
the kiln passes through pre heater where raw meal gets partly calcinied and converted into clinker at a
temperature of about 1400 degree centigrade in the main burning zone of the kiln.
STAGE VII - COAL SECTION
Bituminous and Lignite varieties of coal are used here. The coal from the stock yard is fed into the coal
crusher from where the crushed coal is stored in the coal hopper. This coal to be used as fuel for the kiln
is crushed, pulverized and fed into the kiln along with primary air.
STAGE VIII - CLINKER STORAGE
After the coal is fired into the kiln and the raw meal undergoes chemical reactions, the product, which
emerges, is called the clinker. The clinker obtained from the kiln is cooled and transported to the clinker
storage yard through pan - conveyors.
STAGE IX - CEMENT MILL
The material from the clinker storage is fed into the clinker hopper and gypsum into the gypsum hopper.
The proportionate mixture of gypsum and clinker in the crushed form is sent to the cement mill, which
grinds it into fine powder called cement.
STAGE X - PACKING AND DISPATCH
The cement from the cement mill is pneumatically fed into cement storage silos from where it is packed
in HDPE bags by rotary packing machine and then directly loaded into wagons or trucks. The complete
process is controlled by a most modern process control instrumentation system. There is a well-equipped
laboratory for controlling the quality of the product at various stages in its manufacturing process.
8. A Passion for Quality – Characteristics of Cement
At J.K. Cement, quality is not just a product centric vision but an Omni-organisational vision. With a firm belief that quality begins and ends with people, the management has inculcated a quality culture in the very thought process of the organisation.
J.K. Cement Works - Nimbahera & Mangrol
J.K. Cement has effectively pledged its reputation as the market leader in quality of cement manufactured. At Nimbahera and Mangrol, our labs are equipped with State-of-the-art Process control instrumentation and quality control system. The testing laboratory is manned by qualified personnel to ensure quality of product comparable to the best available in the market at all times. The quality management system at J.K. Cement Works is certified by the Prestigeous Lloyds Register for quality assurance since the year 1995.
Our plants are also ISO 9001:2008 & ISO 14001:2004 certified and are in the process of getting our laboratory accredited with the NABL-National Accreditation Board for Testing and Calibration Laboratories.
Locate our Plants
Grey Cement Works
NIMBAHERA
Nimbahera Dist -
Chittorgarh,
Kailash Nagar - 1,
Rajasthan - 312617
Phone - 01477 - 220087
MANGROL
Mangrol, Tehsil Nimbahera
Dist - Chittorgarh, Rajasthan
Phone - 01477 - 246324
MUDHOL Muddapur
Taluk Mudhol - 587122
Dist - Bagalkot, Karnataka
Phone - 08350-289000
Fax - 08350 - 280710
GOTAN
P.O.Gotan - 342902,
Dist - Nagaur, Rajasthan
Phone - 01591 - 230201
Fax - 01591 - 230206
JHARLI (GRINDING
UNIT)
P.O - Jharli
Dist - Jhajjar
Haryana - 124106
White Cement Works
GOTAN
Gotan - 342902,
Dist - Nagaur,(Rajasthan)
Phone - 01591 - 230201
Fax - 01591 - 230206
Energy optimization in cement manufacturing
Introduction
Cement producers are large consumers of thermal and electrical energy, which on a global level are only available at steadily increasing costs. Efforts to reduce demands by using higher efficiency equipment and substituting fuels and raw materials to lower production costs have been addressed in recent years. These changes have introduced constraints that must now be managed to secure the required quality and productivity. Finding the optimal operating point within the boundaries of these dynamically variable constraints depends on the right price mix of fuels and timely purchases of electrical energy while constantly reducing demands for these resources. This article presents a set of solutions and tools to achieve these goals.
To optimize the overall performance of a cement manufacturing unit requires a plant wide automation strategy. Reducing energy demand in all areas must be combined with the search for the optimal operating point that is consistent with productivity and quality targets, and in line with imposed environmental emission limits. Helping cement manufacturers achieve their operational objectives is ABB’s Knowledge Manager (KM). KM is capable of gathering the information and data used by Expert Optimizer (EO) to model the process and to identify the best possible way of running the plant at all times.
Variable Speed Drives – an electrical energy saver:-
In the cement manufacturing process large fans draw air through the kiln, mills and filters to an exhaust stack. Many smaller fans push the air into the grate cooler to reduce the temperature of the hot clinker leaving the kiln. All these airflows have to be adjusted and controlled as atmospheric conditions, process conditions and ventilation needs greatly affect the flow requirements. The control method employed has a major effect on the running costs. For example, a damper with a fixed speed motor is the least energy efficient solution and the application of variable speed drives (VSD) the most energy efficient. To be more precise, depending on the required flow rate, power savings of up to 70 percent can be achieved when the two are compared.
The difference in power demand for an air flow controlled fan is shown in 2 . Fans are predestined for saving energy due to a quadratic load characteristic. Normal operation of large fans consumes about 90 percent of nominal air flow, which still represents a potential saving of 20 percent power. Nowadays VSD for large fans are usually installed in all new plants. However, the potential for large energy savings still exists in fan replacements, especially in the cooler area.
Optimized solution for Grate Coolers –Multi drive:-
Approximately 10 percent of the electrical energy required to produce one ton of clinker is needed to cool it. It therefore makes good sense to give careful thought to the choice of drive system for the cooler. One such choice is the Multi drive which is often referred to as an “optimized drive solution for the cooler area”. It offers all of the benefits of VSD and eliminates – in an economical sense – many of the drawbacks of single drives. Unlike single drives (which have to have their own rectifier, DC link and inverter), the Multi drive system generates the required DC voltage in a “central” unit and feeds it onto a common DC bus to which the single, independently operated inverters are connected 3 . In a Multi drive system all the desirable features of a single drive are still retained. In addition, the individual inverters do not all have to have the same power rating. On the contrary, a Multi drive package can consist of drives of very different sizes.
Some of the benefits of such a system include:
Reduced cabling due to the single power entry for multiple drives. Energy-saving motor-to-motor braking which is required depending on the grate cooler
type. Reduced space requirement Elimination of the low voltage distribution used for single
drives or dampers and direct online motors in cases of replacement. Cost effective reduction of harmonics using an active front end supply unit or at least a
12-pulse line supply.
Energy monitoring using Knowledge Manager (KM) :-
KM provides the solutions and advanced tools needed to facilitate the collection, organization and distribution of combined production, quality and energy information throughout a plant organization via web-based reports, trends, and graphs. On a single page all relevant key performance indicators (KPIs) for the process are calculated and displayed. Additionally, if an operator wants to maximize production and at the same time maximize the usage of alternative fuels, KM provides the information for proper analysis to establish what is and is not possible.
KM can be adapted and expanded to meet each company’s specific requirements and is part of ABB’s Inform IT application suite which deals with production information monitoring and reporting. It drastically simplifies cement production management by covering manufacturing related functions such as :-
Production tracking and reporting Process. operations monitoring and reporting.
4 Total energy report – thermal and electrical – with energy indicators3 A Multidrive system layout
MV Feeder
Common DC Bus
Material storage management. Energy and emission reporting.
With KM, identifying the influences that process parameters have on product quality, production capacity, energy consumption and emission levels is now easier than ever. It combines production related data, process variability, energy indexes and run-time quality parameters to produce comprehensive operation and production reports and trends. The quality of these reports and trends results in the better utilization of energy, equipment, inventories and capacities. Connectivity to Enterprise Resource Planning (ERP) systems (such as SAP) is essential to bring production data from the floor level to the enterprise management level. Here KM serves as the information broker between realtime control and its production environment, and the transactional based ERP systems.The cost of production is directly influenced by the the energy usage. Different areas of production consume different amounts of energy, and KM tracks the amounts linked to the material being
With specific information available at the right time and at the right place in the right format, decisions become more goal oriented, resulting in optimized processes and increased productivity.
Thermal energy savings using Expert Optimizer (EO):-Cement manufacturing is a complex and energy-intensive process. A key stage in this process is the conversion of ground raw materials (CaCO3, clay and/or shale) into clinker (synthetic cementitious minerals) in the kiln. A typical operation uses kiln exhaust gases to preheat the raw materials before they enter the kiln. Further heating, up to about 1,500 °C, takes place in the kiln’s burning zone where the materials are partially melted and react to form clinker. Subsequent processing is required to convert the clinker to cement. Small amounts of gypsum (CaSO4) are added and finally the mixture is ground to a fine powder.
Conventional control of a cement kiln requires the services of an experienced operator who must constantly interpret process conditions and make frequent adjustments to the set points established by the controller. This task is onerous enough, but it is made even more difficult by complex responses, time delays and interactions between individual process variables. note:- Burning zone temperature (BZT) is the predictor of product quality. If the BZT is low, it is expected that the clinker will be insufficiently burnt and if the BZT is high it is expected the clinker will be over burnt
As a result, conventional kiln control normally forces a conservative approach to kiln operation, with associated temperatures that are higher than the optimum leading to unnecessarily high-energy usage.
EO is based upon the pedigree of proven successes from the well known
and highly regarded LINK man optimization system. It combines rule based control with modern tools like Neural Networks, Fuzzy Control and Model Predictive Control (MPC). EO improves on conventional control by constantly interpreting kiln conditions and initiating appropriate actions. The various input and output signals are identified in.
Proper and stable kiln operation can reduce energy consumption and maintenance costs, increase kiln output, and improve overall product quality. However, while optimum operation involves maintaining Burning Zone Temperature (BZT)1) at minimum levels consistent with stability, this is difficult to sustain for three reasons:
1. Variations in raw material feed composition2. Complexity of kiln operation3. Long time delays between kiln operational changes (i.e., set-point changes and their
effects)
The EO advanced kiln control system, however, operates the kiln in an optimum manner thereby ensuring a good quality product, lower BZT, and consequently, lower energy
costs. The system achieves this by applying the appropriate level of expertise on a consistent and regular basis ie, by making frequent changes (every three or four minutes).
Today, reliable equipment and proven technical solutions are available to ensure the efficient use of energy without jeopardizing the quality and productivity of a plant.
EO is now typically in control of kilns for more than 80 percent of their run time. Calculations based on measured free lime and nitrogen oxide (NOx) levels before and after EO installation estimate that in some cases savings in terms of fuel consumption approach eight percent per kiln.
Kiln fuel mix optimization For some time there has been a need for tools that offer optimal management of the alternative and traditional fuels involved in the kiln process. In answer to this, EO has recently been enhanced with an Alternative Fuels Optimization Module that brings economic performance of kilns to new heights.
This module uses the data gathered by the information management systems (equipment, process, market, and laboratory) to calculate online the lowest cost fuel mix that satisfies the process and business constraints. The constraints to be satisfied are numerous but the most important ones are:
1. Heat balance2. Excess oxygen level
3. Clinker chemistry4. Volatiles concentration5. Emission limits (SO2, NOx, etc.)6. Maximum, minimum and speed of change constraints on actuators7. Operative constraints on fuel consumption8. Separate consideration of combustion process in precalciner and kiln9. Contracts (with customers or suppliers) to be satisfied at any cost
The basic element of this optimization algorithm is a dedicated kiln mathematical model developed in EO, which is used to implement the (model predictive) controller. This model can
estimate cooler, flame, burning zone, backend and preheater temperatures, kiln energy requirements, emission and volatiles levels, etc. The optimization algorithms are able to cope with both hard and soft constraints, and this enhances robustness and reliability of the optimization process.
The input data is updated at sampling times of about 15-30 minutes, computations are executed and the new fuel set points are passed to the EO strategy module for implementation. Between sampling times, the “standard”
(Extract taken from ABB Review 2/2004, pages 13-19) There are several ways in which optimal solutions can be approximated. One widely adopted approach to solving control problems involving systems which are subject to input and output constraints is Model Predictive Control (MPC). MPC is based on the so-called receding horizon philosophy, ie, a sequence of future optimal control actions is chosen according to a prediction of the short- to medium-term evolution of the system during a given time. When measurements or new information become available, a new sequence is computed which then replaces the previous one. The objectives of each new sequence run are the optimization of performance and protection of the system from constraint violations. EO strategy guarantees process stability and the highest performance. In particular, this strategy enforces economically optimal reactions to changing conditions in fuel, waste, and raw meal quality as well as ensuring strict satisfaction of the environmental, contractual and technical constraints.
Electrical energy managementCement production runs 24 hours a day with very limited spare capacity or redundancies installed. Thus, most of the equipment has to run around the clock, or if there are other constraints, during daytime like the quarry. The degrees of freedom available for electrical energy usage are therefore very limited and are mainly restricted to the cement grinding area. In this area scheduling, ie deciding when to produce a certain cement grade
and in which mill, is performed manually using heuristic rules and relying on operator experience. However, the numerous mills, grades and silos, plus the various operating and contractual constraints, make the problem a complex one. Too often, the operator’s choice is far from optimal. The solution described in the following text uses optimized scheduling based on MPC technology.
A typical mill on/off sequence and scheduled cement grades for effective electrical energy management is shown in 6 . Using customer orders and energy price forecasts, the algorithm produces a reference schedule for the entire grinding plant operation defining what each mill will produce and when. Here the modeling functional represents costs associated with electricity consumption and the amount of low grade cement produced (cement produced during the switch from one grade to another). Electricity cost reduction is achieved by committing the production to time periods when the electricity tariffs are lower, and by making sure that contracted thresholds of maximum electrical power are not exceeded. Reductions in low grade cement are obtained by penalizing the number of production switches.
In addition to the physical constraints imposed by the silo capacity and mill availability, other constraints must be considered:
Transition time: A change of grade being produced by a mill might cause a time delay during which the mill throughput is conveyed to a special silo.
Order satisfaction: As input, the optimization algorithm requires sales forecasts for every grade. If the sales forecast cannot be completely fulfilled, the algorithm will choose which grade to produce first according to a given ranking.
Transport system: Whether it is by conveyor belts, bucket elevators or air based systems, there are constraints on the system for transporting the cement from the mills to the silos. For example, there might be three mills but just two independent transport routes. However, multiple mills can simultaneously discharge the same cement grade to the same transport route. On the other hand, one route can serve only one silo at a time and silos can be served by only one route at a time.
SummaryAs shown in the above cases, energy management deals with different aspects of process optimization resulting in reduced thermal and electrical energy demand, and/or reduced costs using less expensive energy and fuel mix. Today, reliable equipment and proven technical solutions are available to ensure the efficient use of energy without jeopardizing the quality and productivity of a plant. The suite of available and integrated solutions discussed in this article – VSD,
Expert Optimizer and Knowledge Manager – is a perfect example of how a plant wide automation strategy can achieve such goals. Since energy prices continue to fluctuate (tending towards an overall increase) the investment payback time is generally good. In addition, it has a positive ecological and environmental impact. All achieved while improving the bottom line.
Bibliography: websites [email protected] jkcement.com https://library.e.abb.com
book and author Electrical machines: - ashfaq Hussain Transmission and distribution: - J.B. Gupta Power generation :-Philip kiameh High voltage engineering:-M.S. Naidu