Excursion of Loesche Mills with

RAMCO Group
N. Ravishankar:

Sr. VP (Manufacturing)

RAMCO Group An Overview

RAMCO Group was founded by Late Sri P.A.C.

Ramasamy Raja, a great visionary of the last
century.

Now it is headed by his Proficient Successor

Sri P.R.Ramasubrahmaneya Rajha.

The groups business interests are in the areas

of cement, cement asbestos sheets, textile and
software.

Groups Total turnover is $ 1000 Million

Groups Employees : >14000

RAMCO Group of Companies at a Glance

Textiles

Rajapalayam Mills Ltd

Sudarshan Spinning Mills
Sri Vishnu Shankar Mill Ltd
Rajapalayam Spintext
Sri Ramco Spinners
Rajapalayam Textiles
Sandhya Spinning Mills Ltd
Thanjavur Spinning Mill Ltd.
Fiber Cement
Ramco Industries Ltd
Ramco Lanka (P) Ltd
Cement
The Ramco Cements Ltd (RCL)
Software
Ramco Systems Ltd
Surgical Cotton
The Ramaraju Surgical Cotton Mills Ltd
Bio Technology
Shri Ramco Biotech

The Ramco Cement Limited An Overview

The Ramco Cement Ltd. (TRCL), formerly known as
Madras Cements Limited, is a flagship company of RAMCO Group.
TRCL is having 5 Integrated cement manufacturing units, 3 cement
grinding units with the total annual capacity of 13 Million TPA.
TRCL is producing mainly OPC and PPC as per Bureau of Indian
Standards (BIS ) quality , meeting all regional market demand.

ISO 14001:2004

ISO 9001:2008

IS 18001:2007
4

The Ramco Cement Limited An Overview

Special emphasis is always given to the highest quality standards

for the product.

The Company believes in continual upgradation of technology

and skill of people.

All its plants are of the latest state of the art technology prevailing
during the time of inception and continually upgraded.

The plants are highly energy efficient and eco-friendly.

Loesche Vertical Roller Mills at TRCL

Location

Material

No. of
Mills

Alathiyur 1&2

Limestone

LM 38.3

Alathiyur 1&2

Coal

LM 20.2 D

Clinker

LM 56.2+2 C

Jayanthipuram1

Slag

LM 46.2+2 CS

Jayanthipuram-2

Limestone

LM 46.4

Jayanthipuram-2

Coal

LM 28.2 D

Ariyalur-1

Limestone

LM 46.4

Ariyalur-1

Coal

LM28.2 D

Ariyalur-1

Clinker

LM56.3+3 C

Alathiyur 2

Mill Size

Alathiyur Plant
Line 1

Line 2

Commissioned
(year)

1997

2001

Kiln

FLS *2300 t/d

FLS - *3000 t/d

Raw Mill

Loesche LM 38.3

Loesche LM 38.3

Coal Mill

Loesche LM 20.2D

Loesche LM 20.2D

Cement Mill

O.K 33.4

Loesche
LM 56.2+2 C

* Kiln Capacity later upgraded to 3500 tpd

8

Alathiyur Plant
Unit

Raw Mills
LM 38.3

Coal Mills
LM 20.2D

Cement Mill
LM 56.2+2C

Rated Output

t/h

215

21

*PPC - 220

Feed Moisture

5-10

15

%R90 /
cm2/g

17

15

3400

Table Diameter

mm

3800

2000

5600

Mill Motor
Rating

kW

1750

400

4000

Fan Motor
Rating

kW

1750

750

2850

** LSKS 52

** LKS 40 ZD

LSKS 85 C

Description

Product
Fineness

Classifier Size

* PPC with 25% Ash ( Ratio of Dry and Wet 50:50)

** Later Upgraded to High Efficiency Classifier

Alathiyur Plant
First Loesche mills in TRCL were commissioned at Alathiyur , Unit-1 in 1997.

- Raw Mill LM 38.3

- Coal Mill LM 20.2D
Looking into successful performance of Loesche mills, same mills were repeated

for Alathiyur, Unit-2 .

Additionally a cement mill LM 56.2+2 C was also ordered for PPC @3400 Blaine

at Alathiyur, Unit-2.
Outstanding performance of all the Loesche mills at Alathiyur plant and efficient after

sales services opened a gateway for Loesche for future projects of TRCL.
Subsequently TRCL decided to enhance the kiln capacity and maximum usage of

petoke for kiln/calciner firing. This necessitated extra output from raw mills and coal
mills at reduced product residue.
10

Alathiyur Plant

11

Alathiyur Coal Mills LM 20.2 D: Classifier Upgradation

Background
Driven by Techno-economical reasons, TRCL started using petcoke
Due to the typical burning characteristics, the petcoke has to be ground to a

fineness below 2% on 90 micron for complete combustion.

The then old generation classifier was not able to provide efficient

separation leading to unstable mill operation.

The kiln capacity was under compromise and therefore it was decided to

replace the classifier from old LKS to latest generation cage wheel type
LSKS classifier.

12

Alathiyur Coal Mills LM 20.2 D: Classifier Upgradation

LKS Vs. LSKS

LKS Classifier

New LSKS Classifier

13

Alathiyur Coal Mills LM 20.2 D: Classifier Upgradation

Comparative Operating Data in Petcoke & Coal Grinding

Description

PETCOKE

COAL

Before

After

Before

After

LKS 40 ZD

LSKS 36 ZD

LKS 40 ZD

LSKS 36 ZD

13

16-17

23

28

1.5 -2

18

< 16

Specific Power: Mill

(kWh/t)

19.2

15.5

12.17

8.21

Specific power: Fan

(kWh/t)

32.3

26.5

19.13

16.96

Total Specific Power

(kWh/t)

51.5

42.0

31.30

25.17

Classifier Size
Output (dry basis)
(t/h)
Product Residue @ 90
m (%)

14

Alathiyur Coal Mills LM 20.2 D: Classifier Upgradation

Benefits Achieved
After

classifier

retrofit,

the

mill

performance improved significantly and

TRCL could use 100% petcoke @1.52% R90.
The homogeneous quality of pulverised

petcoke improved its burning efficiency

Kiln could be operated to its full

potential.
Abnormal

coatings

in

kiln

got

eliminated.

15

Alathiyur Plant

16

Alathiyur Raw Mills LM 38.3: Classifier Upgradation

Background
Raw mills were designed for a feed moisture of 6% normal & 10% maximum.
Over a period of time, the normal feed moisture increased to more than 10% causing
reduced output from raw mills to 205-210 t/h from normal 215-220 t/h.
Since more heat was required for drying, the gas volume was to be increased in mills
and thereby causing higher product residue.
Kiln feed had to be reduced as the raw mills were unable to support the raw meal
requirement.
At high residue of raw meal on 212 m, problems related to clinker burning resulted in
high free lime of >2.5%.
Raw mills with Hot Air Generator (HAG) met the raw meal requirement but residue was
still high.
17

Alathiyur Raw Mills LM 38.3: Classifier Upgradation

Background

MCL decided to further enhance the kiln capacity to 3500 t/d

Accordingly the revised capacity requirement from each raw mill

230 t/h to support the upgraded kiln.

Product residue @212 m was required to be less than 2%.

It was decided to replace the then classifier LSKS52 to higher size LSKS57
equipped with Vortex Rectifier

Due to higher air flow requirements, fans were upgraded and ducts were
enlarged.

was >=

18

Alathiyur Raw Mills LM 38.3: Classifier Upgradation

Classifier Details

Vortex
Rectifier

Rotor

LSKS

LSKS With Vortex Rectifier

19

Alathiyur Raw Mills LM 38.3: Classifier Upgradation

20

Alathiyur Raw Mills LM 38.3: Classifier Upgradation

Vortex Rectifier

Without Vortex Rectifier

With vortex Rectifier

Hard twisted gas flow created by high

speed rotation of classifier rotor

Uniform and Laminar Flow

21

Alathiyur Raw Mills LM 38.3: Classifier Upgradation

Vortex Rectifier
Flow Characteristics

Classifier with Vortex Rectifier

Results of CFD

Classifier without Vortex Rectifier

Laminar Flow

Turbulent Flow
22

Alathiyur Raw Mills LM 38.3: Classifier Upgradation

Comparative Operating Data
Description
Classifier Size
Feed Moisture (%)
Mill Output (t/h) dry
Product Residue
212 m (%)
Product Residue
90 m (%)
Total Specific Power
(kWh/t)
Mill + Fan

Before
Modification

After
Modification

LSKS 52

LSKS 57

>=10

>=10

207

232

2.5-3.0

1.5 - 2.0

19-20

16-17

12 -13

11

23

Alathiyur Raw Mills LM 38.3: Classifier Upgradation

Benefits Achieved
Output increased to 232 t/h at feed moisture >=10% to cater kiln requirement
The mill can be operated at 240t/h-245t/h with increased Hot Gas from HGG.
Saving of about 1-2 kWh/t in specific power drawn by mill and fan.
Product Residue on 212 m (crucial for burning ) came down to 1.5-2%.
With improved particle size distribution of mill product, free lime in clinker
reduced to <2% leading to improved clinker quality : C3S >=55%
Kiln is being operated to its full capacity due to adequate quality and quantity
of raw meal.
Stable Kiln Operation
24

Alathiyur Plant
Summary
Both the raw mills with classifier equipped with vortex rectifier are in smooth
operation and given tremendous advantage.
Both the coal mills upgraded with LSKS classifier are grinding successfully
100% petcoke at 1.5-2% residue on 90 micron.
Performance of LM 56.2+2 C is considered as benchmark in the group.
TRCL is satisfied with overall performance of all the Loesche mills at Alathiyur.
Due to significant energy saving in grinding section, TRCL achieved 63-64
kWh/t in PPC for complete plant, which is benchmark in the industry.
Upgrading LM 56.2+2 C with new LSVS classifier is under discussion.
25

Jayanthipuram Plant

26

Jayanthipuram Plant
Line 1

Line 2

Commissioned
(year)

2000

2008

Kiln

FLS 3200 t/d

FLS - 4200 t/d

Raw Mill

ATOX 37.5

Loesche LM 46.4

Coal Mill

ATOX 20

Loesche LM 28.2 D

Cement Mill

Loesche LM 46.2+2 CS

FLS Ball Mill with

AMCL Pre-Grinder

27

Jayanthipuram Plant
Description

Unit

Raw Mill
LM 46.4

Coal Mill
LM 28.2D

Cement Mill
LM 46.2+2CS

Rated Output

t/h

400

40

Slag - 75

Feed Moisture

12

15

Product
Fineness

%R90 /
cm2/g

15

15

4500

Table Diameter

mm

4600

2800

4600

Mill Main Motor

kW

2400

600

3200

Mill Fan Motor

kW

3200

750

1750

LSKS 76

LKS 43 ZD

*LJKS

Classifier Size

Later Upgraded to High Efficiency LSKS type Classifier for OPC/PPC

28

Jayanthipuram Plant
Summary
In 2000, first Loesche mill LM 46.2+2 CS was commissioned for slag grinding.
Later TRCL started producing OPC and PPC from this mill.
Looking into encouraging results of classifier upgradation at Alathiyur, the
cement mill LM 46.2+2 CS at Jayanthipuram was upgraded with LSKS
classifier.
Later in 2008, one raw mill LM 46.4 and one coal mill LM28.2D were
commissioned in Jayanthipuram Unit-2.
TRCL is satisfied with overall performance of all the Loesche mills at
Jayanthipuram.
Upgrading LM 46.2+2 CS with new LSVS classifier is under discussion.
29

RAMCO CEMENT
ARIYALUR PLANT

30

Ariyalur Plant
Line 1
Commissioned
(year)

2008-2009

Kiln

FLS 4300 t/d

Raw Mill

Loesche LM 46.4

Coal Mill

Loesche LM 28.2 D

Cement Mill

Loesche LM 56.3+3 C

31

Ariyalur Plant
Description

Unit

Raw Mill
LM 46.4

Coal Mills
LM 28.2 D

Cement Mill
LM 56.3+3 C

Rated Output

t/h

335

40

*PPC - 305

Feed Moisture

12

Product
Fineness

%R90 /
cm2/g

2% R212

15

3400

Table Diameter

mm

4600

2800

5600

Mill Main Motor

kW

2400

600

5400

Mill Fan Motor

kW

3200

750

2850

LSKS 76

LSKS 43 ZD

**LSKS 92 C

Classifier Size

* PPC with 25% Ash (Ratio of Dry and Wet 50:50)

** Later Upgraded to High Efficiency Classifier
32

Ariyalur Cement Mill LM 56.3+3C: Classifier Upgradation

Background
All the Loesche mills at Ariyalur were
commissioned in 2008-09
PG test was successfully completed for
all the mills.
Later TRCL started using petcoke for kiln
firing and clinker quality deteriorated.
Performance
deteriorated

of

cement

mill

and

TRCL

decided

also
to

upgrade it by LSVS classifier .

33

Ariyalur Cement Mill LM 56.3+3C: Classifier Upgradation

Pre-Conditions

At the time of retrofit, mill performance was jointly recorded as:

Mill Output

t/h

285-290

Product Blaine

cm2/g

3400

Total Sp Energy

kWh/t

26

Fly Ash

28

Dry Fly Ash & Wet Ash

Ratio

50:50

Total Sp Energy @meter

(Mill+Fan+Classifier)

kWh/t

25.5

Guarantees
Increase in Mill Output

10

Reduction in Specific Power

kWh/t

1-1.5
34

Ariyalur Cement Mill LM 56.3+3C: Classifier Upgradation

Comparative Operating Data
Description
Classifier Size
Mill Output (t/h) dry
Product Fineness cm2/g
Grinding Aid (g/t)
Total Specific Power
(kWh/t) @Meter
(Mill + Fan + Classifier)

Before
Modification

After
Modification

LSKS 92C

LSVS 97C

285

325

3400

3400

Nil

Nil

25.5

22.5 - 23.0

Improvement

40 ( 14% )

2.5 3.0

35

Ariyalur Cement Mill LM 56.3+3C: Classifier Upgradation

Benefits Achieved

Output increased by 40 t/h i.e. about 14 %

Saving of about 2.5 3.0 kWh/t in specific energy .
Reduced vibration trippings and Stable mill operation
Reduced fluctuations in mill motor power.

36

CONCLUSION

Association of TRCL and Loesche has been quite long which is

constantly strengthen by prompt & efficient services of Loesche.
Loesche Mills are the Bone - Marrow of TRCL Cement Plants.
TRCL finds Loesche Mills are the simplest from operation and
maintenance aspects.
TRCL is planning to upgrade Jayanthipuram Cement Mill LM
46.2+2CS and Alathiyur Cement Mill LM 56.2+2C by LSVS classifier.

37

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