Crusher

Crushers are the breaking machines which converts the large sizes particles into
smaller required sizes by the means of the collisions and compressions forces.
There are two types of crushers mainly used and they are:

 Primary crusher(jaw crusher): Capacity 300 T/hr.

They are used to reduce the size of limestone from the mining site into minimum
of 300 mm size up to 100 mm size. They are located at the mining site on the
downward sides to the mining areas from which the limestone crushed are loaded
into the ropeway and forwarded to the plant site.

 Secondary crusher (Impact crusher):

Secondary crusher is also called impact crusher as it uses the impact forces to
break down the particles onto smaller size. It reduces the size of limestone up to 30
mm or less.

Table 1 Specifications of secondary crusher

Description Specification

Type SAP-6/200 N impact crusher

Capacity 300 t/hr (wet basis)

Feed size 300 x 100 x 100mm

Product size 95% under 25mm

No. of striking plate 24 pieces.

Peripheral speed 365 rpm

Motor output 350 KW

 Other types of crusher are gyratory crusher and cone crusher.

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 Stacker
A stacker is a large machine used in bulk material handling. Its function is to
pile bulk material such as limestone on to a stockpile. Stackers are nominally
rated for capacity in tones per hour (tph). They normally travel on a rail
between stockpiles in the stockyard. A stacker can usually move in at least two
directions: horizontally along the rail and vertically by luffing (raising and
lowering) its boom. Luffing of the boom minimizes dust by reducing the
distance that material needs to fall to the top of the stockpile. The boom is
luffed upwards as the height of the stockpile increases.

Figure 1 Stacker creating pile of limestone

Table 2 Specifications of Stacker

Description Specification

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 Material to be handled

Material Limestone

Material Size (Max.) 95% under 25mm

Moisture Content (Max.) 5%

Stacking Capacity Max. 420 t/h,

normal 390 t.hr

Dimensions

Stocking pile height 11719mm

Stocking pile width 30000mm

Capacity 2*20000 ton each length

90m

Re-claimer

Re-claimer is a volumetric machine used in bulk material handling applications.

Re-claimers normally travel on a rail between stockpiles in the stockyard. A
bucket wheel re-claimer can typically move in two directions: horizontally
along the rail; vertically by "luffing" its boom. Bucket wheel re-claimers use
"bucket wheels" for removing material from the pile they are reclaiming.

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 Figure 1 Re-claimer

Reinforced Suspension Pre heater

The RSP facilitates firing of fuel (up to 60% of total requirement) before kiln, to
achieve calcinations degree up to 95% and thus helps in increasing capacity of the
total system substantially, without increasing heat load in the kiln. The RSP system
mainly consists of the Swirl burner (SB), Swirl calciner (SC), Mixing chamber
(MC) and Adjustable Orifice (AO).

 Swirl burner (SB)

Fuel is introduced vertically in the burner and primary air from the cooler enters
tangentially. This part of the calciner helps in providing stable burning of fuel, with
relatively high air/fuel ratio.

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  Swirl calciner (SC)

The oxygen rich hot air tapped from cooler enters tangentially in this furnace.
Material from second stage (from bottom) cyclone is fed at the feed points as
shown. The swirling action provides longer retention time and achieves complete
combustion of fuel at nearly stoichiometric fuel/air ratio. The presence of oxygen
rich air helps in rapid combustion of fuel. These conditions help in rapid
combustion of fuel. These conditions help in rapid calcinations of the raw meal fed
to the calciner.

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  Mixing Chamber (MC)

A duct (CD) connects the SC to MC. The hot gas from kiln gets mixed with the hot
gases with material coming from SC in the MC. The material gets lifted and enters
the bottom stage cyclone. The MC provides further retention time and helps in
accelerating the calcinations up to95% before the material gets separated in the
bottom stage cyclone and is fed to the kiln.

 Adjustable Orifice (AO)

This device installed at kiln inlet before MC helps in adjusting velocity of the air
entering MC and balances quantity of the air passing through kiln and that passing
through duct taking air from cooler to SC.

Raw Mill (Vertical Roller)

Kawasaki's CK Mill, a highly efficient vertical roller mill that is used for raw
materials grinding and finish grinding in the cement manufacturing process,
helps reduce energy consumption by as much as 30% to 50% compared to
conventional pulverizers (tube mills). In cement manufacturing, limestone, the
main ingredient, is mixed with clay, silica, iron to be dried and pulverized
together. The mixture then undergoes burning and finishes grinding before it
becomes a cement product. The vertical roller mill is a grinding device with a
mill table and rollers at the bottom of a pulverizes.

Table 3 Specifications of Vertical Roller Mill

Description Specification

Makers name Vertical Roller CK-

200

Capacity 70T/hr

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Feed material size (max.) 25mm

Product grain size 12% residue on 90

micron sieve.

Number of grinding Roller 3 pieces

Revolution speed of table 36.83 rpm.

Motor for mill drive 750 Kilowatt 6P,

985rpm.

Figure 3 Vertical Roller Mill

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 Grinding process
Clinker from the clinker silo is allowed to pass into the clinker hopper having
capacity of 65T through the bucket elevator. Gypsum one of the additives used
in the cement production is processed like other raw material and allowed to
pass into the gypsum hopper having capacity of 45T. After doing series of
operation these material is allowed to pass into the cement silo having capacity
of 5000T. Finally the material is processed and packed to deliver in the market.

Coal grinding mill

Maker Name KHI Ltd. Japan

Type Vertical roller mill – KVM
Capacity 10 T/hr. (D.B.)
Feed Material size Max 80mm, 20mm residue < 20%
Product size <12% residue on 90 Micron sieve,
Moisture (inlet)
Total moisture <10%
Inherent moisture < 1.5%
Motor for mill drive 160 KW

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 Rotary Kiln

A rotary kiln is a pyro-processing device used to raise materials to a high

temperature (calcination) in a continuous process. The kiln is a cylindrical
vessel, inclined slightly to the horizontal, which is rotated slowly about its axis.
The material to be processed is fed into the upper end of the cylinder. As the
kiln rotates, material gradually moves down towards the lower end, and may
undergo a certain amount of stirring and mixing. Hot gases pass along the kiln,
sometimes in the same direction as the process material but usually in the
opposite direction. The hot gases may be generated in an external furnace, or
may be generated by a flame inside the kiln. The fuel for this pulverized coal
and sometimes diesel.

Table 4 Specifications of Rotary Kiln

Description Specification

Clinker production: 800 TPD

Size of Kiln: ø3.8 x 60 L

Slope: 3.5%

Kiln speed: 1.8-0.18 RPM

Number of support: 3 Support

Rotating direction: Clockwise

Motor 130 KW, DC

Rated power 750 KW

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Figure 4 Rotary Kiln

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 Table 1 Reaction Temperature within the Klin
Temperature Range Product Chemical Reaction
100-110oC Steam H2O Evaporation of free water from the feed H2O
(liquid) = H2O (gas)-586 kcal/kg H2O
450-800oC Dissolution of combined Al2O3.2SiO.2 H2O= Al2O3.2SiO2 - 2 H2O -
water from the clay 233 kcal/kg-kaolin
710-730oC Magnesium oxide MgO Dissociation of MgCO3
MgCO3 = MgO + CO2 -773 kcal/kg-MgO
750-900oC Calcium oxide CaO Dissociation of limestone
CaCO3 = CaO + CO2 -750 kcal/kg-CaO
More than 800oC CaO.Fe2O3 CaO + Fe2O3 = CaO.Fe2O3 + 87 kcal/kg.CaO.
Fe2O3
800-900oC Wollastonite CaO.SiO2 Formation of CaO.SiO2
900-950oC 5CaO.3Al2O3 Formation of 5CaO.3Al2O3
950-1200oC Belite 2CaO.SiO2 2CaO + SiO2 = β.CaO.SiO2 + 193.0 kcal/kg -
2CaO. SiO2 → C2S
950-1200oC 2CaO.Fe2O3 2CaO + Fe2O3 = 2CaO.Fe2O3 + 80 kcal/kg -
2CaO.Fe2O3
1200-1300oC Alminate 3CaO.Al2O3 3CaO + Al2O3 = 3CaO.Al2O3 + 77 kcal/kg -
3CaO.Fe2O3 → C3A
1200-1300oC Ferrite 4CaO.2Al2O3 Formation of 4CaO.2Al2O3, Fe2O3 → C4AF
1250-1280oC liquid First fused product is produced
1280-1450oC Alite 3CaO.SiO2 3CaO + SiO2 = 3CaO.SiO2 + 143.5 kcal/kg,
3CaO.SiO2 → C3S
Actually, Alite is produced by the chemical
reaction of Belite 2CaO.SiO2 and CaO.

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 Kiln Burner

Burner is a mechanical device that burns gas or liquid fuels in presence of

oxygen in the controlled manner. Fuels that have been used for primary firing
include coals and petroleum oils. In rotary kiln, irrespective of the fuel used, the
most obvious common feature of the firing system is the firing pipe or burner
pipe which passes through the kiln hood at the kiln's hot end, arranged more or
less along the kiln's center line, and through which the fuel is projected into the
kiln at high velocity. The effect producing a flame that extends some way up
the kiln. Primary air is high-velocity air that passes up the firing pipe with the
fuel, and gives the fuel momentum. The primary air stream contains only a
small fraction of the air needed to burn the fuel. The air-stream passing into the
kiln outside the firing pipe is the secondary air, and this supplies the bulk of the
oxygen needed for combustion. The flame should be throughout its length
aligned with the center line of the kiln. The primary air is pressurized by the
firing fan. The secondary air usually comes mainly from the clinker cooler, and
is at a high temperature (300-800°C). The ignition distance (the distance
between the end of the firing pipe and the start of the flame) and the flame
length are controlled by the flow rates and temperatures of the primary and
secondary air. The burner used in UCIL for calcination process is of single
suction turbofan type. The ratio of the primary and secondary air in the rotary
kiln is 30% and 70% respectively.

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 Table 6 Specifications of Burner
Description Specification

Maker's Name Nippon Furnace kogyo kaisha Ltd.,

Japan.

Type NFK – CDF

Capacity

Firing rate oil- max 3700 kg/hr.

Normal 3000 kg/hr

Minimum 370 kg/hr

Firing rate coal max 10000 kg/hr

Normal 5350 Kg/hr

Minimum 1000 kg/hr

Pressure & temperature at inlet

Primary air 1300 mm Aq, 250 C

Coal Air 500 mm Aq, 500 C

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 Figure 2 Burner

. Clinker burning process

Raw grinding machine have the vertical roller to grind the material into the fine
powder. This grinded material must have size, which is allowed to pass into the
19 micron sieve size leaving behind residue less than 12%. After grinding these
materials are allowed to pass into the tetra cyclone. It is finally passed into the
blending silo through air blower. Bucket elevator helps to pass these materials
into the rotary kiln. The rotary kiln have different burning zone having length
15-20 m. The burning zone have the temperature of the about 1450 degree
Celsius. It has the rotary speed of 2.5 -4 rev/min. The coal is used to heat the
materials in the burning zone and after completing the reaction the clinker is
allowed to cool in the cooling tower through different blower. This produced
clinker is allowed to pass into the clinker silo through channeled metallic
conveyor.

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