UPGRADATION OF UNIT I & II

Based on
Recommendation By Mr. Larsen
and
Reviewed by BCL
Kiln II

• Present capacity : 6980 TPD

• Max. Capacity identified : 8600 TPD
• Target capacity : 8000 TPD*
* i) Based on minimum modification &
investment level
ii) Limiting thermal loading to max. 5.6
which is practical ( Mr. Larsen suggested
for 6.0 Gcal/m2hr )
iii) Limiting kiln speed to 5.5 RPM which is
practically safe ( Mr. Larsen suggested
for 7.0 RPM)
iv) Limiting pressure drop across PH cyclones
to 850 mmWg (Larsen suggested 900 mmWg )
v) Retention time in Calciners is adequate
Kiln II – Bottlenecks for 8000 TPD

Present Required Action

• Kiln speed 4.65 RPM 5.5 - 6.0 RPM Under examination

by FLS

• Thermal loading 4.9 Gcal/M2.Hr 5.6 Gcal/M2.Hr Will be increased

after increase in kiln speed

• PH Downcomer To increase prodn. Gas cooling system

Gas Cooling by to 7500 TPD under commissiong
max. 90 Deg C

• Tipping of PH Fans To increase prodn. Presently it is deferred.

to 8000 TPD Awaiting result of gas
cooling
P.S.
Kiln specific power consumption will increase from present 7.5 kWh/t to 8.0 kWh/t

Mr Larsen also suggested to modify top stage cyclone to reduce sp. power cons.
However this is not being considered presently; being a major modification.
Other suggestion is to install swing water cooler, which in our opinion is not required.
 Raw Mill – II Bottlenecks for 8000 TPD

Present Required

• Capacity 470 TPH 550 TPH

Suggested Modification Action By BCL

• Increase grinding pressure : Already the pressure is at upper safe practical

upto max.designed value
• Reduce bed thickness
( Potential increase 40 TPH)
• Supply 50 Hz power frequency
( Potential increase 15 TPH)
• Improve separator sealing
( Potential increase 20 TPH)
• Reducing feed size to Mill
( Potential increase 20 TPH)
• Improve running hrs of Raw Mill :
to 22.5 hrs. / day
limit, however we are trying to maximize
pressure under close observation
: Bed thickness has been reduced, results under
observation
: It will be tried to supply better quality of
power through CPP
: Sealing has been improved. Result under
observation
: Option of secondary crushing is under
formulation
Shut down planning rescheduled to improve
running hrs.
Kiln I

• Present capacity : 6050 TPD

• Max. Capacity identified : 7800 TPD
• Target capacity : 6300 TPD*

* i) Based on minimum modification &

investment level (For 7800 TPD, complete
modification of PH tower will be required)
ii) Limiting kiln speed to 5.0 RPM which is
practically safe ( Mr. Larsen suggested
for 6.0 RPM)
iii) Limiting safe pressure drop across PH cyclones
to 850 mmWg of existing level (Larsen suggested
950 mmWg)
iv) Increase in production may be obtained through
increasing load on kiln string as per Mr. Larsen
v) Retention time of 2.6 sec is adequate for 6300
TPD
Kiln I – Bottlenecks for 6300 TPD

Present Required Action

• Kiln speed 4.25 RPM 5.0 RPM Under examination

by FLS

• PH Downcomer Installed but not To be operative Water spray started.

Gas Cooling operative Result under
observation

• Damper before PH fan Louvre damper Shut-off damper Procurement under

process

• Water spray system in No cooling To reduce pressure Inquiry is being sent

top stage cyclone system drop across PH
Tower
Raw Mill – I Bottlenecks
Present
• Capacity 410 TPH
Suggested Modification
• Increase grinding pressure
• Supply 50 Hz power frequency
(Potential increase 10 TPH)
• Replacement of separator rotor
(Potential increase 20 TPH)
• Reducing feed size to Mill
(Potential increase 10 TPH)
• Improve running hrs of Raw Mill
to 22.5 hrs/day
Required
435 TPH
Action By BCL
: Already the pressure is at upper safe
practical limit, however we are trying to
maximize pressure under close observation
: It will be tried to supply better quality of
power through CPP
: Inquiries sent
: Option of secondary crushing is under
formulation
: Shut down planning rescheduled to improve
running hrs.