SUSTAINABLE GROWTH WITH LOW CAPITAL COST

Ajay Sharma DGM (Process) & Neerav Panchal Dy. Manager (Process) JK Lakshmi Cement Ltd., Sirohi Rajasthan

EXECUTIVE SUMMARY-: In order to sustain its operation in the market it is essential for any industry to cut down cost by improving its productivity. Going for a new green-field plant being an expensive proposition, the only alternative left is to sweat out the assets by brown fielding in the existing plant and to utilize the available resources to their full potential. The clinker production capacity of kiln 1 was 2000 TPD when the idea of new VRM installation was conceived. It was decided to increase clinker production capacity up to 3000 TPD & at increased clinker production capacity, the requirement of raw meal was 4560 TPD but the installed capacity of dedicated Raw Mill (Ball mill) to Kiln-1 was only 3500 TPD so to cater the additional raw meal requirement, it was necessary to go for new Raw Mill/ VRM because the existing had been already stretched to maximum output with the help of a pre-crusher. Keeping in view high power consumed by ball mill, it was decided to install VRM having capacity 180 TPH so that running hours of ball mill can be reduced to reduce overall power consumption.

A Vertical Raw Mill was selected to be the best option. Discussions were held to decide the source for supply of new VRM. Since the cost of mill from proven suppliers was very high, decision was taken to search for alternative from China. Team of Engineers visited China for the purpose and held discussion with leading suppliers of China. Major challenges faced were: a) Reliability of major components, b) Smooth operation at desired output. Finally based on references, visit to manufacturing site and studying the accuracy of technical data, M/S TCDRI was preferred for sourcing of new mill. To ensure the quality of product JKLC officials visited China four times during manufacturing of mill. Major sub assemblies were shop assembled and gear box was test run in presence of JKLC officials. M/S TCDRI attended to any suggestions made by JKLC officials. The mill was designed to produce 180 TPH Raw Meal at 15% residue on 90 microns. Technical specifications of VRM are as follows Initially the mill was commissioned with HAG fired with wood due to prohibitive cost of diesel. Mill was frequently tripping on vibration or roller low. After brain storming following activities were carried out stepwise:a. Reduced accumulator pressure b. Roller low gap was reduced from 40mm to 25mm. c. Roller mechanical stoppers were reduced from 30mm to 16mm. d. Nozzle ring area was reduced from 2.27M 2 to 2.0 M2 and again to 1.62 M2. e. Main motor speed was reduced from 990rpm to 915 rpm to help bed formation. f. Dam ring height was reduced from 105mm to 79mm to reduce main motor load. Ultimately the got stabilized at 120 TPH with wood fired HAG without hot air duct. When mill was started after installation of hot air duct, mill got stabilized at 140-150TPH. But still we were far behind the targeted production of 180TPH. Upon thorough analysis and after series of brain storming session it was observed following problems had to be attended a. Short circuiting of hot air to bag house from SD3 and LD6 dampers. b. Mill DP was high due to high velocity across the nozzle ring area. To overcome these problems following activities were carried out, a. Increased the nozzle ring area from 1.62m2 to 1.82m2. b. Proper sealing was done across SD3 and LD6 dampers After all above activities, mill was stabilized at 180TPH. Though the rated capacity target was achieved, the VRM operation team was not fully satisfied as the specific power was high. Therefore it was decided to, a. b. c. d. Increased the nozzle ring area from 1.82m2 to 2.01m2. Main drive RPM increased from 870 RPM to 960 RPM by reducing resistance False air in the system was further arrested. Increased the accumulator pressure.

After doing all these activities mill got stabilized at 205TPH to the great satisfaction VRM team which was also highly appreciated by top management of JKLC. By the successful implementation of the new measures and superior technology we succeeded in execution of state-of-the-art VRM, ensuring the highest standards of quality and safety. The project has achieved all the major milestones sequentially and has successfully reduced our specific energy consumption. BENEFITS: Increase in Clinker Production Overall Sp Power Consumption 1000 TPD 4 Unit / T Raw Mill

COST BENEFIT ANALYSIS (RS/ ANNUM): Annual saving due to increase in Clinker Production Power Saving Total Saving Total Investment (Kiln 1 Up gradation from 2000 TPD to 3000 TPD) Pay Back Period Rs 16.5 Cr Rs 2.38 Cr Rs 18.88 Cr Rs 67.39 Cr 3 & Half Year