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14/03/2011
Raw Mix
Component
Bins
Gas cooling
in GCT
Chimney
Quarry
Gas cooling
in Top Cyclone
Gas
Conditioning in
Downcomer
Duct
Limestone
bin
Seperator
Crusher
Clinker
silos
Pre-Blending
dome
Water
Injection to
Cement Mill
GCT
Gas Cooling Tower
Raw Mill
Cement Mill
Seperator
Homogenizing
silos
Pre-Heating Tower and
Pre-Calciner
Cement
silos
Kiln
Coal Storage
Cement
Dispatch
Coal Mill
application
areas
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Calculations for
GAS COOLING IN THE TOP CYCLONES
CHEMTROLS USES THEIR OWN SOFTWARE FOR
HEAT TRANSFER CALCULATIONS IN GAS COOLING
Calculations for
GAS COOLING IN THE TOP CYCLONES
CHEMTROLS USES THEIR OWN SOFTWARE FOR
HEAT TRANSFER CALCULATIONS IN GAS COOLING
14/03/2011
The overall control of whole system is conducted by PLC incorporating upto-date technological advances where microprocessors enable
incomparable control of the system, user friendly operation, reability, close
loop control and managing almost all components automatically.
CASE STUDY 1
J.K.LAKSMI CEMENT
CASE STUDY 2
KUWAIT CEMENT
CASE STUDY 3
CHETTINAD CEMENT
CASE STUDY 4
SANGHI CEMENT
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AFTER
COOLING
SYSTEM
INSTALLATION
REMARKS
167,3 t/h
199,58 t/h
19,3% capacity
increase
322C
214C
108C
temperature drop
O Content
6,94%
5,21%
ID Fan (rpm)
786,85
686,43
Less 12,7%
ID Fan (KW)
918,24
711,87
Less by 206 KW
Hybrid Bag DP
mmWC
199,36
180,94
Less DP
PARAMETERS
Kiln Feed
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AFTER
GAS COOLING
SYSTEM
INSTALLATION
405 t/h
437 t/h
327 C / 345 C
274 C/271 C
3.8% / 3.6%
3.8% / 3.9%
99% open
20% open
ID Fan (rpm)
982
961
ID Fan (KW)
1321
1326
15A
14A
PARAMETERS
Kiln Feed
Cylone Exit Temp
(C)
O Content
Dilution Damper pos.
REMARKS
8% capacity
increase
53 / 74 C
Improved
collection in
the Cyclone
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GENERAL PROCESS
LAYOUT
BEFORE
AFTER
GAS COOLING
SYSTEM
INSTALLATION
GAS COOLING
SYSTEM
INSTALLATION
Preheater Temp.
(C)
342
290
Preheater Fan
(KW)
995
965
30 KW savings
650
450
200 KW
savings
3 hrs savings
164
102,5
61.5 KW
savings
30
30 KW
additional
power
PARAMETERS
REMARKS
52C
Temperature drop
(Running Hrs)
Pumps Power
Consp (KW)
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Bag-filter
SLC STRING
Junction
BH Fan 1,288,000
m3/hr@2600C
CM-1
C2 STRING
CM-2
1,010,967
1,754,130
1,574,130
Moisture addition %
0.00
Temperature drop
considered
249
1,934,130
180,000
Note: The junction duct gets pressurised even after operation of both coal mill as baghouse gas
handling capacity is 1,288,000 m3/hr @ 2600C and available gas at inlet is 1,574,000 m3/hr @
2500C
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Present Fan
Operating flow rate
in m 3/hr
248
933,731
1,782,818
180,000
1,602,818
1,422,818
Moisture addition %
1.07
Temperature drop
considered
Case-2: Plant operation at 9500 TPD with water spray in ILC top stage cyclone (present
operating condition)- RM Stopped
Note: The junction duct gets pressurised even after operation of both coal mill as baghouse gas handling
capacity is 1,288,000 m3/hr @ 2600C and available gas at inlet is 1,422,818 m3/hr @ 2500C
Dilution
air
Moisture addition %
12
13
Total water
requred m3/hr
Temperature drop
considered
Case-3: Plant operation at 9500 TPD with water spray in ILC, SLC & C2 string top cyclone - RM
Stopped
32
251
683,870
1,312,258
180,000
1,132,258
952,258
5.74
Note: The junction duct will not get pressurised after installation of the water spray system in SLC
& C2 string and operation of both coal mills.
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Maximum Operaring
conditions
802,138
1,506,384
180,000
1,326,384
1,146,384
Moisture addition %
2.98
Temperature drop
considered
Case-5: Plant operation at 10,500 TPD with water spray in ILC, SLC & C-2 (Maximum
Operating capacity)- RM Stopped
19
240
Note: The junction duct will not get pressurised by operating both coal mills as baghouse gas handling capacity
is 1,288,000 m3/hr @ 2600C and available gas at inlet is 1,146,385 m3/hr @ 2400C
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Single fluid
water ~38 bars
SPILLBACK LANCES
No atomising air
PRINCIPLE-II
New generation
HYBRID SYSTEM
Single fluid
water ~38 bar
SPILLBACK LANCES +
HIGH PRESSURE
LANCES
No atomising air
DUAL FLUID
PRINCIPLE
DOUBLE FLUID SYSTEM
Double fluid
water + air mixture
~5-7 bar
AIRMIST LANCES
Atomising air required
Full automation
REFERENCES
HYBRID GAS COOLING
SYSTEMS
WORLDWIDE REFERENCES
SET BALIKESIR, ISTANBUL
DENZILI CEMENT, ISTANBUL 2 SYSTEMS
1.
2.
3.
4.
5.
REFERENCES IN INDIA
ITALCEMENTI, ZUARI CEMENT , YERUGUNTALA
MAIHAR CEMENT, SARALANAGAR 2 SYSTEMS
ORIENT CEMENT , DEVAPUR WORKS 3 SYSTEMS
ULTRATECH CEMENT, HIRMI CEMENT WORKS 2 SYSTEMS
KANORIA CEMENT, BAGALKOT CEMENT WORKS
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In-built
non-return
valve
return
line
FILTER ELEMENT
feed line
butterfly bolts
1.
2.
3.
The most important component in the gas conditioning system is the New generation high
performance lances, which has an inbuilt filter and an NRV as integral part of the lance.
These are user friendly, light and robust for the application.
The inbuilt filter ensures non-clogging feature to the nozzle & increases the nozzle life doublefold.
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HIGH PRESSURE
LANCE SPRAY
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CLUSTER LANCE
SPRAY
HYBRID SYSTEM
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Analyzer
Cabinet with
air conditioning
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