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SMO / JAL 17/04/16 - 1
ARASMETA, India
Debottlenecking
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ARA e o enec ng
SMO / JAL 17/04/16 - 2
Major equipment details
•Kiln : !""m# $ %&m', ( slope, !) R*M, ) $ + k-
• *re.eater : Kiln string / stage
: 0alciner string / " stage
: 0alciner 1essel / %!% m # $ +2 m .eig.t
• 0ooler : IK3 *endulum, 4rate area / ++)!&" m)
• Ra5 mill : 6all Mill 7 !% m# $ & m ' 89 m ' dring 0.amber;
: )+
: Total grinding capacit / tp. 8design;
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ARA e o enec ng
SMO / JAL 17/04/16 - 3
Arasmeta *lant Rating )%
6000
6000
6000
6000
6000
5200
5500
5200
5200
5200
5300
5200
5200
5200
4000 4500 5000 5500 6000 6500
Clcine! "tge 3 loding
Clcine! "tge 2 #el $i$e
Clcine! "tge 2 loding
Clcine! "tge 1 #el $i$e
Clcine! "tge 1 loding
Clcine! line %C&
kiln line %C&
'o(n co#e! d)ct * elocit+
,!eete! Clcine! St!ing .n 'i!ect
,!eete! .n iln St!ing 'i!ect
iln .eed S+"te#
!( #illing
Li#e"tone c!)"e! "econd!+
Li#e"tone c!)"e! ,!i#!+
* l a n t a r e a
Rating 8tpd;
At 564 t$ cie*ed nd o$e!ting 120!" 6000t$d i" $o""ibilt+
At 55 t$ cie*ed nd o$e!ting 120!" 6000t$d i" $o""ibilt+
&!il !e)e"ted
60/40 "$lit
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ARA e o enec ng
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Arasmeta *lant Rating )%
6000
6000
400
6000
400
6000
4300
6000
5200
6000
6000
6000
6000
6000
4000 4500 5000 5500 6000 6500
iln "tge 3 #el $i$e
iln "tge 3 loding
iln "tge 2 #el $i$e
iln "tge 2 loding
iln "tge 1 #el $i$e
iln "tge1 loding
&e!ti!+ Ai! ')ct elocit+
Clcine! loding
Clcine! Re"idence &i#e
Clcine! "tge 5 #el $i$e
Clcine! "tge 5 loding
Clcine! "tge 4 #el $i$e
Clcine! "tge 4 loding
Clcine! "tge 3 #el $i$e
* l a n t a r e a
Rating 8tpd;
!e"idence 2 "ec" o!
4300 t$d t 35#/" 8 &A d)ct )nde!"i9ed nd need" !e$lce#ent
#el c)te loding e:ceed" 12000t$d/#28$lnt to coni!# i blockge
$!oble#
#el c)te loding e:ceed" 12000t$d/#28$lnt to coni!# i blockge
$!oble#
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ARA e o enec ng
SMO / JAL 17/04/16 - 5
Arasmeta *lant Rating )%
5200
500
6000
500
5200
5300
5200
6000
500
6000
4100
5150
6000
0
0
4000 4500 5000 5500 6000 6500
Col Milling
Col .i!ing
Clinke! Con*e+o!
Coole! e"$ loding
Clcine! St!ing e"$ n
Clcine! e"$ loding
iln St!ing e"$ n
iln e"$ loding
iln ood *elocit+
iln et lod
kiln e!t *elocit+
iln *ol)#et!ic loding
iln ")!ce !e
iln "tge 4 #el $i$e
iln "tge 4 loding
* l a n t a r e a
Rating 8tpd;
't needed !o# te $lnt
't needed !o# te ")$$lie! o! inc!e"ed g" lo( eect" on ;S,
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ARA e o enec ng
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Major bottlenecks @or ") tpd
- &e!ti!+ i! d)ct *elocit+ 45 #/"
- Mel $i$e" in $!eete! b"i"= di*< de"ign "td< o 12000 t$d/#2
- ;#i""ion" !o# iln ;, 110>120 #g/?#38 di!ect o$n< @ 5050 &,'
- et botto#" !o# iln St!ing %C& (en o)tlet g" te#$< B 160oC
- Clcine! "t!ing eed b)cket ele*to! c$cit+
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ARA e o enec ng
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Modi@ications done
- ;nl!ged &e!ti!+ Ai! ')ct elocit+= 25 #/"
- Re$lced iln ;, n C$cit+ de-!ting .'
- Cnged iln ;, di"c!ge elect!ode" to $i$e D "$ike t+$e !o# (i!e t+$e
- Modiied iln "t!ing %C& inlet<
- Re$lced Clcine! "t!ing eed b)cket ele*to! 275 t$ !o# 225 t$
- Modiied Clcine! *e""el #el nd )el inEection $oint"=
Mel $oint" C+lind!icl $o!tion to conicl $o!tion F 3# belo( e!lie! le*el
.)el $oint" 1 $oint8 500## belo( clcine! "t!ing eed !o# e!lie! 2 $oint"
F 3# belo( nd t 0o to #el $oint"
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Summar
*ARAMETER 6EBRE ATER
0linker production, T*D "" ") *C an *o5er cons!, k-.>t KK &!2 &!&
Kiln E* an *o5er cons!, k-.>t KK !? !=
Kiln E* emission, mg>3m= 8A1g!; ?+ 50
0alciner String e$it 0B, ( !? !+&/!+2
Sp! Ceat cons!, k0al>Kg KK ?=% 8an7ul ?; ?== 8Bct ?7 eb! &;
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0.allenges
- Modi@ication to tertiar air take7o@@ required
- Cig. 0B @rom calciner string:- ,lnt !ecentl+ cnged to 2 i!ing $oint"
- 500## belo( D 0o
to #el inEection $oint"<- CO !ed)ction noticed !o# 0
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SMO / JAL 17/04/16 - 10
TCA3K BF
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ARA e o enec ng
SMO / JAL 17/04/16 - 11
Kiln String E* an Modi@ication
Fan Details
Design Previous Present
Flow , m³/min 5400 4500
Pressure , mmWG 250 150
Flow controlVariable Flui
cou!ling VFD
"otror400 #W $ %&%
#V' 200 #W $ 415 V'
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ARA e o enec ng
SMO / JAL 17/04/16 - 12
Kiln String 40T Inlet Duct Modi@ication
3500
3500
400
7000
7H
Before 3500
500
7000
71H
After
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ARA e o enec ng
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0alciner: Briginal Meal G uel injection arrangement
Mel inEection
Col InEection
Rice )"k
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ARA e o enec ng
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0alciner: Meal G uel injection modi@ication
COAL
Rice )"k
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0alciner: Meal G uel injection modi@ication b *lant
