NATIONAL CONCLAVE ON RECENTADVANCES

IN CEMENT INDUSTRY

INTRODUCTION My Home Industries Pvt. Limited (MHIPL) is the most ambitious diversification

to cement manufacturing of My Home Group, founded by Dr. Rameswar Rao J.Chairman.

My Home Group has business interests in Cement Manufacturing, Real EstateDevelopment, Transport and Power Generation.

MHIPL had an humble beginning in 1998 with an installed capacity of 0.20MTPA.

Currently a leading cement manufacturer in South India with an annual cementproduction capacity 8.50 MTPA.

MHIPL has two captive power plants with an installed capacity of 75 MW.

MHIPL is a joint venture company with CRH Plc., Ireland.

My Home Industries Pvt. Limited (MHIPL) is the most ambitious diversificationto cement manufacturing of My Home Group, founded by Dr. Rameswar Rao J.Chairman.

My Home Group has business interests in Cement Manufacturing, Real EstateDevelopment, Transport and Power Generation.

MHIPL had an humble beginning in 1998 with an installed capacity of 0.20MTPA.

Currently a leading cement manufacturer in South India with an annual cementproduction capacity 8.50 MTPA.

MHIPL has two captive power plants with an installed capacity of 75 MW.

MHIPL is a joint venture company with CRH Plc., Ireland.

Mellacheruvu Cement Works3.3 mtpa capacity

Vizag Grinding Unit2.0 mtpa capacity

My Home Group - Cement Plants

Sree Jayajothi Cement Private Ltd.,3.2 mtpa capacity

OVERVIEW

At the time of acquisition in August 2013, the Sree JayajothiCement Plant was not operating continuously due to variousbottlenecks.

A detailed study was carried out jointly with FLSmidth to identifyand debottleneck the plant operations, with special emphasis onpyro system.

For grinding system, Loesche has deployed for detailed audit toidentify the critical areas for improvement and recommendsuitable measures for capacity enhancement.

Plant availability and Quality of Cement and Clinker gotimproved after detailed study and relevant modifications.

At the time of acquisition in August 2013, the Sree JayajothiCement Plant was not operating continuously due to variousbottlenecks.

A detailed study was carried out jointly with FLSmidth to identifyand debottleneck the plant operations, with special emphasis onpyro system.

For grinding system, Loesche has deployed for detailed audit toidentify the critical areas for improvement and recommendsuitable measures for capacity enhancement.

Plant availability and Quality of Cement and Clinker gotimproved after detailed study and relevant modifications.

SREE JAYAJOTHI CEMENTS PRIVATE LTD3.2 MTPA CEMENT PLANTEQUIPMENT DATASHEETS

Equipment Type Model/Size Make DesignCapacity

Crusher Impact Crusher APPM 1822 L&T HazemagImpactor 900 TPH

Raw Mill Vertical RollerMill LM 56.4 Loesche 450 TPH

Vertical RollerMillCoal Mill Vertical RollerMill LM 28.2D Loesche 50 TPH

Kiln Rotary Kiln4.4M x 65MLong (3.5°

Slope)Alstom 6000 TPD

Cement Mill Vertical RollerMill LM 56.3 + 3C Loesche 305 TPH

Slag Mill Vertical RollerMill LM 46.2 + 2S Loesche 75 TPH

PackingMachine Roto-Packers 16 RSMEC EEL 4 X 240 TPH

737.7

715.0697.7

698.7

650.0

700.0

750.0

800.0Specific Heat Consumption - (KCal/Kg of Clinker)

500.0

550.0

600.0

650.0

2013-14 2014-15 2015-16 2016-17(Till Sep-16)

52.5

53.0

53.5

54.0

54.554.1

52.352.1

Upto Clinker - Power Consumption (KWH/Ton)

49.5

50.0

50.5

51.0

51.5

52.0

2013-14 2014-15 2015-16 2016-17(Till Sep-16)

51.3

10.00

12.00

14.00

16.00

11.2112.49

14.36

8.08

Clinker Production (Tons in Lacs)

0.00

2.00

4.00

6.00

8.00

2013-14 2014-15 2015-16 2016-17(Till Sep-16)

12.00

14.00

16.00

18.00

20.00

12.24

17.2218.23

9.66

Cement Production (Tons in Lacs)

0.00

2.00

4.00

6.00

8.00

10.00

2013-14 2014-15 2015-16 2016-17(Till Sep-16)

OPERATIONAL DIFFICULTIES

The pressure drop across the Preheater was high and unusual in

lower part of preheater i.e. smoke chamber, Kiln riser duct, Calciner

outlet and down comer duct.

Temperature measurement in smoke chamber showed the re-

entrainment of hot meal in the kiln exit gas.

Uneven distribution of feed material in distribution boxes due to

non-availability of dispersion plates.

Collection efficiency of top stage Cyclone-1 was very poor.

The pressure drop across the Preheater was high and unusual in

lower part of preheater i.e. smoke chamber, Kiln riser duct, Calciner

outlet and down comer duct.

Temperature measurement in smoke chamber showed the re-

entrainment of hot meal in the kiln exit gas.

Uneven distribution of feed material in distribution boxes due to

non-availability of dispersion plates.

Collection efficiency of top stage Cyclone-1 was very poor.

While operating the kiln above 5500 tpd production level, it was

observed that CO formation at Pre-calciner outlet indicating that

calciner burn-out problem.

False air entrance around the tertiary air damper was high, reducing

tertiary air temperature.

No refractory lining in the preheater riser duct 2 to 1 and in cyclone

stage 1.

Cooler mechanical break downs were frequent and fine clinker

spillage was more in under compartment due to frequent damage of

seals.

Contd.

While operating the kiln above 5500 tpd production level, it was

observed that CO formation at Pre-calciner outlet indicating that

calciner burn-out problem.

False air entrance around the tertiary air damper was high, reducing

tertiary air temperature.

No refractory lining in the preheater riser duct 2 to 1 and in cyclone

stage 1.

Cooler mechanical break downs were frequent and fine clinker

spillage was more in under compartment due to frequent damage of

seals.

IMPLEMENTED MODIFICATIONS

Modified kiln inlet smoke chamber, with an introduction of a

“trough” in the inclined portion of Smoke chamber.

Introduced Kiln inlet lamella seal with seal air fan.

Introduced NOx reduction zone.

Calciner length extended downwards.

Cyclone cone and feed chute modification in 5th and 6th stages.

Provided diverting gate in 5th stage cyclone bottom.

New tertiary air duct with hoisting damper installed.

Installed feed boxes with dispersion plates.

Top stage Cyclone -1 replaced with new LP Cyclone .

Modified kiln inlet smoke chamber, with an introduction of a

“trough” in the inclined portion of Smoke chamber.

Introduced Kiln inlet lamella seal with seal air fan.

Introduced NOx reduction zone.

Calciner length extended downwards.

Cyclone cone and feed chute modification in 5th and 6th stages.

Provided diverting gate in 5th stage cyclone bottom.

New tertiary air duct with hoisting damper installed.

Installed feed boxes with dispersion plates.

Top stage Cyclone -1 replaced with new LP Cyclone .

IMPLEMENTED MODIFICATIONS Refractory bricks were lined in cyclone-1 with low density (in order to

restrict mechanical loading within previous design parameters of existingbuilding civil structure) supplied by M/s Skamol A/S, DK-7900NykØbing, Denmark.

Applied castable in riser duct 2 to 1 to increase preheater outlettemperature. Thus providing more heat available to Raw mill & Coal milland improved the efficiency of these mills. Simultaneously, radiation losseswere also reduced.

Preheater down comer duct modified to the same diameter from top ofcyclone-1 to the preheater fan inlet to reduce the pressure drop.

Existing Clinker Cooler replaced with FLS Cross Bar cooler with ABC inletto increase the heat recuperation efficiency and also to ensure better runfactor.

Replaced kiln outlet seal arrangement with lamella seal to avoid false airentry and to improve the life of tip castings.

Existing Burner replaced with new Duoflex burner for better performanceas well as to facilitate use of pet coke.

Refractory bricks were lined in cyclone-1 with low density (in order torestrict mechanical loading within previous design parameters of existingbuilding civil structure) supplied by M/s Skamol A/S, DK-7900NykØbing, Denmark.

Applied castable in riser duct 2 to 1 to increase preheater outlettemperature. Thus providing more heat available to Raw mill & Coal milland improved the efficiency of these mills. Simultaneously, radiation losseswere also reduced.

Preheater down comer duct modified to the same diameter from top ofcyclone-1 to the preheater fan inlet to reduce the pressure drop.

Existing Clinker Cooler replaced with FLS Cross Bar cooler with ABC inletto increase the heat recuperation efficiency and also to ensure better runfactor.

Replaced kiln outlet seal arrangement with lamella seal to avoid false airentry and to improve the life of tip castings.

Existing Burner replaced with new Duoflex burner for better performanceas well as to facilitate use of pet coke.

BENEFITS FROM MODIFICATIONSDescription

Before

Modification

After

ModificationUOM

Specific heat consumption 740 693 Kcal/Kg clinker

Specific power consumption for

pyro system22.0 21.0 Kwh/t.of cl

Specific power consumption for

pyro system

Pressure drop across the preheater 750 650 mmwg

Cooler Heat recuperation

efficiency58 70 %

Top Cyclone efficiency 90 96 %

Nox level 600-650 450-500 mg/Nm3

Primary air % 11 8 %

PC & 1st CYCLONE MODIFICATIONSPRECALCINER 1st CYCLONE

BEFORE AFTER BEFORE AFTER

PREHEATER

Preheater Before Modification Preheater After Modification

Calciner

Calciner Before Modification Calciner After Modification

COOLER REPLACEMENT

Previous Cooler New FLS Cross bar Cooler

BURNER REPLACEMENTGRECO BURNER FLS DUOFLEX BURNER

KILN OUTLET SHELL AND SEALBEFORE MODIFICATION

KILN OUTLET SHELL AND SEALAFTER MODIFICATION

KILN OUTLET SEAL REPLACEMENTKILN OUTLET SHELL AND SEAL

BEFORE MODIFICATIONKILN OUTLET SHELL AND SEAL

AFTER MODIFICATION

Replaced kiln outlet seal arrangement with lamella seal and kiln outlet tip toavoid false air entry and to improve the life of tip castings

CONCLUSION The best practices being followed by MHIPL in all respects viz

safety, quality and productivity etc., are implemented in a short span

of time after taking over the company. In recognition of its efforts in

quality drive, the company has been awarded with ISO 9001:2008

during January-2015.

The cost effective modifications which were carried out with a Capex

of Rs.410 million resulted in plant improvement with a payback

period of less than 2 ½ years.

Thus a sick company was transformed to a healthy company within

18 months span of acquisition, by above technical innovations.

SJCPL always strongly believes in updating the technology to derive

maximum operating performance efficiencies

The best practices being followed by MHIPL in all respects viz

safety, quality and productivity etc., are implemented in a short span

of time after taking over the company. In recognition of its efforts in

quality drive, the company has been awarded with ISO 9001:2008

during January-2015.

The cost effective modifications which were carried out with a Capex

of Rs.410 million resulted in plant improvement with a payback

period of less than 2 ½ years.

Thus a sick company was transformed to a healthy company within

18 months span of acquisition, by above technical innovations.

SJCPL always strongly believes in updating the technology to derive

maximum operating performance efficiencies

Thank You !Thank You !