Perfecting the Art of Energy Efficiencyby
Hassel-free upgrades in Cement Industry
Jegannath KProducts & Upgrades – Cement Project Division
Perfecting the Art of Energy Efficiencyby
Hassel-free upgrades in Cement Industry
Jegannath KProducts & Upgrades – Cement Project Division
Energy is integral to our lives in 21stcentury.
We have developed our abilities to findways to use energy far more efficiently.presently, The world uses about 10% lessenergy per unit of economic output than itdid in 2000.
2
Still, the need of energy remains vast.Global demand for energy rose by aboutone-third from 2000 to 2016.
2
Policies to address Green-house gasemissions will increasingly influence theenergy landscape.
We have developed our abilities to findways to use energy far more efficiently.presently, The world uses about 10% lessenergy per unit of economic output than itdid in 2000.
224 October 2016
Policies to address Green-house gasemissions will increasingly influence theenergy landscape.
Energy Improvements in Cement Industry & Future
Cement Production projected to increase between 3.6 and 6.3 fold between 2010 and 2050
By 2050, India’s Cement Production is expected to be around 20% to 30% of Global production
Upgradation is one of the cost effective option for energy improvements
Energy Improvements in Cement Industry & FutureYear SPC
(kWh/t ofCement)
SFC
(Kcal/Kgclinker)
1995 – 2000 ~ > 100 ~ > 800
2001 – 2005 ~ 90 – 100 ~ 750 – 800
2006 – 2010 ~ 80 – 90 ~ 720 – 750
2011 – 2015 ~ < 75 – 80 ~ < 700
Cement Production projected to increase between 3.6 and 6.3 fold between 2010 and 2050
By 2050, India’s Cement Production is expected to be around 20% to 30% of Global production
2016 … ?? ??
Upgradation is one of the cost effective option for energy improvements
How do we Conceive an Upgrade?
5
Identification ofUpgrade
Possibilities –Plant Study
Definition ofObjective
5The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
How do we Conceive an Upgrade?
5
Possible Options-Identifying thebest/unique
among the lot
Working with theSite to get
approval for theproject with
Payback
4 October, 2016 5The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Discussing withthe Corporate/HOConceiving the
Project
Why to Upgrade?• Improve p roduc t i v i t y f rom cur ren t leve l
• Improve energy sav ings by op t ing fo r la tes t techno log ies and reducethe p roduc t ion cos t
• Meet PAT regu la t ions and emiss ion norms
• Quick re turn on inves tment compared to new p lant
One Source
• Improve p roduc t i v i t y f rom cur ren t leve l
• Improve energy sav ings by op t ing fo r la tes t techno log ies and reducethe p roduc t ion cos t
• Meet PAT regu la t ions and emiss ion norms
• Quick re turn on inves tment compared to new p lant
When to Upgrade?
• Now…….. I t i s cu r ren t l y the r igh t t ime to upgrade s ince upgradedp lan t wi l l be ready when the marke t rev ives
• A f fo rd to take a s toppage
One Source
• Now…….. I t i s cu r ren t l y the r igh t t ime to upgrade s ince upgradedp lan t wi l l be ready when the marke t rev ives
• A f fo rd to take a s toppage
Driving Force for Upgrade Projects
3232The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Power Savings& Power Price
Driving Force for Upgrade Projects
32
CapacityUtilization
4 October, 2016 32The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
ClinkerRealization
7
SUCESS STORIESOF HASSLE FREE ENERGY EFFIECIENT PROJECTS
FOR DIFFERENT ASPECTS (CAPACITY & ENERGY)
7The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. 7
SUCESS STORIESOF HASSLE FREE ENERGY EFFIECIENT PROJECTS
FOR DIFFERENT ASPECTS (CAPACITY & ENERGY)
4 October, 2016 7The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Hassle free upgrade at –TNPL
Existing 4 Stage PH - New Top & bottom stagecyclone with ILC calciner
Production increased from 500 TPD to 800 TPD
MODIFICATIONS DONE
• Limestone Secondary Crusher & Screen• Replacement of separator to cater production increase and better
particle size dist.,• PH In line calciner, top & bottom stage cyclone modification• Inbox modification. of cooler RFT 5X36 with ABC Inlet• Coal dosing (LIW) & Duo-flex Burner• 2 Modules addition to RABH• Alkali By-pass circuit
ADVANTAGES
Increase in Production by 300 TPD approx. 60% production incr.
Specific heat consumption reduction by ~ 47 kcal/kg cl
Focus should always be on a complete solution and not on bits
and pieces to reap the full benefits
Existing 4 Stage PH - New Top & bottom stagecyclone with ILC calciner
Production increased from 500 TPD to 800 TPD
MODIFICATIONS DONE
• Limestone Secondary Crusher & Screen• Replacement of separator to cater production increase and better
particle size dist.,• PH In line calciner, top & bottom stage cyclone modification• Inbox modification. of cooler RFT 5X36 with ABC Inlet• Coal dosing (LIW) & Duo-flex Burner• 2 Modules addition to RABH• Alkali By-pass circuit
ADVANTAGES
Increase in Production by 300 TPD approx. 60% production incr.
Specific heat consumption reduction by ~ 47 kcal/kg cl
Focus should always be on a complete solution and not on bits
and pieces to reap the full benefits
Hassle free upgrade at –TNPL
Existing 4 Stage PH - New Top & bottom stagecyclone with ILC calciner
Production increased from 500 TPD to 800 TPD
MODIFICATIONS DONE
• Limestone Secondary Crusher & Screen• Replacement of separator to cater production increase and better
particle size dist.,• PH In line calciner, top & bottom stage cyclone modification• Inbox modification. of cooler RFT 5X36 with ABC Inlet• Coal dosing (LIW) & Duo-flex Burner• 2 Modules addition to RABH• Alkali By-pass circuit
ADVANTAGES
Increase in Production by 300 TPD approx. 60% production incr.
Specific heat consumption reduction by ~ 47 kcal/kg cl
Focus should always be on a complete solution and not on bits
and pieces to reap the full benefits
Existing 4 Stage PH - New Top & bottom stagecyclone with ILC calciner
Production increased from 500 TPD to 800 TPD
MODIFICATIONS DONE
• Limestone Secondary Crusher & Screen• Replacement of separator to cater production increase and better
particle size dist.,• PH In line calciner, top & bottom stage cyclone modification• Inbox modification. of cooler RFT 5X36 with ABC Inlet• Coal dosing (LIW) & Duo-flex Burner• 2 Modules addition to RABH• Alkali By-pass circuit
ADVANTAGES
Increase in Production by 300 TPD approx. 60% production incr.
Specific heat consumption reduction by ~ 47 kcal/kg cl
Focus should always be on a complete solution and not on bits
and pieces to reap the full benefits
Hassle free upgrade at –The Ramco Cements Ltd., Jayanthipuram
Existing 5 Stage Single String ILC + New 5 Stage Twin String ILC
Expected production increase from 3250 TPD to 4600 TPD
New 5 Stage Twin String ILC
New Cross Bar Cooler of 14 x 43
Modification in kiln drive
Additional Coal Dosing System
Existing 5 Stage Single String ILC + New 5 Stage Twin String ILC
Expected production increase from 3250 TPD to 4600 TPD
New 5 Stage Twin String ILC
New Cross Bar Cooler of 14 x 43
Modification in kiln drive
Additional Coal Dosing System
Benefits
Increase in Production by 1350 TPD Specific heat consumption reduction by ~55 kcal/kg Cl. Specific power consumption reduction by 7.0 kw hr/mt Cl.
Hassle free upgrade at –The Ramco Cements Ltd., Jayanthipuram
Existing 5 Stage Single String ILC + New 5 Stage Twin String ILC
Expected production increase from 3250 TPD to 4600 TPD
New 5 Stage Twin String ILC
New Cross Bar Cooler of 14 x 43
Modification in kiln drive
Additional Coal Dosing System
Existing 5 Stage Single String ILC + New 5 Stage Twin String ILC
Expected production increase from 3250 TPD to 4600 TPD
New 5 Stage Twin String ILC
New Cross Bar Cooler of 14 x 43
Modification in kiln drive
Additional Coal Dosing System
Benefits
Increase in Production by 1350 TPD Specific heat consumption reduction by ~55 kcal/kg Cl. Specific power consumption reduction by 7.0 kw hr/mt Cl.
Hassle free upgrade at –Ultra Tech Cement Limited, Awarpur
Existing 4-stage SLC + New Balancing tower
Production increased from 4150 TPD to 5000 TPD
MODIFICATIONS DONE
Raw mill circuit – New Dynamic separator
Kiln feed system – Additional KF arrangement for balancing tower
PH Tower – New Balancing ILC Tower
Modification in kiln drive ( Gear-Girth, Pinion, Gear Box to 5 rpm)
New CB cooler
New Coal Dosing system for ILC firing with Existing Burner
ADVANTAGES
Production increase by 850 TPD
Specific heat consumption reduced by ~70 kcal/kg cl
Raw mill capacity increment by around 40-50 TPH
Existing 4-stage SLC + New Balancing tower
Production increased from 4150 TPD to 5000 TPD
MODIFICATIONS DONE
Raw mill circuit – New Dynamic separator
Kiln feed system – Additional KF arrangement for balancing tower
PH Tower – New Balancing ILC Tower
Modification in kiln drive ( Gear-Girth, Pinion, Gear Box to 5 rpm)
New CB cooler
New Coal Dosing system for ILC firing with Existing Burner
ADVANTAGES
Production increase by 850 TPD
Specific heat consumption reduced by ~70 kcal/kg cl
Raw mill capacity increment by around 40-50 TPH
Hassle free upgrade at –Ultra Tech Cement Limited, Awarpur
Existing 4-stage SLC + New Balancing tower
Production increased from 4150 TPD to 5000 TPD
MODIFICATIONS DONE
Raw mill circuit – New Dynamic separator
Kiln feed system – Additional KF arrangement for balancing tower
PH Tower – New Balancing ILC Tower
Modification in kiln drive ( Gear-Girth, Pinion, Gear Box to 5 rpm)
New CB cooler
New Coal Dosing system for ILC firing with Existing Burner
ADVANTAGES
Production increase by 850 TPD
Specific heat consumption reduced by ~70 kcal/kg cl
Raw mill capacity increment by around 40-50 TPH
Existing 4-stage SLC + New Balancing tower
Production increased from 4150 TPD to 5000 TPD
MODIFICATIONS DONE
Raw mill circuit – New Dynamic separator
Kiln feed system – Additional KF arrangement for balancing tower
PH Tower – New Balancing ILC Tower
Modification in kiln drive ( Gear-Girth, Pinion, Gear Box to 5 rpm)
New CB cooler
New Coal Dosing system for ILC firing with Existing Burner
ADVANTAGES
Production increase by 850 TPD
Specific heat consumption reduced by ~70 kcal/kg cl
Raw mill capacity increment by around 40-50 TPH
Hassle free upgrade at –SHIVAM CEMENT PVT. LTD., NEPAL
11
• New Preheater tower - Parts
• Atox 35
• MAAG gearbox
• CB Cooler 8 x 36, CC 110 x 220
• E & I
Existing 5-stage PH tower + Additional 5 stage balancing tower
Expected production increase from 1200 TPD to 1900 TPD
11
• CB Cooler 8 x 36, CC 110 x 220
• E & I
Advantages
Increase in Production by 700 TPD
Fuel consumption reduction by ~60 kcal/kg Cl.
Specific power consumption reduction by 7.0 kw hr/mt Cl.
Hassle free upgrade at –SHIVAM CEMENT PVT. LTD., NEPAL
11
• New Preheater tower - Parts
• Atox 35
• MAAG gearbox
• CB Cooler 8 x 36, CC 110 x 220
• E & I
Existing 5-stage PH tower + Additional 5 stage balancing tower
Expected production increase from 1200 TPD to 1900 TPD
10/4/2016Title 11
• CB Cooler 8 x 36, CC 110 x 220
• E & I
Increase in Production by 700 TPD
Fuel consumption reduction by ~60 kcal/kg Cl.
Specific power consumption reduction by 7.0 kw hr/mt Cl.
• ACC, Wadi – Pyro upgradation – 7200 tpd to 13000 tpd (Kiln already sized for10,000 tpd)
• ICL, Chilamkur – Pryo upgradation – 3400 tpd to 4500 tpd
• Grasim, Raipur – Pyro upgradation – 4300 tpd to 5200 tpd
• Keerthi Cement – Pyro upgradation – 900 tpd to 1600 tpd
• Kyber Cement – HRP as Pregrinder – Production of Cement mill increased by ~15%
Other major Upgrades done…
• ACC, Wadi – Pyro upgradation – 7200 tpd to 13000 tpd (Kiln already sized for10,000 tpd)
• ICL, Chilamkur – Pryo upgradation – 3400 tpd to 4500 tpd
• Grasim, Raipur – Pyro upgradation – 4300 tpd to 5200 tpd
• Keerthi Cement – Pyro upgradation – 900 tpd to 1600 tpd
• Kyber Cement – HRP as Pregrinder – Production of Cement mill increased by ~15%
• ACC, Wadi – Pyro upgradation – 7200 tpd to 13000 tpd (Kiln already sized for10,000 tpd)
• ICL, Chilamkur – Pryo upgradation – 3400 tpd to 4500 tpd
• Grasim, Raipur – Pyro upgradation – 4300 tpd to 5200 tpd
• Keerthi Cement – Pyro upgradation – 900 tpd to 1600 tpd
• Kyber Cement – HRP as Pregrinder – Production of Cement mill increased by ~15%
Other major Upgrades done…
• ACC, Wadi – Pyro upgradation – 7200 tpd to 13000 tpd (Kiln already sized for10,000 tpd)
• ICL, Chilamkur – Pryo upgradation – 3400 tpd to 4500 tpd
• Grasim, Raipur – Pyro upgradation – 4300 tpd to 5200 tpd
• Keerthi Cement – Pyro upgradation – 900 tpd to 1600 tpd
• Kyber Cement – HRP as Pregrinder – Production of Cement mill increased by ~15%
Why Alternative Fuels?
Types of Alternative Fuels
Integration of Alternative Fuels solution with Cement plants
FLSmidth Key Products for Alternative Fuel Solutions
FLSmidth Global Experience in Alternative Fuels
Alternative Fuels projects in India
Summary
Alternative fuels for energy improvements
Why Alternative Fuels?
Types of Alternative Fuels
Integration of Alternative Fuels solution with Cement plants
FLSmidth Key Products for Alternative Fuel Solutions
FLSmidth Global Experience in Alternative Fuels
Alternative Fuels projects in India
Summary
Why Alternative Fuels?
Types of Alternative Fuels
Integration of Alternative Fuels solution with Cement plants
FLSmidth Key Products for Alternative Fuel Solutions
FLSmidth Global Experience in Alternative Fuels
Alternative Fuels projects in India
Summary
Alternative fuels for energy improvements
Why Alternative Fuels?
Types of Alternative Fuels
Integration of Alternative Fuels solution with Cement plants
FLSmidth Key Products for Alternative Fuel Solutions
FLSmidth Global Experience in Alternative Fuels
Alternative Fuels projects in India
Summary
o Convert fuel costs into earnings
o Green house gas emissions can be reduced
o Save natural resources and fossil fuels for future
o Put waste to good use by turning it into energy
o Reduce fuel costs
o Contribute in creating clean and green environment
Why Alternative Fuels
o Convert fuel costs into earnings
o Green house gas emissions can be reduced
o Save natural resources and fossil fuels for future
o Put waste to good use by turning it into energy
o Reduce fuel costs
o Contribute in creating clean and green environment
o Convert fuel costs into earnings
o Green house gas emissions can be reduced
o Save natural resources and fossil fuels for future
o Put waste to good use by turning it into energy
o Reduce fuel costs
o Contribute in creating clean and green environment
o Convert fuel costs into earnings
o Green house gas emissions can be reduced
o Save natural resources and fossil fuels for future
o Put waste to good use by turning it into energy
o Reduce fuel costs
o Contribute in creating clean and green environment
SOLID ALTERNATIVE FUEL
ALTERNTIVE
FUELS
Alternative Fuels – Types
LIQUID ALTERNATIVE FUEL
GASEOUS ALTERNATIVE FUEL
ALTERNTIVE
FUELS
Refuse derived fuel (RDF)
Tire derived fuel (TDF)
Wood chips, Saw dust
Rice husk ,Straw, Nut shells
Agricultural and Domestic wastes
Spent Pot Liners (Alumina Refining)
Dried Sewage Sludge
ALTERNTIVE
FUELS
Pharmaceutical wastes
Refinery wastes
Tar derived fuels
Waste oil and Reject Sludges
Pyrolysis gas
Landfill gas
Natural gas
Bio gas
ALTERNTIVE
FUELS
Rice Husk Wood chips Shredded Tires Cut Tires
Alternative Fuels – Samples
RDF Expired Tablets Hazardous Sludge – Pharma Rejects
Saw dust Paint Sludge Plastic chips Rubber Cuts
Rice Husk Wood chips Shredded Tires Cut Tires
RDF Expired Tablets Hazardous Sludge – Pharma Rejects
Saw dust Paint Sludge Plastic chips Rubber Cuts
EmissionsEmissionsFilterFilter
EmissionsEmissions
Overall aspects:• Control/regulation• Clinker production• Heat consumption• Availability• Chemistry• Emissions
Overall aspects:• Control/regulation• Clinker production• Heat consumption• Availability• Chemistry• Emissions
An integrated Alternative fuel solution
DiscReactor
DiscReactor
Kiln BurnerKiln Burner CoolerCooler
Solid FuelProcessingSolid FuelProcessing
Kiln BypassKiln BypassPreheater/Calciner
Preheater/Calciner
Solid Waste FuelReceiving
Solid Waste FuelReceiving
PneumaticConveyingPneumaticConveying
StorageStorage
An integrated Alternative fuel solution
Solid FuelProcessingSolid FuelProcessing
DosingDosing
LWDFReceiving
LWDFReceiving
StorageStoragePumpPump
19
HOTDISCHOTDISC
New JetflexBurner
New JetflexBurner
FLSmidth Key products for Alternative fuels
19
Pipe ConveyorPipe Conveyor
Hopper with ExtractionHopper with Extraction
19
Pfister RotoscalesPfister Rotoscales
New JetflexBurner
FLSmidth Key products for Alternative fuels
19
OBA Burner SetOBA Burner Set
Cold RawMeal BinCold RawMeal Bin
A HOTDISC Reactor:
Burns solid waste, e.g. whole truck tires Co-feeding of different waste material Longer retention time, 10-45 minutes Substitutes Calciner fuel Residues are incorporated in the clinker Emission control
A HOTDISC Reactor:
Burns solid waste, e.g. whole truck tires Co-feeding of different waste material Longer retention time, 10-45 minutes Substitutes Calciner fuel Residues are incorporated in the clinker Emission control
HOTDISC Technology
HOTDISCHOTDISC
Raw Meal toCalciner &HOTDISC
Raw Meal toCalciner &HOTDISC
CalcinerCalciner
Tertiary AirTertiary Air
Raw Meal toCalciner &HOTDISC
Raw Meal toCalciner &HOTDISC
Triple Flap Sluice / AFfeed pointTriple Flap Sluice / AFfeed point
HOTDISCHOTDISC
Requirements:
• Long retention time for solid waste
• Co-feeding of different waste material
• One common waste feeding point
• High fuel substitution rate
• Emission control
Solution:
HOTDISC Reactor + Calciner
Economics:
HOTDISC installation will be profitable due to:
• Reduced amount of fossil fuel to calciner
• Pre-processing of fuels not required
Requirements:
• Long retention time for solid waste
• Co-feeding of different waste material
• One common waste feeding point
• High fuel substitution rate
• Emission control
Solution:
HOTDISC Reactor + Calciner
Economics:
HOTDISC installation will be profitable due to:
• Reduced amount of fossil fuel to calciner
• Pre-processing of fuels not required
HOTDISC Technology
Requirements:
• Long retention time for solid waste
• Co-feeding of different waste material
• One common waste feeding point
• High fuel substitution rate
• Emission control
Solution:
HOTDISC Reactor + Calciner
Economics:
HOTDISC installation will be profitable due to:
• Reduced amount of fossil fuel to calciner
• Pre-processing of fuels not required
Requirements:
• Long retention time for solid waste
• Co-feeding of different waste material
• One common waste feeding point
• High fuel substitution rate
• Emission control
Solution:
HOTDISC Reactor + Calciner
Economics:
HOTDISC installation will be profitable due to:
• Reduced amount of fossil fuel to calciner
• Pre-processing of fuels not required
Requirements:
• Long retention time for solid waste
• Co-feeding of different waste material
• One common waste feeding point
• High fuel substitution rate
• Emission control
Solution:
HOTDISC Reactor + Calciner
Economics:
HOTDISC installation will be profitable due to:
• Reduced amount of fossil fuel to calciner
• Pre-processing of fuels not required
Requirements:
• Long retention time for solid waste
• Co-feeding of different waste material
• One common waste feeding point
• High fuel substitution rate
• Emission control
Solution:
HOTDISC Reactor + Calciner
Economics:
HOTDISC installation will be profitable due to:
• Reduced amount of fossil fuel to calciner
• Pre-processing of fuels not required
Oil Burner – Air Atomized (OBA)
Features• Simultaneous firing of two different liquid fuels possible• Uniform atomization• Low atomizing air consumption• Large turn-down ratio• Simple, robust design, no moving parts• Will accept fluids with solid particles up to 5 mm• Can be supplied for chemically aggressive fluids• Can handle highly viscous and corrosive liquids
Features• Simultaneous firing of two different liquid fuels possible• Uniform atomization• Low atomizing air consumption• Large turn-down ratio• Simple, robust design, no moving parts• Will accept fluids with solid particles up to 5 mm• Can be supplied for chemically aggressive fluids• Can handle highly viscous and corrosive liquids
Features• Simultaneous firing of two different liquid fuels possible• Uniform atomization• Low atomizing air consumption• Large turn-down ratio• Simple, robust design, no moving parts• Will accept fluids with solid particles up to 5 mm• Can be supplied for chemically aggressive fluids• Can handle highly viscous and corrosive liquids
SALONIT ANHOVOHOTDISC Reactor• Upgrade with HOTDISC
• HDR 63 – 250
• Latest generation HOTDISC
• Calciner foreseen for 100%
fuel substitution
FLSmidth global experience in Alternative Fuels
HOTDISC Reactor• Upgrade with HOTDISC
• HDR 63 – 250
• Latest generation HOTDISC
• Calciner foreseen for 100%
fuel substitution
Calciner Upgrade• Pipe Conveyor
• Pfister feeders
• Rapid implementation
• 100 % fuel substitution
SPENNER CEMENT HEIDELBERG
MOLINS
FLSmidth global experience in Alternative Fuels
AF Storage &Pneumatic Feeding
• Fuel flexible
• RDF & Sewage sludge
• Closed conveying
• Designed for ATEX
Kiln firing with AF• Storage & Feeding
• Pfister feeders
• Phased project
HEIDELBERG
AF Storage &Pneumatic Feeding
• Fuel flexible
• RDF & Sewage sludge
• Closed conveying
• Designed for ATEX
HOTDISC ReactorVasavadatta Cements
• BK Birla Group
• AF feeding system
• First in India
• 40% Calciner Fuel substitution
Alternative Fuels Projects in India
Ultratech Cements
• Aditya Birla Group
• First Pipe Conveyor
for AF application in India
• 30 % Calciner Fuel Substitution
Pipe Conveyor
Extraction & Feeding – Biomass
JK Cements, Mangrol
• Existing Hopper – mass flow problems
• Screw Bottom bunker – Live Bottom Extraction
•Best suited for Biomass – rice husk, mustard husk
• Better Availability & Handling capacity
ACC WADI,• HOLCIM Group
• Starter Kit
• 50% Calciner fuel
substitution.
KOCH Bunker
Liquid waste firing systemLiquid waste firing system
Alternative Fuels projects in India
Typical Tank farm area showing unloading system, storage tanks, transfer pumpstation, nitrogen generator kit & Liquid transfer pipe lines
Typical Tank farm area showing unloading system, storage tanks, transfer pumpstation, nitrogen generator kit & Liquid transfer pipe lines
Safety: Nitrogen inertization kit Flame proof type – Electrical SS material – Wetted parts Double walled storage tanks with leak detectors,
pressure & temperature sensors Flame arrestors Emergency recirculation system HAZOP study
Safety: Nitrogen inertization kit Flame proof type – Electrical SS material – Wetted parts Double walled storage tanks with leak detectors,
pressure & temperature sensors Flame arrestors Emergency recirculation system HAZOP study
System Highlights: Calciner firing system OBA Burner & MF Station Upto 100% Calciner fuel substitution Liquid solvents from Pharma industries Nozzle eductors for continuous agitation of liquid fuel
in storage tanks Nitrogen purging system
System Highlights: Calciner firing system OBA Burner & MF Station Upto 100% Calciner fuel substitution Liquid solvents from Pharma industries Nozzle eductors for continuous agitation of liquid fuel
in storage tanks Nitrogen purging system
Typical Tank farm area showing unloading system, storage tanks, transfer pumpstation, nitrogen generator kit & Liquid transfer pipe lines
Typical Tank farm area showing unloading system, storage tanks, transfer pumpstation, nitrogen generator kit & Liquid transfer pipe lines
Safety: Nitrogen inertization kit Flame proof type – Electrical SS material – Wetted parts Double walled storage tanks with leak detectors,
pressure & temperature sensors Flame arrestors Emergency recirculation system HAZOP study
Safety: Nitrogen inertization kit Flame proof type – Electrical SS material – Wetted parts Double walled storage tanks with leak detectors,
pressure & temperature sensors Flame arrestors Emergency recirculation system HAZOP study
HOTDISC™ Solution for burning RDF, Tire Chips & TiresVasavadatta Cements, India
Feed Rate of Shredded Tyres – 3.5 tones/hourFeed Rate of RDF – 10 tones/hour
Shredded Tyres200 x 300 mm
Alternative Fuels projects in India
Shredded Tyres200 x 300 mm
Whole Truck Tyres1200 mm wide
HOTDISC™ Solution for burning RDF, Tire Chips & TiresVasavadatta Cements, India
Feed Rate of Shredded Tyres – 3.5 tones/hourFeed Rate of RDF – 10 tones/hour
Shredded Tyres200 x 300 mm
HOTDISCTM Combustion device
Shredded Tyres200 x 300 mm
Whole Truck Tyres1200 mm wide
Alternative Fuels gives cement producers a great potential for reducing conventional fuel costs
Use of Alternative Fuels are cheap and attractive
No standard solutions available for alternative fuel requirements
Better to have a preferred partner while substituting with Alternative fuels
Optimum solutions to be implemented that can be integrated easily with the existing system
Consitency & Reliability – for both alternative fuels & the feeding system
“Value addition while Fuel Substitution”
Summary
Alternative Fuels gives cement producers a great potential for reducing conventional fuel costs
Use of Alternative Fuels are cheap and attractive
No standard solutions available for alternative fuel requirements
Better to have a preferred partner while substituting with Alternative fuels
Optimum solutions to be implemented that can be integrated easily with the existing system
Consitency & Reliability – for both alternative fuels & the feeding system
Alternative Fuels gives cement producers a great potential for reducing conventional fuel costs
Use of Alternative Fuels are cheap and attractive
No standard solutions available for alternative fuel requirements
Better to have a preferred partner while substituting with Alternative fuels
Optimum solutions to be implemented that can be integrated easily with the existing system
Consitency & Reliability – for both alternative fuels & the feeding system
Alternative Fuels gives cement producers a great potential for reducing conventional fuel costs
Use of Alternative Fuels are cheap and attractive
No standard solutions available for alternative fuel requirements
Better to have a preferred partner while substituting with Alternative fuels
Optimum solutions to be implemented that can be integrated easily with the existing system
Consitency & Reliability – for both alternative fuels & the feeding system
GREEN HOUSE GAS EMISSION
Capacity
Coal NCV
Fuel Savings
Carbon di Oxide is the main green house gas emitted by Cement Plants
GREEN HOUSE GAS EMISSION
Capacity
Coal NCV
Fuel Savings
: 5000 tpd
: 5000 kcal/kg coal
: 50 kcal/kg clinker
Potential CO2 Emission Reduction
30230 T CO2 / Annum
Area of Reduction Possibility
1. High Dust Carry Over
2. High Power Consumption and many
Carbon di Oxide is the main green house gas emitted by Cement Plants
Potential CO2 Emission Reduction
30230 T CO2 / Annum
Area of Reduction Possibility
1. High Dust Carry Over
2. High Power Consumption and many
TIME TO ACT
No single rain drop believes it’s the blame for the flood”. None of us think we are thecreators for the environmental problems we are experiencing.Gentle foot prints today will ensure a path for tomorrow.
Upgrades & Energy EfficientProjects are the Road to Go
Green.It’s not hard going green when
we are therewe dig deeper for your better reap
No single rain drop believes it’s the blame for the flood”. None of us think we are thecreators for the environmental problems we are experiencing.Gentle foot prints today will ensure a path for tomorrow.
Upgrades & Energy EfficientProjects are the Road to Go
Green.It’s not hard going green when
we are therewe dig deeper for your better reap
TIME TO ACT
No single rain drop believes it’s the blame for the flood”. None of us think we are thecreators for the environmental problems we are experiencing.Gentle foot prints today will ensure a path for tomorrow.
Upgrades & Energy EfficientProjects are the Road to Go
Green.It’s not hard going green when
we are therewe dig deeper for your better reap
No single rain drop believes it’s the blame for the flood”. None of us think we are thecreators for the environmental problems we are experiencing.Gentle foot prints today will ensure a path for tomorrow.
Upgrades & Energy EfficientProjects are the Road to Go
Green.It’s not hard going green when
we are therewe dig deeper for your better reap
Questions?
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. 4 October, 2016 31
For more information, please visit www.flsmidth.com/upgrades
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. 4 October, 2016 31
For more information, please visit www.flsmidth.com/upgrades