Kiln Alignment & Shutdown/Major Repairs of Kiln & Mill
Kiln, the heart of a cement plant, is a robust rotating structure and can operate silently without much noticeable problem over a period of time. Any stoppage in kiln corresponds to direct loss of production. Being a rotating machine, deviations do creep in with time, affecting the kiln alignment resulting in unstable operations. Unstable operations induce stress and fatigue on kiln shell, tyre and mechanical rolling elements, resulting in wearing of roller / tyre surface, roller bearings etc. Misaligned kiln consumes additional power to overcome the turning torque.
Technological upgradations to achieve improvement in fuel and power consumption apart from ease of operation. Bettering clinker factor in cement by addition of superfine/ classified flyash
- Conversion of wet process to dry process,
- Addition of Calciner into old preheater string or as additional string
- Replacement of old cyclones by new low pressure cyclones
- Conversion of 2 fan system into 3 fan system in grinding circuits for improving collection efficiency
- Conversion of open circuit grinding mill system into energy efficient close circuit system
- Conversion of oil firing to coal firing etc.
- Flyash classification and superfine grinding and dosing systems
Provide assistance in identification of alternative fuel (agricultural wastes, hazardous industrial waste, municipal waste, used tyres, carbon black powder, shredded plastic/polythene waste etc) and recommend measures in implementation of same so as to save upon the primary fuel costs. Efficient designing of systems for unloading, storage and dosing of various alternative fuels. Installation of flyash superfine grinding and classification systems which allows additional usage of flyash in cement. Also provide all the support in identification and implementation of additives for manufacturing of blended cements thus saving precious clinker and increase of cement production.
