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22 ATC ARA Debottlenecking

The document discusses debottlenecking efforts at an Indian cement plant. Three key modifications were made: 1) The tertiary air duct was enlarged to address high velocities. 2) The kiln ESP fan was replaced and electrodes modified to improve emissions. 3) The calciner string feed bucket elevator and meal/fuel injection points were modified to increase throughput. These changes helped increase production from 5050 tpd to 5200 tpd while maintaining or improving energy efficiency and emissions. Ongoing challenges include further optimizing CO levels from the calciner string.

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293 views15 pages

22 ATC ARA Debottlenecking

The document discusses debottlenecking efforts at an Indian cement plant. Three key modifications were made: 1) The tertiary air duct was enlarged to address high velocities. 2) The kiln ESP fan was replaced and electrodes modified to improve emissions. 3) The calciner string feed bucket elevator and meal/fuel injection points were modified to increase throughput. These changes helped increase production from 5050 tpd to 5200 tpd while maintaining or improving energy efficiency and emissions. Ongoing challenges include further optimizing CO levels from the calciner string.

Uploaded by

mkpq
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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ARASMETA, India

Debottlenecking

SMO / JAL 17/04/16 - 1

ARA debottlenecking

Major equipment details

Kiln

: 4.55m x 68mL, 4% slope, 4.2 RPM, 2 x 410 kW

Preheater

: Kiln string 4 stage


: Calciner string 5 stage
: Calciner vessel 6.6 m x 19 m height

Cooler

: IKN Pendulum, Grate area 112.85 m2

Raw mill

: Ball Mill - 4.6 m x 8 m L (+ 4 m L drying Chamber)


: VRM LM 36 / 41
: Total grinding capacity 347 tph (operating)

Coal mill

: Ball Mill - 3.0 m x 4.52 m L (+ 2.8 m L drying Chamber)


: VRM LM20 / 21
: Total grinding capacity 40 tph (design)

SMO / JAL 17/04/16 - 2

ARA debottlenecking
Arasmeta Plant Rating 2006

Limestone crusher (Primary)

5200

At 564 tph achieved and operating 120hrs >6000tpd is a possibilty

Limestone crusher (secondary)

5200

At 585 tph achieved and operating 120hrs >6000tpd is a possibilty

raw milling

5200

Plant area

Kiln Feed System

Trial requested

5300

Preheater Fan Kiln String (Direct)

5200

Preheater Calciner String Fan (Direct)

5200

Dow n comer duct velocity

5200

kiln line GCT

60/40 split

5500

Calciner line GCT

5200

Calciner stage 1 loading

6000

Calciner stage 1 meal pipe

6000

Calciner stage 2 loading

6000

Calciner stage 2 meal pipe

6000

Calciner stage 3 loading

6000
4000

4500

5000

5500

6000

6500

Rating (tpd)

SMO / JAL 17/04/16 - 3

ARA debottlenecking
Arasmeta Plant Rating 2006

Calciner stage 3 meal pipe

6000

Calciner stage 4 loading

6000

Calciner stage 4 meal pipe

6000

Calciner stage 5 loading

6000

Calciner stage 5 meal pipe

6000

Plant area

Calciner Residence Time

5200

Calciner loading
Tertairy Air Duct Velocity

residence 2 secs for


6000

4300

4300 tpd at 35m/s , TA duct undersized and needs replacement


6000

Kiln stage1 loading


4900

Kiln stage 1 meal pipe

meal chute loading exceeds 12000tpd/m2,plant to confirm if blockage


problem
6000

Kiln stage 2 loading


Kiln stage 2 meal pipe

meal chute loading exceeds 12000tpd/m2,plant to confirm if blockage


problem

4800

Kiln stage 3 loading

6000

Kiln stage 3 meal pipe

6000

4000

4500

5000

5500

6000

6500

Rating (tpd)

SMO / JAL 17/04/16 - 4

ARA debottlenecking
Arasmeta Plant Rating 2006

6000

Kiln stage 4 loading


Kiln stage 4 meal pipe

Data needed from the plant

5150

Kiln surface area


Kiln volumetric loading

4100
6000

kiln hearth velocity

5900

Kiln heat load

6000

Plant area

Kiln hood velocity


Kiln esp loading

Data needed from the supplier for increased gas flow effects on ESP.

Kiln String esp fan

5200
5300

Calciner esp loading


Calciner String esp fan

5200

Cooler esp loading

5900

Clinker Conveyor

6000
5900

Coal Firing
Coal Milling
4000

5200
4500

5000

5500

6000

6500

Rating (tpd)

SMO / JAL 17/04/16 - 5

ARA debottlenecking

Major bottlenecks for 5200 tpd


- Tertiary air duct (velocity > 45 m/s)
- Meal pipes in preheater (basis: div. design std. of 12000 tpd/m2)
- Emissions from Kiln EP (110120 mg/Nm3, direct opn. @ 5050 TPD)
- Wet bottoms from Kiln String GCT when outlet gas temp. < 160oC
- Calciner string feed bucket elevator capacity

SMO / JAL 17/04/16 - 6

ARA debottlenecking

Modifications done
- Enlarged Tertiary Air Duct (Velocity: 25 m/s)
- Replaced Kiln EP fan (Capacity de-rating + VFD)
- Changed Kiln EP discharge electrodes to pipe & spike type from wire type
- Modified Kiln string GCT inlet.
- Replaced Calciner string feed bucket elevator (275 tph from 225 tph)
- Modified Calciner vessel meal and fuel injection points:
Meal points

Cylindrical portion to conical portion (~ 3m below earlier level)

Fuel points

1 point, 500mm below calciner string feed from earlier 2 points


~ 3m below and at 90o to meal points

SMO / JAL 17/04/16 - 7

ARA debottlenecking

Summary
PARAMETER

BEFORE

AFTER

Clinker production, TPD

5050

5200

PH Fan Power cons., kWh/t KK

8.9

8.8

Kiln EP Fan Power cons., kWh/t KK

0.70

0.43

Kiln EP emission, mg/Nm3 (Avg.)

71

50

Calciner String exit CO, %

0.07

0.180.19

Sp. Heat cons., kCal/Kg KK

736 (Jan-Jul 07)

733 (Oct 07- Feb. 08)

SMO / JAL 17/04/16 - 8

ARA debottlenecking

Challenges

- Modification to tertiary air take-off required


- High CO from calciner string:
- Plant recently changed to 2 firing points
- 500mm below & 90o to meal injection points.
- CO reduction noticed from 0.18-0.19% to 0.1%.
- Localized high temperature zones reported in calciner
(temperature variation: 797918oC compared to 794883oC with
single point firing)

SMO / JAL 17/04/16 - 9

THANK YOU

SMO / JAL 17/04/16 - 10

ARA debottlenecking

Kiln String EP Fan Modification


Fan Details
Design

Previous

Present

5400

4500

250

150

Flow control

Variable Fluid
coupling

VFD

Motror

400 KW ( 6.6
KV)

200 KW ( 415 V)

Flow , m/min

Pressure , mmWG

SMO / JAL 17/04/16 - 11

ARA debottlenecking

Kiln String GCT Inlet Duct Modification

Before

3500

3500

After

3500
79
5080

4900
71

7000

7000

SMO / JAL 17/04/16 - 12

ARA debottlenecking

Calciner: Original Meal & Fuel injection arrangement

Meal injection

Rice Husk
Coal Injection

SMO / JAL 17/04/16 - 13

ARA debottlenecking

Calciner: Meal & Fuel injection modification

Rice Husk

COAL

SMO / JAL 17/04/16 - 14

ARA debottlenecking

Calciner: Meal & Fuel injection modification by Plant

SMO / JAL 17/04/16 - 15

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