JSW Cement
JSW Cement
JSW Cement
@ My Home Industries
7th & 8th July 2016
1
Management Systems
2
JSW CEMENT, NANDYAL WORKS
3
INTRODUCTION
• JSW entered the cement market in 2009 with a vision to ensure a sustainable future for
the country by producing eco-friendly cement, using industrial by-products such as slag
• JSW Cement produces three varieties of products: Portland Slag Cement (PSC),
Ordinary Portland Cement (OPC), and Ground Granulated Blast Furnace Slag (GGBFS).
• Not only does JSW Cement manufacture one of the most eco-friendly cements in India,
but it also engineers its products for superior strength and durability.
Product Portfolio and • The plant has a capacity is to produce Clinker ~ 2.50 million ton per annum (mtpa) and
Production Capacity Cement ~ 4.80 mtpa
4
Two Major Encon Projects of FY 2015-16
Operation of
Pyro Floor Cement
Cooler Grinding Roller
Optimization Press in Finish
Mode
5
PYROFLOOR COOLER
OPTIMIZATION
6
Objectives of the project
To Avoid Increase
snowman Reduce Sp.
cooler
formation Heat Cons.
efficiency
7
Design Specification
8
Driving Forces for the Idea
9
Modifications done to increase
cooler efficiency
10
Cooler Horse Shoe Modification
11
Cooler fans upgradation
Flow m3/s 22.5 to 29.7 18.33 to 23.33 16.25 to 18.9 16.83 to 20.0
12
Installation of shock blowers
13
Inter compartment leakage arrest
14
Key Performance Indicators
Recuperation Efficiency % 57 66
Kcal/kg
Sp. Heat consumption 740 709
clinker
15
Report on Savings
16
Operation of Cement Mill
RP in Finish Mode
17
Objectives of the project
18
Evolution of Roller Press
Grinding by RP –
8 COMFLEX SYSTEM
Semi-Finish-Grinding by RP with VS
3
Semi-Finish-Grinding by RP
2
Pre-Grinding by RP
1
19
Design Specification
Sp.
• 26.00 Kwh/ton of OPC @ 320 m2/kg Blaine
Power
20
Implementation Strategy
Modifications
Process optimisation
21
Challenges Faced on Finish Mode
22
Modifications done to overcome
challenges
MAJOR CONSTRAINTS SOLUTIONS
High vibration levels in roller press due to high Homogenised feed to roller press by fines and
fine material re-circulation and material coarse mixing
segregation in pre-bin
Material flushing from RP pre-bin and unstable Maintain consistent pre-bin level by roller
operation press feed chute modification
Not able to achieve the required fineness of Improve the V-separator and dynamic
350 kg/cm2 separator efficiency
23
Not able to achieve the required production Process optimisation
Roller Press Feed Chute Modification
Before After
25
SKS rejects feeding to V-sep Discharge
26
V-Separator Gas Flow Optimization
From the gas flow measurements difference was found between RP1 & RP2 V- separator efficiency
due to blockage of V-separator feed inlet chute.
After blockage removal equal gas flow distribution was achieved and process efficiency increased.
BEFORE AFTER
V-separator inlet V-separator inlet
Parameter unit SKS fan unit SKS fan
RP1 RP2 RP1 RP2
Static pressure mm Wg - 450 -10 -30 mm Wg - 465 -12 -13
Velocity m/sec 17.8 14.38 19.84 m/sec 17.35 17.86 17.68
m3/hr 499243 150971 248423 m3/hr 486872 192801 196696
Flow
Nm3/hr 324005 97979 161225 Nm3/hr 312864 123894 126397
27
Further Improvements for Stable
Operation
Mixing box installation in intermediate feed bin to achieve homogenised fresh feed
Roller press de-dusting system modification for better venting to reduce vibrations
SKS reject bin inlet chute modification and de-dusting system provided for better
distribution
All the belt conveyor and bucket elevator discharge chutes were re-designed by
reducing the opening to avoid material flushing and overloading
28
Key Performance Indicators
Compressive strength
Parameters Semi-finish Finish
Blaine 330 330 70
Water demand 28.6 28.4 60
Setting time 50
215/290 200/270
initial/final RP+BM
40
1 day 23.7 25.2 RP
30
3 days 36.6 40.9
20
7 days 47.2 52.1
10
28 days 62.1 66.4
0
1 day 3 days 7 days 28 days
30
Report on Savings
31
32