22 Atc Ara Debottlenecking

ARASMETA, India Debottlenecking

SMO / JAL 17/04/16 - 1

ARA debottlenecking

Major equipment details •

Kiln

: 4.55mØ 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 Ø x 19 m height

•

Cooler

: IKN Pendulum, Grate area – 112.85 m2

•

Raw mill

: Ball Mill - 4.6 mØ 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 mØ x 4.52 m L (+ 2.8 m L drying Chamber) : VRM – LM20 / 21 : Total grinding capacity – 40 tph (design)

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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)

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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

0

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

0

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 (110–120 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

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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

0.18–0.19

Sp. Heat cons., kCal/Kg KK

736 (Jan-Jul 07)

733 (Oct 07- Feb. 08)

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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: 797–918oC compared to 794–883oC with single point firing)

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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 , m³/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

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ARA debottlenecking

Calciner: Original Meal & Fuel injection arrangement

Meal injection

Rice Husk Coal Injection

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ARA debottlenecking

Calciner: Meal & Fuel injection modification

Rice Husk

COAL

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ARA debottlenecking

Calciner: Meal & Fuel injection modification by Plant

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