Dalmia Cement Bharat Ltd.. Dalmiapuram
Dalmia Cement Bharat Ltd..Dalmiapuram
COMPANY PROFILECOMPANY PROFILE
FOUNDER
Dalmia Group refers to a grouping of Indian companies, which trace their origin to the businesses establishedby Sri Jaidayal Dalmia .
The Dalmia Group refers to a grouping of Indian companies, which trace their origin to thebusinesses established by Jaidayal Dalmia. The Dalmia brothers established a businessconglomerate in eastern India, in the first half of the 20th century.
In the 1930s, the group merged with the businesses of the Sahu Jain Family to form the Dalmia-Jain Group.
Founded in 1935 by Jaidayal Dalmia the cement division of DCBL was established in 1939 andenjoys a heritage of 70 years of expertise and experience.
Dalmiapuram is a small township in the Tiruchirappalli district of Tamil Nadu in India. It is locatedat a distance of 40 km from Tiruchirappalli Junction.Dalmiapuram is the hometown of Dalmia Cements. This region is rich in limestone deposits.Dalmia Cements was the largest cement plant in Asia at its completion. It has a greenish colonycalled Dalmiapuram..
HISTORY
The Dalmia Group refers to a grouping of Indian companies, which trace their origin to thebusinesses established by Jaidayal Dalmia. The Dalmia brothers established a businessconglomerate in eastern India, in the first half of the 20th century.
In the 1930s, the group merged with the businesses of the Sahu Jain Family to form the Dalmia-Jain Group.
Founded in 1935 by Jaidayal Dalmia the cement division of DCBL was established in 1939 andenjoys a heritage of 70 years of expertise and experience.
Dalmiapuram is a small township in the Tiruchirappalli district of Tamil Nadu in India. It is locatedat a distance of 40 km from Tiruchirappalli Junction.Dalmiapuram is the hometown of Dalmia Cements. This region is rich in limestone deposits.Dalmia Cements was the largest cement plant in Asia at its completion. It has a greenish colonycalled Dalmiapuram..
FLOWFLOWDIAGRAMDIAGRAM
OF CEMENTOF CEMENTPLANTPLANT
PROCESSPROCESS
PACKING PLANT
CRUSHERCRUSHER STACKER &
RECLAMIER
FLOWDIAGRAM
FLOWFLOWDIAGRAMDIAGRAM
OF CEMENTOF CEMENTPLANTPLANT
PROCESSPROCESSRAWMILL
COALMILLKILN
RAWMEAL SILOCOOLER
CEMENT MILL
OBJECTIVE OF THE PROJECTOBJECTIVE OF THE PROJECT
TopManagement
B.S Rathore
TEAMSTRUCTURE
P.Balaji
V.Visuventhan – ElectricalS.Suryanarayanan – Instrumentation
S.Vimalraj – Mechanical
Co -Workers
SELECTIONMETHOD
FISH BONEDIAGRAM
BRAINSTORMING
MULTI-VOTING
FISH BONEDIAGRAM
BRAINSTORMING
MULTI-VOTING
Stopping Coal millin
Line-1
Stopping Coal millin
Line-1
Team• P.Balaji• S.Suryanarayanan• V.Visuventhan• S.Vimalraj
DBCL- Dalmiapuram overview
Line-1
• RVRM• Pyro – 4stage (3200 TPD)• Coal mill( Ball)• CVRM
Line-2
• RVRM• Pyro-5stage (3800 TPD)• Coal mill(VRM)• CVRMLine-2
• RVRM• Pyro-5stage (3800 TPD)• Coal mill(VRM)• CVRM
CPP• 27MW• 18MW
Power consumption(2014-15) - Dalmiapuram
1283274
18096950
711871137332414
2416662 1501791(1.24%)(2.42%)
(20.37%)
(8.01%)(42.01%)
(1.69%)
21111343
Crusher Raw Mill Coal Mill Pyro Section Cement Mill Packing Plant Utility
(8.01%)(42.01%)
(23.76%)
Project Statement-Comparison of Line1 & 2
1.3 20.3 8.8 25.4 39.33.2
1.7
1.5 20.4 7.5 22.6 43.92.4
1.7
20%
40%
60%
80%
100%
1.3 20.3 39.3 1.7
0%
20%
Crusher Raw Mill Coal Mill Pyro Section Cement Mill PackingPlant
UtilityLine-1 Line-2
Line-1 coal mill consumes 1.3 % more than Line-2 coal mill
Power comparison for Ball mill Vs VRM
72.94
83.68 85.79
76.4378.29 78.64
81.0269.27
73.31 76.67 77.4778.71
55.3562.97
57.08
67.4061.76
52.10 53.46 53.58 48.89 51.49 51.77 50.91
40.00
60.00
80.00
100.00
0.00
20.00
Apr-14 May-14 Jun-14 Jul-14 Aug-14 Sep-14 Oct-14 Nov-14 Dec-14 Jan-15 Feb-15 Mar-15
Line-1 Line-2
The difference between Line-1 &2 coal mill is – min 20kwh/ton of coal
Fine coal requirement of DPM unit
Line-1 3300 TPD 300Tons/day
Mill capacity25Tph
Line-2 4900TPD 500Tons/day
Mill Capacity33TphLine-2 4900TPD 500
Tons/dayMill Capacity
33Tph
Requirement 8200TPD 800Tons/day
Available58Tph
Brain storming
Conclusion : Fine coal Pumping from Line 2
Coal pumping from Line-2 to Line-1 150mm Pipe line was laid~ 500m ,
Blower used for pumping , having volume of 1330 M3/hr
Initially we started with 4-5 tph of coal pumped from Line-2 to Line 1
For Line-1 operation we need ~310tons/ day of fine coal(Approx 14tph)
Blower (BL-4 )having volume of 3760 M3/Hr connected to screw pump for coal
pumping.
To optimize power - VFD was installed in the blower
Pumping capacity increased to 13 TPH, which is sufficient enough for Line-1 plant
operation with alternate fuel firing of 3 TPH (Carbon black and High CV flyash)
150mm Pipe line was laid~ 500m ,
Blower used for pumping , having volume of 1330 M3/hr
Initially we started with 4-5 tph of coal pumped from Line-2 to Line 1
For Line-1 operation we need ~310tons/ day of fine coal(Approx 14tph)
Blower (BL-4 )having volume of 3760 M3/Hr connected to screw pump for coal
pumping.
To optimize power - VFD was installed in the blower
Pumping capacity increased to 13 TPH, which is sufficient enough for Line-1 plant
operation with alternate fuel firing of 3 TPH (Carbon black and High CV flyash)
Line-1 Coal millstopped
Pressure profile in Line-2 Coal Mill Circuit
.
-50 mmwg
-695 mmwg
-750 mmwg -805 mmwg -820 mmwg-738 mmwg
-490 mmwg
-826 mmwg
-860 mmwg
-60
mm
wg
1. Across the Mill DP is 645 mmwg.2. Across the Louvre DP is 440 mmwg.3. Across the classifier DP is 205 mmwg.4. Across the Main Bag house DP is 67 mmwg.
.
-50 mmwg
-695 mmwg
-750 mmwg -805 mmwg -820 mmwg-738 mmwg
-490 mmwg
-826 mmwg
-860 mmwg
-60
mm
wg
Actions taken to increase Line- 2 Coal mill output
STEP 1: Analyzing the pressure profile, The main contributor for millpressure drop is the nozzle drop. Increasing Nozzle area from 0.85m2 to 1.05m2 Trail of various Nozzle velocity - from 52m/s to 44m/s, which results
in reduction of pressure drop, Resulting in feed increase
STEP 2: Grinding pressure increased from 70 bar to 90 bar, so as increasethe work done by the table and reduce recirculation
STEP 3:Varying GRR – Table speed
STEP 4: Varying Water Flow and Dam ring height
Result : Coal mill output increased from 30 TPH to 40 TPH.
Action Taken to increase Output
STEP 1: Analyzing the pressure profile, The main contributor for millpressure drop is the nozzle drop. Increasing Nozzle area from 0.85m2 to 1.05m2 Trail of various Nozzle velocity - from 52m/s to 44m/s, which results
in reduction of pressure drop, Resulting in feed increase
STEP 2: Grinding pressure increased from 70 bar to 90 bar, so as increasethe work done by the table and reduce recirculation
STEP 3:Varying GRR – Table speed
STEP 4: Varying Water Flow and Dam ring height
Result : Coal mill output increased from 30 TPH to 40 TPH.
Coal mill – Output ( FY 15- 16)
Louver areaincrease
GP increase
Damringheight
29 2933
38 38 37 37 36
30.10
1619
2529
2529 30.10
Apr-
15
May
-15
Jun-
15
Jul-1
5
Aug-
15
Sep-
15
Oct
-15
Nov
-15
Dec-
15
Jan-
16
Feb-
16
Mar
-16
YTD
56.20 56.9
48.243.3 42.3
52.2
46.842.3
36.2 34.837.9 36.6
39.043.04
30.00
60.00
Coal mill – Power consumption (FY 15- 16)
0.00
2014
-15
Apr-
15
May
-15
Jun-
15
Jul-1
5
Aug-
15
Sep-
15
Oct
-15
Nov
-15
Dec-
15
Jan-
16
Feb-
16
Mar
-16
YTD
Power consumption(2015-16) - Dalmiapuram
2015926
28681369
7106874
58209995
38926524663467
(2.87%)(3.44%) (1.49%)
(21.13%)
(5.24%)
(42.88%)
2014-15 – 8.03%
31168023
58209995
Crusher Raw Mill Coal Mill Pyro Section Cement Mill Packing Plant Utility
(22.96%)
(42.88%)
S.no Description Unit Values
1Power reduction due to Fine coalpumping Kwh/ton of coal 20
2Power reduction in clinkerContribution Kwh/ton of cli 2
Savings
3Cost of Per unit Rs/Kwh 2.5
4Savings per ton of cli Rs/ton of cli 5
Apart from power reduction savings :In Line -1 Zero Inventory cost Zero maintenance cost Zero manpower cost