Presentation on j.k cement nimbahera by roshan dhaker

A Presentation on J.K. Cement Ltd.

Maharishi Arvind Institute of Engineering & Technology , Mansarover Jaipur

Submitted byRoshan Lal Dhaker

(13EMTEE043)Electrical Engineering

Submitted to :K.C. Modi (HOD)

Electrical

Introduction to

•J.K.Cement started commercial production in May 1975 in Nimbahera

•J.K. Cement Ltd is an affiliate of the J.K. Organisation •which was founded by Lala Kamlapat Singhania.

Continuous…

• J.K. stands for juggilal kamlapath singhania.

• Today J.K. Cement has an installed grey cement capacity of 10.5 MTPA making it one of the leading manufacturers in the country.

POWER PLANTS AT JK

• J.K. Cement installed first a power plant of 140MW in the year 1987 at Bamania.

• J.K Cement installed a waste heat recovery power plant 23MW to its different locations.

• 23MW thermal plant in Nimbahera

CEMENT manufacturing process • The product obtained by mixing together

calcareous (calcium carbonate or lime) and argillaceous (alumina) or other silica and iron oxide bearing materials, burning them at a clinkering temperature and grinding the resulting clinker.

• When it is mixed with water it forms a paste which hardens and binds aggregates (sand, gravel and/or crushed rock) together to form a hard durable mass called concrete.

Raw materials of cement

• Main materials:– Limestone– Clay

• Additional materials– Aluminium& Iron – Gypsum

THE CEMENT MANUFACTURING PROCESS

1. BLASTING : The raw materials that are used to manufacture cement (mainly limestone and clay) are blasted from the quarry.

Quarry face

1. BLASTING 2. TRANSPORT

3. CRUSHING AND TRANSPORTATION : The raw materials, after crushing, are transported to the plant by conveyor. The plant stores the materials before they are homogenized.

quarry

3. CRUSHING & TRANSPORTATION

2. TRANSPORT : The raw materials are loaded into a dumper.

crushing

conveyor

dumper

storage at the plant

loader


1. RAW GRINDING : The raw materials are very finely ground in order to produce the raw mix.

1. RAW GRINDING

Raw grinding and burning

2. BURNING

2. BURNING : The raw mix is preheated before it goes into the kiln, which is heated by a flame that can be as hot as 2000 °C. The raw mix burns at 1500 °C producing clinker which, when it leaves the kiln, is rapidly cooled with air fans. So, the raw mix is burnt to produce clinker : the basic material needed to make cement.

conveyor Raw mix

kiln

cooling

preheating

clinker

storage at the plant

Raw mill


1.GRINDING : The clinker and the gypsum are very finely ground giving a “pure cement”. Other secondary additives and cementitious materials can also be added to make a blended cement.

1. GRINDING

Grinding, storage, packing, dispatch

2. STORAGE, PACKING, DISPATCH

2. STORAGE, PACKING, DISPATCH :The cement is stored in silos before being dispatched either in bulk or in bags to its final destination.

clinker storage

Gypsum and the secondary additives are added to the clinker.

silos

dispatch

bags

Finish grinding

Energy optimization in cement manufacturing

• Cement producers are large consumers of thermal and electrical energy

• Efforts to reduce demands by using higher efficiency equipment and substituting fuels

• To optimize the overall performance of a cement manufacturing unit requires a plant wide automation strategy

1. Energy Conservation and its Management has become a prime factor for the nation, society and individual due to high cost and non availability of energy.

Why Important?

2. Non awareness of latest technologies and methods, non-conventional energy sources and renewable energy sources and how to run the plant and equipment in an energy efficient manner.

• Crushers

– Powers of the drives typically vary from 500 kW to 3000 kW.– a very high start-up torque. – The drive is typically supported by a flywheel in the drive train.

• Separators

−2.8 – 3.8 kWh electric energy per tonne of raw material can be saved.

– Motors are often used in braking mode to guarantee fast and accurate speed control and also during stopping of the rotating separator. 12

Cement Processing Equipment

• Conveyors– a cost-efficient alternative for transportation– not only for transportation of limestone but they are

also needed for transportation of stones, raw meals.

13

• Fans– used practically in all stages of the producing cement

and consume 30% of all electric energy– Typical motor powers vary between 20kW and

2000kW. – Fans can be propelled by a constant speed motor

with damper or vane or by a variable speed drive

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Variable Speed Drives – an electrical energy saver

• In the cement manufacturing process large fans draw air through the kiln, mills and filters to an exhaust stack

• Many smaller fans push the air into the grate cooler to reduce the temperature of the hot clinker leaving the kiln

• these airflows have to be adjusted and controlled as atmospheric conditions

Continuous...

• fixed speed motor is the least energy efficient solution and the application of variable speed drives (VSD) the most energy efficient.

Optimized solution for Grate Coolers –Multi drive

1. Approximately 10 percent of the electrical energy required to produce one ton of clinker is needed to cool it.

2. It therefore makes good sense to give careful thought to the choice of drive system for the cooler.

3. One such choice is the Multi drive which is often referred to as an “optimized drive solution for the cooler area”.

4. It offers all of the benefits of VSD and eliminates – in an economical sense – many of the drawbacks of single drives. Unlike single drives (which have to have their own rectifier, DC link and inverter), the Multi drive system generates the required DC voltage in a “central” unit and feeds it onto a common DC bus to which the single, independently operated inverters are connected.

Some of the benefits of such a system

• Reduced cabling due to the single power entry for multiple drives.

• Energy-saving motor-to-motor braking which is required depending on the grate cooler type.

• Reduced space requirement Elimination of the low voltage distribution used for single drives or dampers and direct online motors in cases of replacement.

• Cost effective reduction of harmonics using an active front end supply unit or at least a 12-pulse line supply.

Energy monitoring using Knowledge Manager (KM)

• Production tracking and reporting Process.

• operations monitoring and reporting.

• Material storage management.• Energy and emission reporting

Thermal energy savings using Expert Optimizer

• note:- Burning zone temperature (BZT) is the predictor of product quality. If the BZT is low, it is expected that the clinker will be insufficiently burnt and if the BZT is high it is expected the clinker will be over burnt

• So that BZT should be modrete.to maintain BZT expert optimizer is used.

Expert Optimizer• It combines rule based control with modern tools like • Neural Networks, Fuzzy Control and Model

Predictive Control (MPC).• EO improves on conventional control by constantly

interpreting kiln conditions and initiating appropriate actions.

• Proper and stable kiln operation can reduce energy consumption and maintenance costs, increase kiln output, and improve overall product quality.

Now queries ????

Thank you…