SMALL GROUP ACTIVITY ON ENERGY CONSERVATION IN ACC, LAKHERI

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SMALL GROUP ACTIVITY ONENERGY CONSERVATION
INACC, LAKHERI

• Indian Industry Programme for Energy Conservation
  
• (IIPEC)
• On Cement Sector
• 22nd September, 2002

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PYRO PROCESSING

• PREVIOUS ARRANGEMENT
• THE PETCOKE BEING DISCHARGED FROM
• THE PETCOKE HOPPER RAL WAS BEING FED INTO THE
  F.K.PUMP HOPPER WERE IT WAS GETTING MIXED WITH
  THE SCEL COAL COMING OUT OF THE FINE COAL HOPPER
  NO. 2.

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ACC LAKHERI
FROM COAL MILL NO.1
OLD PETCOKE FEEDING SYSTEM
FROM COAL MILL. NO.2
PETCOKE HOPPER FOR MILL NO.1
VARIABLE SPPED RAL
VARIABLE SPEED RAL
FINE COAL HOOPPER NO.2
MIXING CHAMBER
F.K.PUMP NO.2
COAL SCREW
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PYRO PROCESSING

• PROBLEM
• VERIATION WAS OBSERVED IN THE
• PETCOKE PERCENTAGE IN THE FINE COAL
• BEING FIRED INTO THE KILN.
• UNSTEADY RUNNING OF KILN.
• FREQUENT KILN STOPPAGES FOR COOLER
• GRATE CLEANING AND KILN INLET
• CLEANING.
• INCREASING KILN REFRACTORY LIFE.

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PYRO PROCESSING

• MODIFIED ARRANGEMENT
• THE PETCOKE BEING DISCHARGED FROM
• THE PETCOKE HOPPER RAL IS BEING FED
• INTO THE FINE COAL HOPPER NUMBER 2
• USING AIR CONVEYING SYSTEM. IN THIS
• HOPPER THE PETCOKE IS GETTING MIXED
• WITH SCEL COAL

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ACC LAKHERI
MODIFIED PETCOKE FEEDING SYSTEM
PETCOKE HOPPER FOR MILL NO.1
EXISTINGFINE COAL HOOPPER NO.2
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PYRO PROCESSING

• BENEFITS
• VARIATION OBSERVED IN THE PETCOKE PERCENTAGE
  IN THE FINE COAL BEING FIRED INTO THE KILN
  WILL BE REDUCED.
• KILN OPERATION WILL STABILISH RESULTING IN
  STEADY KILN RUN.
• MINIMISE FREQUENT COOLER GRATE PLATE
  JAMMING.
• MINIMISE FREQUENT KILN INLET JAMMING.
• INCREASING KILN REFRACTORY LIFE.
• PETCOKE SCREW MAINTENANCE WILL BE AVOIDED.

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PYRO PROCESSING

• COST OF PROJECT
• Material Rs 20000/-
• Manpower cost Rs 5000/-
• Total cost Rs 25000/-

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PYRO PROCESSING

• PREVIOUS ARRANGEMENT
• The feed of coal into the coal mills is
  controlled by
• the miller by experience
• PROBLEM
• The running of the mill is not constant due to
• various reasons such as frequent change in
  material
• feed size, moisture,draft.It is not possible for
  the
• miller to take instantaneous action at all times.

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PYRO PROCESSING

• MODIFIED ARRANGEMENT
• A SONIC EAR sensor will be provided at the mill
• diaphragm that which will give a signal to VVVF
• drive provided at the feed table drive so as to
• control the feed going into the mill
• COST OF IMPLEMENTATION
• Cost - 120000/-
• Manpower-- 10000/-
• TOTALRs. 13000/-

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PYRO PROCESS
MILL DIAPHRAGM
FEED TABLE
SONIC EAR
V V V F DRIVE
SOUND PROOF WOODEN CHAMBER
CONTROL
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PYRO PROCESSING

• BENEFITS
• CONSISTENT RUN
• CONSISTENT QUALITY
• MILLER CAN CONCENTRATE IN OTHER JOBS
• POWER SAVING.
• INCREASED MILL OUTPUT

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PYRO PROCESSING

• SAVINGS
• THE COAL MILL RUNNING HOURS HAVE
• REDUCED BY 1.5 HOURS PER DAY
• POWER SAVED 250 units PER DAY
• cost saving Rs 1687.5/- PER day
• Rs 5. 06 Lacks / YEAR
• PAY BACK PERIOD 3 MONTHS