Cement Energy & Environment

37 4.1 CM-1 UPGRADE AT ULTRATECH HIRMI CEMENT WORKS: Therewere two identical ball mill circuits for cement grinding along with Line-1 clinkerisation plant. When the group decided to expand the plant with addition of second clinkerisation plant in year 2021, it was decided to upgrade one of these two ball mills with KHD’s COMFLEX circuit (comprising Roller Press, V Separataor and SK separator in SFM-S type) to increase the cement production form this plant premises. Existing CM-1 was considered for upgrade with Roller Press. Design data (Table-1) and operational parameters (Table-2) of existing CM-1 circuit considered for upgrade design are tabulated below: Table-1: UltraTech Hirmi - Design data of existing CM-1 circuit Equipment Specifications Ball mill FLS design 4.4 m dia x 12.95 m long 1st chamber length: 5.0 m 2nd chamber length: 7.95 m mill speed: 15.88 rpm connected motors: 2x 2200 kW Dynamic separator FLS design Sepax 2S-355 rotor diameter: 2340 mm rotor height: 1610 mm connected motor: 140 kW Separator fan volume: 200400 m3/hr, 500 mmWG connected motor: 420 kW Mill vent bag filter volume: 46500 m3/hr Mill vent bag filter fan volume: 50000 m3/hr, 150 mmWG connected motor: 110 kW Mill recirculation elevator conveying capacity: 565 tph Table-2: UltraTech Hirmi - Operational data of existing CM-1 circuit S. No. Parameter OPC (with grinding aid) PPC (with grinding aid) 1 Feed mix 91.5% clinker 3.5% gypsum 5% Performance improver 61.5% clinker 3.5% gypsum 35% dry Fly ash 2 Fly ash feed fineness - 3500 cm 2 /gm 3 Production 140 tph 190 tph 4 Product fineness 2900 cm 2 /gm 18% R45 3500 cm 2 /gm 18% R45 5 Sp. power consumption at meters (for complete grinding circuit from hoppers discharge to cement silo feeding elevator discharge) 33.84 kWh/t at meters 26.47 kWh/t at meters