Cement Energy & Environment

40 The main equipments were planned and erected adjacent to the existing grinding plant without affecting the operation. The final hook up to the mill circuit was done in only 7 days with minimal loss of production. It was a very challenging target since HWI had to deliver complete items within a short span of time. The project could successfully and timely be completed with a joint team effort of UltraTech Cement and KHD Humboldt Wedag. As per understanding of the signed contract, a zero test (Table-5) was conducted just before hook up of the ball mill to verify the base operational data considered for design. The established production figures were less compared to the base data considered in the contractfor the upgradation and accordingly performance figures were revised. Table-5: UltraTech Hirmi – Zero test data of existing CM-1 S. No. Parameter OPC PPC 1 Feed mix 94.7% clinker 2.5% gypsum 2.9% Performance improver 60% clinker 5% gypsum 35% dry Fly ash 2 Fly ash feed fineness - 4141 cm2/gm 3 Production 117 tph 175 tph 4 Product fineness 2872 cm2/gm 18.8% R45 3618 cm2/gm 21.5% R45 5 Sp. power consumption at meters (for complete grinding circuit from hoppers discharge to cement silo feeding elevator discharge) 36.4 kWh/t at meters 25.3 kWh/t at meters Table-6: UltraTech Hirmi – PPC Performance figures as per PG test S. No. Parameter As per contract Revised based on zero test Achieved during PG test 1 Feed mix 61.5% clinker 3.5% gypsum 35% dry Fly ash 61.5% clinker 3.5% gypsum 35% dry Fly ash 62% clinker 3% gypsum 35% dry Fly ash 2 Fly ash feed fineness 3500 cm2/gm 3500 cm2/gm 3400 cm2/gm 3 Production 380 tph 341 tph 354 tph 4 Product fineness 3500 cm2/gm 3500 cm2/gm 3488 cm2/gm 5 Sp. power consumption at meters (for complete grinding circuit from hoppers discharge to cement silo feeding elevator discharge) 23.2 kWh/t at meters 26.0 kWh/t at meters 23.1 kWh/t at meters The execution of the contract went well within the agreed timelines and the plant was commissioned under the supervisonof KHDengineers inNovember 2022. The plant was running in finish mode before the hookup with the ball mill. Finish mode results were encouragable meeting all the cement quality parameters. UltraTech Cement chose PPC product for demonstrating the performance figures. The performance guarantee test was conducted in December 2023 with revised targets based on zero test results. The outcome of PG test (Table-6) is tabulated below: