Cement Plant visit report with photographs

Visit to a cement manufacutring plant

1. Visit At J.K. Laxmi Cement ltd,
Sirohi

2. Purpose Of Visit
To observe their GPP Operation and adopt
good practices in our plant.
To observe their CPP Operation and adopt
good practices in our plant.
To Observe overall performance of their plant
and adopt good practices in our plant.

3. JK Laxmi Cement An Overview
JK Laxmi Cement is located at Village Jaykaypuram, Dist-
Sirohi, Rajasthan. They have installed three cement units of
capacity 3000, 5000 and 5000 TPD respectively. All three units
are running with double pre-heater and to utilize waste heat of
exhaust gases they have installed waste heat recovery boilers
with all cement units which was supplied and operated by M/s.
Thermax India ltd. A 15MW capacity TG set supplied by M/s
Shin Nippon Machinery ltd has been installed to generate
waste heat power. JKLC also installed 3X18 MW CPP with
3X85 TPH capacity AFBC boilers supplied and operated by
M/s Thermax India Ltd.

4. WHR Power Plant
They Have installed AQC Boiler at clinker cooler exhaust at
their Cement Unit 1 & 2 while exhaust Gases of unit-3 are
used at fly as dryer. They have also installed PH boiler at all
three pre-heater units. The Basic design Data for their boilers
are as following :

5. Design Data of Boilers
S.No Description UOM AQC-1AQC-2PH-1 PH-2 PH-3
1 Flue Gas Flow Nm3/Hr NA NA NA NA NA
2 Steam generation TPH 4 10 10 22 22
3 Flue Gas inlet TempDeg C 380 380 265 300 300
4 Flue Gas Outlet TempDeg C 200 200 190 190 190
5 DP Across boiler mmwc 100 100 100 100 100

6. Design Data of Turbine
S.No Description UOM TG
1 Power Generation Capacity MW 12
2 Inlet Steam temperature Deg C 325
3 Inlet Steam pressure Kg/cm2 11.5
4 Exhaust Steam Pressure Kg/cm2 0.85

7. Details And comparison of AQC boilers
S.NoDescription JKLC AQC
boiler
SCL AQC
Boiler
Remarks
1 Duct Tapping Tapping taken
from Cooler
End (cold End)
in AQC-2 while
From Middle of
cooler in AQC-1
Tapping Taken
From Middle of
cooler
Flue Gas
temperature are
very less at JKLC
compare to our
boilers
2 Deduster
System
They Have
installed De-
duster before
Boiler inlet.
De-Dusting
System Not
Available
De-duster avoids
wear and tear of
tubes but approx 5-
10 deg c temp drops
across De-duster
3 Type Of
Dampers
Butterfly
Dampers Has
been used
Guillotine
Dampers Has
been used
Air ingressment is
very less from
butterfly dampers
but sealing is poor

8. S.NoDescription JKLC AQC
boiler
SCL AQC
Boiler
Remarks
4 Expansion
Bellows
Metallic
Expansion
bellows
supplied by
M/s Atulya has
been installed.
We are also
replacing
fabric bellows
by metallic
bellows
Less Air
ingressment from
metallic bellows
compare to fabric
bellows.
5 Dust conveying
system
Drag chain
(Mahindra
make) are
used for clinker
dust
Screw
conveyor used
Less failure of drag
chain compare to
our system.
6 Tube Type Horizontal
arrangement
carbon steel
tubes.
Horizontal
arrangement
carbon steel
tubes except
SSH.
They are facing
Limitation of temp
due to lower
metallurgy.
Details And comparison of AQC boilers

9. S.NoDescription JKLC AQC
boiler
SCL AQC
Boiler
Remarks
1 Air ingressment6% false air
(as per JKLC
WHR team)
10-15% 1.Multilouver
Dampers has been
used instead of
guillotine dampers
at JKLC.
2.Mettelic bellows
are used instead of
fabric bellows at
JKLC.
3. All Headers are
installed inside the
casing at JKLC.
2. Dust
Conveying
system
Mechanical
Dust
conveying.
Pneumatic
Dust
Conveying.
Lower operating
cost of mechanical
conveying compare
to pneumatic.
Details And comparison of PH boilers

10. S.NoDescription JKLC AQC
boiler
SCL AQC
Boiler
Remarks
3 Tube
arrangement
Vertical tube
arrangement
and Horizontal
flow of Flue
gas.
Vertical tube
arrangement
and Horizontal
flow of Flue
gas.
4 Boiler
circulation
Forced
circulation
Natural
Circulation
JKLC has installed
circulation pumps
for circulation in
boilers because of
less height of boiler
drum
5 Boiler DesignDesigned for
only HP steam
generation
Designed for
HP&LP steam
generation
Details And comparison of PH boilers

11. Details Of 3X18 MW CPP
M/s Thermax India Ltd has supplied and operates 3X85
TPH AFBC boilers at JKLC. Plant was in shutdown
condition due to less power requirement. JKLC had a
contract with state govt to purchase 20MW @2.8Rs per unit
so they are only run CPP whenever load demand raised
above 33MW (They could not run less then 13MW on their
TG’s). However they have preserved their boilers with
conventional wet preservation method.

12. Some Good practices of JKLC
All valves are lubricated and cleaned every after 15 days as per
preventive schedule.
They have covered all instruments, actuators and control vales by
polythene to avoid dust deposition.
They have provided SOP of TG and boiler start-up in their CCR.
Proper Tagging has been done on every instrument panel.
They strictly follows 5’s in shutdown activities also.
They did not weld directly on casing cracks, they used to weld a
‘V’ Piece filled by glass wool on cracks.

13. Photographs Of JKLC
5’S’ at
Shutdown
work

14. Photographs Of JKLC
Fins cleaning Arrangement

15. Photographs Of JKLC
Metallic bellow instead of fabric bellow at inlet duct

16. Photographs Of JKLC
Hammering station of PH Boiler

17. Photographs Of JKLC
Tagging At instruments

18. Photographs Of JKLC
Proper maintenance of valves

19. Photographs Of JKLC
SOP in CCR

20. Photographs Of JKLC
‘V’ piece welding at casing cracks

21. Photographs Of JKLC
Multi louver dampers