Вы находитесь на странице: 1из 7

6.

3 Raw Material Preparation


 Key issues:
 No issue
 Main operational measures (incl. costs & benefits)

 Main CAPEX projects (incl. costs & benefits)

1
<Company Name> 6. Manufacturing Process <Plant Name> PMP 2012-2016
6.4 Raw Meal Preparation
 Key issues:
 Mill performance sensitive to moist and sticky material
 False air at Raw Mill N1 and N2 system
 Main operational measures (incl. costs & benefits)
 Improve quality fluctuations of raw material
 Improve wet weather issues (liners, bin and chute design)...
 Main CAPEX projects (incl. costs & benefits)
 Improvement Raw Mill Fan NAR1 with high efficiency Impeller (2 units)
 Replacement NAR2 EP Cooler Fan Variable Speed Drive
 NAR2 non cement grade Fly ash into Raw Meals facility

2
<Company Name> 6. Manufacturing Process <Plant Name> PMP 2012-2016
6.5 Fuel Preparation
 Key issues:
 Coal Mill N1 have high dust load causing NCV drop
 Limited drying capacity Coal Mill N1 & N2, will not support coal with high moisture
(>35%)
 Limited Pfister feeder (Coal dozing system) capacity both in N1 & N2 because of
utilizing LRC up to 70%
 Need to ensure consistency supplied low rank coal quality, especially in Calorific
Value (CV) to meet target 70% in coal proportion
 Propose to review rejection limit of coal quality
 Need to maintain stock coal availability in accordance with mix proportion
 Main operational measures (incl. costs & benefits)
 Propose to reactivate gypsum unloading system for coal unloading facility to improve
coal mixing management
 Maintain coal mixing control in reclaimer area by enhancing coal tripper reliability
 Improve LRC quality control to ensure if Coal drying and dozing system are still able
to handle amount of the coal
 Main CAPEX projects (incl. costs & benefits)
 …
 …

3
<Company Name> 6. Manufacturing Process <Plant Name> PMP 2012-2016
6.6 Clinker Production
Volum es, BDP Summary of key issues
13,000 4,150
12,950  Clinker transport equipment is operated at its
4,100
12,900 maximum capacity in NAR2, need to be
12,850 4,050 upgraded (apron conveyor)
12,800

kt clin
t/day

4,000  NAR2 Clinker temperature problem


12,750
12,700 3,950  ID Fans are operated at it’s maximum capacity
12,650
3,900
and frequently have high vibration problem
12,600
12,550 3,850
 Kiln Tyre cracked caused additional 10 days
2010 2011 2012 2013 2014 2015 2016 during Kiln Overhaul NAR-2 in 2012

Y ear -end B DP as per FRP Cl i nk er pr oduc t i on v ol ume St andar d c l i nk er c apac i t y v ol ume

Proposals for performance improvement


Equipm ent Efficiency
91%
 Propose to buy new high pressure burner fan
90%
 Clarify specs and place order for NAR2 ID Fan
89%
in 2012
88%
87%  Upgrade clinker cooler by prioritizing the
86% installation of fixed inlet grate cooler
85%
84%  Kiln Tyre and shell replacement for Kiln NAR-2
83% During Overhaul in 2013
82%
81%
2010 2011 2012 2013 2014 2015 2016

Net availabilit y index - kilns Gross availabilit y index - kilns


Net OEE - kilns Gross OEE - kilns 4
<Company Name> 6. Manufacturing Process <Plant Name> PMP 2012-2016
6.6 Clinker Production
 Main operational measures (incl. costs & benefits)
 Repair and upgrade of clinker transport Kiln N2
 Improve process to increase kiln feed
 Reduce false air.
 Main CAPEX projects (incl. costs & benefits)
 Improvement of Preheater ID Fan NAR2 with high eficiency impeller (ILC
& SLC)Replace N2 kiln main DC Drive Siemens 6RA24 with latest series
(2012)
 Blower for Burner NAR 1 Kiln
 Replacement kiln shell and tyre for Kiln NAR-2
 NAR2 484-FN1 install high momentum burner fan

5
<Company Name> 6. Manufacturing Process <Plant Name> PMP 2012-2016
6.7 Cement Grinding/Blending
Clinker Factor Production, Volum es Key issues
84% 6,000
Clinker Factor Production  Increase production rate by maintaining
83% 5,000 4 rollers, optimizing ball charge
82% 4,000 management, installing vibrating screen
and use grinding aid

kt cem
81% 3,000

80% 2,000
 Starting October 2012 FM1 will be
reactivated as an impact of demand
79% 1,000
increase
78% 0
2010 2011 2012 2013 2014 2015 2016  Starting in mid 2012, Fly Ash
Cl i nker f act or pr oduct i on Cement pr oduct i on vol ume St andar d cement capaci t y vol ume
consumption will be optimized to reduce
clinker factor (target 74%)
 Narogong grinding capacity using below
assumption:
 Vibrating Screen installation in
FM6 causes capacity increase
similar to FM5
 FM1 Reactivation Starting October
2012

6
<Company Name> 6. Manufacturing Process <Plant Name> PMP 2012-2016
6.7 Cement Grinding/Blending
 Main operational measures (incl. costs & benefits)
 Usage grinding aid to avoid ball coating, reduce power consumption and
increase grinding capacity
 Flyash Usage in NAR-2 to reduce clinker factor
 Main CAPEX projects (incl. costs & benefits)
 Vibrating Screen installation in FM6
 FM1 Reactivation

7
<Company Name> 6. Manufacturing Process <Plant Name> PMP 2012-2016

Вам также может понравиться