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| CEMENT
INDUSTRY |
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Process Control System
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The
process control system also plays a vital part,
in ensuring stable & efficient operation of
the plant. The plant at the design stage itself
should install the following systems
- High level control system
(monitoring & control) for the kiln, raw
mill, coal mill & cement mill. In these
systems, a rule base, a fact base and an inference
mechanism are linked, to operate the plant
in much the same way as the best operator
would do.
- Process control systems
for raw meal blending. This will ensure
consistent quality of kiln feed, resulting
in good clinker quality.
- The present trend is to install a cross-belt
analyser at the crusher outlet belt. This
will help in monitoring the quality of the
material entering the plant. In one of the
recently installed plants, the cross belt
analyser is coupled with pre-blending software.
This is being used for maintaining the quality
of the limestone stockpile. Depending on the
priority of the plant at the project stage,
the cross-belt analyser
with or without the pre-blending software
can be installed.
- Kiln shell-scanning
system for continuously monitoring
the condition of the brick lining. This can
also be used for controlling the operation
of the shell cooling fans.
- CCTV for the kiln & cooler
Lay-out of the plant
The layout of the plant decides the material movement
in the plant and hence the energy consumption.
The layout has to be taken care in the initial
stage itself, as correction is not possible later.
The layout has to be a straight one and the criss-crossing
or backward movement of material is to be avoided.
The bends in the gas ducts and at the entry of
the fans are to be avoided to the extent possible.
It is preferable to locate the coal mill close
to the pre-heater, so that, the loss in pressure
and temperature of the pre-heater gas utilised
in the coal mill, is avoided. The layout should
also ensure that, the transfer points are kept
to a bare minimum. |
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