Globally energy consumption, maintenance costs and reducing plant break downs are the important aspects which a cement producer has to strategically plan to achieve desired production results. Staying ahead of market demand is key to a cement producer?s long-term competitiveness. This competitiveness can be achieved only with a multifaceted strategy, which includes construction of new lines or predominantly by suitable plant upgrades.
The growing Nepal cement market is no exception to these challenges. The market conditions in Nepal are demanding and Arghakhanchi Cement Pvt Limited (ACPL), one of the well-known cement producers of Nepal, decided to enhance its production capacity and save on specific fuel consumption. ACPL?s cement manufacturing unit located at Mainahiya, Rupandehi District of Nepal was originally designed for 650 TPD clinker production. The plant is currently operating at 1100 TPD clinker production. ACPL is presently having mechanical issues owing to higher wear rate, under grate spillage and higher energy consumption. ACPL cannot afford unplanned plant stoppages, with higher energy consumption and higher maintenance cost on a long run. In this situation, FLSmidth being an organisation, which is always committed to deliver results to customers, was approached by ACPL for a suitable solution.
The new FLSmidth? Cross-Bar? cooler has been offered with no major civil modifications. FLSmidth supply and execution will involve the best possible methodology by re-using the existing cooler side frames and installing Cooler fans before shutdown. This makes the project more economical and shall be done with minimum shut down time owing to the inbuilt features of FLSmidth? Cross-Bar? coolers. By considering Nepal market requirement, FLSmidth committed to deliver the cooler on a fast track basis, within 5 months.
FLSmidth? Cross-Bar? cooler, which has a separate conveying and cooling mechanism with no under grate spillage, will eliminate the concerns of ACPL. Post upgrade, the availability of the plant will be far better than the present level of operation with unplanned plant shut downs reduced to the minimum and maintenance cost per ton of cement considerably reduced.
Key benefits of FLSmidth? Cross-Bar? cooler are,
- Superior reliability / Availability
- Conveying system separate from cooling system
- Modular design
- Consistently high thermal efficiency
- Low power consumption
- Low, easy and predictable maintenance
- Fast and simple installation
- Mechanical Flow Regulator (MFR) Technology
- No spillage hoppers, Easy undergrate access and viewing
- Highly flexible – can be used to upgrade most of existing coolers
Apart from the upgrade solution, FLSmidth has been awarded by ACPL a complete new clinkerisation line order for their manufacturing facility located at Mainahiya, Rupandehi District of Nepal. The broad scope of supply includes a limestone crusher, stacker/reclaimer, ATOX? raw mill, 6-stage ILC preheater, 3 support kiln, FLSmidth? Cross-Bar? cooler, complete electrical, instrumentation and plant control systems.
The new cooler of ACPL will be the second FLSmidth? Cross-Bar? cooler for ACPL and overall as sold population of FLSmidth? Cross-Bar? coolers in Nepal is four in number; out of which one is in operation, two are under execution and one is being contracted.
FLSmidth? Cross-Bar? coolers have a proven track record of being consistent in energy efficiency over the years mainly due to its inbuilt technological phenomena. FLSmidth? Cross-Bar? coolers minimise the carbon emissions to a greater extent and preserve the nature for future generations.
(Authored by Pralhad Kulkarni, FLSmidth, Sales Manager – Products & Upgrades)
(Communication by the management of the company)