Concrete
Maximising Kiln Potential through KHD’s Unique Upgradation Concepts
Published
2 years agoon
By
adminTurnaround story of Dalmia Cement, Kalyanpur Works (DDSPL)
Mr. S. K. Gupta†, Executive Director – Projects
† Dalmia Cement Bharat Limited
Mr. A. K. Dembla††, President & Managing Director
Mr. Sitaram Sharma††, Director – Parts & Services
†† Humboldt Wedag India Pvt. Ltd.
- Introduction:
India is the second largest cement producer in the world and accounts for over 7 per cent of the global installed capacity. We are witnessing a consistent increase in cement capacity demand over the years. The Indian cement industry has made remarkable strides in technological upgradation and assimilation of latest technology. Presently, more than 98 per cent of the total capacity in the industry is based on modern and environmental friendly process technologies. The appetite for continuous modernisation and technological upgradation with state-of-the-art solutions is on upward trend to achieve enhanced productivity, improved energy efficiency, environmental and quality standards. The installed capacity of Indian cement industry is expected to reach 550-600 million tonnes per annum (MTPA) by 2025.
Apart from building new production lines to increase the capacity, there is enormous scope for upgradation and modernisation of existing set-ups. Utilisation of existing kiln to its maximum potential is an art. This concept not only enhances clinker production but also significantly contributes in improving the overall operational efficiency.
The reduced thermal and electrical energy demands will aid in reducing the carbon footprint of existing plants.
To cater market demands in this area, KHD, a pioneer in this field offers extensive modernisation solutions which includes PH cyclones modification, optimised dip tubes, suitable riser ducts, high efficiency top cyclones, new generation clinker cooler, cooler plates, state-of-art Low NOx-AF calciner solutions etc. in Pyro section and latest generation separators, milling parts etc. in Grinding section. KHD’s experience in this area is unparalleled and hence established as one of the leading technological solution provider to modernize existing cement plants. - Background:
Dalmia Cement (Bharat) Limited (DCBL), one of the top 5 cement producers in India, has acquired Kalyanpur Cements under the subsidiary name DDSPL in 2018. Within short period after takeover, DCBL has set an immediate target to enhance the clinker production. As the plant was originally supplied by KHD in 80’s, DCBL has approached KHD for the revamping of existing Pyroprocess and Raw material grinding sections and subsequently awarded a contract to complete the machinery supplies within 7 months on EP basis. - Snapshot of Plant Performance before modification:
Before the takeover of DCBL, the Kalyanpur Cements was almost locked-down without active clinker and cement production to market. However, DCBL has restarted the plant after takeover.
Subsequently DCBL has asked KHD to audit the plant to identify debottlenecking areas in both Raw grinding and Pyroprocess systems with prime target to enhance clinker production and further possibilities of improving energy efficiency.
KHD’s technical audit team has performed a
detailed plant audit and established following operating parameters for Pyroprocess and Raw grinding systems. - Implementation of KHD’s Modernisation solutions:
Looking in to the debottlenecking areas identified after the detailed plant audit study, KHD has proposed and implemented the following modifications.
PYROPROCESS SYSTEM:
Taking in to account the existing kiln size and its maximum potential and also considering the layout feasibility in upstream and downstream sections such as Preheater and Cooler sections, the following modifications were proposed and subsequently implemented after several rounds of technical deliberations with DCBL team.
- Kiln feed section has been modified partially to cater the capacity requirement of Preheater section. As part of modification, blending silo extraction gates were replaced with higher capacity and new bucket elevator is installed to feed material from silo bottom to kiln feed bin which is configured in Preheater building. Necessary modifications in material handling equipment such as Air slide etc. are incorporated.
- In preheater, the existing top cyclones were replaced with bigger size latest design twin cyclones keeping in view the capacity enhancement requirement and also to improve the overall collection efficiency of PH system.
- A new bigger In-Line Calciner (PYROCLON-R with PYROTOP) is installed outside the PH building as shown in 3D drawing to increase the retention time at enhanced clinker production and also to take care of solid AF utilisation
- in future.
- KHD’s tubular calciner design aptly suitable for solid AF utilisation due to sufficient velocities, high retention time and good mixing of tertiary air in to gases from kiln stream. Besides the retention time in the calciner, turbulence is the most important criterion for assuring good fuel conversion. To create turbulence, the PYROCLON® calciner is equipped with the so-called PYROTOP® compact. This compact mixing chamber is installed at the reversal point of the calciner and ensures that there is perfect mixing at this point between the residual oxygen, the burning particles, pre-calcined meal and the waste gas. Theoretical studies and practical experience from converted plants prove the effectiveness of this mixing in, achieving better burnout and correspondingly lower CO emissions.
- KHD’s latest generation PYROBOX® calciner firing system is also installed for improved calcination. The PYROBOX® is a sturdy and simple solution for the combustion of pulverised or granular fuels like coal dust, petcoke or dried sewage sludge. The PYROBOX® enables a pre-mixture of fuel and meal. This ensures fast ignition on the hot material, direct heat transfer and therefore a more even heat profile in the calciner with benefits regarding improved combustion and refractory service time will be achieved. The special design of the PYROBOX® burners requires no additional primary air.
- In addition, custom made solutions such as new optimised dip tubes (immersion pipes with improved geometry), PH cyclones inlet area & height increase, raw meal pipes diameter increase along with compensators and flaps, meal inlet boxes with splash plates, kiln riser modification etc. are implemented considering plant specific conditions.
- A new bigger PH fan of suitable specifications is also installed with motor and VFD to take care of enhanced clinker production.
- To increase kiln speed, a new kiln main gearbox is also installed with suitable reduction ratio. The suitability of kiln critical components has been checked for
- higher clinker production through detailed stress analysis matrix.
- By retaining the outer skeleton of existing grate cooler housing the complete moving grate has been replaced with new generation cooler plates along with new fans of adequate capacity.
- Fine coal dosing system is suitably upgraded with latest generation weighing & dosing systems (Coriolis feeders) for both kiln as well as calciner firing applications.
RAW MATERIAL GRINDING SYSTEM:
As the existing raw material grinding capacity is not adequate, following modifications are implemented to enhance the raw grinding capacity to cater the requirement of Pyroprocess system.
- Existing Roller Press (RP) speed has been increased from 1.4 m/s to 1.6 m/s by installing bigger motors of 2 x 900 kW. Also, existing RP hydraulics and ROLCOX® software are upgraded.
- New V-separator (static) for primary classification and drying purposes, and SKS-separator (dynamic) for final product classification are integrated with existing roller press in finish mode.
- For close circuiting of above machines, new bucket elevators are installed for handling and recirculation of V-separator and Roller press discharge material.
- Two set product collection cyclones are installed along with one SKS circulating fan.
- To handle increased gas volume requirement, the existing kiln bag house (BH) was upgraded to 361,000 m3/h and new bigger BH fan of 420,000 m3/h @ 40 mbar is installed.
- Performance after upgradation:
After implementation of above proposed modifications in meticulous manner, the overall performance of the plant is very much satisfactory and all the performance guarantees for both the sections have been achieved successfully. The snapshot of performance guarantee (PG) test results are summarised in below table.
All the performance parameters guaranteed as per contract are successfully demonstrated for specified PG test duration.
For KHD, it’s an immense pleasure to successfully revamp an old plant installed almost 35 years ago and to establish all the performance parameters which are quite close to the modern plants.
This success story is a perfect example on how an old plant can still be modernised subject to layout feasibility, with marginal capital expenditure to enhance productivity and also improve
energy efficiency. - Conclusion:
The scope for utilisation of existing equipment to its full potential is an area which can enhance not only the production but also provides additional benefits in terms of improvement in operational efficiency. KHD through its unique and customised modernisation solutions can improve the existing system productivity. The capacity enhancement by this concept will not only reduce the capital expenditure per ton of clinker produced but benefits can be materialised much earlier than an independent green field project. KHD as your partner is
always willing to extend support in modernising existing plants with state-of-art, environmental friendly technologies.
Gist of tangible gains achieved in Pyroprocess system after upgradation:
- Production increase of around 61 per cent from base line value.
- Specific heat consumption reduction by more than 100 kcal/kg clinker.
- Approx. 2.8 kWh/t cli saving in specific power consumption.
- Significant NOx reduction after conversion to PYROCLON® R type calciner
Gist of tangible gains achieved in Raw grinding system after upgradation:
- Production increase of around 68 per cent from base line value.
- 1.34 kWh/t raw meal saving in specific power consumption.
(Communication by the management of the company)
Concrete
Indian Cement Industry Sees Further Consolidation
Cement industry to face consolidation soon.
Published
6 hours agoon
September 13, 2024By
adminIndia’s cement sector is set for further consolidation in the near-to-medium term, according to a recent report. With increasing competition, rising input costs, and the need for economies of scale, companies are expected to explore mergers and acquisitions (M&A) to strengthen their market positions. As the industry faces various challenges, including high energy costs and fluctuating demand, consolidation is viewed as a strategic move to drive growth and sustainability.
Key Points:
Market Consolidation: The Indian cement industry has already witnessed significant consolidation over the past few years, with several large firms acquiring smaller players to enhance their market share. The trend is expected to continue, driven by the need to optimize operations, cut costs, and gain better pricing power. Consolidation helps companies to expand their geographic reach and strengthen their portfolios.
Rising Costs and Challenges: One of the primary drivers of consolidation is the rising cost of inputs, particularly energy and raw materials. With costs of coal and petroleum coke (key energy sources for cement production) soaring, companies are looking for ways to maintain profitability. Smaller and medium-sized players, in particular, find it challenging to cope with these rising costs, making them more likely targets for acquisition by larger companies.
Economies of Scale: Larger cement companies benefit from economies of scale, which help them absorb the impact of rising input costs more effectively. Consolidation allows firms to streamline production processes, reduce operational inefficiencies, and invest in advanced technologies that improve productivity. These efficiencies become critical in maintaining competitiveness in an increasingly challenging environment.
M&A Activity: The report highlights the potential for more mergers and acquisitions in the cement sector, particularly among mid-sized and regional players. The Indian cement market, which is highly fragmented, presents numerous opportunities for larger companies to acquire smaller firms and gain a foothold in new markets. M&A activity is expected to accelerate as firms seek growth through strategic alliances and acquisitions.
Regional Focus: Consolidation efforts are likely to be regionally focused, with companies looking to expand their presence in specific geographic areas where demand for cement is strong. Infrastructure development, government projects, and urbanization are driving demand in various parts of the country, making regional expansions an attractive proposition for firms looking to grow.
Impact on Competition: While consolidation may lead to a more concentrated market, it could also intensify competition among the remaining players. Larger firms with more resources and market reach could dominate pricing strategies and influence market dynamics. Smaller firms may either merge or struggle to compete, leading to a reshaping of the competitive landscape.
Demand Outlook: The near-term outlook for the cement industry remains uncertain, with demand being influenced by factors such as construction activity, infrastructure projects, and government initiatives. The report notes that while urban demand is expected to remain stable, rural demand continues to face challenges due to slow construction activities in those areas. However, the long-term outlook remains positive, driven by ongoing infrastructure developments and real estate projects.
Sustainability Focus: Companies are also focusing on sustainability and environmental concerns. Consolidation can provide larger companies with the resources to invest in green technologies and reduce their carbon footprint. This focus on sustainability is becoming increasingly important, with both government regulations and market preferences shifting toward greener production practices.
Conclusion:
The Indian cement industry is poised for further consolidation in the coming years, driven by rising costs, competitive pressures, and the need for economies of scale. M&A activity is likely to accelerate, with larger firms targeting smaller and regional players to strengthen their market presence. While consolidation offers opportunities for growth and efficiency, it could also reshape the competitive landscape and influence pricing dynamics in the sector.
Concrete
Cement Companies May Roll Back Hike
Cement firms reconsider September price increase.
Published
6 hours agoon
September 13, 2024By
adminCement companies in India might be forced to reverse the price hikes implemented in September due to weakened demand and pressure from competitive market conditions, according to a report by Nuvama Institutional Equities. The recent price increase, which was expected to improve margins, may not hold as demand falls short of expectations.
Key Points:
Price Hike in September: Cement firms across India increased prices in September, aiming to improve their margins amidst rising input costs. This was seen as a strategic move to stabilize earnings as they were grappling with inflationary pressures on raw materials like coal and pet coke.
Weak Demand and Pressure: However, demand has not surged as expected. In some regions, particularly rural areas, construction activity remains low, which has contributed to the tepid demand for cement. The combination of high prices and low demand may make it difficult for companies to maintain the elevated price levels.
Competitive Market Forces: Cement manufacturers are also under pressure from competitors. Smaller players may keep prices lower to attract buyers, forcing larger companies to consider rolling back the September hikes. The competitive dynamics in regions like South India, where smaller firms are prevalent, are likely to impact larger companies’ pricing strategies.
Nuvama Report Insights: Nuvama Institutional Equities has highlighted that the September price hikes may not be sustainable given current market conditions. According to the report, the demand-supply imbalance and weak construction activities across many states could push cement companies to reconsider their pricing strategies.
Impact on Margins: If companies are compelled to roll back the price hikes, it could hurt their profit margins in the near term. Cement firms had hoped to recover some of their input costs through the price increases, but the competitive landscape and slow demand recovery could negate these gains.
Regional Variations: Price rollback might not be uniform across the country. In regions where infrastructure development is picking up pace, cement prices may hold. Urban areas with ongoing real estate projects and government infrastructure initiatives could see a sustained demand, making price hikes more viable.
Future Outlook: The outlook for the cement sector will largely depend on the pace of recovery in construction activity, particularly in the housing and infrastructure sectors. Any significant recovery in rural demand, which is currently subdued, could also influence whether the price hikes will remain or be rolled back.
Strategic Adjustments: Cement firms may need to adopt a cautious approach in the near term, balancing between maintaining market share and protecting margins. Price adjustments in response to market conditions could become more frequent as companies try to adapt to the fluctuating demand.
Conclusion:
The September price hikes by cement companies may face reversal due to weak demand, competitive pressures, and market dynamics. Nuvama’s report signals that while the increase was aimed at margin recovery, it may not be sustainable, particularly in regions with low demand. The future of cement pricing will depend on construction sector recovery and regional market conditions.
Concrete
Bridge Collapse Spurs Focus on Stainless Steel
Climate change prompts stainless steel push.
Published
6 hours agoon
September 13, 2024By
adminThe Ministry of Road Transport and Highways (MoRTH) is turning its attention to the use of stainless steel in bridge construction to counteract corrosion, an increasing issue linked to climate change. With recent bridge collapses highlighting the vulnerability of existing infrastructure to corrosion and extreme weather events, the ministry is promoting the adoption of durable materials like stainless steel to ensure the longevity and safety of India’s critical transport infrastructure.
Key Points:
Bridge Collapse and Climate Change: Recent incidents of bridge collapses across the country have raised alarm over the durability of current construction materials, with corrosion cited as a leading cause. Climate change, leading to harsher weather patterns and increased moisture levels, has accelerated the deterioration of key infrastructure. This has prompted MoRTH to consider long-term solutions to combat these challenges.
Corrosion: A Growing Concern: Corrosion of structural materials has become a serious issue, particularly in coastal and high-moisture regions. The Ministry has identified the need for a more resilient approach, emphasizing the use of stainless steel, known for its resistance to corrosion. This shift is seen as crucial in ensuring the longevity of India’s bridges and reducing maintenance costs over time.
Stainless Steel for Bridge Construction: Stainless steel, while more expensive initially, offers long-term savings due to its durability and resistance to environmental factors like moisture and salt. The Ministry is advocating for the material’s use in future bridge projects, particularly in areas prone to corrosion. Stainless steel is seen as a solution that can withstand the pressures of both natural elements and increasing traffic loads.
Government’s Proactive Steps: The government, through MoRTH, has started consulting with experts in the field of metallurgy and civil engineering to explore the expanded use of stainless steel. They are considering updates to construction standards and specifications to incorporate this material in new and rehabilitated infrastructure projects.
Economic Considerations: Although the initial investment in stainless steel may be higher than conventional materials, the reduced need for repairs and replacements makes it a cost-effective option in the long run. This approach also aligns with the government’s push for sustainable infrastructure that can withstand the test of time and climate change effects.
Future of Indian Infrastructure: With the push for stronger, more durable infrastructure, the Ministry’s move to adopt stainless steel for bridge construction marks a shift towards building climate-resilient structures. The use of this material is expected to not only enhance the safety and longevity of bridges but also reduce the financial burden on the government for constant repairs.
Industry Perspective: The stainless steel industry sees this shift as an opportunity to expand its market, particularly in the infrastructure sector. Stakeholders are engaging with the government to demonstrate the benefits of stainless steel, advocating for its increased use not just in bridges but across various infrastructure projects.
Conclusion: In response to the growing threat of climate change and its impact on infrastructure, the Ministry of Road Transport and Highways is prioritizing the use of stainless steel in bridge construction to combat corrosion and ensure the long-term durability of critical transport structures.