Milestone Project Rajashree Cement Line-3 Clinkerisation Capacity Enhancement

In the context of HWI successful journey, few plants deserve special mention and Rajashree Cement is one such unit where HWI journey pivoted to the next level through many innovative modernization jobs. One such upgradation to consider for revisiting is clinkerisation capacity enhancement of Pyro Line-3.

Back in 2001, Aditya Birla Group (ABG) placed an upgradation order on HWI to increase the clinkerisation capacity of Line-3 Pyroprocess system. This modernization job was unique in many ways. In the era where capacity growth is achieved by installing green & brown field plants, ABG entrusted KHD’s technology to modernize the existing set-up for significant capacity enhancement.

The major scope of modification work comprised,

* Kiln & Calciner PH strings modification with:

- Installation of triplet cyclones (3600 mm & 4000 mm dia respectively)

in top stage in conjunction with existing twin cyclones

- Existing cyclones upper part modification with new inlet spirals from stage-2,

up to stage-6

- New dip tubes of improved geometry in all cyclones

- Modification of PH meal pipes with new flap valves and feed boxes

* Upgradation of Calciner by increasing its length & dia with PYROTOP mixing chamber

* New PH fans of suitable capacity

* Upgradation in existing kiln gearbox to increase the maximum speed of kiln up to 4.5 rpm

* New kiln main motor

* Kiln hood extension and suitable modification in kiln main burner system

* Clinker cooler first grate modification with Omega grate plates

* Partial new cooling air fans etc.

After implementation of all above modifications, the guaranteed parameters were successfully achieved in Performance guarantee test. Clinkerisation capacity increased from 4,300 tpd (base line value) to 4,950 tpd during the PG test and it was later further optimized to reach approx. 5,200 tpd. From operational efficiency point of view, all the guaranteed parameters were achieved as stated in below table:

The success of this project paved way for a lot of similar upgradation jobs within Aditya Birla Group and outside. Even today, similar modifications with further improved concepts are being implemented in various plants by KHD to utilize the maximum potential of existing systems.