PLANT

LINE
DESIGN DATA MILL1 MILL2
COAL MILL TYPE Ball Mill Vertical Mill
COAL MILL DESIGN CAPACITY 15 25 tph product
POWER CONSUMPTION DESIGN (MILL ONLY) - 24.5 kWh/t
FUEL ANALYSIS - AS PER DESIGN
CV NA 4300 kcal/kg net adb
ASH NA 32.7 % adb
TOTAL MOISTURE NA 20(max) % asr
INHERENT MOISTURE NA 3 % asr
VM NA 25.5 % adb
S NA 0.4 % adb
Cl NA NA % adb
HGI NA 50
PRODUCT RESIDUE 90 um 12 12 %
COAL MILL MOTOR POWER INSTALLED 405 365 kW
COAL MILL GEARBOX POWER NA NA kW
TABLE DIAMETER - 2 m
BALL MILL DIAMETER 3 - m
BALL MILL DRYING CHAMBER LENGTH 2.8 - m
BALL MILL GRINDING CHAMBER LENGTH 4.4 - m
SEPARATOR SUPPLIER FLS/L&T LNVT
SEPARATOR TYPE Static LVT type
MILL FILTER AREA TOTAL 340.34 1000 m2
MILL FILTER AREA ACTIVE (OFFLINE CLEANING) - - m2
MILL FAN DESIGN VOLUME 24600 84000 m3/hr
Kiln coal dosing system capacity 14 tph
Calciner coal dosing system capacity 20 tph
Note:
adb - air dried basis
asr - as received
ARASMETA CEMENT PLANT, INDIA
PLANT
LINE
CURRENT OPERATION
RAW MEAL
Chloride %
KFUI
CLINKER CHEMISTRY
S = SO3 %
Na2O %
K2O %
Chloride %
COAL MILL PERFORMANCE MILL 1 MILL 2
PRODUCTION 15 27 tph product Actual for 2002
PRODUCT RESIDUE 90 UM 15.8 25.26 %
PRODUCT RESIDUE 200 UM 1.92 2.5 %
MILL POWER ABSORBED 371 276 kW
POWER CONSUMPTION 36.0 26.0 kWh/t
PRODUCT MOISTURE 1.85 1.14 %
FUEL 1 PROPORTION 100 100 % total CV input
FUEL 2 PROPORTION 0 0 % total CV input
FUEL ANALYSIS - CURRENT FUEL 1 FUEL 2
CV 4888 4568 kcal/kg net adb
ASH 30.36 34.06 % adb
TOTAL MOISTURE - - % asr
INHERENT MOISTURE 1.85 1.14 % asr
VM 26.16 24.77 % adb
S 0.3 0.3 % adb
Cl 0.015 0.015 % adb
HGI 68 69
ALTERNATIVE FUEL NOT THRU MILLS % cv replacement
KILN FEEDRATE VARIATION % tph
COAL FEED RATE VARIATIONS KILN % tph
COAL FEED RATE VARIATIONS PC % tph
BURNER MOMENTUM Nh/GJ
AXIAL ALIGNMENT OF BURNER
GAS ANALYSIS RELIABILTY
GAS ANALYSIS KILN INLET %
GAS ANALYSIS PC OUTLET %
GAS ANALYSIS P/H OUTLET %
SPLASH BOXES INSTALLED
MEAL CURTAIN INSTALLED
BLASTERS ON RISER AND HEARTH
SILICON CARBIDE ON RISER AND HEARTH
Yes
-
Yes
No
3.8
20 mm down & 20mm
towards feed
70 to 80
95 to 98
95 to 98
-
3.0
1.5 -1.6
0.020 - 0.025
+/- 10
+/- 6
ARASMETA CEMENT PLANT, INDIA
0.012-0.02
3 to 4
0.6 - 0.8
0.25 - 0.3
Actual for 2002
COAL MILL EXPLOSION PROTECTION& FIRE SUPPRESSION
1 PREHEATER EXIT
Preheater gas analysis
Preheater exit gas analyser installed (y/n)
O2 measured (y/n)
CO measured (y/n)
Service factor of analyser >95% (y/n)
2 COAL MILL
Coal mill design pressure
DCS system installed if not what type of control system
Using hot gas from cooler,pre-heater or hot gas generator
coal mill temperature monitoring
coal mill exit thermocouple installed (y/n)
Normal operating exit temperature
Alarms configured for exit temperature
First alarm level for coal mill exit temperature
Second alarm level for coal mill exit temperature
inlet thermocouples installed (y/n)
Normal operating Inlet Temperature
Alarms configured for inlet temperature
First alarm level for mill inlet temperature
Second alarm level for coal mill inlet temperature
Temperature controlled by Recirculation damper (y/n)
Automated shutdown for high high coal mill exit temperature (y/n)
OXYGEN LEVEL at filter (%)
Tramp metal detection installed
Coal mill explosion relief
Explosion relief installed on coal mill (y/n)
Venting direction inside or outside building ?
Position (e.g. on coal mill body in inlet or exit duct etc)
Type of protection explosion flap, rupture panel
Area of explosion flap, panel (m2)
ANSWERS TO THIS QUESTIONNAIRE SHOULD BE ACCURATE
AND SPECIFIC please add any comments you might feel of help at
the end of the questionnaire. If there is an area where the answer is
not know please state not known. Note cells are auto formated yes =
green no = red

Completion target date 10th October 2003
Lifting/ breaking pressure of flap , panel
Manufacturer of explosion relief
Extra Venting fitted on duct from coal mill to filter (y/n)
Venting direction inside or outside building ?
3 COAL MILL BAG FILTER
Bag filter design pressure
Bag filter temperature monitoring
Inlet thermocouple fitted (y/n)
Outlet thermocouple fitted (y/n)
Differential temperature monitored and displayed (y/n)
Position of probes (e.g. in filter or ducts)
Typical differential temperature
First alarm level of differential temperature
Second alarm level of differential temperature
Does second alarm trigger automatic shutdown (y/n)
Temperature measured in bag filter bottom (y/n)
Material discharge temperature of bag filter measured (y/n)
Bag filter Gas monitoring
Bag filter gas exit analyser installed (y/n)
Position inside filter or in exit duct
CO measured (y/n)
O2 measured (y/n)
Normal operating level of CO ppm
Normal operating level of O2 %
First alarm level (O2 %)
Second alarm level (O2%)
First alarm level (CO ppm)
Second alarm level (CO ppm)
Do the second alarms for CO or O2 trigger an automatic shutdown
Bag filter level devices
Any level devices installed in bag filter (y/n)
position of level devices
Any blockage devices fitted to filter discharge (y/n)
Bag filter isolation
Fast acting isolation dampers installed outlet and inlet of filter (y/n)
Bag filter Explosion protection
Explosion relief installed on bag filter (y/n)
Type of protection (self closing doors rupture panels etc)
Area of explosion doors, panels (m2)
Lifting/ breaking pressure of flap , panel
Number of explosion doors panels etc
Position of doors panels (side venting etc)
4 PULVERIZED FUEL STORAGE
Fuel storage design pressure
Pulverized fuel Storage silo gas monitoring
Number of storage silos
Capacity of silos /s (t)
CO analyser installed on individual silo/s (y/n)
Pulverized fuel Storage silo temperature monitoring
Thermocouples installed in silo/s (y/n)
Number of measuring points
Position of points ( silo bottom, body, top etc)
First alarm level
Second alarm level
Any other temperature monitoring devices installed (describe)
pulverized fuel storage silo/s explosion protection
Explosion relief installed on silos (y/n)
Type of protection (self closing doors rupture panels etc)
Number of explosion doors panels etc
Area of explosion flap, panel (m2)
Lifting/ breaking pressure of flap , panel
5 RAW COAL STORAGE HOPPER IF INSTALLED (PRIOR TO MILL)
Fire suppression system installed (y/n)
Temperature monitoring for hopper
Explosion vents installed (y/n)
CO monitoring installed (y/n)
6 OPERATOR TRAINING
Have operators had training on fire suppression techniques
7 DOCUMENTATION
Is there a written procedure in case of fire or suspected fire on the coal mill system
Are there any written procedures covering general house keeping in coal grinding area
Any formal training attend (with suppliers Atc etc)
8 SYSTEM GENERAL
Is there a cleaning schedule for the coal plant area (y/n)
Have earthing straps been installed and tested on all conveying pipes (y/n)
Is there any horizontal ducting in the system
9 FIRE SUPPRESSION SYSTEM
Date installed
Manufacturer
Type of suppression used
CO2 (gas)
CO2 (liquid & gas)
N2
Storage capacity
Storage in bulk or bottles
Refill delivery time from time of order (hrs)
Deliver capacity (M3/hr)
Available discharge areas (coal mill, filter, silos others etc)
Any alternative or secondary system used
Automatic raw meal blanket system installed
Any explosion suppression system fitted ( dry powder or other)
What areas have explosion the suppression system installed
10
COAL MILL EXPLOSION PROTECTION& FIRE SUPPRESSION
1 PREHEATER EXIT
Preheater gas analysis
Preheater exit gas analyser installed (y/n)
O2 measured (y/n)
CO measured (y/n)
Service factor of analyser >95% (y/n)
2 COAL MILL
Coal mill design pressure (bar)
DCS system installed if not what type of control system
Using hot gas from cooler,pre-heater or hot gas generator
coal mill temperature monitoring
coal mill exit thermocouple installed (y/n)
Normal operating exit temperature
Alarms configured for exit temperature
First alarm level for coal mill exit temperature
Second alarm level for coal mill exit temperature
inlet thermocouples installed (y/n)
Normal operating Inlet Temperature
Alarms configured for inlet temperature
First alarm level for mill inlet temperature
Second alarm level for coal mill exit temperature
Temperature controlled by Recirculation damper (y/n)
Automated shutdown for high high coal mill exit temperature (y/n)
OXYGEN LEVEL at filter (%)
Tramp metal detection installed
Coal mill explosion relief
Explosion relief installed on coal mill (y/n)
Venting direction inside or outside building ?
Position (e.g. on coal mill body in inlet or exit duct etc)
Type of protection explosion flap, rupture panel
Area of explosion flap, panel (m2)
Lifting/ breaking pressure of flap , panel
ANSWERS TO THIS QUESTIONNAIRE SHOULD BE ACCURATE
AND SPECIFIC please add any comments you might feel of help at the
end of the questionnaire. If there is an area where the answer is not
know please state not known. Note cells are auto formated
yes =green no =red.

Completion target date 10th October 2003
Manufacturer of explosion relief
Extra Venting fitted on duct from coal mill to filter (y/n)
Venting direction inside or outside building ?
3 COAL MILL BAG FILTER
Bag filter design pressure
Bag filter temperature monitoring
Inlet thermocouple fitted (y/n)
Outlet thermocouple fitted (y/n)
Differential temperature monitored and displayed (y/n)
Position of probes (e.g. in filter or ducts)
Typical differential temperature
First alarm level of differential temperature
Second alarm level of differential temperature
Does second alarm trigger automatic shutdown (y/n)
Temperature measured in bag filter bottom (y/n)
Material discharge temperature of bag filter measured (y/n)
Bag filter Gas monitoring
Bag filter gas exit analyser installed (y/n)
Position inside filter or in exit duct
CO measured (y/n)
O2 measured (y/n)
Normal operating level of CO ppm
Normal operating level of O2 %
First alarm level (O2 %)
Second alarm level (O2%)
First alarm level (CO ppm)
Second alarm level (CO ppm)
Do the second alarms for CO or O2 trigger an automatic shutdown
Bag filter level devices
Any level devices installed in bag filter (y/n)
position of level devices
Any blockage devices fitted to filter discharge (y/n)
Bag filter isolation
Fast acting isolation dampers installed outlet and inlet of filter (y/n)
Bag filter Explosion protection
Explosion relief installed on bag filter (y/n)
Type of protection (self closing doors rupture panels etc)
Area of explosion doors, panels (m2)
Lifting/ breaking pressure of flap , panel
Number of explosion doors panels etc
Position of doors panels (side venting etc)
4 PULVERIZED FUEL STORAGE
Fuel storage design pressure
Pulverized fuel Storage silo gas monitoring
Number of storage silos
Capacity of silos /s (t)
CO analyser installed on individual silo/s (y/n)
Pulverized fuel Storage silo temperature monitoring
Thermocouples installed in silo/s (y/n)
Number of measuring points
Position of points ( silo bottom, body, top etc)
First alarm level
Second alarm level
Any other temperature monitoring devices installed (describe)
pulverized fuel storage silo/s explosion protection
Explosion relief installed on silos (y/n)
Type of protection (self closing doors rupture panels etc)
Number of explosion doors panels etc
Area of explosion flap, panel (m2)
Lifting/ breaking pressure of flap , panel
5 RAW COAL STORAGE HOPPER IF INSTALLED (PRIOR TO MILL)
Fire suppression system installed (y/n)
Temperature monitoring for hopper
Explosion vents installed (y/n)
CO monitoring installed (y/n)
6 OPERATOR TRAINING
Have operators had training on fire suppression techniques
7 DOCUMENTATION
Is there a written procedure in case of fire or suspected fire on the coal mill system
Are there any written procedures covering general house keeping in coal grinding area
Any formal training attend (with suppliers Atc etc)
8 SYSTEM GENERAL
Is there a cleaning schedule for the coal plant area (y/n)
Have earthing straps been installed and tested on all conveying pipes (y/n)
Is there any horizontal ducting in the system
9 FIRE SUPPRESSION SYSTEM
Date installed
Manufacturer
Type of suppression used
CO2 (gas)
CO2 (liquid & gas)
N2
Storage capacity kg
Storage in bulk or bottles
Refill delivery time from time of order (hrs)
Deliver capacity (M3/hr)
Available discharge areas (coal mill, filter, silos others etc)
Any alternative or secondary system used
Automatic raw meal blanket system installed
Any explosion suppression system fitted ( dry powder or other)
What areas have explosion the suppression system installed
10