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Case study 2-Yishui Shanshui Cement

[Feb 20,2020]

Time: June,2018

Client: Yishui Shanshui Cement,China 

VRM: Raw meal grinding

Case study 2-Yishui Shanshui Cement

  • 1.Higher hourly output of raw meal mill: Before the retrofit, in 2018, the average hourly output of raw meal mill was 392.2t/h.During the 2 months after the retrofit, the average hourly output of raw meal mill increased by 24t/h to 2t/h. With the increase of hourly output, the raw meal mill has more idle time to receive maintenance and the prolonged idle periods allow further optimization of operation schedule and avoidance of peak power periods, which is conducive to cost reduction.
  • 2.Less system air leakage, significantly lower energy consumption of raw meal system: After the retrofit, the combination of buffer bin + sealed feeder effectively prevents the air leakage phenomenon at the raw meal inlet pipe of the mill. The O2content in the exhaust gas at kiln tail declined by 1.3% from 7.6% before the retrofit to 6.3% after the retrofit. The system exhaust rate reduced by about 23,000 Nm³/h. Due to the reduction of air leakage in the system, the speed of the ID fans declined by 40rpm, and their operating power reduced by  The power of the main motor of raw meal mill reduced by 295kWh, the energy consumption per ton of raw meal reduced by 1.27kwh from 17.32kw/t to 16.05kw/t, equivalent to an energy consumption reduction of 1.97kw/t (clinker). Based on the average purchased electricity price of 0.62 yuan/kWh, considering that our annual clinker production is 1.15 million tons, the energy consumption saving each year equals to 1.15 million tons * 1.97kwh * 0.60 yuan = 1.359 million yuan.
  • 3.Reducethe impact of the externally circulated materials of raw meal mill on the mill, and improve the mill’s operating stability: Before the retrofit, the discharged slag from raw meal mill was sent to the grinding belt through the external circulation system, and then directly fed into the mill for regrinding. The fluctuation of the slag discharge rate directly causes the fluctuation of the inlet rate of the mill, which leads to instability of the raw meal layers in the mill and large fluctuation of the operating power of the mill, bringing hidden dangers to the safe operation of the equipment. After the retrofit, a weighing buffer bin is added. The raw meal entering the mill is fed by a sealed constant weight feeder after passing through the buffer bin, which effectively impedes the raw meal fluctuation caused by the instability of slag discharge  So, the mill’s operation stability has been greatly improved (see Figure 5 and Figure 6 for comparison of mill running power of before and after the retrofit).

Case study 2-Yishui Shanshui Cement

Running power curve of raw meal mill before the retrofit

 Running power curve of raw meal mill after the retrofit

 
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