Introduction
Since 2016, SUZUKI Consultant have started catering to the Clients all over the world the specialized technologies on upgradation/optimization of existing plants, specialized equipment, through their services directly and/or through licensing & technical collaborations, with the reputed consulting and cement machinery manufacturers in overseas.
Upgradation / Optimization
The process and operational factors of the plant changes (widely at some times) from the time of establishment to the years go by, due to some of the major factors :
- Variations in quality of raw materials/additives.
- Life of equipment and machinery.
- Operational and maintenance procedures.
- Increasing the capacity of main core equipment but with unstable operation due to :
- rise in pressure drop across Preheater Cyclones.
- rise in exhaust temperature.
- rise in heat consumption.
- rise in power consumption.
- unstable operational conditions of Pyrosection.
- improper Kiln burning efficiency.
- Other factors etc.
- Cooler air loading and balancing of cooling air.
- Conditions of measuring equipment/instrumentation as well as its present location of installation.
Special Techniques
Irrespective of type of Kiln process and make, SUZUKI Consultant had developed successful techniques to diagnose the existing plants and to overcome the existing process/operational problems and to improve the capacity of Pyro section with an economical investment and assuring stable operation. Also techniques developed for reducing the pressure drop across Preheater Circuit, for reducing the exhaust gas temperature and for improving the Kiln/Calciner burning efficiency and for improving the efficiency of Clinker Cooler, and for solving the existing process and operational problems. Also to utilize 100(%) Petcoke (Petro coke) for the Kiln and Calciner, for OPC and White Cement production.
ASSIGNMENTS
SUZUKI Consultant has carried out number of assignments successfully on plant optimization and for increasing production of existing of Pyrosections and its connected departments, in various countries, such as Japan, China, Thailand, India, Taiwan and Egypt etc. SUZUKI Consultant had received repeat assignments from the same Client to render the services also for other existing Kilns in the plant. In some assignments, the production was increased from 2000(t/d) to 2250(t/d) and 5300(t/d) to 5500(t/d) respectively, with stable operation at minimum investment. Details on some assignments are indicated in the following table.
It is difficult to put in writing the total aspects of optimization procedures because it varies from plant to plant and also as per existing operational conditions. This subject requires on- the-spot observations and need discussions with the plant operational personnel with convincing technical explanations. We believe in practical approach than theoretical one.