Coal Mill Performance Questionnaire Corrected

8/12/2019 Coal Mill Performance Questionnaire Corrected

1/15

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 DESIGNCV 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


2/15

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

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 inputFUEL 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 % tphCOAL 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


3/15

002


4/15

COAL MILL EXPLOSION PROTECTION& FIRE SUPPRESSION

1 PREHEATER EXIT

Preheater gas analys is

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 mi l l temperature moni tor ing

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 mil l explosio n rel ief

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 ACCURATEAND SPECIFIC please add any comments you might feel of help atthe end of the questionnaire. If there is an area where the answer isnot know please state not known. Note cells are auto formated yes =green no = red

Completion target date 10th October 2003


5/15

Lifting/ breaking pressure of flap , panel

Manufacturer of explosion relief

Extra Venting fitted on duct from coal mill to filter (y/n)


3 COAL MILL BAG FILTER


6/15

Bag filter design pressure

Bag fi l ter temperature mon itor ing

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 f i l ter Gas mo ni tor ing

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 fi l ter 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 fi l ter isolat ion

Fast acting isolation dampers installed outlet and inlet of filter (y/n)

Bag f i l ter Explos ion pro tect ion

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 etcPosition of doors panels (side venting etc)

4 PULVERIZED FUEL STORAGE

Fuel storage design pressure


7/15

Pulverized fuel Storage si lo gas monitor ing

Number of storage silos

Capacity of silos /s (t)

CO analyser installed on individual silo/s (y/n)

Pulverized fuel Storage si lo temperature mon itor ing


8/15

Thermocouples installed in silo/s (y/n)

Number of measuring points

Position of points ( silo bottom, body, top etc)

First alarm level

Second alarm levelAny other temperature monitoring devices installed (describe)

pulv erized fuel storage si lo/s explo sion p rotect ion

Explosion relief installed on silos (y/n)


Number of explosion doors panels etc


Lifting/ breaking pressure of flap , panel5 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


9/15

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


10/15

COAL MILL EXPLOSION PROTECTION& FIRE SUPPRESSION

1 PREHEATER EXIT

Preheater gas analys is

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 mi l l temperature moni tor ing

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 mil l explosio n rel ief

Explosion relief installed on coal mill (y/n)


Position (e.g. on coal mill body in inlet or exit duct etc)

Type of protection explosion flap, rupture panel


Lifting/ breaking pressure of flap , panel

ANSWERS TO THIS QUESTIONNAIRE SHOULD BE ACCURATEAND SPECIFIC please add any comments you might feel of help at theend of the questionnaire. If there is an area where the answer is notknow please state not known. Note cel ls are auto fo rmatedyes = green no = red.

Completion target date 10th October 2003


11/15


12/15

Bag filter design pressure

Bag fi l ter temperature mon itor ing

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 f i l ter Gas mo ni tor ing

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 fi l ter 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 fi l ter isolat ion

Fast acting isolation dampers installed outlet and inlet of filter (y/n)

Bag f i l ter Explos ion pro tect ion

Explosion relief installed on bag filter (y/n)


Area of explosion doors, panels (m2)Lifting/ breaking pressure of flap , panel

Number of explosion doors panels etcPosition of doors panels (side venting etc)

4 PULVERIZED FUEL STORAGE

Fuel storage design pressure


13/15

Pulverized fuel Storage si lo gas monitor ing

Number of storage silos

Capacity of silos /s (t)

CO analyser installed on individual silo/s (y/n)

Pulverized fuel Storage si lo temperature mon itor ing


14/15

Thermocouples installed in silo/s (y/n)

Number of measuring points

Position of points ( silo bottom, body, top etc)

First alarm level

Second alarm levelAny other temperature monitoring devices installed (describe)

pulv erized fuel storage si lo/s explo sion p rotect ion

Explosion relief installed on silos (y/n)


Number of explosion doors panels etc


Lifting/ breaking pressure of flap , panel5 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


15/15

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

Documents

Coal Mill Performance Questionnaire Corrected