4 PROjECT PRIDE
In an era of a high competition within India and the
global cement industry, it was a challenge to design a
new cement plant with a vision for the lowest thermal
and electrical energy consumption with the lowest carbon
footprint. The selection of equipment and its design was
carried out after a lot of brainstorming, keeping global
benchmarking standards in view. Intense discussions were
carried out within the group along with cement equipment
original equipment manufacturers (OEMs) in India and
their respective global principals, with an objective to
create pride in this project.
Pyro Process
The project team held discussions with all pyro suppliers in
order to explore their technical design feasibilities for sizing
of critical equipment like kiln, pre-heater (PH) cyclones,
pre-calciner, downcomer duct, and tertiary air duct.
Discussions were also held on burner and cooler for lowest
possible velocity and pressure drop in order to minimize
losses and achieve better potential on capacity, minimum
specific fuel and power consumption and also NOX, SOX,
dust emission guarantee.
The DCBL project team emphasized on optimizing
the insulation and refractory thickness in pre-heater
cyclone and pre-calciner from their standard to reduce
the radiation losses. Suppliers upgraded critical equipment
sizing accordingly.