FLSmidth’s OK™ Cement mill at Zuari Cement - A classic example of Operational Excellence

March 17, 2017

An industrial town in the Kadapa district of the Indian state of Andhra Pradesh, Yerraguntla is home to several cement plants. One of these is Zuari Cement, owned by the Italcementi Group, one of the leading cement producers in the world. 

All major equipment for Zuari Cement’s two lines was supplied by FLSmidth. A common feature is the modern, sometimes unconventional solutions aimed at delivering low emissions and high reliability.

Zuari Cement Line 2 is equipped with an OK™ 36-4 vertical cement mill with 3750 kW main motor. This most reliable solution for clinker grinding supplied by FLSmidth has once again proven its ability to deliver high performance across a range of operating conditions.

In response to the market demand for an energy-efficient and reliable solution, Zuari Cement entered the conventional OPC cement market with blended Portland cement, incorporating pozzolanic and cementitious materials.

The OK™ mill supplied by FLSmidth met stringent market demands. The feed system and auxiliaries were designed specifically to suit the feed materials’ higher moisture levels. In addition, the entire layout was carefully planned for an optimised arrangement without compromising on any safety requirements, including the environmental requirements stipulated by Italcementi and Zuari Cement.

A classic example of Operational Excellence
For a system to achieve ‘operational excellence’, it must be able to adapt quickly to any changes carried out on site. According to Mr. Mandeo Yadav, Sr. Vice President – Works at Zuari Cement, FLSmidth’s OK mill has achieved this level:

 “We had to make certain changes to the feed circuit. A separate belt conveyor for slag and wet fly ash feeding was causing choking in the mill rotary feeder and transfer point chutes. In order to prevent this choking, the wet fly ash and slag feed was connected to the common belt conveyor (clinker). With this mixed feed, mill operation has improved further, and operational excellence was achieved.” - Mandeo Yadav, Senior Vice President - Works, Zuari Cement Limited

Performance Guarantees:
The OPC guarantees were achieved with 4816 successful hours of operation at guaranteed power consumption. After a few months of operation and achieving the guaranteed figures, FLSmidth’s OK™ mill was outperforming guarantees in terms of output, quality and cost economics.

The mill was fitted with a FLSmidth MAAG® gear box that worked extremely well maintaining its vibration levels within the appropriate limits. The wear performance of the mill grinding elements was extremely satisfactory as the reported wear rate was as low as 0.88 grams per hour and the run hours achieved before the first hard facing was reported to be 11,000 hours.

Zuari Cement was extremely happy about the exemplary cooperation from FLSmidth, in which both achieved a ‘win-win’ and set new standards in the industry.

The incomparable performance of FLSmidth’s OK™ 36-4 mill at Zuari Cement is another example of FLSmidth’s efforts to provide customers with superior products and technology that delivers sustainable cement production.

Previous Article
Introducing the first CataMax™ catalytic filter
Introducing the first CataMax™ catalytic filter

The first CataMax™ catalytic filter begins to take shape and will be ready for start-up in September 2017.

Next Article
India’s biggest OK™ mill – A story of reliable operations and smoother performance
India’s biggest OK™ mill – A story of reliable operations and smoother performance

Operations at OCL cement plant at Midnapore, India have been boosted by the successful commissioning of an ...