Kiln shell installed in record time

June 19, 2014 Raveenran Chalil

When leading Indian cement producer J.K. Cement decided to build a brownfield plant with a capacity of 5,000 tpd at Mangrol, Rajasthan, they chose FLSmidth as their technology partner.

The contract was signed in 2012 and site installation started in June 2013. FLSmidth is supplying the pyroprocessing, coal mill, air pollution control equipment and material handling equipment 
(see table 2) plus a Robolab automatic quality control system. The installation contract has been awarded to Ayoki Cembol Erectors Private Limited, one of India’s leading installation contractors in the cement industry.

Meticulous planning

FLSmidth’s supervisors together with Ayoki ensured that the installed equipment met the high FLSmidth quality level and was safe for the client to operate. On 28 October 2013, all six kiln sections were installed within 2 hours and 18 minutes. There were six lifts with a total weight of 383.5 tonnes including the kiln tyres. Details of the kiln section weights are shown in table 1.

Kiln shell installed in record time

2. FLSmidth scope of supply

3. Project timeline

The first section was lifted into position at 06.05 hours and the last one was in place by 08.23. Two cranes lifted in parallel at either end (feed and discharge ends) of the sections. To begin with, four sections were fitted with the necessary lifting gear, and when the first two sections were in place, their lifting gear was removed and transferred to the last two sections.

This was a fine example of good and respectful cooperation  between J.K. Cement, Ayoki and FLSmidth. Two 250 tonne cranes, four sets of lifting gears and two 6 tonne hydra cranes were used for the entire operation.

Modern, environmentally sustainable plant

The plant will be an energy efficient and pollution controlled  production facility with outlet emission less than 50 mg /Nm3 - far below the limit set by the Central Pollution Control Board.

The target date for the commissioning of the Mangrol brownfield plant is June 2014 (See table 3 for project timeline).

Read more about Project Execution >

Highlights of this project
• For the first time in India, we indigenised and manufactured ATOX coal mill rollers, table and centre piece for the JK Cement, Mangrol cement plant project
• The calciner has provision for an alternate fuel firing system, customer has planned to use alternate fuel in the longer term
• The customer is highly satisfied as the manufacturing and delivery of equipment were within the contractual delivery dates.

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