Humboldt Wedag India has been at the forefront of technological developments taking place in the cement industry of Indian subcontinent. ASHOK DEMBLA and BALESH SINGH open up a window for us on various aspects of developments.
The Indian cement industry continues to be second largest producer of this commodity in the world. This sector is expected to continue its fast-paced growth and attain installed capacity of 850 million tonnes (MT) per annum by 2030 and 1,350 MT by 2050. The industry has made tremendous strides in technology assimilation and upgradation.
Single production lines of over 12,000 TPD (tonnes per day) with multi-stream pre-heaters and calciner, thermal energy consumption of 685 Kcal/Kg clinker, or electrical energy consumption of 70 kWh/ton of cement were unimaginable two decades ago when these figures hovered at around 850 Kcal/Kg clinker and 110 KwH ton of Cement respectively.
Some of the important plants supplied by Humboldt Wedag India which are achieving results comparable to best figures in the Industry and sometimes best in the Industry are;
Dalmia Cement, Belgaum - Achieving Electrical Energy Consumption of Less than 10 kWh/t for Raw Material Grinding in Roller Press finish grinding KHD has been pioneer in many technologies, to name a few;
I) First 4-stage Preheater Technology - The first plants with 300 tpd capacity and 600 tpd capacity, came in from Humboldt in Andhra Pradesh at the end of the 1960´s.
II)Roller Press Technology - First plants again came from Humboldt in Diamond Cement, Rajashree Cement and Vikram Cement, in the year 1986-87 which have now been upgraded.
III) V Separator Technology - This technology came as a boon for energy-savings and reliability for semi-finish grinding technology in the year 1995.
IV) Alternative Fuels - Extended PYROCLON® and KHD´s Combustion Chamber came as excellent technology to use pet coke, city waste and other waste derived fuels.
V) 5 & 6 Stage Preheater Technology - The first of these type of plants came on line in India e.g. Diamond Cement, Vikram Cement and Rajashree Cement in order to reduce thermal energy consumption.
VI) Latest Generation Grate Coolers - The KHD Grate Cooler got its start at Vikram Cement. Later came the PYROSTEP® Cooler and now PYROFLOOR® cooler. In addition there has been many innovations in Burner Technology, where the original KHD design has become the world standard.
Energy, Efficiency and Environment
KHD-Humboldt Wedag buzz word for Technology is Energy, Efficiency and Environment.
Energy: The COMFLEX® grinding system consumes less energy compared to other process circuits.. More and more customers began to use this roller press-based system in the finish-grinding mode for Slag, Limestone, and clinker.
Potential in saving with selection of KHD Roller Press circuit than the VRMs:
Potential in saving with Selection of KHD Pyro process Technology.
About the authors:
Ashok Dembla, Managing Director, Humboldt Wedag India.
Balesh Singh, Process Head, Humboldt Wedag India.