An industrial town in Kadapa district 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 3,750 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.
For a system to achieve ‘operational excellence it must be able to adapt quickly to any changes carried out on site. According to Mandeo Yadav, Sr Vice President – Works at Zuari Cement, FLSmidth’s OK mill has achieved this level.
The OPC guarantees were achieved with 4,816 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 an 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. midth's OK mill has achieved this level.