Rain Cement’s South India-based Ramapuram plant has achieved impressive performance results following the successful replacement with FLSmidth Cross-Bar® cooler.
Rain Cements Limited (RCL) has been producing cement since 1986 at an annual output of up to 3.6 million tonnes. Its two integrated plants located in South India are self-sufficient in all critical raw materials – limestone, additives and coal.
RCL made an important decision to address inefficiencies in one of its existing systems at the cement plant based in Ramapuram, Mallacheruvu, Kodad in Nalgonda. The project team paid particular attention to the grate cooler, which was an older generation with low thermal efficiency, and high-energy consumption and requiring more maintenance.
Mr. VM Moorthy, VP (Technical) at RCL, comments: “We previously had an old-generation grate cooler, which was becoming problematic for us. We wanted to improve thermal efficiency, so it was necessary to move to a new-generation cooler.”
With a complete FLSmidth production line already implemented at one of its plants, RCL approached FLSmidth to audit the cooler system in 2016. The audit involved taking detailed measurements of the existing cooler’s performance. The findings identified the potential to reduce cooler losses and create thermal and electrical energy savings, and as a result, FLSmidth recommended replacing and installing a more reliable, efficient cooler.
The Cross-Bar® cooler met the needs of RCL in terms of possessing high thermal efficiency, reduced power consumption, relatively low maintenance requirements and low civil construction and operating costs. The optimised design is flexible enough to enable partial or complete upgrades of most existing old-generation clinker coolers. The return on investment for RCL can be realised within an estimated four-year period, just from the energy benefits and fuel savings alone. It was clear that this was the solution for RCL, and FLSmidth’s extensive experience in retrofits gave a certain boost of confidence.
“Despite requiring extensive civil structure modifications, the project was completed on time thanks to the support and experience of FLSmidth in completing retrofits,” says Mr. Moorthy, Vice President, RCL.
FLSmidth believe guarantees achieved on performance parameters is seen as an indication of the Cross-Bar® cooler’s exceptional performance and reliability.
“It pays to make the initial investment to reap the performance benefits well into the future. The success of this project demonstrates FLSmidth’s commitment to deliver impressive results through collaboration with our valued customers.”
Author: G Renga Prasad, Product Line Manager-Pyro, FLSmidth.
(Communication by the management of the company)