Plant Audits

Report
Of
st
1
Year
Santhalakshmi RSM Engineering Solutions Pvt. Ltd.,
Serve the Industry with Quality On Time
At Competitive Price
SRSMES is a growing Cement Plant and Waste
Heat Recovery (WHR) System designer and
supplier of machinery in collaboration with
reputed
machinery suppliers. Have good
engineering consultancy capability.
Our Managing Director Mr. R.S.Mani, has
served for MNCs and played a key role in
winning orders and executing several projects.
We provide comprehensive range of services
Santhalakshmi
Engineering
and solutions
to our RSM
client’s
technicalSolutions
and Pvt. Ltd.,
 New Cement Plant Design
 Small Projects
 Customized Solutions
 Modernization, Improvements & Upgrade
 Process Plant Audit
 Plant Operational Support
 Perform, Achieve, Trade (PAT)
 Waste Heat Recovery System
 Alternate Fuel Solutions
 Onsite Training
JK LAKSHMI CEMENT SIROHI LINE-I PH UPGRADATION
 Successfully upgraded and increasing the capacity from 3300 to 4500 TPD
 Excess air Calciner was replaced by New In-Line Calciner and Tertiary Air Duct.
 Three PH cyclones modifications were completed.
 Three more PH cyclones engineering completed
and will be executed during next shut down.
GUJARAT SIDHEE CEMENT PYROPROCESS UPGRADATION
 Separate Line Calciner Preheater - Successfully modified the Cyclones 3 & 4 in
both Kiln and Calciner towers
 Capacity increased from 4000 to 4600 TPD
 Substantial savings in pressure drop of
50-135 mmwg per cyclone was achieved
 Good savings in Sp. Power consumption.
ULTRATECH CEMENT, RATNAGIRI
CEMENT MILL SEPARATOR REPLACEMENT
 Designed and Supplied Cement Mill Separator successfully on time
 Capacity will increase with this latest design separator
 Specific power consumption will reduce considerably
CHETTINAD CEMENT PULIYUR - PYRO UPGRADATION
 PH Cyclones 2 & 3 were upgraded.
 Substantial savings in pressure drop, 50 mmwg per
cyclone and savings in specific power consumption of
0.4 kWh/ton in PH fan were achieved
 Calciner up-gradation is being planned to increase the
residence time and to fire pet coke
CHETTINAD CEMENT PULIYUR - PYRO UPGRADATION
 PH Cyclones 4 & 5 Engineering completed and will be modified during next
shut down.
 Substantial savings in pressure drop, 50 mmwg per cyclone and savings in
specific power consumption of 0.4 kWh/ton in PH fan envisaged
 Cooler up-gradation is being planned to reduce
the specific fuel consumption by 3 Kcal/kg cl
and reduce wear
JK LAKSHMI CEMENT SIROHI LINE-I WHRS AQC
 Successfully designed ,supplied and
commissioned WHRS-AQC Boiler in collobaration
with VEESONS
 Steam generation up to 8.0 TPH achieved
against guaranteed 6.2 TPH
 Overall power generation increased
NAGARJUNA CEMENT, SIMHAPURI
Operational Support Contract for one year period to improve the performance of
the Plant, Capacity, Fuel, Power consumption and Raw Mix optimization in the
following areas
o Line 1 pyro process
o Line 2 pyro process
o Raw grinding - Vertical Roller Mill
o Coal grinding - VRM & Ball Mill
o Various cement grinding systems
Cement Plant Design and Supply
 Complete Cement Plant Design and Supply.
 Overall Exposure and capabilities are high in all sections viz. Pyroprocess, WHRS,
Alternative Fuels, Raw, Coal and Cement grindings.
 Consultancy services.
 High Degree of Technical Expertise in
Cement Plant Design & Engineering,
Operation, Commissioning and Maintenance.
Plant Upgrade
 Expertise in Cement Plant up-gradation with unique skills and possess highly
experienced professionals.
 Customized and best Solutions are provided in up-gradation instead of standard
solutions.
Waste Heat Recovery System
 Complete design of WHRS for the cement plant.
 WHRS Engineering and Supply with reputed Suppliers.
 SRSMES can conduct audit / feasibility study to establish the availability of hot gases
from Pre Heater and Cooler and calculate the Possible Power Generation.
 Up-gradation of WHR
 With expert knowledge on cement plant our WHRS solutions are customised
Alternate Fuels
 Design a suitable alternative fuel feeding system.
 Calculation of alternative fuel substitution rate.
Plant Audits
 Establish the present performance, identify the bottlenecks and scope for
improvement.
 Suggestion of methods to improve overall process and operation, increase production,
improve fuel efficiency, reduce the power consumption, gaseous emissions and the
overall plant operating costs.
Cement Plant Process Training
 Customized Training modules in Cement process, Chemistry and Process
measurements & plant performance evaluation.
Perform Achieve Trade (PAT)
 Based on the process audit, recommendations are provided to match the PAT rules in
order to improve the efficiency of the plant.
We will enter into a Contract for 1 year duration with the customer and send our
expert for 2 days every month to support plant operation and optimize the plant.
Complete process analysis
 Specialists will visit and carry out complete analysis of the plant. Prime challenges will be
identified. Baseline parameters will be established.
Expert suggestions to eliminate prime challenges
 Suggestions to eliminate the prime challenges will be offered. Plant personnel will
implement the same and send the feedback. SRSMES will analyse the reports and further
improvements will be suggested.
Continuous support for sustaining and enhancing the capacity
 In addition from eliminating the challenges identified, capacity enhancement possibility
in different sections will be studied and improvements required will be suggested.
Exploring possibilities for efficient fuel and power consumption
 Fuel & Power consumption will be calculated and support offered to reduce the same to
optimum value. This ultimately reduces the operating cost.
Suggestions for improving raw mix and reduce production cost
 Raw material details will be studied and possibilities to improve raw mix design will be
explored.
Suggesting and executing essential modifications and up-gradation
 Modifications necessary to improve plant performance will be proposed. Engineering
and design for the same will be submitted as a separate proposal .
MOU with IKN (Global) on selected WHRS
 IKN is a German based cement plant supplier
 Engineering and Design by SRSMES
 Joint venture on supply of WHRS
Agreement with FIVES-FCB
 FIVES-FCB is a 200 years old French supplier of
complete cement plant
 Fives-FCB has various ranges of grinding mills
including Horomill
 SRSMES and FIVES will jointly promote grinding
technology/Products to Indian customer.
ORDERS REFERENCE LIST
S.No
Plant Name
Scope of Work
1
My Home Cement, AP
Pyroprocess audit and feasibility from 2600 TPD to 3000 TPD
2
Nagarjuna Cement, AP
Plant audit and feasibility study for Line-1 & 2
3
UltraTech Cement, Ratnagiri
Cement Grinding system audit
4
JK Lakshmi, Sirohi
Line-1 AQC boiler for existing WHR system
5
JK Lakshmi, Sirohi
Line-1 PH upgradation from 3300 TPD to 4500 TPD
6
Gujarat Sidhee Cement
PH upgradation, TAD modification, Raw mill internal and system
modification to enhance from 4000 TPD to 5000 TPD
7
Chettinad Cements, Karikkali
Line 2 complete plant audit
ORDERS REFERENCE LIST
S.No
Plant Name
Scope of Work
8
Chettinad Cements, Ariyalur
Line 1 & 2 complete Plant audit
9
Chettinad Cements, Puliyur
Complete Plant audit
10
Chettinad Cements, Kallur
Pyroprocess, Cooler & Waste Heat recovery system optimization
11
JK Lakshmi, Durg
Plant up gradation feasibility from 4500 TPD to 6000 TPD
12
JK Paper Ltd., Rayagada
Feasibility Study to setup a new green field cement plant
13
Shree JayaJothi, (My Home)
Process audit for capacity enhancement from 5100 to 6000 TPD
14
Chettinad, Puliyur
Feasibility study for implementing Waste heat recovery system
15
JK Lakshmi, Sirohi
Feasibility study for Waste heat recovery system for Line-1,2 &3
ORDERS REFERENCE LIST
S.No
Plant Name
Scope of Work
16
UltraTech,Narmada Cement,
Ratnagiri GU, Maharastra
17
Chettinad Cement Corporation Preheater stage-2,3,4&5, Calciner & Cooler Upgrade Ltd., Puliyur Cement Works
Engineering Order
18 Binani Cement Ltd., Rajasthan
19
Cement Grinding Separator upgradation - Engineering & Supply
Order
Line-2, 7800 tpd Pyroprocess process audit for overall system
improvement
Mangalam Cement Ltd., Morak, Feasibility study for conversion of coalmill (ballmill) system to
Rajasthan
flyash drying system - consultancy & engineering study
20 Binani Cement Ltd., Rajasthan
Line-1, 6000 tpd Pyroprocess process audit for overall system
improvement
21 Binani Cement Ltd., Rajasthan
Four numbers Cement Grinding System Process audit for overall
improvement
22 Sanghi Industries Ltd., Gujarat Semi-finish grinding system process audit
23
UltraTech,Narmada Cement,
Jaffarabad
Cement grinding system process audit
ORDERS REFERENCE LIST
S.No.
Plant Name
Scope of Work
24
UltraTech,Narmada Cement, Madgalla
Cement grinding system process audit
25
Chettinad Cements, Karikkali
Complete Plant audit for Line-1
26
JK Lakshmi, Sirohi
Consultancy for Line-1 Pyroprocess optimization
27
Chettinad Cements, Ariyalur
Complete Plant audit for Line-2
28
Nagarjuna Cement, Simhapuri, A.P
Plant Operational support for Pyroprocess, raw
grinding, coal grinding & cement grinding for Line1 & Line-2
29
UltraTech Cement, Kotputli
Pyroprocess study
30
Dalmia Cement, Dalmiapuram
Pyroprocess study
31
UltraTech Cement, Tadipatri
Precalciner study
Contact Details
Santhalakshmi RSM Engineering Solutions (P) Ltd.,
# 3308, Block 3, TVH Svasti, Eswaran Koil Street,
Thoraipakkam, Chennai – 600 097
Tamilnadu, India
Web : www.srsmes.com
Tel : 91 44 2985 7765
E-mail : [email protected]

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