Introduction:

Process optimization is to improve the plant performance in terms of:

• Improved capacity utilization.
• Reduced power consumption.
• Reduced fuel consumption.
• Reduction of wear rate of dynamic equipment.
• Improved product quality.
• Improved equipment availability.
• Improved working environment due to reduction in dust nuisance.
• Reduced dust emission.
• Conservation of natural resources like water, minerals and fossil fuel.

Coverage/ Methodology:

It covers:

• Collection of plant data and interaction with plant personnel.
• Down time analysis of all the major equipments and identification of bottlenecks/ problem areas.
• Carrying out process measurements during steady operation of plant covering temperature, pressure, flow & power.
• Carrying out mass gas and heat balancing of Pyro section.
• Finding out efficiency of all the process fans.
• Particle size analysis for all the raw materials, fuel, clinker & cement.
• Proximate & Ultimate analysis of fuels.
• Recommendation of measures for improvement of plant operations on short term and long term basis with financial implications.
• Estimation of Capital Investments of the proposed measures.
• Estimation of Return on investment in terms of Simple Payback period.

Benefits:

Plant Optimization will lead to increased profitability due to:

• Reduction in unit cost of production.
• Improved availability of the plant.
• Increase in plant life.
• Improved working environment.
• Reduction of heat & power consumption.
• Conservation of natural/ mineral resources.