New pyro system and cement mills for Manikgarh Cement

Manikgarh Cement Limited, owned by India’s BK Birla Group of Companies, has successfully commissioned a three million t/a cement plant. The cement producer first announced its plans to build a brownfield integrated cement plant in 2010. ­Located in Gadchandur, a town in the Chandrapur District in the State of Maharashtra, Manikgarh Cement (Fig. 1) is a division of Century Textiles & Industries Ltd., owned by the BK Birla Group, which operates within a variety of industries, including textiles, rayon, chemicals, paper & pulp, and cement.

Following a lengthy series of technical and commercial negotiations, during which many different solutions were weighed up, Manikgarh ­Cement awarded the contract for supply of pyro processing system and cement mills to FLSmidth. The project kicked off immediately after the signing of the contracts for both projects in May 2010.

The scope of the 8000 t/d pyro processing system (Fig. 2, 3) includes the design, engineering, manufacture and supply of the complete array of equipment to build up a modern pyro processing system. It features a CF silo for homogenising and storing raw meal with a capacity of 24000 t and bulk density of 0.9 t/m^³. With a six-stage twin string Inline Calciner (ILC), its preheater was designed to optimise fuel and power consumption and minimise emissions. The rotary kiln was lit up on 17.08.2014 and was soon producing the desired clinker output of 8000 t/d.

Scope of supply – pyro process:

CF silo – 22.4 m in diameter, 55 m in height

Kiln feed system

ILC preheater – 8 m in diameter, 160 m in height

3-base rotary kiln – 5.5 m in diameter, 87 m in length

SF Cross Bar^® 5 x 7 F clinker cooler, with heavy-duty roller breaker MF 418

Coal dozing and firing system

Clinker transport to storage

The cement mill contract included the complete design, engineering, manufacturing and supply of equipment. The UMS ball mills supplied as part of the contract grind at the rate of 150 t/h. All three mills have been commissioned and are currently running at the expected production rate, while performance guarantee tests are currently in progress.

Scope of supply – Cement grinding:

UMS Ball mill – 4.6 m in diameter, 15.5 m in length

Dynamic separator Sepax 500 M-22

Razal Ali, Project Manager, was responsible for the project delivery from FLSmidth. He is very pleased that the project ran smoothly, saying, “There was no delay in deliveries, which is one of the most essential aspects of completing a project on time and at the expected level of perfection.” He adds that the cooperation between FLSmidth and Manikgarh’s cement execution teams was highly efficient.