In 2002, D.G. Khan and FLSmidth teamed up to build a new coal meal silo for kiln No. 1 at D.G. Khan's cement plant in Pakistan. Meanwhile, close co-operation combined with excellent results encouraged D.G. Khan to invest in additional plant upgrades, culminating with the commissioning in February of a modernised preheater tower. The plant originally featured two cement production lines, kiln No. 1, an old 2,200 tpd kiln of Japanese design, and kiln No. 2, a 3,200 tpd kiln of more recent date supplied by FLSmidth. Following the upgrades the production capacity of the two lines has increased to 2,700 tpd and 4,000 tpd, respectively.
Background
- The project was prompted by D.G. Khan's request for a new coal meal silo for kiln No. 1. Later, the customer decided to also invest in a new coal mill.
- An upgrade of the hot air system subsequently enabled the coal mill to serve both cement production lines.
- A new burner was installed.
- The project developed into an upgrade of both production lines.
Kiln No. 1 upgrades
- New SF Cross-Bar cooler 2x5
- New kiln hood
- Partly new cyclones
- New kiln feed system and
- New motors
Preheater tower upgrades
- Replacement of cyclones
- New ILC-E calciner
- new raw material feeding system
The project was completed in February 2005 with the last of several upgrades being finished.
Co-operation particularly important in upgrade projects
Close contact between the customer and the contractor is a must to be able to co-ordinate the many complex issues:
- The new equipment must be adapted to the existing equipment and building structures.
- Unforeseen situations invariably crop up, necessitating project adjustments as well as ingenuity and attentiveness on the part of the engineers.
What next?
The D.G. Khan project has prompted several other Pakistani cement producers to turn to FLSmidth for similar upgrades of their plants.
- Maple Leaf is upgrading its plant
- Cherat is upgrading its plant
