Cimentas-Izmir Cimento wanted to increase the clinker output of its FLSmidth kiln from 2,300 to 3,000 tpd, at a down-time not exceeding 83 days.
Defining the project
Cimentas-Izmir and FLSmidth teams reviewed the plant's machinery and equipment together and thoroughly considered the options available for reaching the target. They defined and initiated an upgrade of the existing line.
The technical solution included the following major modifications:
Increasing the raw milling capacity was essential to the project, and incorporation of a TUMS ball mill in the milling circuit ensured that proven technology – employed in a new way – was used to solve the issues relating to drying and pre-grinding of the additional raw materials.
Selecting a ball mill for pre-grinding instead of any other crushing machine also ensured that normal wear-related operational down-time would be kept at a minimum.
The limited space available on site presented a number of challenges, especially during the reconstruction and reinforcement of the preheater tower. The preassembled civil works structures and the preassembled new cooler also took up significant space, further complicating matters. Employees, machinery, cranes and contractors were all cramped together in a small area while goods were delivered, assembled and fitted within a short, hectic period.
However, efficient site management and a sense of team spirit among everyone involved complemented the innovative technical solution.
The actual kiln stoppage lasted 82 days. The kiln production increased by 1,000 tpd, exceeding the original target of 700 tpd. Other results are shown in the table.
It took only 82 days to upgrade the plant by 1,000 tpd.
Mill transport was only one of the many challenges presented by limited space.
The TUMS pre-grinding raw mill was the first of its kind ever supplied.