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INTRODUCTION Project title- MINIMIZATION OF COAL MILL REJECTION - PowerPoint PPT Presentation

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INTRODUCTION Project title- MINIMIZATION OF COAL MILL REJECTION Area- BOILER Methodology- DMAIC SBU Head- BIRAJA SHANKAR MUND Project Mentor- SUSHEEM KUMAR BEHERA Team Leader- UPENDRA KUMAR PATHY Team members- SUDHANSU SEKHAR PANDA

  1. INTRODUCTION Project title- MINIMIZATION OF COAL MILL REJECTION Area- BOILER Methodology- DMAIC SBU Head- BIRAJA SHANKAR MUND Project Mentor- SUSHEEM KUMAR BEHERA Team Leader- UPENDRA KUMAR PATHY Team members- SUDHANSU SEKHAR PANDA (SSL) MANOJ KUMAR NAYAK (SSL) Support taken from M/S AIA Engineering

  2. PROJECT CHARTER PROJECT CHARTER (Tick / fill all that apply) Minimization of Coal mill rejection Project Title Mentor Susheem kumar Behera Project Leader Upendra Pathy SBU Head Biraja Shankar Mund PROBLEM STATEMENT (why are we doing this project?) What needs to be improved - Reduction in coal mill rejection, increase in mill Grindability, no clinker formation in Primary air inlet to Mill Current Performance Level - Coal rejection is 1.3 % of coal feeding Target Performance- Reduction in coal rejection by 0.3 % Savings of 12 Lacs/ annum per coal mill The Tangible(Rs/ Annum) and/or intangible Increase in Mill outlet temperature impact due to this project are:- Improvement in Mill loading PROJECT TEAM MEMBERS Sl. No. Name of the Team Member GRADE Function MOBILE NUMBER 1 Sudhansu Sekhar panda M6 Area in charge 9777049307 2 Manoj Nayak M6 Support member 9937298735 PROJECT TIMELINES Project Deadlines: DEFINE MEASURE ANALYSE IMPROVE CONTROL PROJECT CLOSURE (indicate the Date and month) 10.12.2013 15.12.2013 27.12.2013 10.01.2014 05.03.2014 15.03.2014 FINANCIAL BENEFITS Projected Financial Benefits: Rs. 12 lacs / annum Cost of Project: Rs.3 lacs SUBMITTED BY Project Leader: Upendra Pathy SBU Head: Biraja Shankar Mund

  3. COAL MILL OVERVIEW Coal & Hot Air flow path Mill – HP 703 ,Bowl Mill Roller Deflector Bowl capacity: Vane wheel 26 TPH, Bowl Extension Ring Power:280 KW

  4. DEFINE PHASE Problem statement (waste or loss identified)- High coal reject in Mill rejection system Scope for improvement- • Reduction in rejection quantity • Increase in Grindability • Increase in mill outlet temperature • Reduced spare consumption and increase in Grinding roller life period Current performance state- Coal rejection is 1.3 % of coal feeding Target performance state- Minimizing coal rejection by 0.3 %

  5. MEASURE PHASE Coal consumption per day: 480 Ton/day (20 TPH) % of coal reject :1.3 % Coal consumption per annum : 175200 T Mill power capacity : 280 KW Cost of coal : Rs. 1950/ Ton Amount of coal in rejection : 6.2 T / day Mill Current @ 20 T load : 30 Amp Target rejection % : 1 % Saving in coal : 525 Ton (saving by 0.3 % rejection coal) Saving in Cost: Rs.1020000 /- CHP running hrs : 4 hrs / day For 1 hour running of CHP , power consumed :500 KW Coal Mill Rejection 1.3 1.4 1.2 1 1 0.8 0.6 0.4 0.2 0 Current Level Target Level PARAMETER VALUE

  6. QC Tool-Fish Bone Diagram MATERIAL MAN Higher size coal rejection No proper Man hour loss separation between Sufficient coal & stone Reduced mill grindability manpower for rejected coal More coal Low HGI coal feed handling Lack of awareness rejection quantity High coal mill reject Improper air & coal Increased clearance Deflector liner ratio between vane reducing velocity of wheel and seal plate PA air Excess feeding Big size coal spillage Free flow required for LESS Improper TURBULENCE material handling MACHINE METHOD

  7. ANALYSIS PHASE Slope provision in hot air inlet Increase in length of centre MOC of grinding roll changed duct to reduce clinker feed pipe from Hi-chrome to sinter cast formation Reduction in bowl depth to increase Grindability Restrict higher size coal feeding Reduction in turbulence in coal at mill inlet mill Air port Ring assembly installation in stead of Conventional vane wheel assembly

  8. ANALYSIS PHASE Air Port Ring Assembly :- Airport ring assembly(Vane Wheel) is designed to minimize turbulence in the mill and allow smooth entry of hot air. Airport ring shall be fabricated from SAILMA plates, which shall be hard faced at critical locations to enhance the service life Bowl extension ring Air port ring assembly

  9. IMPLEMENTATION & IMPROVE PHASE Mile Task to be done Target Date Actual Date Remarks Stones 1 Planning & procurement of 15.02.2014 20.02.2014 Liners,Air port Ring, resources Welding Electrode 2 25.01.2014 20.01.2014 Decided to install in coal Provision for installation & mill-2D MOC signed off 3 Machining of Bowl extension 10.01.2014 20.01.2014 Bowl extension ring depth Ring reduced from 140 mm to 90 mm 4 Fabrication of Air port ring 28.02.2014 02.03.2014 Removed the existing vane assembly inside Mill wheel assembly and installed the air port ring and liners 5 Commissioning of Air port 05.03.2014 Commissioned successfully ring assembly

  10. IMPLEMENTATION & IMPROVE PHASE Body Liners Deflector liner Bowl extension ring After Before

  11. IMPLEMENTATION & IMPROVE PHASE Airport Ring assembly OEM Vane wheel Assembly Side Ring

  12. IMPLEMENTATION & IMPROVE PHASE By comparing two Mills of Existing & modified system operation data

  13. CONTROL PHASE Sl no Parts to be Check points Inspection Remarks inspected Frequency 1 Mill fineness % through 200 mesh , 74-78 Daily Maintained micron 2 Mill rejection Quantity of mill rejection and Every day Training Monitoring its percentile from amount of provided to coal consumption operators 3 Wear out of Mill Mother plate condition In every PM Included in Body Liner Mill PM SMP 4 Wear out of 1.Condition of welding part In every PM Included in Airport Ring 2.Condition of plate mill PM SMP

  14. COST SAVINGS ACHIEVED Tangible Benefits : • Savings towards coal : 525 Ton per annum • Saving in cost @ Rs. 1950 per Ton : 10.2 lacs • Saving in power due to reduction in mill current :240 KWH / day & 87600 KWH/ Annum • Considering power cost @ Rs.2.10/kwh , Total cost : Rs. 183960 /- • Total savings Rs. 12 lacs per annum Intangible Benefits : • Consistent & Better coal fineness • Increase in mill outlet temperature • Reduction in amount of cold air supply • Even distribution of air-coal mixture and reduction of turbulent flow in the mill results in lower wear on the mill components and more uniform wear on grinding elements. Total investment : 3 lacs Cost saving is calculated per Mill modification.

  15. THANK YOU

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