Sawan Jasoliya

1. Plant Condition and Major Operational Issues Since Commissioning Since commissioning, the plant has experienced several persistent mechanical, process and operational issues that adversely affected reliability, productivity, energy efficiency and clinker quality. A. Kiln and Cooler Reliability 1. Frequent breakdowns and stoppages associated with kiln supporting roller mechanisms, including high bearing temperatures. 2. Frequent cooler mechanical problems and breakdowns. 3. Frequent kiln coating collapses, resulting in red-hot clinker reaching the DPC and causing clinker quality deterioration. 4. Very low and inconsistent refractory life. 5. Frequent material puffing from the kiln inlet, accompanied by continuous material spillage. 6. Excessively hot kiln hood, with almost zero draft, resulting in unstable kiln operation and frequent hood roof damage. B. Preheater / Calciner Problems 7. Frequent material flushing / build-up at different locations in the preheater. 8. Very high prehea...

In my decades of working with cement plants across Asia, Europe and the Middle East on optimization and operational excellence, I have seen a consistent pattern. While most plants celebrate rising Thermal Substitution Rates (TSR) of 50-70%+, very few openly discuss the hidden operational challenges that accompany higher Alternative Fuel (AF) usage. Alternative Fuels do not simply replace coal or pet coke. They fundamentally alter flame characteristics, heat transfer mechanisms and secondary/tertiary air behavior inside the kiln. If not properly managed, these changes quietly erode the expected benefits - lower fuel cost, reduced CO₂ and stable clinker quality. This is one of the most critical yet under-discussed aspects of modern pyro-processing. Understanding the Fundamental Shift Conventio...

For cement plants that do not have advanced coal dosing systems such as Pfister, Coriolis, or Multicore, traditional coal feeding systems still dominate operations.  These include: Venturi-Based Coal Transfer and Firing System,   V1 – A successful project. FK Pump-Based Coal Transfer and Firing System, F1. FK Pump-Based Direct Coal Firing System, FD1 –  Two successful projects. Challenges in Traditional Coal Feeding Systems In these setups, coal transport starts when the coal firing bin reaches its lower limit and stops when it reaches the higher limit. However, this method introduces several challenges: SFM Draft Variation: Sudden coal transport starts and stops create fluctuations in the SFM (Solid Flow Meter) draft, leading to inconsistent feeding. Bin Pressurization & Flushing: During transport, the coal firing bin gets pressurized, causing erratic coal flushing, which disrupts stable firing. Continuous monitoring and regulating is a headache for operators. ...