he RSP facilities firing of fuel (upto 60% of total
requirement ) before kiln, to achieve calcinations degree upto 95% and thus
helps in increasing capacity of the total system substantially, without
increasing heat load on the kiln. The RSP system mainly consists of the
Swirl burner (SB), Swirl Calciner (SC), Mixing Chamber (MC) and Adjustable
- Swirl Burner (SB)
Fuel is introduced vertically in the burner and primary air from the
cooler enters tangentially. This part of the calciner helps in providing
stable burning of fuel, with relatively high air/fuel ratio.
- Swirl Calciner (SC)
The oxygen rich hot air tapped from cooler, enters tangentially in this
furnace. Material from second stage (from bottom) cyclone is fed at the
feed points as shown. The swirling action provides longer retention time
and achieves complete combustion of fuel at nearly stoichiometric fuel /
air ratio. The presence of oxygen rich air helps in rapid combustion of
fuel. These conditions help in rapid calcinations of the raw meal fed to
- Mixing Chamber (MC)A duct (CD) connects the SC to MC. The hot
gas from kiln gets mixed with the hot gases with material coming from
SC, in the MC. The material gets lifted and enters the bottom stage
cyclone. The MC provides further retention time and helps in
accelerating the calcination upto 95% before the material gets separated
in the bottom stage cyclone and is fed to the kiln.
- Adjustable Orifice (AO)
This device installed at kiln inlet before MC helps in adjusting
velocity of the air entering MC and balances quantity of the air passing
through kiln and that passing through the duct taking air from cooler to
The six stage preheater helps in achieving better heat consumption.
- Smaller kiln size for the same capacity, or higher output from the
same kiln size. (Doubling of the capacity is normal).
- Lower heat consumption.
- Use of low grade, high ash coal at relatively coarse particle size is
- Non conventional fuels can be used in the calciner efficiently.
- No coating formation in the SC & MC since the decarbonation is
achieved at a temperature below 1000°C.
- Combustion in presence of oxygen rich air in SC ensures complete
combustion at nearly stoichiometric fuel air ratio, which is the main
criterion for stable operation.
- Low pressure preheater cyclones help in lowering the pressure drop at
preheater fan inlet and thus saving in power consumption.
JMC rotary kilns are mainly known for their
constructional strength. Those parts which are subjected to high mechanical
stresses such as kiln shell, tyres, supporting rollers bearings kiln drive
are designed to withstand the most hostile conditions and are constantly
being modified and kept technically upto date.
Rotary Kiln & Pre-heater tower : The kiln shell is fabricated from
IS-2062 Tested plates. The unit consists of tyre rings, Girth gear, Gear
guard, Inlet and outlet seal, supporting Roller assembly feed &
discharge hood etc.
Tyres are made either in the form of a loose ring or they are fixed to the
kiln shell in a toothed form. The toothed tyre attachment reduces the
deformation of the kiln shell, and therefore also that of the refractory
lining, to a minimum. Kilns with toothed tyres have particularly low lining
wear. The bearings for supporting the roller are compact and robust in
design and are interchangeable. Cooling is achieved by water circulation.
- Most efficient pneumatic inlet seal.
- Modern graphite block outlet seal.
- Hydraulic thruster for adjusting the kiln position.
- Modern three channel coal burner for efficient combustion of coal.
JMC has completely indigenized the grate coolers design.
JMC has supplied grate coolers for various plants which are working
satisfactorily. In its effort to modernize, JMC is in touch with the recent
trends in grate cooler design and has already taken steps to bring the
modern features, so the recuperation efficiency is improved, total cooling
air requirement is reduced and as a result, total specific power consumption
for the cooler is reduced.
JMC also offers planetary coolers which are simple in design, do not
require separate dedusting, drive and also make the total system compact.
Drying chamber can be provided before first chamber. The grinding length of
the mill can be suitably divided in two chambers by a control diaphragm
which allows fines toriove to the second chamber and large particles get
further ground in the first chamber. The grinding media grading can thus be
optimized to suit the particle size. Lifting liners are provided in the
first chamber. Classifying liners are provided in the second chamber.
This mill can be used in open circuit without separator with larger L/D
Material Handling Equipment
Deep Bucket conveyors using the double strand roller
chain are specially designed to handle abrasive and hot materials (such as
clinker from grate cooler) on a horizontal & inclined profile with the
lowest power consumption. Till date such large installations have been
supplied by JMC.
JMC offers bucket elevators of chain & U-link design
as per the DIN Standard. Both centrifugal discharge (for free flowing,
granulator material) and central discharge (for lumpy and sticky material)
can be offered for capacities ranging from 10m3 / hr to 400 m3/hr.
Pneumatic Conveyors Air
Vertical pneumatic (VP) conveyor is a unique pneumatic
conveying equipment offered by JMC for conveying fine powders vertically at
heights as high as 100M. Due to its features such as no moving parts (and
hence practically no maintenance), relatively low power consumption as
compared to the pneumatic screw pumps, possibility to design a control
system based on differential pressure and very low capital cost, the VP
Conveyor is extremely popular in Indian Industry.
The low pressure compressed air enters the conveying pipe
of the VP CONVEYOR at a high velocity through a nozzle.
The fluidized material around the conveying pipe combines with the air in
the gap between nozzle and conveying pipe and is carried upward along with
the air stream.
As the material fed from the top of the vessel builds its height in the
vessel, the air pressure develops gradually and the discharge rate increases
automatically and stabilizes, depending upon the height of the material
allowed to be achieved in the conveying vessel. The same procedure is
reversed while stopping the operation. As such, no separate shut-off device
or seal is required, as the custom of material in the vessel itself acts as
a sealing element for avoiding the back pressure.
Gravity Conveyors : PG Conveyors
This equipment uses the principle of transporting the
powders under gravity in fluidized condition. JMC P.G. Conveyors are known
for its optimum design and very low power consumption.
Rotary Air Locks
JMC Rotary air locks are known for high sealing
efficiency & robustness. Precision machining is adopted to achieve the
best sealing effect.