An ISO 9001:2008 Certified Company Bold Innovation About Us We provide tailor-made engineered solutions, products, spares and services. Founded as an engineering Company in 2005, headquartered in Gurgaon, India, bqb has quickly built a reputation in the cement industry for its innovation, precise engineering and construction work. With experience in plant operation and system knowhow, bqb has pioneered technologies for optimising entire plants from Raw Material Grinding to Cement Grinding. In depth process knowhow and a strategic partnership with one of the best in grinding and separation technologists, has put bqb on the global cement map with the references acquired in the last 3 years. All of bqbs modification and implementations till date have helped set new efficiency benchmarks for the Industry. OUR VISION
Help companies achieve sustainability in production processes by applying innovative engineering concepts Provide high quality engineering services to support the cause of energy reduction in the cement industry while driving higher total efficiency, higher productivity and system availability. Our Scope Turn Key Projects Feasibility Studies Plant commissioning Process Engineering Supply of complete cement/lime plant or unit operations Operation and Maintenance Contracts for Cement Plant NOx and SOx reduction-Technical Audit & Equipment Supply Engineering Consultancy Services for cement and power generation plants
Complete Plant Restoration Upgrades and Capacity enhancement Sourcing of raw material and fuel Power generation from waste heat Trained manpower supply Supply of Critical & Non Critical Spare parts Supply of Grinding Media, Refractory, Consumables Our Team Director, Technical & Ops has 30+ years of rich experience in the cement industry and design applications. His experience includes leadership roles in several prestigious organizations
Senior Consultant | PEGSA, Geneva, SwitzerlandSA, Geneva, Switzerland Technical Director (APAC) | ATEC General Manager (Process Engg) | Enexco, New Delhi, India In charge (Process Engg) | Saurashtra Cement, Porbandar, India Earliest stint at Andhra Cement Projects designed and concluded demonstrates innovation and remarkable results. They continue to remain industry benchmarks till date. The extended bqb team comprises of the following experts Process and Quality Operations Design Mechanical Instrumentation Electrical Projects Management The Company We have worked with
Green Island Cement Some Of The Work We Do Pyro Modification LOW PRESSURE tailor made cyclones with vanes Highlights Special design features offer maximum separation efficiency Customised solutions pressure loss Energy savings with improved GV guide vanes design Optimised utilisation of the inventory of plant and buildings Gujarat Siddhi Cement Top two stages in both strings and calciner Pressure drop reduced from 750 to 450mmwg Production increased from 3800 tpd to 4200 tpd Low Pressure High Efficiency Cyclone DT Double dip tube cyclone Applications Product separation after mills or classifiers DE dusting of clinker cooler exhaust air Product separation anywhere DE dusting of many different plants Best Pre collector Birla white TOP Stage conversion. 91% collecting eff. 70 mmwg DP Advantages Maximum separation performance
50% LOWER PRESSURE 50% LESSER diameter for same volume Low civil and structural load and cost Low requirements for lining material and insulation Cyclone p Reduction by Only Dip Tube Modificationp Reduction by Only Dip Tube Modification New Improved GV (Guide vanes) 3900mm Advantages Reduction of pressure loss by up to 40% Energy savings through reduced power requirement at the fan Optimised utilisation of the plant inventory Easy to retrofit (installation) Reliable operation up to 750C Low investment required for increased production Satna Cement Works Stage 3 Cyclone 50% DP reduction achieved Pyro Process Modification Tailor-made optimisation concepts Optimisation of an existing cyclone preheater requires a tailor-made system solution. When re-engineering one or more cyclone stages, the effects of and on the complete pyro must be considered What we do Optimization of all Cyclone Preheater Stages Redesign of Calciner Satna Cement Works Modification
2nd ,3rd,4th , 5thCyclone& Calciner. Prod. Increased 3300-4400 TPD What we can help achieve Production increase with lesser system downtime and significantly less investment Reduction of pressure loss/ Higher performance without change of pressure loss Improved collecting efficiency Increase in capacity Best utilization of existing plant & structure Improved energy savings Improved separation performance and thermal efficiency Calciner Redesign For Alternate Fuel Firing and Lower NOx generation Upgrade existing Calciners More residence time and intensive mixing ,call for tailor-made solutions. Customised mixing chambers for ideal reaction conditions Special solutions for increased volumes in restricted spaces Design and redesign of all types of Calciners The special secondary firing concept of an integrated combustion chamber enables an implementation of favourable technical process solutions, even under difficult structural conditions. Gujarat Siddhi Cement : Calciner RT from 2.5 to 4.5 sec. (capacity increased from 3800 to 4500 TPD) KILN INLET CHAMBER MODIFICATION
Advantages Reduce coating formation Minimize reentrainment of feed back to the preheater circuit. Reduction of pressure drop Better breathing of the kiln Redesign of Kiln Inlet Chamber for CMCL Year: 2016 Note: All the above results contributes to energy saving, which varies from plant to plant and it can be computed. CALCINER REDESIGN For Alternate Fuel Firing and Lower NOx generation Upgrade Existing Calciners Increased residence time and intensive mixing, call for tailormade solutions. Customised Mixing Chambers for ideal reaction conditions Special solutions for increased volumes in restricted spaces Design and Re-design of all types of Calciners The special secondary firing concept of an integrated combustion chamber enables an implementation of favourable technical process solutions, even under difficult structural conditions. Calciner Re-design at Gujarat Siddhi Cement Limited (Mehta Group) Resident Time increased from 2.5 Seconds to 4.5 Seconds Other Services Kiln plant audit / Bottleneck analysis/
Reengineering /grinding/ classification Evaluating thermal efficiency of kilns on the basis of calculated plant parameters Determining cyclone potential for energy saving and clinker production increase Kiln mechanical work Optimal Design of Venting system. Alternate Fuel firing complete solution. Designing of SNCR & SCR systems to reduce NOx below the government new emission norms. Separation Technology 4G th Generation |Secondary Separation 4G G Ultracut Classifier high performance classifier from Reject cone (TM) The 4G G classifier is equipped with the static and dynamic vane technology similar to the 3rd gen Classifier. Blades are aero dynamically designed for lower resistance and therefore lower power and lower wear. 4G th Generation Classifier:(added secondary classification) Secondary Separation from the Reject Cone by measured circulating air and separation device in the
cone. This technology has been applied in Europe. Flexibility of 3rd Generation Upgradation Classifier Feed Classifier Feed Case Study of a New Generation Classifier for Cement Mill Installed 3 years ago in India. Static Blades Dynamic Blades PRODUCT OUTLET REJ ECT CLASSI FI ER EFF. +90 2.9% 15.1% 41.1% 75 TPH SPOT +45 -45 12.5% 87.50% 55.6% 44.40%
75.4% 24.60% BLAI N 3630 1800 62% Note that higher % of -45, a fine product, is going back to the mill for regrinding. Classifier Reject Flexibility of 3rd Generation Upgradation Classifier Feed Classifier Feed Static Blades Dynamic Blades Parameters Eff. @ - 45 Mill Power (kWh/ T) Production (TPH) Blain Cement Type - 45 in Return Secondary Classifier (SCRC) Damper SCRC AIR Air For SCRC
Classifier Reject Existing With SCRC 62% 22.537 75.00 3600 PPC 24.60% 70% 21.98 76.92 3600 PPC 21% A Typical Case Projection Existing Classifier Efficiency Enhancement WHAT SCRC (Secondary Classification in Return Cone) WHY (SCRC came into picture?) Product fineness of cement has increased from 2800 - 3200 Blain to 3600 -4400 Blain ( true for PPC and slag cement contributing to >65/70% plant capacity) While it is possible to produce cement with higher fineness ( 3700 to 4400 Blain) with the latest 3 rd Generation Classifiers from any OEM, but the major loss in this process of classification is the % of 45 that goes back to the mill for regrinding, which in turn reduces Classifier efficiency. CASE Cement Mill of AN INDIAN CEMENT PLANT PRODUCT OUTLET REJECT CLASSIFIER
82.00% 44.80% 21.00% 71% BLAIN 3630 1800 A Typical Case Projection Results PRODUCTION INCREASE Secondary classification at the return cone - to recoup the maximum particles -45 should not go back to the mill for further grinding RECUPERATI ON OF PRODUCT FROM REJ ECT CONE WI TH SCRC CI R. LOAD % TPH 175% 131.25 Return Line Mill Vent 56.25 8% 4.285714286 REDUCTION IN SP. POWER SCRC will bring down the Sp. Power Consumption by 0.56
kWh/T of Cement Reject -45 in reject 51.9643 24.60% 12.78321429 Parameters FEED TPH Recuperation from Reject 15% 1.917482143 Existing With SCRC 75 76.91 27% 27% 3% 3%
Clinker (%) in Feed 70% 70% kWh of Mill 1690 1690 Sp. Power of Mill 22.54 21.97 Flyash (%) in Feed Gypsum (%) in Feed A Typical Case Projection - Results RETURN ON INVESTMENT: ROI ranges between 65% to 125%. % TPH EXISTING FEED MIX Mill #1 FEED 75 TPH
Flyash 27% 20.25 Gypsum 3% 2.1 Clinker 70% 52.65 TPH 75 WITH SECONDARY CLASSIFICATION IN RETURN CONE Return -45 in CIR. LOAD Mill Vent Reject Line reject 175% 8% 24.60% 131.25 56.25 4.28571 51.9643 12.78321 Recuperation 15% 1.917482143 1.
Total Recuperated quantity per day (@21 running hours per day) = 40.267125 Tones/day 2. Therefore, Total recuperated quantity per annum (@310 running days per annum) = 12,482.81 Tones/annum 3. Saving by production increase per annum (@ $14.15/Tone realization cost of cement) = $ 176,643.52 USD/annum References PLANT MODIFICATION/ENGINEERING/SUPPLY Sl. No. 1. 2.
PLANT Lafarge Egypt Birla White 3. Satna Cement Works 4. Arghakhanchi Cement COMPANY Holcim Ultratech Cement Limited Birla Corporation India Pvt. Ltd. COUNTRY Egypt INDIA INDIA
Nepal YEAR PROJECTS Remarks 2014 Engineering, Design and Supply of Cement Cooler to bring down the temperature of oil well cement from 130 degC to 70 degC. Scope also includes the design & supply of cement silo and bulk loading system 2014 Supply of 2 units (1 left turning & 1 right turning) of Spare Guide Vanes (Dia. 1060 mm). 2012 Supply of Guide Vanes (Dia. 3900mm) for stage 3 and modification of Cyclones and PreCalciner for production increase. Reduction in pressure drop achieved in result by
50% . 2012 Design, Engineering and Supply of Kiln Shell and Special Design of Kiln Chairpads. Supply and Erection Project on going References PLANT MODIFICATION/ENGINEERING/SUPPLY Sl. No. COMPANY COUNTRY YEAR Satna Cement Works Birla Corporation India Pvt. Ltd. INDIA
2010 Design and modification of Preheater 3rd Stage Cyclone. Production increased by 150 TPD. Implemented and running well 6. Satna Cement Works Birla Corporation India Pvt. Ltd. INDIA 2010 Detailed engineering and manufacturing drawing supply for New Coal Mill VRM. Implemented and running well 7. Satna Cement
Works Birla Corporation India Pvt. Ltd. INDIA 2010 Cyclone design for preheater stage 3 supplied to SCW implemented by FLS. Implemented and running well 8. Gujarat Sidhi Cement The Mehta Group INDIA 2010 Pyro Process Modification for production increase from 3800 to 4800 TPD.
implemented and running well 9. Saurashtra Cement The Mehta Group INDIA 2010 Pyro Process Modification. implemented and running well 5. PLANT PROJECTS Remarks References PLANT MODIFICATION/ENGINEERING/SUPPLY Sl. No. PLANT
COMPANY COUNTRY YEAR PROJECTS Remarks implemented and running well. Design and Concept by Mr. Debasis Bera Birla Corporation India Pvt. Ltd. INDIA 2007 Supply of Guide Vane in Preheater Stage 2. Cyclone and riser duct modification & production increase in stage 4 (Cyclone Dia. 9 mts) and stage 5. Ultratech Birla White
INDIA 2006 Preheater Top Stage Re-Designing Design and Concept by Mr. Debasis Bera 12. Chanderia Cement Works Birla Corporation India Pvt. Ltd. INDIA 2007 Complete Preheater & Calciner Modification for a production level of 4300 TPD Design and Concept by Mr. Debasis Bera 13.
Ding Gao Lafarge China 2006 Calciner Modification 2005 LINE-III: All cyclone and calciner modification for production increase from 3600 TPD to 4300 TPD. LINE-II: All cyclone and calciner modification for production increase from 3600 TPD to 4300 TPD. 10. Satna Cement Works 11. 14. Assiut Cement CEMEX
Egypt Design and Concept by Mr. Debasis Bera References PLANT MODIFICATION/ENGINEERING/SUPPLY Sl. No. 15. PLANT Pakland Cement 16. Cement Grasic 17. Green Island Cement COMPANY DEWAN HATTAR COUNTRY
Pakistan YEAR 2005 PROJECTS Complete plant upgradation from 1600 TPD to 3200 TPD. The plant was in package but was installed with re-engineering to acieve 3200 TPD for GAS, OIL & COAL FIRE. CEMEX Indonasia 2004 Preheater Modification for capacity increase from 7400 TPD to 9300 TPD Green Island Group, Hong Kong China 2003 All cyclones modification for production increase.
Remarks Design and Concept by Mr. Debasis Bera References PLANT DETAILED TECHNICAL ANALYSIS/AUDIT/CONSULTING Sl. No. 1. PLANT Port Elizabath 2. Line SK8 3. Hirmi Cement Works 4. Ambuja Cement 5. Arghakhanchi Cement Pvt.
Ltd. COMPANY PPC Ltd. COUNTRY South Africa YEAR PROJECTS 2014 Detailed Plant Analysis for Raw Material Grinding, Venting System, Pyro Process, Finish Mill and Coal Mill for plant capacity enhancement from 550 TPD to 900 TPD. PPC Ltd. South Africa 2013/ 2014 Detailed Plant Analysis for Raw Material Grinding, Venting System, Pyro Process and Coal Mill for plant capacity enhancement from 2250 TPD to 5000 TPD. Ultratech
Cement Ltd INDIA 2014 Cement Mill Audit for reduction of Power Consumption Holcim (Ambuja) INDIA 2012 Detailed pyro process study and proposal for pyro process upgradation. NEPAL 2012 Basic engineering done for pyro process. Remarks Via ERCOM References PLANT DETAILED TECHNICAL ANALYSIS/AUDIT/CONSULTING Sl. No.
PLANT 6. Satna Cement Works 7. JK Lakshmi Cement 8. Andhra Cement Ltd. 9. Poineer Cement COMPANY Birla Corporation India Pvt. Ltd. Jaiprakash Associated Ltd. COUNTRY YEAR
PROJECTS INDIA 2012 To evaluate the reason for 300 TPD shortage in production. Plant was modified by FLS and was not operating at designed capacity. INDIA 2011 Pyro Process detailed study. INDIA 2010 To check the pyro process upgrade design and failure of not reaching the 60% of target. Plant was designed to operate at 5500 TPD by IKN but wasn't running beyond 3000 TPD. UAE 2010 Detailed Plant Study and proposal for Pyro Process upgradation
Remarks Design and Concept by Mr. Debasis Bera References PLANT OPERATION & MAINTENANCE Sl. No. 1. 2. PLANT COMPANY Arghakhanchi Cement Pawan Cement Co. (P) Ltd. COUNTRY Nepal Maharaja Cement Ltd.
INDIA YEAR PROJECTS Remarks 2012 Operation & Maintenance of Plant. Plant was unoptimized and was not able to utilize more than 66% of designed 600 TPD capacity. After deputation of BQB personnel and taking care of design defects the same plant is running at a level of >700 TPD. Plant running successfully. 2012 Operation & Maintenance of Plant. Pawan Cement was in idle state since 1990. It was designed to operate at 500 TPD but was running at 60% efficiency level. Now it is running at designed capacity. Plant running successfully.
Case Study A Complete Plant Upgrade PAKLAND CEMENT, PAKISTAN YEAR 2005 COMPLETE PLANT UPGRADE FROM 1600 TPD TO 3200 TPD (GAS, OIL AND COAL FIRED) Case Study Detailed Engineering of Coal Mill VRM VRM Coal Mill (20TPH) Satna Cement Works Year- 2010 VRM was purchased from China, rest of the jobs (Engineering/Erection/Installation/Supe rvision) were done from BQB platform Case Study Designing & Engineering for Plant Upgrade PPC South Africa Unit: SK8 Year: 2013 Design and Engineering for complete plant upgrade from 2200 TPD to 5000 TPD. OUR RECENT INNOVATION POWDER COOLER Compact and highly efficient Flexibility of operation and easy maintenance. Complete design engineering and supply of cement silo, material handling , packing
and bulk loading, complete electrical & instrumentation OUR RECENT INNOVATION Client: Gujrat Sidhee Cement Limited Year: 2014G Lower 2 Stages (in both strings) cyclone modification to correct the temperature and collecting efficiency Project was designed and implemented in a record time of 10 days! Return Dust reduced by 3-4% Reduction in PH outlet temperature: 20 degC WHATS NEW WITH US !!! Building Smarter Manufacturing With the Internet of Things (IoT) Advantages: Better than PLC and PC based controller & management system as these are largely disconnected from IT and Operational system IoT would resolve the wiring issues by 80%. We have experts with more than 10 years of experience in handling and developing IoT. ALTERNATIVE FUEL (Utilization of MSW (Municipal Solid Waste) in Cement Plant) INTRODUCTION Cement production is the second most energy
consuming large scale industrial process. Cement industry is an essential key factor in the waste management system for a safe and environmental friendly recycling of waste derived materials. No negative influence on the properties of the cement and its application occurs. WASTE MATERIAL HANDLING Waste material incineration Effective method to cater to waste and for power generation. Incineration is expensive to the public as its having maximum number of unit operations. Incineration plant should be replaced by recycling concept. Its impossible to reduce the emission of gases( Dioxine, Furans and SOx, NOx) and residue ( Ash disposal, heavy metals) Co-processing in cement plant Cost Efficient for the public Environmental friendly solution with almost no emission of heavy metals, dioxine, furans, SOx, and NOx. No influence on product(Clinker). Saving of imported fossile fuel and reduction of CO2 emissions. COMPARISON OF WASTE PROCESSING IN CEMENT
PRODUCTION AND WASTE INCINERATION Waste coprocessing in cement plant Waste processing in the incineration plant Saving of primary fuels (Coal, Gas, Oil) 100 % substitution of primary fuel according to the calorific value of the waste addition of primary fuel (oil or gas) necessary for ignition and complete combustion of the waste An organical compounds of waste (ashes) Ashes are completely recycled into the product clinker and cement Ashes have to be processed or in most cases deposed in landfills Heavy metal content of waste and related emissions Due to the alkalinity of the process complete immobilization of heavy metals in the crystal structure of clinker (Except Mercury) Heavy metals will be mainly evaporated and extremely expensive and complicated
filtering and washing systems have to be installed. Formation of dioxins and fuarans by chlorine and flourine compounds in the waste Combustion at 1450 c with Complete cracking of all Oranical compounds into the base molecule methane. Time window of denovosynthesis of dioxine neglectable. combustion at appr. 850 c with high retention time for complete combustion. time window for denovosynthsis of dioxins and furans high. after burning of waste gas sometimes necessary. Transportation of Waste Cement plants are located at the source of limestone. Transportation is necessary waste incineration plants are installed at the source of the waste. CLASSIFICATION OF WASTE DERIVED MATERIAL Waste Derived Material Non Re-generatable material Industrial Waste Solid - Electrical Waste
- Waste plastic - Crating material - Tire/Tire chips Liquid - Used lubricants - Photo chemical waste Municipal waste Solid - Plastic waste - Sewage sludge - Food rests Re-generatable material Agricultural Waste Solid - Wood chips - Saw dust - Agricultural husks - Raps oil resins - Animal and bone meal Liquid - Sun flower oil rests - Raps oil Gaseous - Bio gas - Composition gas FLOW SHEET- PREPARATION OF MSW COPROCESSING OF RDF IN CLINKER MANUFACTURING PROCESS SCOPE OF BQB (In association with Leading European companies)
Techno-commercial feasibility study the current operation philosophy and assessing the bottlenecks. Cooperating with local waste management systems, industrial and communities Design and installation of Preparation, Handling, Dosing and Feeding technology Suggestion to improve the combustion in calciner. Suggestion to control the emissions like heavy metals, Dioxine furans, SOx, NOx and CO2. Our Associates EURO KILNS ALL KIND OF KILN MECH. WORKS THANK YOU
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