Specification of coke-breeze or any other fuel for the VSK process:

Ash 25-25 per cent

Volatile matter Preferably below 10 per cent
Calorific value 4500 kcal/kg or more

Substituted for coke-breeze for the manufacture of cement by the VSK process ::

1. Natural fuels - 1. Borgua coal, 2. SLV coal.

2. By-product or waste-product fuels - 1. SICCO fines, 2. Leco fines, 3. Petroleum coke,
4. Carbon-waste sludge, 5. Spent pot lining.

Type of mini- Raw materials Fuel

cement plant
Limestone Additives Type needed Quality prescribed
and quantity
Long dry rotary Cement grade Clay/laterite/bauxite etc., to Coal used for Ash content not more than
kiln satisfy raw-meal composition cement, 23-24 25 per cent. Caloric value
per cent of of me order of 4700
clinker kcal/kg
Semi-dry rotary Cement grade with Same as above; to satisfy Coal used for As above
kiln proper nodulizing raw-meal composition as well cement, 23-24
properties as with good plasticizing per cent of
properties clinker
Dry-process Cement grade with very Same as above; to satisfy raw Coal used for As above
rotary kiln with low alkali content. Raw meal composition, as well as cement; 19 per
suspension pre- meal needs thorough with low alkali content cent of clinker
heater homogenization (more for small
kilns)
CRI-modern Cement grade with Same as above; but Low-volatile Ash content 25-35 per
vertical-shaft proper nodulizing preferably more of clay, fuel; 19 per cent cent, caloric value 4500
kiln properties especially one with good clinker kcal/kg and above, volatile
plasticizing properties matter should be low
(preferably less than 10
per cent)

Natural fuels

1. Borgua coal.
 2. SLV coal.

Proximate analyses of natural fuels

Particulars (percentage) SLV coal Borgua coal

Kustore Ena Kenduadih
Sample I Sample II
Moisture 1.85 1.18 0.17 3.0 0.64
Ash 22.39 25.10 19.59 25.0 43.87
Volatile matter 4.42 6.88 13.97 6.0 13.90
Fixed carbon 71.34 66.84 66.27 66.0 41.59
Calorific value(kcal/kg) 5593 5738 6448 5600 4412

By-product/waste-product fuels

1. SICCO fines
2. Leco fines

Analyses of Sicco fines

Particulars (air dried basis) (percentage) Coke Medium-coke fines Small-coke fines
Moisture 3-5 3-6 3-6
Ash 32-36 34-38 34-40
Volatile matter 4-8 6-10 6.1-
Fixed carbon 52-58 50-56 50-56
Sulphur 0.4-0.5 0.4-0.5 0.4-0.5
Calorific value kcal/kg 4500-5500 4000-4500 4000-4500

3. Petroleum coke
4. Carbon-waste sludge
5. Spent pot lining

Comparative analysis of various fuels

Particulars (percentage) Leco fines Petroleum coke Carbon sludgea SPL

Moisture 5-8 8.67 1-3 0.25
Volatile matter 3-12 0.12 7-10 5.98
Ash 10-30 90.54 0.5-3 36.09
Fixed carbon - 85-90 57.68
Calorific value (kcal/kg) 50000.67 8900 7000 4747a

VSK Technology is used to manufacture clinker on small scale. The plant is small and easy to operate.
Raw Materials : 

S .No. Raw Material Percentage

1. Lime Stone 71 - 72
 2. Clay ( Black Soil) 16 – 18
3. Pet Coke 8
4. Iron dust 1% if required

VSK Technology It technology is used to manufacture clinker on small scale. The plant is small and easy to operate. The Raw
Materials :

The process is divided in 3 parts: 

Raw Materials :

1. Raw Mill Section

2. Kiln Section
3. Clinker Grinding Section

1. Raw Mill Section :

All the raw materials should be of less than 25 mm size. If the size of the raw material is bigger than 25 mm, It has to be crushed
through a crusher and Hammer Mill. All the materials are crushed stored in the storage yards through belt conveyors.

Now, the raw materials are taken as per their required percentage with the help of a weigh belts( Control by PLC ).The measured
materials is went to feed belt conveyor and after that shifted to a feed hopper through elevator .The feed of material is controlled
with the help if ratchet Feeder/Table feeder.

2. Kiln Section :
From Surge silo the mixed raw materials are taken to Nodulizer with the help of a screw conveyor.Then water is sprayed on the mix
(10%) to make nodules with the help of nodulizer. These nodules are fed into the Kiln through feed chute for burning and Fusion.
The temperature goes up to 1350OC in the burning zone. The material travels very slowly in the Kiln. All the material get fused
here. After passing through the burning zone the material starts cooling slowly. The Clinkerisation starts and the clinker finally
comes out of the Kiln.

3. Clinker Grinding Section :

The clinker so obtained is crushed to make its size less than 25 mm. The crushers/Roller crusher are used to crush the clinker. The
Gypsum is used as an additive. Both material crushed together and went into feed hoppers through elevator. They are collected
through the feeders provided below the feed hoppers. The clinker and gypsum are mixed in certain ratios (5%). So, the weigh belt
is used to weigh the ingredients for mixing. A modern electronic weighing & control system may also be used to weigh and
measure the ingredients The ratchet/Tables feeder is used to control the feed in the mill and control the fineness of the Cement.

The ground Cement is taken to the aeration and storage silo with the help of elevator or air lift.The aerated Cement is filled in 50Kg
bags with the help of packing machine. The product is stored in the godown through belt conveyor and stacking/dispatched as per
requirements. The pollution control equipments are necessary as there may be dusting in the plant.