INTRODUCTION

Founded by Shri S.K. Gupta, SKG Group delivers top-quality refractory solutions for the Cement and Lime industries. With extensive collaborations with industry leaders like KHD and Promac, SKG offers expert design, manufacturing, and installation services, positioning itself as a trusted, one-stop partner for comprehensive refractory solutions.

ROADBLOCK

The company used four pet coke hoppers to ignite their kilns, with the hoppers being filled manually by workers pouring bags of pet coke into them. To improve efficiency, they installed a conveyor system with a blower and rotary air valve to fill the hoppers from a storage hopper. They required automation of the conveyor system depending on the individual hopper levels. Additionally, they needed remote level monitoring for all hoppers and an alert system for low levels to ensure smooth operation.

THE SOLUTION

Pune Techtrol proposed a complete solution with installation and commissioning of automation system comprising custom-designed MCC panel for automating the blower, valve (RAV), and conveying system along with RF admittance level switches to detect high low level in hopper. Additionally, HMI panel provides visual representation of the process and the conveying system. The system was automated based on hopper levels, with a hooter alarm integrated to notify operators when any hopper reaches a low level, ensuring timely action and improved operational efficiency.

RESULT

The company team is satisfied with the successful integration of remote level monitoring, the company now benefits from enhanced reliability in their operations, minimizing downtime and ensuring timely refilling of pet coke. The solution resulted in a smoother, more efficient workflow, reduced labor costs, and improved productivity.

This project showcases our capability to deliver end-to-end automation solutions, from design and development to commissioning, aimed at improving system reliability and performance in industrial environments.