century cement division presentation for 19 cii national ... · wagon tippler make –elecon...

Century Cement Division Presentation for

19th CII National Energy Award 2018

Unit : Sonar Bangla Cement

TEAM MEMBERSMR. PANKAJ SIL – SR. MANAGERMR. NIKHIL KUMAR - MANAGER 1

TABLE OF CONTENT

SR. NO.

CONTENTS

1 COMPANY PROFILE

2 MAJOR PLANT AND MACHINERY

3 CEMENT MANUFACTURING PROCESS

4 PLANT PERFORMANCE OVER THE YEARS

5 ENERGY EFFICIENCY AND BENCHMARKING

6 LIST OF ENCON TAKEN IN LAST THREE YEARS

7 UTILIZATION OF RENEWABLE ENERGY

8 REDUCTION IN PROCESS WATER CONSUMPTION

2

SR. NO.

CONTENTS

9 CARBON FOOT PRINT REDUCTION

10 DETAILS OF INNOVATIVE PROJECTS

A. 2 PACKER 8 POINT SYSTEM

B. OPTIMIZATION OF BAG FILTER FAN RPM

11 GREEN SUPPLY CHAIN

12 ENCON ORGANIZATION CHART

13 INVOLVEMENT OF EMPLOYEES / TEAM WORK

14 ENERGY MONITORING SYSTEM

15 AWARDS AND ACCOLADES

SONAR BANGLA CEMENT AT A GLANCE

➢ Sonar Bangla Cement , a group of Century Textile & Industry Ltd, is operating a Cement Grinding Unithaving installed capacity of 1.50 MTPA, later up-graded to 2.0 MTPA, situated at Murshidabad District inWest Bengal.

➢ Cement Plant commissioned on 29-03-2013.

➢ A Solar PV Power Plant of 102 KWp capacity commissioned on 21-10-2016.

➢ Presently operating FLS Ball Mills with 2.0 MTPA capacity for Clinker grinding .

➢ Predominantly manufacture Portland Pozzolana Cement (PPC) and catering to the East India Zone as well as northern & central part of India with 45% road dispatch and 55% rail dispatch.

3

MAJOR PLANT AND MACHINERY

WAGON TIPPLERMAKE – ELECON

CAPACITY – 1500 TPH

BALL MILL ,MAKE – FLS


CIRCULATING AIR FANFLS

PROCESS BAG FILTERTHERMAX

ROTO PACKERENEXCO


WAGON LOADER & TRUCK LOADER


H0T AIR GENERATOR MAKE – SINGHANIA AND

WESMAN

SEPERATORMAKE - FLS

4

WAGON TIPPLER

CLINKER TANK

GYPSUM YARD

HOPPERS

CEMENT MILL

ROTOPACKER

GYPSUM

FLYASH

CLINKER

6CEMENT SILO

TRUCK LOADING

WAGON LOADING

FLY ASH BULKER

DRY FLY ASH SILO

PLANT PERFORMANCE OVER THE YEAR

7

Unit’s Performance

14.5

15

15.5

16

16.5

17

17.5

14-15 15-16 16-17 17-18

Cement Production (LMT)

Cement Production (LMT)

16.52

17.26

16.95

15.53

30

31

32

33

34

35

14-15 15-16 16-17 17-18 Target

34.33

32.08

33.58

34.82 35

Fly Ash Addition %

In Q-1 : FY 2018-19 Fly Ash Addition is 35 %

8

Electrical Energy Performance

0

10

20

30

40

14-15 15-16 16-17 17-18

Specific Power Consumption (KWh/Ton) of Cement Grinding

Specific Power Consumption (KWh/Ton) of CementGrinding

38.99

32.29 30.47 29.30

0

0.5

1

1.5

2

2.5

3

3.5

14-15 15-16 16-17 17-18

Specific Power Consumption (KWh/Ton) of Cement Despatch

Specific Power Consumption (KWh/Ton) of CementDespatch

3.293.05 2.81

2.41

9

Electrical Energy Performance

0

10

20

30

40

50

14-15 15-16 16-17 17-18

Total Specific Power Consumption (KWh/Ton) of Cement

Total Specific Power Consumption (KWh/Ton) of Cement

45.61

37.22 35.25 33.60

10

OUR PRESENCE IN BENCHMARK

35.25 33.6

2528

0

10

20

30

40

KW

H/T

ON

BENCHMARKS

FY-16 FY-17 INTERNATIONAL BENCHMARK NATIONAL BENCHMARK

11National Benchmark :- CII and CMA Energy Benchmarking for Cement Industry Manual May2015International Benchmark :- http://ietd.iipnetwork.org/content/cement#benchmarks

LIST OF ENCON TAKEN IN LAST THREE YEARS

12

Energy Saving Projects implemented in FY 2015-16 with No Investment

S. No Energy Saving projectAnnual Savings

(Rs. In Lakh)

Investment Required

( Rs. In Lakhs)

Payback Period

( In Months)

1 Avoid Damper Loss in CM-2 Circulating Fan & Mill Vent Fan 17.08 Nil Immediate

2 Avoid Damper Loss in CM-1 Circulating Fan & Mill Vent Fan

11.17 Nil Immediate

3 Avoid compressed air leakage in the plant 13.00 Nil Immediate

4 Reduced the compressed air generating pressure for feed building compressor

3.50 Nil Immediate

5 Reduced the compressed air generating pressure for Cement Mill compressor

3.00 Nil Immediate

6 Reduce the voltage of Load Centre No-1 Transformer -2 2.68 Nil Immediate

7 Optimize the capacity of Identified Motor 2.50 Nil Immediate

8 Optimize Lighting Voltage in Plant 2.30 Nil Immediate

13

Energy Saving Projects implemented in FY 2015-16 With Investment


(Rs. In Lakh)

Investment Required

( Rs. In Lakhs)

Payback Period

( In Months)

9 Improve the power factor of the system 7.47 15 24

10 Optimize the operation of Packer 1 Bag Filter 14.80 13 10

12 Optimize the operation of Packer 2 Bag Filter 12 12 12

13 Optimize the operation of weigh feeder venting bag filter 6.57 3.00 5

14 Maintain optimum DP across the bag filter 2.19 2.00 11

15 Avoid venting of air in packing plant area blower 0.88 0.50 7

16 Install string switch for lightning in cable room 1.00 0.20 2

14

Energy Saving Projects implemented in FY 2016-17 With No Investment


(Rs. In Lakh)

Investment Required

( Rs. In Lakhs)

Payback Period

( In Months)

1 Reduce compressed air generating pressure for packingplant compressor

3.2 Nil Immediate

2 Optimize the lighting voltage 2.0 Nil Immediate

3 Optimize capacity of identified motors 0.6 Nil Immediate

4Optimize the loading of distribution transformers

0.22 Nil Immediate

15



(Rs. In Lakh)

Investment Required

( Rs. In Lakhs)

Payback Period

( In Months)

5Rerouting of compressed air line to operate 02packers by 01 compressor

9.2 4.0 5

6 Optimize the operation of Packer 03 Bag Filter 3.99 NIL Immediate

7 Optimize the operation of Packer 04 Bag Filter 4.51 NIL Immediate

8 Avoid compressed air leakage in the plant 10.00 Nil Immediate

9 Increase specific surface area of grinding media in 2nd

chamber of CM-1&230 Nil

10 Optimize the bag filter DP in cement silo-2 topbag filter

1.70 2.00 14

16



(Rs. In Lakh)

Investment Required

( Rs. In Lakhs)

Payback Period

( In Months)

1 Optimize the suction of bag filter inlet for weigh feederventing bag filters – 201 FN 01

0.76 0 0

2 Optimize the suction of bag filter inlet for weighfeeder venting bag filters – 202 FN 01

0.65 0 0

3 Optimize the operation of Packer 01 & 02 Bag Filters 1.0 0 0

4 Optimize the operation of Packer 03 & 04 Bag Filters 2.0 0 0

5 Optimize the lighting voltage 2.0 0 0

6 Optimize capacity of identified motors 0.6 0 0

17



(Rs. In Lakh)

Investment Required

( Rs. In Lakhs)

Payback Period

( In Months)

1 Replace cooling water pumps with high efficiencyapplications

6.25 5.0 9

2 Improve cooling tower performance 4.0 4.8 15

3 Install VFD for feed building compressor 5.3 9.5 22

4 Avoid compressed air leakage in packing plant 10 2 2.5

5 Avoid unloading of identified compressor by installinglower capacity compressor

3.5 6 20

6 Optimize the operation of wagon tippler bag filter 4.2 0 0

18



(Rs. In Lakh)

Investment Required

( Rs. In Lakhs)

Payback Period

( In Months)

1 Optimizing the lighting voltage1.0 0 0

2 Optimize capacity of identified motors 0.6 0 0

3 Optimizing the loading of distribution transformers 0.22 0 0

4 Optimize the operation of Packer 1 Bag Filters Under Progress - -




19



(Rs. In Lakh)

Investment Required

( Rs. In Lakhs)

Payback Period

( In Months)

1 Replace identified compressor with energy efficient screwcompressor

Under Progress - -

2 Improve the power factor at Main Incomer Under Progress - -

3 Replace cooling water pumps with high efficiency pump Under progress - -

4 Improve cooling tower performance Under Progress - -

5 Increase specific surface area of grinding media in 2nd

chamber of CM-1& 2Under Progress - -

6 Install latest control systems for mill Under study - -

20

21

61447

118722

020000400006000080000

100000120000140000

16-17 17-18

UN

ITS

GEN

ERA

TED

YEAR

Solar Power Generation

GREEN TOWNSHIP• 102 KWp Solar Power Panel installed in Plant.• Working since October 2016.• Colony Power requirement mainly catered

through Solar Power Generation.

UTILIZATION OF RENEWABLE ENERGY

22

Reduction in Process Water Consumption

• Zero Water Spray for PPC• Reduction in process water consumption

4871.5

4553.2

4320.8

4000

4200

4400

4600

4800

5000

PROCESS WATER CONSUMPTION (KL)

15-16 16-17 17-18

CARBON FOOTPRINT REDUCTION

• Initiative to reduce Carbon Footprint

1. Installation of 102 KWp Solar Power Plant to utilize renewable energy.

2. Reduction of total KWh consumption through various initiatives.

3. Improving Clinker Factor by higher addition of Fly Ash.

4. Installation of 110 kw vacuum pump in place of diesel operated TPS machine to clean clinker dust

23

DETAIL OF INNOVATIVE PROJECTS

24

INNOVATIVE PROJECT NO-1

2 PACKER 8 POINT SYSTEM

25

• OBJECTIVES

1) TO REDUCE IDLE RUN OF PACKING PLANT

2) USE OF ONE COMPRESSOR IN PLACE OF TWO

PROJECT DESCRIPTION:

• IT WAS OBSERVED THAT IDLE HOUR OF PACKING PLANT WAS NEAR ABOUT 38 -40 %.

• WE HAD TO RUN ALL 4 PACKERS AT 8 POINTS TO LOAD TRUCKS. EACH TRUCK PLACEMENT TIME TOOK ATLEAST 8 -10 MIS.

• FOR 4 PACKERS WE HAD TO RUN 2 COMPRESSORS WHICH CONSUMED HUGE POWER

26

TRU

CK

LOA

DIN

G P

OIN

TSCONVEYOR

TRU

CK

LOA

DIN

G YA

RD

BAG DIVERTERS

PREVIOUS 4 PACKER 8 POINT SYSTEM

RUNNING BELT

STOP BELT

8 TO 10 MINS PLACEMENT TIME

1

2

3

4

5

6

7

8

P1 P2 P3 P4

27

P1 P2

TWO PACKER 8 POINT SYSTEM

TRUCK LOADING POINT

TRUCKYARD

PLACEMENT DELAY 1MIN APPROX

1

2

3

4

5

6

7

8

RUNNING BELT

STOP BELT

CONVEYOR

BAG DIVERTERS

28

29

FIXED CLOSED DIVERTER DIVERTER TO BE

OPERATED

• TOTAL RUNNING LOAD FOR ONE PACKER GROUP= 158 KW

TOTAL RUNNING LOAD FOR TWO PACKER GROUP= 158*2= 316 KW

• COMPRESSOR LOAD = 70 KW

• TOTAL LOAD = 316+70 =386 KW

HENCE, SAVING FOR 180 MINS=386 *3=1158 UNITS

RESULTS

UNIT SAVED PER DAY UNIT SAVED PER YEAR TONNAGE 16-17 UNITS PER TON

1158 416880 1695191 0.25

30

INNOVATIVE PROJECT NO-2

INTERLOCK OF CONVEYOR BELTS AND ELEVATOR LOAD WITH BAG FILTER TO REDUCE RPM

31

STORAGE BINMATERIAL FROM SILO

ROTO PACKER

LOAD 48 KW

RPM 1150KW 19.6

AUXILLARY BAG FILTER FAN

STORAGE BIN

LOAD 30 KW

RPM 900KW 9.3

SAVING OF 10 KW

NO MATERIAL FROM SILO

LOW SUCCTION NREQUIRED

32

TRU

CK

LOA

DIN

G P

OIN

TSCONVEYOR

TRU

CK

LOA

DIN

G YA

RD

RUNNING BELT

STOP BELT

2 T0 3 MINS PLACEMENT TIME

4

P1

Air in

DUST GENERATED AT THIS POINT

ONLY

RPM 1150KW 50

RPM 900KW 24

SAVING =26 KW

AIR OUT

BAG FILTER FAN

BELT – BAG FILTER INTERLOCK SYSTEM

33

NO DUST GENERATION

RPM 800KW12

SAVING = 38 KW

BENEFITS

• CONSIDERING 20 RUN- HRS FOR EACH PACKER AND 25 % IDLE RUN HOUR

IDLE HRS DURATION RPM KW SAVING(UNITS)

5ONE BELT OFF 3.5 900 24 91

BOTH BELTS OFF 1.5 800 17 49.5

TOTAL SAVINGS FOR 2 PACKERS 281 UNITS/DAY

BIN EMPTY FREQUENCY 15 TIMES/DAY

TIME TAKES TO FILL IT 5 MINS

TOTAL EMPTY TIME 1.25 HRS

SAVINGS (KW) 10 KW

SAVINGS (UNIT/DAY) 12.5 PER DAY PER PACKER

SAVINGS FOR 2 PACKERS 25 PER DAY FOR 2 PACKER

TOTAL SAVINGS 306 UNITS/DAY

34

GREEN SUPPLY CHAIN

• Office order issued for procurement of materials considering Energy efficiency.

• Procurement of Energy Efficient Motor only, calculating the landed cost considering the energy efficiency.

• Requesting quotation/offers from various suppliers, energy efficiency criteria must be mentioned on the quotation request form.

• Idle running of equipment, wastage of water, air, fuel etc. will impact performance rating of contractor and the unit will impose penalty on observing such incidence.

35

ENCON ORGANISATION CHART

UNIT HEAD

TECHNICAL HEAD

CEMENT MILL PACKING PLANTRAW MATERIAL HANDLING AND WAGON TIPPLER

ENERGY COORDINATOR

AGENDA• MONITORING OF SECTIONWISE SPECIFIC

POWER ON DAILY BASIS.• WHY- WHY ANALYSIS• REVIEW OF ACTION PLAN• TEAM BUILDING• GENERATION OF NEW IDEAS AND

CONCLUSION WITH ACTION PLAN

36

37

INVOLVEMENT OF EMPLOYEES / TEAM WORK

38

ENERGY MONITORING SYSTEM

39

DAILY POWER REPORT

AWARDS AND ACCOLADES

40

GOLDEN BIRD EXCELLENCE AWARD 2018 Towards Excellence in Health & Safety for Worker

NATIONAL CONVENTION ON QUALITY CONCEPTS

century cement division presentation for 19 cii national ... · wagon tippler make –elecon...

Documents