dalmia cement (bharat) limited, kadapa … · founded in 1935 by shri jaidayal dalmia. the group...

$: Dalmia Cement (Bharat) Limited, Kadapa … · Founded in 1935 by Shri Jaidayal Dalmia. The Group interests includes Cement, Sugar, Power and Refractory with Pan India Presence. The$
19th National Award for Excellence in Energy Management - 2018

Dalmia Cement (Bharat) Limited, Kadapa

Mentor: Mr. Anil BajajUnit Head

Leader : Mr. K Karunakara Rao Technical Head

Presenting Team MembersMr. P Kamalanathan - ElectricalMr. V Ramachandra Raju - ProcessMr. K Srikanth Reddy - Mechanical

Save Energy - Save Money - Save the Planet.

➢ Founded in 1935 by Shri Jaidayal Dalmia.➢ The Group interests includes Cement, Sugar, Power and Refractory with Pan

India Presence.➢ The Group established India’s first Cement Plant with 250 TPD in 1939.➢ Overall Cement Manufacturing Capacity 25 MTPA➢ Kadapa Unit Commissioned during Dec 2008 with a Capacity of 2.5MTPA

Cement and Standing 4th Largest Cement Manufacturing Capacity in theCountry

ISO 50001:2011

FY 2017

FY 2016

FY 2015

FY 2014

FY 2013

Commissioning 1. All Motors are Energy Efficient Series

2. More than 60% Motors are with VFD

3. All Process Fans with VFD and w/o Damper

FY 2013 – Expert Optimizer for Plant Energy Efficient

Operation

FY 2014 - EnMS 50001: 2011 Certified

Alternative Fuel Feeding Enhancement

FY 2015 – Liquid & Solid AFR

RABH & CM Fan Impeller Replaced

FY 2016 – Raw Mill Fan Impeller Replaced.

Kiln Burner & Pipe Modified

FY 2017 – Liquid Al. Fuel

RM Cyclone CFD & Modified,

Clinker Cooler Modified

FY 19 Current Plan & Actions

Waste Heat Recovery System

Raw Mill Classifier and Fan Upgradation

10MW Solar Plant

Current Plans

FY 2018

FY 2018 – Secondary Crusher

Cement Mill Petcoke HAG

Solar Roof Top, Pump Coating

Flyash LP Compressor

FY 2018 – Kiln Inlet

& Outlet Seal

Upgradation

10.516.5

20.8 23.634 36.236.5

41.3 45.0

5

15

25

35

45

55

Million Units Saving / Annum (Cumulative)

Better82.64

77.1175.88 74.87

73.91 74.1 73.8

70

75

80

85

Units / Ton of Cement

Better

55

.3

54

.3

52

.2

51

.7

50

.5

50

.9

50

.5

47

49

51

53

55

57

KWH/Ton of Clinker781

760

710 704701 701 701

685

705

725

745

765

785

Kcal / Kg Clinker

Better

Better

Description UnitZero

InvestmentWith

InvestmentTotal

Total No. of Projects No. 25 55 80

Electrical Energy Saving / Annum

LakhsUnits

9.34 78.64 87.97

Fuel Energy Saving / Annum

Tons 428.6 2722.4 3151

Total Cost Saving / Annum (Elect + Thermal)

Rs. Lakhs

49.35 998.84 1048.19

66.3

63.463.03 63.10

62.50 62.61 62.54

60.00

57

59

61

63

65

67

69

2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 Target

Kwh/Ton of Cement (PPC)

NB – National BenchmarkINB – International Benchmark

NB (67)

INB (65)

Present 73.8 U/T of Cement

1

2

Red. Pr. Drop in PH Cyclones (Red. of 1 U/T)

Red. Pr. Drop in Down Comer Duct

(Red. Of 1 U/T)

3 Waste Heat Recovery(Red. of 23 U/T)

Increase PPC Sales (Red. of 7 U/T)

4

Target - 42 U/T of Cement

Present 685 Kcal/Kg of Clinker

1

Clinker Cooler Upgradation(Red. Of 15 Kcal/Kg)

Burnability ImprovementBy Minerlizer (5 Kcal/Kg)

4

Target - 665 Kcal/Kg of Clinker

No Investment ( FY 2015-16)

Title of ProjectAnnual Electrical

Saving (kWh)

Annual Elect. Cost Saving (Rs

Lakhs)

Operation of Limestone Cross Country Belt Conveyor from 85% to 50% as per the Interlock with Apron Conveyor

43200 2.59

Minimized Separator Seal Gap and Increased CementMill Productivity

145000 8.70

Installed Bypass Chute and Eliminated the Belt Conveyor L21BC3 at Coal Crusher

21600 1.30

Converted PC Firing and Kiln Firing Blowers from Delta to Star Connection

52000 3.12

Optimized Operation of Reverse Air Fan as per Bag House DP

24000 1.44

No Investment ( FY 2016-17)


Saving (kWh)


Lakhs)

Interlock for Cement Silo Top Bag Filter Fan as per Mill Operation and Respective Grade

3400 0.21

Operation of Cement Silo Exhaust Fan as per Occupancy Sensor Command and DCS Time Delay

57500 3.45

Packing Plant Bag Filter Fans Operation Interlocked and Auto Speed Reduction with Packer Rotation and Spout Discharges

109500 0.66

Optimized Operation of Reverse Air Fan as per Bag House DP

24000 1.44

Provided Interlock for Crusher Load Center AC with Crusher Main Drive

43800 2.63

No Investment (FY 2017-18)


Saving (kWh)


Lakhs)

Improved the Load Factor of Coal and Additive Stacking Group by detailed Study.

2700 1.60

Improved Operation Efficiency of Cooler Tower Fan by replaced 1500RPM to 1000 RPM motor and Diversion of Heat Exchanged Warm Water to Water Spray

70000 4.20

Interlocking of Cement Silo Top Venting Bag Filters Operation as per Mill Operation Grade.

72000 4.32

Title of Project Year

Annual Thermal Saving

(Ton/Year)

Annual Thermal

Saving (Rs Lakhs)

Operation of Cooler Fans (1 to 4) with 106% Speed and Improved the Heat Recuperation at the Current Improved Production Rate

FY 2015-16 250 27

TAD Inlet Joint Modificiation and Achieved Reduction of False Air

FY 2015-16 30 3.20

Removing of Silencers from the Cooler Fans (Fan 1 to Fan 4), observed more pressure drop and pressure drop reduced without increase in the Sound Levels

FY 2016-17 310 32.55

Reduction of False Air from 5.0% to 4.4% by PH Outlet Expansion Joint Inhouse Modification

FY 2016-17 10.00 1.05

Increased SF Cooler Stroke Length and Reduced Clinker Bed Height. Reduction of Heat Consumption 1 Kcal / Kg Clinker

FY 2016-17 250 27

Replaced the Flap Valve with Double Rotary Air Lock for the Alternative Fuel Feeding System

FY 2017-18 15.00 1.575

No Investment – Thermal (FY 2015-16 to FY 2017-18)

Title of ProjectAnnual Elect. Saving (kWh)

Annual Electrical Cost Saving (Rs

Lakhs)

Invest. (Rs Lakhs)

Reduction of Raw Mill False Air by Installing Additional Flap Valve

125000 6.25 0.25

Raw Mill Fan Impeller Replacement for Efficiency Improvement

1200000 720 45

Replacement of Primary Air Fan with Blower and Power Reduction

60000 3.00 10

Upgradation of Cement Mill Fans SPRS to Operate upto 95% of Fan Speed with Recovery

550000 27.50 8.0

With Investment (FY 2015-16)



Lakhs)

Invest. (Rs Lakhs)

Installed Portable Crusher for Size Reduction of Performance Improver and Reduction of Cement Mill Specific Power Consumption

495000 29.70 24.00

Cement Mill Bag House false Air Reduction by RAL Operation through VFD as per BH Hopper Levels

90000 5.40 8.80

Completely Avoided Compressed Air for Cleaning by Installing Dedicated Man Cleaning Blower at all Sections

24000 1.44 1.40

Installed Day Light with Turbo Ventilator at Stores and Workshop Building and Stopped the Lighting & Exhaust Fans

23000 1.40 2.50

LED Lighting Project (Well Glass, Street Lights, Tube Lights, CFL & Building Lights...)

64000 3.84 8.61




Lakhs)

Invest. (Rs Lakhs)

Dry Flyash Handing Power Reduction by installing LP Compressor 116820 7.01 20.00

Hydrophobic Coating at Plant Process Water Pumps

23000 1.38 1.00

Installed Secondary Crusher for Raw Mill Circuit for Feed Size Reduction from 75 to 50mm

2074600 124.48 110.00

Installation of VFDs for Nuisance Bag Filter Fans (15 Nos. Additional VFDs Installed)

573840 34.43 28.55

Installation of AC Energy Savers for 4TR and 2TR ACs and Reduction of AC Power Consumptions

7400 0.44 0.42


Title of Project Year

Annual Thermal Saving

(Ton/Year)

Annual Thermal

Saving (Rs Lakhs)

Invest. (Rs

Lakhs)

Relocated Higher KW Cooler Fans at Heat Recuperation Zone & Recovered More Heat

FY 2015-16 439 47.4 1.5

Installed VFD and Reduced the Speed of Kiln Coal Blower and Reduced the Fresh Air Entry

FY 2015-16 423 38.0 4.0

Kiln Burner Pipe Retrofit by Conveying Pipe Size Reduction, Turbojet Blower and Swirl Air Fan with New Design Burner

FY 2016-17 470 50.70 11

Kiln Inlet False Air Reduction by Adopting Latest Generation Graphite Seal.

FY 2017-18 642 57.68 35

Kiln Outlet False Air Reduction by Adopting Latest Generation Graphite Seal.

FY 2017-18 642 57.68 35

With Investment – Thermal (FY 2015-16 to FY 2017-18)

Project : IP-1Title : Reduction of Water Treatment Power

by Reducing the Heat & Recycling Load

Objective:

1. To Reduce the Water Treatment Plant Power Consumption

2. To Reduce the Recycling of Cooling Water System

3. To Optimize the Requirement of Cooling Tower Fan

Action Taken:

1. Studied the Utilities System of Cooling Water Requirement2. Studied the Requirement Water Requirement of Mills and

Cooler Water Spray3. Studied the Load on Pumps for Water Recycling4. Studies the Heat Load on Cooling Tower

Observation :

WTP Capacity : 350 M3/Hr.Operating Capacity : 120 M3/Hr.Capacity Utilization : 34%



Actions Taken1. WTP Cooling Tower Motor Replaced from 4P to 6P Motor (Power

Reduction from 22 KW to 7 KW) 2. WTP Cooling Tower Fan Operation taken through VFD and

Reduced Speed from 100% to 80%. (Power Reduction from 7 KW to 4 KW)

3. WTP Process Water Pump Speed Controlled & Reduced from 98% to 85% (Power Reduction 40 KW to 27 KW)

0.4

64

0.4

60

0.4

62

0.4

68

0.4

68

0.4

72

0.4

71

0.4

64

0.3

96

0.3

76

0.3

38

0.3

30

0.3

31

0.3

33

0.3

31

0.250

0.305

0.360

0.415

0.470

0.525Units / Ton of Clinker

0.125 U/T X 1,35,000 Clinker Production / Month = 16875 Units Saving/Month

(Equivalent to 675 Units Saving / Day)

Plant - Water Treatment Plant Power Consumption

0.125 U/T of Clinker (Reduction)

28%

CFT : UTILITIES



Warm Water to WTP

Warm Water to Water Spray



Parameters UOM Before After%

Improvement

Cooling Tower Fan Motor Speed

RPM 1500 500 67 %

Process Water Pump Speed

RPM 1425 1200 16 %

Overall SECU/T of

Clinker0.464 0.331 27.6 %

Cooling Tower I/L Temp.

Deg C 31.5 29.5 6%

Cooling Tower O/L Temp.

Deg C 28.1 28.1 0 %



Project : IP-2Title : Raw Mill SEC Reduction by Feed Size

Reduction

Objective:

1. To Reduce the Raw Mill Specific Energy Consumption

2. To Improve the Raw Mill Productivity

Action Taken:

1. Studied the Raw Mill Feed Material Size by Sieve Analysis2. Trial Taken with Smaller Size Feed Material3. Observed the Better Energy Performance with Smaller sized Feed

Material4. Proposed and Installed Secondary Crusher with Vibrating Screen5. Screen Allows the Smaller Feed Material through Bypass Chute6. Above 50mm Feed Material Passes through Secondary Crusher


Reduction


Reduction

Parameters UOM Before After%

Improvement

Sieve Analysis >50mm 25% 0% 100 %

Production TPH 400 425 6 %

Sp. Power U/T 17.4 16.4 6 %

Savings : 20.74 Lakh Units / AnnumReduction of SEC : 1 Unit / Ton of Raw Meal

Project : IP-3Title : Cement Mill Operation with

Dual Fuel HAG during Kiln Shutdown

Objective:

1. To Sustain the Better Performance of Cement Mill during Kiln Shutdown

2. To Generate Hot Air during Kiln Shutdown by using Petcoke and Waste Oil (Liquid AFR)

Action Taken:1. Designed and Installed Dual Fuel Fired Hot Air Generator for Cement

Mill2. Designed the Fuel Pumping System from Coal Mill and AFR Station

(Fine Petcoke and Liquid AFR)3. Utilizing the Storage Bin of PC / Kiln Firing4. Operating the Cement Mill as per Best Performance Parameters

Diesel Firing from Kiln HAG during Kiln Shutdown

Advantages:

1. Cement Mill SEC Sustained during Kiln Shutdown2. Reduction of Heat Loss / Fuel Consumption towards Hot Gas Pumping

from Kiln HAG (400 Mtrs. Distance)3. Usage of Petcoke / Liquid AFR for the Cement Mill HAG4. Elimination of Booster Fan Power Consumption during Kiln S/D

Savings:1. Diesel (Thermal) Saving of 160KL / Annum (Rs. 104 Lakhs / Annum)2. Cement Mill Energy Performance Improvement. Energy Saving of 4.80

Lakh Units / Annum (Cost Saving : Rs. 28.80 Lakhs / Annum)3. AFR Consumption during Kiln Shutdown also.

Project : IP-3Title : Cement Mill Operation with

Dual Fuel HAG during Kiln Shutdown

Type of Renewable

Energy Source

Installed Capacity in KW

Savings

Energy Generated

(Lakhs Unit)

Cost Saving(Rs. Lakhs)

Non Solar REC - 50.33 -

Portable Wind Power

1.5 0.013 0.075

Solar Power 25 0.19 1.14

Solar REC - 25.17 -

Bio Gas Plant - 2800 M3/Yr. 1.20

Solar Water Heater

36 0.15 0.75

Pet Coke Using 100% Petcoke for Clinkerisation

Carbon Black Waste of Tyre Pyrolysis process. Using 5% on TSR

OrganicResidues & Solvents

2 % of Alternative Fuel for Clinkerisation.FCE is the Hazardous Waste of Pharmaceutical Industry

Red MudWaste From Alumina Industry as the Additive for Raw Mix, Which boost up utilization of Pet coke 100%

Chemical Gypsum

Chemical Gypsum for Additive for Cement Grinding( 2%)

Flyash Utilization of Flyash 34% for Cement Grinding

STP WaterUtilizing the STP Water for the Cement Mill Water Spray100% STP Water is Consumed

Total Fuel Consumption TSR in %

Pet Coke Pyrolysis Ash

Spent Solvent FCE

Waste Process Salt

81%

10%3%

5%

AFR Consumption in %

Pyrolysis Ash Spent Solvent

FCE Waste Process Salt

94% Pet Coke

6% AFR

• Rain Water Harvesting and Use – 150% Water PositiveWater

• Energy Conservation ProjectsEnergy

• Solar Power & Wind Power

Non-Conventional

Energy

• Mass Tree Plantation on Every Occasions Department wise ownership

Plantation

• Dry Fog System & Stack Emissions Control

• Recycling of Floor Spills & Reuse of WasteEnvironment

• Vermi-compost & Use of Bicycles

• Formation of pond & Rain water harvesting

• Distribution of Solar lamps & Practice of integrated Pest Management

Community

•Under Pipe Line Projects

• Installation of Waste Heat Recover & Solar CDM Project

Carbon Foot Print Activities

Year

Scope 1 emissions

CO2e (MT)

Scope 2 emissions

CO2e (MT)

Scope 3 emissions

CO2e (MT)

kg CO2e/MTof Cement

MitigationTotal Reduction

in emission intensity since baseline year

study CO2e (MT)

2012 - 13 (Baseline Year)

731 70 28 829 Baseline Year

2013 - 14 722 76 24 822 7

2014 - 15 689 80 27 796 33

2015 - 16 705.6 77 10 793 36

2016 - 17 694 76 10.8 780.8 48.2

2017 - 18 698 75 12.87 785.87 43.1

- Process Electricity Transport Overall5.2% Reduction from Base Line

DescriptionNo. of

ProgramsMan Days Total Hours

Training on Energy Conservation 14 82 656

Green Supply Chain Projects:

1. Reverse Hauling of Raw Material, Cement, Clinker Trucks (35%)

2. Reverse Hauling of Trucks between Ariyalur, Kadapa and Belgaum Plants as well as Material Shifting.

3. Best Rate Contracts & Buisness Oppurtunity to Transporters & Vendors

4. Common Logistics for Stores and O&M Contractors

5. Fuel Efficiency Improvement Programs by Training to Driving

Zero Plastic Rain Water Harvesting (150% Water Positive)

Birthday & Wedding Day Plantations Energy Conservation Campaign

In Plant To Associates

16

00

0

23

50

0

24

00

0

95

00

10000

56000 7

9500

10

35

00

11

30

00

12

30

00

0

20000

40000

60000

80000

100000

120000

140000

Upto 2013-14 2014-15 2015-16 2016-17 2017-18

Green Development in the Plant & ColonyNo. of Plants

No. of Plantations for the Year No. of Plantations in Cumulative

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Battery Operated Vehicle

Battery Operated Cars for Employees & Guests Internal Movement

E-Rickshaw for Employees

Certified Energy Auditors & Energy Managers in the Plant

Mr. K Santhosh Kumar (EA – 1832)

Mr. P Kamalanathan (EA – 15097)

Mr. A Chandilyan (EA – 18891)

Mr. V Ramachandra Raju (EA – 17555)

Mr. B Venkatesham (EM – 18832)

Mr. M Ganesh (EA-19674)

EA – 18327 EA – 15097 EA – 18891 EA – 17555 EM – 18832 EA – 19674

Energy Policy

Unit Head

Technical Head

Unit Energy Task

Force Leader

Task Force Team

Conveyors & Elevators

Task Force Team

Pumps

Task Force Team

Compressors

Task Force Team

Fans

Task Force Team

False Air

Task Force Team

Utilities

Task Force / Energy Management Team

Online SEC Monitoring by CCR Operator and taking Immediate action during increase in SEC Indication

Rs. 1 Crore Kitty Budget for Innovative 'Encon` Projects by any Employee

Final Video 01.mpg

dalmia cement (bharat) limited, kadapa … · founded in 1935 by shri jaidayal dalmia. the group...

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