Dalmia Cement Bharat Ltd..Dalmiapuram

COMPANY PROFILECOMPANY PROFILE

FOUNDER

Dalmia Group refers to a grouping of Indian companies, which trace their origin to the businesses establishedby Sri Jaidayal Dalmia .

The Dalmia Group refers to a grouping of Indian companies, which trace their origin to thebusinesses established by Jaidayal Dalmia. The Dalmia brothers established a businessconglomerate in eastern India, in the first half of the 20th century.

In the 1930s, the group merged with the businesses of the Sahu Jain Family to form the Dalmia-Jain Group.

Founded in 1935 by Jaidayal Dalmia the cement division of DCBL was established in 1939 andenjoys a heritage of 70 years of expertise and experience.

Dalmiapuram is a small township in the Tiruchirappalli district of Tamil Nadu in India. It is locatedat a distance of 40 km from Tiruchirappalli Junction.Dalmiapuram is the hometown of Dalmia Cements. This region is rich in limestone deposits.Dalmia Cements was the largest cement plant in Asia at its completion. It has a greenish colonycalled Dalmiapuram..

HISTORY

The Dalmia Group refers to a grouping of Indian companies, which trace their origin to thebusinesses established by Jaidayal Dalmia. The Dalmia brothers established a businessconglomerate in eastern India, in the first half of the 20th century.

In the 1930s, the group merged with the businesses of the Sahu Jain Family to form the Dalmia-Jain Group.

Founded in 1935 by Jaidayal Dalmia the cement division of DCBL was established in 1939 andenjoys a heritage of 70 years of expertise and experience.

Dalmiapuram is a small township in the Tiruchirappalli district of Tamil Nadu in India. It is locatedat a distance of 40 km from Tiruchirappalli Junction.Dalmiapuram is the hometown of Dalmia Cements. This region is rich in limestone deposits.Dalmia Cements was the largest cement plant in Asia at its completion. It has a greenish colonycalled Dalmiapuram..

FLOWFLOWDIAGRAMDIAGRAM

OF CEMENTOF CEMENTPLANTPLANT

PROCESSPROCESS

PACKING PLANT

CRUSHERCRUSHER STACKER &

RECLAMIER

FLOWDIAGRAM

FLOWFLOWDIAGRAMDIAGRAM

OF CEMENTOF CEMENTPLANTPLANT

PROCESSPROCESSRAWMILL

COALMILLKILN

RAWMEAL SILOCOOLER

CEMENT MILL

OBJECTIVE OF THE PROJECTOBJECTIVE OF THE PROJECT

TopManagement

B.S Rathore

TEAMSTRUCTURE

P.Balaji

V.Visuventhan – ElectricalS.Suryanarayanan – Instrumentation

S.Vimalraj – Mechanical

Co -Workers

SELECTIONMETHOD

FISH BONEDIAGRAM

BRAINSTORMING

MULTI-VOTING

FISH BONEDIAGRAM

BRAINSTORMING

MULTI-VOTING

Stopping Coal millin

Line-1

Stopping Coal millin

Line-1

Team• P.Balaji• S.Suryanarayanan• V.Visuventhan• S.Vimalraj

DBCL- Dalmiapuram overview

Line-1

• RVRM• Pyro – 4stage (3200 TPD)• Coal mill( Ball)• CVRM

Line-2

• RVRM• Pyro-5stage (3800 TPD)• Coal mill(VRM)• CVRMLine-2

• RVRM• Pyro-5stage (3800 TPD)• Coal mill(VRM)• CVRM

CPP• 27MW• 18MW

Power consumption(2014-15) - Dalmiapuram

1283274

18096950

711871137332414

2416662 1501791(1.24%)(2.42%)

(20.37%)

(8.01%)(42.01%)

(1.69%)

21111343

Crusher Raw Mill Coal Mill Pyro Section Cement Mill Packing Plant Utility

(8.01%)(42.01%)

(23.76%)

Project Statement-Comparison of Line1 & 2

1.3 20.3 8.8 25.4 39.33.2

1.7

1.5 20.4 7.5 22.6 43.92.4

1.7

20%

40%

60%

80%

100%

1.3 20.3 39.3 1.7

0%

20%

Crusher Raw Mill Coal Mill Pyro Section Cement Mill PackingPlant

UtilityLine-1 Line-2

Line-1 coal mill consumes 1.3 % more than Line-2 coal mill

Power comparison for Ball mill Vs VRM

72.94

83.68 85.79

76.4378.29 78.64

81.0269.27

73.31 76.67 77.4778.71

55.3562.97

57.08

67.4061.76

52.10 53.46 53.58 48.89 51.49 51.77 50.91

40.00

60.00

80.00

100.00

0.00

20.00

Apr-14 May-14 Jun-14 Jul-14 Aug-14 Sep-14 Oct-14 Nov-14 Dec-14 Jan-15 Feb-15 Mar-15

Line-1 Line-2

The difference between Line-1 &2 coal mill is – min 20kwh/ton of coal

Fine coal requirement of DPM unit

Line-1 3300 TPD 300Tons/day

Mill capacity25Tph

Line-2 4900TPD 500Tons/day

Mill Capacity33TphLine-2 4900TPD 500

Tons/dayMill Capacity

33Tph

Requirement 8200TPD 800Tons/day

Available58Tph

Brain storming

Conclusion : Fine coal Pumping from Line 2

Coal pumping from Line-2 to Line-1 150mm Pipe line was laid~ 500m ,

Blower used for pumping , having volume of 1330 M3/hr

Initially we started with 4-5 tph of coal pumped from Line-2 to Line 1

For Line-1 operation we need ~310tons/ day of fine coal(Approx 14tph)

Blower (BL-4 )having volume of 3760 M3/Hr connected to screw pump for coal

pumping.

To optimize power - VFD was installed in the blower

Pumping capacity increased to 13 TPH, which is sufficient enough for Line-1 plant

operation with alternate fuel firing of 3 TPH (Carbon black and High CV flyash)

150mm Pipe line was laid~ 500m ,

Blower used for pumping , having volume of 1330 M3/hr

Initially we started with 4-5 tph of coal pumped from Line-2 to Line 1

For Line-1 operation we need ~310tons/ day of fine coal(Approx 14tph)

Blower (BL-4 )having volume of 3760 M3/Hr connected to screw pump for coal

pumping.

To optimize power - VFD was installed in the blower

Pumping capacity increased to 13 TPH, which is sufficient enough for Line-1 plant

operation with alternate fuel firing of 3 TPH (Carbon black and High CV flyash)

Line-1 Coal millstopped

Pressure profile in Line-2 Coal Mill Circuit

.

-50 mmwg

-695 mmwg

-750 mmwg -805 mmwg -820 mmwg-738 mmwg

-490 mmwg

-826 mmwg

-860 mmwg

-60

mm

wg

1. Across the Mill DP is 645 mmwg.2. Across the Louvre DP is 440 mmwg.3. Across the classifier DP is 205 mmwg.4. Across the Main Bag house DP is 67 mmwg.

.

-50 mmwg

-695 mmwg

-750 mmwg -805 mmwg -820 mmwg-738 mmwg

-490 mmwg

-826 mmwg

-860 mmwg

-60

mm

wg

Actions taken to increase Line- 2 Coal mill output

STEP 1: Analyzing the pressure profile, The main contributor for millpressure drop is the nozzle drop. Increasing Nozzle area from 0.85m2 to 1.05m2 Trail of various Nozzle velocity - from 52m/s to 44m/s, which results

in reduction of pressure drop, Resulting in feed increase

STEP 2: Grinding pressure increased from 70 bar to 90 bar, so as increasethe work done by the table and reduce recirculation

STEP 3:Varying GRR – Table speed

STEP 4: Varying Water Flow and Dam ring height

Result : Coal mill output increased from 30 TPH to 40 TPH.

Action Taken to increase Output

STEP 1: Analyzing the pressure profile, The main contributor for millpressure drop is the nozzle drop. Increasing Nozzle area from 0.85m2 to 1.05m2 Trail of various Nozzle velocity - from 52m/s to 44m/s, which results

in reduction of pressure drop, Resulting in feed increase

STEP 2: Grinding pressure increased from 70 bar to 90 bar, so as increasethe work done by the table and reduce recirculation

STEP 3:Varying GRR – Table speed

STEP 4: Varying Water Flow and Dam ring height

Result : Coal mill output increased from 30 TPH to 40 TPH.

Coal mill – Output ( FY 15- 16)

Louver areaincrease

GP increase

Damringheight

29 2933

38 38 37 37 36

30.10

1619

2529

2529 30.10

Apr-

15

May

-15

Jun-

15

Jul-1

5

Aug-

15

Sep-

15

Oct

-15

Nov

-15

Dec-

15

Jan-

16

Feb-

16

Mar

-16

YTD

56.20 56.9

48.243.3 42.3

52.2

46.842.3

36.2 34.837.9 36.6

39.043.04

30.00

60.00

Coal mill – Power consumption (FY 15- 16)

0.00

2014

-15

Apr-

15

May

-15

Jun-

15

Jul-1

5

Aug-

15

Sep-

15

Oct

-15

Nov

-15

Dec-

15

Jan-

16

Feb-

16

Mar

-16

YTD

Power consumption(2015-16) - Dalmiapuram

2015926

28681369

7106874

58209995

38926524663467

(2.87%)(3.44%) (1.49%)

(21.13%)

(5.24%)

(42.88%)

2014-15 – 8.03%

31168023

58209995

Crusher Raw Mill Coal Mill Pyro Section Cement Mill Packing Plant Utility

(22.96%)

(42.88%)

S.no Description Unit Values

1Power reduction due to Fine coalpumping Kwh/ton of coal 20

2Power reduction in clinkerContribution Kwh/ton of cli 2

Savings

3Cost of Per unit Rs/Kwh 2.5

4Savings per ton of cli Rs/ton of cli 5

Apart from power reduction savings :In Line -1 Zero Inventory cost Zero maintenance cost Zero manpower cost