Hearty welcome to

KEP - Small Group Activity

Presented by M/s DALMIA CEMENT (BHARAT) LTD, DALMIAPURAM

Building Young India since 1939

Pan India Player • Operating 13 Cement Plants with a total

capacity of 30 MTPA

Plant Profile - Dalmiapuram: • Installed Capacity (Clinker) - 2.3 MTPA • Installed Capacity (Cement) - 3.4 MTPA • Captive power plant (CPP – 1) - 27 MW • Captive power plant (CPP – 2) - 18 MW

Uniqueness: • Producing 16 varieties of cement in one

location • Operating 7 Management Systems • First in India to produce High strength cement

(Since 1976) • First in India to produce Oil well cement (Since 1986)

Energy to Monetary (ETM)

S.NO SGA PROJECTS QTY ONE TIME INVESTMENT

(LACS)

SAVINGS (KW/HR)

SAVINGS (LACS/YR)

1 IMPLEMENTED

5 7.5 185 56

2 UNDER PROGRESS

3 13.5 32 9

3 UNDER APPROVAL

4 16 65 15

4 UNDER STUDY

6 32.5 120 17

TOTAL 18 69.5 402 97

Our SGA journey started from Dec'17

Conversion Of Bag Filter Purging system

Team Victory

Background

To reduce the Compressor air leakage in Pyro section

Observation made

Leakage from Aux Bag filter purging system was on higher side due to

Old system - Piston operated purging type

Frequent failure of internal spare parts

Online maintenance not possible

Action Taken

Purging system upgraded to diaphragm type.

This modification was implemented in 5 number of Aux Bag filters

Piston Operated Purging

Piston in Receiver tank

Project 1

Conversion Of Bag Filter Purging system

Benefits

Compressed air leakage arrested completely

Online maintenance possible.

Minimum Spares & Maintenance cost

Investment made

One Time - 2.4 lacs

Savings Achieved

Energy : 15 kWh

Monetary : 3.62 lacs/annum

Payback : 8 months

Diaphragm Operated Purging

Installation of VFD for Packing House Bagfilter Fan

Team DSP

Background

To improve the efficiency of the bag filter, thereby controlling the dust and to save energy

Observation made

Bag Filter Fan was operated in DOL mode at full speed of 1450 rpm resulting in

Optimisation of Suction line dampers to avoid fan overload tripping

Insufficient suction leading to more dust pollution

Frequent choking of bags leading to reduced life and more maintenance hours

Action Taken

VFD drive installed for one of the Auxillary bag filter fan

Variable Frequency Drive

Project 2

Benefits

Fan running at a speed of 800 rpm, which is sufficient

Suction line dampers were removed.

Better suction with effective dust control.

Investment made

One Time - 5.05 lacs

Savings Achieved

Energy : 15 kWh

Monetary : 3.27 lacs/annum

Payback : 19 months

Installation of VFD for Packing House Bagfilter Fan

Nuisance Dust Collector

Team Spartans

Background

To optimize Raw meal silo circuit to save energy

Observation made

Both Raw meal silos were simultaneously operated for infeed and extraction

Auxiliary Power consumption was higher

All the drives in the circuit were running

Action Taken

Single silo operation logic was implemented without affecting product quality

Variable Field Drive

Optimisation of Power in Rawmeal silo group equipments

Project 3

Benefits

Six drives were stopped in the circuit

Ready standby circuit available to avoid breakdowns

Reduction in spares and maintenance cost

Investment made

Nil

Savings Achieved

Energy : 40 kWh

Monetary : 9.5 lacs/annum

Payback : NA

Optimisation of Power in Rawmeal silo group equipment's

10

DALMIA CEMENT (BHARAT) LIMITED - ARIYALUR

Installed Capacity (Clinker) - 2 MTPA Installed Capacity (Cement) - 3 MTPA Captive Power Plant (CPP) - 27MW Product Type - OPC, PPC

Overall Summary

S.NO SGA PROJECTS QTY ONE TIME

INVESTMENT (LACS)

SAVINGS (KW/HR)

SAVINGS (LACS/YR)

1 IMPLEMENTED 6 2.72 145.5 16.12

2 UNDER PROGRESS 3 4.3 9.96 3.14

3 UNDER APPROVAL 3 52.5 134 22.83

4 UNDER STUDY 2 6 20.3 3.61

TOTAL 14 65.52 309.76 45.7

Optimization of Compressed air in Rawmill HAG

Team ADSS Background: Compressor power consumption was more in Rawmill HAG.

Observation Made: More pressure drop in Raw mill HAG due to Non uniformity of compressor pipeline between coal mill to HAG

Action Taken: Compressor air pipe line size was modified from 1” to 2” (Coal mill to HAG).

Savings Achieved: Energy : 241 KW/Day

Cost : 1.27 Lakhs/Annum

Project 1

Optimization of Compressed air in Rawmill HAG

Receiver tank

Coal mill

HAG

2” pipeline

Friction loss -

0.39 bar

1” pipeline

Friction loss -

1.32 bar

Receiver tank

Coal mill

HAG

2” pipeline

Friction loss -

0.39 bar

2” pipeline

Friction loss -

0.39 bar

Before After

Reduction of 1 bar = 7% of Power Reduction

Raw mill productivity enhancement

Team ADSS Background: We are not able to achieve the desired production of 440 TPH, due to raw meal

residue was around 2 % on 212 microns even at full speed of Raw mill fan.

Observation Made: Raw mill classifier seal gap was found 12 mm which leads to higher raw meal

residue

Action Taken: Classifier seal gap was reduced from 12 to 6 mm by providing the felt seal

Savings Achieved: Energy : 2112 KW/Day Cost : 10 Lakhs/Annum

Project 2

Raw mill Classifier seal gap reduced from 12 to 6mm by

providing the felt seal

Raw Mill Classifier Seal Gap

Reduction of False air in Cement mill

Team 2.0 Background: Cement mill false air was more which leads to increase the sp. power

consumption of fan

Observation Made: Cement mill bag house rotary air lock bottom false air enriching was more

because of gap in both rotor end

Action Taken: Bag house RAL rotor end opening was fully closed and false air was reduced

from 11 to 9.8 %

Savings Achieved: Energy : 240 KW/Day Cost : 1.7 Lakhs/Annum

Project 3

Cement Mill Bag House RAL

Cement mill bag house rotary air lock - rotor both end

opening was closed and false air was reduced from

11% to 9.8%

THANK YOU