Post on 04-Apr-2020
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)
Title of ProjectAnnual Electrical
Saving (kWh)
Annual Elect. Cost Saving (Rs
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)
Title of ProjectAnnual Electrical
Saving (kWh)
Annual Elect. Cost Saving (Rs
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)
Title of ProjectAnnual Elect. Saving (kWh)
Annual Electrical Cost Saving (Rs
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
With Investment (FY 2016-17)
Title of ProjectAnnual Elect. Saving (kWh)
Annual Electrical Cost Saving (Rs
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
With Investment (FY 2017-18)
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%
Project : IP-1Title : Reduction of Water Treatment Power
by Reducing the Heat & Recycling Load
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
Project : IP-1Title : Reduction of Water Treatment Power
by Reducing the Heat & Recycling Load
Warm Water to WTP
Warm Water to Water Spray
Project : IP-1Title : Reduction of Water Treatment Power
by Reducing the Heat & Recycling Load
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-1Title : Reduction of Water Treatment Power
by Reducing the Heat & Recycling Load
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
Project : IP-2Title : Raw Mill SEC Reduction by Feed Size
Reduction
Project : IP-2Title : Raw Mill SEC Reduction by Feed Size
Reduction
Project : IP-2Title : Raw Mill SEC Reduction by Feed Size
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
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