AFR EXCELLENCEAT JK CEMENT MANGROL

About the Organisation

CII National Energy Efficiency Circle Competition 2

A. About JK Cement :-❖ JK Cement has an installed grey cement capacity is 10.5 MnTPA and 103 MW CPP & 23 MW WHR power generation

Capacity. ❖ JK Cement has 7 integrated grey Cement Plant and 01 white cement plant

(India’s 2nd largest white cement producer)❖ We have complete low cost of production and high efficiency among the industry.❖ JK Cement believe to have maximum Cement volume from energy efficient location like Mangrol and to improve

company’s profitability.

B. Certifications it possesses :- JK Cement Works, Mangrol is certified with❖ ISO 9001:2008 - Quality Management System❖ ISO 14001:2004 - Environment Management system❖ OHSAS 18001:2007 - Occupational Health and Safety Management System❖ ISO 50001:2011 - Energy Management System

C. Highlights of JK Cement Mangrol.:-❖ Two integrated lines (Line-1 and Line-2)❖ Lower Manufacturing cost of production of Clinker and Cement.❖ Strong capability of loading of cement by rail as well as by road❖ Line-2 efficiency is the best among the other cement industries.

3

• Recently JK Cement Mangrol won the SEEM National Energy Management Awards 2017

• Category :- Industries

• Sector & Organization :- Cement - JK Cement works, Mangrol

• Position :- PLATINUM

Awards Achieved in 2017-18

4

One of the most prestigious award amongst the Industries i.e. “Golden Peacock Awards” Won by “JK Cement Works Mangrol” under the leadership of our Unit Head Sh. S. K. Rathore Sir, in the Category “Eco-Innovation Award” at Institute Of Directors (IOD), India’s 19th World Congress on ENVIRONMENT MANAGEMENT and Golden Peacock Awards Presentation Ceremony at The HICC - Novotel in Hyderabad (India) on 07th – 08th July’17.

Awards Achieved in 2017-18

5

Private Sector waste Management Award :- JK Cement Works, Mangrol Best Waste Management Officer :- S.K. Rathore (Unit Head)

Awards Achieved in 2017-18

• Ever Highest Clinker Production 2.42 million Ts. (2.25 million Ts. in 2016-17)

• Ever Highest Fly Ash Consumption – 30.94% (30.69% in 2016-17)

• Ever Lowest Thermal consumption of Line-1– 753 kcal/kg of clinker. (771 kcal/kg of clinker in 2016-17) and Line-2 of 681 Kcal/Kg of Clinker (5 stage Preheater).

• Ever Lowest clinker consumption (Overall clinker factor) – 76.6 % (80.47% in 2016-17)

• Ever Lowest PPC clinker factor – 62.85%. (63.68% in 2016-17)

• Ever Lowest OPC clinker factor Line-1 – 89.69%.(94.13% in 2016-17)

• Ever Lowest OPC clinker factor Line-2 – 90.35%.(95.53% in 2016-17)

• Ever highest TSR% achieved in Line-1 – 4.9%.(4.3% in 2016-17)

• Ever highest TSR% achieved in Line-2 – 8.5%.(8.0% in 2016-17)

• Ever Highest AFR consumption: 57744 MT (30405 MT in 2016-17)

• Ever Highest Clinker Movement – 0.75 million Ts. {0.62 million Ts. (Jajjhar-Grinding Unit) and 0.13 million Ts. (Sold)} (0.46 million Ts. in 2016-17)

Executive Summary FY 2017-18

• Ever Highest WHR Gross Generation – 580.53 Lakhs KWH. (428.70 Lakhs KWH in 2016-17)

• Ever Highest WHR Generation Capability – 24.61 KWh/MT Clinker. (20.2 KWh/MT Clinker in 2016-17)

• Ever Highest WHR PLF% - 73.02%. ( 60.91 % in 2016-17)

• Ever Highest WHR Average Load – 7.01 MW. (5.84 MW in 2016-17)

• Ever Lowest WHR Auxiliary Consumption – 4.51%. ( 4.94% in 2016-17)

• Ever Highest CPP Generation 1550.31 Lakhs KWH. (1467.99 KWH in 2016-17)

• Ever Highest CPP PLF% - 82.81% ( 72.99 % in 2016-17)

• Ever Lowest CPP Auxiliary Consumption – 8.70%. (10.97% in 2016-17)

• Ever Lowest CPP Station Heat Rate – 3213 Kcal/KWh. (3229 Kcal/KWh in 2015-16)

Executive Summary FY 2017-18

The types of AFR are using at JK Cement Works, Mangrol

Alternative Fuels:-

• Solid Mix Waste.

• Waste Mix Liquid.

• Carbon Black.

• Fiber Mass.

• Agro Waste.

• ETP Sludge.

• Plastic Waste.

• Plastic and Resin Waste.

• Pyrolysis Oil.

Alternative Raw Materials:-

• Chemical Gypsum.

• Slag/Zinc Slag.

• Iron Sludge.

• Marble Khanda

8

• We are committed to use alternative materials and fuels for clinker and cement production when technically, ecologically and economically feasible.

• We developed this policy to define the conditions and criteria for a safe and secure way to use waste-derived materials and fuels or byproducts coming from society or other industries

• The burning processes used for clinker production – high temperatures and long residence times under controlled conditions – make it feasible to use alternative fuels completely without any ash.

• The quality of our products is of the highest importance to us and our customers.

• Health and Safety of our employees, neighbors and customers is important for us.

• Our production processes are characterized by the use of modern technology, appropriate safety and environmental measures and rules.

• We are aware of our responsibility to our employees, the public and the environment.

• The dialogue with our employees, neighbors and other stakeholders is of high value for us.

AFR Policy

Solid AFR Feeding System in Line-1

10

Hopper Mesh Hopper & Screw Conveyor Feeding Belt Conveyor

Feeding system in Calciner

Solid AFR Feeding System in Line-2

11

AFR Yard Feeding Belt Conveyor

Solid AFR Feeding in Calciner

Hopper & EOT Crane

12

1212

0.00

470.00

1128

361

79 810

23470

296.68

665

8.03

0.00 5.16

7.12

2.610.85 0.76 0 4.96 1.61

4.19

12.6

01234567891011121314

0

200

400

600

800

1000

1200

1400

Apr-16 May-16 Jun-16 Jul-16 Aug-16 Sep-16 Oct-16 Nov-16 Dec-16 Jan-17 Feb-17 Mar-17

Quantity (Ts) TSR %

Usage of AFR in Line-1&2 (2016-17)

0409.00

1080.001553

1062

25263081

1463

3114

3945 3844

4891

01.40 3.64

6.043.53

9.60 9.847.73

10.212.13 13.4

15.16

0

2

4

6

8

10

12

14

16

0

1000

2000

3000

4000

5000

6000

Apr-16 May-16 Jun-16 Jul-16 Aug-16 Sep-16 Oct-16 Nov-16 Dec-16 Jan-17 Feb-17 Mar-17

Quantity (Ts) TSR %

Line-2

Line-1

Major Challenges faced by JK Cement, Mangrol 2016-17

13

1. Process Stabilization: We have installed In house made Liquid waste firing system with the available old pumps etc. Stabilization to be done in line-1 with liquid waste as kiln stopped just after trial in the calciner firing and now kiln running with restricted output. Solid waste feeding system is not available in line-1 where only agro waste feeding system is installed. We have stabilized our process in line-2 with approximately 100TPD of solid waste and 20 TPD of Liquid waste firing. For stabilization we have used the installed AFR Feeding system for solid waste firing while for liquid waste firing we have developed in house firing system.

2. Process Equipment:For Further stabilization with increased usage of AFR in Line-2 refractory of the calciner has to be upgraded with higher version compatible with HW firing. With the usage of HW firing we have observed deterioration in our main Bag house like corrosion problem in main body.

3. Quality and Supply: Consistency in the supply of HW is hampering utilization percentage even after close monitoring and follow up for consistent supplies with satisfactory Heat value.

4. Environmental Aspects:With the usage of Liquid AFR potential risk of undesirable emissions are yet to be assessed in terms of concentration and quantity.

Action taken to overcome Co-Processing Challenges in 2016-17

14

1. Process Stabilization: Trial of Solid and Liquid waste to be taken after kiln-1 Tyre replacement at normal output.

2. Process Equipment:Planning for the replacement of Calciner refractory with higher version is under process. Anti-corrosion coatings applied by different agencies to observe suitability w.r.t anticorrosion.To find out root cause for corrosion suitable sample submitted to external agency for study.

3. Quality and Supply: For consistent supplies follow up with supplier on daily basis. Besides follow up preplanned usage are also intimated to supplier.Joints Sampling and checking of Heat value done and supplier intimated to take actions accordingly to improve heat value.

4. Environmental Aspects: To minimize the undesirable emissions stack monitoring done by external agency and doses of liquid reduced as a precautionary measure.

5. Handling & storage:AFR Yard Flooring to be done as per CPCB norms in Line-2 (Concrete flooring with PVC base).Skilled Manpower engaged for feeding and storage.Hazardous Waste handling compatible suits provided to workmen.Regular safety Tool Talk and training started

15

0

620.0

1965.8

1169.3

709.68879.34

1413.53

1097.20

357545.56

93.23

2279.46

0

8.3

9.26.9

23.1

3.94.35

7.260.23 0

12.3

0123456789101112131415

0

500

1000

1500

2000

2500

Apr'17 May'17 June'17 July'17 Aug'17 Sep'17 Oct'17 Nov'17 Dec'17 Jan'18 Feb'18 Mar'18

Quantity (Ts) TSR %

Usage of AFR in Line-1&2 (2017-18)

4965.24514.74 4301.51

3995.92

2764.272425.76

3853.88

4599.38 4843.11

3481.37 3641.913207.10

14.06

10.948.62

7.889.61 7.92 7.7 9.34 9.04 5.7

4.7

5.5

0

2

4

6

8

10

12

14

16

0

1000

2000

3000

4000

5000

6000

Apr'17 May'17 June'17 July'17 Aug'17 Sep'17 Oct'17 Nov'17 Dec'17 Jan'18 feb'18 Mar'18Quantity (Ts) TSR %

Line-1

Line-2

New EOT crane Of Line-1 Commissioned Successfully On

09.12.17

Small Feeding hopper at D/C of 261WF350

Additional hopper installed for feeding of Plastic waste.

Initiatives to increase AFR consumption

Fire Safety Training ODC Spray System

Air Filtration Unit (AFU) Fire Fighting Water hydrant System

Contaminated water sewage pit First Aid Box

Dispensary at Mangrol Fire Brigade

Working with safety PPEs

Ambulance

Activities Done in Line-1 (2017-18)

S.NO DESCRIPTION EFFECT OF MODIFICATION RESPONSIBILITY STATUS

1Blaster installation at Solid waste

feeding RBC D/C Reduction in Jamming Frequency. Process Completed

2Solid waste Quality check Before Entry

in gateOnly suitable lot will be Recieved Quality Control

Completed/

Running

3 Menpower UtilizationIncrease AFR consumption with SWP &

Better HousekeepingProcess Completed

4 Secondary access Nearby hopper For Emergency evacuation Civil completed

5 New ECS selection for Screw conveyor Smooth Feeding of AFRProcess/

InstrumentCompleted

6 Poking window created at Solid waste

D/C To decrease jamming removal time Process Completed

Activities Done in Line-1 (2017-18)

S.NO DESCRIPTION EFFECT OF MODIFICATION RESPONSIBILITY STATUS

1A secondary passage near AFR

hopper construction doneFor safe evacuation in Emergency Mechanical Completed

2Liquid firing Pump Teflon Seal

replaced by Brass seal

Seal leakage Frequency reduced resulting

Reduced Downtime Of pump. Mechanical Completed

3 EOT crane commisioning done AFR consumption will improve All Dept. Completed

4Discharge Airsluice LPB Location

change

During jamming Airsluice operation in

local mode can be done easily

Process/

ElectricalCompleted

Activities Done in Line-2 (2017-18)

S.NO DESCRIPTION EFFECT OF MODIFICATION RESPONSIBILITY STATUS

1Solid waste Quality check Before

Entry in gateOnly suitable lot will be Recieved Quality Control Completed/ Running

2 Menpower UtilizationIncrease AFR consumption with SWP &

Better HousekeepingProcess Completed

3 261BC650 Guide Roller installed Belt out Problem solved Mechanical Completed

4Stand by liquid feeding pump

installed

To continue liquid firing if seal leakage

in main pumpMechanical Completed

5Small Feeding hopper at D/C of

261WF350

To feed Plastic waste from outside to

increase consumption Process Completed

6New source Shredded plastic trial

conducted successfully

suitable AFR will support to increase

TSR%Process Completed

Activities Done in Line-2 (2017-18)

S.NO DESCRIPTION EFFECT OF MODIFICATION RESPONSIBILITY STATUS

1Used solid waste plastic bag heap

relocated

Agrowaste/Fibermass stored under the heap is

utilizedProcess Underprogress

2A concrete wall is made surrounding

of Liquid Firing at P.H. 2nd floor

To isolate surronding area from Haz. Liquid in

case of spillage /Leakage / OverflowProcess/civil Completed

32 Nos. of Exhaust Fan Installed in

AFR yard Better ventillation

Process/

ElectricalCompleted

4 Trial Of Biowish Odour Control Making AFR area Odour less As well as

Compliant with OH&S requirement Process Completed

5Installation of Blaster at AFR D/C

bend to avoid jamming

Frequency of Chute jamming as well as

probability of Fire will be eliminated

Process/

Mechanical

underprogress

complete by

25.02.18

Future Plan in Line-1

S.NO DESCRIPTION EFFECT OF MODIFICATION RESPONSIBILITY

1 AFR D/C modification in line-1 Jamming will be reducedProcess/

Mechanical

2 AFR feeding system to run in auto mode in line-1 smooth Feeding of AFRInstrument/

Process

3Magnetic seal Liquid Firing pump to be installed If

Successfully run in Line-2

Downtime due to frequent sealing

leakage will be removedMechanical

4 New Line-1 EOT crane operation will start Increase AFR consumption Process

Future Plan in Line-1

S.NO DESCRIPTIONEFFECT OF

MODIFICATIONRESPONSIBILITY STATUS

1 AFR D/C modification in line-1 Jamming will be reducedProcess/

Mechanical

Next Planned

shutdown

2Antistick Coating to be done in AFR D/C to

reduce JammingJamming will be reduced

Process/

Mechanical

Next Planned

shutdown

3Magnetic seal Less Liquid Firing pump to be

installed If Successfully run in Line-2

Downtime due to frequent

sealing leakage will be

removed

MechanicalLine-2 pump perf.

Under observation

Future Plan in Line-2

S.NO DESCRIPTION EFFECT OF MODIFICATION RESPONSIBILITY

1New AFR Additional Hopper & BC600 length increase will be

commisioned Increase Plastic waste consumption Civil/ Mechanical

2 Magnetic seal Liquid Firing pump to be installed & evaluate Perf.Downtime due to frequent sealing leakage

will be removedMechanical

3261SC300 Main conveyor will be remove & WF350 will be extended

backwardScrew conveyor jamming will be eliminated Mechanical/ Process

4 Shock Proof Exhaust fan will be Installed AFR yard Environment More suitable for

Human workingElectrical/ Process

5 To install Blaster at AFR D/C bend to avoid jamming line-2 Jamming will be reduced Process/ Mechanical

6 Flexco Scrapper to be install in 261BC650Roller coating will be avoided so downtime

will reduceMechanical

7 ODC-50 Odour control fogging System to be install in AFR yardTo make Yard area Compliance with OH&S

standard Process

Future Plan Line-2

S.NO DESCRIPTIONEFFECT OF

MODIFICATIONRESPONSIBILITY STATUS

1New AFR Additional Hopper & BC600

length increase will be commisioned

Increase Plastic

waste consumption

Mechanical/

Electrical

Hopper and Length Increase

Arrangement Erected ,

Agitator’s Erection And Power

Source Awaiting.

2

261SC300 Main conveyor will be

removed & WF350 will be extended

backward

Screw conveyor

jamming will be

eliminated

Mechanical/

Process

Under Discussion Due to safety

reasons

3 Installtion Of Fire Hydrant systemFire Emergency

PlanningSafety

Procurement of system

Initiated

4ODC-50 Odour control fogging System

to be install in AFR yard

To make Yard area

Compliance with

OH&S standard

Process Trial done

Shredder

We installed one shredder ( Capacity 3-4 TPH) , to shred in house waste like tires , wooden blocks and bags of solid waste

Summary

Quantity of Alternative Fuel used (Ts.)

Quantity of Alternative Raw Material used (Ts.)

TSR% in Line-1

TSR% in Line-2

Quantity of Fuel Saved (Ts.)

FY 2016-17 30405 13821 4.3 8.0 15454

FY 2017-18 57744 51110 4.9 8.5 17378

29