19 TH National Award For Excellence In Energy Management-2018 J K LAKSHMI CEMENT, SIROHI, RAJASTHAN

Transcription

1 19 TH National Award For Excellence In Energy Management-2018 J K LAKSHMI CEMENT, SIROHI, RAJASTHAN Presented By:- Pradip Kr. Ghara, Sr. Mgr. (Elect.) Kanish Kr. Singh, Asst. Mgr (Process)(EM-13473)

2 ISO 9001 ISO OHSAS ISO TH National Award For Excellence In Energy Management-2018 Brief Introduction of JKLCL Sirohi, Rajasthan

3 Products Manufactured Here. 53 GRADE 43 GRADE PPC GRADE PRO+ GRADE RMC AAC BLOCK POP

4 Journey Towards Up gradation.. Established in Aug1982 with 0.5 MTPA capacity. Unit II Commissioned in 1995 with 0.9 MTPA capacity. Unit III Commissioned in 1996 with 0.9 MTPA capacity. Present Cement Production Capacity 4.64 MTPA. PLANT YEAR OF COMMISSIONING INSTALLED CAPACITY (TPD) PRESENT STATUS (TPD) KILN KILN KILN

5 Energy Performance Since 2014 Year (April March) Specific Energy Consumption Electrical Redn. in SEC Over previous years Thermal Elect. Thermal Kwh/Ton of Cement (excl. Crusher) KCal/kg of clinker % % * (- 1.52)** (- 0.14) ** (- 3.25) *** ** Increased because of Less PPC production and increase in Ball Mill run hrs * Reduced due to easy burning material from mines *** SEC up to clinker reduced for energy saving in SPRS, VRM & more PPC production

6 Kcal/ Kg CLINKER Thermal Energy Consumption (Kcal/KG Clinker) A Comparison with National & International Benchmark Reference : CII Energy Benchmarking study carried out at JKLC in May,2018

7 KWH/ MT CEMENT Electrical Energy Consumption(Unit/ton cement ) A Comparison with National & International Benchmark International Benchmark National Benchmark Reference : CII Energy Benchmarking study carried out at JKLC in May,2018

8 KWH/ MT MATERIAL Electrical Energy Consumption(For Raw Grinding Section) JKLC U-I VRM JKLC U-II VRM JKLC U-III VRM COUNTRY BEST Incl: Main drive, Mill Fan, Classifier & Reject Elevator Power Reference : CII Energy Benchmarking study carried out at JKLC in May,2018

9 KWH/ MT CLINKER Electrical Energy Consumption(For Clinkerization) Due to High PH Fan Power due to High Pressure Drop Across PH Reference : CII Energy Benchmarking study carried out at JKLC in May,2018

10 KWH/ MT CLINKER Electrical Energy Consumption(Up to Clinkerization) JKLC U-I JKLC U-II JKLC U-III OVERALL JKLC COUNTRY BEST

11 Kcal/ Kcal Kg / CLINKER Kg of Clinker A Comparison Thermal Energy Consumption with Plants in same cluster (Kcal/Kg of Clinker) JKLC CII CLUSTER FIGURE A B C

12 KWH/ MT CEMENT A Comparison Electrical Energy Consumption with Plants in same cluster (Unit/ton cement ) JKLC A B C

13 Improving separator efficiency of Cement mill-1(0.3 Kwh/T cement) Road Map to achieve the National / International Benchmark Energy Benchmark study through CII-GBC, Hyderabad, May18. To Reduce Pressure drop From Mill O/L to Fan I/L In VRM(0.2Kwh/t of material) To reduce Pressure drop across Cyclone of VRM(1 Kwh/T material) Installation of Pre-Grinder in Cement Mills. To reduce pressure drop by 40 mmwc across down comer duct(0.5 Kwh/t of Clk) PH fan efficiency improvement by 5 %.(0.5 Kwh/t of Clk) Top cyclone efficiency improvement (3 kcal/kg clk)

14 Road Map to achieve the National / International Benchmark Energy saving Proposals based on Internal Audits (SGA/CFT/KAIZEN/Technical cell Replacement of AQC fan with high efficient fan. Installation of AQC boiler in Line-3 Reduce the pressure drop across Mill body in Raw mill-4 Replacement of conventional lights with Led(Ongoing). Installation of New Louver Ring in RM-2 in upcoming shut down

15 MTOE/ton product PAT (Performance, Achieve & Trade) PAT Performance Target Reduction 4.91% Achieved Reduction 14.82% Target Reduction 4.86% Base Line (On PPC)- PAT cycle-1 Target (On PPC)-PAT cyce-1 Achieved(On PPC) PAT cycle-1 Base Line(On OPC)- PAT Cycle-2 Target(On OPC) PAT cycle-2

16 Energy Conservation projects since 2015

17 Energy Efficiency Improvement Activities Last Three Years Project ( , , ) Sr. No. DESCRIPTION UNITS ZERO INVESTMENT WITH INVESTMENT A B C D TOTAL PROJECT IMPLEMENTED TOTAL ELECTRICAL ENERGY SAVINGS TOTAL THERMAL ENERGY SAVING TOTAL SAVING NO.S MILLION KWH MT OF COAL I ELECTRICAL RS MILLION II THERMAL RS MILLION E TOTAL SAVINGS RS MILLION F TOTAL INVESTMENT RS MILLION NIL *All savings calculation is on per annum basis

18 Major Energy Saving Projects Zero Investment ( ) S. No List of Major Energy Saving Projects ( ) Optimization of VRM by modification of Nozzle ring and optimization of mill bed height. (133 kw) Optimization of Coal Mill by grinding media and modification of intermediate diaphragm. (61 kw) Optimization of Kiln-3 Compressors Operation by reducing the operating pressure of Compressor. (15 kw) Modification in discharge circuit of Ball mill and TCDRI VRM. (6.88 kw) Annual Saving Rs. Million Elect. Thermal Invest. Made Rs. Millions

19 Major Energy Saving Projects Zero Investment ( ) S. No 05 List of Major Energy Saving Projects ( ) Replacement of 2 nos. of screw conveyors with chain conveyors. (8 kw) Annual Saving Rs. Million Invest. Made Elect. Thermal Rs. Millions Optimization of kiln operation. (16630 MT Coal Saving /Annum) Replacement of 18 KW Analyzer water pump with 5.5 KW water pump (8 kw)

20 Major Energy Saving Projects Zero Investment ( ) S. No List of Major Energy Saving Projects ( ) Optimization of Dam Ring Height in China VRM (70 mm to 56 mm) (110 kw ) Arresting of false air in pre-collector and replacement of expansion joint in china VRM (22 kw) Reduction in PH fan power consumption in Kiln-3 by arresting false air ingress (30 kw ) Remove 35 BE1 Bucket elevator in precrusher (Feeding belt discharge in vibrating screen instead of bucket elevator) (15 kw ) Annual Saving Rs. Million Invest. Made Elect. Thermal Rs. Millions

21 Major Energy Saving Projects Zero Investment ( ) S. No 12 List of Major Energy Saving Projects ( ) One air slide blower stopped in PH-1 VRM (To be remove from group and interlock air slide blower made it stand by for 2606 ) (7 kw) Annual Saving Rs. Million Invest. Made Elect. Thermal Rs. Millions

22 Major Energy Saving Projects Zero Investment ( ) S. No List of Major Energy Saving Projects ( ) Blended appron feeder and spillage conveyor removal from the circuit (5 KW) Reduced power consumption in 10FN-1 Dust collector Fan (18 KW) Reduce power consumption in Kiln-1 cooler fans through optimization (15 KW) Saved Power consumption by reducing the pressure drop across the dampers of Silo Top Bag Filter Fan in Kin-2 (9 KW) Reduced Power consumption in Kiln-1 CV Fan by removing the damper as fan always runs with VFD (10 KW) Optimization of cooling air in kiln-1 by cleaning of grate plates (46 KW) Annual Saving Rs. Million Invest. Made Elect. Thermal Rs. Millions

23 Major Energy Saving Projects Zero Investment ( ) S. No 19 List of Major Energy Saving Projects ( ) Removal of Bag filter fan from dry fly ash Circuit in CM-2 (9 KW) Annual Saving Rs. Million Invest. Made Elect. Thermal Rs. Millions False air Arresting in RM-4 (5 KW) Optimization of separator BH DP in CM-1, CM-3,CM-5,CM-6 (16 KW) Sphere slot of outlet diaphragm has been blocked in cement mill-1 (25 KW) Modification Of Cheek Plate in CM-2 HRC (10 KW)

24 S. No List of Major Energy Saving Projects ( ) Modification in Pre crusher Circuit by removal of Belt Conveyor 35-BC-3 (11 KW) Booster Fan Inlet Damper replaced by Distance Piece in coal mill-1(3 KW) Pre crusher dust collector fan damper Removal(35-FN-1 & 35-FN-2) (10 KW) Apron Feeder DC Drives replace with AC drives in RM-2 (3 KW) Reduction in Electrical & Heat Consumption by Optimizing the Coal Conveying Volume in Kiln- 1(18 KW & 1 Kcal/Kg Clk) Annual Saving Rs. Million Elect. Thermal Invest. Made Rs. Millions VFD Installation in Tippler Bag filter fan (9 KW) Major Energy Saving Projects Zero Investment ( ) Interconnection of RM-1 Compressor 36CP-3 with Raw Mill-4 Bag House Compressor 361CP- 1 (29 KW)

25 S. No Major Energy Saving Projects Zero Investment ( ) List of Major Energy Saving Projects ( ) Annual Saving Rs. Million Invest. Made Elect. Thermal Rs. Millions Reduce pressure drop across Bag House Fan 31 inlet damper in Raw Mill-4 (12 KW) Reduce power consumption of Kiln-2 32 andkiln-3 Blaster compressor by optimization of Blaster Operating freq. & compressor loading-unloading pressure (55 KW) Interconnection of Kiln-2 PH blaster compr 33 with Kiln-2 inlet seal compr (22 KW) Interconnection of Kiln-1 PH Blaster compr 34 with 3 nos. of other compr (KGG; Cooler Blaster & Chemical Lab) (25 KW) Optimization of CM-1,CM-3,CM-5,CM-6 Bag 35 house system (34 KW) CM-1 CA Fan I/L Damper Removal (22KW)

26 Major Energy Saving Projects With Investment Since Total Projects Implemented : 19 Total Electrical Energy Saving : 7.33 Million KWH Total Thermal Saving Total Savings in Rs : Electrical Thermal Total Savings Total Investment : 0 MT of Coal : Rs Million : Rs. 0 Million : Rs Million : Rs million *All savings calculation is on per annum Basis

27 Major Energy Saving Projects With Investment ( ) S. No List of Major Energy Saving Projects ( ) Installation of 02 Nos. of 75 KW VFD s in Pre Crusher Bag filter Fans. (10 kw) Installation of 650 KW SPRS in Fly Ash Drier Fan. (10 kw) Modification in 465 KW Kiln-2 CV Fan SPRS system. (42 kw ) Replacement of 50 Nos. CFL 15 W to LED lamp 7W in colony (0.17 kw ) Annual Saving Rs. Million Invest. Made Elect Thermal Rs. Millions

28 Major Energy Saving Projects With Investment ( ) S. No List of Major Energy Saving Projects ( ) Replacement of 27 Nos. 40W Tube lights to 20 nos. LED 7 in ADM Building (0.94 kw ) Installation of high efficient fan with VFD in cement mill-1 (60 kw) Re-Routing of dry fly ash transportation line. (60 kw) Kiln inlet riser duct modification in kiln-1 (60 kw) Modification of Raw Mill -2 by CFD of Cyclones and duct (60 kw) Annual Saving Rs. Million Invest. Made Elect Thermal Rs. Millions

29 Major Energy Saving Projects With Investment ( ) S. No List of Major Energy Saving Projects ( ) Modification of Raw Mill -3 by CFD of Cyclones and duct. (60 kw) Installation of IGBT based digital SPRS in place of thyrister based analolouge SPRS in raw mill-3 (50 kw) Installation of recirculation damper in CM-2 Stack (12 kw) 23 nos 150 watt HPSV street light lamp replace with 40 watt LED lamp. (2.5 kw) Annual Saving Rs. Million Invest. Made Elect Thermal Rs. Millions

30 Major Energy Saving Projects With Investment ( ) S. No List of Major Energy Saving Projects ( ) 735 nos. 36 watt fluroscent tube rod replace with 22 watt LED tube rod. (10.2 kw) 20 nos. 150watt HPSV street light lamp replace with 60 watt LED lamp. (1.8 kw) Annual Saving Rs. Million Invest. Made Elect Thermal Rs. Millions

31 Major Energy Saving Projects With Investment ( ) S. No List of Major Energy Saving Projects ( ) 417 Nos. Conventional HPSV Lights replaced with Energy Efficient LED lights (33 KW) Installation of HOT Air Recirculation in Kiln-2 to increase the Green Power Generation (Through WHRS) (9500 Units/Day) Installation of Active Harmonic Filter (AHF) for Power Factor improvement Installation of New Louver Ring in RM-3 (150 KW) Annual Saving Rs. Million Invest. Made Elect Thermal Rs. Millions

32 at JK Lakshmi Cement

33 Innovative Project-I Reduction in Raw mill fan power consumption by installation of aerofoil design louver ring in VRM-III Background: Pressure drop across Mill (892 mmwg) Probable reason : Non uniform distribution of air across louver ring Action taken : Thorough study and replacement of louver ring aerofoil louvers

34 Innovative Project-I Reduction in Raw mill fan power consumption by installation of aerofoil design louver ring in VRM-III This modification helped us to reduce pressure drop by 62 mmwg. Production Increased by 3 Tph. There is saving of 150 units/hour in Raw mill fan Power Savings in terms Power Consumption Total units saved : KWH/Year Total Savings : 5.98 Million/Annum (@5. 5Rs/Unit) Total Investment : 0.35 Million Payback Period : 1 Month

35 Innovative Project-II Installation of Hot Air Recirculation in Kiln-II to generate more green power Duct From CV Stack Entry At Fans Hot Air Recirculation in Fan Nos.6, 7 & 8. Commissioned in January,2018. Gross Power Generation Increased by 9500 Units/Day. Reduction in Green House gases Kg CO2/Day.

36 Particulars Innovative Project-II Benefit & Savings Increase in Power Generation from WHR System Units/Day KW 9500 Reduction in Green House Gases Kg of CO Cost Benefit Analysis Total units generated : KWH/Year Total Savings : Million/Annum (@5.5 Rs/Unit) Total Investment : 22.2 Million Payback Period : 15 Months

37 Innovative Project-III Reduction In Numbers of Hammers in Pre Crusher Background :Heavy Wear pattern of Hammers &(40%) of Hammers running Idle. :Total No. Of Hammers : 102 : To reduce Maintenance time Idea Generation: Study of the wear pattern Action Taken : Decision to eliminate alternate row of Hammers : Keeping 54 Hammers in line in combination first : Later on 51 Hammers in line with combination

38 Innovative Project-III Reduction In Numbers of Hammers in Pre Crusher Results : Vibration of Rotor Bearing reduced by 1 mm/sec. Power saving by 40 Kw at same output Maintenance period reduced from 3 days to 1 day Savings Power saving : 40 KW Annual Power Savings : 0.95 Million Rs Annual Mechanical maintenance saving : 3.45 Million Rs Total Savings : 4.4 Million Rs

39 Renewable Energy

40 Bio-Mass As A Renewable Energy Use of Bio Mass Such as Mustard, Moong, Mahendi, Soyabean husk, Sarason to replace some quantity of Coal used in PC firing of the kiln section. Benefits Conservation of natural Resources. Reduction in net CO2 emission in the atmosphere. Low Cost. Year Used Quantity (MT) ** Less due to Unavailability 704** 2223**

41 Utilization Of Waste Material as Fuel S No Fuel Used ( MT) ( MT) (MT) 1 Waste Mix Solid TDI Tar TPP Fly Ash De Oil Cake Pulp Waste RDF Fluff Total % TSR

42 Bio Mass Handling System

43 WHR Generation (Million KWH/Annum Co2 Reduction (Kg Co2/T Clk) Renewable Energy From WHRS and GHG Reduction JK LAKSHMI CEMENT, JAYKAYPURAM Co2 Reduction (Kg Co2/T Clk) WHR Generation Kg CO 2 / T Clk Reduction YEARS

44 Co2 Reduction (Kg Co2/T Cement GHG Inventorisation Kg Co2 / T Major Product

45 Solar Water Heater At Transit House BENEFITS Saving of units/ year CO2 emission reduction 40 Tonne/ Year

46 Solar Power Plant At Village Lumbaniya, District Jodhpur (RAJ.) Capacity-: 6.12 MW

47 Solar Power Plant At Jaykaypuram Colony Capacity- 232 KW

48 Green Supply Chain

49 Energy Management Policy (Integrated Management System)

50 Employee Association In Encon Activities CFT KAIZEN QUALITY CIRCLE TECH CELL SHOP FLOOR ENCON TEAM

51 Employee Association In ENCON Activities Suggestion Scheme Methodology Suggestion at Concerned Section review Committee review Suggestion Approval Feasibility Test Trail Successful Review Of Implemented Idea for benefits & Sustainability Documentation & Implementation of Suggestion Audit Team Confirmation Rewards, Recognition & Appreciation

52 Sustainability Daily, weekly& monthly monitoring & analysis of SEC. Online display of SEC in DCS Inter-firm comparison for SEC. Adoption of best practices. Attending task force meeting with BEE Internal & external audits. Regular training programmes. CFT, SGA, Kaizen, Quality circle

53 Energy Management Tool Feedback Decision Making Management Level Action Operator Decision Making Operations Level Action Decision Making Real Time Action Off Line Feedback On Line Data Real Time Information System Monitoring And Analysis Data Plant

54 Energy Management Team Plant Head WTD Departmental Heads Energy Manager (Process) Energy Manager (Electrical) Section In charge / CFT JKLC HAS DEDICATED ENERGY CELL WITHIN TECHNICAL SERVICES Plant Operator

55 Energy Monitoring Methodology Energy management cell with clear cut responsibilities. Daily monitoring of Energy Deviation report. Benchmarking National/International/group wise/cluster units. Regular study of equipments on deviation and their analysis. Process evaluation & identification of energy conservation scope. Feasibility study of suggestions and designing proposals for sanctions. Taking corrective and preventive measures and ensuring implementation. Organizing internal and external Energy Audit survey.

56 Certificate Observations Actions Taken OHSAS 18001:2007 ISO 9001:2015 ISO 14001:2015 Implementation of Integrated QEnHSE Management System External Audit Report: 1. White wash of Canteen may be considered. 2. Better housekeeping near Electrical Panels by removing unwanted items Monitoring of inter locking system may be recorded Energy Efficiency criteria in the procurement process is already implemented to be recorded properly. Implemented. The new record sheet made & system implemented. Doc No: DSP/07/F/16 Rev: th Oct 2017 Implemented Stage2 Note- There was no any non-conformity but observations for opportunity to improvement

57 Environment

58 Environment Greenery in Plant, Colony and nearby area

59 m 3 m 3 Cap Cap Rain Water Harvesting in Pond Environment Watershed Management in Mines Hills Surface and Roof Top Water Harvesting

60 KFP Patented Rain Water Harvesting Systems to augment ground water recharge.

61 Environment

62 SNCR System In All Three Kilns. 4NH 3 +4NO+O 2 4N 2 +6H 2 O NOX (mg/nm³)@ 10 % O2 < 800 NOX (mg/nm³)@ 10 % O2 < 1000

63

64 Safety Innovation Inauguration on 29 Th November 2017

65 65

66 Road Safety Week Safety Celebration National Safety Month Fire Service Week

67 Corporate Social Responsibility (CSR)

68 Corporate Social Responsibility (CSR) Swatch Bharat Mission Ek Abhiyaan Adopted Primary Health Centre

69 Corporate Social Responsibility (CSR) Literacy Projects Reward and recognition to academically bright children and talented sportspersons Free Medical Services to Nearby Villages Family Welfare Programs in Nearby Villages

70 Blood Donation Camp At Jaykaypuram

71 Rewards and Recognition One of Top 25 Most Innovative Companies

72 Rewards and Recognition CII Excellent Energy Efficient Unit Award & 2015 CII Excellent Energy Efficient Unit Award & Most Innovative Project Award

73 CII Energy Efficient Unit Award Rewards and Recognition CII ExcellenceEnergy Efficient Unit Award National award for energy efficiency in cement industry ( )

74 Energy Concervation Award By State Rewards and Recognition Energy Consevation Award by BEE National award for excellence in energy management 2010-energy efficient unit Best Energy Efficient Practice Exhibitioner- 1st Prize

75 Rewards and Recognition International Safety Award from British Safety Council London FAME-Excellence Award 2016 Best Innovative CSR Project GOLD AWARD"

76 Thanks 76