2 ND National Conclave On Recent Advances In Cement Industries Energy Excellence J K LAKSHMI CEMENT, SIROHI, RAJASTHAN

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1 Presented By : Kanish Kr. Singh 2 ND National Conclave On Recent Advances In Cement Industries Energy Excellence J K LAKSHMI CEMENT, SIROHI, RAJASTHAN

2 Brief Introduction of JKLCL Sirohi, Rajasthan ISO 9001 ISO OHSAS ISO 50001

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

4 (Integrated Management System)

5 Energy Conservation Team in JKLC CFT KAIZEN QUALITY CIRCLE TECH CELL SHOP FLOOR ENCON TEAM

6 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

7 Energy Performance Since to 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 % % *** *** SEC up to clinker reduced for energy saving in SPRS, VRM & more PPC production

8 Energy Performance Since to PARAMETER UOM CHANGE OVER PREVIOUS YEAR(%) SP. Energy Consumption MTOE/Ton Major MTOE/Ton Of Major Product Product Specific Electrical Energy Consumption Up to Cement Kwh /T Cement Specific Electrical Energy Consumption Up to Kwh /T Clk Clinkerization Specific Electrical Energy Consumption For Cement Grinding Kwh /T Cement Specific Thermal Energy Consumption Kcal/Kg Clk CPP Heat Rate Kcal/ Kwh Auxiliary Consumption % TSR % Clinker Factor Blended Cement Of Total Cement % Renewable Energy (RPO) Lakh Kwh REC Purchased -Solar NA NA

9 Kcal/ Kg Clk. Thermal Energy Consumption (Kcal/Kg Clinker) Intr.Benchmark National Benchmark

10 KWH/ MT CEMENT Electrical Energy Consumption(Unit/ton cement ) Intr.Benchmark National Benchmark

11 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

12 KWH/ MT CLINKER Electrical Energy Consumption(For Clinkerization)

13 KWH/ MT CLINKER Electrical Energy Consumption(Up to Clinkerization)

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

15 Energy Conservation projects since 2015

16 Energy Conservation Activities ( ) 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 28.9 *All savings calculation is on per annum basis

17 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

18 Major Energy Saving Projects Zero Investment ( ) S. No 7 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)

19 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)

20 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 19 inlet damper in Raw Mill-4 (12 KW) Reduce power consumption of Kiln-2 20 andkiln-3 Blaster compressor by optimization of Blaster Operating freq. & compressor loading-unloading pressure (55 KW) Interconnection of Kiln-2 PH blaster compr 21 with Kiln-2 inlet seal compr (22 KW) Interconnection of Kiln-1 PH Blaster compr 22 with 3 nos. of other compr (KGG; Cooler Blaster & Chemical Lab) (25 KW) Optimization of CM-1,CM-3,CM-5,CM-6 Bag 23 house system (34 KW) CM-1 CA Fan I/L Damper Removal (22KW)

21 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

22 at JK Lakshmi Cement

23 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 with aerofoil louvers

24 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

25 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.

26 Particulars 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

27 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

28 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

29 Innovative Projects Under Implementation Installation of Aerofoil designed Louver ring in Kiln-II VRM. To reduce pressure drop by 40 mmwc across down comer duct PH fan efficiency improvement by 5 %. Improving separator efficiency of Cement mill-1 Reduce the pressure drop across Mill body in Raw mill-4

30 Renewable Energy

31 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**

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

33 Bio Mass Handling System

34 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

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

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

37 Solar Power Plant At Village Lumbaniya, District Jodhpur Capacity-: 6.12 MW

38 Solar Power Plant At Jaykaypuram Colony Capacity- 232 KW

39 Environment

40 Greenery in Plant, Colony and nearby area

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

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

43 Environment

44 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

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46 Safety Innovation Inauguration on 29 Th November 2017

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

49 Corporate Social Responsibility (CSR)

50 Swatch Bharat Mission Ek Abhiyaan Adopted Primary Health Centre

51 Literacy Projects Reward and recognition to academically bright children and talented sportspersons Free Medical Services to Nearby Villages Family Welfare Programs in Nearby Villages

52 Blood Donation Camp At Jaykaypuram

53 Rewards and Recognition One of Top 25 Most Innovative Companies

54 CII Excellent Energy Efficient Unit Award & 2015 CII Excellent Energy Efficient Unit Award & Most Innovative Project Award

55 CII Energy Efficient Unit Award CII ExcellenceEnergy Efficient Unit Award National award for energy efficiency in cement industry ( )

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

57 International Safety Award from British Safety Council London FAME-Excellence Award 2016 Best Innovative CSR Project GOLD AWARD"

58 Thanks 58