Dalmia Cement (Bharat) Limited, Kadapa 1 st Workshop on Energy Efficiency in Cement Sector 23 rd June 2015
Presented by :Mr. P. Kamalanathan Manager Electrical p.kamalanathan@dalmiacement.com Dalmia Cement (Bharat) Ltd., Kadapa (A.P.) Save Energy - Save Money - Save the Planet.
Founded in 1935 by Shri Jaidayal Dalmia. The Group interests includes Cement, Sugar, Power and Refractory. The Group established India s first Cement Plant with 250 TPD in 1939. Put up Cement Plants in Tamil Nadu and Andhra Pradesh. Kadapa Unit Commissioned during Dec 2008 with a Capacity of 2.5MTPA Cement. Holds a stake of 75 % in OCL India Ltd., OCL total cement capacity 14.3 million tones.
Acquired 50% Stake in Calcom Cement India Limited (2.1 MTPA) at Assam Acquired Adhunik Cements (1.5 MTPA) in Meghalaya, Established a green field unit at Belgaum. Overall Cement Manufacturing Capacity 23 MTPA. OPC 53 OPC 43 PPC SRPC
We are committed to produce cement of required Quality & Quantity, by Continuous Improvement on Energy Performances through effective implementation of Energy Management System, also by Effective utilization of available Energy resourcesby Optimization and alternates. Enhancing the Energy efficiency, Reduction in Energy Wastage Strive to be a bench marking organization in the Cement Industry. Abide to all the applicable legal requirements and other requirements Anil Bajaj Executive Director
Current Plan & Actions Enhancement of Alternative Fuel Feeding Development of Renewable Power EnMS 50001 Alternative Fuel Feeding Enhancement upto 50% on Quantity 3 rd Year Operation Stage Improved Energy Saving : 43.88 Lakhs Units/Annum 2 nd Year Operation Stage Improved the Equipt Perfor. Energy Saving : 114.77 Lakhs Units/Annum 1 st Year Operation Stage Optimized Startup Time, Idle Run Solar Heaters & Solar Lights at Mines Energy Saving by Case Studies : 11.5 Lakhs Units/Annum Commissioning Stage Developed EMS Software in Plant Automation Energy Saving by Efficient Eqpt. & Energy Savers: 85.5 Lakhs U/Annum Plant Execution Stage Considered Energy Saving Equipments Plant Ordering Stage Took Initiative for Energy Efficient Equipments
Sl. No. Best Practices Advantages 1 2 3 4 Display of Online Specific Power Immediate action by CCR Consumption of Individual Sections in Operator during any deviation the Plant DCS from the Nominal Sp. Power Idle Power Report Generation in DCS from the Input Signals of Mill Critical For Analysis to reduce the Idle Drive Run Feedback and KW Loading Power of the Drives Energy abnormality Observation Rounds by Energy Management Team Operating the Plant with the Benchmarking False Air Level of 7.3% Identification of Energy Loss and Elimination Reduction in Specific Power & Fuel Consumption
Sl. No. 5 Best Practices Inhouse Study Conducted and Interlinked the Bag Filter Suction lines and Energy Savings achieved on the Bag Filters Advantages Energy Savings on Nuisance Bag Filters 6 7 Installed Bag Counters and Packer Bags Discharge Interlock with the Bag Counters VRM Classifier Seal Gap Reduction by Inhouse Modification using the waste Belt Materials Elimination of Bag Burstage, Reduction of Packing Plant Sp. Power Quality Improvement
Sl. No. 8 9 10 Best Practices Removed the MFR from the SF Cooler and improved the Heat Recuperation Inhouse Study Conducted on the Process Fans, replaced the Impellers of Cement Mill Fan and Bag House Fan to improve the Efficiency Inhouse Study Conducted on the Process Fans, Carriedout the Tipping of Raw Mill Fan to improve the Efficiency and SPRS Recovery Power. Advantages Reduction in Specific Fuel Consumption Energy Savings on Process Fans Energy Savings on Process Fans
Objective: Action Taken: To Replace 100% of the Fuel for Calciner by Alternative Fuel 1. Explored availability of Alternative Fuel and Identified the following i. Carbon Black ii. Spent Carbon iii. FCE Concentrate iv. Agro Waste v. Polimer Waste
Action Taken: 2. Developed Vendors 3. Receiving the Alternative Fuel (Carbon Black) in following forms a. 35 Kg Bags b. Jumbo Bags 600 Kg c. Bulk Tankers 4. Developed In-House Design for Handling the Carbon Black
Action Taken: a. Installed Fixed Tanker with Mechanised Unloading System
Action Taken: b. Installed Bag Slitting Machine by In-house design to feed the 35Kg Carbon Black Bags
Action Taken: c. Made arrangements to unload the Carbon through Bulk Tanker
Alternative Fuel TSR in % 25 21.62 20 15 10 5 2.01 4.88 0 2012-13 2013-14 2014-15
Overall Units / Ton of Carbon Black 33.2 35 30 25 20 15 10 5 0 With Compressor 11 With Blower
Results: Carbon block feeding at a rate of 14 T/Hr. Utilization of waste rubber carbon as alternative fuels. Utilization of available resources for carbon feeding without spending extra cost for equipment. Reduced Consumption of natural resources like Coal/Coke. Reduced impact on environment as compared with manual feeding. Reduced Power consumption comparatively feeding through mill from truck tippler.
Savings: Saved Unloading & feeding time. The Overall Improved Capacity of Carbon Black Feeding is at the rate of 14.0 T/Hr directly to PC. (Started with 0.125 to 0.187 T/Hr by manual feeding). Savings Rs. 78,41,310 /Month of Carbon Black. Savings Rs. 9,40,95,720/- per annum @ rate of 100 Tons/Day. Reduction in usage of pet coke
Problem Faced : Accumulation of Lime Stone at Mill Inlet Air Duct Gradual Reduction of Raw Mill Productivity Increase in Specific Power Consumption due to reduction in Productivity Uneven Wear Rate in the VRM Internals
Route Cause Identified : Horizontal Inlet Duct for the VRM (OEM Design) Lime Stone Spillage due to Centrifugal Force from the Table Dropping Height of Feed Material (Lime Stone) on the Table from the Centre Chute Fabricate and Install a Discharge Chute at Inlet Duct with Manual Gate (Modifying the OEM Design) and Diverted to the Reject Belt Conveyor To Extend the Centre Feed Chute for reducing the Height / Dropping Force of Raw Material on the Table (Modifying the OEM Design)
Extended 300mm
Discharge Chute - 2 Discharge Chute - 1
410 400 Productivity (TPH) 406 389 Better 300 Mill Inlet Draft (mmwg) 260 390 380 200 130 Better 370 100 Before After Before After 18 17 16 Sp. Power Consumption (Units/Ton of Matl.) 17.7 Before 16.79 After Better
Raw Mill TPH Vs Power 17.78 375 17.4 389 17.98 381 17.7 388 406 16.79 411 16.36 18.5 18 17.5 17 16.5 16 15.5 Guaranteed/ Design -350 TPH Guaranteed-19.90 Units
1. Mill Productivity Increased 18 TPH (388TPH to 406TPH) 2. Improved Specific Energy Consumption (Reduction of 0.91 Units/Ton of Lime Stone Grinding). a. Units Saving = 17.29 Lakhs Units/Annum. b. Power Cost Saving = Rs. 89.91 Lakhs/Annum (at 19 Lakh Ton of Lime Stone Grinding / Annum) 3. Mill DP remains Constant and average Mill Draught Reduced from 260mmwg to 130mmwg. 4. Uniform Air Velocity Distribution (Reduced Abnormal Wear Rate) 5. Eliminated the Man Power Requirement / Manual Cleaning & Avoided the Requirement of Tractor for handling the Cleaned Material
1. Horizontal Implementation at our Group Units and got the better results. 2. Can be Deployed in all the Vertical Roller Mills having Horizontal Inlet Duct 3. Communicated to the OEM (Pfeiffer) about the Modifications. OEM Representative appreciated the Modified Design 4. OEM Engineer informed that the modification method will be communicated to their Design Department
Before Dilution Air Duct : Mill Outlet Temperature : 90 to 95 deg C Hot Air Temperature : 260 to 270 deg C Temperature with Hot Air & Recirculation Air : 150 deg C Fresh Air Damper Position : 30% Open
Effects : Higher Recirculation Air Density Variation Higher False Air Water Consumption of 4.5 Cub. M / Hr. Higher Reject Rate 180 to 200 TPH
Action Taken : Installed Dilution Air Duct from RABH Fan Outlet to Raw Mill Inlet Duct.
Action Taken : Connected to Raw Mill Inlet Duct. Raw Mill Inlet Duct Dilution Air Duct from RABH Fan Outlet
Results : RABH Fan Outlet Air Temperature is 90 deg C, which is connected to Raw Mill Inlet Duct Raw Mill Circulation Air Temperature is 90 deg C, hence no variation in the Density 30000 Cub. M of Air taken from RABH Fan Outlet Closed the Fresh Air Damper 100% Water Spray reduced from 4.5 Cub M / Hr. to 3.0 Cub. M / Hr. Mill Productivity Improved 8 Tons per Hr. Specific Power Consumption Reduced by 0.32 U/T of Material
5 4.5 4 3.5 3 2.5 2 Water Consumption in Cub. M / Hr. 4.5 Better 3 Before After 412 410 408 406 404 402 Productivity (TPH) 411 406 Before After Better Water Consumption in Cub. M / Hr. Productivity (TPH) 16.9 16.8 16.7 16.6 16.5 16.4 16.3 16.2 16.1 Specific Power 16.79 16.36 Before After Specific Power Better
Way Forward : As per Estimation, 3.5 M Dia of Dilution Air Duct required for the Raw Mill Inlet Duct Installed 1.2 M Dia of Dilution Air Duct (Old Available) on Trial Basis. Planned & Work in Progress to upgrade the DA Duct to 3.5 M Dia Expected Results : Further Scope to Improve 8 TPH on Raw Mill Scope to Reduce Sp. Power of 0.2 U/T of Material
Raw Mill TPH Vs Power 17.78 375 17.4 389 17.98 381 17.7 388 406 16.79 411 16.36 18.5 18 17.5 17 16.5 16 15.5 Guaranteed/ Design -350 TPH Guaranteed-19.90 Units
THANK YOU P. Kamalanathan (Manager Electrical) Mobile : 9989625095 Mail : p.kamalanathan@dalmiacement.com