Dalmia Cement (Bharat) Limited, Kadapa 18 th National Award for Excellence in Energy Management - 2017
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 4 th Largest Cement Manufacturing Capacity in the Country ISO 50001:2011
Current Plan & Actions Enhancement of Alternative Fuel Feeding Development of Renewable Power, WHRS FY 2017 Liquid Alternative Fuel Raw Mill Cyclone CFD & Modification Kiln Burner Pipe Retrofit FY 2016 Raw Mill Fan Impeller Replaced. Cooler Efficiency Improvement FY 2015 21% TSR of Alternative Fuel RABH & Cem M Fan Impeller Replaced Cum. Energy Saving : 36.2 Million U/Annum FY 2014 - EnMS 50001: 2011 Certified Cum. Energy Saving : 34 Million U/Annum Alternative Fuel Feeding Enhancement FY 2013 Expert Optimizer for Plant Energy Efficient Operation Commissioning Stage Developed Best Practices on Energy Front 100% Process Fans without Dampers Energy Saving by Efficient Eqpt. & Energy Savers: 10.5 Million U/Annum Plant Ordering Stage Took Initiative for Energy Efficient Equipments Selected 1. All Motors are Energy Efficient Series 2. More than 60% Motors are considered with VFD for Energy Efficiency
Description Unit Without Investment With Investment Total Total No. of Projects No. 32 49 81 Electrical Energy Saving / Annum Fuel Energy Saving / Annum Total Cost Saving / Annum (Elect + Thermal) Lakhs Units Million Kcal Rs. Lakhs 16.49 84.08 100.57 3160 20072 23232 135.93 984.44 1120.37
No Investment Elect Energy Saving Title of Project Installed VFD for Flyash Compressor (By Reviewing of all VFDs and Operating Parameters and Diverted the VFD from Optimized Equipment) Operation of Cement Silo Exhaust Fan as per Occupancy Sensor Command and DCS Time Delay Packing Plant Bag Filter Fans Operation Interlocked and Auto Speed Reduction with Packer Rotation and Spout Discharges Modification in VRM Classifier and Reduction of Seal Gap to improve the Performance Stopping of CRD Motors in the Stackers and Reclaimers during Unwinding. Improved the Loading Factor of Coal and Additive Stacking Group by detailed Study Improved Operation Efficiency of Cooler Tower Fan by replaced 1500RPM to 1000 RPM motor and Diversion of Heat Exchanged Warm Water to Water Spray Annual Electrical Saving (kwh) Annual Elect. Cost Saving (Rs Lakhs) 45000 2.70 57500 3.45 109500 0.66 145000 8.70 30000 1.80 2700 1.60 70000 4.20
No Investment Thermal Energy Saving Title of Project Operation of Cooler Fans (1 to 4) with 106% Speed and Improved the Heat Recuperation at the Current Improved Production Rate TAD Inlet Joint Modificiation and Achieved Reduction of False Air 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 Reduction of False Air from 5.0% to 4.4% by PH Outlet Expansion Joint Inhouse Modification Replaced the Flap Valve with Double Rotary Air Lock for the Alternative Fuel Feeding System Increased SF Cooler Stroke Length and Reduced Clinker Bed Height. Reduction of Heat Consumption 1 Kcal / Kg Clinker Annual Thermal Saving (Ton/Year) Annual Thermal Saving (Rs Lakhs) 250 27 30 3.20 310 32.55 10.00 1.05 15.00 1.575 250 27
Electrical Energy Saving Title of Project Operation of Blending Silo Exhaust Fan through VFD (Auto Speed Increase by Occupansy Sensor) Cement Mill Grinding Specific Power Reduction by Reducing the Size of Performance Improver Crusher Installed Additional Hydraulic Pump for Rollers Lifting Time Reduction during Mill Tripping and Reduction of Restarting Time Converted the Coal & Additive Unloading Group Operation from DCS to Local Control Station and Reduced the Change over time & Idle Power LED Lighting Project (Well Glass, Street Lights, Tube Lights, CFL & Building Lights...) Annual Elect. Saving (kwh) Annual Electrical Cost Saving (Rs Lakhs) Invest. (Rs Lakhs) 21000 1.26 0.50 450000 27.00 25.00 16800 1.01 0.70 30000 1.80 0.75 111690 6.72 10.49
Electrical Energy Saving Title of Project Annual Elect. Saving (kwh) Annual Electrical Cost Saving (Rs Lakhs) Invest. (Rs Lakhs) Stopped Centralized ACs during Plant Stoppages and Installed Portable / Split ACs at CCR, Robo Lab, Server Room and QC Labs. Cement Silo Extraction Blowers Operation Through VFD for Speed Reduction as per Bin Level Installed Day Light with Turbo Ventilator at Stores and Workshop Building and Stopped the Lighting & Exhaust Fans 56000 3.36 3.00 11200 6.72 4.00 23000 1.40 2.50
Title of Project Kiln Burner Pipe Retrofit by Conveying Pipe Size Reduction, Turbojet Blower and Swirl Air Fan with New Design Burner Relocated Higher KW Cooler Fans at Heat Recuperation Zone & Recovered More Heat VFD for Kiln Coal Blower and reduced the Primary Air Volume Installed Liquid AFR Pumping System and Consumed Pharma Waste and Liquid Solvents Thermal Energy Saving Annual Thermal Saving (Ton/Year) Annual Thermal Saving (Rs Lakhs) Invest. (Rs Lakhs) 470 50.70 11 439 47.4 1.5 423 45.7 0.4 500 54 100
45 35 25 15 5 Million Units Saving / Annum (Cumulative) Better 10.5 16.5 20.8 23.6 34 36.2 36.5 41.3 85 80 75 70 Units / Ton of Cement 82.64 77.11 75.88 74.87 Better 73.91 74.1 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17
50.5 52.2 51.7 50.9 55.3 54.3 785 765 745 725 705 685 781 Kcal / Kg Clinker 760 710 704 Better 701 701 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 57 55 53 51 49 47 KWH/Ton of Clinker Better 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 KWH/Ton of Clinker Thermal SEC without Kiln Start Stop : 685 Kcal / Kg Clinker (Benchmarking Thermal SEC)
Kwh/Ton of Cement (PPC) 69 67 65 63 66.3 63.4 63.03 63.10 62.50 62.61 NB (67) INB (65) 61 60.00 59 57 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 Target NB National Benchmark INB International Benchmark
LS Secondary Crusher (Red. 1.30 U/T) Waste Heat Recovery Sys. (Red. 23 U/T) LP Compressor for Flyash (Red. 0.25 U/T) Target 42 U/T of Cement Increase of PPC Sales (Reduction of 7 U/T) HAG for Cement Mill (Reduction of 0.5 U/T) Present 74.1 U/T of Cement
Target 661 Kcal/Kg of Clinker Clinker Cooler Upgradation (Red. of 15 Kcal) Kiln I/L Seal with Graphite (Red. of 4 Kcal) Burnability Impr. by Minerlizers (Red. of 5 Kcal) Present 685 Kcal / Kg of Clinker
Project Title : IP-1 : Raw Mill Cyclone Exit Ducts Pressure Drop Reduction by CFD Study Objective: 1. To Reduce the Pressure Drop across the Cyclone and Ducts 2. To Maximize the Air Flow to increase Mill Production 3. To Reduce the Specific Power Consumption for the Mill Fan Action Taken: 1. Conducted CFD Study on the Existing Cyclones and Ducts to understand the Velocity Profile & Abnormal Pressure Drops 2. Observed Pressure Drop is 150 mmwg and having Potential bring upto 100 mmwg 3. Prepared New Duct Design for the Cyclone Exit Duct to achieve Lowest Pressure Drop as per the Results from CFD
Project : IP-1
Project : IP-1 Parameters UOM Before After % Improvement Pressure Drop mmwg 150 100 33 % Air Flow M 3 /Hr. 790,000 810,000 2.5 % Fan Power KW 2950 2850 3.5 % Fan Sp. Power KWH/T 7.28 6.95 4.5 % Mill Production TPH 405 410 1.23 %
Project Title Objective: 1. To Improve Cement Mill Productivity : IP-2 : Improving CM Productivity by Extending Nozzle Ring at Bottom by 20 mm 2. To Optimize Air Flow and Velocity at the Nozzle Ring Exit 3. To Improve the Dispersion Time of the Fine Grouded Material 4. To Reduce the Specific Power Consumption of Cement Mill Action Taken: 1. Studied the Inlet Entry Velocity Profile, Reject Rate, Power Consumption and Productivity 2. Carried out Sieve Analysis on the Reject Material and Observed more Fines in the Reject. 3. Concluded, More Fine Material entraping into the Reject through Nozzle Ring 4. Hence, Increased the Nozzle Ring towards Bottom side by 20mm to improve the Dispersion Time and to Reduce the Entraping of Fine Material.
Project : IP-2 Parameters UOM Before After % Improvement Sieve Analysis % on 500 μ 5% 2% 60 % Production TPH 290 295 1.7 % Sp. Power U/T 29.1 28.6 1.7 %
Project Title Objective: : IP-3 : Reduction of Kiln Specific Power by Increasing SF Cooler Cylinder Stroke Length 1. To Decrease the Sp. Power by Increasing Kiln Production 2. To Increase the Heat Recuperation Efficiency 3. To Decrease the SF Hydraulic Strokes and Power Consumption 4. To Minimize DPC Spillages and Breakdowns Action Taken: 1. Studied on Clinker Transport Efficiency, Cooler Strokes, Cooler Heat Recuperation and Clinker Bed Height 2. Observed Scope in Improving Clinker Transport Efficiency, Hence Cooler Stroke Lengths Increased (150 to 170 mm) and No. of Strokes per Minute Decreased (From 20 to 10) 3. Hence, Cooler Clinker Bed Height decreased from 880 to 700 mmwg and Heat Recuperation Improved 4. Debottleneck for Clinker Production and Improved the Productivity, Hence Sp. Power Reduced from 19.5 to 19.2 U/T of Clinker
Project : IP-3 Action Taken: 5. Cooler Hydraulic Pumps Power Consumption decreased from 40KW to 35KW (Each Pump), Hence achieved Power Saving of 20 KW/Hour in total 4 Pumps 6. Clinker Variation in the DPC Reduced and minimized the DPC Overflow Issues and related Kiln Stoppages. Parameters UOM Before After % Improvement Kiln Sp. Power U/T 19.5 19.2 1.5 % Production TPH 6350 6450 1.6 % Strokes / Minute No. 20 10 50 % Stroke Length mm 150 170 13.3 % Clinker Bed Height mmwg 880 700 20 %
Water Rain Water Harvesting and Use 150% Water Positive Energy Energy Conservation Projects Non- Conventiona l Energy Solar Power & Wind Power Dry Fog System & Stack Emissions Control Environment Recycling of Floor Spills & Reuse of Waste Mass Tree Plantation on Every Occasions Plantation Department wise ownership Vermi-compost & Use of Bicycles Formation of pond & Rain water Community harvesting
Year 2012-13 (Baseline Year) Scope 1 emissions CO 2 e (MT) Carbon Foot Print Activities Scope 2 emissions CO 2 e (MT) Scope 3 emissions CO 2 e (MT) kg CO 2 e/mt of Cement Mitigation Total Reduction in emission intensity since baseline year study CO 2 e (MT) 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 - Process Electricity Transport Overall 6% Reduction from Base Line Description No. of Programs Man Days Total Hours Training on Energy Conservation 12 44 355
Zero Plastic Rain Water Harvesting (150% Water Positive) Birthday & Wedding Day Plantations Energy Conservation Campaign In Plant To Associates
15000 16000 9500 23500 24000 40000 56000 79500 103500 113000 120000 100000 80000 Green Development in the Plant & Colony No. of Plants 60000 40000 20000 0 Upto 2012-13 2013-14 2014-15 2015-16 2016-17 No. of Plantations for the Year No. of Plantations in Cumulative
Battery Operated Vehicle E-Rickshaw for Employees Battery Operated Cars for Employees & Guests Internal Movement Rain Water Harvesting & Created Green Nature in Plant
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) Energy Policy EA 18327 EA 15097 EA 18891 EA 17555 EM 18832 EA 19674
Online SEC Monitoring by CCR Operator and taking Immediate action during increase in SEC Indication