Presentation for 18 th National Award For Excellence in Energy Management-2017 1
COMPANY PROFILE Mangalam Cement Limited belongs to B.K.Birla Group of Companies. Our first Plant was commissioned in the year 1981, with an installed capacity of 4 lacs tons of cement per annum. Present capacity of cement production is 3.25 MTPA. 2
COMPANY PROFILE UNIT-I UNIT-II UNIT-III CPP WIND MILL CRUSHER TO PACKING PLANT FLS, KILN 3000 TPD WITH SIX STAGE PREHEATER, INLINE CALCINER,SF 12X33 CROSS BAR COOLER, ATOX VCM and ATOX VRM. CRUSHER TO PACKING PLANT THYSSENKRIPP, KILN 4000 TPD WITH 5 STAGE PREHEATER, INLINE CALCINER, REPOL SR 312-IKN GRATE COOLER,VCM and VRM NEW CEMENT GRINDING UNIT & PACKING PLANT THYSSENKRUPP, CEMENT MILL 1.25 MTPA 2 X17.5 MW 13 Nos WIND MILLS OF 13.65 MW CAP. INSTALLED AT JAISALMER (RAJ.) ABL, CEMENT MILL WITH VRPM AS PREGRINDER IN CLOSED CKT, LNV SEPARATOR, CAPACITY 0.8 MTPA. THYSSENPRUPP ROLLER PRESS, CEMENT MILL WITH ROLL PRESS IN CLOSED CKT. CAPACITY 1.2 MTPA THYSSENKRUPP ROLLER PRESS, CEMENT MILL WITH ROLL PRESS IN CLOSED CKT. CAPACITY 1.25 MTPA 3
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S.No. Year Description of measures Saving in TOE FY 01 2015-16 Implementation of auto start/stop software logic in both compressor. 02 2015-16 Implementation of software logic in both bag filter fan (G581FN1 & G581FN3) for auto stop of bag filter fan. 03 2015-16 Logic made in PLC for auto start / stop of heater. 04 2015-16 Changed loading pressure setting from 6 bar to 5.5 bar and unloading pressure setting from 7 bar to 6.5 bar of all 4 compressors of MGU packing plant. 26.43 19.51 5.34 97.56 6
S.No. Year Description of measures Saving in TOE FY 05 2015-16 After optimisation of lighting system 44 Nos 400 watt light fittings were removed from different towers. 06 2015-16 Bag house discharge material taken directly to final air slide via direct chute. 07 2015-16 Bag filter fan inlet damper controlled & tuned from CCR with fan current to save the power of fan. 20.73 12.57 21.94 08 2015-16 Electrical consumption reduced by controlling ESP field current as per dust emission through stack. 29.52 7
S.No. Year Description of measures Saving in TOE FY 09 2016-17 Sealed false air from 37.0 % to 23.3 % in Coal Mill-I, resulted in power saving of power Coal Mill Fan. 23.54 10 2016-17 Sealed false air from 56% to 42.5 % in Coal Mill-II, resulted in power saving of Coal Mill Fan. 32.51 12 2016-17 Sealed false air from 28.0 % to 14.2 % in VRM-I Circuit, resulted in power saving of VRM Fan. 67.46 13 2016-17 Improved Power Factor in Kiln-II PCC Incomer 6.6 KV from 0.85 to 0.95. 8.69 8
S.No. Year Description of measures Saving in TOE Investment in lacs 01 2014-15 Kiln-II: Duplex Graphite Lemmela Seal Installation in place of Pneumatic Seal to reduce false air entry. 450 13.20 02 2014-15 CM-II: Installation of DD Cones in all the four Sepol Cyclones to reduce pressure drop and replacement of double flap valves by RALs to reduce false air ingress. 03 2014-15 Replacement of push feeder by sector gate in Cement Mill-2. 04 2014-15 Removal of two belt conveyors from LS feeding circuit of VRM-1 by providing direct chute to hopper. 37 7.11 9.87 5.00 35.62 0.50 9
S.No. Year Description of measures Saving in TOE 05 2014-15 Installation of de dusting cones (DD cones ) in LNVT separator of VRPM and both the cyclones of SEPOL separators in Cement Mill-1. 06 2014-15 Installation of de dusting (DD) cone in dynamic separator of VRM -1. 07 2015-16 08 2015-16 Made a Dam of height 800 mm in TAD to restrict Tertiary Air flow rate and to reduce excess air in secondary firing from 20 % to 10 %. Removed Silencers from all the cooler fans to reduce the pressure drop ranging from 60-150mmWG in all cooler fans of KILN-1. 58.92 Investment in lacs 2.20 92.79 1.75 102.21 5.00 141.14 0.05 10
S.No. Year Description of measures Saving in TOE Investment in lacs 09 2015-16 10 2015-16 11 2015-16 Filler material feeding arrangement by PS pump in place of dense phase. Enlargement of Cooler Exhaust Duct Area from 4.91 m2 to 9.62 m2 to reduce dust loading in ESP KILN-2. Enlargement of Preheater Down comer Duct from 5.72 m2 to 10.00 m2 IN KILN-2. 105.26 1.00 12.45 1.20 168.41 23.35 12 2015-16 Increase of Calciner Length from 48.0 meter to 64.0 meter IN KILN-2. 194.63 66.12 11
S.No. Year Description of measures Saving in TOE Investment in lacs 13 2015-16 14 2015-16 Increase in cross section area of Tertiary Air Duct (TAD) from 1.61 m2 to 3.36 m2 in KILN-2. 1550.27 42.55 Enlargement of Smoke Chamber Area from 4.74 m2 to 6.51 m2 in KILN-2. 62.33 4.09 15 2015-16 Increase of Inlet Duct Area of Bottom Cyclone from 9.92 m2 to 13.03 m2 in KILN-2. 16 2015-16 Enlargement of Take off Duct Area from 5.58 m2 to 8.20 m2 in KILN-2. 37.98 5.00 19.21 9.15 12
S.No. Year Description of measures Saving in TOE FY Investment in lacs 17 2015-16 18 2015-16 19 2015-16 20 2015-16 Replacement of Kiln Inlet Seal from Pneumatic Seal to Graphite Seal in KILN-1. Replacement of belt conveyor 501BC3 & fixing of DPC of 150TPH in KILN-1. Through modification of discharge chute of 903BC5 lime stone fed in hopper directly without running of 961BC1 and 961BC2 belts in KILN- 1. Installation of auto delta to star starter in G501BC6 & BC7 conveyor belts drives. 165.31 5.00 77.05 44.60 50.73 7.78 9.76 0.01 13
S.No. Year Description of measures Saving in TOE FY 21 2016-17 Reducing the preheater exit oxygen from the level of 7% to 4% for Kiln-I by restricting excess air flow through TAD. Reduced the pressure drop through 22 2016-17 modification in the separator fan inlet duct of Cement Mill-3. 23 2016-17 Installed VFD for 975BL1 (132kw) root blower in KILN-1. 24 2016-17 Installed VFD for 212FN2 (75kw) BF fan in crusher section. 25 2016-17 Replacement of chain type elevator 150 TPH by belt bucket elevator of 250 TPH in KILN-1. Investment in lacs 301.95 10.00 58.52 20.00 21.28 8.00 22.04 5.00 85.12 30.00 14
88 85.61 kwh/ton of cement 83 82.55 * 80.74 78 78.23 78.27 75.44 74.73 73 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 * Unit-I, Plant shutdown for Rehabilitation work 15
880 869 860 THERMAL SEC (GCV BASED) 840 KILN-I 798 800 COMBINED 781 803 773 760 720 680 755 748 760 765 764 738 739 KILN-II 731 720 716 709 699 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 16
National Benchmark International Benchmark Mangalam Cement Limited Specific Energy Consumption Thermal (Kcal/kg of clinker) (GCV BASED ) 680 650 KILN-I 699 KLIN-II 738 COMBINED 720 Specific Energy Consumption Electrical kwh/t of cement (Actual) (100% PPC) 68 65 66.55 (ON PPC ONLY) (YEAR 2016-17) 17
12.00% 10.00% 8.00% 6.00% 4.00% % OF WIND MILL POWER IN TOTAL POWER CONSUMPTION OF PLANT 6.20% 8.30% 11.50% 10.20% 7.60% LOW DUE TO CABLE THEFT PROBLEM 8.90% 8.56% 9.32% 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 Wind Power for Captive Use 2016-17 = 163.6 Lacs Units So Saving in Mkcal = 53194.54 Mkcal Saving in TOE = 5319.45 TOE 18
35.00% FLY ASH CONSUMPTION IN % 30.00% 25.00% 26.05% 27.47% 31.11% 30.57% 31.08% 20.00% 15.00% 10.00% 15.35% 2007-10 2012-13 2013-14 2014-15 2015-16 2016-17 19
REDUCTION CO 2 EMISSION Kg/Kg PPC CEMENT CO 2 Reduction in ton CO 2 0.58 0.56 0.54 0.52 0.50 0.48 REDUCTION DUE TO HIGHER CONSUMPTION OF FLY ASH IN PPC WITH REFERENCE TO 2011-12 0.5600 18004 0.5500 33551 66421 0.5064 Highest ever PPC Production 78055 0.4973 Less reduction due to less PPC Production. 0.4962 15495 90000 80000 70000 60000 50000 40000 30000 20000 10000 0.46 2012-13 2013-14 2014-15 2015-16 2016-17 0 CO2 Reduction in Tonne CO2 Emission, Kg/Kg Cement 20
20.00% 18.00% 16.00% 14.00% 12.00% 10.00% 8.00% 6.00% 16.90% 100% INDIAN COAL USED PETCOKE CONSUMPTION IN % OF CLINKER PRODUCTION 18.10% 100% INDIAN COAL USED 12.50% 57% PETCOKE & 43 % INDIAN COAL USED 10.20% 10.50% 9.50% 9.56% 9.33% 100% PETCOKE USED 85 % PETCOKE & 15 % INDIAN COAL USED 100% PETCOKE USED 100% PETCOKE USED 96.4% PETCOKE, 1.4 % INDIAN COAL & 2.2 % US COAL USED 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 21
19.00% 17.00% BY USING PETCOKE REDUCTION IN % HGLS CONSUMPTION 17.01% 15.00% 13.00% 16.14% 13.45% 11.00% 9.00% 10.80% 10.22% 9.40% 7.95% 9.02% 7.00% 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 22
SR. NO MEASURES TAKEN FOR CO 2 REDUCTION 1. DUE TO REDUCTION IN SPECIFIC HEAT AND POWER CONSUMPTION OF CLINKER W.R.T. YEAR 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 4123 14798 49101 48202 59003 2. DUE TO HIGHER USE OF FLY ASH IN PPC PRODUCTION W.R.T. YEAR 2011-12 3. DUE TO USE OF GREEN POWER (WIND MILL POWER FOR CAPTIVE USE) 18004 33551 66421 78055 15495 20367 13960 20477 17524 19638 TOTAL 42494 62309 135999 143781 94136 23
SR.N O MEASURES TAKEN FOR CO 2 REDUCTION 2015-16 2016-17 1. BY NOT USING VEHICLES ON EVERY MONDAY WHILE COMING TO OFFICE 2. BY REDUCING SP HEAT RATE IN CPP 2.477 2.821 27155 37677 TOTAL 27157 37680 24
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GREEN BELT DEVELOPMENT (PLANT, COLONY & MINES) 35000 30000 25000 20000 15000 10000 5000 0 30047 11715 10432 11486 8926 10063 2831 2011 2012 2013 2014 2015 2016 2017(JAN-JULY) GREEN BET DEVELOPMENT -YEAR WISE TOTAL PLANTATION 243967 (1991 TO July 2017) 27
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MANGALAM CEMENT LIMITED REVIEW STATUS OF DEPARTMENTAL OBJECTIVES (Frequency - Monthly) FORMAT NO. : F02-4460 UNIT : DEPT : REV : No : VER : No : Date : Obj No. Objective Baseline Status Desired Status Final Target MONTHWISE STATUS 2015-16 2016-17 Date APR-16 TO MAR-17 YTD Prepared By Approved By : Checked By 30
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Sr. No 1 2 ENCON EFFORTS PLANNED FOR THE NEXT THREE YEARS Description of projects Installation of WHR in KILN I & II of 8.5 MW & expected generation (net) is 545 lacs units /year. Upgradation of KILN II by modifying preheater from 5 stage to 6 stage and upgradation of cooler 3 Modification in UNIT -II CEMENT MILL V- separator material feeding system for increase in output & reduction in specific power consumption Investment Rs Rs 63 CRORES RS 15 CRORES Expected saving Thermal energy saving 17493 TOE 40 kcal/kg of clinker 20.16 LACS 8.88 LACS KWH 4 Modification in lime stone feeding system of VRM -I 10 LACS 3.15 LACS KWH 5 Reduction in plant lighting consumption by using of high efficient led lights in place of conventional lights. 23.3 LACS 10.10 LACS KWH 34
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National Safety Award (Mines) 2011 ON LOWEST INJURY FREQUENCY RATE in the category of Highly Mechanized Opencast Mines was given by the President of India in association with Minister of Labour & Employment (Government of India) at Vigyan Bhawan- New Delhi. 36
CFBP (Council of Fair Business Practices) Jamanalal Bajaj Uchit Vyavahar Puraskar for Fair Business Practices in Manufacturing Enterprises SME category for the year 2014 was received from Hon ble Former President of India late Dr. A.P.J. Abdul Kalam. 37
Rajasthan Energy Conservation award - 2014 Was given by Honorable Energy Minister of Rajasthan. 38
National Award For Excellence in Energy Management - 2015 from CII This National award is given in recognition of Excellence in Energy management in cement sector by CII. Award was given by chairman Bureau of Energy Efficiency (BEE) Dr.Ajay Mathur on 3rd September 2015 at Hyderabad. 39
Productivity Award 2013-2014 from Rajasthan State Productivity Council. This award is given in recognition of Improvement in Productivity Performance by Rajasthan State Productivity council. Award was given by Honorable Minister for Industries Govt. of Rajasthan Shri Gajendra Singh on 30th September-2015. 40
Energy Conservation Merit award 2015 from Rajasthan State Government. This award is given in recognition of Energy Conservation in Cement Sector by Govt. of Rajasthan. Award was given by Energy Secretary of Rajasthan state Govt. Shri Sanjay Malhotra on 14th December-2015. 41
National Energy Conservation Merit Award 2015 by Ministry of Power Government of India. This award is given in recognition of Energy Conservation for Cement Sector. Award was given by chairman Bureau of Energy Efficiency (BEE) Dr.Ajay Mathur on 22nd January 2016. 42
Award for outstanding Performance in Rural Development by Employer Association of Rajasthan for the Year 2014-15. This award is given in recognition for outstanding Performance in rural development work by Employer Association of Rajasthan. Award was given by Honorable Minister for Higher Education Shri Kalicharan Sarraf on 25th Feb 2016 at Jaipur. 43
26th MINES ENVIRONMENT & MINERAL CONSERVATION AWARDS 2015-16 (Under the aegis of Indian Bureau of Mines, Ajmer Region) I st prize in the field of TOP SOIL MANAGEMENT. 44
26th MINES ENVIRONMENT & MINERAL CONSERVATION AWARDS 2015-16 (Under the aegis of Indian Bureau of Mines, Ajmer Region) II nd prize in the field of AFFORESTATION. 45
Rajasthan Energy Conservation Award 2016 I st prize in Large Cement Sector of Rajasthan. This award is given in recognition of Energy Conservation in Cement Sector by Govt of Rajasthan. Award was given by Energy Secretary of Rajasthan state Govt Shri Sanjay Malhotra on 14th December-2016. 46
Star Award Sustainable Development by Ministry of Mines, Govt. of India at National Mineral Conclave -2016 Four Star Award to Morak Limestone Mines of M/s Mangalam Cement Ltd. for Sustainable Development by Ministry of Mines, Govt. of India at National Mineral Conclave -2016 at Raipur 47
Award for outstanding Performance in Rural Development by Employer Association of Rajasthan for the Year 2016-2017 This award is given in recognition for outstanding Performance in rural development work by Employer Association of Rajasthan. Award was given by Honorable State Finance Minister Shri Arjun Ram Meghwal. 48
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Thank You All 51