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2nd ‘National Workshop cum Technology Exhibition for Promoting Energy Efficient

and Cleaner Production for Sustainable Industrial Growth’

Mr. Sukhwinder Singh(Sr.Eng, Inst.)

Mr. Manish Vijay (Dy. Manager, Pro.)

Mr. Devraj Sharma (Asst.Manager, Mech.)

Mr. Manoj Ubana (Asst.Manager, ELe.)

Brief Introduction of JKLCL – Sirohi, Rajasthan

ISO 9001 ISO 14001 OHSAS 18001 ISO 50001 2

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Sirohi Clinker Capacity 4.85 MnMT

TOWARDS UPGRADATION

Capacity - 4.75 Mn MT

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OPC 53 OPC 43 PPC

RMC AAC BLOCK POP

PRODUCTS PRO+

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SMALL GROUP ACTIVITY (SGA) PROGRAM FOR CONTINUOUS IMPROVEMENT”

under KEP-SPARC Membership Model

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S.No. Group Name No. Of Members No. Of Implemented Projects-

1 Grind Boosters 04 05

2 Lakshya 05 07

3 S.P.A.R.K ian 06 04

4 Urja Sarnkashak Boosters 07 05

5 JEET 07 04

6 Search 04 02

7 Warriors 06 06

Total 39 33

Benefits S.No. Particulars Units Year Wise

1. Total Energy Saving Achieved

a) Thermal Saving Mt of Pet-coke 205

b) Electrical Saving Million KWH 3.61 ( 498 Unit/Hr)

2. Monetary Gain Million INR 18

3. Investment

Million INR 3.5

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Project1: Reduction in Specific Power of VRM

Observation:

• Pressure Drop across Mill was 892 mmwg.

• Pressure Drop across Nozzle Ring 677 mmwg.

• Pressure Drop across Classifier 215 mmwg.

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Background: Specific Power Consumption of VRM was 14.2 Kwh/Mt.

Project1: Reduction in Specific Power of VRM

Benefits:

1. Pressure Drop across mill has been reduced by 62 mmwg.

2. Mill fan power has been reduced by 158 Kw.

3. Mill specific Power has been reduced by 0.54 Unit/Mt.

4. Mill reject elevator power has been reduced by 50%.

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Project Implementation: Installation of Aerofoil Design Louver Ring and Armour Ring.

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Project 2: Reduction in Specific Heat Consumption of Kiln

Observation:

Studied of coal to air velocity.

Velocity of Conveying Air.

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Background: Electrical and Thermal Energy Saving by Optmization of Coal Conveying Volume

Project 2: Reduction in Specific Heat Consumption of Kiln

Benefits:

1.Coal Conveying Volume reduced by 12%.

2. Coal Conveying Blower Power has been reduced by 19 kW.

3. Heat Consumption has been reduced by 1 Kcal/Kg.clk.

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Project Implementation: Installation of VFD in Blower Increased the coal to air ratio by optimizing the speed of Blower .

Project 3: Reduction in Power Consumption of Compressors

Background:

Compressed air distribution system is a major potential area in any Cement plant to reduced the power consumption

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S/N Compressor Tag no. Air requirement Loading % Unloading % Motor Rated KW Measured KW by

Analyzer

KILN-1 COMPRESSORS

1 4CP3 (1600 m3/hr.) Pre heater Blaster 65% 35% 150 KW 73

2 5CP3 (500 m3/hr.) Cooler Blaster 58% 42% 55 KW 40

3 5FCP (300 m3/hr.) LAB 31% 69% 37 KW 9

4 4CP4 (150 m3/hr.) Girth Gear 48% 52% 15 KW 10

KILN-2 COMPRESSORS

1 6415 (1800 m3/hr) Pre heater Blaster 62% 38% 180 KW 103

2 4125 (600 m3/hr) Kiln inlet seal 42% 58% 75 KW 39

TCDRI MILL COMPRESSORS

1 361 CP1 Bag House (1800 m3/hr) 17% 83% 160 53

2 36CP3 Raw Mill Bag House

(600 m3/hr.) 0 0 75 0

Observation:

Project 3: Reduction in Power Consumption of Compressors

Project 3: Reduction in Power Consumption of Compressors

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S/N Compressor Tag

no. Air requirement

(Kiln-1) Loading % Unloading % Motor Rated KW

Measured KW by

Analyzer

KILN-1 COMPRESSORS

1 4CP3 Pre heater Blaster 82% 18% 150 KW 97.51

2 5CP3 Cooler Blaster 0% 0% 55 KW 0

3 5FCP LAB 0% 0% 37 KW 0

4 4CP4 Girth Gear 0% 0% 15 KW 0

KILN-2 COMPRESORS

1 6415 Pre heater Blaster 74% 26% 180 KW 120

2 4125 Kiln inlet seal 0% 0% 75 KW 0

TCDRI MILL COMPRESSORS

1 360CP1 Bag House 0 0 160 0

2 36CP3 Raw Mill Bag House 39 61 75 24

Implementation:

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Compressor-4

Compressor-1

Compressor-3 Compressor-2

Project Implementation:

1. Interconnection of the Kiln-1 Pre Heater blaster compressors air line with the air line of 3 other compressors.

2. Interconnection of the Kiln-2 Pre Heater blaster compressor air line with air line of inlet seal compressor.

3. Interconnection of the Raw Mill-4 Bag house–compressors air line with air line of Hybrid Bag house Compressor.

Benefits:

1. Power saving achieved in Kiln-1= 34 kW

2. Power saving achieved in Kin-2= 22 kW

3. Power Saving achieved in Raw Mill-4= 29 kW

Total Saving= 85 kW

Project 3: Reduction in Power Consumption of Compressors

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Project 4: Reduction in power consumption of blaster compressor through optimizing operating Frequency and Unloading Pressure

Background:

The most expensive component in the total cost of compressor air is energy. In efforts

to explore the energy saving opportunity in Blaster compressor of PH-1 and PH-2, an

innovative idea came into mind that we can reduced power consumption of blaster

compressors through optimization of blaster operating frequency and compressor

unloading pressure.

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Project 4: Reduction in power consumption of blaster compressor through optimizing operating Frequency and Unloading Pressure

Kiln-2 Observations: S.NO. CYCLONE NOS OF

BLASTER

EXISTING OPERATING

FREQ / HR

MODIFIED OPERATING

FREQ / HR

REDUCTION IN

FREQ / HR

1 New Cyclone-2 04 16.5 16.5 NONE

2 New Cyclone-3 05 75 60 15

3 Old Cyclone-3 04 110 40 70

4 New Cyclone-4 05 140 140 NONE

5 Old Cyclone-4 05 72 50 22

6 New Cyclone-5 04 40 40 NONE

7 Old Cyclone-5 03 42 30 12

8 New Cyclone-6 06 60 60 NONE

9 Old Cyclone-6 03 42 30 12

10 Riser Duct 19 68 29 39

11 PC Drop out 07 22.5 22.5 NONE

12 Swan Duct 05 18 10 8

13 PH fan inlet 01 60 12 48

Total 71 766 540 226

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Project 4: Reduction in power consumption of blaster compressor through optimizing operating Frequency and Unloading Pressure

Kiln-3 Observations: S.NO. CYCLONE NOS OF

BLASTER

EXISTING OPERATING

FREQ / HR

MODIFIED OPERATING

FREQ / HR

REDUCTION IN

FREQ / HR

1 New Cyclone-2 04 15 15 NONE

2 New Cyclone-3 04 40 40 NONE

3 Old Cyclone-3 04 40 40 NONE

4 New Cyclone-4 07 381 140 241

5 Old Cyclone-4 04 80 40 40

6 New Cyclone-5 05 50 50 NONE

7 Old Cyclone-5 02 20 20 NONE

8 New Cyclone-6 10 150 150 NONE

9 Old Cyclone-6 09 81 81 NONE

10 Riser Duct 23 79 79 NONE

11 PC Drop out 07 76 12 64

12 Swan Duct 04 8 8 NONE

13 PH fan inlet 01 12 12 NONE

Total 84 1032 687 345

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Project Implementation: • Optimization Of Blaster Operating Frequency. • Optimization of Compressor Unloading Pressure from 7kg/cm2 to

6.5 kg/cm2.

Benefits: • Power saving in KILN-2 Blaster compressor 25 Kw. • Power saving in KILN-3 Blaster compressor 30 kw.

Project 4: Reduction in power consumption of blaster compressor through optimizing operating Frequency and Unloading Pressure

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Project 5: Reduction in Power Consumption of Air Conditioner

Background: Air Conditioner is one of the largest energy consumer in industrial sector. By anticipation the scope of power saving in Air Conditioner , we carried out a study on CCR building centralized Air Conditioner

Observation: Day hours (7.00 AM to 8 .00 PM) power consumption was 1400 kWh Night hours (8.00 PM to 7 .00 AM) power consumption was 1200 kWh

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CCR Centralized Air Conditioner Flow Diagram of First Floor

AC Comp. 37 KW

AHU Ground Floor 11KW

Chemical LAB ground Floor

Inst LAB

Drawing Office 1 st. Floor

ground floor LAB

SR. GM (Mech.) Off. Area

1 st. Floor

Inst LM Room + SR. GM ( Elect.)

AC Duct

Timer Panel

VFD

Project 5: Reduction in Power Consumption of Air Conditioner

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Project Implementation: • Installation of Damper in AC Duct • Control of damper through Timer circuit • Installation of VFD in AHU

Benefits: Power saving =26 kW

Project 5: Reduction in Power Consumption of Air Conditioner

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Total SGA Group Formed

Total Members in 7 Groups

Total Projects Identified

Project Implemented

Electrical Energy Saving Target

Electrical Energy Saving Achieved

Thermal Energy saving Target

Thermal Energy Saving Achieved

Investment Made (in INR)

Monetary Gain per Annum (in INR)

7 39 40 33 617 kW 498 kW (81 % of Target)

1 kCal/kg of Clinker

1 kCal/kg of Clinker (100 % of

Target)

35 Lacs 180 Lacs

Small Group Activities Outcome……

Intangible Benefits:- Increased interpersonal relations between CFT Confidence enhancement Increased motivation of teams Increased team working

This is not end of the journey, This is the beginning of new model

manishvijay@lc.jkmail.com

manojubana@lc.jkmail.com

drsharma@lc.jkmail.com

@lc.jkmail.com 23

Thanks