Post on 06-Feb-2018
An Energy & Environment Conscious, Sustainable & Prosperous Organization
Shree Cement Ltd. Beawar, INDIA
National Award for Excellence in Energy Management 2009
Presented by Sanjay Singh
An Energy & Environment Conscious, Sustainable & Prosperous Organization
Presentation Sequence
Shree Cement Profile
Cement Manufacturing Process
Energy Performance
Energy Saving Projects
Innovative Projects: case studies
Energy Management Practices in SCL
Climate Security
Recognitions
An Energy & Environment Conscious, Sustainable & Prosperous Organization
Shree Cement Profile
Among the Top Five Cement Groups in India.
Operating at Beawar, Ras, Khushkhera, Suratgarh & Roorkee.
Largest Cement Player of North India.Entered into Merchant power business.One of the Highest Operating Profit Margins.Turnover- US$ 773 Million
An Energy & Environment Conscious, Sustainable & Prosperous Organization
Rising Trend in Cement capacityShree Cement Profile
An Energy & Environment Conscious, Sustainable & Prosperous Organization
Rising Trend in Power generationShree Cement Profile
Shree Power Gen Capacity (MW)
An Energy & Environment Conscious, Sustainable & Prosperous Organization
Vision & Guiding PrinciplesShree Cement Profile
“To drive and sustain industry leadership of the company within aglobal context- by developing individual leadership competencies at every level, through a robust back bone of Trust, Support, Innovation and Reward.”
Vision
Guiding PrinciplesEnforce good corporate governance practices
Encourage integrity of conduct
Ensure clarity and unambiguity in communication
Remain accountable to all stakeholders
Encourage socially responsible behavior
An Energy & Environment Conscious, Sustainable & Prosperous Organization
Management Systems
ISO-14001 – Environmental Management System
OHSAS-18001 – Occupational Health & Safety
SA- 8000 – Social Accountability
ISO-9001 Quality Management
BS-EN 16001 – Energy Management System
Shree Cement Profile
MANAGEMENT SYSTEMS
An Energy & Environment Conscious, Sustainable & Prosperous Organization
SHREE ULTRA
BANGUR CEMENT
ROCK STRONG
Marketing Strategy Shree Cement Profile
Market Leader in Rajasthan, Delhi and Haryana
Convey social messages along with brand building such as ‘Save Water’, ‘Blood donation’, ‘Swatantarta keRakshak’ etc.
An Energy & Environment Conscious, Sustainable & Prosperous Organization
First Indian Cement Company to join Cement Sustainability Initiative of WBCSD.
Global Reporting Initiative to improve information sharing on Environment and Social issues.
Endorsed the Global Roundtable Joint Statement on Climate Change to discuss issues for shaping public policy on climate change..
Shree Cement ProfileGlobal Partnership
Member of Cement Sector Task Force of APP-7, formed by Govts. of India, USA, China, Japan, Korea, Canada and Australia.
An Energy & Environment Conscious, Sustainable & Prosperous Organization
Appointed Leader of Cement Sector Task Force for the 7th
consecutive year by Bureau of Energy Efficiency, Ministry of Power, Government of India.
One of the lowest Power & Fuel Consumption in the industry.
Shree remains the benchmark for other companies in terms of overall energy efficiency.
Recognized R&D Centre by Govt. of India
Shree Cement ProfileAchievements
Highest 4 star rating for 9th consecutive year by Whitehopleman U.K.
An Energy & Environment Conscious, Sustainable & Prosperous Organization
Plant in India to develop process for production of synthetic gypsum.
Cement company of the World to receive 4.5 LacsCertified Emission Reductions (CER’s) on its Clean Development Mechanism project “Optimal Utilisation of Clinker”.
Company in the World to utilize 100% petcoke in its operations.
Shree Cement ProfilePioneer Activities
Indian cement company to issue Corporate Sustainability Report according to GRI guidelines.
Clinkerisation Unit (U-VII) of 1 MTPA capacity commissioned in record time of 367 days .
An Energy & Environment Conscious, Sustainable & Prosperous Organization 12
Cement Manufacturing Process
PackingWagon & trucks
Cement silo Roller press cum Cement mill
Cement Millhopper
Clinker stock yard
KilnPreheater
Raw millsilo
Raw mill Raw mill hopper Reclaimer
StackerMines
An Energy & Environment Conscious, Sustainable & Prosperous Organization
Annual Comparison of Power Consumption
Annual comparison of Thermal Consumption
Energy PerformanceDecreasing Trends & Targets
2009-10 NCBM Avg. Benchmark
84
An Energy & Environment Conscious, Sustainable & Prosperous Organization
AverageShree
Cement Best
Aux
Packing
Cement Grinding
Kiln
Raw Materials Grinding
Total
0.00
20.00
40.00
60.00
80.00
100.00
120.00
kwh/t
Power Consumption
The graph shows Shree power consumption is well below the average
BenchmarkingEnergy Performance
An Energy & Environment Conscious, Sustainable & Prosperous Organization
Energy Saving ProjectsImplemented during 2007-08 & 08-09
An Energy & Environment Conscious, Sustainable & Prosperous Organization
SN
Title of Project Annual Electrical Savings Investments Rs. Million
Units Million Million Rs.
1. Installation of SPRS in Raw Mill Fan 0.48 2.92 6.8
2. Installation of SPRS in (SKS) Fan0.12 0.72 2.4
3. Implementation of Slip Power Recovery System in Raw mill ESP fan 0.43 2.59 2.5
4. Installation of VFD in damper controlled Cooler fan (4Nos) 0.36 2.16 1.94
5. Replacement of Cooler ESP fan HT Motor with LT motor and VFD 0.45 2.7 2.0
6. Increase the stack Height of Cooler ESP Fan 0.12 0.72 0.2
Energy Saving ProjectsImplemented during 2009-10
An Energy & Environment Conscious, Sustainable & Prosperous Organization
Innovative Projects - Case Study - I
Installation of flame analysis system from Powitech for reduction of fuel consumption in Kiln
Before the installation of Powitech system = 741 kcal/kg.cl
Annual Saving in Coal consumption = 2460 MT
After the installation of Powitech system = 720 kcal/kg.cl
Annual saving in Rs = 19.7 million
Cost involved in this project = 20 million
Simple pay back = 12.17 months
Reduction of CO2 Emission = 8019.6Ton / Annum* As per clinker production for 2008-09
An Energy & Environment Conscious, Sustainable & Prosperous Organization
Increase the stack Height of Cooler ESP Fan by 7.8 meters
Before the increase of stack height After the increase of stack height
Fan Efficiency* measured before
= 35.33%
Fan Efficiency measured after
= 57.53%
Saving in Power Consumption of ESP fan = 16kWh
*Reduction of CO2 Emission = 108 Ton / Annum
* As per clinker production for 2008-09
Innovative Projects - Case Study - II
An Energy & Environment Conscious, Sustainable & Prosperous Organization
Innovative Projects - Case Study - III
Waste Heat Recovery at Six Stage Preheater – A Milestone
Flue gases are released from preheater andCooler. WHR installed for the recovery ofthe waste heat from exit gases.
Barriers:vLow heat content in gases that exit from 6 stage PHvHigh Dust ContentvHigh cost of installation
Solution:vSpecific design of boiler in view of high dust load
and low enthalpy in waste gasesvHammering system
8 MW WHR resulted in 349916 tons/ annum CO2 emission reductions
An Energy & Environment Conscious, Sustainable & Prosperous Organization
Pre-
Heater (PH
)
Air Quenched Cooler (AQC)
GCT
KilnESP
Kiln Feed
Coal Mill
Clinker from Kiln
Hot Gas to Kiln
Hot Gas to TAD
Pre-heated Kiln feed Hot
gas
Clinker
Pre-heater Exit gases
(300ºC)
Exit gases(150ºC)
Fuel
Exit gases
Innovative Projects - Case Study – III cont.
Pre-Heater
(PH)
Air Quenched Cooler (AQC)
GCT
Kiln
ESP
Kiln Feed
Coal Mill
Clinker from Kiln
Hot Gas to Kiln
Hot Gas to TAD
Raw mill and Vented out
Pre-heated Kiln feed
Hot gas
Vented out
Clinker
AQC Boiler
PH Boiler
HP, LP header & Flusher Turbine
Pre heater
Exit gas (300ºC)
Pre heater Exit gas (300ºC)
Exit gas (150ºC)
AQC gas (400ºC)
Air
Air
An Energy & Environment Conscious, Sustainable & Prosperous Organization
SR.V P (Works)
Energy Monitoring CELL Headed by Energy Manager Engineer Utilities
(Steam, Power & Water)
Energy Audit Benchmarking Contact Process Equipment Supplier
Energy MonitoringMeasure Identification& Implementation
Investment & Return Analysis
Idea Generation Activities Small Group Activities
Chemical Engineer
Electrical EngineerPower Utilization
Managers(Process & Engg)
UnitsHead
Energy Management Practices in SCL Monitoring and Reporting System
An Energy & Environment Conscious, Sustainable & Prosperous Organization
To communicate ideas
To bring all the members into the mainstream
To encourage active participation
To tap into the latent potential of employees, reduce costs, increase productivity and ultimately, profits.
Idea Generation Activities Energy Management Practices in SCL
Implementation of Suggestion Scheme Measures adopted in SCL
“Jo Soche Who Paave”
Employees to think like leaders by providing them a platform
Resulted in
An Energy & Environment Conscious, Sustainable & Prosperous Organization
Identification of Energy conservation areas in the plant.
Prioritization of identified energy conservation areas.
Finding out of technical feasibility including, market availability and cost benefit analysis.
Renewable energy identification
Benefits :Implementation of Energy Monitoring
Plan and energy analysis thereby optimizing energy consumption.
Benefits through cost reduction.
Adoption of BS-EN 16001
Development Without Destruction
Commitment for Climate Security
An Energy & Environment Conscious, Sustainable & Prosperous Organization
Initiatives for Carbon Emission ReductionCommitment for Climate Security
S.N Title of project implemented Year of Implementation
Total CO2 Reduction
1 Optimal utilization of clinker by using fly ash in cement 2001-02
293818(Project completed
in July-2010)
2 *Waste heat recovery from Preheater & Cooler for power generation 2008-09 51051
3 **Utilization of Biomass fuels for Pyro processing in Cement plant 2006-07 33232
*Project is under validation for CDM. **Registered at UNFCC
An Energy & Environment Conscious, Sustainable & Prosperous Organization
CO2 Reduction as per CSI Protocol
When We Put the Environment First, Development Will Last
Commitment for Climate Security
An Energy & Environment Conscious, Sustainable & Prosperous Organization
“Use of 100% Petcoke, a waste from Oil Refineries, thereby conserving Fossil Fuels.
Maximized use of slag, a waste from smelting plant, thereby conserving iron ore.
Developing new environment friendly alternative raw materials & conserving natural resources.
Optimal Utilization of ResourcesCommitment for Climate Security
An Energy & Environment Conscious, Sustainable & Prosperous Organization
Alternatives Percentage
46 MW Green Power Plant (WHR based) 49.5 % of total power used
Fly ash 30 – 32 % replacement of clinker
Petcoke 100 % replacement of coal
Slag from Smelter 2.4 % of Raw Material
Use of AlternativesCommitment for Climate Security
An Energy & Environment Conscious, Sustainable & Prosperous Organization
Cultivation of micro algae for 5% replacement of petcoke.
Installation of 50 MW Solar Power Plant.
LED and Solar power for lighting.
Installation of Flue Gas Desulphurization Unit at Power Plant.
Adoption of Powitech Process Optimization with Intelligent Technologies.
Development of system design for use of pond fly ash.
Futuristic Approach to Mitigate CO2 Emissions
Our Earth - Our Future - Just Save It
Commitment for Climate Security
An Energy & Environment Conscious, Sustainable & Prosperous Organization
Recognitions
µFirst prize for Energy Conservation by Bureau of Energy Efficiency.
µFICCI SEDF Corporate Social Responsibility Award.
µ CII Sustainability Award
µQuality Excellence Award –By NCCBM
µGolden Peacock Award for Climate Security
µExcellent Water Efficient Unit –Awarded by CII
An Energy & Environment Conscious, Sustainable & Prosperous Organization
µEnergy Efficiency Award -Awarded by CII
µGreen Business Award by Emergent Venture India & Financial Express
µNational Award for Excellence in Cost Management
µ Energy Conservation Award by Bureau of Energy Efficiency.
Recognitions
An Energy & Environment Conscious, Sustainable & Prosperous Organization
May our earth with all its beauty produce a harvest of PEACE and PROSPERITY
- Rigveda
Thank you
Visit us at: www.shreecementltd.com