18th National Award for Excellence in Energy Management 2017

Presented By:-Calcom Cement India Limited,Umrongso , AssamSubsidiary of Dalmia Cement (Bharat) Limited.

Major Plant Specification: -Installed Clinker Capacity : 3400 TPD Highest clinker Production Achieved : 4177 TPD1st Clinker Production : Apr’15

2004 Established by Other Group

2012

Taken over by Dalmia Cement Bharat Limited

2015

Plant Commissioned

2010Lanka Grinding

Unit Commissioned

1935 Group Founded by Shri Jaidayal

Dalmia.

Company Profile

Our Existence• Assam• Meghalaya• West Bengal• Bihar• Orissa• Tamil Nadu• Karnataka• Andhra Pradesh

Our Core values : - Integrity , Trust , Respect ,Humility and Commitment.

811

743

FY16 FY17

SHC , Kcal/Kg

Key Highlights :-

0.62

0.98

FY16 FY17

Clinker Production in MTPA

66

56

FY16 FY17

SPC , KWH/T

259327

FY 15-16 FY16-17

Kiln Running Days

Plant Process Flow:-

LS CrusherCap : 700 TPH

Stacker Reclaimer

LS HopperCap : 425 T

Additive HopperCap : 150 T

Raw MillCap : 285 TPH

Raw Meal SiloCap : 4800 MT

KilnCap : 3400 TPD

Clinker SiloCap : 15000 MT

250 TPH Cap 4 Nos. Loading Station

Coal MillCap : 25 TPH

Coal HopperCap : 100 MT

Coal & Additive

Yard

811

743707

681711 710

FY16 FY17 National Benchmark Global Benchmark Best Achieved Our Target

SHC in Kcal/Kg Clinker

Our Presence in Benchmark:-

6656

49 45 50.3 49

FY16 FY17 National Benchmark Global Benchmark Best Achieved Our Target

SPC in KWH/T Clinker

National Benchmark –CII and CMA Energy Benchmarking for Cement Industry Manual May 2015

International Benchmark -http://ietd.iipnetwork.org/content/cement#benchmarks

Project with “Nil Capital Investments” for SPC reduction.

Sl. No Description Saving (KW)Annual

Saving (KW)Annual Saving

(Lakhs)

1Replacement of Bulk loading Clinker hopper feeding belt with Y diverter chute.

6.87 45,342 2.27

2 Modification of PH fan inlet Y piece and removal of damper 25.00 198,000 9.90

3Replacement of additive hopper feeding belt with Y diverter chute.

11.00 65,340 3.27

4Modification of bag filter Duct for common usages for Kiln feed BE boot venting and Surge bin venting.

7.50 59,400 2.97

5Modification of interconnecting pipes of Silo Areation for usages of one blower instead of two.

11.00 87,120 4.36

6Interconnection of Surge bin & Mixing bin blowers pipe line for usages of 37KW motor (blower) in stead of 45KW (Blower)

8.00 63,360 3.17

Project with “Nil Capital Investments” for SPC reduction.

Sl. No DescriptionSaving (KW)

Annual Saving (KW)

Annual Saving (Lakhs)

7Cooling tower temp sensor (RTD) installed to reduce running hour during winter season.

18.50 146,520 7.33

8Modification of cooling water distribution pipes for common usages in raw mill water spray.

11.00 65,340 3.27

9 Modification of water pipeline & reduced running of one pump. 18.50 122,100 6.11

10Clinker breaker shaft cooling air fan interlocked with bearing temperature.

11.00 87,120 4.36

11 Delta to Star Connection for underloaded motors. 21.27 125,315 6.3

Total 150 10,64,957 53

Sl. No

DescriptionSaving (KW)

Annual Saving (KW)

Annual Saving (Lakhs)

Investment (Lakhs)

ROI (Months)

1Modification of RM fan inlet box/Y piece & removal of fan inlet damper by installing GRR.

29 193,050 10 13.8 17

2 Installation of VFD at Kiln Firing Blowers. 25 198,000 10 4.0 5

3 Installation of VFD at PC Firing Blowers. 14 110,880 6 4.0 9

4 Installation of VFD at PA fan. 22 174,240 9 2.4 3

5 Installation of VFD at RA fan of RABH. 24 190,080 10 2.4 3

Project with “Investments” for SPC reduction.

Sl. No

DescriptionSaving (KW)

Annual Saving (KW)

Annual Saving (Lakhs)

Investment (Lakhs)

ROI (Months)

6 Modification of RM dam ring heightener 745 4,916,764 246 3.5 0.2

7 Installation of VFD at Bag filter Fans. 67 353,760 18 18.2 12

8 Installation of VFD at Compressor. 28 221,760 11 3.8 4

9 Installation of VFD at Water Pump. 27 212,520 11 2.4 3

10Installation of Double flap valve at RM rejectelevator top discharge chute (Reduction of false air by 4% leads saving in fan SPC)

36 237,600 12 4.4 4

Total 1017 6,808,654 340 90 3

Project with “Investments” for SPC reduction.

Reduction of False Air:-

Sl. No Area Before After ReductionSaving

KWH Kcal/Kg Rs. Lakhs1 Preheater 7.38% 5.20% 2.18% 27.96 4.27 692 Raw Mill 37.7% 19.4% 18.30% 232.32 - 77

Total 260 4 146

37.733.6 32.8

18.416.2 16.7

18.521.4

23.319.7

17.514.7 14.8

19.4 19.315.7 15.2 13.4

18.7 18.0 17.9

13.0 11.99.8

0

5

10

15

20

25

30

35

40

Raw Mill false air

Project for SHC reduction.

7.385.97

9.147.21

5.32 5.60 5.50 5.22

02.11.2015 02.02.2016 19.03.2016 13.04.2016 25.04.2016 13.07.2016 02.01.2017 06.04.2017

Preheater False Air Reduction

Sl.No

Description UoM Before After ReductionAnnual Heat

Saving (Kcal/Kg)

Annual Cost Saving (Lakhs)

Investment in Rs. Lakhs

ROI (Months)

1Up gradation to Pyro jet Burner from traditional burner

% of Cold Air

16% 11% 5% 4.5 61 99.43 20

2Installation of Kiln Outlet Seal

M3/Hr of False Air

6750 Nil 6750 4.6 62 15.95 3

3Optimization of Coal conveying air

M3/Hr 7000 4555 2445 1.7 23 Nil n/a

Total 11 145 115

Summary of EnCon Projects :-

Sl. No

Description

SavingAnnual Cost

SavingAnnual Electrical

EnergyAnnual Thermal

Energy

Mn Kw Mn Kcal Rs. Lakhs

1 Project Without Capital Investment 1.06 1,907 76

2 Project With Investment 6.81 10,210 463

3 False Air Reduction 1.75 4,786 145

Total 9.62 16,903 684

Innovative Project : -

Modification of Raw Mill Dam ring segment.

Usages of Discarded water bottles @ blasting.

Reduction of Standard Deviation of firing Coal Ash.

Modification of Raw Mill Dam Ring Segment:-

Problem faced: Main drive motor was running at 100% load @ 250 TPH.

Action taken: Dam ring segment of the VRM has been modified.

Two segments of 60 & 30 mm thickness were removed.

Dam ring heightener of 60 mm installed.

Investment of Rs 3.5 Lakhs (Steel & Manpower) .

Modification of Raw Mill Dam Ring Segment:-

Output:

Mill main drive load reduced to 2020 KWh @ 290 TPH from 2430 KWh@250 TPH.

Annual electrical savings of 4.916 Million KW achieved.

Annual cost savings of INR 24.58 Million Rs achieved.

Removed

Original Design After Modification

Newly fabricated

Usages of Discarded water bottles @ blasting :-

• Discarded water bottles are used to provide air deck in blasting between the explosive column• Total explosive cost was reduced by 15-20%.

• This technique was found very effective in reducing explosive consumption and other environmentalimpacts of blasting like ground vibration and fly rock.

• By adopting this technique the precious land can be saved as it takes more than 1000 years for PET to

decompose.

• Saving of 2.6 Lakhs on Last FY 16-17 in Blasting Cost.

2.0

1.5

2.22.4

1.8

1.31.0

0.0

0.5

1.0

1.5

2.0

2.5

3.0

Sep-16 Oct-16 Nov-16 Dec-16 Jan-17 Feb-17 Mar-17

S/D of Firing Coal Ash

Reduction of Standard Deviation of firing Coal Ash :-

• USO plant is using Coal with wide variation of Ash (From 10 to 45%) without a Stacker Reclaimer & covered storage shed.

• This in house system has been Commissioned without any Capital Investment (Approx. 25 Lakhs) by using Scrap / Surplus material.

• Standard deviation of firing Coal Ash has reduced from 2.0-2.4 to 1.1-1.8.

• Results in smooth Kiln operation.

BeforeAfter

In house fabrication and installation of Coal Blending System.

Utilization of Renewable Energy Sources

• Techno economic feasibility study has been completed by M/s Holtec.

• Estimated Net Power Generation Capacity is 5.38 MW.

• Estimated payback period is 3 Year 9 Month.

• Proposal is under approval.

WHRS

• Installation of new solar street lights in Mines area is under progress.

• Replacement of existing HPSV lights with solar light in plant colony area is under progress.

• Installation of Solar rooftop above all the load centres/points is under review.

Solar Power

Utilization of Waste Material As Fuel :-

• Usages of Saw Dust along with Pet Coke / Coal.

• In-house Screening System of Saw Dust .

• Usages of FMCG Waste product.

• Usages of Rice Husk through Calciner.

• Usages of Wooden Chips through Calciner.

2% 2% 2%4% 5%

3% 4%

6%

3% 3% 3% 4% 3.2%

Apr-16 May-16 Jun-16 Jul-16 Aug-16 Sep-16 Oct-16 Nov-16 Dec-16 Jan-17 Feb-17 Mar-17 YTD FY17

% TSR

3577 69

29

210

0

50

100

150

200

250

Q1 FY17 Q2 FY17 Q3 FY17 Q4 FY17 YTD FY17

Saving in Rs. Lakhs

AFR Usages Initiatives (Saw Dust Screening And Stacking System):-

The receipt Saw dust is mixed with Wooden pieces / Berks, which is not possible to directly mix with Coal / Pet Coke. Site team has developed a screening arrangement with the help of unused material. • Average wood pieces in Saw Dust : 10 - 15 % • Average screening capacity per day : 50 – 60 MT / Day (Wet basis)

Before Screening After Screening

AFR Usages Initiatives (Wood chipping machine):-

• Screened Wooden Pieces are used as AFR at Calciner after chipping by Wood Chipper Installed at Site.

• Cap – 1.5 TPH , Output Size – 5-20mm

GHG emission

Carbon Foot Print Activities

YearScope-1 emissions

CO2e (MT)Scope-2 emissions

CO2e (MT)

Kg CO2e/MT of Cementitious

Product

2015-16 (Baseline Year) 528545 37484 848

2016-17 807495 61318 824

Following initiatives were taken to reduce GHG emissions:-• Utilization of Alternative fuels like Saw Dust, Rice husk, FMCG waste, chipped wooden pieces etc.

• Reduction in diesel consumption by constructing check dam at Raw water source.

Future Road Map for Specific Power Consumption:-

High Efficiency RM Fan with SPRS

High Efficiency PH Fan

High Efficiency RABH Fan

SPC 49KWH/T

Future Road Map for Specific Heat Consumption:-

Stacker Reclaimer and Covered shed

for Coal

Reduction of False Air

Retrofitting of Cooler Fans

SHC 710 Kcal/Kg

Future Road Map (Others) :-

• Usages of Pyrolysis oil for kiln firing.

• Installation of Multicore system for kiln feed.

• Procurement of De Bricking and Brick laying machine.

• Up Gradation of Coal mill for higher productivity.

• Increase of Calciner height for better retention time at Calciner.

Approach for Energy Conservation Initiatives:-

CFT Based team

Responsibility to Energy

Committee.

Energy Committee

meeting.

Brain Storming in Daily

meeting.

Action plan & implementation.

Achievement & Rewards.

Monitoring & Reporting

Monitoring & Reporting

Monitoring & Reporting

.

Monitoring & Reporting

Replication arising out of Best Practices from Other Industries:-

Executed at Umrongso

PH fan Inlet Box

Modification.

RM fan Inlet Box

Modification

Installation of Sensor at

Cooling tower.

Installation of VFD at

Root Blower.

Installation of VFD at

Compressor

Reduction of Diesel Consumption in Water Supply :-

Water Reservoir at

SourceSou

rce

10HP pump

Boosting Station90HP pump

Water Reservoir at 250 Bigha90HP pump

Water Treatment Plant45KW pump

Tea Garden to WTP (6.5 KM) – Currently not operated

Water Tank # 1 (Near Mines road)So

urc

e

75KW pump

Water Tank # 2

(Near CSP)55KW pump

Water Tank # 3

(Near VCL Plant)75KW pump

Water Treatment Plant18.5KW pump

Mines source to WTP (2.5 KM) – Currently running

Description Uom Amount in Rs

Tea Garden to WTP Rs./KL 23

Mines Source to WTP Rs./KL 11

Saving Rs./KL 12

Annual Saving (450 Cum/day)

Rs. Lakhs

20

Closed

Zero Usages of Ground WaterCheck Dam Construction @ MinesReduction in Diesel Consumption 250 -300 Ltr./Day

CSR Activities:-

CSR Activities:-

Thank You