18th National Award for Excellence in Energy Management - 2017

Dalmia Cement (Bharat) Limited, Kadapa

➢ 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 4th Largest Cement ManufacturingCapacity in the Country

ISO 50001:2011

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

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

FY 2013 – Expert Optimizer for Plant Energy Efficient Operation

FY 2014 - EnMS 50001: 2011 Certified

Cum. Energy Saving : 34 Million U/Annum

Alternative Fuel Feeding Enhancement

FY 2015 – 21% TSR of Alternative Fuel

RABH & Cem M Fan Impeller Replaced

Cum. Energy Saving : 36.2 Million U/Annum

Current Plan & Actions

Enhancement of Alternative Fuel Feeding

Development of Renewable Power, WHRS

FY 2016 – Raw Mill Fan Impeller Replaced.

Cooler Efficiency Improvement

FY 2017 – Liquid Alternative Fuel

Raw Mill Cyclone CFD & Modification

Kiln Burner Pipe Retrofit

Description UnitWithout

InvestmentWith

InvestmentTotal

Total No. of Projects No. 32 49 81

Electrical Energy Saving / Annum

LakhsUnits

16.49 84.08 100.57

Fuel Energy Saving / Annum

MillionKcal

3160 20072 23232

Total Cost Saving / Annum (Elect + Thermal)

Rs. Lakhs

135.93 984.44 1120.37

Title of ProjectAnnual Electrical

Saving (kWh)

Annual Elect. Cost Saving (Rs

Lakhs)

Installed VFD for Flyash Compressor (By Reviewing of all VFDs and Operating Parameters and Diverted the VFD from Optimized Equipment)

45000 2.70

Operation of Cement Silo Exhaust Fan as per Occupancy Sensor Command and DCS Time Delay

57500 3.45

Packing Plant Bag Filter Fans Operation Interlocked and Auto Speed Reduction with Packer Rotation and Spout Discharges

109500 0.66

Modification in VRM Classifier and Reduction of Seal Gap to improve the Performance

145000 8.70

Stopping of CRD Motors in the Stackers and Reclaimers during Unwinding.

30000 1.80

Improved the Loading Factor of Coal and Additive Stacking Group by detailed Study

2700 1.60

Improved Operation Efficiency of Cooler Tower Fan by replaced 1500RPM to 1000 RPM motor and Diversion of Heat Exchanged Warm Water to Water Spray

70000 4.20

No Investment – Elect Energy Saving

Title of ProjectAnnual Thermal

Saving (Ton/Year)

Annual Thermal Saving (Rs

Lakhs)

Operation of Cooler Fans (1 to 4) with 106% Speed and Improved the Heat Recuperation at the Current Improved Production Rate

250 27

TAD Inlet Joint Modificiation and Achieved Reduction of False Air

30 3.20

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

310 32.55

Reduction of False Air from 5.0% to 4.4% by PH Outlet Expansion Joint Inhouse Modification

10.00 1.05

Replaced the Flap Valve with Double Rotary Air Lock for the Alternative Fuel Feeding System

15.00 1.575

Increased SF Cooler Stroke Length and Reduced Clinker Bed Height. Reduction of Heat Consumption 1 Kcal / Kg Clinker

250 27

No Investment – Thermal Energy Saving

Title of ProjectAnnual Elect. Saving (kWh)

Annual Electrical Cost Saving (Rs

Lakhs)

Invest. (Rs Lakhs)

Operation of Blending Silo Exhaust Fan through VFD (Auto Speed Increase by Occupansy Sensor)

21000 1.26 0.50

Cement Mill Grinding Specific Power Reduction by Reducing the Size of Performance Improver Crusher

450000 27.00 25.00

Installed Additional Hydraulic Pump for Rollers Lifting Time Reduction during Mill Tripping and Reduction of Restarting Time

16800 1.01 0.70

Converted the Coal & Additive Unloading Group Operation from DCS to Local Control Station and Reduced the Change over time & Idle Power

30000 1.80 0.75

LED Lighting Project (Well Glass, Street Lights, Tube Lights, CFL & Building Lights...)

111690 6.72 10.49

Electrical Energy Saving

Title of ProjectAnnual 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.

56000 3.36 3.00

Cement Silo Extraction Blowers Operation Through VFD for Speed Reduction as per Bin Level

11200 6.72 4.00

Installed Day Light with Turbo Ventilator at Stores and Workshop Building and Stopped the Lighting & Exhaust Fans

23000 1.40 2.50

Electrical Energy Saving

Title of Project

Annual Thermal Saving

(Ton/Year)

Annual Thermal

Saving (Rs Lakhs)

Invest. (Rs

Lakhs)

Kiln Burner Pipe Retrofit by Conveying Pipe Size Reduction, Turbojet Blower and Swirl Air Fan with New Design Burner

470 50.70 11

Relocated Higher KW Cooler Fans at Heat Recuperation Zone & Recovered More Heat

439 47.4 1.5

VFD for Kiln Coal Blower and reduced the Primary Air Volume

423 45.7 0.4

Installed Liquid AFR Pumping System and Consumed Pharma Waste and Liquid Solvents

500 54 100

Thermal Energy Saving

10.516.5

20.8 23.6

34 36.2 36.541.3

5

15

25

35

45

Million Units Saving / Annum (Cumulative)

Better

82.64

77.1175.88

74.8773.91 74.1

70

75

80

85

2011-12 2012-13 2013-14 2014-15 2015-16 2016-17

Units / Ton of Cement

Better

Thermal SEC without Kiln Start Stop : 685 Kcal / Kg Clinker(Benchmarking Thermal SEC)

Better

55

.3

54

.3

52

.2

51

.7

50

.5

50

.9

47

49

51

53

55

57

2011-12 2012-13 2013-14 2014-15 2015-16 2016-17

KWH/Ton of Clinker

KWH/Ton of Clinker

781

760

710 704701 701

685

705

725

745

765

785

2011-12 2012-132013-14 2014-15 2015-162016-17

Kcal / Kg Clinker

Better

66.3

63.463.03 63.10

62.50 62.61

60.00

57

59

61

63

65

67

69

2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 Target

Kwh/Ton of Cement (PPC)

NB – National BenchmarkINB – International Benchmark

NB (67)

INB (65)

Present 74.1 U/T of Cement

LS Secondary Crusher (Red.

1.30 U/T)

Increase of PPC Sales (Reduction

of 7 U/T)

HAG for Cement Mill (Reduction of

0.5 U/T)

Waste Heat Recovery Sys. (Red. 23 U/T)

LP Compressor for Flyash (Red.

0.25 U/T)

Target42 U/T of Cement

Present 685 Kcal / Kg of Clinker

Clinker Cooler Upgradation

(Red. of 15 Kcal)

Target661 Kcal/Kg of Clinker

Burnability Impr. by Minerlizers (Red. of 5 Kcal)

Kiln I/L Seal with Graphite (Red.

of 4 Kcal)

Project : IP-1Title : 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

Parameters UOM Before After%

Improvement

Pressure Drop mmwg 150 100 33 %

Air Flow M3/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 : IP-1

Project : IP-2Title : Improving CM Productivity by Extending

Nozzle Ring at Bottom by 20 mmObjective:

1. To Improve Cement Mill Productivity

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.

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 : IP-2

Project : IP-3Title : Reduction of Kiln Specific Power by

Increasing SF Cooler Cylinder Stroke Length

Objective:

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 Height2. 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

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.

Project : IP-3

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 %

• Rain Water Harvesting and Use – 150% Water Positive

Water

• Energy Conservation ProjectsEnergy

• Solar Power & Wind Power

Non-Conventiona

l Energy

• Mass Tree Plantation on Every Occasions Department wise ownership

Plantation

• Dry Fog System & Stack Emissions Control

• Recycling of Floor Spills & Reuse of WasteEnvironment

• Vermi-compost & Use of Bicycles

• Formation of pond & Rain water harvesting

• Distribution of Solar lamps & Practice of

Community

Carbon Foot Print Activities

Year

Scope 1 emissions

CO2e (MT)

Scope 2 emissions

CO2e (MT)

Scope 3 emissions

CO2e (MT)

kg CO2e/MTof Cement

MitigationTotal Reduction

in emission intensity since baseline year

study CO2e (MT)

2012 - 13 (Baseline Year)

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 Overall6% Reduction

from Base Line

DescriptionNo. of

ProgramsMan 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

15

00

0

16

00

0

23

50

0

24

00

0

9500

400

00 56000

79

50

0 10

35

00

11

30

00

0

20000

40000

60000

80000

100000

120000

Upto 2012-13 2013-14 2014-15 2015-16 2016-17

Green Development in the Plant & ColonyNo. of Plants

No. of Plantations for the Year No. of Plantations in Cumulative

Battery Operated Vehicle

Battery Operated Cars for Employees & Guests Internal Movement

E-Rickshaw for Employees

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)

EA – 18327 EA – 15097 EA – 18891 EA – 17555 EM – 18832 EA – 19674

Energy

Policy

Online SEC Monitoring by CCR Operator and taking Immediate action during increase in SEC Indication

Final Video 01.mpg