Installed Capacity (Clinker) - 2 MTPA Installed Capacity ... · 4 Up-gradation of Raw Mill Fan to...

Human Resources Department Building Culture Nurturing Talent1

Installed Capacity (Clinker) - 2 MTPAInstalled Capacity (Cement) - 3 MTPACaptive Power Plant (CPP) - 27MWProduct Type - OPC, PPC


Major Process Equipment Specifications

Equipment Supplier Rated OperatingBeyond Capacity

Crusher MMD 900 TPH 800 TPH -11%

Raw mill Pfeiffer 400 TPH 450 TPH 13%

Pyro-5Stage Preheater

FLsmidth 4500 TPD 6500 TPD 44%

Coal Mill Pfeiffer40TPH-HG,25-Pet-coke

24 TPH -4%

Cement mill Pfeiffer 300TPH 350 TPH 17%

Human Resources Department Building Culture Nurturing Talent

2015-16 2016-17 2017-18 National Best

3

1. Specific Energy Consumption in last 3 years

2015-16 2016-17 2017-18


2014-15 2015-16 2016-17 2017-18 National Best



2014-15 2015-16 2016-17 2017-18 National Best

5


Due to high volume model


2015-16 2016-17 2017-182015-16 2016-17 2017-18

6


2015-16 2016-17 2017-182015-16 2016-17 2017-18


2014-15 2015-16 2016-17 2017-182014-15 2015-16 2016-17 2017-18

7



2. Information on Competitors, National & Global benchmark

ENERGYBENCHMARKING

ParametersElectrical SEC

(kWh / T of Cement )Thermal SEC

(kcal / kg of Clinker)

Comparison of specific energy consumption (SEC)

SEC : Dalmia Cement –Ariyalur Plant 64.8 702SEC Values for Competitor - 1 : (Ultra Tech) 65.5 735SEC Values for Competitor - 2 : (Ramco) 73.0 690SEC Values for Competitor - 3 : ( Chettinad) 78.0 730National Benchmark for SEC : 62.0 687International Benchmark for SEC : 60.5 680SEC Target for FY Year 2018 - 2019 : 63.0 685

Please mention the sources / references for the furnished data

(National & International Data)

http://ietd.iipnetwork.org/content/cement#benchmarks(international Benchmark)

http://www.indiaenvironmentportal.org.in/files/Cement.pdf(national Benchmark)


Road Map To Achieve Benchmark/National/Global Best

Action plan for Reduction of Upto Clinkerization Power from 48.5 to 45.5 kWh/Mt

S. No Energy Conservation ProjectsExpected Saving

Kwh/ Mt of clinkerTarget

1 New Impact Crusher (Tertiary) to reduce power consumption 0.10 Jun'19

2 Separate Crusher for Additives to improve the productivity 0.11 Mar'19

3Up gradation of Raw mill Classifier to increase mill productivity by 3-5%

0.30 Jan'19

4 Up-gradation of Raw Mill Fan to increase the efficiency 0.21 Mar'19

5 Up-gradation of Preheater Fan to increase efficiency from 77 to 83% 0.52 Nov'18

6 Reduction of False Air from 5.6 to <4% 0.09 Mar'19

7Up-gradation of Top Cyclones to reduce the pressure drop from 130 to <100 mmwg as well as to reduce the power consumption

0.38 Jun'19


Road Map To Achieve Benchmark/National/Global Best

Action plan for Reduction of Specific Heat Consumption

Action plan for Reduction of Grinding Power

S.No Thermal Energy Conservation ProjectsExpected Saving Kcal/kg clinker

Target

9 Cooler CIS to ABC inlet to increase the Cooler efficiency by 2% 5-6 May'19

10 Cooler 4th compartment bifurcation to increase the Cooler efficiency by 1% 3 Dec'18

11 Extending PC height to increase the calcination 3-5 Jun'19

12 Up-gradation of Cooler to achieve Cooler efficiency 70% 8-10 Jun'19

13 Reduction of False Air from 5.6 to <4% 1 Oct'18

S.No Energy Conservation ProjectsExpected Saving

KW/Mt of cementTarget

14 Up-gradation of Mill Fan to increase from 77 to 82 % 0.26 Mar'19

15Cement Mill Productivity increase by 3% by modification of Classifier Annular Gap

0.22 Oct'18

16 Cement Mill Productivity increase by 2% by up-gradation of Classifier 0.12 Mar'19

17 Cement Mill Productivity increase by 1% by up-gradation of Booster Fan 0.05 Jun'19


3a. Energy Saving projects implemented in FY 2015-16

S. No. Title of ProjectTotal Annual

Savings (Rs million)

Investment Made

(Rs million)

Payback

(Months)

1Reduction of Crusher Sp. Power Consumption by avoiding Primary crusher tripping

0.3 0 0.0

2 RVRM Grit Cone Modification 2.3 1 5.3

3 RVRM HAG Root Blower Installation instead of Compressor Air 0.6 0.2 3.7

4 HAG Coal Blower VFD Installation 0.3 0.2 6.9

5 RVRM False Air Reduction from 11.2 to 8.3% 0.8 0.2 3.2

6 Silo Feed Elevator Discharge chute & VFD installation 1.9 1 6.4

7 In-House Modification of Raw Mill Hot gas inlet duct 2.6 1.4 6.5

8 Sp. Heat Consumption reduction 8.0 0.3 0.4

9 Compressor Power Reduction 3.0 0 0.0

10 Coal Mill Sp. Power Reduction by output increased 4.2 0.25 0.7

11 CVRM Sp. Power Reduction in OPC grinding 0.5 0.2 4.4

Total Saving 26 5.00 2.27


Higher Pressure drop across the Mill inlet duct

❖ Team decided to increase the mill inlet duct area to reduce

the pressure drop in the circuit.

❖ Mill inlet duct area was increased from 6 m2 to 18 m2.

✓ Pressure drop got reduced by 70 mmWg

✓ RVRM Specific Power consumption reduced by 0.3 kWh/MT

✓ Cost Saving -26 Lakhs/annum

In-House Modification of RVRM Hot Gas Inlet Duct



Silo Feed Elevator current high, due to material

recirculation because of “vacuum” created in top portion

around -500mmwg

To reduce the material recirculation as well as

current

❖ Silo feed elevator discharge chute was modified and

Vacuum pressure came down from 500 to 90mmwg

simultaneously reduced the material recirculation.

❖ Silo feed elevator motor changed from DOL to VFD.

Modification of Silo Feed Elevator discharge chute and VFD installation

Benefits:✓ Supported for Mill TPH Improvement

from 375 to 450 TPH✓ Specific Power got reduced from

0.2Kwh/Ton ✓ Cost Saving – 19 Lakhs/annum



3b. Energy Saving projects implemented in FY 2016-17



Investment Made

(Rs million)

Payback

(Months)

1Innovative Reverse start sequence for Lime stone Crusher Transport Group

0.36 0 0.0

2 Raw Mill Classifier Annular Gap Reduction 0.6 0.82 16.1

3 Raw Mill Fan Cone Up-gradation 0.2 0.52 30.6

4 Raw Mill Cyclone Rotary air lock stopped 0.1 0.01 1.2

5 RVRM False Air Reduction from 8.6 to 7.6% 0.1 0.2 20.5

6 Reclaimer Output increased from 450 to 550 TPH 0.1 0.2 23.5

7 Reduction of Coal Mill False Air 0.2 0.2 16.0

8 Coal Mill Rotary Air Lock reverse logic provided 0.1 0 0.0

9 Cooler MFR modification 1.1 0.5 5.4

10 Kiln Riser Duct Modification 1.1 0.58 6.5

11 Reduction of False Air in Preheater from 5.7 to 4.7 % 0.84 1.0 14.3

12 Kiln Coal pumping line changed from 250 to 200 mm 0.87 0.55 7.6

13 Reduction of False Air in Cement Mill from 14 to 11% 0.1 0.2 19.0

Total Saving 6 4.72 9.88


3b. Energy Saving projects implemented in FY 2016-17

Cost Saving – 3.6 Lakhs/annum

Reduction of Idle Running Hours in Crusher


Area -4.58M2Velocity – 32m/s

✓Kiln Riser Duct area was

increased from 4.58 to 5.7m2

✓Kiln riser Duct Velocity

reduced from 32 to 26 m/sec

✓ kiln inlet O2 was increased by

1.0 %

✓Preheater Fan Speed reduced

by 1%

✓Kiln Coating Tendency

ReducedKILN KILN

Area – 5.7 m2Velocity – 26 m/s

SmokeChamber

SmokeChamber

Increased Clinker production = 100 TPD

Modification Of Kiln Riser Duct By In-house Design3b. Energy Saving projects implemented in FY 2016-17


3c. Energy Saving projects implemented in FY 2017-18



Investment Made

(Rs million)

Payback

(Months)

1Reduction of Crusher Sp. power consumption by elimination of primary crusher tapper tooth problem

0.13 0.1 9.5

2 Raw mill classifier seal gap reduced from 12 to 6 mm 0.3 0.4 15.2

3 Raw Mill False Air reduced from 7.5 to 6.5% 0.1 0.2 19.3

4 Coal Mill Dam Ring & Nozzle Ring optimization 0.7 0.1 1.7

5 Reduction of Kiln radiation losses by applying the heat resistant paint 0.44 0.1 2.7

6 Cooler Recuperation Efficiency increased from 63 to 64 % 0.9 0.2 2.7

7 CVRM Bag House purging sequence modified 0.5 0 0.08 CVRM Classifier seal gap reduced from 10 to 6mm 0.4 0.1 3.09 CVRM Bag house False air arrested by adjusting Rotary Airlock Gap 0.3 0.05 1.8

10 CVRM Fan cone Gap reduced 0.3 0.1 4.5

11 Installation of Fresh Air Damper at mill inlet duct 0.39 0.05 1.5

12 Packing plant Bag Filter optimized the DP 0.3 0.02 0.9

13 Packing Plant Lighting replaced with LED 0.4 0.05 1.4

Total Saving 5.2 1.47 3.42



Dam ring was reduced from 180 to 80 mm

Nozzle Ring Blockage also reduced from 20%

make into 0%

Thereby Specific power consumption got

reduced by 4 Kwh/Mt of Material

Cost Saving – 12 Lakhs/ Annum

Reduction Of Coal Mill Specific Power Consumption


Kiln Shell painted with Lithophone + Sodium Silicate to reduce the Radiation Losses


Kiln Radiation loss reduced by

1.2 Kcal/ kg clinker

Cost Saving – 15 Lakhs/Annum

Surface

Area (m2)

Clinker

Productio

n TPH

Shell

Temp C

Shell

Temp KTa oC Ta oK

Convection

(Qc) Kcal/Hr m2

Radiation Qr

Kcal/Hr m2

Total Heat

Loss Q

Kcal/Hr m2

Heat Loss

Kcal/ kg

clinker

Before 915 250 264 537 35 308 1291022 2714618 4005640 16.0

After 915 250 253 526 35 308 1220550 2472759 3693309 14.8

Reduction of Radiation Loss( Kcal/ kg clinker) 1.2


Increased OPC Productivity


Problem:

▪ Mill output <260 TPH

▪ Water injection high

▪ Higher clinker temperature

Our CFT Team taken initiative to install the

fresh air

Thereby mill output increased by 10 TPH

Hence, Sp. Power consumption reduced by

0.2 Kwh/Mt


4. Innovative Project - 1Cement Mill Bag House Purging Sequence Modified

Problem Statement:

Silo feed Bucket elevator is bottle neck to increase the Output

Material flushing from Bag house to Bucket elevator

Frequent tripping of Bag house transport group due to High Bucket elevator load

Existing

Sequence

Chamber L1 L2 L3 L4 L5 L6 L7 L8

B/H Inlet

1 5 3 7 2 6 4 8B/H Out Let

3 7 1 5 4 8 2 6

Chamber R1 R2 R3 R4 R5 R6 R7 R8

Root Cause:


4. Innovative Project - 1

CVRM Bag House Purging Sequence Modification

Benefits: Elevator current optimized from 150 to 140 Amps. Cement mill output increased from 350 to 375 TPH Sp. Power consumption reduced by 0.5 kW/Mt Cost saving of Rs.18.05 lakhs per annum

Source - QC CircleInnovation – BH Purging based on the Elevator LoadReplication - Possible


4. Innovative Project - 2Increased Cooler Re-cuperation Efficiency from 63 to 64%

Cooler Static PartCompartment -1

Compartment -2

Compartment -3

Cooler Fan -1Fan speed -100%



TAD Temperature -1020 Deg CCooler Efficiency – 63 %

Cooler Static PartCompartment -1

Compartment -2

Compartment -3


Cooler Fan -2Fan speed -

105%

Cooler Fan -3Fan speed -

105%

TAD Temperature -1050 Deg CCooler Efficiency – 64 %

Before After



Increased Cooler Re-cuperation Efficiency by modification of higher size MFR

✓ Cooler MFR size increased for increasing the air quantity

✓ Cleaning the ADP for uniform distribution of air

Benefits:

Cooler Recuperation Efficiency increased by 1%

Heat Rate reduced by 4 Kcal/ kg clinker

TAD Temp increased from 1000 to 1050 Degc

Cost Saving – 48 Lakhs per annum

Source - OEMInnovation - Achieved Beyond limit Replication - Possible


Cement Mill Bag House RAL Modification

Reduction in False air entry from 11.5% to 9.85%.

Easier access while removing bags through RAL.

Cost saving of Rs.5.70 lakhs per annum


Source - Front line TechnicianInnovation - Reduce the False airReplication - Possible

Before Modification After Modification

Our sister concern, Kadapa plant have installed

this modification

Horizontal deployment – It is applicable to all

the cement industries.


5. Utilization of Renewable Energy Sources

Replacement of Electrical Energy with Renewable Energy

Annual Energy Generated in 2015-

16 (million kWh)% Share

Annual Energy Generated in 2016-

17 (million kWh)% Share

Annual Energy Generated in

2017-18 (million kWh)

% Share

Wind Energy 10 10.22 14 14.26 14.65 14.96

Replacement of Thermal Energy with Renewable Energy

Equivalent Annual Fuel Savings in

2015-16 (million kcal/year)

% Share



% Share



% Share

Solar Thermal Energy

65 0.01 65 0.01 65 0.01

Biomass Plant 12 0.00 12 0.00 12 0.00


6. Utilization of waste material as fuel

3.4%

1.63%

4.3%

2015-16 2016-17 2017-18

146

97

187

2015-16 2016-17 2017-18

Green Fuel 2015-16 2016-17 2017-18

Dolachar 0.05 - -

Charcoal 0.82 - -

Carbon black 0.77 0.64 2.47

Plastic waste/RDF 0.04 0.02 -

Spent wash 0.24 0.03 -

DFA-HCV 0.07 0.34 0.68

Solid Waste Mix 1.38 0.60 0.50

Tyre chips - - 0.60

Resin Waste - - 0.05

% TSR 3.37 1.63 4.30

Alternate Raw Material 2015-16 2016-17 2017-18

Tannery Sludge - MT - 233 543

Lime Sludge - MT - 1403 3696


7. GHG Inventorisation

848

762 759 762

723 721

2012 - 13(Baseline

Year)

2013 - 14 2014 - 15 2015 - 16 2016-17 2017-18

CO2 emission – Kg/ MT of Cement


7. GHG Inventorisation

Note : As per the GNR data published by Cement Sustainability Initiatives (CSI) in 2016

… in the cement world

Lowest Carbon footprint globally…

CO2 emission – Kg/ MT of Cement


8.1 Green Supply Chain – Cement Bulker %FY 16-17 FY 17-18

Bag/BulkDispatch Quantity

Avg Distance

Dispatch Quantity

Avg Distance

BAG 1159790 171 1103392 172

BULK 352224 324 430718 326

Grand Total 1512014 194 1534110 200

Bulker Quantity increased = 78494 MT

Fuel Savings = 54157 Lits * 70 Rs/ Lits of Diesel

Cost Saving = 38 Lakhs


Results:

✓Increased Backhaul Quantity =

19712 MT

✓Distance from Karikal = 126 Km

✓Fuel Saved = (939*126)/4.5 =

26292 Lits of Diesel

✓Cost Saving = 18.4 Lakhs/annum

31

8.2 Green Supply Chain – Back Hauling %

Plant

Distributor Pet-coke from Karikal


8.3 Green Supply Chain – Round Trip

Results:

Limestone Quantity increased by

round trip -34,000 MT

If direct Trip - 1.94 Lits/ Mt

If Round Trip – 1.25 Lits/ Mt

Fuel Saved – 23,460 Lits of Diesel

Cost Saving – 16.42 Lakhs/ Annum

DPM Plant

Ariyalur PlantPNR & PTK

Mines

DPM Mines


✓On line Energy management System (EMS)

✓Online Specific power consumption is monitored by CCR operators

✓ Software for Compressors, Idle running hours of Major Equipment & Raw

water Consumption.

✓ Energy reports were taken from Energy management system

✓ Best Energy saving initiatives are awarded periodically.

9.1 Daily Monitoring and Reporting System

9. Team work, Employee Involvement & Monitoring


9.2 Daily Review Meeting Chaired by Technical Head

10056 102489912 10128 10248

10008 996010128 10248

7982

419 427 413 422 427 417 415 422 427 409

24.0 24.0 24.0 24.0 24.0 24.0 24.0 24.0 24.0

19.5

14.8 14.6 15.2 14.6 14.314.3

14.0 13.5 13.9 13.4

13.25

10.71

12.3011.33

12.68 12.85 12.79 12.86 12.86 12.86

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

0

2000

4000

6000

8000

10000

M T TPH R/HRS POWER LS Moisture



❖ Energy Task Force Team formed with cross functional team members and

best energy saving initiatives discussed and implemented.

❖ Best tracking system for speedy implementation

❖ Quick fund allocation by the management based on the pay back period

less than 40 months

❖ Best Energy saving initiatives are awarded every Monthly Gate meeting.

❖ Visiting Energy Efficient plant & Participating seminars for new

technology adoption

❖ Conducting energy Audit by CII every year

❖ Investment for energy conservation projects for FY 2017-18– 611 Lakhs

ENCON Project Suggestion Box


9.3 Separate budget for Energy Conservation


10. Implementation of ISO 50001/Green Co/IGBC rating

Keys to Success By Implementation of ISO 50001

✓ Well defined energy policy to become excellent energy efficient plant

✓ Gap analysis for the targets and corrective actions for acheiving the targets.

✓ Energy task force team consisting of people at different levels.

✓ Systematic approach to improve the energy performance

✓ Periodical review by top management.

✓ Availability of advanced tools like Knowledge Manager , Expert optimizer & online

reporting, etc.

✓ Inter-departmental cross-functional energy audits.

✓ Active participation in national level energy management programs, workshops.

✓ Young enthusiastic work force always quick to learn and eager to innovate and implement

out-of-the-box ideas.

✓ Reduction of GHG Emission & Carbon footprint


IMS Certification

ISO 9001:2015, 14001:2015, 50001:2011 & OSHAS 18001:200637


Carbon Pricing leadership

Dalmia Cement (Bharat) Ltd is the first cement company to join RE100 (100% Renewable Energy by 2030)


BEE - Energy Awards

National Energy Conservation award from

Ministry of Power FY 2013National Energy Conservation Award From

Ministry Of Power FY 2012National Award in an Two Categories (Energy & Environment) FY 2017


CII - Energy Awards

6 Consecutive Years

2011-12

2014-15

2013-142012-13

2015-16 2016-17


Thank you

Conclusion:Our plant is one among the

Top 5 Energy efficient plant

in India as per CII Bench

marking.

41

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