hearty welcome - greenbusinesscentre.com · spc –kw/ton of clinker- line2) ... existing coal...

HEARTY WELCOMEDate : 29th, 30th & 31st Aug’ 2018

Venue: Novotel & HICC Complex, Hyderabad

Team : R.Balaji, Energy Manager, D.Kumaresan Head-E&I and

R.Rajamohan, Head-Sustainability,PH&Systems

M/s DALMIA CEMENT (BHARAT) LTD, DALMIAPURAM

16 Varieties of Cement from one location

Operating 7 Management Systems

Won 21 National Awards in year 17-18

Presentation Coverage

I. Specific energy consumption trend in last three years

II. Benchmarking & Roadmap to achieve Target

III. Key Encon Projects out of 53 implemented in last 3 years (27 Nil Investment Projects)

IV. Innovative Projects implemented

V. Renewable energy sources

VI. Waste Utilization as Fuel

VII. GHG Inventorisation

VIII.Best Practices on energy front in Green Supply Chain

IX. Team Work in Encon / Employee Involvement in Encon/Monitoring & Reporting

X. ISO 50001, Green Pro Certification

XI. Awards Accolades

28.2727.33

27.92

25.85

24

25

26

27

28

29

Fy' 14-15 Fy' 15-16 Fy' 16-17 Fy' 17-18

over all

Specific Energy consumption

Line-2 KILN HEAT RATE (Kcal/Kg)

SPC – Kw/ton of clinker- Line2)

CVRM 2 - Kw/ton of cement

SPC – Kw/ton of PPC- Line2

49.55

46

47.9

49.9848.85

44

45

46

47

48

49

50

51

Fy' 14-15 Fy' 15-16 Fy' 16-17 Fy' 17-18 Fy' 18-19

July'18

SPC Clinker

58.6

61 61.3

58.27

56

57

58

59

60

61

62

Fy' 15-16 Fy' 16-17 Fy' 17-18 Fy' 18-19…

SPC Cement

778

747758

775

720

740

760

780

800

Fy' 14-15 Fy' 15-16 Fy' 16-17 Fy' 17-18

AFR-wise Consumption – YTD Mar'18AFR Consumption in TSR%

8.93%

7.53%

9.33% 9.21%

11%

9.40%8.55% 8.28% 8.45%

4.04% 4.32% 4.36%

7.65%

0.00%

2.00%

4.00%

6.00%

8.00%

10.00%

12.00%

Apr'17 May'17 Jun'17 Jul'17 Aug'17 Sep'17 Oct'17 Nov'17 Dec'17 Jan'18 Feb'18 Mar'18 YTD

Mar'18

TSR%

3.36%

7.08%

10.31%

7.05% 6.88%

0.00%

2.00%

4.00%

6.00%

8.00%

10.00%

12.00%

Apr'18 May'18 Jun'18 Jul'18 YTD Jul'18

TSR%

0.88%

3.19%

0.22%0.00%

0.81%

0.00%

1.39%

0.03%0.29%0.08%0.00%0.00%

6.88%

0.00%

1.00%

2.00%

3.00%

4.00%

5.00%

6.00%

7.00%

8.00%

TSR%

Specific Energy consumption in PPC

15-16 16-17 17-1818-19

YTD July'18

Crusher with Stopp Units/Mt Lime stone 0.85 0.83 0.84 0.85

Raw Mill with Stopp Units/Mt Raw meal 12.7 12.2 12.5 12.1

Coal Mill with Stopp Units/Mt Clinker 42.8 48.9 54.2 53.3

Kiln with Stopp Units/Mt Coal 19.59 21.24 22.09 21.6

Upto Clinker excl Stopp

w/o servicesUnits/Mt Clinker 43.5 45.1 47.0 45.72

Services Units/Mt Clinker 2.50 2.81 2.99 3.13

Upto Clinker excl Stopp

with servicesUnits/Mt Clinker 46.0 47.9 49.98 48.85

Cement Grinding excl

Stopp

Units/Mt of Cement

PPC26.99 27.75 25.7 23.81

Packing Units/Mt of Cement 1.54 1.45 1.43 1.44

Total Cement Excl Stopp

with Services

Units/Mt of Cement

PPC58.6 61.0 61.3 58.27

Line 2 Specific Power

Energy Bench Marking - Internal

Sl.No SectionLowest

AchievedPlant

AElectrical Power

Consumption

1LS CRUSHER (Kwh/MT of

Limestone)0.73 Unit-1

2RAW MILL (Kwh/MT of

Rawmeal)10.15

Unit-2

3 COALMILL (Kwh/MT of Coal) 22.34Unit-3

4 KILN (Kwh/MT of Clinker) 18.84Unit-4

5SPC Upto Clinkerisation

(Kwh/MT of Clinker) with Shutdown Power

46.34 DPM

6PACKING PLANT (Kwh/MT of

Cement)0.78

Unit-5

7TOTAL (Kwh/MT of Cement)

OPC72.33

Unit-6

8TOTAL (Kwh/MT of Cement)

PPC56.41

Unit-7

BFuel Consumption

( Kcal/Kg of Clinker)689

Unit-8

Energy Bench Marking - External

Parameters ( 17-18 )Electrical

SEC (kWh / T

of Cement )

Thermal

SEC (kcal /

kg of

Clinker)

Comparison of specific energy

consumption (SEC)

SEC : Dalmia Dalmiapuram 67.71 775

SEC Values for Competitor - 1 63.93 734



National Benchmark for SEC : 62.00 680

International Benchmark for

SEC :60.50 675

II. Energy Bench Marking

Detail Unit 15-16 16-17 17-18Over All

(FY16, 17,18)

Total No. of Encon projects Nos. 20 15 18 53

Encon projects With NilInvestments

Nos. 12 6 9

27

Total Investment made Rs.Million - 19 28.5 47.5

Total Savings made Rs. Million 167.04 12.86 55.46 235.36

Electrical energy savedLac units 235.02 15.03 35.34 285.39

Rs. Million 133.77 6.67 14.2 154.64

Thermal Energy SavedTonsofcoal 8353.13 814 35893 45060.13

Rs. Million 33.27 6.19 41.25 80.71

III. Energy conservation projects

Installation of Pyrojet burner Challenges :✓ Primary air percentage including transport

air was 16%

✓ Less FCao control at higher production due to less burner momentum is 8.7 N/MW

Action Taken :✓ Installed Pyrojet burner

Results :✓ Primary air percentage reduced to 10 %

✓ Kiln production increased from 3100 to 3350 TPD

✓ Fcao control at higher production due to

higher burner momentum of 10.5 N/MW

✓ Annual Savings – 30 Lakhs

Energy Con.

Proj.- 1

Increase Coal mill Productivity Challenges :✓ Higher power consumption due to petcoke

grinding

✓ Higher nozzle ring velocity of 55m/s and System pressure drop high

Action Taken :✓ Louver area increased by removing the

inserts

✓ Armour ring angle modified from 25 to 15 deg

Results :✓ SPC reduced from 52 to 46 kwh/T

✓ Nozzle ring velocity decreased from 55 to 42 m/s

✓ Output Increase from 26 TPH to 30 TPH

✓ Annual Savings - Rs 26.3 Lakhs

Energy Con.

Proj.- 2

Before After

Conversion Of Bag Filter Purging system

Challenges:

✓ Higher compressor air & power consumption

✓ Old system - Piston operated purging type

✓ Frequent failure of internal spare parts

✓ Online maintenance not possible

Action Taken

✓ Purging system upgraded to diaphragm type.

✓ This modification was implemented in 5 number of Auxiliary Bag filters

Savings Achieved

✓ One Time Investment - 2.4 lacs

✓ Power saving - 15 kWh

✓ Annual saving - 3.1 lakhs

Piston Operated Purging

Diaphragm Operated Purging

Energy

Con. Proj-3

11

Cooler vent duct modification

Challenges :✓ Higher velocity - Higher wear rate -

leads to spillage

✓ Higher SPC

Action :✓ Increase the duct size from

3 M to 3.5 M

Result:✓ Power Saving of 0.1 kWh/ T of

clinker.

✓ Annual Saving - Rs 4.5 Lakhs + Maintenance benefits

Energy Con.

Proj.-4

Raw Meal - Single silo operation

Challenges :✓ High SPC of Raw meal circuit.

✓ Two Silo's are in simultaneous operation for

in feed & Extraction

Action :✓ Filling and extraction of raw meal started

from Single silo without affecting product quality

✓ Second Silo Extraction blower and gates

stopped.

Result:✓ Power Saving of 40 KW / Hr

✓ Annual Saving - Rs 7.4 Lakhs

Energy Con.

Proj.-5

13

Increase Cement mill productivity

Challenges :✓ Mill output is comparitively lesser

✓ Power consumption is high

Action :✓ Dam ring replaced with wear ring

✓ Scheduled dam ring hard facing - once in 15 days

✓ Recommended gap between Roller & Dam ring to be maintained (20 to 25 mm)

Results :✓ Mill output increased from 280 to 300

TPH in OPC & 300 to 330 TPH in PPC

✓ Power saving 2.5 kWh / T of cement

✓ Annual Saving = Rs 1.4 Cr

Energy Con.

Proj.- 6

Stopping one Auxiliary dedusting bag filter fan in Roto packer

Challenges :✓ High SPC of Packing plant.

✓ Two No's of fans in operation for one dedusting bag filter

✓ Loading men's concern on working atmosphere

Action :✓ Air flow study done and Single fan made

operation.

Result:✓ Power Saving of 45 KW / Hr

✓ Annual Saving -Rs 8.3 Lakhs

Energy Con.

Proj.-7

Spent wash for Nox Reduction as well as AFR

Challenges :✓ Stack Nox emission high

Action :✓ Initially Spent wash firing started in

kiln burner.

✓ Spent wash firing relocated to precalciner after pyrojet burner installation.

Results :✓ NOx reduction upto 50 PPM at stack

i.e., 100 mg/NM3 .

✓ For 3 TPH firing of Spent wash which reduces 0.5 MT fine coal in PC firing.

✓ Annual Saving - Rs 14 Lakhs

Energy Con.

Proj.- 8

False air Reduction

Challenges :✓ Increase in SPC and SHC in mills and Pyro .

Action :✓ Rigorous monitoring and arresting of false air

✓ In-house modification of rocker arm seals VRMs.

✓ Application of steel putty in flange gap

Result:✓ RVRM - 20 % to 11 %

✓ Pyro - 6 % to 4.5%

✓ Coal mill - 18 % to 10%

✓ CVRM - 25 % to 10.5%

Energy Con.

Proj.-9

Water Cooled Condenser Coils for Package A/C’s

Energy Con.

Proj.- 10

Compressor Power Optimization

Challenges :✓ Higher Utility Power consumption

✓ Air Leakages

✓ Lesser operating Efficiency of Compressor

Action :✓ VFD installed for the compressor.

✓ Energy Efficient Compressors Upgraded.

✓ Level sensor based drain valves used.

Results :✓ SPC reduced from 2.77 KWh/MT to

2.13 KWh/MT cement

✓ Annual Power Savings – 36.4 Lakhs

Energy Con.

Proj.- 11

CFD modification in Top stage cyclone

Challenges :✓ High pressure drop in Top cyclone

Action :✓ Cyclone-1 inlet area increased by

630 mm as per the CFD recommendation.

Results :✓ Pressure drop reduced by 70 mmwc in

cyclone-1.

✓ Power saving - 150 Kwh.

✓ Annual Saving - Rs 31.5 Lakhs

Energy Con.

Proj.-12

Sl.NoFan

RPMFan KW

Fan.St pressure @ downcomer

Fan flow (m3/hr)

Remarks

1 1000 1850 760 705000 Without modification

2 985 1830 745 7200001st Cyclone inlet opening by

250mm

3 960 1830 710 7320001st Cyclone inlet opening by

250+380 mm

4 940 1700 690 715000kiln inlet O2 <0.3% and AFR

stopped for an hr

Reduction in Idle running of Lime stone stacker feeding conveyors

Challenges :✓ High SPC of crusher circuit

Action :✓ Idle run of Belt conveyors is more. Field

survey conducted.

✓ All belt conveyor's emptying out time observed, imposed interlocks with optimum time.

Result:✓ There by reduced the idle run time of belt

conveyors by 5 min per Start/Stop

✓ SPC reduction of 0.15 KWH/ T of clinker

✓ Annual saving - Rs 6.6 Lakhs

Energy Con.

Proj.- 13

Energy Efficiency in Lighting

Challenges :✓ Non-Energy Efficient light fittings are in use

✓ Premature Failure is more during rapid cycling

✓ Non - Eco Friendly

✓ Poor performance in Low voltage.

Action :✓ 3000 Light Fittings were replaced with LED.

Results :✓ Annual Power Savings - 330 kWH/day

✓ Annual saving - Rs 4.2 Lakhs + Maintenance benefits

Energy Con.

Proj.- 14

IV.1 Grinding Pet coke in Cement Ball mill - 5 A. Purpose:✓ Utlization of low cost fuel - in PYRO process.✓ Existing coal grinding ball mill design is 20 T/ Hr✓ The low grade fine coal requirement is 25 T/ Hr.B. Action Plan:

Decided to convert the existing unused open circuit cement ball millto grind petcoke.C. Challenges:✓ High residue due to open circuit operation✓ Mill Jamming due to with out hot gas operation✓ Handling of fine coal through bulker reduced the availability of mill✓ Spillage of fine coal D. Action taken:✓ 30 % of Mill output again diverted to mill to control the residue✓ New hot air duct line connection given from cooler.✓ Screw pump with blower installed for pumping fine coal to binsE. Result :

Cement ball mill converted to coal mill with 10 T/ Hr capacity with an 10 % residue in 90 MicronsF. Saving :

✓ Avoided the cost of new coal ball mill - Rs. 15 Cr

IV. Innovative projects -1

Coal

Bin

Cement

Silo

Hot Gas

Recirculation

Conversion of Cement ball mill to Coal mill

Bin

Screw

Pump

IV.2 Introdcution of new cement varietyA. Purpose:✓ To meet the customer requirement .✓ To become market leader .

B. Action Plan:✓ Decided to set up new system for producing Cement.

C. Challenges.✓ Capital investment is high✓ Ensure uniform product quality ✓ Standard equipment not available in market.

D. Action taken Decided to utilize the unused

✓ Fly ash dryer structure with modified existing packing plant blender

✓ Installtion of full automated plant to ensure quality✓ In house design

E. Result ✓ New Variety of Dalmia Magic cement

of 250 TPD commisioned.

✓ Avoided structural & Blender cost - Rs 2.7 Cr


IV. 3. Nox reduction in PYRO processA. Purpose:✓ To reduce the Nox emission level ( present - 1350 mg/

Nm3 ).

B. Action Plan:✓ Coal Firing point relocated to approx. 12 M below the

existing point i.e., Riser duct

C. Challenges:✓ Abormal coating formation in kiln raiser duct.

D. Action taken:✓ In Coal firing point anti coating castable applied.✓ Installation of additional air blaster ✓ Injection of cold raw meal through SFM with in house

design

E.Result:✓ Reduction of Nox emission level form

1350 to 980 mg/ Nm3 ✓ To meet norms full fledge system planned

to installed


Process Flow

Bin

From

Silo

Bucket

Elevator

SFM

RAL

Coal Firing Point

Shifted 12m down

Raw meal Conveying Line

Kiln

kiln Feed

IV. 4 Maximization of AFR utilizationA. Purpose:✓ To increase TSR %

B. Action Plan:✓ Increase in No of feeding location in PC

C. Challenges:✓ Permanent AFR transportation system to PC is not there.✓ Low volume Shredding Machine✓ Increase in false air

D. Action taken:✓ New Shredding Machine of 5 TPH nstalled with feeding grab crane arrangement✓ Two tippling vehicle for shifting the material✓ Installed winch with the capacity of 2 TPH✓ Two Triple feed gate arrangement for feeding AFR in Line-1 & 2.

E. Result:✓ Increase in AFR utilization to 7.65%

✓ Annual Saving - Rs 6.4 Cr


IV. Other Innovations in projects implemented 17-18

Sl.No Title of Project Brief Description of the Project Reason To ChooseAnnual Savings, Rs

million/ y ear

1

Blaster installation in cooler wing panel toward kiln side to avoid aumund conveyor overloading while surging

Sudden surging of fine clinker dust from cooler wing panel (towards TAD take off) resulted in aumund conveyor bucket overflow with hot clinker dust for once in a every shift. To avoid over flow cooler grate will stop for over loading of bucket and kiln feed reduction

To avoid over loading of bucket and kiln feed reduction

11.10

2

Cooler water spray installation to avoid cooler ESP inlet temperature reduction and dust emission control

Installation of Cooler water spray at cooler 2nd grate roof to reduce ESP inlet temperature and thereby increase the cooler air SPC & SHC reduction 1.460

Sl.No Title of Project Brief Description of the Project Reason To ChooseAnnual Savings, Rs million/ y

ear

3

Changing the Bag filter purging system from Piston (old) type to Diaphragam (new) type

1. To upgrade the existing Piston operated pulse type solenoid valve with Diaphragm type purging system in line1 Pyro section Auxiliary Bagfilters.2. By doing this conversion in 5 no's of bag filters, the present 50% Compressor air leakage will be minimized less than 10%.Benefits: 1. Line1 Pyro compressor power will reduce by 0.06 units/MT of clinker after conversion. 2. Minimum Spares & Maintenance cost . 3. Easy online Maintenance.

SPC reduction 0.292

4

CO2 purging manually done for individual hoppers to reduce temperature before opening bag house

Common CO2 purging line for Fine coal bins and bag filter chamber and hopper , changed the common line to individual line to dedicated location so that excess CO2 cyclinder also not used while controlling the temperature rise. Benefits: 1. Line loss avoided by providing cyclinder to near by location 2. Excess CO2 cyclinder not consumed

0.05


Sl.No Title of Project Brief Description of the Project Reason To ChooseAnnual Savings,

Rs million/ y ear

5

3KS flap gate opening timer adjusted to reduce false air

Jamming of 3KS flap due to high moisture limestone , flap not closed properly due to more time interval between the individual flaps . Opening time duration and flap run time duration further reduced to avoid false air entry through gap during that closing duration

to avoid false air entry throughgap during that closingduration

0.198

6

AFR shredder machine roof cover provided to operate in rainy condition

Presently we are not shredding AF during raining duration. Presently provided with roof sheet so that shredding will be happen also raining period

-

7Raw meal silo extraction single silo operation done to reduce 40 kWH/Hr savings

Line 1 PYRO - Raw meal blending silo - Single silo operation from december'17 ( 22 - 40 KW/ Hr ) and another 25 KW to get after silo areation blower modification To reduce Power Consumption

SPC reduction0.965



ear

8

Pipe convyeor PC-29 Belt torn sensor provided.

Provided torn sensor arrangement across the belt. Belt saved from damage and Minimised to patch work of just 4 hour & Production loss minimised

Production loss minimised

9

VRM-3 mill feed belt 33N-BC1 diverter gate compressor air pressure insufficient

Provided additional compressor air receiver tankTangible benefit:1) Avoid proper gate operation2) Material spillage 3)Daily cleaningIntangible benefit:1)To reduce manpower

Avoid proper gate operation

10

To eliminate production loss in Line-2 Pyro section

Pan conveyor -2 got damaged due to pans derailedsensors introduced for avoid pulling torque of the links. (both sides fixed)

avoid pulling torque of thelinks.



ear

11

Auxiliary power reduction in our Captive Power Plant

1.In all process industries one of the lowest efficient equipment is compressors, so we started our work over the use of compressed air reduction in our process. Our process demands compressed air mainly in 2 areas namely Instrumentation and ash conveying :

12

FREQUENT HUMAN INTERVENTION DURING PRODUCT CHANGE OVER

IMPLEMENTATION OF AUTOMATION TO AVOID HUMAN ERRORIMPLEMENTATION OF LOGICOPC TO PPC VARIETY CHANGE OVER AUTO LOGIC

TO AVOID HUMAN ERROR

13

To eliminate rubber cable damage in linear stacker

Changed the orientation of cable reeling drum arrangement, so that cable prevailing portion lays inside the rail.



ear

14

Losing the full length belt in line1

TORN SENSOR PROVIDED AT THE FEED POINT

15

Remote Closing of EB Breakers at 110KV SS Yard from Shift Operator desk through LMSTo avoid Kiln Burner swirler and Cooler CIS plate damage due to delay in Power supply restoration..

1.Feasibility of Hardware interlocks analysed and executed and Trail taken.2. Software logic Operation provided and Switched ON EB breakers through LMS . 3. Given clearance for Shift Operation to Switch ON TNEB yard remotely during Power Black out

16

DPM Innovative Case study for CEM Energy Management Leadership Award

1.Got a structured platform for energy consumption, energy conservation & energy management activities.2.Easy approach for identification and prioritization of major energy consuming activities and equipment.3.Close monitoring of high energy consuming processes and developed mechanism to be informed regarding any change in energy consumption pattern.


➢ Wind Mill

➢ We had installed windmill Farm - First in Cement Plant in the Tamil Nadu. Location and

Capacities are as mentioned as below:

➢ Site-I : In Muppandal,Kanyakumari District

Capacity : 11.5 MW

➢ Site-II : In KarungulamVillage at Thirunelveli District

Capacity : 5.025 MW

V. Renewable energy

VI. Waste Utilisation (17-18)

0.88%

3.19%

0.22%0.00%

0.81%

0.00%

1.39%

0.03%0.29%

0.08% 0.00% 0.00%

6.88%

0.00%

1.00%

2.00%

3.00%

4.00%

5.00%

6.00%

7.00%

8.00%

TSR%

VII. GHG Emission - Low Carbon Technology Road Map- Dalmia

Cement & IFC Disclosure to Public thro’ Dalmia Sustainability Report

Resource Efficiency Study in

partnership with IFC and CII

MD Signing the new Charter at

Seoul , Oct 2012

702 700676

550

650

750

Fy'16-17 Fy'17-18 Fy'18-19

➢ Reverse logic system for Limestone & Gypsum trucks

➢ Round Trip - Rs.118/Ton Straight Trip - Rs.168/Ton

➢ Savings - Rs.50/Ton Average Receipt/Day - 2500 Tons

➢ Installation of GPS tracking system, Monitoring of Supplier Rating

Green Policy followed in our Purchase Order

➢ Pyro Jet Burner in Line-1 & 2..., Coriolis Feeding system in Line-1 & 2...➢ Turbo Blowers in Line-1 & 2 - Coal Pumping..., VFD for Plant Compressors...➢ Spent wash Feeding System in both Lines..., Inter Coal Pumping from both

Lines..., Higher Production in both Lines..., Louver Velocity Optimzation in VRM's...,Retrofitting of LED Light Fittings in both Lines...

VIII- Green Supply ChainReplication of Best Practices /

LINE 2 PLANT POWER STATEMENT

1-Jun-17

Plant SectionsKWH

ConsumpRun Hrs

Production

(tonnes)TPH KWH/hr KWH / T

June'17

BP

Crusher 4 - Total 7773 12.8 9167 716 607 0.85

Section Stoppage Power

Crusher-4 w ith Stoppage Power 7773 12.8 9167 716 0.85

VRM 3 - Total 126041 24.0 9912 413 5252 12.72

Total FLS Raw Mil l Power 126041 24.0 9912 12.72


VRM 3 w ith Stoppage Power 126041 24.0 9912 413 12.72

FLS Kiln section Total 108561 24.0 5213 217 4523 20.83


FLS Kiln w ith Stoppage Power 108561 24.0 5213 217 4523 20.83

Crusher 4

VRM 3 Section

FLS KILN Section

0.80

Main drive 51067 24.00 9912 413 2128 5.15

11.70

Mill Fan 56804 24.0 9912 413 2367 5.73

Auxiliaries 18170 24.0 9912 413 757 1.83

Transfer Power to KHD

Bag House Fan 18629 24.00 5213.00 217 776 3.57

21.30

Pre heater Fan 46276 24.0 5213 217 1928 8.88

Kiln Main drive 5711 24.0 5213 217 238 1.10

Cooler vent Fan 4229 24.0 5213 217 176 0.81

Cooler fans & Grates 15887 24.0 5213 217 662 3.05

Auxiliaries 17829 24.0 5213 217 743 3.42

LS TO CLINKER(without Stoppage)

LS TO CLINKER(with Stoppage)

RAW MEAL TO CLINKER(without Stoppage)

RAW MEAL TO CLINKER(with Stoppage)

1.23

1.23

19.33

19.33

IX.Team Work in Encon / Monitoring & Reporting / Employee Involvement in Encon

IX. Team work in Encon

Description Project - 1 Project - 2 Project - 3 Project - 4

Source of En-Con Idea : Workmen Engineer Senior Management Senior Management

Whether Idea Implemented : Yes Yes Yes Yes

Name of the Project

To Provide individual

indication lamps for each of

the 15 Nos. of emergency stop

& limit switches for easy

trouble shooting.

Separate Compressor

Air Line from Line-1

Comp. 132 KW Main

Header to coal mill to

avoid pressure loss

through the line.

Reject Re handling

system for CVRM-II

Up gradation of fly ash

compressor with energy

efficient compressor

from existing BDJL

Compressor

Details of Members in the

Implementation Team / Core

Group (Nos, & Designation):

1.Mr. V. Murugesan-

Electrician

2.Mr. Chandra Mohan Reddy -

SPE

1. Arokiaraj S - 2846 -

PE

2. Mr. Karunanithi

3. Mr.Suresh - 11582 -

Vinayaga Engg

4. Mr.Ramesh - 15768 -

Vinayaga Engg

Mr.P.Gunasekaran

Mr.Nagesvararao

Batchu Mr.Jayaraman

Mr.U.Venkateswarlu

Mr.H.S.Nagesh,

Mr.G.Rajamanickam

Implementation : Mar’16 Mar’16 July'17 July'17

Description Project - 5 Project - 6 Project - 7 Project - 8 Project - 9

Source of En-Con Idea :Senior

Management

Senior

Management

Senior

Management

Senior

Management

Senior

Management

Whether Idea Implemented : Yes Yes Yes Yes Yes

Name of the ProjectELGI Make screw

compressor integrated

with VFD model

Hybrid blower for

pyro jet burner

AFR feeding system

for Line-2 and

Shredder machine

Replacement of Air

slide with screw

compressor in old

silo

BE-I & BE-2 Gear

box, Preheater fan,

Pan Conveyor &

ESP Fan & ESP up

gradation for

increasing the Line 1

kiln volumetric

loading

Details of Members in the

Implementation Team / Core

Group (Nos, & Designation):

Mr.H.S.Nagesh,

Mr.R.Sekar

Mr.M.Gopalakrishna

n

Mr.Sendil

Mr.L.Karunakaran

Mr.M.Gopalakrishna

n

Mr.L.Karunakaran

Mr.A.MoideenKutti

Mr.R.Sekar

Mr.H.S.Nagesh

Mr. R. Saravanan,

Mr. P. Balaji,

Mr. Visuventhan

Mr. A. Rajesh

Implementation : June'17 June'17 July'17 July'17 July'17

IX. Team work in EnconContd..

IX.Team Work Involvement of employees

✓ Suggestion Scheme

✓ Good Work Award

✓ Long Service Award

✓ Employee of the Month

✓ EOM Training and Dinner

✓ Workers Education Class

✓ Nomination for Tamilaga Arasin Uyarntha Ulaipalar Virudhu

✓ Safety Quizzes in Gate Meeting

✓ Safety Messages Sharing in Gate Meeting

✓ Productivity week/ Environmental Day Celebrations Various Contests

✓ National Safety Day Celebrations Various Contests

✓ Safety Committee Meeting Members Participation

✓ Various External Awards Participation

✓ Birthday Fiesta/Long service Mass Tree Plantation

✓ Trained for New Safety Approaches

X. IS/ISO 50001:2011,Green Pro Certification

Energy Management SystemCertifiion

IS/ISO 50001:2011

Dalmia PPC - Green Pro Certified by CII

Road Map & Initiatives in 2018-2019

No Title of Project YearAnnual Electrical

Saving (kWh)Expected

Savings in Lacs

1Line 2 - Packing plant - Bag filter fan VFD required to avoid damper loss & damper control

2018-19 73440 4

2Upgradation of Bag Filter Purging System in Line 1 Raw Meal Silo

2018-19 81360 4

3Optimization of CPP 1 & 2 Supply Frequency Optimised at 49.5 Hz

2018-19 775200 38

4

Line 1 PYRO - Raw meal blending silo - Single

silo operation from december'17 ( 22 - 40 KW/

Hr ) and another 25 KW to get after silo areation

blower modification

2018-19 216960 11

5Optimization of Raw meal Silo Aeration Blowers - Line 2

2018-19 116280 6

6

Heat load requirement after reducing the false ceiling height

in the CVRM 2 MCC 10 Inst VFD room2018-19 105120 5




Savings in Lacs

7

Starvation switch/Current based operation for line2 linear stacker Boom belt conveyor and to be interlocked with long belt ( Flyash, Coal,Limestone)

2018-19 51680 3

8

Bag counting system for Roto Packer to reduce idle running of belt conveyors

2018-19 48960 2

9

VFD to be installed to 2 more bag filter fans in Line 2 PH

2018-19 146880 7

10Line 1 CCR 2nd floor AC - timer based switching operation with damper control

2018-19 131400 6

11

Horizontal deployment of Occupancy Sensor in Load Centres in Line1 & 2 Load Centers

2018-19 43800 2

12Polysius LP Compressor to be shifted to Line 1 Carbon black / CPP fly ash unloading Point

2018-19 11300 1




Savings in Lacs

13 Partition for VFD room - RABH load Centre

2018-19 31200 2

14Replacement of conventional Aluminum/Cast iron

fan blades with FRP Blades in Axial Fans(Kiln

shell Cooling fan & Tyre cooling).

2018-19 62400 3

15

Line 1 Coal Mill feeding - existing double flap to

be replaced with the SPARE RAL of Line 2 Coal

mIll for trail purpose. (To reduce false air )

2018-19 52800 3

16Temperature based AC Plant operation for Line 1

& 2 CCR

2018-19 87600 4

17

Line 1 Clinker silo bagfilter damper optimization

using softstarter2018-19

52800 3

18

All the auxillary Bad Filter fans Line 1 & 2 power

to be optimized,Bag filter list with operation

mode, posibility for energy savings to be

summarized

2018-19




Savings in Lacs

19 Line 1 Admin Bldg, CCR Bldg new AC to be

selected with higher efficiency conditioning units

2018-19 105120 5

20Line 2 cyclone 1 inlet duct further widening by

400 mm

2018-19 124800 6

21CVRM 1, 3 KS to be replaced with RAL

2018-19 312000 15

22 Stopping of one package AC in RTC

2018-19 52560 3

23 water cooled condenser for the MCC 10 VFD

room

2018-19 30240 1

With these Best Practices Clean and Green DPM Plant 80 years Young

Greenery Development

HIGHLIGHTS-Greenery Development

XI. AWARDS & ACCOLADES

CII - Excellent Energy Efficient Unit - 2016 CII - Excellent Energy Efficient Unit - 2017

CII - Green Pro Certyified -2016

National Energy Award-BEE

XI. AWARDS & ACCOLADES

Bagged TNPCB- Green Award-2016Received from Tamil Nadu Chief Minister on 11th Oct'17

National Award from NCCBM- Dec'17

Our Unit Bagged 4 Awards from NCCBM for Best Environmental Excellence, Bestelectrical energy Performance, Best Thermal energy Performance andImprovements.

APEX INDIA AWARDS -2017 Energy Efficiency &

Environmental Excellence – Apr’18

CII-SR 5S Excellence Award 2017-18

CII EHS AWARD 2015– 4 STAR RATING CII-ITC Sustainability Award 2014

CII-ITC Sustainability Award 2013 CII-ITC Sustainability Award 2012

Sustainability & EHS Awards

Lowest Carbon footprint as a Group in the cement world

Also the First cement Company Globally to sign RE 100

and EP 100

Our GCEO with Mr. Ban Ki Moon,

Secretary General, United Nations at the

Paris Climate Agreement signing

Ceremony

What is Unique in Assessment year 17-18?

1) Focus on AFR-7.75%TSR (as against national avg of approx. 4% ) Fossil Energy conservation.

2) Over 15 Innovations & 27 Nil investment Projects in 17-18 , as highlighted in PPT, all contributing to Energy. Four key innovations are as below :

i. New product development within existing resource ii. Conversion of cement mill for coal (in order to ensure fuel mix change).iii. Nox new emission norm compliance thro’ in house innovation.iv. In-house innovation to enhance AFR

3) Our DPM plant won 21 National Awards in 17-18. Predominantly on Energy & Innovation.

4) 4 Energy papers in NCCBM Dec’17 (Most by any cement plant) 5) Platinum award from APEX Award-Feb’18 (only plant amongst our group units)6) Out of several participants,33 plants shortlisted for TN Govt. CM Award for Green. Dalmiapuram

was one of three among overall & only cement plant to get this CM award –Oct’17

7) Only Plant in the World making 16 Varieties . (still energy efficient with innovations )

66

TEAM DPM’s Manthra

We have never said

“Yes to No”

(Made the impossible, Possible)

26.14

20.85 20.31

23.65 23.15

0

5

10

15

20

25

30

Fy'13-14 Fy'14-15 Fy'15-16 Fy'16-17 Fy'17-18

Cement Production ( in Lakh MT)

AFR Consumption - % TSR

0.3

1.59

11.88

13.36

10.75

7.65

0

2

4

6

8

10

12

14

16

Fy'12-13 Fy'13-14 Fy'14-15 Fy'15-16 Fy'16-17 Fy'17-18

Lowest Carbon footprint as a Group in the cement world

Also the First cement Company Globally to sign RE 100

and EP 100

Our GCEO with Mr. Ban Ki Moon,

Secretary General, United Nations at the

Paris Climate Agreement signing

Ceremony

70

III. Other Energy conservation Initiatives

✓ Special cement grinding shifted from Ball Mill to CVRM’s – savings SPC .

✓ Minimized compressed air SPC reduced from 4.5 to 1.9kwh/ton of cement

✓ Kiln coal conveying air line bends 3 No’s reduced.

✓ VFD’s taken in line for energy conservation and optimization(More than

200 No’s of VFDs for Fans, Compressors are in inline)

✓ Continuous Monitoring by Energy Committee at Unit & Group Level.

✓ Continuous monitoring of false air in each section and reduction activities

✓ Operation & Optimization of Air Blasters in Kiln inlet raiser duct &cooler

to reduce the compressor air consumption

✓ Best practices of other cement plants adopted.

ENCON PROJECTS WITH NIL INVESTMENT

No Title of Project Year

Annual Electrical

Saving (kWh)

Annual Electrical

Cost Saving (Rs million)

Annual Thermal Saving Annual Thermal

Cost Saving (Rs

million)

Total Annual Savings

(Rs million)

QuantityUnit of

Measurement

1 Maximization of Line 2 Operation 2015-16 3913 Ton / Year 20.815858 20.82

2 Product Mix 2015-16 1956 Ton / Year 10.407929 10.41

3Commissioning of weigh bridge for Bulk Loading of Cement at Line-II Packing House

2015-16 19667 0.12 0.12

4

Optimisation of compressor air by replacing 75 kw with 55Kw air cooled compressor in line 2 Packing House

2015-16 87420 0.52 0.52

5optimizing bag filter fans operation in line-2 Packing House

2015-16 28500 0.17 0.17

6Power consumption reduced for PPC & OPC Cement Grinding in CVRM-2

2015-16 4500000 27.0 27.00



Annual Electrical

Saving (kWh)

Annual Electrical



Cost Saving (Rs

million)


(Rs million)

QuantityUnit of

Measurement

7

LastspecialcementgrindingshiftedfromBallmilltoGrindingOilWellcementinCVRM-1Toavoidruningtheoldballmill-savings20Kwh/mt

2015-16 230720 1.38 1.38

8Special cement grinding shifted from CVRM-1 Grinding SRPC in CVRM2 - savings 3 Kwh/mt

2015-16 546285 3.28 3.28

9Change of SRPC production from line 1 to line 2 - savings 4 Kwh/mt

2015-16 802928 4.82 4.82

10

Initiatives taken to reduce compressed air power.Arresting of all air leakages , Carrying out leakage test every fortnight, VFD drive installation for compressor units and Modification & rerouting of pipe lines In Line-2 Pyro, Cement Grinding and Packing House

2015-16 11998172 71.99 71.99



Annual Electrical

Saving (kWh)

Annual Electrical



Cost Saving (Rs

million)


(Rs million)

QuantityUnit of

Measurement

11

Separate Firing of High CV flyash and Carbon black replaced with single blower operation from 2 different bins

2015-16 100000 0.6 0.60

12Energy saving thro' clinker subtitution by way of increased flyash utilisation in PPC

2015-16 1208963 0.73 2484 Ton / Year 1.321 2.05

13Optimize Service air pressure in 18 MW and 27 MW

2016-17 71050 0.41 - - - 0.41



Annual Electrical

Saving (kWh)

Annual Electrical



Cost Saving (Rs

million)


(Rs million)

QuantityUnit of

Measurement

14Optimize the phase density of PC coal conveying blower in Line 1

2016-17 73728 0.43 - - - 0.43

15Arrest compressed air leakages in the plant

2016-17 179861 1.05 - - - 1.05

16Switch off idle running compressed air dryers in line 2 compressors

2016-17 35971 0.21 - - - 0.21

17Energy saving thro' clinker subtitution by way of increased flyash utilisation in PPC

2016-17 355566 0.21 746 Ton / Year 0.397 0.61

18Reduce pressure drop in Line 1 PH Fan from downcomer to fan inlet

2016-17 3 Ton / Year 355556 0.36



Annual Electrical

Saving (kWh)

Annual Electrical



Cost Saving (Rs

million)


(Rs million)

QuantityUnit of

Measurement

19Raw meal silo extraction single silo operation

2017-18 115200 0.40 0.40

20Reduction in pressure drop in cyclone 3 to improve heat transfer

2017-18 23859 0.08 1 Kcal/Kg clinker 0.43 0.51

21Cooler optimization by replacing cooler grate -1 plates

2017-18 - - 3 Kcal/Kg clinker 2 1.87

22Reducing size of Crusher output from max 75mm to max 65mm -Rawmill

2017-18 407921 1.43 1.43

23Optimizing of Fuel mix depending on the physical characteristics -Coal Mill

2017-18 536738 1.88 1.88



Annual Electrical

Saving (kWh)

Annual Electrical



Cost Saving (Rs

million)


(Rs million)

QuantityUnit of

Measurement

24Optimization of stoppage power in Pyro

2017-18 733865 2.57 2.57

25 Replacement of Master Roller tyre 2017-18 212538 0.74 0.74

26Replacement of Table liner & dam ring

2017-18 680121 2.38 2.38

27 AFR Consumption 2017-18 35884 Tonnes 36.00 36.00

Why Dalmiapuram Plant should be Chosen?What is Unique in Assessment year 17-18?

1) Focus on AFR-7.75%TSR (as against national avg of approx. 4% ) Fossil Energy conservation.

2) Over 15 Innovations & 27 Nil investment Projects in 17-18 , as highlighted in PPT, all contributing to Energy. Four key ones as below :

i. New product development within existing resource ii. Conversion of cement mill for coal (in order to ensure fuel mix change).iii. Nox new emission norm compliance thro’ in house innovation.iv. In-house innovation to enhance AFR

3) Our DPM plant won 21 National Awards in 17-18. Predominantly on Energy & Innovation.

4) 4 Energy papers in NCCBM Dec’17 (Most by any cement plant) 5) Platinum award from APEX Award-Feb’18 (only plant amongst our group units)6) Out of several participants,33 plants shortlisted for TN Govt. CM Award for Green. Dalmiapuram

was one of three among overall & only cement plant to get this CM award –Oct’17

7) Only Plant in the World making 16 Varieties . (still energy efficient with innovations )

ENCON PROJECTS WITH INVESTMENT


Annual Electrical

Saving (kWh)

Annual Electrical


Annual Thermal Saving Annual Thermal Cost

Saving (Rs million)


(Rs million)

QuantityUnit of

Measurement

1Upgradation of H & B, 3

spout stationary packer

2015-16

400000 2.4 2.40

2Energy efficient FRP

hollow bladed axial flow

2015-16

1193500 7.161 7.16

3

Replacing existing less

efficient motors with

advanced energy

efficient motors.

2015-16

246813 1.480878 1.48

4

Conversion of existing

mode of operation from

LRS and Damper to

GRR in VRM-2 Fan.

2015-16

292307 1.753842 1.75

5

Variable Frequency

Drive For Compressor

Application

2015-16

121275 0.72765 0.73



Annual Electrical

Saving (kWh)

Annual Electrical



Saving (Rs million)


(Rs million)

QuantityUnit of

Measurement

6Up gradation of CVRM -1

Mill fan SPRS

2015-16

490339 2.94 2.94

7

Coal (Ball) mill stopped in

Line-1 by pumping fine

coal from Line-2

(i) Line- 1 coal grinding

power 80 kWH/MT coal

(ii) Line-2 coal grinding

power 36 kWH/MT coal

(ii) Pumping power 12

kWH/MT coal

2015-16

720000 4.32 4.32

8

PD Blower replaced with

Turbo Blower for Kiln and

PC Firing

2015-16

516667 3.1 3.10

9Optimize the operation of CEP by installing VFD

2016-17

332640 1.94 - - - 1.94

10

Optimize performance of HP pump in RO plant by installing VFD

2016-17

7000 0.04 - - - 0.04

11Install VFD in Instrument air compressors

2016-17

134050 0.78 - - - 0.78



Annual Electrical

Saving (kWh)

Annual Electrical



Saving (Rs million)

Total Annual

Savings (Rs million)

QuantityUnit of

Measurement

12

AFR feeding system for Line-2 and Shredder machine

2016-17

60 MT 2689200 2.7

13

ELGI Make screw compressor integrated with VFD model (Line2 )

2016-17

65266.6 0.38 - - - 0.38

14

Replacement of Air slide with screw compressor in old silo

2016-17

227168 1.32 - - - 1.32

15

Install VFD for line 1 packing plant compressor

2016-17

21460.32

0.12 - - - 0.12

16

Pyrojet Burner installation in Line-1 kiln

2016-17

4Kcal/Kg clinker

2.4 2.41

17Spent wash firing in Line- 1 Pyro system

2016-17

0.5Kcal/Kg clinker

0.1 0.13



Annual Electrical

Saving (kWh)

Annual Electrical



Saving (Rs million)

Total Annual


QuantityUnit of

Measurement

18

Replacement of Multi louvere dampers with Guilitione Dampers for energy savings

2017-18 47520 0.28 0.28

19MPY-High Efficient Compressor for Line-2 Pyro Section

2017-18 214214 1.25 1.25

20

Replacement of Multi louvere dampers with Guilitione Dampers for energy savings

2017-18 316800 1.84 1.84

21Conversion of Purging System in Line-I Auxiliary Bag Filters

2017-18 50125 0.29 0.29

22

Line 2 cooler outlet duct (increase in diameter to reduce pressure drop & power)

2017-18 147557 0.86 0.86

23

Replacement of CVRM -1 ELGI Compressor with energy efficent Gogrej Compressor

2017-18 57672 0.20 0.20



Annual Electrical

Saving (kWh)

Annual Electrical



Saving (Rs million)

Total Annual


QuantityUnit of

Measurement

24Installation of Spent Wash firing system

2017-18 - - 1.43 Kcal/Kg clinker 1.023 1.02

25Installation of Shredder for AFR

2017-18 - - 1.58 Kcal/Kg clinker 1.798 1.80

26Cooler water spray system installation in cooler vent duct

2017-18 - - 2.0 Kcal/Kg clinker 0.136 0.14

External Awards, Recognition & Certifications received from FY15-16,17

Sl.NoName of Award / Rating /

CertificationName of Awarding / Rating /

Certifying OrganisationYear Theme of the Award*

1 National Level Award from FIMI.FIMI (Federations of Indian

Mineral Industries).2017

National Award on “Health & Safety” for PNR Mines ( Recd on 22.06.2017)

2StarRatingAwardsforMines&MineralstoourPTKMines

Ministry of Mines, Govt. of India. 2017 5 Star Rating Award

3 7th POKA-YOKE Competition Award Award - QCFI Chennai 2017 First prize Outstanding awards

4 ABK - AOTS Quality CircleAOTS AFQDIQCC quality circle

competition2017

GOLDEN AWARDS Recd on 18.7.17

5National Award for outstanding Industrial Relations

All India Organisations for Employers (AIOE) National Award

20173rd PLACE in All India ( 2nd Runner)

6Presentation on Safety & Environment Practices

ABK - AOTS DOSOKAI Kaizen Competition - Chennai

2017 GOLDEN AWARDS

7PresentationonWasteManagement(ProductivityWeekCelebration12thFeb'2017)

Madurai Productivity Council 2017Third prize Dr.APJ AbdulKalam Productivity Award





8 5s Practices ABK-AOTS-Chennai 2017 5s Platinum Award

9 5s ExcellenceCII - Confederation of Indian

Industry2016

Certificate of Excellence in Large Scale – Manufacturing Category in the CII -SR 5S Excellence Award

10 5s ExcellenceCII - Confederation of Indian

Industry2016

SRDPITI , Dalmiapuram has won the first prize in Small Scale –Service Category in the CII –Southern Region 5 S Excellence Award for the year 2016

11 Sustainability Award CII-ITC 2016Commendation for Significant

Achievement in CSR Recd. on 5th Dec’16.By Dalmia Bharat Group

12 5s ExcellenceQuality Circle Forum of India –

Chennai2016

5S- PAR EXCELLENCE AWARD(Recd.on 27Aug’16)

13 Runner up Manufacturing Today 2016 Large Excellence in Supply Chain

14 Green Pro CII 2016 Green Product Certification





15 EHS 4 Star Rating Confederation of Indian Industry 2016 EHS Practices.

16State Level Productivity /Process

ImprovementMadurai Productivity Council 2016

First prize and cash award & Second Special Award for Outstanding case study

17 6th POKA-YOKE Competition Award Award - QCFI Chennai 2016First prize Outstanding awards & Second Excellent awards

18Annual Convention /Competition on

“Innovative QC’S ”ABK - AOTS DOSOKAI-Chennai 2016

2 Nos. of First prizes Gold Category For Two Teams.

19 Best Paper Award Madurai Productivity Council 2015 Major Vetrinathan Award

20 2nd Place CII & Directorate of Factories 2015 Best Safety Practices

21 First PlaceDirectorate of Industrial Safety &

Health, Trichy2015 Zonal Safety Skit Competition





22 First PlaceDirectorate of Industrial Safety &

Health, Trichy2015

Zonal Safety Elocution Competition

23 First Place NCCBM 2015 Environment Excellence

24State Level Safety Competitions-2015

Family Essay- TamilNational Safety Council

Tamil Nadu Chapter2015

Mrs.C.SuryaW/oMr.Chandrahasan–CivilConsolation-1

25State Level Safety Award

Competitions-2015 Family Essay -English

National Safety Council Tamil Nadu Chapter

2015Mrs.Jayanthi Ramakrishnan

W/oRamakrishnan Prodn II nd Prize

26State Level Safety Award

Competitions-2015 PostersNational Safety Council

Tamil Nadu Chapter2015 Mr.Thirumoorthi II nd Prize

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