sree jayajothi cements private limited … cement... · sr.gm-engineering sr.gm-operations ... 5...

Team Members:

R Venkateswarlu-Sr.DGM (Safety)

R.Laxmana Rao-DGM (Instrumentation)

E.Parameswara Rao-Dy.Manager (Process)

SREE JAYAJOTHI CEMENTS PRIVATE LIMITED

YANAKANDLA-KURNOOL-A.P

CII ENERGY EXCELLENCE AWARD-2017-18

➢ My Home Industries Pvt. Ltd. (MHIPL) was

established in the year 1998 with an installed

capacity of 0.2 MTPA, which has now risen to

10 MTPA.

➢ My Home Group have Various businesses like

Cement ,Construction, Real Estate, Power and

Education.

➢ MHIPL is a joint venture with CRH plc.

Ireland, an international leader in building

materials.

➢ SJCPL was taken Over by MHIPL in August

2013.

➢ SJCPL, YCW has Single line (capacity 3.2

MTPA) with state-of-the-art-Technology from

LNVT, the world’s leading suppliers of Cement

manufacturing equipment.

Company Profile

Location Capacity

SJCPL-Yanakandla Cement Works-Kurnool 3.2 MTPA

Mellacheruvu Cement Works- Kodad 3.3 MTPA

Vizag Grinding Unit- Yalamanchili 2.0 MTPA

Tuticorin Grinding Unit- Tamilnadu 1.5 MTPA

Total 10 MTPA

My Home Group Cement Businesses

Cement Process Flow Diagram

Management Systems

SJCPL Policies

Energy Review Methodology

Review of Energy Consumption with

respect to production in Daily

Production Meeting

Energy Committee Cell meeting for

Review of Energy Conservation

Projects

Setting of Annual Targets for

achieving National and International

Benchmark

Daily Monthly Yearly

Unit Head

Sr.GM-Engineering Sr.GM-Operations

HOD-Mech HOD-ProcessHOD-Elect Energy Manager HOD-Inst HOD-Mines HOD-QC HOD-Stores

Section

Incharges

Section

Incharges

Section

Incharges

Section

Incharges

Section

Incharges

Section

Incharges

Section

Incharges

Energy Management System Organization Structure

737.70

715.00

697.70695.10

692.58

670.00

680.00

690.00

700.00

710.00

720.00

730.00

740.00

750.00

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

Sp.Thermal energy Consumption -Kcal/Kg Clinker

45 Kcal/Kg cl

6.2% Reduction

Energy Performance From last 5 Years

54.1

52.3252.06

51.16

49.77

47

48

49

50

51

52

53

54

55

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

Electrical SEC: Up to Clinkerisation, Kwh/Ton of Clinker

4.33 Kwh/Ton of cl

8 % Reduction


78.8075.46

78.26 76.35 75.53

55.28 55.84

62.74 64.1267.44

0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

80.00

90.00

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

Electrical SEC : Total Plant ,Kwh/Ton of Cement

Kwh/ton of Cement % of OPC Production


1443.56 1428.73 1366.33

750.58 704.14610.34

0200400600800

1000120014001600

2015-16 2016-17 2017-18

Lakh Units Units cost Rs.Lakhs

46

48

50

52

54

56

Top 10 BestPlants

Top 3 BestPlants

SJCPL

54.08

49.17 49.77

Electrical SEC up to Clinkerisation

Kwh/Ton of Cl

60.00

65.00

70.00

75.00

80.00

Top 3 BestPlants

Top 10 BestPlants

SJCPL

66.20

70.76

75.53

Total Plant Electrical SEC

Kwh/Ton of Cement

680

685

690

695

700

705

Top 10 BestPlants

Top 3 BestPlants

SJCPL

703

690692

Thermal SEC -Kcal/Kg Clinker

National Benchmarking

Electrical Energy Bill

Ref :CII Energy Benchmarking for Cement Industry Version. 2.0, May 2015

Major Modification in 2014-15

S.No Project Description Reason for Modification

1 Precalciner height was extended downwardsTo Complete burn out of fuel and to

enhance the Production Capacity

2Entire Clinker Cooler was replaced with FLS CB Cooler with ABC

inlet

To increase the Heat Recuperation

efficiency and also to ensure better run

factor

3 Top Stage cyclone-1 was modified To improve the Collection efficiency

from 90-96%

4Low density Refractory bricks were lined in Cyclone-1 supplied by

M/s Skamol A/S, DK-7900 NykØbing, DenmarkTo reduce the Radiation losses

5

Preheater down comer duct was modified to the same diameter from

top of cyclone-1 to the preheater fan inlet to reduce the pressure

drop.

To reduce the pressure drop from Top

cyclone to PH fan inlet

6 Replaced kiln inlet & outlet seal arrangement with lamella seal

To avoid false air entry and to improve

the life of tip castings.

7 Modified kiln inlet smoke chamber with introduction of “Trough”To reduce Hot meal entrainment in Kiln

exit gases

Pre-calciner Modification Cyclone-1 Modification

KILN OUTLET SHELL AND SEAL BEFORE MODIFICATION

KILN OUTLET SHELL AND SEAL AFTER MODIFICATION

Kiln Outlet Seals ModificationPrevious Cooler FLS CB Cooler

Major Modification in 2014-15

S.No Project type

EnCon

Projects

2015-16

EnCon

Projects

2016-17

EnCon

Projects

2017-18

Total Annual

Savings

(Rs. In Lakhs)

CO2

Mitigation-

MT/Year

1 Zero Investment 3 13 5 250.41 1813

2 Investment 5 9 4 516.96 15506

Total 8 22 9 767.37 17319

Energy Conservation Initiatives

Zero Investment Investment

EnCon Projects 2015-16

S.No Project Description

Annual Electrical Savings Lakh Kwh

Annual ThermalSavings

Annual Electrical Savings

Total Cost Savings

Lakh Units Rs. Lakhs MT of Fuel Rs. Lakhs Rs. Lakhs

1 a).Entire burner replacement with new FLS

Duoflex burner

b).Kiln outlet sealing arrangement with

lamella seal.

1.74 9.03 5139.4 272.39 281.42

2 Conversion of 15 no's of kiln shell cooling

fan motor from delta to star connection 3.26 16.96 0 0.00 16.96

3 25 nos. of 90 watts LED Lamps fitted

instead of 250 watts SV lamps0.16 0.84 0 0.00 0.84

4 Timer Based ON/OFF lighting programmed

for colony street lighting0.04 0.19 0 0.00 0.19

5 Conversion of motor from delta to star

connection of Packing plant bucket Elevator

for 4 nos.3.36 17.46 0 0.00 17.46

6 Provided ON/OFF inter lock system for

GGBS Bin aeration blower based on

controlled bin weight0.38 1.97 0 0.00 1.97

7 Replacement of Raw Mill fan inlet Venturi

duct to reduce pressure drop3.60 18.72 0 0.00 18.72

8 Replacement of Coal Mill fan inlet Venturi

duct to reduce pressure drop1.56 8.11 0 0.00 8.11







Total Cost Savings


1Interlock Cooling tower fans operation

with cold well temperature0.18 0.96 0 0 0.96

2 Reduce False Air in Coal Mill Circuit 1.28 6.63 0 0 6.63

3 Reduce False Air in Raw Mill Circuit 1.22 6.35 0 0 6.35

4 Reduce false air across preheater 3.68 19.16 0 0 19.16

5Avoid venting air in Raw Mill Silo Aeration

Blowers0.26 1.35 0 0 1.35

6Reduce pressure drop across damper in

crusher bag filter fan by installing VFD0.57 2.95 0 0 2.95

7 Optimization of Slag Mill inlet pressure 1.28 6.66 0 0 6.66

8Avoid head loss across Venturi in Slag Mill

fan0.80 4.16 0 0 4.16



Annual Thermal Savings


Total Cost Savings


9 Avoid damper loss in Cement Mill Fan 2.44 12.71 0 0 12.71

10Reduce pressure drop across Clinker silo

top bag filter fan damper0.13 0.68 0.00 0.00 0.68

11Avoid head loss across Venturi in

Cement Mill fan4.63 24.07 0.00 0.00 24.07

12Avoid damper loss in coal mill bin venting

bag filter fan by installing VFD0.26 1.35 0.00 0.00 1.35

13Inlet Louver dampers of Cooler FD Fans

are removed5.23 27.20 0.00 0.00 27.20

14 Optimization of packing plant bag filters 0.71 3.71 0.00 0.00 3.71

15Raw Mill Cyclone RAL Motor connection

changed from Delta to star connection

(4No’s).

0.66 3.42 0.00 0.00 3.42






Annual Thermal Savings


Total Cost Savings


16Replaced 55 Kw Laterite Belt conveyor

(221 BC-9)) motor with 37 KW motor 0.52 2.69 0.00 0.00 2.69

17Star / Delta panels are arranged for

Cement Mill Reject Bucket Elevator0.10 0.54 0.00 0.00 0.54

18Changed Raw mill Magnetic separator

Motor connection from delta to Star

connection

0.09 0.46 0.00 0.00 0.46

19

Changed 2 nos of Cement mill Magnetic

separator Motor connection from delta to

Star connection

0.22 1.16 0.00 0.00 1.16

20Installed HT Capacitor banks to improve

the Power Factor18.25 94.90 0.00 0.00 94.90

2190 W LED Fittings replaced in place of

250W SV LAMP Fittings (150 No’s) 0.88 4.56 0.00 0.00 4.56

22Introduced the high efficiency Transformer

for the cooler ESP field 1 & 22.34 12.17 0.00 0.00 12.17








Total Cost Savings

Lakh Units Rs. Lakhs MT of FuelRs. Lakhs

Rs. Lakhs

1Improved Coal Conveying phase density by

re-rooting the coal conveying line7.865 47.19 383 28.89 76.08

2Avoided Raw water pump running in Pump

House0.45 2.70 0 0 2.70

3 Optimization of Nitrogen compressor air 6.99 41.92 0 0 41.92

4Installation of VFD for Cement Mill Booster

fan 2.25 13.50 0 0 13.5

5Modification of Gypsum feeding belt

conveyor with Y-Chute0.21 1.26 0 0 1.26

6Installation of High Efficiency impeller for

Cooler ESP fan1.885 11.31 0 0.00 11.31

7Removal of Cooler fans Silencers for

reduction of pressure drop across silencers2.925 17.55 0 0.00 17.55

8

Installation of VFD drive for 511 BC3

Venting Bag Filter for reduction of damper

loss-Cement Mill Section

0.32 1.94 0 0 1.94

9Installation of LP Compressor for fly ash

unloading1.61 9.66 0 0 9.66

Innovative Projects

PROJECT-1

INSTALLATION OF Y-CHUTE FOR GYPSUM FEEDING

Project Description:

In our Cement Mill & Slag Mill section, we have 3 belts conveyors for

Gypsum feeding. At Gypsum Hopper top, spillages was happening daily

under the belt conveyor.so, every day Man Power were deploying for

spillage cleaning.

Action Taken:

After Brain Storming, On view of Energy Conservation and to avoid

spillages, our team has decided to install a In-house designed Y-Chute for

Gypsum Feeding at top of the hopper in place of reversible belt.

Benefits:

Annual Power Saving :0.21 Lakh Kwh

Annual Cost Saving :Rs.1.26 Lakhs

Investment :Zero

Pay Back :Immediate

Before

After

Before After

PROJECT-1

INSTALLATION OF Y-CHUTE FOR GYPSUM FEEDING

PROJECT-2

INSTALLATION OF SOLAR LIGHTING SYSTEM IN MINES AREA


Earlier Mobile lighting Diesel generator was used for lighting purpose in

our new Limestone Mining area. Diesel generator consumes more HSD oil

at around 493 Lts/Month (5.75 KL/Yr.). On Energy Conservation View and

environmental protection View our team has decided to replace the Mobile

lighting Diesel generator with Solar Lighting System.

Action Taken:

Our team has installed a Solar Lighting System in place of Mobile Lighting

Diesel Generator at New Limestone Mining area.

Benefits:

Annual GHG Reduction :17.25 MT of CO2

Annual HSD Saving :5.75 KL

Annual Cost Saving :Rs.3.74 Lakhs

Investment for Solar Panels :Rs.2.85 Lakhs

Pay Back :9 Months

Mobile Lighting DG Set

Solar Lighting System

PROJECT-3

REMOVAL OF VENTURIES FOR ALL PROCESS FANS

Project Description :

Installed Raw Mill (LM 56.4+4 ), Cement Mill (LM56.3+3), Slag Mill (LM46.2+2) & Coal Mill

(LM28.2+2) for raw materials Grinding. All mill fan inlet ducts are designed with Venturies for

online flow indication. It was identified and measured that Venturi pressure drop was 15-25 mmwg.

Reviewing the Venturies Pressure drop, management decided to remove the venturies for all

process fan inlet ducts.

Action Taken :

All venturies were removed and hooked up with In- house fabricated same diameter duct at all

process fans inlet ducting to avoid pressure drop across venturies.

Benefits:

Area Annual Electrical

Saving - Lakh Units

Annual Cost Saving

Rs. Lakhs

Investment

Rs. Lakhs

Pay Back-

Months

Coal Mill 1.56 8.11 2 3

Slag Mill 0.8 4.16 2.2 6

Raw Mill 3.6 18.72 12.5 8

Cement Mill 4.63 24.07 6.76 3

Coal Mill Slag Mill

Raw Mill Cement Mill

Before

BeforeBefore

BeforeAfter After

After After

PROJECT-3

REMOVAL OF VENTURIES FOR ALL PROCESS FANS

EnCon PROJECT-1

REPLACEMENT OF PRESENT BURNER WITH DUOFLEX BURNER


Previous burner was designed for lower capacity and

consumes more primary air at around 13-14%. It was decided

to reduce the Primary air consumption for reduction of STEC

by installing the FLS Duoflex burner.

Action Taken:

With management’s approval ,Existing burner was replaced

with New Duoflex Burner to reduce Primary air consumption

for reduction in STEC

Benefits:

Primary Air percentage reduced from 13% to 8%

Sp.Heat Consumption reduced by 3 Kcal/Kg Clinker

Project Description :

Earlier high pressure compressor (6 bar ) was used for fly ash unloading

by regulating the pressure from 6.0 bar to 3.0 bar. It was decided to install

a dedicated Low Pressure compressor for pumping the flyash into

Concrete silo to reduce the Power consumption and safety concerns.

Action Taken :

With management’s approval, LP compressor was installed dedicatedly for

flyash tankers unloading and pumping into the concrete silo.

Benefits:

Annual Power Saving = 1.61 Lakh Kwh

Annual Cost saving = 9.7 Lakhs

Investment = Rs.25.6 Lakhs

Pay back = 2.6 Years

Before-6.0 bar After-3.0 bar

EnCon PROJECT-2

INSTALLATION OF LP COMPRESSOR FOR FLY ASH UNLOADING

Utilization of Renewable Energy

0

2

4

6

8

10

12

14

16

18

20

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

0 0

11.65

18.15

Lakh Kwh

Installed in August-2016

Utilization of Waste Oils instead of HSD Oil

➢ Petro Polymer Fuel & Pyrolysis Oils are used for Kiln Light up and

Hot air Generator Light Up.

➢ Pyrolysis Oil is generated from Tyres waste

➢ PPF is generated from Plastic Waste

➢ 1MT of HSD oil releases the 3 MT of CO2 Gases.

➢ By using this PPF & Pyrolysis oil, the Carbon emissions are also reduced.

25

31.31

0

5

10

15

20

25

30

35

2016-17 2017-18

Pyrolysis Oil-KL

75

94

0

20

40

60

80

100

2016-17 2017-18

Co2 emissions reduction-MT/Yr

Green House Gases Mitigation

830

840

850

860

870

880

890

900

910

920

930

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

922.60

911.57904.13

864.71

Kg CO2/MT Clinker

Good

Green House Gases Mitigation

Year

Scope 1 emissions Scope 2 emissions Scope 3 emissions Total

Kg CO2/MT

Clinker

Kg CO2/MT

Clinker

Kg CO2/MT

Clinker

Kg CO2/MT

Clinker

2014-15 835.67 86.41 0.52 922.60

2015-16 825.16 85.46 0.95 911.57

2016-17 822.17 81.03 0.93 904.13

2017-18 786.80 77.04 0.87 864.71

Scope-1 Cement Process-Calcination , Fuel burning in Kiln and HAG

Scope-2 Electricity Consumption form Grid

Scope-3 Raw Material Transport

PAT CYCLE-2 status

1059

1005

995

960

980

1000

1020

1040

1060

1080

Base Line

2014-15

Target

PAT Cycle-2

Achieved

2017-18

GTG SEC- (Kcal/Kg Eq.of Cement)

S.No Project Description Investment Rs.Lakhs

1 Installation of 7 MW Waste Heat recovery System 7500

2 Installation of 10Mwp Solar Power Plant (Phase-2) 8000

3 Improving the TSR 1% to 3 % by installing the AFR System 150

4 Installation of Pfister pumps for pulverized coal pumping system 400

5Optimize the pressure drop across preheater from cyclone 4 to

cyclone 280

6 Installation of High efficiency impeller for Cement mill fan 35.20

7 Installation of High efficiency impeller for Raw Mill Bag House fan 33.74

8 Replacement of all conventional lights with LED lights 42.25

Road Map for Achieving National & International

Benchmarking (2018-19)

0

2000

4000

6000

8000

10000

12000

14000

16000

18000

20000

15000

18898

11639

9098

Saplings

Green Belt Development

Water Conservation Methods

Mines Pit

STP -300 KL

Rain Water Harvesting Pits

Capacity-1.36 Lakh m3

Online AAQS

Water Sprinkling at Mines Roads Vanam Manam Program Plantation on 44th World Environment Day

Environmental Activities

Employees involvement & Awareness on Energy Conservation

Water & Energy Conservation Pledge on Every Saturday Energy Cell Meeting

Training Programs on Energy Conservation for Employees & Employee’s spouse


Awareness Program for Promotion of Blended Cements for reduction of Green House Gases

for Cement dealers, Marketing & Sales department

National Energy Conservation Day-2017 Celebrations

44th World Environment Day-2017 Celebrations


INDIA’ S MOST PROMISING BRAND 2015 AWARD

By World Consulting & Research Corporation, LONDON

Awards & Accolades

Awards & Accolades

SEEM National Energy Management Award-2016 SEEM National Energy Management Award-2017

APEX India Excellence Award-2017NCCBM Best Energy Practices Award-2016

sree jayajothi cements private limited … cement... · sr.gm-engineering sr.gm-operations ... 5...

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