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Trusted Technology – Solid Strength

Trusted Technology - Solid Strength

PRODUCTS

MINE SITE

GULBARGA

☺❖

❖

PLANT SITE

Mining Crushing Stacking & Reclaiming

Clinkerisation

ClinkerGrinding

Packing

Delivery Truck

Coal Grinding

Delivery Rack

Delivery Bulk

Raw MealGrinding

Stacking & Reclaiming


Total Sp. Power Consumption Overall (All Grades) (Kwh/Ton of Cement )

10-11 11-12 12-13 13-14

Kw

h/T

on

of

Ce

me

nt

14-15 15-16 16 - 17

High producti

on in pet coke

Sp. Power Consumption up to Clinkerisation (Kwh/Ton of Clinker )

14-15 15-16 16 - 17


Sp. Power Consumption on cement grinding (Kwh/Ton of Cement )

Kw

h/T

on

of

Ce

me

nt

14-15 15-16 16 - 17

Sp. Power Consumption on cement Packing (Kwh/Ton of Cement )


SP. POWER CONSUMPTION ON PPC GRADE (Kwh/Ton of Cement )

Kw

h/T

on

of

Ce

me

nt

Year

Even after Use of pet coke

&Premium cement Trials with 18% FA

Clinker Factor for OPC cement


Specific Thermal Energy Consumption

K.C

al/K

g C

lk

Low Sp. Heat value even

after regular pet coke use

Bench Mark Comparison with other Industry:

S.No Energy UnitNational

bestInternational best

VC Value

1Thermal

energyKcal / kg clinker 682

667 (Japan)

(values for 16-17)

706.94

(Avg of all four

units)

2Electrical

energy

KWH /MT

Cement (Actual)

(100 % PPC)

65.67 65 (Japan) 56.98


PAT Requirement• New Target of 4.53 % reduction from 949 to 906 K.Cal /Kg Equivalent major Cement

Product given to us

• M/s. Zenith Energy Ltd. has carried out M&V audit, VC has Earned 50741 E-Certs in cycle 1

Base Line value

2010-11 2011-12 2012-13 2013-14 2014-15 2015-16

Heat Value KCal / Kg of Equ of cement

1098.82 1102.30 1097.56 1076.05 996.606 910.00 734.00

Green House Gases Sl.No

YearScope 1 emissions

KgCO2/MT of cement

Scope 2 emissionsKgCO2/MT of

cement

Scope 3 emissionsKgCO2/MT of

cement

Total KgCO2/MT of

cement

1 2014-15 441 238 0 679

2 2015-16 458 260 0 718

3 2016-17 457 247 0 704

4 2017-18 440 240 0 680

Green House Gases


Utilization of Waste as fuel (Alternate Fuel Utilization)

AFR Consumed MT

2015-16 2016-17 2017-18

Consumed, MT

Coal Saved

Consumed, MT

Coal Saved

Consumed, MT

Coal Saved

Benzo Feron 249 121 261 169 27 10

Tire Chips 7430 10484 21 24.7 Nil Nil

Carbon Black 9865 10139 18429 19010 14336 15292

PU Waste 94 102 Nil Nil Nil Nil

Rubber Chips 129 159 Nil Nil Nil Nil

Plastic Waste 4618 3225 5688 2193 7384 772

Municipal Waste Nil Nil 77 22 29 22

Total 22386 24230 24475 21416 21776 16097

Trusted Technology

- Solid Strength

10

Best Practices implemented in Green Supply chain:

Laterite

• Procurement of Laterite from nearest source, resulting in reduction of CO2

emission from vehicles.

• Procurement ratio is 54% from nearest source i.e., Thatepally (90 kms) and 46%

from the range of 110kms (Vikarabad Area)

Gypsum

• Utilization of Gypsum (By-product from fertilizer companies) in Cement Industry.

• Road movement has been reduced and initiated Rail movement.

Fly Ash

• Utilization of Fly Ash (By-product from Power plants) in Cement Industry.

• Transportation of fly ash by Rail through closed wagons.

Rail - 98% Road – 2%

Rail - 57% Road – 43%

Trusted Technology

- Solid Strength

11

Bauxite

• Procurement of Bauxite from Kolhapur area which is nearest source to our

plant.

Coal

• 100% receipt of coal by Rail.

Pet Coke

• Utilization of Pet Coke (By-product from Petrochemical companies) in

Cement Industry.

Rail – 46% Road - 54%

Rail – 100% Road - 0%


Projects With Very Less In House Investments

S.No

Project Description Investment RsLac

Saving(Rs.Lac )

1 Optimization of running hours of 91 No's Air Dryers of IR compressors by introducing Interlock with Compressor.

0 58.50

2 Silencer Removed And Inlet Cone Fabricated For Suitable Condition For Cooler Fans Inlet Duct(Line -3)

0 10.20

4 Optimizing Lighting system in Mines area tower lighting . 0 7.50

5 Avoiding Idle running of Compressors At Different Locations (Pre Heater / Raw Mill / Cement Mill)

0 4.79

6 optimization the HR recirculation fan in Cement Mill 0 6.00

7 Replacement of conventional light fittings with LED light fittings at various locations

5 15.62


Projects With Very Less In House Investments S.

NoProject Description Year Investment

Rs lacSaving

( Rs.Lac )

7 Avoided the running of 1L12BC (Gypsum belt) 17-18 0 1.532

8 Reduce the false air in Polycom 4 circuit & optimise Operation of HR Bag house.

16-17 0 15.25

9 Removed 1N11BF fan from the circuit 17-18 0 1.123

10 Energy conservation by stopping 2N23ABC, 2N23BBC, 2N22RA & 2N28BF

16 - 17 0 14.68

11 Reduction of false air in coal mills 16-17 0 4.79

12 Removed 2N33BF fan & its RAL from the circuit 17-18 0 2.139


Projects With Cost Benefits

S.No Project Description SavingRs Lac or Kcal

1 Compressor air line integration between U-3 to U-2. 19.8 Lacs

2 Installation of 75 KW VFD Drive for PC Firing ROS Blower (Unit II Kiln Section)

4.75 lacs

3 Main PA fan 132 KW motor replaced with existing spare 90KW motor. (Unit 3 Kiln)

5.180 lacs

4 Replacement of Unit-1 Cooler fan-2 motor with energy efficient motor

1.40

5 Avoid the running of higher capacity compressor for Raw mill 1&2 hopper top bag filter top bag filters

5.52

6 Provided VFD Drives for Packer bag filters. 4.90

7 Reduction in pressure drop across damper in CM – 4 HR, BH & Sepol fan

82.2 Lacs

Duo Flex Burner tip life enhancement in Unit – 3 & 4.

Innovative Project-1

Theme : Duo Flex Burner tip life enhancement in Unit – 3 & 4.


Before:

➢ Lot of Pits observed on burner tip, even after maintenance of burner as

given by OEM recommendation (annular gap) after few days in operation &

also there was observation that flame was off centre.

➢ To correct the flame, inner pipe of burner was retracted to make the flame

positioned at centre. The deformation in flame i.e off centre was increasing

with increasing in operation time & burner tip life was around 30-45 days

only.

Idea:

Maintain the uniform annular gap across the periphery of

burner tip in between inner & outer pipe, wedge to be

provided in all four quarters of burner.

After installation of wedges(April’18 U-4), burner tip was kept at Zero

position, flame was observed on daily basis for any deviation from

centre. Even after operating the same burner for three months

(checked in U-4 stoppage), tip was found to be in good condition.


Benefits:

1. No deformation in flame shape

2. Burner flame in center.

3. Increase in Flame momentum by maintaining Burner tip

at zero position.

4. Reduction in Sp Fuel consumption & better clinker

quality.

5. No frequent adjustment inner pipe to make the flame

center.

6. Burner tip life enhancement.

7. Reduction in SEC at the time of Cooling, ramp-up &

pickup.

8. Reduction in Kiln Thermal shocks.


Savings:I) In terms of coal consumed to restart the plant after Burner pipe

replacement (8-10Hrs)

Coal Consumed for plant heat-up 15-20MT

Coal Cost - Rs. 5700/MT(including grinding cost)

Saving - Rs 5700 x 18MT Coal consumed

- Rs. 102600 for one burner pipe

Considering two burner replacement due to tip wear in Unit – 3 & 4

which accounts to four stoppages to replace burner pipe

Net Saving - 4no x Rs102600

= Rs. 4,10,400

II) Welding material & man power cost for rebuild up.

For One Burner pipe - Rs 65000 x 4no

= Rs. 260000

III) Total saving annually = 410400 + 260000

= Rs 6,70,400


RABH below mass flow conveyors (MFC) are getting over loaded during module cleaning.


Description Before After Remarks

* Main air valve close time 8 sec 10 sec

* Lag between Main air valve close and

reverse air valve open

8 sec 10 sec

* Reverse air valve open 35 sec 25 sec

* Settling time 5 sec 40 sec

* Dwell time 10 sec 120 sec

* Cycle time for one module 56 sec 85 sec

* Total cycle time for 14 module 924sec(15.4

min)

2870sec(4

7min)

Brain storming session carried out and decided RABH

module cleaning sequence and timings to be modified.

RABH Cleaning Sequence chamber wise:


1 3 5 7 9 11 13

2 4 6 8 10 12 14

Gas In

CHAMBERSBefore

1 8

2

3

4

5

6

7

9

10

11

12

13

14

1

13

3

5

7

9

11

2

4

6

8

10

12

14

After

Gas outMFC Discharge


RAL

Reverse Air bag house

Mass flow conveyorMFC

RABH END VIEW RABH FRONT VIEW

RH side modules-7Nos LH side modules-7 nos

Gas

inlet

Gas

out


1 2 3 4 5 6 7

MFC-1

Reverse Air purging

Dust Dislodging from Filter bag

Dust accumulation

Before :Modification

RALHopper

Filter

bags

Reverse air valveOutlet valve


1 2 3 4 5 6 7

MFC-1

Reverse Air purging

Dust Dislodging from Filter bag

No Dust accumulation

After : Modification

Benefits:


• No MFC over loading after module cleaning.

• No MFC tripping.

• No frequent hopper high level alarm during module

cleaning.

• Maintained stack emission level resulted in clean

environment.

• Reduced cleaning cycle in increase of bag life.

Savings:

• Reduced RA fan start / stops from 6 to 4 times.

• Reduced run hours of RA fan resulted in power saving

90KW/day 90*4.9*330=Rs,1,45,530.

• Avoided manpower for dust spillage

Power Reduction in Unit-3 Bag House Fan.


Theme : Power Reduction in Unit-3 Bag House Fan.


After checking the operating parameters of RABH & fibre

glass bags, with I/L temp 240 Deg C continuously & peak

value of 260 Dec C, we have consulted different major

suppliers of Bags regarding the observation, all the

suppliers had given clearance to raise the temperature

against present operation. With this the matter was raised

with OEM.

OEM has accepted our observation & given consent to

revise the setting of RABH I/L Temp.

Before:

1. Two fresh air dampers are

operating in PID to control

RABH I/L temperature as

per set point of 175 Deg C

(as defined by OEM)

2. Third damper is provided to

further control the

temperature, if these two

dampers are in open

condition & temperature is

going beyond 175 Deg C.

Setting of Temperature was

as given below.

Full open at 180 Deg C &

Close at 160 Deg C


After:

➢ Fresh Air Dampers 1 & 2

Operating in PID, Set Point

Increased From 175 to 195

Degree Celsius.

➢ Interlock Provide to third

damper to Open @ 208 Deg C &

Close @ 195 Deg C Instead of

Operating @ 180 & 160 Deg C

Respectively.

Benefits:

➢ Power Saving.

➢ Improvement in Existing System.

➢ Before Modification:

May-2018 Specific Power of BH Fan:2.74

KWH/MT Clinker.

➢ After Modification:

June-2018 Specific Power of BH Fan:2.48

KWH/MT Clinker.

➢ Power Saving:

1. 0.26 KWH/MT of Clinker.

2. BH Fan Power Earliear:549.46 KWH.

3. BH Fan Power After:489.74 KWH.

4. Saving:59.72 KWH.


Investm

ent:

---

ZE

RO

--

-


1. Feasibility study conducted & Techno – economic feasibility reportsubmitted by Ms. Holtec for WHR system for line 1,2,3 & 4.

2. Increase in injection of Limestone % from 4% to 4.5%.

3. Use of 0.5% CPP bed ash in clinker coolers.

4. Up gradation of Unit -1 cooler.

5. Use of Membrane bags in all Bag filters.

6. Replacing all motors by Energy Efficient Motors.

7. Few more Instillation of Wind mills at Out let of Bag filters.

8. Planned for solar project, under initial study.

9. Use of Day light Pipes wherever possible.

10. Use of Turbo Ventilators for TG Building of CPP.

Projects in Pipe Line


IS/ISO 9001/2008 IS/ISO 14001/2004 IS/ 18001/2007

ISO / 50001:2011


MANDATORY REQUIREMENT ENERGY POLICY

Awareness & Training to

Employees. Periodic Energy Audit, Continuous monitoring, Bench Marking . Identify Energy potential areas for energy conservation. Purchase energy efficient equipment. Process optimization to minimize SEC. Utilization of RE & AFR.

Last Reviewed Date : April - 2018

Next Review Due On : Oct - 2018

Frequency : Every 6 Months


ENERGY MANAGEMENT CELL FORMED UNDER ISO 50001

System Co-ordinator Mr. C M Bagwan

TEAM-1 MINES

HMODr. CHANDAR KUMAR JAIN

No of Members- 05

TEAM-2 MINES

CRUSHER

No of Members-08

TEAM-3, 4 RAW MILL -1&2 COAL MILL-1&2

No of Members-12

TEAM-5 & 6 KILN-1&2

No of Members- 12

TEAM-7& 13 CEMENT MILL-1, 2

3&4

No of Members- 15

TEAM-8 & 14 PKG PLANT-

1,2,3 &4

No of Members- 09

TEAM-9, 10 RAW MILL-3&4 COAL MILL-3&4

No of Members-14

TEAM-11 & 12 KILN-3&4

No of Members-13

TEAM-15 AUTO GARAGE

No of Members-04

TEAM-16 & 17TPP-1 2 3 4 & 5

No of Members-19

PURCHASE

No of Members-02

HRD

No of Members-02

Management Representative Mr G Raja Rao


ENERGY MANAGEMENT CELL & ENERGY MANAGERS

LIST OF ENERGY CONSERVATION COMMITTIES

WATER MANAGEMENT

COMMITTEE

PACKING PLANT-POWER

CONSUMPTION REDUCTION COMMITTEE

CEMENT MILLS-POWER

CONSUMPTION REDUCTION COMMITTEE

IDLE RUNNING EQUIPMENTS DETECTING

COMMITTEE

STEAM LEAKAGES DETECTION

COMMITTEE AT THERMAL POWER

PLANTS

TEAM LEADER : Mr. S.S. Rao

(VP Civil)

TEAM LEADER:Mr. Revankumar Patil

(GM PP)

TEAM LEADER:Mr. K. Srinivasu

(GM Elect)

TEAM LEADER:Mr. Alibin Mohammed

(DGM PROCESS)

TEAM LEADER:Mr. Chandrashekhar Ujja

Team Members :1) Mr. Ravindra L2) Mr. Rajarao3) Mr. Shankar

Rao Patil4) Mr. K. Srinivasu5) Mr. N.P. Singh

Team Members :1) Mr. NP Singh2) Mr. Y. Srinivasa Rao3) Mr. Venkatesh

Marla4) Mr. Jaganath Adki5) Mr. V. Nagesh

Team Members :1) Mr. Udaykumar Mugli2) Mr. Rabbani3) Mr. Vijender Janib4) Mr. B. Praneeth5) Mr. D. Kranti6) Mr. Sanket K7) Mr. Ganapati8) Mr. Rajkumar

Team Members :1) Mr. Sriram Arsid2) Mr. Manjunath3) Mr. V. Madhukrishna

Team Members :1) Mr. Vishveshwarayya

Hiremath2) Mr. K.V. Ramana3) Mr. R.D.B. Patil


1.1 REVIEW PERTAINING TO ENERGY EFFICIENCY.

FREQUENCY REPORT/SYSTEM RESPONSIBILITY

24 Hrs X 7days

➢ “Prevention is better than Cure” So On line SP power Monitoring facility provided for Unit-3 & 4 at CCR.

➢ Energy consumptions reviewed in Production Meeting headed by HMO.

➢ Daily review meeting with power plant O & M teamby HOD to optimize plant performance by monitoringand controlling of parameters like auxiliary power,coal, water and plant heat rate.

➢ Energy consumptions reviewed in Cross functional Meeting headed by HMO.

➢ Stoppage , OEE & Benchmark Presentation (Specific Power Consumption, Details of Stoppages, Heat Balance ,Power plant performance )

CCR Operator

Daily HMO

HOD

HMOWeekly

Monthly

Daily

HMO


1.1 REVIEW PERTAINING TO ENERGY EFFICIENCY.

FREQUENCY REPORT/SYSTEM RESPONSIBILITY

➢ Review of Energy Management System ISO-50001Section Wise.

➢ Review of Packing Plant Power consumption.

➢ Review of Cement Mills Power consumption.

➢ Review of equipments running Idle.

➢ Review of steam leakages detection

➢ Review of Water consumption trends.

➢ Review of AOP headed by President/ HMO.

➢ Review of Energy Management System ISO-50001 with Top management , MR & Team Leaders .

➢ Surveillance Audit by external Auditor.

TEAM LEADER

Half Yearly HMO

Monthly

PRESIDENT / HMO


AMOUNT SPENT ON ENERGY EFFICIENCY PROJECTS

FOR LAST THREE YEARS

Sl NO YearAmount Spent In

Rs.Crores

1 2012-13 57.21

2 2013-14 46.38

3 2014-15 31.69

4 2015-16 60.30

5 2016-17 74.58

6 2017-18 43.6


Employees and team work1. Suggestion Scheme

2. Brain Storming

3. 5s Activity

4. Kaizen Mela

5. Fugai Finding

6. Leakage Detection

Leakage Detection Area Points Detected Points Attended

Power Plant 1110 1002

Cem Mills and Pack Plant

980 948

Crusher 520 482

YearTotal

SuggestionsSuggestions

ImplementedSuggestions

Rejected

2014-15 580 318 70

2015-16 599 451 101

2016- 17 685 414 23

2017-18 860 838 22

YearNo Of

Kaizens Registered

No Of Kaizens Completed

No.of Best Kaizens

2014-15 463 451 54

2015-16 563 497 57

2016-17 613 542 56

2017-18 684 666 62

• Energy Conservation week.

• Door to Door campaign.

• Distribution of pamphlets.

• Organizing Competitions.

• Training class to near by villages

• No Vehicle Day Celebration

• Safety Gate Meeting.

• Attending all External Trainings


ENERGY WEEK KICK START BY HMO BY WAVING FLAG

DRAMA ON ENERGY SAVING BY VVV SCHOOL

ENERGY OATH AT ENERGY CONSERVATION DAYINAUGRATION OF EC WEEK BY HMO

ENERGY CONSERVATION WEEK -2017

Energy saver Rath

On line Electrical SP Power Monitoring at CCR


•Every 15 Days

• Every 15 days

•Monthly•Monthly

Heat Balance / Radiation

Loss

False Air Monitorin

g

Cement Circuit

Sampling / Crash

Sampling

HT Fans Performance Monitoring

• Quarterly

• Half Yearly

• Half Yearly

• Half

YearlyBag

Filters Audit

Compressor Audit

Ball Mill

Audit

Comprehensive

Heat Balance

Monitoring Schedule Mini audits


➢Continuous Increase of Blended Cement share in total production shows our eco- friendly nature.

➢35.0 % of fly ash injection is achieved by continuous trials in our Laboratory and by Installing Roto

Scale for Accurate Feeding.

➢Addition of performance improvers in cement, resulting in fuel and natural resources

conservation.

➢Hot Disc Installed at Unit -3 Pre heater, First in India, to consume wastes like Tyre , Paper , plastic ,

Coconut shell, and Segregated Municipal waste.( Full Fledged AFR feeding system at Unit -4 PH to

consume more and more AFR is under progress)

➢Lab trials for composite cement is being taken, which can reduce clinker factor drastically.

➢First Cement Plant to Participate in GREENCO rating Project actively conducted by M/s CII and

awarded as First GREENCO PLATINUM cement company in India.

Our Commitment Towards Green Tomorrow


FLY ASH INJECTION


Utilization of renewable Energy sources1. Solar heating system for Industrial Canteen.2. Installed Steam Cooking in our Canteen3. Solar Lightening at New ADM building.4. Wind Mill for Bag filters installed for two bag filters

1. Techno-feasibility studies completed for Installation of Wasteheat recovery system on cooler and PH exit gases.

2. There is possibility of 17MW power generation with WHRS.3. In Advanced stage for installation of 5MW solar power

generation.

Initiative

implemented

Action

Planned

For future


Environmental Projects

Initiatives

On

Environment

Conservation

1. Obtained Authorization From CPCB & KSPCB For Burning OfHazardous waste /Non Hazardous Waste , like Tire Chips, PlasticWaste etc.

2. Fly ash transportation by rail.

3. Reduced the bauxite consumption percentage by optimizing theraw mix.

4. Planted Huge number of trees with 53 % of survival.

5. Rain water storage capacity of 40.00 Lac cu.mt at Mines & 4.00Lac cu.mt at Power plant pit.

6. Majority % of water requirement is full filled by Rain Water.

7. Installed Two On line Ambient Air Quality Equipment in Up Wind& Down Wind Direction.

8. Recorded 96 % of plant water requirement is managed with Rainwater Harvesting. Planning to reach 100 %.

9. Signed MOU with Goa Government for Supply of Plastic Waste.

10. Signed agreement with Ramkey for supply of 75 Tons/Day waste

Still Long way to go …………. Let us Start now with new Aim

THANK YOU

trusted technology solid strength cement_61_kesoram...trusted technology - solid strength pat...

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