1

WELCOMES THE DELEGATES &

PARTICIPANTS OFExcellence in Energy Management -2008

COMPANY PROFILEØ Vasavadatta Cement is a unit of Kesoram Industry belongs to B.K.Birla group of companies. It has state of art Cement Plant of 4.10 MTPA located at Sedam in the state of Karnataka.

ØWe have three lines in operation.

ØOur Line –4 is under erection & as per schedule it will start in first quarter of 2009.

ØWe have Three Captive Thermal Power plant with 15 MW , 9.0 MW & 17.5 MW capacity each and 4th unit of 17.5 MW is under execution.

Ø Our products are 43 Grade Vasavadatta Super , 53 Grade Vasavadatta Super & PPC Birla Shakti.

2

0.384Switching off circulating pump at R/M & Cem.Mill of unit –3 polycom LRS

5.

25.0 TPH Increased

Reversing the HR separator rotor direction of rotation.

4.

0.35 By-passing the HR-grits to mill. 3.

0.054De rating of PC firing coal bin dust collector fan motor.

2.

5.0 TPH Increased

Addition of Gypsum to polycom1.

Savings Description SL No.

PROJECTS WITH VERY LESS IN HOUSEINVESTMENTS ( 2005 – 2008 ) Rs. Lacs

3

PROJECTS WITH COST BENEFITS( 2005 – 2008 )

1.4025.0Chain bucket elevator replaced with belt bucket elevator in Packing plant –1(**)

4.

1.644.0 Installation of refrigerated air dryers at unit –1 & 2 packing plant.

3.

7.10

83.74

Investment

9.17Energy saving & Optimization of compressed air supply in pre heater –1 & 2

2.

9.0Installation of belt bucket elevator for kiln feed in line-II (**)

1.

Savings / Annum

Description SL NO

Rs. Lacs

** - B/E Chain ,Head & Tail drum , & Sproc ket replacement was due so Belt B/E ins talled.

PROJECTS WITH COST BENEFITS( 2005 – 2008)

13.230.0SPRS system for unit –1 ESP fan 8.

20% Fright charge

25.0Cement loading in open wagon with existing loading machine.

7.

2432.00120Conversion of Cement mill to Raw mill.6.

Nil

Investment

50 ton of clinker per day

Installation of Kiln Control System for Unit –3 Kiln.

5.

Savings / Annum

Description SL NO

Rs - Lacs

4

TOTAL SP. POWER CONSUMPTIONTOTAL SP. POWER CONSUMPTION ONONCEMENT (UNIT CEMENT (UNIT –– I,II,&III OVERALL )I,II,&III OVERALL )

69.874.2 72.3

75.0974.00

80.0 80.0 79.00

50

60

70

80

90

100

K

W

H

/

M

T

3.399

3.399

00- 01

BETTER

01- 02 02–03 03-04 04- 05 05- 06 06- 07 07- 08

**

**Power Consumption Till 06 – 07 is only for Unit-1 & 2 Power Consumption For 07 – 08 is for all the Three Units.

TOTAL SP. POWER CONSUMPTION TOTAL SP. POWER CONSUMPTION OF UNIT OF UNIT –– I ,II, & III (ON PPC )I ,II, & III (ON PPC )

73.0

66.262.14

66.8 66.0668.41

73.9

80.4

50

60

70

80

90

100

K

W

H

/

M

T

3.399

3.399

BETTER

01- 0200- 01 02–03 03-04 04- 05 05- 06 06- 07 07- 08

**

**Power consumption Till 06 – 07 is only for Unit -1 & 2 Power consumption For 07 – 08 is for all the Three Units.

5

796

757

727 725715 709 712 706 711

640

680

720

760

800

840

Kca

l/Kg

Clin

ker BETTER

SPECIFIC FUEL CONSUMPTION OVERALL

02-03 03-04 04-05 05-06 06-0701-0200-0199-00 07-08

Average15.5018.7920.11R Mill –25.

Below Avg.11.5316.3720.03R Mill –14.

Above Avg.17.0525.8217.05Kiln –23.

Remarks by CMA

Best in group

Avg. in Group

Above Avg.

Above Avg.

14.2223.3916.59Kiln – 12.

0.402.00.99Crusher1.

VC Value

SectionSr.No.

BENCH MARK DATA PUBLISHED BY CMA( Jan – Mar 2007 )

Electrical Energy ( Kwh / Ton of Material )

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Above Average

673.0753705Kiln –29.

Best in Class

701743.5708Kiln –18.

THERMAL ENERGY FOR BURNING ( KCAL/ Kg OF CLINKER )

Remarks by CMA

Best in group

Avg. in Group

Above Avg.

Best in Class

19.4926.7023.05Cement Mill-27.

23.5431.9625.11Cement Mill-16.

VC Value

EquipmentSr.No.

Capacity Utilization

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Unit –1

PolysiusPolysiusPolysiusPolysiusSupplier

107105.5100120%Utilization

150191402400Present Capacity

140181402000Installed Capacity

Cem.MillCoal Mill Raw MillKiln

Unit -2

PolysiusPolysiusPolysiusPolysiusSupplier

95112100144% Utilization

200272603600Present Capacity

21024210+502500Installed Capacity

Cem.MillCoal Mill Raw MillKiln

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Unit –3

PolysiusPfisterPolysiusFLS Supplier

111108.5100100% Utilization

250382753800Present Capacity

225352753800Installed Capacity

Cem.MillCoal Mill Raw MillKiln

CASE STUDY - 1

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PROBLEM : - RAW MILL POLYCOM ROLL SLEEVE GOT CRACKED.

•A Major breakdown of Raw Mill Polycom Roller was reported on 7th June 2007. On inspection it was found entire moveable roll sleeve got cracked through out the length.

•Polysius informed non availability of Spare Roller.

•Delivery period of new Roller was approximately 12 months.

•Plant was stopped due to non availability of Raw Meal.

PREMATURE FAILURE OFPOLYCOM ROLL SLEEVE

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BRAIN STORMING

A Meeting of all Executives under the leadership of Sr.President and President was held to discuss following.

a) To get replacement from Polysius at the earliest.b) To find out alternative means to start plant.

It was decided after lot of deliberation to see possibility of converting Cement Mill No.3 to Raw Mill and start clinker production at the earliest.

CHALLENGESTo Run Cement Mill as Raw Mill following were challenges.

1) Limestone and additive feeding to Cement Mill.

2) Drying moisture of Limestone.3) Modifications required to convert Cement Mill.

4) Transportation of Raw Meal from Cement Silo toRaw Meal Silo.

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22.08.2007Raw Mill-3 restarted.12.08.2007New Forged Roll received12.07.2007Clinkerization started

23.06.2007Cement Mill-3 converted to Raw Mill

07.06.2007Raw Mill Polycom Roll Sleeve cracked on

SEQUENCE OF EVENTS FOR UNIT-3 RAW MILL ROLL FAILURE

AND RESTARTING OF UNIT-3

Limestone Transport by Truck Limestone from Reject Hopper

Two Belt Conveyors for transportation of Limestone

Limestone to CementMill DBC

TRANSPORTATION OF LIME STONE

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Hot Air Generator to dry Limestone

HAG connected to HRSeparator out let

HAG out let duct at Mill inlet.

DRYING OF LIMESTONE

View of Dense Phase placed below the Cement Silos.

Pipe line to convey the Raw Meal to Raw Mill Silo

TRANSPORTATION OF RAW MEAL FROM CEMENT SILO TO RAW MEAL SILO.

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RAW MEAL TRANSPORTATION COMPRESSOR HOUSE.

We are very proud of producing Clinker by converting Cement Mill to Raw Mill within 40 days of stoppage due to Polycom Roll Sleeve breakdown.

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BENEFITS

• Longer period Stoppage of kiln avoided. • With The raw meal produced by cement

mill we have produced 1.08 lac ton of clinker .

• A saving of 24.32 Crores .• A perfect time gap filling proposal.

CASE STUDY - 2

• NO PROVISION TO LOAD OPEN WAGONS IN THE EXISTING WAGON LOADER

ARRANGMENT

PROBLEM

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SOLUTION :SOLUTION :

• ADDITIONAL WAGON LOADER DRIVE FEED CONVEYOR FABRICATED AND SUPPORTED WITH FABRICATED STRUCTURE AND BAG DIVERTOR ARRANGEMENT.

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BENEFITS:BENEFITS:

v IT IS DIRECT SAVING OF 20% ON FREIGHT.v EASY TO LOAD OPEN WAGONS.v LESS DUST EMISSION.v POWER SAVING OF 3.7 kW.v EASY FOR THE LOADING LABOUR TO LOAD

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CASE STUDY - 3

Reduction of Harmonics at Design Stage

Previous Condition

6 - Pulse

TRF PCC I/C

6.6 KV

PCC

SFU

MCC

VFD 6-Pulse

Breaker - HT

LT - Breaker

LT- Breaker

00

00

00

VFD

00

18

6.6 KV

PCC St ar Delt a

HT - Breaker

00

Star

Delta

12 Pulse VFD

Present Condition

BENEFITS• Avoided Nuisance tripping of Electrical circuit

breaker.• Maintain the Harmonics level in current &

voltage well within the limit.• Avoided the 3rd ,5th & 7th more predominant,

Harmonics.• This is first time of it’s kind instillation in any

Cement industry.• M/s Holtec consultancy accepted that this is one

of the best configuration & know they have made this as Standard Configuration.

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METHODOLOGY OF ENERGY SAVING / SUSTAINABILITY

Ø Awareness and training to employees for energy conservation .

Ø Periodic energy audit , continuous monitoring , review of targets & bench marks for energy consumption.

Ø Identifying potential areas & equipments for energy conservation.

Ø Implement , innovative Ideas / Modifications , Improvements and up gradation of the equipments.

Ø Process optimization to minimize specific energy consumption.

Ø Adopted the concept of TPM in the year 1997 .

Ø ISO 9001 , ISO 14001 and IS 18001 implemented .

ØMultifunction meters for power monitoringinstalled .

Ø All predictive maintenance tools are used tominimize break downs .

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ENERGY MONITORING FORMAT

Specific Power Consumption for the date : 28/03/2008

75.081.361.0222.624.4620.8623.141.600.01

TotalMiscP.PlantCement Mill

Coal Mill

KilnRaw Mill

CrusherMines

29.5031.028.5Cement mill working days /month

680.55698.42684Cement mill running hours

148.6166.83104Cement mill out put rat e (Tons/Hr)

636.57728684Raw mill running hours

141.14146.63148Raw mill out put rat e (Tons/Hr)

30.031.028.5Kiln working days

716744684Kiln running hours

100107.42100Kiln out put rate (Tons/Hr)

Jun -08Best Achieved

Purta Section

Best Achieved Performance

Unit –1

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- 0.65276.70276.049PPC Grade ---Nil Nil 53 Grade

- 1.4587.72686.27643 Grade Unit -3

- 0.02369.4269.40PPC Grade

+ 0.35185.73086.08153 Grade - 0.10179.64879.54843 Grade

Unit –2- 1.31366.09164.778PPC Grade - 0.98683.89682.90953 Grade

---Nil Nil 43 Grade Difference May –08Jun - 08Unit –1

Power Allocation for the month of June -08

VASAVADATTA CEMENT