Dalmia Cement (Bharat) Limited, Kadapa -...
Transcript of Dalmia Cement (Bharat) Limited, Kadapa -...
18th National Award for Excellence in Energy Management - 2017
Dalmia Cement (Bharat) Limited, Kadapa
➢ Founded in 1935 by Shri Jaidayal Dalmia.➢ The Group interests includes Cement, Sugar, Power and Refractory
with Pan India Presence.➢ The Group established India’s first Cement Plant with 250 TPD in
1939.➢ Overall Cement Manufacturing Capacity 25 MTPA➢ Kadapa Unit Commissioned during Dec 2008 with a Capacity of
2.5MTPA Cement and Standing 4th Largest Cement ManufacturingCapacity in the Country
ISO 50001:2011
Plant Ordering Stage – Took Initiative for Energy Efficient Equipments Selected
1. All Motors are Energy Efficient Series
2. More than 60% Motors are considered with VFD for Energy Efficiency
Commissioning Stage – Developed Best Practices on Energy Front
100% Process Fans without Dampers
Energy Saving by Efficient Eqpt. & Energy Savers: 10.5 Million U/Annum
FY 2013 – Expert Optimizer for Plant Energy Efficient Operation
FY 2014 - EnMS 50001: 2011 Certified
Cum. Energy Saving : 34 Million U/Annum
Alternative Fuel Feeding Enhancement
FY 2015 – 21% TSR of Alternative Fuel
RABH & Cem M Fan Impeller Replaced
Cum. Energy Saving : 36.2 Million U/Annum
Current Plan & Actions
Enhancement of Alternative Fuel Feeding
Development of Renewable Power, WHRS
FY 2016 – Raw Mill Fan Impeller Replaced.
Cooler Efficiency Improvement
FY 2017 – Liquid Alternative Fuel
Raw Mill Cyclone CFD & Modification
Kiln Burner Pipe Retrofit
Description UnitWithout
InvestmentWith
InvestmentTotal
Total No. of Projects No. 32 49 81
Electrical Energy Saving / Annum
LakhsUnits
16.49 84.08 100.57
Fuel Energy Saving / Annum
MillionKcal
3160 20072 23232
Total Cost Saving / Annum (Elect + Thermal)
Rs. Lakhs
135.93 984.44 1120.37
Title of ProjectAnnual Electrical
Saving (kWh)
Annual Elect. Cost Saving (Rs
Lakhs)
Installed VFD for Flyash Compressor (By Reviewing of all VFDs and Operating Parameters and Diverted the VFD from Optimized Equipment)
45000 2.70
Operation of Cement Silo Exhaust Fan as per Occupancy Sensor Command and DCS Time Delay
57500 3.45
Packing Plant Bag Filter Fans Operation Interlocked and Auto Speed Reduction with Packer Rotation and Spout Discharges
109500 0.66
Modification in VRM Classifier and Reduction of Seal Gap to improve the Performance
145000 8.70
Stopping of CRD Motors in the Stackers and Reclaimers during Unwinding.
30000 1.80
Improved the Loading Factor of Coal and Additive Stacking Group by detailed Study
2700 1.60
Improved Operation Efficiency of Cooler Tower Fan by replaced 1500RPM to 1000 RPM motor and Diversion of Heat Exchanged Warm Water to Water Spray
70000 4.20
No Investment – Elect Energy Saving
Title of ProjectAnnual Thermal
Saving (Ton/Year)
Annual Thermal Saving (Rs
Lakhs)
Operation of Cooler Fans (1 to 4) with 106% Speed and Improved the Heat Recuperation at the Current Improved Production Rate
250 27
TAD Inlet Joint Modificiation and Achieved Reduction of False Air
30 3.20
Removing of Silencers from the Cooler Fans (Fan 1 to Fan 4), observed more pressure drop and pressure drop reduced without increase in the Sound Levels
310 32.55
Reduction of False Air from 5.0% to 4.4% by PH Outlet Expansion Joint Inhouse Modification
10.00 1.05
Replaced the Flap Valve with Double Rotary Air Lock for the Alternative Fuel Feeding System
15.00 1.575
Increased SF Cooler Stroke Length and Reduced Clinker Bed Height. Reduction of Heat Consumption 1 Kcal / Kg Clinker
250 27
No Investment – Thermal Energy Saving
Title of ProjectAnnual Elect. Saving (kWh)
Annual Electrical Cost Saving (Rs
Lakhs)
Invest. (Rs Lakhs)
Operation of Blending Silo Exhaust Fan through VFD (Auto Speed Increase by Occupansy Sensor)
21000 1.26 0.50
Cement Mill Grinding Specific Power Reduction by Reducing the Size of Performance Improver Crusher
450000 27.00 25.00
Installed Additional Hydraulic Pump for Rollers Lifting Time Reduction during Mill Tripping and Reduction of Restarting Time
16800 1.01 0.70
Converted the Coal & Additive Unloading Group Operation from DCS to Local Control Station and Reduced the Change over time & Idle Power
30000 1.80 0.75
LED Lighting Project (Well Glass, Street Lights, Tube Lights, CFL & Building Lights...)
111690 6.72 10.49
Electrical Energy Saving
Title of ProjectAnnual Elect. Saving (kWh)
Annual Electrical Cost Saving (Rs
Lakhs)
Invest. (Rs Lakhs)
Stopped Centralized ACs during Plant Stoppages and Installed Portable / Split ACs at CCR, Robo Lab, Server Room and QC Labs.
56000 3.36 3.00
Cement Silo Extraction Blowers Operation Through VFD for Speed Reduction as per Bin Level
11200 6.72 4.00
Installed Day Light with Turbo Ventilator at Stores and Workshop Building and Stopped the Lighting & Exhaust Fans
23000 1.40 2.50
Electrical Energy Saving
Title of Project
Annual Thermal Saving
(Ton/Year)
Annual Thermal
Saving (Rs Lakhs)
Invest. (Rs
Lakhs)
Kiln Burner Pipe Retrofit by Conveying Pipe Size Reduction, Turbojet Blower and Swirl Air Fan with New Design Burner
470 50.70 11
Relocated Higher KW Cooler Fans at Heat Recuperation Zone & Recovered More Heat
439 47.4 1.5
VFD for Kiln Coal Blower and reduced the Primary Air Volume
423 45.7 0.4
Installed Liquid AFR Pumping System and Consumed Pharma Waste and Liquid Solvents
500 54 100
Thermal Energy Saving
10.516.5
20.8 23.6
34 36.2 36.541.3
5
15
25
35
45
Million Units Saving / Annum (Cumulative)
Better
82.64
77.1175.88
74.8773.91 74.1
70
75
80
85
2011-12 2012-13 2013-14 2014-15 2015-16 2016-17
Units / Ton of Cement
Better
Thermal SEC without Kiln Start Stop : 685 Kcal / Kg Clinker(Benchmarking Thermal SEC)
Better
55
.3
54
.3
52
.2
51
.7
50
.5
50
.9
47
49
51
53
55
57
2011-12 2012-13 2013-14 2014-15 2015-16 2016-17
KWH/Ton of Clinker
KWH/Ton of Clinker
781
760
710 704701 701
685
705
725
745
765
785
2011-12 2012-132013-14 2014-15 2015-162016-17
Kcal / Kg Clinker
Better
66.3
63.463.03 63.10
62.50 62.61
60.00
57
59
61
63
65
67
69
2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 Target
Kwh/Ton of Cement (PPC)
NB – National BenchmarkINB – International Benchmark
NB (67)
INB (65)
Present 74.1 U/T of Cement
LS Secondary Crusher (Red.
1.30 U/T)
Increase of PPC Sales (Reduction
of 7 U/T)
HAG for Cement Mill (Reduction of
0.5 U/T)
Waste Heat Recovery Sys. (Red. 23 U/T)
LP Compressor for Flyash (Red.
0.25 U/T)
Target42 U/T of Cement
Present 685 Kcal / Kg of Clinker
Clinker Cooler Upgradation
(Red. of 15 Kcal)
Target661 Kcal/Kg of Clinker
Burnability Impr. by Minerlizers (Red. of 5 Kcal)
Kiln I/L Seal with Graphite (Red.
of 4 Kcal)
Project : IP-1Title : Raw Mill Cyclone Exit Ducts Pressure Drop
Reduction by CFD Study
Objective:
1. To Reduce the Pressure Drop across the Cyclone and Ducts
2. To Maximize the Air Flow to increase Mill Production
3. To Reduce the Specific Power Consumption for the Mill Fan
Action Taken:
1. Conducted CFD Study on the Existing Cyclones and Ducts to understand the Velocity Profile & Abnormal Pressure Drops
2. Observed Pressure Drop is 150 mmwg and having Potential bring upto 100 mmwg
3. Prepared New Duct Design for the Cyclone Exit Duct to achieve Lowest Pressure Drop as per the Results from CFD
Project : IP-1
Parameters UOM Before After%
Improvement
Pressure Drop mmwg 150 100 33 %
Air Flow M3/Hr. 790,000 810,000 2.5 %
Fan Power KW 2950 2850 3.5 %
Fan Sp. Power KWH/T 7.28 6.95 4.5 %
Mill Production TPH 405 410 1.23 %
Project : IP-1
Project : IP-2Title : Improving CM Productivity by Extending
Nozzle Ring at Bottom by 20 mmObjective:
1. To Improve Cement Mill Productivity
2. To Optimize Air Flow and Velocity at the Nozzle Ring Exit
3. To Improve the Dispersion Time of the Fine Grouded Material
4. To Reduce the Specific Power Consumption of Cement Mill
Action Taken:
1. Studied the Inlet Entry Velocity Profile, Reject Rate, Power Consumption and Productivity
2. Carried out Sieve Analysis on the Reject Material and Observed more Fines in the Reject.
3. Concluded, More Fine Material entraping into the Reject through Nozzle Ring
4. Hence, Increased the Nozzle Ring towards Bottom side by 20mm to improve the Dispersion Time and to Reduce the Entraping of Fine Material.
Parameters UOM Before After%
Improvement
Sieve Analysis % on 500 μ 5% 2% 60 %
Production TPH 290 295 1.7 %
Sp. Power U/T 29.1 28.6 1.7 %
Project : IP-2
Project : IP-3Title : Reduction of Kiln Specific Power by
Increasing SF Cooler Cylinder Stroke Length
Objective:
1. To Decrease the Sp. Power by Increasing Kiln Production
2. To Increase the Heat Recuperation Efficiency
3. To Decrease the SF Hydraulic Strokes and Power Consumption
4. To Minimize DPC Spillages and Breakdowns
Action Taken:1. Studied on Clinker Transport Efficiency, Cooler Strokes, Cooler Heat
Recuperation and Clinker Bed Height2. Observed Scope in Improving Clinker Transport Efficiency, Hence Cooler Stroke
Lengths Increased (150 to 170 mm) and No. of Strokes per Minute Decreased (From 20 to 10)
3. Hence, Cooler Clinker Bed Height decreased from 880 to 700 mmwg and Heat Recuperation Improved
4. Debottleneck for Clinker Production and Improved the Productivity, Hence Sp. Power Reduced from 19.5 to 19.2 U/T of Clinker
Action Taken:
5. Cooler Hydraulic Pumps Power Consumption decreased from 40KW to 35KW (Each Pump), Hence achieved Power Saving of 20 KW/Hour in total 4 Pumps
6. Clinker Variation in the DPC Reduced and minimized the DPC Overflow Issues and related Kiln Stoppages.
Project : IP-3
Parameters UOM Before After%
Improvement
Kiln Sp. Power U/T 19.5 19.2 1.5 %
Production TPH 6350 6450 1.6 %
Strokes / Minute No. 20 10 50 %
Stroke Length mm 150 170 13.3 %
Clinker Bed Height mmwg 880 700 20 %
• Rain Water Harvesting and Use – 150% Water Positive
Water
• Energy Conservation ProjectsEnergy
• Solar Power & Wind Power
Non-Conventiona
l Energy
• Mass Tree Plantation on Every Occasions Department wise ownership
Plantation
• Dry Fog System & Stack Emissions Control
• Recycling of Floor Spills & Reuse of WasteEnvironment
• Vermi-compost & Use of Bicycles
• Formation of pond & Rain water harvesting
• Distribution of Solar lamps & Practice of
Community
Carbon Foot Print Activities
Year
Scope 1 emissions
CO2e (MT)
Scope 2 emissions
CO2e (MT)
Scope 3 emissions
CO2e (MT)
kg CO2e/MTof Cement
MitigationTotal Reduction
in emission intensity since baseline year
study CO2e (MT)
2012 - 13 (Baseline Year)
731 70 28 829 Baseline Year
2013 - 14 722 76 24 822 7
2014 - 15 689 80 27 796 33
2015 - 16 705.6 77 10 793 36
2016 - 17 694 76 10.8 780.8 48.2
- Process Electricity Transport Overall6% Reduction
from Base Line
DescriptionNo. of
ProgramsMan Days Total Hours
Training on Energy Conservation 12 44 355
Zero Plastic Rain Water Harvesting (150% Water Positive)
Birthday & Wedding Day Plantations Energy Conservation Campaign
In Plant To Associates
15
00
0
16
00
0
23
50
0
24
00
0
9500
400
00 56000
79
50
0 10
35
00
11
30
00
0
20000
40000
60000
80000
100000
120000
Upto 2012-13 2013-14 2014-15 2015-16 2016-17
Green Development in the Plant & ColonyNo. of Plants
No. of Plantations for the Year No. of Plantations in Cumulative
Battery Operated Vehicle
Battery Operated Cars for Employees & Guests Internal Movement
E-Rickshaw for Employees
Rain Water Harvesting & Created Green Nature in Plant
Certified Energy Auditors & Energy Managers in the Plant
Mr. K Santhosh Kumar (EA – 1832)
Mr. P Kamalanathan (EA – 15097)
Mr. A Chandilyan (EA – 18891)
Mr. V Ramachandra Raju (EA – 17555)
Mr. B Venkatesham (EM – 18832)
Mr. M Ganesh (EA-19674)
EA – 18327 EA – 15097 EA – 18891 EA – 17555 EM – 18832 EA – 19674
Energy
Policy
Online SEC Monitoring by CCR Operator and taking Immediate action during increase in SEC Indication