Energy Excellence

Shree Cement Ltd.,

Unit-I, Beawar

National Awards for Cement Industry and Conclave on Sustainability

Excellence of Indian Cement Industry

15th & 16th Oct 2018, Hyderabad

Contents

• Overview

• Energy Conservation Awareness

• Energy Management System

• Energy Peformance Improvement

• Targets & Achievements

• Conclusion

Shree Cement Limited is a rapidly growing as one of the most efficient and

environment friendly cement company in India.

41.9 MTPA Cement

production capacity till

date

646 MW power generation capacity till

date

Among the top 3 cement

groups in India

Largest WHRP producer in the global cement

industry excluding china

86,117 ESCertsissued to

Beawar plant for WHRP generation

5 star rating for Beawar and

Ras limestone mines for

sustainable development

by IBM

An Energy & Environment Conscious Sustainable Organization

Shree Cement Profile

25245

3950943270

5067059293 59557

30/06/14 30/06/15 31/03/16 30/06/16 31/03/17 31/03/18

Market Capitalization (Rs. in Crore)

Financial Performance

“Lead in Creating Prosperity & Happiness for all Stakeholders through Innovation

& Sustainable Practices”

Our Vision

Guiding Principle

Enforce good corporate

governance practices

Encourage integrity of

conduct

Ensure clarity and un-

ambiguity in communication

Remain accountable to

all stakeholders

Encourage socially

responsible behavior

Total Prosperity

Sustainability

Total

Prosperity

Profit

Stakeholder

+Happiness

Workforce

+

Innovations

Ethics

+

Integrity

Clean

+

Green

1985: 0.6 MTPA

Energy Cons.- 118 Kwh/t Cement

Heat Cons.-902 Kcal/Kg Clk

1995 : 1.0 MTPA

Energy Cons.- 110 Kwh/t Cement

Heat Cons.-860 Kcal/Kg Clk.

2018: 1.2 MTPA

Energy Cons.- 74.57 Kwh/t Cement

Heat Cons.-705 Kcal/Kg Clk.

Unit-I in 1985 Unit-I in 2018

Shree Cement’s Journey

780

718

705

640

660

680

700

720

740

760

780

800

2015-16 2016-17 2017-18

Specific Thermal Energy (kCal/Kg Clk.)

81.85

80.91

74.57

2015-16 2016-17 2017-18

Specific Power Consumption (KWh/t Cement.)

Shree Cement’s Journey

SCL Approach

Adopted 7 ‘R’ philosophy to ensure energy and resource conservation

Reduce: Energy & water consumption

Release: Lesser emissions

Reuse: Waste gases

Replace: Conventional fuels

Restore: Natural resources

Raise: Green Power generation

Research: Capacity enhancement

ISO-50001• Energy Management System

ISO-14001• Environmental Management System

SA-8000• Social Accountability

ISO-9001• Quality Management System

OHSAS-18001

• Occupational Health & Safety Assessment Series

Management Systems

Energy Conservation Awareness

Energy Conservation Awareness

Sharing of Information

• Awareness program in association with BEE since 2002.

• SCL has been identified as a cement Stock Task Force Leader.

• First awareness program regarding energy efficiency and target setting process

was held at Shree Cement Unit.

• “Best Energy saving initiatives are Awarded in every Monthly

safetymeeting”

Dedicated Team

Energy Task Force Team formed with cross functional team members and best energy saving

initiatives discussed and implemented.

Energy Conservation is the foundation of Energy Independence

Energy Management System

Energy Professionals

Shree Cement Ltd. encourages employee to become

CEM & CEA by reimbursing the BEE Exam fee. Till

date SCL have more than 50 Nos. BEE Certified

Energy Managers and EnergyAuditors.

SCL is also engaged various external energy

professionals and experts from agencies.

Energy Saved is Energy Produced

Energy Management System

Monitoring of Energy Consumption:

• Daily monitor energy consumption and discuss in production / power meeting

• False air study of Preheater, Raw Mill Section & Coal Mill Section

• Identification of Compressed air leakages

• Thermography of Electrical Panels & Plant

• FAD test of Compressors

• Performance evaluation of efficiency of Pumps, Fans

Energy Efficiency leads to Lower Monthly Bills & a Lower Carbon Footprints

Energy Management System

Power quality analyzer

Compressed air flow meter

Ultrasonic water flow meter

Hot wire anemometer

IR-Temperature indicator

Thermal imager

Compressed Air leak detector

Digital pressure manometer

Digital pressure gauge

Power Packed with latest Instruments for Energy Audit

Energy Management System

Energy Management team is equipped with following list of calibrated instruments

Energy Management Certificate- ISO 50001-2001

Energy Management Certificate- ISO 50001-2001

CSI has developed roadmap to reduce energy consumption of Indian cement industry which

was co-chaired by Shree Cement.

To meet the CSI roadmap and the PAT targets SCL has develop its own roadmap.

0.08130.0776

0.0585 0.0562 0.0541

0

0.02

0.04

0.06

0.08

0.1

FY 07-10

Baseline

SEC

FY 12-15

PAT Cycle-1

Target SEC

FY 14-15

Achieved

SEC

FY 14-15

Baseline

SEC

FY 16-19

PAT Cycle-2

Target SEC

SCL Specific Energy Consumption (Gate to Gate)

844

549 555

828

547 553

0

100

200

300

400

500

600

700

800

900

Per ton of clinker Per ton of cement Per ton of cementious

material

Specific Net CO2 (Kg.) Emissions

2016-17 2017-18

Energy Performance Improvement

0.3660.350

0.264

0

0.05

0.1

0.15

0.2

0.25

0.3

0.35

0.4

Present Target AchievedEn

erg

y C

on

su

mp

tio

n (

MT

OE

)

• Energy reduction target = 4.55%

• Target achieved = 29.16%

• Target overachieved = 24.61%

• ESCerts Issued = 86117Nos.

PAT Performance

Energy Performance Improvement

Energy Saving Projects Implemented in FY 17-18

Sl No. Energy Efficiency Improvement Measures Category

Investment

(Lakh

Rupees)

Savings

(Lakh

Rupees)

1 Up-gradation of Preheater Unit-I Thermal 5600.00 1112

2 Additional cyclone 3rd in raw mill circuit at U-1 Electrical 154.17 64.80

3 Installation of SPRS in SG fan Unit-1 Electrical 1.00 25.20

4Modification of down comer duct and removal of gct of ph

U-1Electrical 136.83 22.81

5 Installation of LED lights in place of conventional light Electrical 7.83 1.51

6Modification of kiln outlet shell, hood & graphite seal in

U-1

Thermal &

Electrical148.39

Under

Evaluation

7Replacement of GPP Boilers PH-1 and AQC-1 of Kiln-1

BeawarElectrical 3894.00 -

Energy Performance Improvement - Energy Saving Projects

Sl. No Description Units 2016-17 2017-18

1 MTOE reduction MTOE 1877

2 Kiln Thermal SEC kCal/kg clinker 718 705

3 Specific Electrical Energy – clinkering kWh/T of clinker 60.35 53.5

4 Specific Electrical Energy – Grinding kWh/T of cement 92.03 84.35

5 CPP Heat rate kCal/kWh 3007 2998

6 CPP auxiliary consumption % 8.4 7.2

7 Thermal Substitution Rate % 0.063 0.0923

8 Clinker factor % 0.739 0.73

9 Blended cement *%) of total cement % 48.17 51.08

10 Renewable Energy (RPO) NA NA

11 REC Purchased – Solar REC NA NA

12 REC Purchased – Non Solar REC NA NA

13 Specific CO2 emission Kg CO2/ kg cement 0.549 0.547

Daily Power Report

Installation of High Efficiency Classifier with Additional Triplet

Cyclone In Raw Mill

New high efficiency classifer along

with additional triplet cyclone have

been installed in Unit 1 Raw Mill as a

result specific power consumption of

raw mill has reduce due to reduction in

pressure drop and increase in

production.

Approx. saving of 14.9% achieved.

Achievements - Innovative Projects

Up-gradation of Pre-heater from 4-stage to 6-stage with WHRB

Achievements - Innovative Projects

• Replacement of 4 stage preheater with 6 stage preheater without affecting the

WHRB generation.

• Reduced temperature of gases leaving from top stage cyclone of preheater to

280oC-290oC from around 400oC.

• Saving of approx 12% achieved in coal consumption.

Before After

• Installation of centrifugal compressor in place of reciprocating compressor first

installation in cement industries

• Formation of Computational fluid dynamics (CFD) Cell for plant operations

• Coal Mill Classifier modification and modication of ducts.

• Enlargement of Kiln riser orifice area.

• Removal of Dust Settling Chamber.

• Clinker cooler grate area enlargement.

Achievements - Innovative Projects Under Implementation

Investments made in Energy Saving Projects

• Total investment by 65 DCs = 2568 Crore

• Total investment by Shree Cement Ltd = 250.9 Crore

• Overall paypack period = <3Years

• % Share by Shree Cement = 9.7 %

250.9, 9.7%

2568.0, 90.3%

Investment in Cement Sector

Total investment by SCL Total Investment by 65 DC's

Achievements

15.01

14.20

13.53

12.5

13

13.5

14

14.5

15

15.5

Present Target Achieved

En

erg

y C

on

sum

pti

on

(M

TO

E)

Cement Sector Performance

0.3660.350

0.264

0

0.05

0.1

0.15

0.2

0.25

0.3

0.35

0.4

Present Target Achieved

En

erg

y C

on

sum

pti

on

(M

TO

E)

SCL Beawar Performance

Achievements

Cement Sector

• Energy reduction target = 5.74%

• Target achieved = 10.43%

• Target overachieved = 4.68%

SCL Beawar plant

• Energy reduction target = 4.55%

• Target achieved = 29.16%

• Target overachieved = 24.61%

• ESCerts Issued = 86117Nos.

Saving energy saves you money

Shree Cement has been awarded Best performer in Cement sector by BEE,

Ministry of Power. On occasion Shree Cement delivered presentation on Energy

Efficiency in Industrial Sector on National Energy Conservation day 14-12-2017

at Vigyan Bhawan, Delhi.

Outcome of Our Best Practices

Shree has been entitled for following awards by NCCBM-

• Best Improvement in Thermal Energy Performance in the year 2015-16.

• Award for Best Quality Excellence for the year 2016-17

• Award for Best Quality Excellence for the year 2015-16

Outcome of Our Best Practices

Conclusion

• Dedicated energy audit team to reduce energy

consumption of plant

• Small-small activities and efforts results in huge

saving to achieved targets

• R&D and Innovation is the zest of achieving goals.