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CII National Award for Excellence in Energy Mangement2013 19th 20th A!g!"t2013#
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AF
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99#69
09210
10211
11212
12213
)*h 5 % of Cement
4o!rce'NCC;M /ear 0 A1r2Mar3 09210 10 211 11212 12213 41ecific Elect Energy Con"# )*h 5 % Cement 61#72 60#38 99#86 99#69
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990 988
09210
10211
<cal 5<g of Clin)er
11212
12213
4o!rce'NCC;M /ear 41ecific %hermal Energy Con"# )Cal 5 <g of Clin)er 990 990 990 988
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Development and Commercial Production of new product like Active Belite Cement, Portland Composite Cement and Portland lime stone Cement after getting approval from BIS. By 2 !"#!$ Installation of %&' System ! (%. By 2 !$#!) )"#* + production of ,lended cement. By 2 !-#!" Increase t.e percentage fly as. from 2- to 2)+ in Blended Cement. By Dec 2 !/ P&#! 0 2 1p gradation to increase t.e plant capacity from / 2PD in consultation wit. 3&D . By 2 !"#!$ 2PD to /"
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5C#/ raw material 0 cement ,all mill in closed circuit along wit. 5#separator 0 roller press in closed circuit. By 2 !-#!" $ Stages pre.eater wit. 6P cyclones in all t.ree kilns. By 2 !-#!" (odification in 5C#/ pre.eater cyclones#2,/,- as per C7D in ,ot. stream. By 2 !-#!" 'eduction in pressure of 5'( ,y C7D modeling.By Dec 2 !/ Installation of online particle si8e analyser for optimi8ation of 9uality and product mi: cement; By 2 !-#!" Installation of new !$< water transport system from S3! and S32 mines to Plant for power saving ,y 2* 3%; By Dec 2 !/ Installation of rotoscale for fine coal 0 kiln feed feeding system; By 2 !-#!"
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'eduction in power consumption and Capacity en.ancement of feeding System of Alternate fuel in (S% feeding System.
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Problem Statement
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Belt A36
;elt A3A
Slide gate
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2angi,le !.Power saving of 2"." 3%. Saving in terms of 'upees =2"." :2- &rs : // Days : 's. -.$/ =>./" 6acs per annum /.(aintenace cost reduced . -.Increased (S% consumption from 2$ to -" 2?day.
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+ro-ect ' 2 $tiliBation of %yre ?!"t in <iln >iring and de.elo1ment of >eeding 4y"tem
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4a.ing" Achieved
Name of Alternati.e >!el Act!al @C( of Material A.ailaCility 0M%3
!
%otal &anded co"t +M% %otal Material co"t 0In :"3 0A?;3
3700 "#!
68
+artic!lar"
Act!al @C(
:e1lacement %otal landed %otal Material co"t Dty co"t +M% 0In :"3 0A?;3
A08 8021 32# 6#$
+etco)e
8338
Net 4a.ing
172096A
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Installation of air receivers at VC-I and VC II Kiln common header line. We utilized the receiver available in Inert gas plant . Saving Achieved = 18KW (which is 3% of total power consumption) In terms of Rs. = 4.6 Lacs / annum
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We were having 5 nos. of low efficiency compressors having high specific power consumption of 14-17 KW/100m3
Com1re""or No
800.51 800.52 800.53 800.01 800.11
Total
At!al )*
107.00 84.00 82.50 40.00 86.00
4+C 5100m3
17.48 14.26 14.72 14.77 17.10
399%!
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+ro-ect ' A In"tallation of 4crew Com1re""or to meet ;a"e &oading reF!irement of the "y"tem re"!lting "a.ing in energy
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+ro-ect ' 3 $tiliBation of old Air :ecei.er" of inert ga" a" ;!ffer 4toc) for control airE re"!lting in red!ction of 1ower con"!m1tion d!e to fl!ct!ation in control air line 1re""!re#
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We have installed energy efficient compressors of 2500 m3/hr (ZR 250-7.5) resulted in reduction of specific power consumption from 17 to 10KW/100m3
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Reduction in electrical energy consumption : 150KWh In terms of Rs. : 150 x 24hr x 330 days x Rs. 4.63 / Unit = 55.1 Lacs
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Action %a)en
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2"
"#%"9
9%9"
"
& AF weig't
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>ir"t time in India .se o/ 0on 1a2ardous 3aste in Ce4ent 5iln 6rocess o/ +S3 7 use o/ (8F 6lastic 7 6olyt'ene *Below 2 +icron Si2e, 9ovt% Sei2ed 8oda C'ura *6o::y Straw, 1a2ardous 3aste ;:iu4 +arc o/ ;:iu4 Alkaloid Factory< 0ee4uc' 6aint sludge *Auto4obile =ndustries, .se o/ Alternate /uelState o/ art environ4ental /riendly dis:osal syste4 >nergy (ecovery wit' e//ective utili2ation >4ission reduction Conservation o/ 0atural (esources
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$"e of =aBardo!" and Non =aBardo!" *a"te a" Alternate >!el in Cement <iln
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Cost Bene/its-
?e"cri1tion )uantity o/ AF( .sed *+T, T'er4al Substitution (ate *TS( &, Cost Saving *(s% =n lak's, Fuel Saving *+T, Material 6aint Sludge ;:iu4 +arc
2009210 66 " "%8! *-, "36% 2#26 D!antity 0M%3 $$"%26 3 #%3$
201321A D1 3##8 #%39 3#%39 "9!! %otal Negati.e Co"t till G!ne 13 0In &a)h"3 3!%3 !!%32
>nergy Saving on account o/ @(eduction in Coal +ill (unning 1rs (eduction in >nergy Consu4:tion by !%$ Aacs k3'
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%angiCle ;enefit"
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2010211 #$3
2011212 6!
2012213 632
Environmental Projects for carbon emission reduction 1.Consumption of MSW is 3555,59 ! " 9#!$ M% in last 3 &ears. '.Consumption of ()ro Waste is 3 ! , 19! " $1$3 M% in *ast 3 &ears. 3. +se of Copper sla) as a alternate ra, material actin) as minerali-er. .. /ncreased t0e production of 1lended Cement from !$ to 1 2. 5./ncreased in t0e 2 of 3l4 as0 Consumption from'. to '!2. !./ncreased t0e Performance /mprover from ..5 to 5 2 in 5PC .3 and 53 6rade Cement.
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Societal Bene/its- Better 3aste +anage4ent Syste4 Co-:rocessing o/ (8F in Ce4ent 5iln is bene/icial to 'u4an 'ealt' 6lastic 7 6olyt'ene is a//ecting to >nviron4ent 7 1ealt' 8is:osal o/ Sei2ed 8oda C'ura in 5iln solved t'e :roble4 o/ 6olice 8e:art4ent 8is:osal o/ ;:iu4 +arc in 5iln% 6aint Sludge-8is:osal % (ecognition 7 a::reciation /ro4 8istrict Collector and S%6%
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IntangiCle Cenefit"
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Partial s&bstit&tion of fossil f&el in 3iln 4it' MS(5 %ric<&re 4aste etc.
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1se of 2PP Bed As. as @ypsum an.ydrite 1se of Copper Slag as raw mi: component acting as minerali8er 1tili8ation of 6ow @rade 6imestone 1tili8ation of Apium (arc, t.e .a8ardous waste of Apium Alkaloid Plant 1tili8ation of paint Sludge, t.e .a8ardous waste of Automo,ile Industries
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Rally Poster
Quiz
%ree +lantation
3<39< 8 3< 9<$"3 2<#!<9$2
2005-06
2006-07
2007-08
2008-09
2009-10
2010-11
2011-12
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2012-13
Market & Customer Orien tation
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?arious co4:etitions on >nergy Conservation 6rogra4 *6oster< Slogan< etc%%, involving all Co4:any e4:loyees< Contract e4:loyees< 1ouse wi/e< Sc'ool c'ildren etc%% 6oster 8is:lay su::lied by B>> ?ideo dis:lay letters%
" % (ecognition 7 a::reciation by distribution o/ Awards< token gi/t and a::reciation ""% Suggestion Sc'e4es%
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CA6>C /or 2 +3 Solar :ower :lant :ro:osed /or t'e year 2 "$-"! % To increase AF( substitution at Aine-3 /ro4 9%3! to "!& and its eBtension to line " 7 2 =nstallation o/ 31( Syste4 " +3% (oller 6ress =nstallation in C+ " 7 2 To en'ance t'e :roduction o/ Blended Syste4% =ncrease t'e :ercentage /ly as' /ro4 2#& to 3 & in Blended Ce4ent
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61-" 7 2 .: gradation to increase t'e :lant ca:acity /ro4 3 3! T68 in consultation wit' 518
T68 to
=nstallation o/ new "6D water trans:ort syste4 /ro4 S5" and S52 4ines to 6lant /or :ower saving by 28 53 8evelo:4ent o/ new :roduct like Active Belite Ce4ent< 6ortland Co4:osite Ce4ent and 6ortland li4e stone Ce4ent% =nstallation o/ (oto scale /or /ine coal 7 kiln /eed /eeding syste4
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Steps taken to reduce SOx and NOx emission in the stack to meet the proposed norms.
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EN 5 - Total energy saved due to conservation and efficiency improvements. Sr. Sources of Energy Savings Unit FY 2010-11 No. Process Optimization 1 Energy savings due to process re-design Modification in cyclone 1.1 1A 1! " #A $#! as per %&' recommendation. E,uipment -pgradation . modification - /avings due " to conversion and retrofitting of e,uipment Modification of 0iln-1 ".1 %ooler E/P Modification in Pyro Outlet "." duct ".* 3&' 4nstallations at &ans 7educed energy usage due * to c8anges in employee 9e8avior *.1 0aizens *." /uggestions # Ot8ers Total FY 2012-13 Apr-11May-11 Jun-11 Jul-11 Aug-11 Sep-11 Oct-11 Nov-11 Dec-11 Jan-12 Feb-12 Mar-12 TOTAL
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Bnergy Audits carried out ,y; Central 2ec.nical and Bnergy Services CC2BSD in t.ree years
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5nowledge s'aring on co :rocessing o/ waste wit' steel< :ower 7 and Ce4ent =ndustries%
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Bducating t.e suppliers?5endors?Contractors and customers on energy reduction measure. 2ransporters; 2o transport t.e fly as. in "2 (2 Bulker instead of / (2 ,ulker leading to ,ot. reduction in energy and cost. 2o transport all ot.er raw materials like red oc.re ,,au:ite,laterite and pet coke in ,ig trailer instead of mini trucks. 2ankers carrying fly as. is ,eing utilised for transporting of cement during return trip.
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Thank You!
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7u88y 6ogic controller for 3iln and Cooler Circuit. 2emperature rise in Primary and Secondary Air. S.ifting of 7eed Bo: In Centre of 6ine to a,sor, more .eat ;Pre.eater /. Bliminate Air Ingress ,y improving Sealing. Pre.eater Duct replacement in 6ine /
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