Dalmia Cement (Bharat) Limited, Kadapa

18th National Award for Excellence in

Energy Management - 2017
➢ 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 Manufacturing
Capacity in the Country
ISO 50001:2011
 Current Plan & Actions
Enhancement of Alternative Fuel Feeding
Development of Renewable Power, WHRS
FY 2017 – Liquid Alternative Fuel
Raw Mill Cyclone CFD & Modification
Kiln Burner Pipe Retrofit
FY 2016 – Raw Mill Fan Impeller Replaced.
Cooler Efficiency Improvement
FY 2015 – 21% TSR of Alternative Fuel
RABH & Cem M Fan Impeller Replaced
Cum. Energy Saving : 36.2 Million U/Annum
FY 2014 - EnMS 50001: 2011 Certified
Cum. Energy Saving : 34 Million U/Annum
Alternative Fuel Feeding Enhancement
FY 2013 – Expert Optimizer for Plant Energy Efficient Operation

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

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
 Without With
Description Unit Total
Investment Investment
Total No. of Projects No. 32 49 81
Electrical Energy Lakhs
16.49 84.08 100.57
Saving / Annum Units
Fuel Energy Saving / Million
3160 20072 23232
Annum Kcal
Total Cost Saving /
Rs.
Annum (Elect + 135.93 984.44 1120.37
Lakhs
Thermal)
 No Investment – Elect Energy Saving
Annual Elect.
Annual Electrical
Title of Project Cost Saving (Rs
Saving (kWh)
Lakhs)
Installed VFD for Flyash Compressor (By Reviewing of
all VFDs and Operating Parameters and Diverted the 45000 2.70
VFD from Optimized Equipment)
Operation of Cement Silo Exhaust Fan as per
57500 3.45
Occupancy Sensor Command and DCS Time Delay
Packing Plant Bag Filter Fans Operation Interlocked
and Auto Speed Reduction with Packer Rotation and 109500 0.66
Spout Discharges
Modification in VRM Classifier and Reduction of Seal
145000 8.70
Gap to improve the Performance
Stopping of CRD Motors in the Stackers and Reclaimers
30000 1.80
during Unwinding.
Improved the Loading Factor of Coal and Additive
2700 1.60
Stacking Group by detailed Study
Improved Operation Efficiency of Cooler Tower Fan by
replaced 1500RPM to 1000 RPM motor and Diversion of 70000 4.20
Heat Exchanged Warm Water to Water Spray
 No Investment – Thermal Energy Saving
Annual Thermal Annual Thermal
Title of Project Saving Saving (Rs
(Ton/Year) Lakhs)
Operation of Cooler Fans (1 to 4) with 106% Speed and
Improved the Heat Recuperation at the Current 250 27
Improved Production Rate
TAD Inlet Joint Modificiation and Achieved Reduction
30 3.20
of False Air
Removing of Silencers from the Cooler Fans (Fan 1 to
Fan 4), observed more pressure drop and pressure drop 310 32.55
reduced without increase in the Sound Levels
Reduction of False Air from 5.0% to 4.4% by PH Outlet
10.00 1.05
Expansion Joint Inhouse Modification

Replaced the Flap Valve with Double Rotary Air Lock

15.00 1.575
for the Alternative Fuel Feeding System

Increased SF Cooler Stroke Length and Reduced Clinker

Bed Height. Reduction of Heat Consumption 1 Kcal / Kg 250 27
Clinker
 Electrical Energy Saving
Annual Electrical
Annual Elect. Invest. (Rs
Title of Project Cost Saving (Rs
Saving (kWh) Lakhs)
Lakhs)
Operation of Blending Silo Exhaust Fan
through VFD (Auto Speed Increase by 21000 1.26 0.50
Occupansy Sensor)
Cement Mill Grinding Specific Power
Reduction by Reducing the Size of 450000 27.00 25.00
Performance Improver Crusher
Installed Additional Hydraulic Pump for
Rollers Lifting Time Reduction during
16800 1.01 0.70
Mill Tripping and Reduction of Restarting
Time
Converted the Coal & Additive Unloading
Group Operation from DCS to Local
30000 1.80 0.75
Control Station and Reduced the Change
over time & Idle Power

LED Lighting Project (Well Glass, Street

Lights, Tube Lights, CFL & Building 111690 6.72 10.49
Lights...)
 Electrical Energy Saving
Annual Electrical
Annual Elect. Invest. (Rs
Title of Project Cost Saving (Rs
Saving (kWh) Lakhs)
Lakhs)

Stopped Centralized ACs during Plant

Stoppages and Installed Portable / Split
56000 3.36 3.00
ACs at CCR, Robo Lab, Server Room and
QC Labs.
Cement Silo Extraction Blowers Operation
Through VFD for Speed Reduction as per 11200 6.72 4.00
Bin Level

Installed Day Light with Turbo Ventilator

at Stores and Workshop Building and 23000 1.40 2.50
Stopped the Lighting & Exhaust Fans
 Thermal Energy Saving
Annual Annual
Invest.
Thermal Thermal
Title of Project (Rs
Saving Saving (Rs
Lakhs)
(Ton/Year) Lakhs)
Kiln Burner Pipe Retrofit by
Conveying Pipe Size Reduction,
470 50.70 11
Turbojet Blower and Swirl Air
Fan with New Design Burner
Relocated Higher KW Cooler Fans
at Heat Recuperation Zone & 439 47.4 1.5
Recovered More Heat
VFD for Kiln Coal Blower and
423 45.7 0.4
reduced the Primary Air Volume
Installed Liquid AFR Pumping
System and Consumed Pharma 500 54 100
Waste and Liquid Solvents
 Million Units Saving / Annum
(Cumulative)
45
Better 36.2 36.5 41.3
34
35
20.8 23.6
25 16.5
10.5
15
5

Units / Ton of Cement

85 82.64

Better
80 77.11
75.88
74.87
75 73.91 74.1

70
2011-12 2012-13 2013-14 2014-15 2015-16 2016-17
 Kcal / Kg Clinker
781
785
760
Better
765
745
725 710 704
701 701
705
685
2011-12 2012-13 2013-14 2014-15 2015-16 2016-17

KWH/Ton of Clinker
Better

55.3
57

54.3
55

52.2

51.7

50.9
50.5
53
51
49
47
2011-12 2012-13 2013-14 2014-15 2015-16 2016-17
KWH/Ton of Clinker

Thermal SEC without Kiln Start Stop : 685 Kcal / Kg Clinker

(Benchmarking Thermal SEC)
 Kwh/Ton of Cement (PPC)

69

66.3 NB (67)
67
INB (65)
65 63.4
63.03 63.10
62.50 62.61
63

61 60.00
59

57
2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 Target
NB – National Benchmark
INB – International Benchmark
 Waste Heat
Recovery Sys.
(Red. 23 U/T)
Increase of PPC
Sales (Reduction
of 7 U/T)
LP Compressor
for Flyash (Red.
0.25 U/T) HAG for Cement
Mill (Reduction of
LS Secondary 0.5 U/T)
Crusher (Red.
1.30 U/T)
Target
42 U/T of Cement

Present 74.1
U/T of Cement
 Target
661 Kcal/Kg of Clinker

Kiln I/L Seal with

Graphite (Red.
of 4 Kcal) Burnability Impr.
by Minerlizers
Clinker Cooler (Red. of 5 Kcal)
Upgradation
(Red. of 15 Kcal)

Present 685 Kcal /

Kg of Clinker
 Project : IP-1
Title : 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
 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-2
Title : Improving CM Productivity by Extending
Nozzle Ring at Bottom by 20 mm
Objective:
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.
 Project : IP-2

%
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-3
Title : 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 Height
2. 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
 Project : IP-3

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.

%
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
Water
Positive

Energy • Energy Conservation Projects

Non-
Conventiona • Solar Power & Wind Power
l Energy • Dry Fog System & Stack Emissions Control
Environment
• Recycling of Floor Spills & Reuse of Waste

• Mass Tree Plantation on Every Occasions

Plantation
Department wise ownership
• Vermi-compost & Use of Bicycles
• Formation of pond & Rain water
Community harvesting
 Carbon Foot Print Activities
Mitigation
Scope 1 Scope 2 Scope 3 Total Reduction
kg
emissions emissions emissions in emission
Year CO2e/MT
CO2e CO2e CO2e intensity since
of Cement
(MT) (MT) (MT) baseline year
study CO2e (MT)
2012 - 13
731 70 28 829 Baseline Year
(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
6% Reduction
- Process Electricity Transport Overall
from Base Line

No. of
Description Man Days Total Hours
Programs
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
 Green Development in the Plant & Colony

113000
No. of Plants

103500
120000

79500
100000

80000
56000
40000

60000

24000
23500
16000

40000
15000

9500
20000

0
Upto 2012-13 2013-14 2014-15 2015-16 2016-17

No. of Plantations for the Year No. of Plantations in Cumulative

 Battery Operated Vehicle E-Rickshaw for Employees

Battery Operated Cars for Employees & Rain Water Harvesting &
Guests Internal Movement Created Green Nature in Plant
 Certified Energy Auditors & Energy Managers in the Plant
Energy
Mr. K Santhosh Kumar (EA – 1832)
Policy
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

Online SEC Monitoring by CCR Operator and taking
Immediate action during increase in SEC Indication