Electrical Energy Module Final Draft 20

Strength. Performance. Passion.
Electrical Energy Module Final Draft 20.1.2013
Presentations with title image
Short title, Department, Date yymmdd, Classification © 2012 Legal entity

Objectives of the electrical energy module
 This module is to help teams drive electrical energy improvements in plants.
 It explains how teams could leverage benchmarking, identifies and addresses

10 cross-cutting themes related to electrical energy in the plant (e.g. false
air leakages, idle running, B level audit).
 It then describes the methodology to calculate potential limit through gap

analysis for all critical machines in the plant to drive improvement at
machine level
 It also illustrates the “energy circle” approach to drive electrical energy in the
continuous improvement mode
 In order to make it easier for the user, there are several real examples from
the actual cement plant project to improve electrical energy.
 In addition, several best practices and ideas implemented across Op Co have

also been collected in this module.
 This module does NOT contain fundamental change in plant configuration

(e.g. wet vs dry grinding); it also is not just a list of top ideas that could be
directly applied in a specific plant
2
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Table of contents – electrical energy module (1/2)
Section 1 Section 2 Section 3 Section 4
Benchmarking and Approach to drive Machine level

Cross cutting levers
aspiration setting electrical energy deep dive
 Aspiration setting  Academy and line team  Methodology to improve  Identification of critical
 Overall benchmarking architecture  Compressed air loss equipments
Focus  Section benchmarking  Energy circle approach  Idle running  Technical limits
area to involve frontline analysis
 Best of best approach  Power factor
 Meeting and review  Trends analysis for
 Machine level waterfall -  Transformer losses
architecture different operating
electrical energy build up  Power factor
 Performance heat map parameters
 Aspiration for  Approach and  Standardized approach  Equipment level

individual plants based methodology to drive for most critical levers energy loss analysis
on benchmarking electrical energy  How to measure  Machine level action
Outputs  Identification of improvement plan to address losses
 Benchmarks
section level best of  Responsibility matrix in electrical energy
 SOPs/ SMPs
best performance to drive EE  Sweet spots for
across plants transformation  Key ideas
operating parameters
© 2012 Legal entity 3

Using this module – Key sections and coverage (2/2)
Appendix 1 Appendix 2
Compilation of best
Idea bank
practices
Best
Practices
 Collection of energy  Collection of best practices

efficiency improvement from several plants
Key ideas from several plants
activities
 A compilation of top 50  Elaboration on 6 best

energy efficiency practices including auditing,
improvement ideas by training and awareness
Outputs section and equipments programs, maintenance
based on inputs from practices, etc
several plants


Linked to heat map Linked to academy
Focus  Section benchmarking  Energy circle approach to  Idle running  Technical limits analysis
area involve frontline  Trends analysis for
 Meeting and review different operating
architecture parameters
electrical energy buildup  Power factor
 Performance heat map
 Aspiration for individual  Approach and  Standardized approach  Equipment level energy
plants based on methodology to drive for most critical levers loss analysis
benchmarking electrical energy  How to measure  Machine level action plan
Outputs  Identification of section improvement to address losses in
 Benchmarks
level best of best  Responsibility matrix to electrical energy
 SOPs/ SMPs
performance across drive EE transformation  Sweet spots for operating
plants  Key ideas
parameters

Specific energy cost versus practice scores
Practices score
On a scale of 1 to 4
3.9
Gagal 2 Gagal 1
3.8 High
3.7
Opportunity 3.6
to develop Lakheri
into model 3.5
plants as 3.4
already 3.3
strong on
3.2 Jamul
practices and Wadi 2
energy cost 3.1 Hon Chong Saraburi 3
Madukkarai Opportunity to
3.0 Saraburi 2 Chanda improve
High performance
2.9 Wadi 1
performers Chaibasa Darlaghat through
Kymore
who have 2.8 improvement of
Maratha Bargarh
been able to 2.7 Rabriyawas practice
Ambuja Nagar 2
spot Narogong 2 implementation
2.6 Cilacap 2 Narogong 1 Ambuja Nagar 1
opportunities quality
for further 2.5 Low
Bhatapara 1 Palavi
improvement 2.4 High
Low
0
0 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Specific energy cost (2011)
USD/t cement

Performance across all pillars
2012 June YTD data
EE TE CF Coal Geocycle
SEEC STEC Clinker Factor Net as fired Specific GAV

kWh / t cem MJ / t clinker % USD / GJ CHF / t
ACC 87.7 3080 64.9 5.22 0.60

• Potential
ACL 79.4 3080 68.0 5.62 0.19 areas of
opportunity
SCCC 95.6 3064 80.5 5.05 1.15 across all
pillars as
gaps
HVL 88.2 3414 67.8 5.74 2.36
between
current
HIL 93.5 3368 80.2 4.89 0.85 performance
and possible
100.7 3566 81.7 6.15 4.78 best in class
HLL
for plants
Best in 60 - 70 2932 - 3517 61.51 3.2 – 4.5 4.78

class
• Bases on best • Based on kiln • 1For PPC • 3.2 for India • Pallavi
of sections and type • Palavi- 4.78
• Varies by type • 4.5 for SE Asia
equipment of cement

Overall practices summary
Based on self assessment of plants , Scale of 1 -4 ; 4 being close to best practice,
~ 700 respondents from plants
EE TE CF Coal Geocycle
• Several plants
3.1 3.5 3.4 3.2 3.5 have identified
ACC
opportunity for
improvement
ACL 2.5 2.9 2.9 2.4 2.6 on the best
practices
SCCC 2.6 3.3 2.9 3.0 3.2 • Opportunities
for practices
HVL 2.5 3.1 2.8 2.8 3.2 improvement
across all
2.2 2.9 3.2 2.4 2.4 pillars
HIL
HLL 2.5 3.0 2.4 2.0 3.3

Best in class performance is dependent on both equipment
and practices
Thermal Coal
• SPC implementation in operations • 100% usage of alternate low cost coal
• Certified PPEs in plants types (e.g., petcoke, lignite)
• False air leakages <7% in all circuits • >95% materialization of low cost linkage
• >75% cooler efficiency, >400 hrs Kiln MTBF coal on consistent basis
• Dry process, >6 stage pre heater configuration, >7000 TPD kiln • No slippage in coal quality during transit
and <0.1% transit losses for quantity
• Dedicated coal manager with competent
team
Geocycle
• Design capacity for relevant infrastructure
supporting >50% TSR
• 100% design capacity utilization
• Dedicated Geocycle technical manager
• Long time sourcing contracts with
Electrical Clinker factor consistent stock availability
• >80% fan efficiencies • >28 Mpa Clinker 1 day strength
• >0.98 power factor • >94 clinker LSF, >90% gypsum
• >80% PM adherence, >400 hrs purity
kiln MTBF • High precision MIC dozing
• Full time, certified energy systems
manager backed by section level • Implementation of latest
energy circles technologies (e.g., blending,
• False air leakages <10% in all separate grinding)
circuits • Set up enabling trials of new
• VRMs in raw mill and cement additives / grinding media
grinding sections

Raw Meal preparation – SEEC of VRM and Ball Mill
All SEEC are converted into same product fineness ,i.e 15% R on 90 mic
Best of best - SEEC of Raw Mill is 18.7 kWh/t clk at N1 ( JP is not

considered as slurry is being fed at 20% )
Short title, Department, Name/Function or Event/Creator, Date yymmdd, Classification © 2012 Legal entity 10
Raw meal preparation
• Major contribution of SEEC in Raw Meal Preparation are material grindability, type of mill system and
product fineness.
• All SEEC of raw mill are converted into VRM basis ( SEEC of BM/1.15 = SEEC of VRM) and same product
fineness.i.e15% R on 90 mic ~New SEEC =Old SEEC X ( 2- log(Old residue))/(2-log15)
• Cluster are divided into three category – Soft, Medium and hard grindability
• RVRM performance index is the ratio of actual SEEC of raw mill department and
best SEEC of raw mill in that cluster
• Highest improvement potential in raw mill – C2,A2,PA,RU,BG,MK
• Medium improvement potential – N2,A1,KY,S2,GG
Raw Mill performance -ACL
Region best achieve false air %age of 8% in GG against high false air in B1,DL,RB ( >20 %)
Region best achieve NAI of 96.8% in S3 against lower NAI( <80%) in B2,DL.
Region best achieve MTBF(VRM) of 133 h in B1 – MTBF improvement potential in A2,DL
PRI improvement higher potential in A1.A2,RB
Raw Mill performance -ACC
Improvement in MTBF, NAI and false air are key potential area for ACC plant
SEEC of Clinker production
Best of Best : SEEC of clinker

Production ~ 26.5 kWh/t at RU
Clinker production
4 stage
6 stage
5 stage
Performance of clinker production - HIL
• Improvement potential of NAI in C2,N2

• False air reduction in C2- target to reduce from 10% to 7%
• MTBF improvement potential in C2,N1 and N2 ~ Target > 300 h
• Improve cooler fan efficiency at N1 and N2
• Study and reduce SEEC of aux in Clinker production ~ 11-14 kWh/t is very
high
• Reduce SEEC of PH fan at N1 and N2 ~ currently 11-13 kWh/t against
BOB of 5.0 kWh/t
Performance of clinker production – HVL and HLL
• MTBF improvement potential in HN and PA ( > 300 h)

• NAI improvement in PA ( >90%)
• Reduction of SEEC of PH fan by reducing pressure drop across cyclone
• Reduce false air in PA from 15% to 7%
Cement grinding
Best of Best :SEEC

of cement grinding
without common aux
– 29.2 kWh/t at RX
SEEC of common aux upto clinker production and cement
grinding
-Study the high SEEC
of com aux upto clinker production at
B1,RB,RU,BG,GG,JL,JP,MK,W1
And high SEEC of com aux in cement
grinding at DD,NL,RR,RX,BY,JP
-Check the reporting as per HARP
Performance of cement grinding - ACC
Improvement potential in MTBF,NAI, increase of absorbed power in Mill and

pregrinder
Performance of cement grinding - SCCC
Potential to improve MTBF,PRI and increase power absorption in pregrinder

 Benchmarks
 SOPs/ SMPs
parameters
22

Energy circles are a critical mechanism for driving
optimization and improvement
 Energy circles are informal groups of people who operate as custodians of their
sections, and meet together on a weekly basis to identify, define, analyze, and
Concept
resolve issues related to Energy efficiency in the plant
 The main objectives of Energy circles are to create a focused effort

to target Energy related issues and to create healthy competition,
Objective and awareness among the employees
 Energy circles also help in improving job involvement, problem
solving capability, and promotes leadership qualities among
employees
 A team for each section (Raw material preparation, Raw meal

preparation, etc) has been created
Approach
 Each team constitutes a cross-functional association of members
with 2 NMS employees
 Each energy circle team meets once a week for 1 hour

Meeting and  Plant rounds are conducted once a week to identify and investigate
Review issues first hand at the floor level
mechanism
 Key issues are recorded, analyzed and discussed with plant teams to
create an action plan
23

Critical equipment (Running
Section wise energy circles should be formed to drive >10 % of design power)
improvement in respective areas (1/2)
ACC CHANDA EXAMPLE
Text Sp. Power (KwH / T of clinker)

Participants:
Section in charge, 2.2
Raw material
Mechanical, Process, 1.1 0.8
extraction and
Electrical, Instrument
preparation
and 2 NMS LS OLBC LS
employees Crusher Stacker

Participants: 14.2
Raw meal Mechanical, Process, 2.3 1.6 1.0 0.5
preparation Electrical, Instrument
and 2 NMS Mill RM Fan Other Ho- LS Sep.
employees main Aux. mog'n Reclaimer drive
drive
Participants: Section
9.1
5.1 2.9 2.8 2.7 2.6
in charge, Mechanical, 2.0 0.4
Clinkerisation
Process, Operation,
Environment, E&I, & Cooler Fuel Kiln PH PH Bag Kiln Fuel
2 NMS employees drive prep cooler fan-1 fan-2 House main Trans
aux Fan drive
24

Section wise energy circles should be formed to drive Critical equipment (Running
>10 % of design power)
improvement in respective areas (2/2)
ACC CHANDA EXAMPLE

Participants:
Section in charge,
Mechanical, Process, 5.1
Coal mill 0.4
Electrical, Instrument
and 2 NMS
Fuel prep Fuel Trans
employees
Text Sp. Power (KwH / T of cement)

Participants:
New Cement Mechanical, Process, 11.8
mill Environment, Elec,
2.6
Instrument, and 2 CM Main Drive CM Fan Aux+ Prod
NMS employees Hndlg
Text Sp. Power (KwH / T of cement)

Participants: Section 20.0
Old cement in charge, Mechanical, 11.8
mill Process, Elec,
2.6
Instrument, and 2 NMS
CM Main Drive CM Fan Aux+ Prod
employees
Hndlg
25

Energy circles to use performance and practice heat
maps to identify and drive improvement across levels
How to use HEAT maps How not to use HEAT maps

• HEAT maps are not a replacement for a
• Benchmark to define aspirations (“moons”) diagnostic / deep dive to determine
by looking at best in class and comparable opportunity and initiatives. Provides
plants performance direction and not the answer
• Use as a tool to identify opportunity areas • Do not expect HEAT maps to determine
through L3, L4 metrics and practices the exact $ improvement potential
• Initiate a dialog between plants across the • Do not use performance and practices
region on sharing best practices HEAT maps separately, use them in
• Treat Red as potential opportunity and not conjunction
a performance score card • HEAT maps are a dynamic tool that
• For areas which are Green push for needs to be constantly updated and fine
achieving best in class performance tuned as it is used. Do not consider best
• Use equipment and process difference to practices list to be static
generate capex proposals • Do no attempt to account for all
contextual differences for a plant in the
HEAT map
26

Energy circles to use performance heat maps to
identify and drive improvement across levels (1/3)
L1 L2
 Performance
heat map is
categorised SEEC SEEC
into three (up to clinker production) (raw material preparation)
levels.
 Level 1 is the
overall
SEEC SEEC
electrical (cement grinding) (raw meal preparation)
consumption
of the plant
SEEC of auxiliary SEEC
 Level 2 is the (up to clinker production) (clinker production)
section wise SEEC of
electrical plant
consumption, SEEC of auxiliary
power factor (cement grinding)
and
transformer
efficiency .
Power factor
Transformer efficiency
27

L2 L3
Fan efficiency
SEEC
PRI of crusher
(raw material preparation)
MTBF of crusher
SEEC of raw mill main motor
SEEC of raw mill ID fan
 Level 3 is Type of mill
equipment Product fineness
wise electrical Fan efficiency
consumption SEEC False air
(raw meal preparation) PRI of raw mill
 L3 also SEEC GAI of raw mill
includes (up to NAI of raw mill
section wise clinker
MTBF of raw mill
process production)
Pressure drop
parameters % fans with VSD
such as fan
efficiency, SEEC of kiln
PRI, false air SEEC of PH fan 1
affecting SEEC of PH fan 2
SEEC of cooler fans
electrical
Number of stages in pre-heater
consumption
Fan efficiency
SEEC
False air
(clinker production)
PRI of kiln
GAI of kiln
NAI of kiln
Pressure drop
% fans with VSD
% fans with VSD 28

L2 L3
SEEC of cement mill main motor
SEEC of roller-press/pre-grinder
Type of mill
Presence of roller-press/pre-grinder
Fan efficiency
SEEC
False air
(cement grinding)
PRI of raw mill
GAI of raw mill
NAI of raw mill
MTBF of raw mill
Pressure drop
% fans with VSD
SEEC of auxiliary
Major compressor efficiency
(up to clinker production)
SEEC of auxiliary
Major compressor efficiency
(cement grinding)
Power factor
Transformer efficiency
29



 Methodology to improve
 Aspiration setting  Academy and line team  Identification of critical
 False air leakage
 Overall benchmarking architecture equipments
 Idle running
Focus  Section benchmarking  Energy circle approach to  Technical limits analysis
involve frontline  Power factor
area  Best of best approach  Trends analysis for
 Meeting and review  Transformer losses different operating
 Machine level waterfall -
architecture  B level audit for BM and VRMparameters
electrical energy buildup
 Performance heat map  Gas handling efficiency
 Compress air loss
 Standardized approach  Equipment level energy

 Aspiration for individual  Approach and
for most critical levers loss analysis
plants based on methodology to drive
improvement to address losses in
Outputs  Identification of section  Benchmarks
electrical energy
level best of best  Responsibility matrix to  SOPs/ SMPs
 Key ideas parameters
plants
30

There are 10 cross-cutting levers critical for
optimization of electrical energy efficiency
(A)False air
leakage
(J) Monitor
(B) Idle
quality
running
parameter
(I) Feed (C) Over

size control rated motor
Cross cutting
levers
(H)
(D) Power
Compress
factor
air loss
(E)
(G) Gas
Transformer
Handling eff
loss
(F) B level
audit
Short title, Department, Name/Function or Event/Creator, Date yymmdd, Classification © 2012 Legal entity
(A) False air leakages
False air leakage is a common occurrence across sections,
and it is critical to minimize it
What is False air, and why is it important to monitor it?
False air is referred to the leakage of air in the process from Kiln pre-heater,
Coal mill, Raw mill, etc
It results in lower productivity and increase in power consumption, and

hence lower energy efficiency
For example, in Raw mill section alone, a reduction in False air by 10~15%
can lead to a power saving of upto 1 kWh/ton of clinker
33 © 2012 Legal entity

False air leakage should be measured and monitored on a daily
basis
How to measure false air?
 Evidence of “noise” of air leakage confirms the existence of false air
 False air is calculated based on % of Oxygen (O2) in the gas mixture
Monitoring false air: Role of energy circles

 Daily inspection rounds to investigate for noise of air leakage in their
Walk by Inspection respective sections, and reporting to maintenance teams for corrective
(WBI) actions
 Weekly plant rounds to measure and record the leakages, and following
Weekly False air it up with analysis to identify root causes and preparing action plan
investigation (FAI)  Plant can change the measurement frequency if false air target achieved
for last two years
 Presenting findings of WBI (daily) and FAI (once a week) during the daily
False Air
Location % (Holcim False Air Difference Flow Power
Norms) % Actual (%) M3/hr KW
Operations review False Air Across the Mill 4 17 13 70030 229
MIS and review  Circulating MIS with findings and corrective actions False Air Across the
Cyclones
1 2.2 1.2 6464 21
False Air Across the Mill

1 3.4 2.4 12929 42
Fan system
Total 6 22.6 16.6 89423 293

Typical example – source of false air
Difficulties to detect
false air source due
to insulation
Example 1: Analysis on false air in Raw mill unit reveals
saving of 0.7 kWh/t mat from 25% to 15%
Mill output t/h 300 300
Mill Inlet volume knm³/h 329 322
Mill fan inlet volume knm³/h 466 420
False air % 25 15
Mill Fan power kW 2066 1856
False air reduction from 25% to 15% in VRM can save 0.7 kWh/t mat which
is equivalent to 0.1 m USD per annum
For Loesche/Atox Mill ,Target of false air is 15% from mill inlet to fan outlet
For Pfeiffer/Polysius Mill .target of false air is 10% from mill inlet to fan
outlet
For 6th stage Preheater, target of false air is 7% from calciner outlet to PH
fan inlet
For BM for cement grinding ,False air target is 10% from mill inlet to mill
vent fan inlet
Key issues should be discussed during the daily operations
review to create a detailed action plan
ACC CHANDA EXAMPLE
S.No Issues Responsibility Date
Mill Reject Flap to be given in line to control

1 - -
false air across the mill
Pull rod sealing area leakage observed

2 - -
which has to be arrested
Leakage around the cyclones to be

3 - -
corrected
Heavy False air suction is observed around
4 mill fan casing area and flanges which is to - -
be controlled
Mill Fan Static Efficiency (without dust)
5 - -
found to be 71.8% against 74-76%

Case study :Rocker arm sealing arrangement to reduce false air in
Loesche mill
Develop sealing cover made of special

Fabric to minimise false air through
Rocker arm in Loesche Mill at Cilacap
Tools of false air measurement
1. False air measurement tools by temperature difference
2. False air measurement of kiln system
3. Guide line of false line across preheater
4. Problem solving in false air
(B) Idle equipment running
Idle running is a common occurrence across sections, and it
is critical to minimize it
What is idle running, and why is it important

to monitor it?
Idle time here is referred to the unproductive time, when the equipment is
consuming power but not producing
Typically, the control logic has a built in time lag between the stoppage of
the main drive and the auxiliaries (motors, belts, etc) to avoid frequent
Start/Stop’s, which leads to idle running of these equipments
Idle running should be minimized to the extent feasible for smooth running
of the operation to conserve energy

Idle running should be measured and monitored on a daily
basis
How to measure idle running?
 Idle running is determined by studying the trend of difference in running hours of

main motors and the running hours of auxiliaries
Monitoring idle running: Role of energy circles
 Daily analysis of trends of running hours of Main drive

Analysis of and auxiliaries of their respective sections to calculate
running hours idle running
 Discussion on idle running for major power consumers

MIS and during daily Operations review meeting
review
 Circulating MIS with and action plan for interlocking of
equipment wherever necessary

Energy Dash Boards – Create awareness to stop idle run

Example: Sample analysis of idle running in Raw mill shows a potential saving of
0.3 Kwh/T based on reduction in idle time by 53 mins in a day
ACC CHANDA EXAMPLE
Power Savings by Idle Running – Raw meal preparation

Current Idle Power
Running Time Proposed time Savings
Equipment (min) (min) (Kw) Units
Mill Fan 10 2 200 KW
Cyclone Discharge
Rotary airlocks 15 5 4.5 KW
Bucket Elevator 30 5 17 KW
391 AS5 Airlside
blowers 15 5 7
Total 70 17 228.5 KW
Assuming 1 stop/day 228.5 KW

Production 22hrs/day 11880 MT
Power Kwh/Ton
mat 0.3 Kwh/T mat

(C) Over rated Motor
Analysis of loading on drives should be done to check if a replacement of motor
is required for reduction in power consumption
What is over rated motors, and why is it important

to monitor it?
Motors which run less then 60% load are referred to overrated motors
Map the motor usage against the rated capacity and study the feasibility for
its replacement and optimization of production process such as high initial
torque , uneven load pattern.
Replacing the over rated motors with lower rated motors gives the
advantage of lower current consumption and hence lower electrical energy

Optimization of motor usage impacts electrical energy saving
How to measure over rated motors?
 Over rated motors are measured by tracking the percentage usage of running
power with rated power
How to optimize the over rated motors
 Identify the motor usage (running power vs rated power) across the plant.
Motor  Map the usage of high rated motors with applicability and check for the
swapping feasibility of swapping it with low rated motors .e.g In case of drive where
initial torque requirement is high, check the option for using VVVF
 Install star-delta convertor for converting between star circuit and delta
Connection- circuit wherever applicable (e.g., belt drive)
modification

Analysis of loading on drives should be done to check if a replacement of motor is
required for reduction in power consumption
ACC CHANDA EXAMPLE
S.NO LOCATION MOTOR FULL LOAD (Rated Capacity) KW RUNNING KW LOADING
1 Raw Mill Main Motor 5400 5041 93%

RAW MILL
2 Raw Mill Fan Motor 4200 3156 75%
SECTION
3 Raw Mill Classifier 250 63 25%
4 COAL MILL Coal Mill Main Drive 938 847 90%
5 SECTION Coal Mill Fan Motor 1200 669 56%
6 Kiln Main Drive 730X2 235&210 30% For motors with
7 Pre-heater Fan-1 1600 637 40%
8 Pre-heater Fan-2 1600 638 40% loading (%) less
9 Rabh Fan 1700 680 40% than 60; these
10 Cooler Fan-1 300 207 69%
11 Cooler Fan-2 250 116 46% should be
12 Cooler Fan-3 300 190 63%
13 Cooler Fan-4 170 845 497%
considered for
14 Cooler Fan-5 250 172 69% replacement or
KILN SECTION
15 Cooler Fan-6 340 163 48%
16 Cooler Fan-7 300 144 48%
further
17 Cooler Fan-8 200 148 74% optimization of
18 Cooler Fan-9 205 125 61%
19 Cooler Esp Fan 575 103 18% operation is
20 Pa Fan-1 250 55 22%
required to
21 Pa Fan-2 250 59 24%
increase the
22 Pa Fan-3 250 STAND BY -
23 Cement Mill Main Motor 5400 3885 72% utilization of
CEMENT MILL
24 Cement Mill Fan Motor 3500 3320 95%
SECTION
25 Cement Mill Classifier 560 NA - these motors
26 OLBC-1 400 134 34%
27 RAW MATERIAL OLBC-2 400 128 32%
28 PREPARATION& OLBC-3 400 130 33%
29 TRANSPORT OLBC-4 400 127 32%
30 LS CRUSHER MOTOR 1250 NA -
* Kiln & related equipment data is taken in 3.4 RPM

(D) Power factor
Significance of power factor in electrical energy efficiency
improvements
What is Power factor, and why is it important?
 Power factor is the ratio of the kW (shaft power or true

power required) and the kVA (actual electrical load on the
distribution system)
 Typically, the electricity loads vary in power factor from 0.8

to 0.9, and the distribution network is stressed for capacity
at low power factors
 A poor power factor leads to I2R power losses because of

higher current in the system resulting form higher reactive
component of power

Typical improvements methods and cost benefits of Power
factor improvements
How to improve Power factor?

 Power factor can be improved by adding power factor correction capacitors
to the plant power distribution system
 By adding capacitors, the requisite shortfall of reactive power is met and

hence there is a reduction in reactive power (and in turn total power)
generated by utilities
Some cost benefits by improving Power factor

 Reduced kVA (Maximum demand) charges in utility bill
 Reduced distribution losses (KWH) within the plant network
 Better voltage at motor terminals and improved performance of motors
 Investment on system facilities such as transformers, cables, switchgears, etc for

delivering load is reduced

How to improve the P.F
•Theoretically if all loads have unity Power Factor, maximum

power can be transferred for the same distribution capacity.
However as the loads are inductive in nature, the distribution
network is stressed for capacity at low Power factors.
• P.F can be improved by addition of capacitor banks to the

distribution system. They act as reactive power generators and
compensates the needed reactive power.
Selection of Capacitor banks
The capacitor banks are selected based on the following relation:
KVAr Rating = KW ( Tan Φ1 - Tan Φ2)
Where
Φ1 =Existing (Cos‾ PF1)
and
Φ2 = Improved (Cos‾ PF2)
CHAPTER-4 PAGE-4.1
Location of Capacitor Banks
Installation of Capacitor Banks will improve the Power Factor between

the point of application and Power source. However the Power factor
between the utilisation equipment and capacitor bank remains
unchanged.
Capacitors are usually added at:
 on the equipment
Ahead of motor control centres (distribution panels)
At Mains Incomers
There are advanatages and disadvantages in each type of these

installations.

Location of Capacitor Banks – near the equipment
Advantages:
 Reduction in Transmission losses ahead of the motors and hence

Increase load capabilities of distribution system
Can be switched with the equipment, and no additional switching

required.
Better voltage regulation because Capacitor use follows load.
Sizing of the capacitor is simplified
Disadvantages:
 Small capacitor banks cost more per KVAr than larger units
It should always be noted that rating of capacitor banks (while installed at motor
end) should not be greater than the No-load magnetising KVAr of the motor.

Location of Capacitor Banks – at distribution panels
Advantages:
Increase load capabilities of the service
Reduced material costs relative to individual correction
Disadvantages:
 Switching means may be required to control amount of

capacitance used.(APFC could be the option)

Location of Capacitor Banks – at Mains Service
Advantages:
Low material costs
Disadvantages:
 Does not improve the load capabilities of the distribution

system
Switching will usually be required to control the amount of

capacitance used

Location of Capacitor Banks - benefits
From Energy Efficiency point of view , capacitor bank installation at

tail end will help to reduce the loss reduction within the plant’s
distribution network as well and directly benefit the user by reduced
consumption .
Reduction in Distribution loss% in Kwh ,when tail end Power factor is

raised from PF1 to PF2 ,is proportional to:
(1- (PF1/ PF2 )^2)*100

Location of Capacitor Banks - Considerations
Where loads contributing to P.F are constant and system load

capabilities are not a factor ,correcting at the mains service could
provide cost advantage. But when low P.F is derived from the
individual equipment operating (as is the case in Cement industry),the
equipment level correction would be effective.
However the growing use of non-linear loads (like VVFDs etc..),has

increased the complexity of system Power factor and it’s corrections.
The application of PF correction capacitors without a thorough
analysis of the system by experts can aggravate rather than
correcting the problem, particularly if the 5th and 7th harmonics are
present in the system.

Completed
Typical action plan to improve power factor to best in In progress
Yet to start
class level CHANDA EXAMPLE
Implementation Plan
Potential
Idea & Activity Potential Responsibility Start End Achieved Status Remarks
RABH LC Two incomer and one Bus SHIBU 04/04/2012 07/04/2012 Completed
coupler pcc trafo. One incomer of trafo VARGHESE
switched off and bus coupler switched on
Cooler LC Two incomer and one Bus OM PRAKASH 13/04/2012 15/04/2012 Completed
coupler pcc trafo. One incomer of trafo
Cement LC Two incomer and one Bus KAILASH 17/04/2012 22/04/2012 In progress
coupler pcc trafo. One incomer of trafo CHAUHAN
Packing plant LC Two incomer and one KAILASH 22/04/2012 25/04/2012 In progress
Bus coupler pcc trafo. One incomer of CHAUHAN
trafo switched off and bus coupler
switched on
Old cement plant LC Two incomer and KAILASH 25/04/2012 28/04/2012 In progress
one Bus coupler pcc trafo. One incomer CHAUHAN
of trafo switched off and bus coupler
switched on
Adding of Capacitor bank in parallel of Krishnamoorty 28/04/2012 30/10/2012 Yet to start

PCC & HT Panel at RABH
Adding of Capacitor bank in parallel of KAILASH 28/04/2012 30/10/2012 Yet to start

PCC & HT Panel at NCM CHAUHAN
Adding of Capacitor bank in parallel of Karunakar rao 28/06/2012 30/12/2012 Yet to start
PCC & HT Panel at ECM

(E) Transformer losses
Significance of transformer losses in energy efficiency
improvements
What are transformer losses?

 Transformers receive High Tension voltage from the grid and
step it down to the required voltage
 Transformer losses consist of 2 parts: No-load loss and Load

loss
No-load loss (core loss) is the power lost due to
magnetizing current needed to energize the core of the
transformer. They are constant and occur at all times,
regardless of load
Load loss (copper loss) is the power lost in the primary and
secondary windings of a transformer due to the Ohmic
resistance of the windings (P=I2R)

Ways to measure and reduce transformer losses
How to measure transformer losses?

 For a given transformer, the total transformer loss can be calculated using the no-
load loss and the load loss values which are typically supplied by the
manufacturer
PTOTAL = PNO-LOAD + (% Load/100)2 x PLOAD
How to reduce transformer losses?

 One way to reduce transformer losses is to optimize the distribution transformers
for efficient loading:
For example, consider a plant where distribution transformers are running at
30% loading. The transformer should be operated at more than 50% loading.
This can be achieved by switching OFF one transformer and transferring the
load on the adjacent transformer, thereby increasing the transformer efficiency
and reducing the no-load losses

Loading optimization of a transformer
Maximum transformer Efficiency is realised at that percentage

loading at which No-load Loss is equal to Full load Loss.
In other words:
Optimum % Loading of the Transformer

=
Sqrt( Iron Loss/ Copper Loss)
CHAPTER-4 PAGE-4.1
Case Study: Two Transformers in Line (Before Case)

Case Study: One Transformer in Line (After Case)
Annual Energy Saving in Rs. = 1.2 Lakhs per Annum

Precautions to be taken
 Periodic load changeover needs to be done, in

order to ensure the stopped transformer
availability at any point of time.
 Periodic maintenance of breather to be taken to

avoid formation of moisture.

PAGE-4.3
(F) B Level Audit
What is a “B” Level Audit?
KPI Standard
measurements
time
Cement Manufacturing Course © 2012 Legal entity

Targets of a “B” Level Audit
• Estimate the saving potential on mill system in terms of reduction in SEEC
about 5 -15% and increase of output by evaluating the mill performance and
benchmarking
• Routine performance test

The performance test should be carried out on a regular basis (at least once per
year) to allow:
Routine "health check “ of the grinding systems
Preventive process efficiency evaluation
• Identify potential for further improvement .
• Address the issue if any

Constant deterioration of mill performance
Constant performance but below nominal
Fluctuations in performance (t/h,kWh/t) and quality parameter like blaine, R 45
mic,
strength
It is mandatory to conduct B level audit for each mill system once in a year
and maintain the document of report, action plan
Standard Measurements – Tasks & Frequency
one year
1. Circuit mat. granulometry
2. Mill longitudinal sieving
3. Ball charge filling degree
4. Mill material level
5. Mill ventilation
6. Separator Tromp curve
B-level audit
7. Separator ventilation
8. Mill internal conditions
9. Weigh feeder calibration
10. Instrument verification
11. Control loop verification
yearly stop
Vertical Mill –Operation checks
Vertical Mill – Check during stoppage
Ball Mill – Operational check
Ball Mill – Inspection check
Case study: Improvement after systematic B level audit
• Objective:
 Reduce specific electrical energy consumption of cement mill department from
29.84 kWh/t to 26.86 kWh/t
Project Project
Parameter Unit Achieved
Baseline Benefits
Main Drive kWh/t 16.54 15.79 0.75
Mill Fan kWh/t 10.54 8.87 1.67
Auxiliary kWh/t 2.75 2.48 0.27
Total Department kWh/t 29.83 27.14 2.7
Output t/h 248 255 7

Residue on 45 µm % 11 8.5 2.5
Blaine cm2/g 3818 3826 -
• Key Actions:
 Mill feed distribution made in center of the table.
 Hydraulic pressure increased from 55 bar to 70 bar.
 Separator dynamic seal gap reduced from 20 mm to 5 mm.
 False air reduced from 20% to 7% across mill system.

Tools of B level audit
• Guideline to conduct B level audit
• Calculation sheet for B level audit
(G)Gas Handling Efficiency
 Can the efficiency of your fans

be improved ?
 What is the potential to lower
the system pressure drop ?
Gas handling efficiency
• Gas handling efficiency mainly depend on the performance of
• Process fans
• Pressure drop across
different system like
Cyclone
Bag filter
Duct
Mill systems- VRM
Ball Mill
Gas Handling - Action
Significance of Main Process Fans
It is YOUR task to ensure the highest possible
availability, capacity and efficiency
of all main process fans!
 Main Fans:
 kiln ID fan
 mill fans (raw material, coal & cement)
 main filter fans (kiln, cooler and mills)
 cooler cooling air fans
 bypass fans
 booster fans energy
 30% to 50% of the plants total electrical

energy consumption are from main fans!
 Main fans are most important to control
the mechanical and thermal processes! 82
Holcim Group Support Rev. 02.11.2011/HKL
Main Process Fans PPE 2011 Presentation HKL.ppt
Plant Characteristic (system resistance curve)
 gas flow (v: [m3/s] actual flow!) causes friction with duct walls and
internals, resulting in pressure drop (Dp)
 as a “rule of thumb” Dp in general increases approx. proportional to the

square of gas velocity; however, the resistance curve is system specific
and a function of the gas density.
 each flow disturbance (e.g. duct bend, flow  the higher the gas density, the
split, flow combination, damper) causes higher the pressure drop (Dp) for
additional Dp and should thus be avoided the same actual gas flow
Dp Dp
higher flow resistance higher gas density: r2 > r1
p2 plant characteristic p2
Dp ~ v2 r2
p2   p1
Dp = f(v) r1
p1 general Dp ~ v2.0 p1
bag filter Dp ~ v1.4
vertical roller mill (VRM) Dp ~ v1.0
clinker cooler cooling air fans Dp ~ v1.0
v v83
PPE Fan Equations (Variable Speed)
n2
volume flow v2   v1
n1
2
 n2 
static pressure pst 2     pst1
 n1 
3
 n2 
power requirement P2     P1
 n1 
 first approach, as equations do not consider changes in density, compressibility and efficiency
 for detailed calculation application of HGRS fan tools recommended; ask for support
84
PPE Fan Shaft Power
3
v  Dp  10
Pshaft  kW 
imp
Pshaft required power at fan shaft [kW]

v fan inlet gas flow [m3/s]
Dp total increase of static pressure by fan [Pa]
imp impeller efficiency [-]
 in case of significant dust load additional shaft power to be considered

 for detailed calculation application of HGRS fan tools recommended; ask for support
85
Power Consumption: VSD vs. Fixed Speed
 Remember for VSD:
3
Dp  n2 
P2     P1
plant characteristic  n1 
design point
operating point
fan characteristic
pO reduced
fan speed 100% fan speed
power required
with VSD
vO v 86
 Additional Dp leads to increased power
consumption
Dp  VSD fans are much more efficient than
fixed speed fans
plant characteristic
pO design point
power required
with fixed
additional Dp operating point
speed fan
by throttle fan characteristic
100% fan speed
power required
with VSD
vO v 87
88
Impeller Efficiency
 The fan efficiency  is typically
near the optimum at design point
Dp  With VFD the efficiency field moves
with shifting the fan characteristic,
such the fan efficiency is high in a
wide operating range
design point
max
pD
operating point


fan characteristic
pO 
reduced
fan speed 100% fan speed

vO vD v 89
Pressure Drop Calculation- Duct
Straight duct pressure drop:
P.D.(Straight duct) = V.P. x Hf x L

Where,
P.D. = Pressure drop (mmWC)
V.P. = Velocity pressure (mmWC)
Hf = Frictional factor (dimensionless)
L = Duct length (m)
V.P. = V^2.r/2g
Where,
V = Gas Velocity in duct (m/s) Duct material a b c
r = gas density (kg/m3) Galvanized iron 0.0155 0.533 0.612
g = acceleration due to gravity (m/s2) Black iron, S.S., P.V.C., Aluminum 0.662 0.645 0.602
Flexible (Fabric covered wires) 0.0186 0.604 0.639

Hf = a.V^b/Q^c
Where,
a, b, c = constants, depend on duct material (refer table)
Q = Gas flow rate (m3/s)
Pressure Drop Calculation
Elbow pressure drop
PD(elbow) = V.P. x Elbow loss factor x No. of elbows

Elbow loss factor = consider table
Type R/D ratio

--- 0.50 0.75 1.00 1.50 2.00 2.50
5-piece --- 0.46 0.33 0.24 0.19 0.17
4-piece --- 0.50 0.37 0.27 0.24 0.23
3-piece 0.90 0.54 0.42 0.34 0.33 0.33
Pressure Drop in Ball Mill
∆ P = K . ½. Gas density. ( Mill Velocity)^2/ g mmwg
K = 300-800 for Single chamber mill

K = 2500 for double chamber mll

Pressure drop calculation across cyclone
Technology – Cleaning Principles
• Various cleaning principles used for bag filters
Transport and Dedusting Workshop © 2012 Legal entity

Design Guidelines (1/5) – General
• Maximum 6 (8) dust sources to be connected to one filter
• The following maximum air to cloth ratios based on a bag
length of 4.5 m shall apply:
 1.5 m3/(m2min) for general dedusting
 1.2 m3/(m2min) for slag, coal, bypass, fly ash and clinker dust
• Can velocity (theoretically calculated raw gas velocity between
the filter bags in the area of the bag bottom) valid
independently of raw gas inlet design shall be maximum 1.3
m/s
• The hopper valley (corner) angles should not be less than 55°

Design Guidelines (2/5) – Fabrics
• Filter cloth:
 General application (dry gas) up to 120 °C (long time operation),
needle felt fabric made from high quality Polyester fibers are used.
 Application in drying/grinding (humid gas) up to 120 °C (long time
operation), Polyacrylnitrile or similar fiber cloth is recommended.
 Application for temperatures above 120 °C, Polyamide (Nomex),
Polyphenylene, Glass-fiber, Teflon/graphite coated or similar.
 Pleated filter bags and star bags shall not be used (except for
electrical room pressurization and only with engineer’s approval)

Design Guidelines (3/5) – Duct Work
• Dedusting Ducts
 Up- and downward sloping a minimum slope of:
 60° for limestone, slag, cement

 50° (45°) for clinker
 70° for coal
 Horizontal ducts are not accepted
 The maximum velocity in these runs shall be 18 m/s, for slag/clinker 16

m/s
 For fan discharge duct, the velocity preferably shall be in the range of 15
to 20 m/s
 Minimum duct diameter shall be 133 mm (outside)
 Velocity (v1) at dedusting hood entries shall not exceed 1.5 m/s
 Minimum duct and hood wall thickness to be 3 mm (1/8”)

Design Guidelines (4/5) – Duct Work
Recommended elbow

Cleaning Control (1/2) – Cycle
• Bag cleaning cycle guidelines:
 The bag cleaning shall be controlled by timer and differential pressure
measurement across the bag filter
 Cleaning pressure: max. 5.8 - 6.0 bar for polyester bags, max. 5.0 - 5.2
bar for polyester bags with membrane
 Pulse duration: 0.1 sec
 Pulse frequency: between two pulses 5 to 30 sec or more, depending the
differential pressure over tube sheet
 Cycle time: each solenoid valve should pulse within 120 to 240 sec (max)
 Differential pressure adjustment: lower set point 10 mbar, upper set point
12.5 mbar

Cleaning Control (1/2) – Sequence
• Recommended cleaning sequence
Typical cleaning sequence Recommended cleaning sequence
• Example of recommended cleaning sequence for a dust

collector with 17 bag-rows and 10 timer positions:

Case study -1 : PC fan
Situation:
 PC fan was running at full speed with no margin in flow to increase
Kiln production.
 It was observed that velocity increased from 22 m/s in duct to about 37
m/s at fan inlet resulting in a turbulent flow and a high pressure drop in
the system.
Action:
 Fan inlet area was increased form 7.07 m2 to 8.85 m2 to reduce

velocity profile.
Result:
 Improvement in flow by 9% at the same fan speed giving margin to
increase Kiln production.
 Increase in fan efficiency from 67 to 76%.


Parameter UOM Before After

Period Feb 2009 April 2009
Vol Flow m3/hr 790677 865692
St Pressure mmwg 853 874
Fan pressure mmwg 796 840
Feed (Calciner string) t/h 363 381
Fan shaft power kWh 2559 2585
Efficiency % 67 76

Case study -2: Raw mill fan
Situation:
 High power consumption in Raw mill fan.
 High velocity at fan inlet box with an incremental increase form 18m/s
in duct to 41m/s .
Action:
 Fan inlet duct area increased from 4.98 to 6.42 m2.
Result:
 Improvement in flow by 5.4% at a reduced rpm from 930 to 890.

 Fan shaft power reduced by 9.5%.
 Fan velocity at inlet reduced by 20%.


Parameter UOM Before After
Period Dec’2003 May’2004
Vol Flow m3/hr 738706 778900
St Pressure mmwg 1176 1140
Fan pressure mmwg 1236 1125
Fan inlet velocity m/s 41.2 33
Fan speed rpm 930 890
Fan shaft power kWh 3533 3197
Efficiency % 70 75
Reduce outlet PH elbows drop pressure from 9mbar to
4mbar to reduce by 0.64 kWh/t cli
• Modify elbows at the outlet PH to

reduce pressure drop by 5mbar
• Project investment budget: Mio
A USD 0.39
• Time: 2013
B
Pstatic (A) – Pstatic (B) = 9 mbar
Outlet to ID Fan
Inlet from top
cyclone C1
• To reduce SEEC by 0.64 kWh/t cli
106 EARN Steering Committe Meeting,

© 2012 2012-11-21
Legal entity
Tools
• Fan efficiency calculation file & guide line
(H) Compress air loss
Typically compressed air efficiency 10-15% -Use it wisely
Compressor energy efficiency
•It is worth noting that the running cost of a compressed air system is far higher than
the cost of a compressor itself.
•Energy savings from system improvements can range from 20 to 50 percent or
more of electricity consumption, resulting in thousands to hundreds of thousands of
dollars.
•A properly managed compressed air system can save energy, reduce maintenance,
decrease downtime, increase production throughput, and improve product quality
Power loss due to leakage in compress air system
Minimize Compressed Air – Improvement Area
Specific Improvement area to minimize compressed
air
Example 2: Inspection of air leakages in lime stone crusher
reveals 42 leakage points in the circuit
ACC CHANDA EXAMPLE
3 points 3 points 4 points 1 points 3 points 3 points 3 points 2 points 5 points

leakages leakages leakages leakages leakages leakages leakages leakages leakages
Header
Valve
Air manifold
Total leakage points in Bag filter I = 32
Total leakage points in Bag filter II = 5 Total leakage points in Bag filter III = 5
Total leakage points in Circuit= 42

Example 2: Analysis of leakages indicate potential saving of 0.08 kWh/t
clinker by reducing compressor losses by 25%
ACC CHANDA FIGURES
Power Saving Calculation
Power
Eq. Opn Saving
Avg. Avg load Op load clinker load / KWh/Tn
Existing condition Time (s) Load (A) load (A) (KW) per hr per hr Tn Cl Cl
loading 34.44 60 54.8 31.53 1594
unloading 36.78 50
800.00 1.99
Cycle time 71.22
Leakage loss (%) 48.36
Eq.
Avg load Avg load Op load Opn load
Time (s) Load (A) clinker 0.08
(A) (KW) per hr / Tn Cl
per hr
ideal condition
load 18.00 60
unload 53.22 50
52.53 30.20 1526.77 800.00 1.91
Cycle time 71.22
Leakage loss (%) 25.27
By reducing the compressor losses by 25 %, a power saving of 0.08 KWh/T of clinker can be achieved

Compress air leakage detection by ultra sonic detector
 Com air leakage detection by using Ultra sonic detectors

 Practice at ACL Darlaghat plant to detect in comp air line
 Long distance ( approx 10 m) auditable and visual indication of air leakage

Tools
1. Compressed air presentation
(I) Feed size control
Crusher are more efficient at crushing than Mill

- Optimize feed size at changing crusher setting
and maintenance
Wear parts & electrical energy consumption
• Both machines consume electrical energy and wear parts
1.7 kWh/t – 3.0 kWh/t 16kWh/t – 25 kWh/t
• Wear at the crusher results in coarser feed size for the raw mill and
lowers its efficiency
kWh/t
time
118

Mill Feed size control
Maintenance & inspections - crusher internals
 e.g: Clinker crusher
- High abrasion
- Rebuild disk with
MG 790 & MG
710/750 welding
electrode
 Vibration control
 Data collection
120
© Holcim Group Support Ltd 2011
Maintenance & inspections – crusher internals
Gap and wear of bar grate
121
Actions to control feed size
 Set target maximum feed size (also for VRM max fines
% passing 1mm) – Decide based on mill size ,max 100
mm as per HGRS guide line
 Define & implement inspection plan (Production &
maintenance) to include:
 Mill feed size as well as MIC feed size observation (weekly)
 Crushers & screens inspection
 Incoming materials feed size
 Occasional size grading check (monthly, depending upon crusher wear)
 Consider possibility to produce a smaller crusher

product to reduce power consumption, but take care to
also consider:
• Increased crusher wear
• Reduced crusher throughput - Increased operating time
• Potential for excessive fines (low level dust & VRM vibration) 122
Case Study –Raw Mill Bhatapara
Raw mill output increase by 3% reducing feed size of limestone
After Before
Cumulative Cumulative
100mm 0.00 5.77 0.00 1.41 100mm 3.83 7.40 5.71 5.77
90mm 2.37 6.73 2.07 2.63 90mm 10.92 10.13 10.71 12.81
80mm 5.63 8.79 5.81 3.96 80mm 13.29 12.28 17.54 17.26
70mm 12.45 11.21 10.51 6.09 70mm 16.10 16.03 23.41 21.38
60mm 20.95 14.94 13.97 11.39 60mm 22.07 28.45 34.68 24.64
50mm 28.95 22.64 21.72 18.81 50mm 25.68 37.61 39.76 29.77
40mm 39.03 27.33 30.29 25.06 40mm 28.38 46.13 46.51 36.39
30mm 48.12 34.79 40.39 34.46 30mm 35.81 53.00 57.94 47.97
20mm 56.82 44.46 49.52 47.33 20mm 46.85 66.06 63.65 57.38
10mm 69.96 65.10 66.53 65.38 10mm 66.33 80.48 78.02 71.16
5mm 81.03 81.29 80.64 78.60 5mm 79.28 88.61 87.22 82.74
2mm 88.24 89.07 88.11 88.54 2mm 84.35 91.73 91.43 88.13
1mm 94.86 96.46 94.88 94.06 1mm 91.55 95.23 94.84 92.96
,-1mm 5.14 8.03 5.12 5.94 ,-1mm 8.45 4.77 5.16 7.04
Problem Faced : Crusher wear rate increased
123
(J)Monitor quality parameter to minimize energy
consumption without affecting quality standard
Quality parameter has huge impact on energy

consumption
124
Quality impact on electrical energy consumption
125
Quality impact on energy consumption
 Improve blending efficiency of lime stone pile,CF Silo
 Ensure the feeding consistency and accuracy of additive
feeder in raw mill.
 Plan to optimize clinker reactivity
 Minimize increase of cement grinding power
 Ensure burnability in good range
 Use of microscope to optimize burning condition
 Operate at optimum cement sulfate
 Ensure good control of product surface area - avoid

over-grinding
 Consider to use/optimize grinding aid
 Proper functioning of auto sampler

126

 Benchmarks
 SOPs/ SMPs
parameters
127

Key steps in machine level deep dive
 Based on pareto of consumption Typical loss levers to be measured

Identify list of and difference from design
1  Measure false air: % false air=
critical equipment identify top 3-5 critical machines (Oxygen at outlet-Oxygen at
in each section inlet)/(21- Oxygen at outlet)
 Check for the idle running in the
Identify the ▪ Determine losses due to current logic and possible
2 potential/gaps different cross cutting levers optimization opportunities
for key machines and corresponding potential  Measure the running hours of main
motor and the running hours of
auxiliaries
Identify key  Identify areas of improvement  Check for the time delay in the group
3 improvement with minimum capex based on or optimization of groups for
areas for M/C gap analysis elimination of idle running of
equipments
 Measure differential pressure across
Create  Segregate actions which can damper
4 implementation be done online vs shutdown,  Measure fan efficiency: Derive the
plan create plan with timelines and flow (m3 / sec) across fan by
responsibilities measuring temperature, static
pressure, dynamic pressure
12
8
List of critical equipment section wise selected to carry out the
machine level deep dives Critical equipment (Running
ACC CHANDA FIGURES
Raw material extraction

Raw meal preparation Clinkerisation Cement Mill
and preparation
CM Main
LS Crusher 2.2 Mill main drive 14.2 Cooler drive 9.1 20.0
Drive
OLBC 1.1 RM Fan 8.9 Fuel prep 5.1 CM Fan 11.8
Aux+ Prod
LS Stacker 0.8 Other Aux. 2.3 Kiln cooler aux 2.9 2.6
Hndlg
Homog’n 1.6 PH fan-1 2.8
LS Reclaimer 1.0 PH fan-2 2.7
Sep. drive 0.5 Bag House Fan 2.6
kiln main drive 2.0
Fuel Trans 0.4

A B C D
129

analysis Critical equipment (Running
ACC CHANDA FIGURES

and preparation
CM Main
Drive
Aux+ Prod
Hndlg
kiln main drive 2.0
Fuel Trans 0.4

A B C D
130

Gap analysis should applied on the critical equipment
A (Crusher) and idea generation to be conducted (1/2)
ACC CHANDA FIGURES
Lime stone crusher
Gap analysis Ideas Impact
Compressor loss
Actual consumption 2.20  Arresting 42 leakages will
reduce compressor loss from
48% to negligible losses
Compressor loss 0.08  Installing energy meter at 0.08 Kwh / T of
compressor clinker
 Installation of DP transmitter
for bag filter
Opt. damper control 0.02  Periodic check for the
compressor piping for avoiding
leakages
False air leakages 0.04
 Opt. damper control & false
air leakages
Idle run 0.20  Installation of VFD for fan
motor
 Replacement of current motor 0.06 Kwh / T of
PRI Loss 0.20 to lower kw rating motor clinker
 100% opening of the damper
 Replacement of the fan to
70000 m3 / hr from 69000 m3
Aspiration value 1.66 / hr
1 This is a combination of Fan & Motor

2 All values calculated considering kiln output 7000 TPD 131

Gap analysis should applied on the critical equipment
A (Crusher) and idea generation to be conducted (2/2)
ACC CHANDA FIGURES
Lime stone crusher
Idle run
Actual consumption 2.20  There is an average idle
0.20 Kwh / T of
running of 43 Hr/ month due
clinker
to non availability of raw
Compressor loss 0.08 material , this can be reduce to
24 hr by relaying the circuit
logics.
 Bag filter purging should close
Opt. damper control 0.02 during idle run
 Tripping time can be reduced
to 5 minutes from the current
False air leakages 0.04 10 minutes
Idle run 0.20

PRI loss
 SOP should be maintained to 0.20 Kwh/ T of
run the plant in full TPH clinker
PRI Loss 0.20  Increasing the number of
tippers for constant feeding
Aspiration value 1.66
1 This is a combination of Fan & Motor

2 All values calculated considering kiln output 7000 TPD 132

Detailed action plan should be created to address the issues with
A clear responsibility and time line
Potential Implementation Plan

Idea & Activity Kw/t
clinker Responsibility Start End Status Remarks
Roy 22/05/2012 22/05/2012 Yet to start
Arrest 42 leakages at the compressor
0.08
circuit
Periodic check of the leakages at the Roy 22/05/2012 Yet to start

compressor circuit
Install energy meter for compressor for Ravi Aswale 20/05/2012 25/05/2012 Yet to start
compressor usage monitoring 0.06
Install VFD for Fan motors and replace the Ravi Aswale 30/05/2012 25/06/2012 Yet to start
motor with lower rating
Reduce Idle time from current 42 Hrs per JoJo Agustin 21/05/2012 23/05/2012 Yet to start
month to 24 hrs per month 0.2
Close bag filter purging during idle JoJo Agustin 23/05/2012 25/05/2012 Yet to start
running
Install DP Transmitter for bag filter Lokesh sharma 25/05/2012 27/05/2012
133

analysis Critical equipment (Running
ACC CHANDA FIGURES

and preparation
CM Main
Drive
Aux+ Prod
Hndlg
kiln main drive 2.0
Fuel Trans 0.4

A B C D
134

Gap analysis should be applied on the critical equipment (Raw mill fan) and
B idea generation sessions should be conducted (1/2)
ACC CHANDA FIGURES
Raw mill fan
False air leakages

Actual
consumption 8.90
 Mill Reject Flap to be given 0.89 Kwh/ T of
in line to control false air clinker
Opt damper across the mill
0
control
 Pull rod sealing area
False air leakage observed which
0.89 has to be arrested.
leakages
 Heavy False air suction is

Idle run 0.03 observed around mill fan
casing area and flanges
which is to be controlled
PRI loss 0.14
Aspiration
7.84
value
All values calculated considering kiln output 7000 TPD and Raw mill output 560 TPD 135

Gap analysis should be applied on the critical equipment (Raw mill fan) and idea
B generation sessions should be conducted (2/2)
ACC CHANDA FIGURES
Raw mill fan
Raw mill Fan Ideas Impact
Idle run
Actual consumption 8.90
 Mill Fan has to trip within 2
minutes of raw mill tripping
Opt damper control 0  Cyclone discharge group to
be stopped in 5 minutes
after fan stop
False air leakages 0.89  395AS5 Air slide Group to be
stopped in 5 minutes after 0.03 Kwh / T of
fan stop clinker
Idle run 0.03  Silo Feed Bucket Elevator to
be stopped in 5 minutes
after fan stop if selection is
PRI loss 0.14 direct operation
PRI loss
 Maintaining consistent feed 0.14 Kwh/ T of
at 560 TPH will give power clinker
saving
All values calculated considering kiln output 7000 TPD and Raw mill output 560 TPD 136

B clear responsibility and time line
ACC CHANDA EXAMPLE

Idea & Activity Kwh/t
Clinker Responsibility Start End Status Remarks
Roy Yet to start
Periodic check of the leakages at the 0.89
compressor circuit
Periodic check of false air leakages Lokesh sharma 23/05/2012 Yet to start
( once in two months )
False air across the cyclone, fan to be Srinivas 21/05/2012 25/05/2012 Yet to start
arrested.
Periodic check of false air leakages Lokesh sharma 23/05/2012 Yet to start
( once in two months )
For reducing idle stoppage of equipments , Srinivas 21/05/2012 23/05/2012 Yet to start
new logic system to be incorporated in the 0.03
overall circuit design
Periodic check & track of all the dust Srinivas 23/05/2012 Yet to start
collector parameters
Mill reject double flap valve presently not in Mohan Khond / 20/05/2012 23/05/2012 Yet to start
operation, so it has to be taken in line Srinivas
137

List of critical equipment section wise selected to carry out
the analysis Critical equipment (Running
ACC CHANDA FIGURES

and preparation
CM Main
Drive
Aux+ Prod
Hndlg
kiln main drive 2.0
Fuel Trans 0.4

A B C D
138

D
List of critical equipment section wise selected to carry out
the analysis Critical equipment (Running
ACC CHANDA FIGURES

and preparation
CM Main
Drive
Aux+ Prod
Hndlg
kiln main drive 2.0
Fuel Trans 0.4

A B C D
139

Gap analysis should be applied on the critical equipment (Cement mill fan) and
D idea generation sessions to be conducted (1/2)
ACC CHANDA FIGURES
Cement mill fan

Opt damper control
Actual consumption 12.00  Optimisation across fan inlet 0.68 Kwh / T of
damper by applying GRR cement
 Operating at normal load,
Dam ring height can be
Opt damper control 0.68
increased
False air leakages
 Reduction in False air 0.40 Kwh / T of
False air leakages 0.40
leakage in Bag house cement
hoppers (14 nos.) to be
arrested
Idle run 0.17  Bag house I/L & O/L flange
joint leakage. (2 nos) to be
arrested
PRI loss 0.20  Bag house fan inlet damper
flange joint leakage to be
arrested
 Mill I/L duct leakage. (2 nos)
to be arrested
 Re-circulation duct leakage.
(2 nos) to be arrested
140

D clear responsibility and time line

Idea & Activity Kwh/T
Cement Responsibility Start End Status Remarks
Shrad Sharma 21/5/2012 15/6/2012 Yet to start
Arrest bag house I/L & O/L flange joint 0.40
leakage. (2 nos)
Arrest bag house fan inlet damper flange Ravi Lingappa 20/05/2012 30/05/2012 Yet to start
joint leakage
Arrest false air leakage in Bag house hoppers 0.68 Sharma shrad 21/5/2012 30/5/2012 Yet to start
Arrest Mill I/L duct leakage. (2 nos) Ravi Lingappa 21/05/2012 30/05/2012 Yet to start
Arrest recirculation duct leakages Ravi Lingappa 21/05/2012 30/05/2012 Yet to start
Logic setting for turning off the fan 0.17 Arun Garg 23/05/2012 23/05/2012 Yet to start
immediately after mill trips
141

D Gap analysis should be applied on the critical equipment (Product handling and
auxiliaries) and idea generation sessions to be conducted (1/2)
ACC CHANDA FIGURES
Product Handling system & Auxiliaries

Compressor loss
 Separate compressed air line 0.03 Kwh / T of

Actual consumption 2.61 to be provided for packing cement
plant
 Operation of 561-LD4 (fresh

air) and 561- LD3 (Stack
Compressor loss 0.03 damper) in auto PID.
 Rectifying all the Venting

duct leakages in Feed &
transport section near
Idle run 0.20 Dampers and bends. (30
points)
142

D Gap analysis should be applied on the critical equipment (Product handling and
auxiliaries) and idea generation sessions to be conducted (2/2)
ACC CHANDA FIGURES
Product Handling system & Auxiliaries

Idle run
 Minimizing the idle running 0.20 Kwh / T of
of Fly-Ash unloading circuit. cement
Actual consumption 2.61  Minimizing the idle running
of Clinker extraction circuit
by ensuring the start in
sequence.
 All the Bag filters purging
Compressor loss 0.03 time difference is 11.5 secs
which can be increased to
18 secs thereby saving
considerable amount of
compressed air in 22 nos of
Idle run 0.20 BF’s
 All the timer panels to be
started and stopped in
sequence with RA’s to avoid
idle run
Aspiration value 2.38  Lighting on the Top of bag
filters (22 nos) to be
modified as per req of
maintenance team to save
energy
143

D clear responsibility and time line
Implementation Plan
Idea & Activity
Potential Responsibility Start End Status Remarks
Ravi Lingappa 21/5/2012 30/6/2012 Yet to start
Install pressure transmitter switch to stop the
blowers once unloading is completed.
0.20
Separate the blowers for individual unloading Ravi Lingappa 21/5/2012 15/6/2012 Yet to start
points
Installation of DP transmitters in nuisance Sharad Sharma 20/05/2012 30/07/2012 Yet to start

dust collectors
All the timer panels to be started and stopped Ravi Lingappa 21/05/2012 30/05/2012 Yet to start
in sequence with RA’s to avoid idle run.
Install feedback for operating load of DPC,while Ravi Lingappa 21/05/2012 30/05/2012
it runs idle
144

Trends analysis for all sections can give insights into sweet
spot of operation for optimizing electrical energy
Activity Output
▪ Trending of key performance ▪ Optimization for most power

Trends indicators against the output efficient ranges to run respective
analysis equipments
▪ Quantification of pan equipment
Kiln Main drive Power v/s Kiln TPH
factor like Idle Running & False air
340
1 2
▪ Identifying specific points of
330
320
310
instance of best performance and

Kiln o/p in TPH
300
y = -0.3305x + 308.87
290
3
Series1
280
replicate that situation

Linear (Series1)
270
260
250
240
20 22 24 26 28 30 32 34 36 38 40
Kiln Main drive Power Kwh/T Clinker
145

ACC CHANDA
Raw Mill TPH vs. Kwh/ton of Clinker FIGURES
Increase of average TPH from 500 to 560 results in reduction of 2 KWh/MT
146

ACC CHANDA
FIGURES
Kiln TPH vs. Kwh/ton of Clinker
Kiln Main drive Power v/s Kiln TPH

340
1 2
330
320
310
Kiln o/p in TPH
300
y = -0.3305x + 308.87
290
3 Series1
280
Linear (Series1)
270
260
250
240
20 22 24 26 28 30 32 34 36 38 40
Kiln Main drive Power Kwh/T Clinker
 The ideal operating range is 300-330 TPH with a power of 26-28Kwh/T Clinker
 Need to identify & eliminate the major power consumer of +2-3 Kwh/t at a continuous level
 Process optimization is critical as there are too many outliers
147

Cement Mill TPH vs. Kwh/ton of Clinker
ACC CHANDA FIGURES
 Increase of average TPH from 230 to 250 results in reduction of 2 KWh/MT

 Process optimization is critical as there are too many outliers
148

Compilation of best
Idea bank practices
Best
Practices

activities

several plants
149

Electrical Energy - Idea Bank (1/5)
- Variable Speed Drive Implementations in compressor, Bucket Elevator, Major fans

- Designing LED Lighting System and Occupancy Sensor For Optimal Light and Power
- Power Factor Improvement using capacitor bank to reduce apparent power and energy loss
- Optimal Power Management using Distribution Temperature Control Air Conditioner
- Conversion into mono-chamber from duo chamber at Cement Mill No. 2 and 4 as mill is equipped
with preginder.
- Monitoring Water Pump & compressor efficiencies.
- Optimization of compressor air requirement
- Optimization of JPF solenoid purging sequence and leakage arresting if any
- Automation of water pumps located at very far location through wireless radio communication
- Use of Air Conditioning savers & welding energy savers.
- Conversion of Lightly loaded motors from Delta to Star.
- Lighting circuit to be divided in categories for different usages e.g continuous & alternate lighting as &
when required.
- Bag Filter fans in tippler/LS crusher to be provided with variable speed & PID loop for automatic
control air venting.
- Bag Filter purging to be controlled through DP switch automatically.
- Power saving Controllers for ESP Chambers.

 Kiln shell cooling fans to be interlocked with Shell scanner to run as per the temperature.
 All the 60 Watt bulbs to be replaced with energy efficient 9 watt CFL Fittings.
 Use automatic tap changer to maintain optimum HT voltage
 Transparent Sheets to be provided where ever possible to get natural light, hence saving
illumination power.
 Removal of air slide blowers by increasing slope of slide wherever feasible .
 Feasibility of increasing chimney heights to reduce load on ID fans.
 Installation of vertical Turbine Pumps in place of split casing pumps for power saving.
 Replacement of Pneumatic conveying with Mechanical conveying.
 Under loading of tube mills for Cement Grinding may lead to higher power consumption.
 Water heating system from Kiln shell radiations, thus saving power
 Replacing FRP Blades for HT Motor cooling Fans & Kiln shell cooling fans
 Use the water from overhead tank where ever possible and stop the small
water pump
 Provide solar power for street lights

 Optimize residue of raw mill like increase from 3.8% to 4.25%on 212 mic
 Operate separator with maximum efficiency
 Install High level control in mill operation
 Replacement of Pneumatic conveying system with mechanical Conveying
system in Cement Mill.
 Install switches at the entrance of DBC tunnels, Pre heater floors and pits so
that lights are switched off when no one is present.
 Modify /adjust damper to minimize damper loss
 Star connection of <40% loaded motors and use of Del-Star converters for
variable load motors
 Installation of Compressed Air Management Solution in compressors
 Provide ceramic/Epoxy coating in water pumps
 Installation of electrical SV drain ( ball valve) for removing moisture in comp
air from receiver and optimize the operation time
 Use solar water heating system instead of geysers
 Use only one photocell to control the plant lighting. Contact of photo cell
should be given to PLC and the output from there can start/stop the plant
lighting

Compilation of best
Idea bank
practices
Best
Practices

activities

several plants
153

Several best practices can be adopted to minimize
loss of Energy
A. Continuous monitoring and review of energy performance in

the plant
B. Periodic energy audits both internal and external to identify

areas of improvements
C. Creating awareness and motivation among employees to

conserve energy
D. Online monitoring of performance indicators
E. Maintenance practices
F. Effective power management at Plant and Colony
154

Continuous monitoring and review of energy performance
A in the plant
 Daily preparation and monitoring of cost centre wise Electrical Energy

performance
 Review the daily performance during PD’s
 Circulation of MIS to all related employees in the plant
 Energy Observation Tours (EOT’s) conducted by assigned officers and
senior NMS staff to be conducted to identify areas of improvement
Picture of MIS Review from

Jamul
155

Periodic energy audits both internal and external to identify
B areas of improvements
 Periodic energy audits to be conducted by 3rd party (eg. TERI, CII)

every 6 months
 Regular internal audit to be conducted to determine the plant
equipment idle running, compressor efficiency and false air leakages
 Based on the findings of the audit, an action plan should be created
and implemented to bridge the energy gaps
Example of findings by CII during a plant audit 156

Creating awareness and motivation among employees to
C conserve energy
 Conduct training programs with the help of CII

 Sharing of best practices adopted by competitive plants such as
Dalmiya, Chettinad, etc
 Display posters and banners across plant for creating awareness
 Devise reward scheme of for successful identification and rectification
of issues during EOT’s
Nov 1st to 14th Energy Conservation Fortnight
I ‘m committed …
ACC Energy saving campaign 2011
Energy Conservation Cell

Madukkarai Cement Works
157

D Online monitoring of performance indicators
 Online monitoring of key performance indicators i.e. KW/CFM ,

Pressure , Temp, Running Hours, etc for key compressors – cost
centre wise to help take corrective actions
158

EMaintenance practices
 Thermography: Thermography of critical machine, Motors, MCC

panel feeders, etc should be conducted every 6 months
 EMD to be carried out of all the motors above 75KW & corrective
action to be taken on the faults
Over-heated Motor Bearing

159

F Effective power management at Plant and Colony
 Implement timers to automatically switching of unwanted lights after

12 midnight at substations & load centers, belts, etc
160

Specific Electrical Energy monitoring
• Monthly review SEEC in Manufacturing meeting
• Competition campaign between HVL plants
• Team building for competition team yearly
New improvement ideas to reduce electrical energy
1. Modification in vertical mill body to increase velocity resulting in reduction

of spec elec energy consumption – ACL Bhatapara,Darlaghat
2. Installation of felt type seal in ball mill as well as vertical mill separator
to reduce residue on 45 mic – Reference plant – Nalagarh/ MCW – ACL
3. Reduction of false air in vertical mill supplied by Loesche by new design of sealing
arrangement to arrest false air through rocker arm.- Plant Cilacap, Darlaghat,Hon
chong,Saraburi-3.
4. Optimization of percentage loading of transformer loading resulting into stopping
some transformer- ACC Chanda
5. Installation of del star converter in VRM reject elevator.
6. Utilize heat energy from kiln shell to heat up water for consumption in canteen and
packing plant - Darlaghat.
7. Combine separator reject with mill feed chute to reduce the pressure drop inside
Mill resulting in 0.7 kWh/t raw meal- Saraburi.2 and 3
8. Raw mill ( VRM) output increase by 3% by reducing feed size- Bhatapara
9. Modification in raw mill inlet duct to reduce pressure drop by 25 mmwg resulting
into saving of 0.1 kWh/t material- ACL Darlaghat

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Presentations with title image

Short title, Department, Date yymmdd, Classification © 2012 Legal entity

 It explains how teams could leverage benchmarking, identifies and addresses

 It then describes the methodology to calculate potential limit through gap

 In addition, several best practices and ideas implemented across Op Co have

 This module does NOT contain fundamental change in plant configuration

© 2012 Legal entity

Benchmarking and Approach to drive Machine level

 Aspiration for  Approach and  Standardized approach  Equipment level

© 2012 Legal entity 3

 Collection of energy  Collection of best practices

 A compilation of top 50  Elaboration on 6 best

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Benchmarking and Approach to drive Machine level

Linked to heat map Linked to academy

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© 2012 Legal entity 6

SEEC STEC Clinker Factor Net as fired Specific GAV

ACC 87.7 3080 64.9 5.22 0.60

Best in 60 - 70 2932 - 3517 61.51 3.2 – 4.5 4.78

© 2012 Legal entity 7

HLL 2.5 3.0 2.4 2.0 3.3

© 2012 Legal entity 8

© 2012 Legal entity 9

Best of best - SEEC of Raw Mill is 18.7 kWh/t clk at N1 ( JP is not

Best of Best : SEEC of clinker

• Improvement potential of NAI in C2,N2

• MTBF improvement potential in HN and PA ( > 300 h)

Best of Best :SEEC

Improvement potential in MTBF,NAI, increase of absorbed power in Mill and

Potential to improve MTBF,PRI and increase power absorption in pregrinder

Benchmarking and Approach to drive Machine level

Linked to heat map Linked to academy

© 2012 Legal entity

 The main objectives of Energy circles are to create a focused effort

 A team for each section (Raw material preparation, Raw meal

 Each energy circle team meets once a week for 1 hour

© 2012 Legal entity

Text Sp. Power (KwH / T of clinker)

Text Sp. Power (KwH / T of clinker)

Text Sp. Power (KwH / T of clinker)

© 2012 Legal entity

Text Sp. Power (KwH / T of clinker)

Text Sp. Power (KwH / T of cement)

Text Sp. Power (KwH / T of cement)

© 2012 Legal entity

How to use HEAT maps How not to use HEAT maps

© 2012 Legal entity

© 2012 Legal entity

© 2012 Legal entity

© 2012 Legal entity

Benchmarking and Approach to drive Machine level

Linked to heat map Linked to academy

 Standardized approach  Equipment level energy

© 2012 Legal entity

(I) Feed (C) Over

What is False air, and why is it important to monitor it?

It results in lower productivity and increase in power consumption, and

33 © 2012 Legal entity

 Evidence of “noise” of air leakage confirms the existence of false air

 False air is calculated based on % of Oxygen (O2) in the gas mixture

Monitoring false air: Role of energy circles