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Dalmia Cement (Bharat) Limited, Kadapa 1 st Workshop on Energy Efficiency in Cement Sector 23 rd June 2015
Dalmia Cement (Bharat) Limited, Kadapa
1st Workshop on Energy Efficiency in Cement Sector 23rd June 2015
Presented by :Mr. P. Kamalanathan Manager – Electrical
Dalmia Cement (Bharat) Ltd.,
Kadapa (A.P.)
Save Energy - Save Money - Save the Planet.
Founded in 1935 by Shri Jaidayal Dalmia. The Group interests includes Cement, Sugar, Power and
Refractory. The Group established India’s first Cement Plant with 250
TPD in 1939. Put up Cement Plants in Tamil Nadu and Andhra Pradesh.
Kadapa Unit Commissioned during Dec 2008 with a
Capacity of 2.5MTPA Cement. Holds a stake of 75 % in OCL India Ltd., OCL total cement
capacity 14.3 million tones.
Acquired 50% Stake in “Calcom Cement India Limited” (2.1
MTPA) at Assam
Acquired “Adhunik Cements” (1.5 MTPA) in Meghalaya, Established a green field unit at Belgaum.
Overall Cement Manufacturing Capacity 23 MTPA.
OPC 53 OPC 43 PPC SRPC
We are committed to produce cement of required Quality & Quantity, by Continuous Improvement on Energy Performances through effective implementation of Energy Management System, also by Effective utilization of available Energy resourcesby
Optimization and alternates. Enhancing the Energy efficiency, Reduction in Energy
Wastage Strive to be a bench marking organization in the Cement
Industry. Abide to all the applicable legal requirements and other
requirements Anil Bajaj Executive Director
Plant Ordering Stage – Took Initiative for Energy Efficient Equipments
Plant Execution Stage – Considered Energy Saving Equipments
Commissioning Stage – Developed EMS Software in Plant Automation
Energy Saving by Efficient Eqpt. & Energy Savers: 85.5 Lakhs U/Annum
1st Year Operation Stage – Optimized Startup Time, Idle Run
Solar Heaters & Solar Lights at Mines
Energy Saving by Case Studies : 11.5 Lakhs Units/Annum
2nd Year Operation Stage – Improved the Equipt Perfor.
Energy Saving : 114.77 Lakhs Units/Annum
3rd Year Operation Stage – Improved
Energy Saving : 43.88 Lakhs Units/Annum
EnMS 50001
Alternative Fuel Feeding Enhancement upto
50% on Quantity
Current Plan & Actions
Enhancement of Alternative Fuel Feeding
Development of Renewable Power
Sl.
No. Best Practices Advantages
1 Display of Online Specific Power
Consumption of Individual Sections in
the Plant DCS
Immediate action by CCR
Operator during any deviation
from the Nominal Sp. Power
2
Idle Power Report Generation in DCS
from the Input Signals of Mill Critical
Drive Run Feedback and KW Loading
of the Drives
For Analysis to reduce the Idle
Power
3 Energy abnormality Observation
Rounds by Energy Management Team Identification of Energy Loss and
Elimination
4 Operating the Plant with the
Benchmarking False Air Level of
7.3%
Reduction in Specific Power &
Fuel Consumption
Sl.
No. Best Practices Advantages
5
Inhouse Study Conducted and Interlinked the Bag Filter Suction lines and Energy Savings achieved on the Bag Filters
Energy Savings on Nuisance Bag Filters
6 Installed Bag Counters and Packer Bags Discharge Interlock with the Bag Counters
Elimination of Bag Burstage, Reduction of Packing Plant Sp. Power
7
VRM Classifier Seal Gap Reduction by Inhouse Modification using the waste Belt Materials
Quality Improvement
Sl.
No. Best Practices Advantages
8 Removed the MFR from the SF Cooler and improved the Heat Recuperation
Reduction in Specific Fuel Consumption
9
Inhouse Study Conducted on the Process Fans, replaced the Impellers of Cement Mill Fan and Bag House Fan to improve the Efficiency
Energy Savings on Process Fans
10
Inhouse Study Conducted on the Process Fans, Carriedout the Tipping of Raw Mill Fan to improve the Efficiency and SPRS Recovery Power.
Energy Savings on Process Fans
Objective: To Replace 100% of the Fuel for Calciner by Alternative Fuel
Action Taken:
1. Explored availability of Alternative Fuel and Identified the following
i. Carbon Black
ii. Spent Carbon
iii. FCE Concentrate
iv. Agro Waste
v. Polimer Waste
Action Taken:
2. Developed Vendors
3. Receiving the Alternative Fuel (Carbon Black) in following forms
a. 35 Kg Bags
b. Jumbo Bags 600 Kg
c. Bulk Tankers
4. Developed In-House Design for Handling the Carbon Black
Action Taken:
a. Installed Fixed Tanker with Mechanised Unloading System
Action Taken:
b. Installed Bag Slitting Machine by In-house design to feed the 35Kg Carbon Black Bags
Action Taken:
c. Made arrangements to unload the Carbon through Bulk Tanker
0
5
10
15
20
25
2012-13 2013-14 2014-15
2.01
4.88
21.62
Alternative Fuel TSR in %
0
5
10
15
20
25
30
35
With Compressor With Blower
33.2
11
Overall Units / Ton of Carbon Black
Results:
• Carbon block feeding at a rate of 14 T/Hr.
• Utilization of waste rubber carbon as alternative fuels.
• Utilization of available resources for carbon feeding without spending extra cost for equipment.
• Reduced Consumption of natural resources like Coal/Coke.
• Reduced impact on environment as compared with manual feeding.
• Reduced Power consumption comparatively feeding through mill from truck tippler.
Savings:
• Saved Unloading & feeding time. The Overall Improved Capacity of Carbon Black Feeding is at the rate of 14.0 T/Hr directly to PC. (Started with 0.125 to 0.187 T/Hr by manual feeding).
• Savings Rs. 78,41,310 /Month of Carbon Black.
• Savings Rs. 9,40,95,720/- per annum @ rate of 100 Tons/Day.
• Reduction in usage of pet coke
Problem Faced :
Accumulation of Lime Stone at Mill Inlet Air Duct
Gradual Reduction of Raw Mill Productivity
Increase in Specific Power Consumption due to reduction in Productivity
Uneven Wear Rate in the VRM Internals
Route Cause Identified :
Horizontal Inlet Duct for the VRM (OEM Design)
Lime Stone Spillage due to Centrifugal Force from the Table
Dropping Height of Feed Material (Lime Stone) on the Table from the Centre Chute
Fabricate and Install a Discharge Chute at Inlet Duct with Manual Gate (Modifying the OEM Design) and Diverted to the Reject Belt Conveyor
To Extend the Centre Feed Chute for reducing the Height / Dropping Force of Raw Material on the Table (Modifying the OEM Design)
Extended 300mm
Discharge Chute - 1
Discharge
Chute - 2
370
380
390
400
410
Before After
389
406
Productivity (TPH)
100
200
300
Before After
260
130
Mill Inlet Draft (mmwg)
16
17
18
Before After
17.7 16.79
Sp. Power Consumption
(Units/Ton of Matl.)
Better
Better
Better
375 389
381 388
406 411
17.78 17.4
17.98 17.7
16.79
16.36
15.5
16
16.5
17
17.5
18
18.5
Raw Mill TPH Vs Power
Guaranteed/ Design -350 TPH Guaranteed-19.90 Units
1. Mill Productivity Increased 18 TPH (388TPH to 406TPH)
2. Improved Specific Energy Consumption (Reduction of 0.91 Units/Ton of Lime Stone Grinding).
a. Units Saving = 17.29 Lakhs Units/Annum.
b. Power Cost Saving = Rs. 89.91 Lakhs/Annum
(at 19 Lakh Ton of Lime Stone Grinding / Annum)
3. Mill DP remains Constant and average Mill Draught Reduced from 260mmwg to 130mmwg.
4. Uniform Air Velocity Distribution (Reduced Abnormal Wear Rate)
5. Eliminated the Man Power Requirement / Manual Cleaning & Avoided the Requirement of Tractor for handling the Cleaned Material
1. Horizontal Implementation at our Group Units and got the better results.
2. Can be Deployed in all the Vertical Roller Mills having Horizontal Inlet Duct
3. Communicated to the OEM (Pfeiffer) about the Modifications. OEM Representative appreciated the Modified Design
4. OEM Engineer informed that the modification method will be communicated to their Design Department
Before Dilution Air Duct :
Mill Outlet Temperature : 90 to 95 deg C
Hot Air Temperature : 260 to 270 deg C
Temperature with Hot Air & Recirculation Air : 150 deg C
Fresh Air Damper Position : 30% Open
Effects :
Higher Recirculation Air Density Variation
Higher False Air
Water Consumption of 4.5 Cub. M / Hr.
Higher Reject Rate 180 to 200 TPH
Action Taken :
Installed Dilution Air Duct from RABH Fan Outlet to Raw Mill Inlet Duct.
Action Taken :
Connected to Raw Mill Inlet Duct.
Dilution Air Duct from RABH Fan
Outlet
Raw Mill Inlet Duct
Results :
RABH Fan Outlet Air Temperature is 90 deg C, which is connected to Raw Mill Inlet Duct
Raw Mill Circulation Air Temperature is 90 deg C, hence no variation in the Density
30000 Cub. M of Air taken from RABH Fan Outlet
Closed the Fresh Air Damper 100%
Water Spray reduced from 4.5 Cub M / Hr. to 3.0 Cub. M / Hr.
Mill Productivity Improved 8 Tons per Hr.
Specific Power Consumption Reduced by 0.32 U/T of Material
4.5
3
2
2.5
3
3.5
4
4.5
5
Before After
Water Consumption in
Cub. M / Hr.
Water Consumption in Cub. M / Hr.
406
411
402
404
406
408
410
412
Before After
Productivity (TPH)
Productivity (TPH)
16.79
16.36
16.1
16.2
16.3
16.4
16.5
16.6
16.7
16.8
16.9
Before After
Specific Power
Specific Power
Better
Better
Better
Way Forward :
As per Estimation, 3.5 M Dia of Dilution Air Duct required for the Raw Mill Inlet Duct
Installed 1.2 M Dia of Dilution Air Duct (Old Available) on Trial Basis.
Planned & Work in Progress to upgrade the DA Duct to 3.5 M Dia
Expected Results :
Further Scope to Improve 8 TPH on Raw Mill
Scope to Reduce Sp. Power of 0.2 U/T of Material
375 389
381 388
406 411
17.78 17.4
17.98 17.7
16.79
16.36
15.5
16
16.5
17
17.5
18
18.5
Raw Mill TPH Vs Power
Guaranteed/ Design -350 TPH Guaranteed-19.90 Units
