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Number 1 in aggregates, number 2 in cement,and number 3 in ready-mixed concrete in World
Company Profile- HeidelbergCement India Ltd
HeidelbergCementItalcementiHeidelbergCement andItalcementi
63000 no. of employees3000 locations in more than
60 Countries
MILESTONES OF JHANSI PLANT ..…
Major Equipment Capacity
Cement Mill-1 (Ball Mill) Capacity-105 TPHMake: KHD Humboldt
Cement Mill-2(VRM) Capacity-215 TPHMake: Loesche
Packer- 4 Nos. Capacity- 4* 240 TPHMake: EEL
Wagon Tippler Capacity: 1000 TPHMake: Metso
Expansion Byinstallation ofLoesche VRM
ModifiedDry fly ash
feedingsystem
Wagon Tippler Capacity: 1000 TPHMake: Metso
0.8 MTPA-19910.5MTPA 1989
Installed Capacity
1.0 MTPA-2010
2.7MTPA-2013
InstalledRollerPress
InstalledKHD Ball
Mill
ModifiedDry fly ash
feedingsystem
2006- HC Take Over
Integrated Management Policy
Excellent EnergyEfficient Unit
Award by CII-2016
ROADMAP FOR CONTINOUS IMPROVEMENTROADMAP FOR CONTINOUS IMPROVEMENT
CIP ENCON Organization StructureCIP ENCON Organization Structure
Plant HeadV.P.(Technical)
ENCON PROJETHEAD
HOD (E&I)
ENERGYMANAGER
Process In charge(Grinding & MH)
Team-4
Maintenance &Utility In charge
Team-9
Packing &Dispatch In charge
Team-4
ENCON PROJETHEAD
HOD (E&I)
ENERGYMANAGER
Daily EnergyMonitoring
Proposals for
ENCON
Review through
Concern Deptt.
Review byENCON CellFeasibility TestFast Track
Approval
Energy Monitoring Methodology For Evaluation of SavingEnergy Monitoring Methodology For Evaluation of Saving
CIP IDEA GENERATION PROCESS
Documentation&
Implementation
Review OfBenefits
AppreciationConcern Team
**Energy Conservation Cell meet once in a month for review of Energy ConservationProjects and their status.
IDEA IMPLEMENTATION PROCESS
Energy Performance ( Cement Grinding Unit)
SNo
Description Units 2014-15 2015-16
1 MTOE reduction MTOE 321.82 976.0264
2 Specific Electrical Energy – Grinding kWh/T of cement 31.86 29.74
3 Clinker factor % 60.56 61.77
4 Blended cement (*% of total cement) % 100 100
5 Specific CO2 emission Kg CO2/ kg cement 553.74 546.945 Specific CO2 emission Kg CO2/ kg cement 553.74 546.94
SEC Break-up –VRM+BM
VRM+BM Specific Power Consumption Break Up Mill-wise
Section 2014-15 2015-16
Main Drive (VRM+BM) 16.75 15.91
Bag House Fan VRM 4.76 4.40Roller Press BM 0.49 0.49Mill Aux., Mill Dedusting, Silo Feed, mill feed, CementTransport (VRM+BM) 4.03 3.83Mill Aux., Mill Dedusting, Silo Feed, mill feed, CementTransport (VRM+BM) 4.03 3.83
VRM+BM Cement Grinding Power KWH/T 26.03 24.63
Raw Material Handling (VRM+BM) 2.01 1.88
VRM+BM Packing Plant 1.72 1.58
VRM+BM Power Upto packing KWH/T 29.76 28.09
VRM Utility + T&D Losses 1.76 1.42
VRM+BM Total Power KWH/T 31.52 29.51
Total Sp. Power Consumption - Kwh/T of Cement
6.4 %31.5229.51
24.4521
Benchmark - Cement Grinding SEC -KWH/T-VRM & BM
24.95 23.75
Main Drive
Mill Aux.
Mill FanMain Drive
Mill Aux.RPGS
** Bench Mark data taken by CII Analysis Report
SI.NO. Description Of Project
AnnualSaving in
Units
Total AnnualSaving ( Rs. In
Lakhs)
1 Diesel saving by process optimisation 246
2 Optimization of wagon tippler compressor 21500 1.6
3 Optimisation of Bag filter & rotary air lock – (de-dusting systemof Bag Filter) 100676 7.1
4 Optimisation of air slide blower - ( feeding to VRM silo feedelevator & fly ash feeding circuit) 100021 7.2
Saving from major ENCON ProjectsWithout/Marginal investment 2015-16 financial year
Optimisation of air slide blower - ( feeding to VRM silo feedelevator & fly ash feeding circuit)
5 Hardwired interlock of LT capacitor banks done with drivestarting sequence 388000 29.1
6 Power saving by Mill optimisation & new support ring of VRM 3001333 225.1
7 Installed flap gate in place of rotary airlock of Bag filters of silotop 15540 1.1
8 Stopped one Bag filter fan with RAL of VRM clinker hopper topby connecting venting line from other Bag filter 88320 6.3
TOTAL 3715390 523.5
SI.No. Description Of Project
InvestmentAmount(In lacs)
Total AnnualSaving ( Rs. In
Lacs)
1 Installation of solar street lights in colony in place of 150 wattHPSV fittings 16.15 2.50
2 Installation of delta to star energy saver kit in compressor 1.00 0.90
3 Installation of refrigerated air dryer 10 16
4 Installation of High Efficiency Motor 3.00 1.50
Saving from ENCON ProjectsWith investment 2015-16 financial year
4 Installation of High Efficiency Motor 3.00 1.50
5 Installation of VFD drives 6.5 18.0
TOTAL 36.65 38.9
Innovative Projects- 1Modification in Support Ring of VRM
Innovation: Modification in support ring has been done to reduce Gapbetween roller & table support ring to accommodate the surface loss insinter cast tyre face. This helped to bridge the gap between dam ring andtyre & resulted in increase of grinding efficiency.
Figure 3: Support Ring welding
Innovative Projects- 1Benefits by Modification in Support Ring of VRM
• Stopped the Hot air generator oncontinuous basis.
• HAG is being used for only 2-3 Hrsin starting of VRM.
• Reduced the water sprays.• Storage of inbound materials in
covered storage yard.
Innovation: Utilization of exit gases from Stack by forced Recirculation ofgases back to the VRM Inlet.
Innovative Projects- 2Reduction of fuel consumption in VRM
Figure 2: Gas Flow Circuit
• Stopped the Hot air generator oncontinuous basis.
• HAG is being used for only 2-3 Hrsin starting of VRM.
• Reduced the water sprays.• Storage of inbound materials in
covered storage yard.
Innovative Projects- 2Reduction of fuel consumption in VRM
Fuel Saving in VRM by Hot gas Optimization
Description UOMAs per
LoeschePG Test
AfterOptimization-March13 toDec13
AfterOptimization-Jan14 toDec14
Design 1st Step 2nd Step 3rd StepFEED RATE TPH 215 235 242 243FEED RATE TPH 215 235 242 243
Fuelconsumption perton of cement
Lit/ton 3.22 2.11 0.38 0.32
ProductionPeriod
Months
Jan- Feb13 March-Dec13 Jan-Dec14
Innovative Projects- 2Reduction of fuel consumption in VRMInnovation: Utilization of exit gases from Stack by forced Recirculation ofgases back to the VRM Inlet.
Saving: Rs. 847 Lacs in three years
Renewable Energy Project
Installation of 20 Solar Water HeatingSystem for Guest House and colony .Size of the solar water heating system is200 ltr & 100 ltr.Annual Energy Savings = 36000 KWh Total Investment : 4.08 Lakhs Annual Savings in : 3.0 Lakhs
Installation of Solar Light
60 Nos. of solar lights were installed inPlant as well as colony area for streetlighting purpose.
Annual Energy Savings = 32400 KWh Total Investment : 42 Lakhs Annual Savings : 2.5 Lakhs
Installation of Solar Geyser
Installation of 20 Solar Water HeatingSystem for Guest House and colony .Size of the solar water heating system is200 ltr & 100 ltr.Annual Energy Savings = 36000 KWh Total Investment : 4.08 Lakhs Annual Savings in : 3.0 Lakhs
60 Nos. of solar lights were installed inPlant as well as colony area for streetlighting purpose.
Annual Energy Savings = 32400 KWh Total Investment : 42 Lakhs Annual Savings : 2.5 Lakhs
Utilization of Renewable Energy
Uses of Renewable energy Use of Turbo Vent to Improve the Air
circulationEnergy Saving =5.23 Lakhs
Use of Day light in workshop areaEnergy Saving =11.30 Lakhs
Use of solar Energy for streetIllumination.Energy Saving=2.5 Lakhs
Use of Solar Water Geyser inPlant Colony and Guest House.Energy Saving=3.0 Lakhs
TOTAL SAVING: 22.03Lakhs
Uses of Renewable energy Use of Turbo Vent to Improve the Air
circulationEnergy Saving =5.23 Lakhs
Use of Day light in workshop areaEnergy Saving =11.30 Lakhs
Use of solar Energy for streetIllumination.Energy Saving=2.5 Lakhs
Use of Solar Water Geyser inPlant Colony and Guest House.Energy Saving=3.0 Lakhs
TOTAL SAVING: 22.03Lakhs
GHG Inventorisation
Decrease in emission of CO2by reduction in clinker, diesel& Power consumptions.
Prohibition of LMV vehiclesinside plant area to decreaseCO2 emission.
19.79 19.64
18.81
18
19
20
2013 - 14 2014 - 15 2015 -16
Reduction in CO2 Emissionby reduction in Power Cons.
(CO2 Kg/Ton of cement)
1. Optimization of VRM CompressorCurrent Condition:- 2 Compressors (132KW Each) were in use for VRM compressed air
requirement. One was running on Load for 24 Hrs. whereas another one was on load
for 2-3 Hrs.
Action plan:- Adjusted Sump air pressure to reduce the unloading power consumption. Use of Auto start mode of compressors were taken in line for operation. Air pressure interlocking has been done for the start up of 2nd
compressor in case of pressure drop less than 5 Kg/cm2.
Result During Trial:- Power Units (Before)– 6729KWH/Day, Power Units (After) –
4278KWH/Day Saving in Power Units – 2451/Day. Total Annual Saving – 808830 KWH @ Rs. 7.5 / KWH Net Saving in INR: 60 Lacs/Annum
Innovative Projects Under ImplementationInnovative Projects Under Implementation
Current Condition:- 2 Compressors (132KW Each) were in use for VRM compressed air
requirement. One was running on Load for 24 Hrs. whereas another one was on load
for 2-3 Hrs.
Action plan:- Adjusted Sump air pressure to reduce the unloading power consumption. Use of Auto start mode of compressors were taken in line for operation. Air pressure interlocking has been done for the start up of 2nd
compressor in case of pressure drop less than 5 Kg/cm2.
Result During Trial:- Power Units (Before)– 6729KWH/Day, Power Units (After) –
4278KWH/Day Saving in Power Units – 2451/Day. Total Annual Saving – 808830 KWH @ Rs. 7.5 / KWH Net Saving in INR: 60 Lacs/Annum
2. Saving By Installation of VFD in 75 KW Motor of Dust Collector Fan.Current Condition:- Bag filter fan (75 kw) are running with DOL starter in 50 % damper open
condition always. Consumption of Unit when Motor run in DOL is approx. 42 U / Hr.
Action plan:- After installation of VFD, we have opened damper 100% and control flow
by reducing RPM of Motor. It is taking approx. 12 U / Hr power, which is less than 75% of previous
power load.
Result:- Power Units (Before)– 1008KWH/Day, Power Units ( After)– 288KWH
/Day Saving in Power Units – 720 KWH/Day. Total Annual Saving – 237600 KWH @ Rs. 7.5 / KWH Net Saving in INR: 18 Lacs Approx.
2. Saving By Installation of VFD in 75 KW Motor of Dust Collector Fan.Current Condition:- Bag filter fan (75 kw) are running with DOL starter in 50 % damper open
condition always. Consumption of Unit when Motor run in DOL is approx. 42 U / Hr.
Action plan:- After installation of VFD, we have opened damper 100% and control flow
by reducing RPM of Motor. It is taking approx. 12 U / Hr power, which is less than 75% of previous
power load.
Result:- Power Units (Before)– 1008KWH/Day, Power Units ( After)– 288KWH
/Day Saving in Power Units – 720 KWH/Day. Total Annual Saving – 237600 KWH @ Rs. 7.5 / KWH Net Saving in INR: 18 Lacs Approx.
4. Removal of Bag House Fan inlet damper in VRM
5. Installation of high efficiency Separator in Ball Mill.
6. Installation of VFD in Bag filter fan motor.
7. Changing angle of Armour ring in VRM.
8. Minimize False Air Intake.8. Minimize False Air Intake.
9. Manage Equipment Ideal Running
10.Instalation of Smart Solar Panel for Day time Office Operation
11. Replacement of HPSV light by LED light .
Energy monitoring & Methodology used for quantificationDaily Power Report
Annual Plan & monitoringAnnual Plan & monitoring
BEST PRACTICES
Use of turbo- Ventilator No Need of Electrical Energy . Zero Maintenance. Cost Effective.
Fan Less Water Cooling System Use of Natural Draft. Reduction In Maintenance Cost
Use Of Natural Light in Electrical WorkShop Avoid the Use of electricity during
day time. Energy Saving. Improve the Working Conditions.
10-Nos. Installed in Mech.Workshop Building
Use of turbo- Ventilator No Need of Electrical Energy . Zero Maintenance. Cost Effective.
Fan Less Water Cooling System Use of Natural Draft. Reduction In Maintenance Cost
Use Of Natural Light in Electrical WorkShop Avoid the Use of electricity during
day time. Energy Saving. Improve the Working Conditions.
10-Nos. Installed in Mech.Workshop Building
Fan Less water cooling
BEST PRACTICES
Energy Saving Device for Light Maximum Use of Day Light . Reduce the wastage of Electricity . Lower Maintenance Cost.
Solar Street Light Installation of 60 no’s Solar lights. Utilization of Renewable Energy.
Unity Power Factor Power Factor benefits by UPPCL Reduction in Line Losses. Increase In Efficiency of Electrical
system
Energy Saving Device for Light Maximum Use of Day Light . Reduce the wastage of Electricity . Lower Maintenance Cost.
Solar Street Light Installation of 60 no’s Solar lights. Utilization of Renewable Energy.
Unity Power Factor Power Factor benefits by UPPCL Reduction in Line Losses. Increase In Efficiency of Electrical
system
BEST PRACTICES
VFD application For ENCON Project Significant Reduction In Energy
Consumption . Highly Efficient. Used In Compressor ,Electric Motor
,Pumps etc.
Electronic Ballast Improvement in PF Energy Saving of 60-70% Increase the Lamp Life
Use of Energy Efficient Motor Energy Reduction From 15%-20%. Long Life. Less Pay Back Period.
VFD application For ENCON Project Significant Reduction In Energy
Consumption . Highly Efficient. Used In Compressor ,Electric Motor
,Pumps etc.
Electronic Ballast Improvement in PF Energy Saving of 60-70% Increase the Lamp Life
Use of Energy Efficient Motor Energy Reduction From 15%-20%. Long Life. Less Pay Back Period.
Distribution of Portable Solar Lamps to 800 Students & VillageTemple Illumination by solar lights
To Promote use of Solar Energy& Power Saving village templeilluminated by solar light HCIL arranged for portable solar
lamp to each 800 girl student ofKasturba Gandhi Balikavidyalaya to support their studynot being interrupted by power
Distribution BY IG JHANSI
Awards & Appreciation'sCII National Award for Energy Efficiency-2016
Next Focus Areas & Improvements
Replacement of HPSV lampthrough LED In Plant Lighting
Commitment TowardsGreen Development
Utilization of RenewableEnergy Source by more using
solar light
For Energy Conservation Adoptedsmart Office automation
equipment
Next Focus Areas & ImprovementsInstallation of Solar panels on Roof top
Thank you
for better building
Energy Conservation isour Foremost priority
Jhansi Unit, home for manybeautiful distinct species.
Some of the birds seen in thecampus are: Grey Hornbill
Black Drongo
Little Egret
White Throated Kingfisher
Oriental Magpie Robin
Golden Oriole
BIODIVERSITY
Jhansi Unit, home for manybeautiful distinct species.
Some of the birds seen in thecampus are: Grey Hornbill
Black Drongo
Little Egret
White Throated Kingfisher
Oriental Magpie Robin
Golden Oriole
Jan Jagran Rally on World Environment Day (5th June)For Awareness on Energy Saving & Tree Plantation
600 members of HCIL familyhave participated in this rally.
This rally marched (2.5Kms) inJhansi city with a motive tocreate awareness for energyconservation and greenenvironment protection.
WASH Program
A small initiative taken by HCILGroup to improve Water ,sanitation & Hygienic conditions. Various awareness programs
were organised not only insidethe Plant but also in villagesassociated with plant site.
A small initiative taken by HCILGroup to improve Water ,sanitation & Hygienic conditions. Various awareness programs
were organised not only insidethe Plant but also in villagesassociated with plant site.
