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PENNA CEMENT INDUSTRIES LIMITED GANESHPAHAD
BEST PRACTICES TOWARDS ENERGY EFFICIENCY
BY K.PRAMOD KUMAR
ENGINEER -ELECTRICAL
Introduction
• The company was started by Visionary Entrepreneur Shri. P. Pratap Reddy Garu in 1994 with the first unit being
commissioned at Talaricheruv ,Andhra Pradesh.
• The company over the past 20 years has grown significantly adding three new plants and in the process
expanding the capacity from 0.5 Million Tons to the levels of 10.0 Million Tons.
• Penna Cements has over the years introduced state of the art technology to enable it achieve significant cost and
quality advantages in the market place. The consistent quality matched with its committed deliveries have
enabled it to establish a commendable position in the market place.
• The company has aggressive plans for growth in the future and has embarked on a multi point strategy for
achieving leadership position in the country by being amongst the top 8-10 cement companies.
National Energy Conservation Award
2nd Prize in National Energy Conservation Award 2016
5
Energy Policy
• Penna Cement Industries Ltd is committed to all applicable legislation and other requirements related to Energy
Management System. We are committed to improve energy efficiency as a continuous improvement process in all
our business processes and ensuring the availability of information and resources to meet the energy objectives
and targets.
• We are committed to incorporate energy efficiency as a key component for new equipment, major innovation,
new design and to promote energy saving awareness to our staff and stake holders.”
Unit Head
Energy ManagerProduction
TeamMechanical
TeamElectrical Team
ENERGY MANAGEMENT TEAM
Specific Energy Consumption
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S.No Description Units 2014-15 2015-16 2016-17 2017-18
1 Kiln Thermal SEC TOE/Ton 748 745 750 748
2Specific Electrical Energy Consumption(up to Clinkerazation)
kWh/ton 55 55 56 53
3Specific Electrical Energy Consumption (Grinding)
kWh/ton 30 30 30.84 30.35
4Energy Savings (WHR & Energy Efficient Projects)
MTOE 98.7 7,080 67185 79505
5Equivalent to Coal (tons) savings @ 4500 GCV
Tons 219 15,734 11997 14197
Carbon Foot Print Trend - Ganeshpahad
8
2014-15 2015-16 2016-17 2017-18
347
24974
19043.4
22535.5
TONS OF CO2
Carbon Foot Print Trend–Boyareddypalli
92014-15 2015-16 2016-17 2017-18
777
48092
28279
56767
TONS OF CO2
WHY WHR .. ? (WASTE HEAT RECOVERY)
• In Cement Industry 65% Energy will be utilized for clinkerization & the remaining 35% energy will be getting
wasted.
• In Cement production Energy (Power) cost is one of the major contributors.
• To tap & recover the exhaust gases generating from pre heater and cooler and utilize it for generating power.
• To conserve and avoid the reduction of fossil fuels for future generations.
• To reduce CO2 emissions and protect environment.
• To meet continuous increase in fuel and energy prices.
• To use waste heat from Cement plant exhaust gases and generate power that reduce the fossil fuel consumption
and help to resolve air pollution problems associated with the use of conventional fuels. Hence it becomes
necessary to generate power by using exhaust gases from cement Plant and conserve the natural resources for
future.
Power Generation - WHR
Project Synopsis:
Description WHR – Ganeshpahad works WHR – Boyareddypalli works
Capacity 3.6 MW 6.5 MW
Cost of Project 65.22 Crores 84.55 Crores
Technology Rankine Cycle Rankine Cycle
Waste heat sources Pre-Heater and Cooler Pre-Heater and Cooler
Gross Output 3.5 MW 5.7 MW
APC 360 kW 480 kW
Net Output 3.2 MW 5.2 MW
Technical Data - WHR
S. No. Description Unit Ganeshpahad Boyareddypalli
1 Kiln Capacity TPD 3100 4500
1 Heat Source - Preheater Preheater
2 Exhaust Gas Volumetric Flow at Boiler Inlet Nm3/hr 185000 302500
3 Exhaust Gas Mass Flow at Boiler Inlet kg/hr 264038 431738
4 Exhaust Gas Temperature at Boiler Inlet Deg.C 335 340
5 Exhaust Gas Temperature at Boiler Outlet Deg.C 202 204
6 Net Total Heat Recovery in Boiler kcal/hr 8822012 14723000
7 Maximum Pressure Drop Across WHRS mmWC 125 125
8 Heat Source - Clinker Cooler Clinker Cooler
9 Exhaust Gas volumetric Flow from mid tap Nm3/hr 70812 122015
10 Exhaust Gas mass Flow from mid tap kg/hr 91348 157400
11 Exhaust Gas Temperature from mid tap Deg.C 380 400
12 Exhaust Gas Temperature at Boiler Outlet Deg.C 80 104
13 Net Total Heat Recovery in Boiler kcal/hr 5451419 9124600
S.No. Description Unit Ganeshpahad Boyareddypalli
1 High Pressure Steam Parameters At Superheater Outlet At Superheater Outlet
a Pressure kg/cm2(a) 21 27
B Temperature Deg.C 347 374
C Total Quantity kg/hr 17867 29871
2 Low Pressure Steam Parameters
a Pressure kg/cm2(a) 3.5 3.5
b Temperature Deg.C 180 176
c Total Quantity kg/hr 1647 3068
3 HP Steam Required to Ejector kg/hr 400 350
4 Power Generation Equipment - Steam Turbine with Alternator Steam Turbine with
Alternator
5 Condenser Type - Water Cooled Condenser Air Cooled Condenser
6 Wet Bulb Temperature for WCC Design Deg.C 28 42
7 Design Condensing Pressure kg/cm2(a) 0.11 0.2
8 Gross Electric Power Generation kWe 3590 5710
9 Power generation Voltage / Frequency kV / Hz 6.6 / 50 6.6 / 50
Technical Data - WHR
WHY WHR .. ? (WASTE HEAT RECOVERY)
Specifications of suspension pre-heater and Air quenching cooler Boiler.
Location
Boiler I/L Temperature
(O C )
Boiler O/L Temperature
(O C )
Flow Nm3/hrPower Generation
(MW)
Base Line Base Line Base Line
SP 335 202 185000
3.6
AQC 380 100 117838
WHY WHR .. ? (WASTE HEAT RECOVERY)
• PCIL installed and commissioned waste heat recovery system in december’2015 with a capital expenditure of
about INR. 65.22 crores and started utilizing waste heat from pre-heater and cooler for power generation.
• The waste heat recovery system was installed and commissioned with the support from
M/s. TESPL, Pune and achieving PLF of 85% on an average.
• The WHR power plant comprises one air quench cooler (AQC) boiler, one suspension pre-hater (SP) boiler in
a single line and connected to one common turbine (rated 7.0 mw). The AQC boiler generates both high
pressure (HP) and low pressure (LP) steam which induces the turbine for generating power. The dual
pressure system maximizes the use of waste heat and provides approximately 5% more power than a single
pressure system.
WHY WHR .. ? (WASTE HEAT RECOVERY)
AQC Boiler PH Boiler Steam Turbine
Operating Process…
• Waste Heat Recovery power plant operates with Steam Rankine Cycle which is the basis for conventional thermal
power generation station and consists of a pre heater source (Boiler) that converts the water to high pressure
vapor (steam in a power station) by the heat exhaust from pre-heater and cooler then expanded through a turbo
generator producing power. Low pressure vapor exhausted from the turbo generator is condensed back to a
liquid state, with condensate from the condenser returned to the boiler feed water pump to continue the cycle.
Waste heat recovery consists of heat exchanger or heat recovery steam generators (HRSGS) those transfer the
heat from the exhaust gases to the working fluid inside turbines, electric generator, condensers and a working
fluid cooling system.
SPECIFICATIONS OF TURBINE …
MAKE QINGDAO GIENENG
MODEL BN 7-2.845/0343/KN1514
RATED POWER 7.0 MW
RATED SPEED 3000 RPM
INLET HP STEAM PRESSURE 2.845 Mpa
INLET HP STEAM TEMPARATURE 410 OC
INLET HP STEAM FLOW 28.33 TPH
INLET LP STEAM PRESSURE 0.343 Mpa
INLET LP STEAM TEMPARATURE 180OC
INLET LP STEAM FLOW 5.207 TPH
CRITICAL CRITERIA CONSIDERED PRIOR TO INSTALLATION OF WHRPP
• In cement industries pre heater gases, dust load is high, and is sticky and in cooler dust is very abrasive in nature.
Hence care has been taken for selection of the suitable design & specific equipment for dust dislodging system.
Dampers and configuration of the boiler, turbine and condenser etc.
• Because of WHRPP, the additional pressure drop will be there in pre-heater & cooler pump, hence the same are
modified as required.
• It is a routine that the kiln performance vary from time to time, resulting in fluctuating exhaust gas conditions
and so the waste heat Boiler and the connected turbine generator but, suitable designed/selected, to take care of
such fluctuations to the extent possible.
CENTRAL COTROL ROOM (CCR) FOR WHRPP
BENEFITS DERIVED FROM WHR POWER PLANT & CONTINUING
• Reduced purchased power consumption and the burden on Captive Power Plant which in turn reduced
operating costs.
• Mitigated the impact of future electric price increases.
• Enhanced Plant power reliability.
• Improved plant competitive position in the market.
• Lowered Plant specific energy consumption, reducing the green house gas emission based on credit for
reduced fossil fired captive power generation.
• The requirement of power from grid is reduced.
• Complied with Energy efficiency targets of PAT scheme to grid Energy Saving Cerificates purchase.
BENEFITS DERIVED FROM WHR POWER PLANT & CONTINUING
• As a result of the above intervention annual cost saving INR 9 crores/annum from the Electrical energy
savings (248 lakhs Kwh /Annum) was achieved and an overall savings of 14,197 MT of oil equivalent
(MTOE) was obtained in this implementation.
• Power Generation 2,47,83,434 Kwh/Annum
• CO2 emission reduction 22,536 Tons/Anum
ENERGY PERFORMANCE CONCLUSION:
• Cement Industry being a power intensive industry. One has to think in terms of Energy Optimization and
savings by commissioning waste heat recovery power plants, those contribute significantly, to the electrical
energy savings.
• The reduction in CO2 emission makes it Environment & Eco friendly.
• Essentially in an Endeavour to improve industrial energy efficiency with a focus on reducing energy
consumption forced the industry to implement latest technologies like installation of WHRPP
CONCLUSION:
Substantial potential for energy efficiency improvement exists in the cement industry individual plants,
persistent efforts are also being made to continue to improve energy efficiency and reduce the energy cost for
the cement Industry for survival and growth. One baby step towards arresting “FLASE AIR” can contribute
immensely towards cost cutting by cement manufacturing and improve energy efficiency. It is needless to
mention that our efforts to improve energy efficiency will also minimize green house gas and mitigate the
environmental problems associated with cement production.
STATISTICAL HISTORY OF WHR
WHR PERFORMANCE
FROM - 14TH NOVEMBER 2015
TO - 30TH SEPTEMBER 2018
WHR POWER GENERATION REPORT - YEARWISE
Sl. No.
Financial Year
Power Generation
ExportAux.
ConsumptionAvg.
GenerationAvg.
Export
Avg. Aux. Consumpt
ion
% Aux. Consumpt
ion
Running Hours
Running Days
kwh kwh kwh MW MW MW % Hours Days
1 2015-16 7,345,255 6,794,342 550,913 3.56 3.29 0.27 7.50 2063.64 85.98
2 2016-17 20,942,771 18,771,583 2,171,188 3.61 3.24 0.37 10.37 5796.05 241.50
3 2017-18 24,783,394 22,178,698 2,604,696 3.81 3.41 0.40 10.51 6,512.83 271.37
4 2018-19 12,401,554 11,024,270 1,377,284 3.47 3.09 0.39 11.11 3,573.41 148.89
Total 65,472,974 58,768,893 6,704,081 3.65 3.27 0.37 10.24 17945.93 747.75
WHR POWER GENERATION - YEARWISE
2015-16 2016-17 2017-18 2018-19
3.56 3.61 3.81 3.47 3.29 3.24 3.41
3.09
0.27 0.37 0.40 0.39
7.50
10.37 10.51 11.11
FINANCIAL YEAR (up to 30th September 2018)
WHR -POWER GENERATION (kwh)
2015-16 2016-17 2017-18 2018-19
73
,45
,25
5
2,0
9,4
2,7
71
2,4
7,8
3,3
94
1,2
4,0
1,5
54
67
,94
,34
2
1,8
7,7
1,5
83
2,2
1,7
8,6
98
1,1
0,2
4,2
70
5,5
0,9
13
21
,71
,18
8
26
,04
,69
6
13
,77
,28
4
FINANCIAL YEAR ( Upto 30th September 2018)
Power Generation in kwh
Export in kwh
Aux.Consumption in kwh
WHR RUNNING & BREAKDOWN/STOPPAGE HOURS
SL. NO. YEAR
RUNNING BREAK DOWN / STOPPAGE
TOTAL HOURS
HOURSRUNNING
HOURS
% RUNNING
HOURS
RUNNING DAYS
HOURS
BREAK DOWN /
STOPPAGE HOURS
% BREAK DOWN /
STOPPAGE HOURS
BREAK DOWN /
STOPPAGE DAYS
1 2015-16 2063:38:00 2063.63 61.86% 85.98 1272:22:00 1272.37 38.14% 53.02 3336:00:00
2 2016-17 5796:03:00 5796.05 66.16% 241.50 2963:57:00 2963.95 33.84% 123.50 8760:00:00
3 2017-18 6512:50:00 6512.83 74.35% 271.37 2247:10:00 2247.17 25.65% 93.63 8760:00:00
4 2018-19 3573:25:00 3573.41 81.36% 148.89 818:35:00 818.58 18.64% 34.11 4392:00:00
TOTAL 17945:56:00 17945.93 71.08% 747.75 7302:04:00 7302.07 28.92% 304.25 25248:00:00
PERCENTAGE % 71.08% 28.92% 25248:00:00
RUNNING DAYS BREAK DOWN / STOPPAGE DAYS
747.7
304.3
(From 14th Nov'2015 To 30th Sep' 2018)
WHR RUNNING AND STOPPAGE/BREAK DOWN DAYS
WHR AVERAGE LOAD Vs % AUX. CONSUMPTION
2015-16 2016-17 2017-18 2018-19
Financial Year (Upto 30th September 2018)
Average Load in MW% Aux.Consumption
2015-16 2016-17 2017-18 2018-19 Average
61.86%66.16%
74.35%81.36%
71.08%
Percentage of WHR Running Yearwise
2015-16 2016-17 2017-18 2018-19 Average
38.14%
33.84%
25.65%
18.64%
28.92%
Percentage of WHR Stoppage/Breakdowns Year wise
WHR RUNNING AND STOPPAGE/BREAK DOWN HOURS
Sl. No.
Description
2015-16 2016-17 2017-18 2018-19 Total
Hours Days % Hours Days % Hours Days % Hours Days % Hours Days %
1 WHR Running Hours 2063.63 85.98 61.86% 5796.05 241.50 66.16% 6512.83 271.37 74.35% 3573.41 148.89 81.36%17945.9
3747.75 71.08%
2WHR Stoppage (KILN) Hours
1056.65 44.03 31.67% 2766.00 115.2531.58
%1966.67 81.94
22.45 %
551.83 22.9912.56
%6341.15 264.21
25.12 %
3WHR Trips and Breakdown Hours
215.72 8.996.47
%197.95 8.25
2.26 %
280.50 11.693.20
%266.75 11.11
6.07 %
960.92 40.043.81
%
4WHR Stoppage & Trips/Breakdown Hours
1272.37 53.02 38.14% 2963.95 123.50 33.84% 2247.17 93.63 25.65% 818.58 34.11 18.64% 7302.07 304.25 28.92%
Total 3336.00 139.00100.00
%8760.00 365.00
100.00%
8760.00 365.00100.00
%4392.00 183.00
100.00%
25248.00
1052.00100.00
%
WHR POWER GENERATION REPORT – 2018-19
Sl.No. Month
Generation ExportAux.
ConsumptionAvg. Gen. Avg.
Export
Avg. Aux. Consum-
ption
%Aux. Consum-
ption
Running Hours
Running Hours
Cum.Running
Hours
Running Days
Cum.Running
days
kwh kwh kwh MW MW MW % Hours Hours Hours Days Days
1 Apr-18 2,628,456 2,325,134 303,322 3.74 3.312 0.432 11.54 702:00:00 702.00 702.00 29.25 29.25
2 May-18 2,637,272 2,329,434 307,838 3.74 3.303 0.436 11.67 705:15:00 705.25 1407.25 29.39 58.64
3 Jun-18 1,475,644 1,318,682 156,962 3.61 3.230 0.384 10.64 408:15:00 408.25 1815.50 17.01 75.65
4 Jul-18 1,894,624 1,689,534 205,090 3.43 3.056 0.371 10.82 552:50:00 552.83 2368.33 23.03 98.68
5 Aug-18 1,720,052 1,540,609 179,443 3.08 2.760 0.321 10.43 558:15:00 558.25 2926.58 23.26 121.94
6 Sep-18 2,045,506 1,820,877 224,629 3.16 2.82 0.35 10.98 646:50:00 646.83 3573.41 26.95 148.89
Total 12,401,554 11,024,270 1,377,284
3.47 3.09 0.39 11.11
3573:25:00 3573.41 148.89
Average 2,066,941 1,837,393 229,547 595:34:10 595.57 24.82
WHR POWER GENERATION (Avg.) - MW
Avg. Generation Avg. Export Avg. Aux. Consumption % Aux. Consumption
3.65 3.27
0.37
10.24
(From 14 Nov'2015 to 30th Sep' 2018)
WHR RUNNING AND STOPPAGE/BREAK DOWN HOURS – 2018-19
Sl. No. Month
Running Break Down / Stoppage
Hours Hours Days % Hours Hours Days %
1 Apr-18 702:00:00 702.00 29.25 97.50% 18:00:00 18.00 0.75 2.50%
2 May-18 705:15:00 705.25 29.39 94.79% 38:45:00 38.75 1.61 5.21%
3 Jun-18 408:15:00 408.25 17.01 56.70% 311:45:00 311.75 12.99 43.30%
4 Jul-18 552:50:00 552.83 23.03 74.31% 191:10:00 191.17 7.97 25.69%
5 Aug-18 558:15:00 558.25 23.26 83.07% 185:45:00 185.75 7.74 24.97%
6 Sep-18 646:50:00 646.83 26.95 89.84% 73:10:00 73.17 3.05 10.16%
Total 3573:25:00 3573.41 148.89 81.36% 818:35:00 818.59 34.11 18.64%
WHR RUNNING AND STOPPAGE/TRIPS/BREAK DOWN HOURS – 2018-19
Sl.No. DescriptionDuration in
HoursDuration in Hours
Duration in Days
Percentage
1 WHR Running 3573:25:00 3573.41 148.89 81.36%
2 WHR Stoppage (KILN) 551:50:00 551.83 22.99 12.56%
3 WHR Trips and Breakdown 266:45:00 266.75 11.11 6.07%
Total 4392:00:00 4392.00 183.00 100.00%
WHR POWER GENERATION – 2018-19
Apr-18 May-18 Jun-18 Jul-18 Aug-18 Sep-18
26
,28
,45
6
26
,37
,27
2
14
,75
,64
4 18
,94
,62
4
17
,20
,05
2
20
,45
,50
6
23
,25
,13
4
23
,29
,43
4
13
,18
,68
2
16
,89
,53
4
15
,40
,60
9
18
,20
,87
7
3,0
3,3
22
3,0
7,8
38
1,5
6,9
62
2,0
5,0
90
1,7
9,4
43
2,2
4,6
29
11
.54
%
11
.67
%
10
.64
%
10
.82
%
10
.43
%
10
.98
%
GENERATION
EXPORT
AUX.CONSUMPTION
% AUX.CONSUMPTION
WHR RUNNING AND STOPPAGE/BREAK DOWN HOURS – 2018-19
Apr-18 May-18 Jun-18 Jul-18 Aug-18 Sep-18
70
2
70
5
40
8
55
3
55
8
64
7
18 3
9
31
2
19
1
18
6
73
Running Hours
Breakdown Hours
% OF WHR RUNNING AND STOPPAGE/BREAK DOWN HOURS -2018-19
Apr-18 May-18 Jun-18 Jul-18 Aug-18 Sep-18
97.50%94.79%
56.70%
74.31% 75.03%
89.84%
2.50%5.21%
43.30%
25.69% 24.97%
10.16%
% Running Hours
% Breakdown Hours
3.74 3.74 3.61 3.43 3.08 3.16
11.54 11.67
10.64 10.8210.43
10.98
0.00
2.00
4.00
6.00
8.00
10.00
12.00
14.00
Apr-18 May-18 Jun-18 Jul-18 Aug-18 Sep-18
Avg
. Lo
ad in
MW
/ P
erce
nta
geAvg.Load in MW% Aux. Consumption
WHR AVG. LOAD Vs AUX. CONSUMPTION – 2018-19
NAME:K.PRAMOD KUMARDESG: ENGINEER(ELECTRICAL)QUAL: B.TECH(ELECTRICAL)
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