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Page 1: PowerPoint Presentation - greenbusinesscentre.comgreenbusinesscentre.com/energyaward2017presentations/Cement/22... · Energy Saving Projects Implemented during last 3 years with No

Slide 1

Page 2: PowerPoint Presentation - greenbusinesscentre.comgreenbusinesscentre.com/energyaward2017presentations/Cement/22... · Energy Saving Projects Implemented during last 3 years with No

Slide 2

Plant history & Details

1985:

TEXMACO LTD

1993:

Enhanced

Production

1500 to 1800TPD

1995:

Management

Took over by

ZCL

1998-99 :

Enhanced

Clinker Prod

1.6 to

1.8MTPA

2000:

50:50 Joint

venture

with

Italcementi

Group

2006:

Italcementi

become

100 % share

holder in ZCL

2009:

Enhanced

Clinker Product

1.8 to

2.0 MTPA

2010 :

New

Clinker Line

(2.3 MTPA)

Commissioned

2016 :

Management

Took over by

HEIDELBERG

CEMENT

❖1985 –M/s M/S TEXMACO LTD Capacity – 1500TPD Cement Plant

❖1993 –Enhanced production capacity from -1500 TPD to 1800TPD

❖1995–Management Change to ZUARI INDUSTRIES LIMITED

❖1998 –Plant capacity has enhanced to 5000 TPD (1.8MTPA- Clinker) .

❖2000 –50:50 Joint venture with Italcementi Group

❖2006 –Become 100 % share holder in ZCL.

❖2009 –Clinker production cap. increased to 1.8 to 2.0MTPA Clinker

❖2010 –Second Clinker Line(2.3 MTPA) Commissioned

❖2016 – Management took over by HEIDELBERG CEMENT

Page 3: PowerPoint Presentation - greenbusinesscentre.comgreenbusinesscentre.com/energyaward2017presentations/Cement/22... · Energy Saving Projects Implemented during last 3 years with No

Slide 3

ZCL – Yerraguntla Plant

Installed Capacity (Clinker) - 4.3 mMTPA

Installed Capacity (Cement) - 5.4 mMTPA

Wind Power Installed Capacity - 6 MW

Solar Power Installed Capacity - 550 Kw

Product Range - OPC , PPC , PSC and MC

Page 4: PowerPoint Presentation - greenbusinesscentre.comgreenbusinesscentre.com/energyaward2017presentations/Cement/22... · Energy Saving Projects Implemented during last 3 years with No

Slide 4

Energy Saving Projects Implemented during last 3 years

with No Investments

Sl. No.

Title of Project Year

Annual Electrical

Saving (kWh)

Annual Electrical

Cost Saving (Rs million)

Annual Thermal Saving

(Ton/year)

Annual Thermal

Saving (Rs million)

Total Annual Savings

(Rs million)

Investment Made

(Rs million)

Payback

(Mon)

1 Reduction of damper loss in line-2 cooler vent fan2014-

15158400 0.95 0.00 0.00 0.95 0.00 0

2 Optimization of Quarry Water Pumps2014-

15175200 1.05 0.00 0.00 1.05 0.00 0

3Optimized use of pet coke with red mud & Increased clinker production

2014-15

1500000 9.00 650.00 3.25 12.25 0.00 0

4 Optimization of Raw Mill grinding media2014-

15270000 1.62 0.00 0.00 1.62 0.00 0

5 Optimization of Cement Mill-3 grinding media2014-

15288000 1.73 0.00 0.00 1.73 0.00 0

6Optimization idle running power by logic modification

2014-15

401500 2.41 0.00 0.00 2.41 0.00 0

7 Punch plate removal in Raw mill-32014-

15693000 4.2 0 0 4.2 0 0

8Avoiding Coal crusher running during imported & pet coke unloading

2014-15

74880 0.4 0 0 0.4 0 0

9Reducing the line-2 water pump speed during kiln shut down

2015-16

20300 0.1 0.1 0 0

10 Replacement of diesel with pyrolysis oil2015-

16436 7.2 7.2 0 0

Page 5: PowerPoint Presentation - greenbusinesscentre.comgreenbusinesscentre.com/energyaward2017presentations/Cement/22... · Energy Saving Projects Implemented during last 3 years with No

Slide 5

Energy Saving Projects Implemented during last 3 years

with No Investments

Sl. No.

Title of Project Year

Annual Electrical

Saving (kWh)

Annual Electrical Cost

Saving (Rs million)

Annual Thermal Saving

(Ton/year)

Annual Thermal Saving

(Rs million)

Total Annual Savings

(Rs million)

Investment Made

(Rs million)

Payback

(Mon)

11 Reduction of surface in 43 grade cement 2015-16

249480 1.6 1.6 0 0

12Coal Crusher bypass during fine (imported) coal unloading.

2015-16

149760 1.0 1.0 0 0

13 Increased OK mill PPC grinding2015-

16229635 1.5 1.5 0 0

14Maximizing unloading fly ash in bin instead of unloading in silo

2015-16

59705 0.4 0.4 0 0

15 Coal mill CA fan inlet damper removal2016-

1714932 0.1 0.1 0 0

16 K String PH fan trimming 2016-

17396000 2.4 2.4 0 0

17 Arresting leakages in VRM-12016-

17158400 1.0 1.0 0 0

18Arresting leakages in Line-1 PH and optimised PC fan

2016-17

198000 1.2 1.2 0 0

19 OK Mill Reject pipe modification2016-

17158400 1.0 1.0 0 0

20Installation of Fly ash feeding to mill discharge arrangement

2016-17

36324 0.2 0.2 0 0

Page 6: PowerPoint Presentation - greenbusinesscentre.comgreenbusinesscentre.com/energyaward2017presentations/Cement/22... · Energy Saving Projects Implemented during last 3 years with No

Slide 6

Energy Saving Projects Implemented during last 3

years with Investments

Sl. No.

Title of Project Year

Annual Electrical Saving (kWh)

Annual Electrical Cost

Saving (Rs million)

Annual Thermal Saving

(Ton/year)

Annual Thermal Saving

(Rs million)

Total Annual Savings

(Rs million)

Investment Made

(Rs million)

Payback

(Months)

21Optimization of Raw mill-3 circuit air flow volume after reject BE installation

2014-15

2079000 12.47 0.00 0.00 12.47 9.00 8.7

22Reduction of Pressure drop across venturi in VRM-1

2014-15

726000 4.36 0.00 0.00 4.36 3.00 8.3

23 Optimization of coal transport blower in kiln-22014-

15363000 2.18 0.00 0.00 2.18 0.05 0.3

24 Line-2 Pyro section compressors Optimization2014-

151815000 10.89 0.00 0.00 10.89 1.00 1.1

25Line-2 Cement Mill section compressors Optimization

2014-15

1485000 8.91 0.00 0.00 8.91 1.00 1.3

26 Line-1 Pyro section compressors Optimization2014-

15360000 2.16 0.00 0.00 2.16 1.20 6.7

27 Optimization of pyro cooling water circuit 2014-

15363000 2.18 0.00 0.00 2.18 1.00 5.5

28Optimization of line-1 Cement cooling water circuit

2014-15

330000 1.98 0.00 0.00 1.98 1.00 6.1

29Reduction of pressure drop between bag house outlet to Fan inlet in CM-4

2014-15

330000 1.98 0.00 0.00 1.98 0.15 0.9

30 Street lights Optimization2014-

1562480 0.37 0.00 0.00 0.37 0.49 15.7

Page 7: PowerPoint Presentation - greenbusinesscentre.comgreenbusinesscentre.com/energyaward2017presentations/Cement/22... · Energy Saving Projects Implemented during last 3 years with No

Slide 7

Energy Saving Projects implemented during last 3

years with Investments

Sl. No.

Title of Project Year

Annual Electrical Saving (kWh)

Annual Electrical

Cost Saving (Rs million)

Annual Thermal Saving

(Ton/year)

Annual Thermal

Saving (Rs million)

Total Annual Savings

(Rs million)

Investment Made

(Rs million)

Payback

(Months)

31Cement Mill-2 bag house fan replaced with high efficiency fan

2014-15

72600 0.44 0.00 0.00 0.44 3.00 82.6

32Optimization of Line-2 water pump by Installation of VFD

2015-16

486382 3.2 3.2 0.8 3.0

33Damper and LRS losses reduced by installation of VFD for CM-2 sepax fan

2015-16

316800 2.1 2.1 1.6 9.3

34Damper and LRS losses reduced by installation of VFD for CM-3 sepax fan

2015-16

356400 2.3 2.3 1.6 8.3

35Optimised EEL packer Bag filter by Instaltion of VFD

2015-16

158400 1.0 1.0 0.45 5.3

36 Line-2 PA Fan optimised by Instaltion of VFD 2015-

16158400 1.0 1.0 0.95 11.1

37Direct feeding of cement to EEL packer-2 vibrating screen bypassing CB-2 circuit

2015-16

633600 4.1 4.1 0.6 1.8

38 OK mill separator Felt seal arrangement 2015-

16150480 1.0 1.0 0.1 1.2

39Line-1 Calciner coal firing blower speed reduced by 10%

2015-16

198000 1.3 1.3 0.05 0.5

40 CM-2 Grinding media optimisation2015-

16522720 3.4 3.4 2.275 8.1

Page 8: PowerPoint Presentation - greenbusinesscentre.comgreenbusinesscentre.com/energyaward2017presentations/Cement/22... · Energy Saving Projects Implemented during last 3 years with No

Slide 8

Energy Saving Projects implemented during last 3

years with Investments

Sl. No.

Title of Project Year

Annual Electrical Saving (kWh)

Annual Electrical Cost

Saving (Rs million)

Annual Thermal Saving

(Ton/year)

Annual Thermal Saving

(Rs million)

Total Annual Savings

(Rs million)

Investment Made

(Rs million)

Payback

(Months)

41Cooler vent fan HT motor replaced with LT Motor and installed VFD

2015-16

633600 4.1 4.1 1.6 4.7

42Installation of VFD for Line-1 Post Clinker Water Pupms

2015-16

157680 1.0 1.0 0.45 5.3

43Replacement of 250w HPSV street lights with 60 W LED lights

2015-16

48545 0.3 0.3 0.525 20.0

44Coal firing blower optimised with reducing blower speed by changing pully

2015-16

201818 1.3 1.3 0.05 0.5

45Installation of high efficiency bag house fan in cement mill -2

2015-16

31680 0.2 0.2 0.8 46.7

46Installation of high efficiency bag house fan in cement mill -3

2015-16

31680 0.2 0.2 0.8 46.7

47Installation of Solenoid Valve system In packing Plant for optimization of compressed air

2015-16

298935 1.9 1.9 0.6 3.7

48Rawmix optimisation after installation of crosbelt analyser

2016-17

477 2.73 2.7 18 79.2

49Avoiding pnumatic conveying by Installation of new steel silo for export and slag cement.

2016-17

330523 2.0 2.0 50 302.6

50Replacement of 250w HPSV street lights with 60 W LED lights

2016-17

138700 0.8 0.8 0.92 13.3

Page 9: PowerPoint Presentation - greenbusinesscentre.comgreenbusinesscentre.com/energyaward2017presentations/Cement/22... · Energy Saving Projects Implemented during last 3 years with No

Slide 9

Energy Saving Projects implemented during last 3

years with Investments

Sl. No.

Title of Project Year

Annual Electrical Saving (kWh)

Annual Electrical

Cost Saving (Rs million)

Annual Thermal Saving

(Ton/year)

Annual Thermal Saving

(Rs million)

Total Annual Savings

(Rs million)

Investment Made

(Rs million)

Payback

(Months)

51 Installation of VFD for Coal Mill FK Pump2016-

17184800 1.1 1.1 1.0 10.8

52Optimisation of CF silo dedusting bag filter fan by Installing VFD

2016-17

158400 1.0 1.0 0.3 3.8

53Optimisation of post clinker compressor power by installing dedicated small compressor with VFD

2016-17

615938 3.7 3.7 1 3.2

54Replacement of line-1 VCLM CA Fan HT motor with high efficiency motor along with VFD

2016-17

209052 1.3 1.3 1.2 11.5

55 Calciner Coal firing points connecting to feed box2016-

17203 1.16 1.2 0.2 2.1

56 Coal Mill-2 separator rotor replacement2016-

17237600 1.4 1.4 0.5 4.2

57Increased usage of liquid pharma waste by installing storage system

2016-17

2877 16.47 16.5 12 8.7

Page 10: PowerPoint Presentation - greenbusinesscentre.comgreenbusinesscentre.com/energyaward2017presentations/Cement/22... · Energy Saving Projects Implemented during last 3 years with No

Slide 10

710

712

714

716

718

720

722

724

726

2013-14 2014-15 2015-16 2016-17 2017-18Target

720

718

717

725

715

Specific Energy Consumption

Pet coke usage

56.0

57.0

58.0

59.0

60.0

61.0

62.0

63.0

64.0

65.0

66.0

67.0

2013-14 2014-15 2015-16 2016-17 2017-18Target

66.5

63.6

59.9

61.8

61.0

7.6 % Reduced

74.0

76.0

78.0

80.0

82.0

84.0

86.0

88.0

90.0

92.0

2013-14 2014-15 2015-16 2016-17 2017-18Target

91.5

85.5

82.1

82.181.1

11.4 % Reduced

Description Unit 2013-14 2014-15 2015-16 2016-17

Kiln-1 Utilization ( 4th stage PH ) % 57.5 43.6 27.6 65.8

Pet coke usage % 0 20.0 28.5 72.0

CK Ratio % 82.3 79.3 78.9 80.8

Page 11: PowerPoint Presentation - greenbusinesscentre.comgreenbusinesscentre.com/energyaward2017presentations/Cement/22... · Energy Saving Projects Implemented during last 3 years with No

Slide 11

Specific energy consumption ZCL AchievedNational bench

markInternational bench mark

Thermal - Kcal/Kg clinker 725 667 660

Electrical-kWh/T of cement 82 67 65

Specific energy consumption

ZCL Achieved

ICL,Chilamkur

Bharathi Cements

UltratechCement

Thermal - Kcal/Kg clinker

725 834 722 723

Electrical-kWh/T of cement

82 102.5 78 84.1

Comparison with Global Benchmark Data

Comparison with nearest competitors

Global norms/Bench mark Data & Competitors

Page 12: PowerPoint Presentation - greenbusinesscentre.comgreenbusinesscentre.com/energyaward2017presentations/Cement/22... · Energy Saving Projects Implemented during last 3 years with No

Slide 12

Energy conservation projects planned 2017-2018

Sl. No Title of Project Year

Estimated Annual

Electrical Savings

(kWh/year)

Thermal Savings

(Ton/year)

1 Kiln-1 K-String top HP cyclones (1A,1B&1C) modification to LP cyclone 2017-18 1650000

2 Kiln-1 Old Pre heater Fan replacing with high efficiency fan. 2017-18 1868545

3 Raw Mill-3 rollers and Mill internals modification 2017-18 848232

4 Kiln-1 cooler modification ( ABC inlet ) 2017-18 1422.4

5 Installation of line-1 fine coal dosing system 2017-18 1832

6 Reduction of Pressure drop in C - line bag house out let to fan inlet duct 2017-18 372240

7 Installation of Pyrojet burner for line-2 2017-18 916

8 Kiln-2 cooler modification ( ABC inlet ) 2017-18 1650

9 Replacement of 70w HPSV area lights with 30 W LED lights 2017-18 29200

10 Replacement of 250w HPSV street lights with 70 W LED lights 2017-18 131400

11 Installation of mill scan for cement mill-2 2017-18 435600

12 Installation of mill scan for cement mill-3 2017-18 435600

13 Installation of WHR system for Line-1 and Line-2 2017-18 83397600

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Slide 13

2282 Kwh / day , 10.2 Tons of coal /Day

380 Lakhs per Annum

30 Lakhs

1 month

✓Pond ash is having higher moisture and high foreign materials ( wood, stone) resulted jamming

of chutes damaging belt conveyors.

✓Also unable to feed fly ash requirement to the Mill resulted lesser fly ash consumption and

frequent stoppages of the mill. ZCL developed vibro feeder as a pilot plant for improving feeding

and separating foreign materials

Increased usage of Pond Ash from 30% to 33.5%

Installing vibro feeder

Utilizing 100% pond ash for PPC production is first in India and In-housedesign of vibro feeder for separating foreign materials and improvingfeeding is known concept but applied differently and also it is beyond thescope of OEM and having high Replication Potential in the sector

Innovative project- 1: Increased usage of Pond Ash

Page 14: PowerPoint Presentation - greenbusinesscentre.comgreenbusinesscentre.com/energyaward2017presentations/Cement/22... · Energy Saving Projects Implemented during last 3 years with No

Slide 14

✓ZCl installed Atox 20 coal mill in 1998. Mill Main drive is designed with LRS system for running

full speed 980 RPM for normal coal grinding. As a sustainable and cost economic initiative ZCL

decided to use pet coke for kiln firing. Main drive full speed is not required for Pet coke grinding

but present LRS system is not possible to control the speed. So ZCL decided to modify LRS system

to LRC system by Installing heat exchanger, installing circulating pump and arranged controlled

electrodes movements from CCR resulted Main drive speed reduced from 980 RPM to 760 RPM

Inhouse convertion of LRS system to LRC system in Atox-20 coal mill

Innovative project- 2 : Inhouse Convertion of LRS system to LRC system in Atox-20 coal mill

In-house modification of LRS system to LRCsystem is known concept but applieduniquely. This project is high ReplicationPotential for the similar companies

60 Kw

10.8 Lakhs per Annum

1.5 Lakhs

2 month

Page 15: PowerPoint Presentation - greenbusinesscentre.comgreenbusinesscentre.com/energyaward2017presentations/Cement/22... · Energy Saving Projects Implemented during last 3 years with No

Slide 15

✓ATOX-55 is the first mill in Asia order by Zuari cement ltd with design capacity of 430 TPH. Mill is

taking higher power So ZCL decided to take the risk and modified the mill internals

1. Mill Fan trimming by 120 mm 2.Armour ring removed 3. Mill Internal Reject pipes extended

4.Water spray nozzle modified 5. Mill table area blocked by 50 Installed small receiver tanks for

critical locations

Innovative project- 3 : Optimization of VRM-2

Mill Fan Trimming

ZCL taken the risk and modified the mill internals . All those modifications are in-house andbeyond the scope of OEM and having high Replication Potential in the sector

0.5

Kwh / Ton of mat

77.3

Lakhs per Annum

After removing Armour ring Water SprayReject Pipe extension

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Slide 16

Replacement of Electrical Energy with Renewable Energy

DescriptionInstalled Capacity

(kW)

2014-15 (million kWh)

% Share2015-16

(million kWh)%

Share2016-17

(million kWh)%

Share

Wind Energy 6000 3.08 1.19 14.81 6.68 16.31 6.27

Solar Energy 550 0.7 0.27 0.75 0.34 0.71 0.27

Total 3.79 1.46 15.57 7.02 17.01 6.54

Utilization of Renewable energy ( % of Total Energy)

Replacement of Thermal Energy with Renewable Energy

DescriptionFuel Savings in

2014-15 (million kcal/year)

% Share

Fuel Savings in 2015-16 (million

kcal/year)

% Share

Fuel Savings in 2016-17 (million

kcal/year)

% Share

Biomass 91324 4.80 83067 4.84 17165 2.8

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Slide 17

Utilization of Waste as Fuel

Name of the Fuel

2014-2015 2015-2016 2016-2017Waste Fuel as

% of total energy used

Quantity of waste Fuel used (MT)

Heat Value (million

kcal/year)

Quantity of waste Fuel used (MT)

Heat Value (million

kcal/year)

Quantity of waste Fuel used (MT)

Heat Value (million

kcal/year)

Rice husk 11285 36891 13925 45855 5107 13568 1.75Ground nut shell 2744 8827 1790 6866 329 975 0.30Bangal gram 41 121 20 69 1 1 0.00Sun flower 0 0 0 0 0 0.00Sugar cane 42 107 59 203 0 1 0.01Coconut 1169 2490 33 104 1019 2287 0.09RDF 5683 13872 4931 17263 1426 4830 0.65Ecalyptus 5812 9415 0 1 2 0.17Areca nut waste 0 0 0 1 0 0.00Mangokarnel 1582 2977 173 648 0 2 0.07Carbon waste 0 0 0 0 0 0.00Dolachar 17242 41950 1862 5094 3031 8540 1.01Shredded tyres 0 0 424 2798 943 5697 0.15Jawar husk 9076 27019 6408.5 22513 119 326 0.91Supari Husk 0 0 0 0 0.00Subabul bark 1078 3475 1951 6809 1 3 0.19

Liquid Alternative Fuel 0 123.5 764 27 73 0.02

Spent carbon 0 630 1859 3655 4799 0.12

Liquid pharma waste 0 2543 6762 13187 16306 0.42

Solid pharma waste 0 2423 5781 14344 17963 0.43Solid cake 52 246 0.00

Total 55754 147145 37296 123390 43242 75620 6.29

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Slide 18

YearScope 1

emissions CO2e (MT)

Scope 2 emissions CO2e (MT)

Scope 3 emissions CO2e (MT)

kg CO2e/ MTof

cement

MitigationTotal Reduction in emission intensity since baseline year

study CO2e (MT)

2013 (Baseline Year)

2005334 223291 304517 838 Baseline Year

2014 2170295 232377 273047 786 142,577

2015 1815948 185529 228503 773 -303,163

2016 2365370 214562 290683 773 337,473

2017 Target 2280667 215328 293333 761

GHG Emission Inventorisation

8.4 % Specific CO2 emission reduced compared to baseline year

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Slide 19

GreenCo and ISO Cetification

GreenCo Gold , ISO 9001:2000 and ISO 14001 certified Cement Plant

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Slide 20

% Investment for Energy Conservation Projects on turnover

S.No Description Units Investment

1 Total budget MINR 348.3

2 CBA MINR 20

3 ATS MINR 50

4 Silo MINR 54.5

5 VFD MINR 6

6 Bag filter MINR 5

7 Dip tubes MINR 20

8 PLC upgrade MINR 15

9 Nox measure MINR 4

10 Pharma waste syst MINR 25

11 Cooler esp MINR 17.5

12 Lights LED MINR 0.92

13 Total MINR 217.9

14 % in total budget % 63

15 Turnover of the Unit MINR 11660

16 % investment on turnover % 2

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Slide 21

✓ Energy management cell formed with cross function team members.✓ The coordinator for the Energy management cell is Energy Manager.✓We launched ‘’CIP Continues improvement program‘’ program as plat form for key performance improvement✓ Ideas generation from the all the employees and tracking the work process based on the priority.✓ The daily review of energy monitoring by each section .✓Weekly review by plant head. ✓ Awards for the best idea & Energy savings implemented✓SMS alert system for stoppages to control the down time.

Monitoring , Reporting & Implementation Methodologies

Power Consumption Report for 21-Aug-15

Description

On Date MTD YTD

Prod

in

Ton

s

R.Hr

sTPH Kwh

Kw

h/H

r

Kw

h/

T

Of

mat

Kw

h/

T

Cli

Kw

h/

T

OP

C

K

w

h/

T

P

P

C

Kwh/

T

ceme

nt

Pro

d

in

Ton

s

R.Hr

sTPH Kwh

Kw

h/H

r

Kw

h/

T

Of

ma

t

Kw

h/

T

Cli

Kw

h/

T

OP

C

Kw

h/

T

PP

C

Kwh

/

T

cem

ent

Prod

in

Tons

R.

Hr

s

TPH Kwh

Kw

h/H

r

Kw

h/

T

Of

mat

Kw

h/

T

Cli

Kw

h/

T

OP

C

Kwh

/

T

PPC

Kwh

/

T

cem

ent

Crusher #3

MD

Aux

VRM

MD

Fan

Aux

KILN -2 &

Cooler

MD

ID Fan-1

ID Fan-2

BH Fan

C Vent fan

C Fans

Aux

VCLM

MD

Fan

Booster fan

Aux

OK Mill

MD

BH Fan

Booster fan

Aux

OK Mill

total

P.Plant

Utilities

All sections

Total

Incomer

power

Misc

Total

0.0 0.0 0.0 0.00.

00.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0

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Slide 22

Head production

DGM-process

Maintenance head

GM- Mech

Quality headG.M -QC

Head Electrical &

Instrumentation

Team 2:

Kiln & Coal mill section head &

engineers

Team 3:

Crushers & raw mill section engineers

Team 5:

Cement grinding

incharge & engineers

Team 4:

Packing & dispatch section

engineers

Plant Head S.V.P-Works

Energy Manager

Head MinesGM-Mines

Team 1:

Mines section head &

engineers

Energy Management Committee

Monitoring , Reporting & Implementation Methodologies

Energy Management Committee includes One Energy Auditor & Two Energy Managers :

➢ Mr. Jignesh Kumar Duva – DGM (Production) - EA

➢ Mr. P. Raghuram – DGM (Electrical & Instrumentation) - EM

➢ Mr. G.SaiSunil Bharathbabu – Dy. Manager (Electrical) - EM

Idea generation and Tracking Form

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Slide 23

Team work Efforts made in Encon Projects

S.NoDescription of En-

Con ProjectSource of En-

Con Idea

Idea Originated

Year

Extent of man power involved

Progress of implementati

on

Methodology adopted to overcome the constraints

1

Avoiding pnumatic

conveying by Installation of

new steel silo for export and slag

cement.

Senior Management

2016-17

Mr.P.S Murthy D.G.M - Mech , Mr.Krishna Reddy

Sr.Manager - Elect Mr.Ravi subrahmanyam

Asst.Manager - Inst Mr.Satya Narayana Asst.Manager -

Mech

Implemented

1.New steel silo 2 no'sInstalled 2. Ensuring Grinding of PSC and Export in steel silos

3.Planning the dispatch accordingly

2

Replacement of VCLM CA fan HT motor with high efficiency motor along with VFD

Engineer 2016-17

Mr. P.Raguram D.G.M – E&I , Mr.Janardhan Reddy Dy.Man

- Mech , Mr.Madhu babu Man - Op Mr.Subba Reddy

Sr.Man -Inst Mr.Satyanarayana D.M –

Elect

Implemented1.HT motor replaced with LT motor 2. VFD installed

3. Reducing fan speed

3

Optimization of CF silo dedusting bag filter fan by Installing VFD

Workmen 2016-17

Mr.G.Venkateshwarlu S.M-Op , Mr.Ashok Kumar D.M - Inst Mr.N.Rajesh A.M-Elect Mr.

Ravi Varman D.M-Mech

Implemented

1.Core team formed for monitoring the bag filter

2.VFD installed 3. Reducing fan speed

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Slide 24

Team work Efforts made in Encon Projects

S.NoDescription of En-

Con ProjectSource of En-

Con Idea Idea Originated

Year Extent of man power

involved

Progress of implementatio

n

Methodology adopted to overcome

the constraints

4

Installation of Fly ash feeding to mill

discharge arrangement

Supervisor 2016-17

Mr.Phani Kiran Manager-Prod , Mr.

Murali Sr.Man -Mech , Mr.Subramanyam

Sr.Officer -Op , Mr.Ragava employee

- Prod

Implemented

1.Extended Airslide 2.Arranged chute to feed fly ash in BE 3.

Continuous monitoring of quality

and power

5

Raw mix optimization after

installation of crosbelt analyzer

Top Management

2016-17

Mr.K.Suresh G.M-QC , Mr.Nareshkumar

A.G.M -Proces ,Mr.Madhusudan

Sr.Officer - Op , Mr. P.Ramesh AGM -Inst

Implemented

1.Installed cross belt analyzer 2.Continuous

monitoring of the quality parameters.

6Installation of VFD

for Coal Mill FK Pump

Engineer 2016-17

Mr. K.Ravi , Manager-Mech, Mr. Subhash, Engineer-Process, Mr.Sunil-

Man- Elec , Mr. Srinivas DM –Inst

Implemented

1.Core team formed for study FK pump2.VFD installed 3.

Reducing fan speed

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Slide 25

Best Suggestion

Ideas Contribution

Rcognisation Program for Encon Efforts

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Slide 26

……..aiming to conserve natural resources

26

When we heal the earth, we heal ourselves ~ David Orr

Great things are not done by impulse, but by a series of small things

brought together


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