Team Members:
S.Venkateshwer Rao-DGM (Process) [email protected]
P.Saidireddy-Sr.Manager (Mechanical) [email protected]
E.Parameswara Rao-Dy.Manager (Process)[email protected]
SREE JAYAJOTHI CEMENTS PRIVATE LIMITED
YANAKANDLA-KURNOOL-A.P
NATIONAL AWARDS FOR CEMENT INDUSTRY & CONCLAVE ON
SUSTAINABILITY EXCELLENCE IN INDIAN CEMENT INDUSTRY-2018
My Home Industries Pvt. Ltd. (MHIPL) was established in the year 1998 with an installed capacity of 0.2 MTPA, which has now risen to 10 MTPA.
My Home Group have Various businesses like Cement ,Construction, Real Estate, Power and Education.
MHIPL is a joint venture with CRH plc. Ireland, an international leader in building materials.
SJCPL was taken Over by MHIPL in August 2013.
SJCPL, YCW has Single line (capacity 3.2 MTPA) with state-of-the-art-Technology from LNVT, the world’s leading suppliers of Cement manufacturing equipment.
Company Profile
Location Capacity
SJCPL-Yanakandla Cement Works-Kurnool 3.2 MTPA
Mellacheruvu Cement Works- Kodad 3.3 MTPA
Vizag Grinding Unit- Yalamanchili 2.0 MTPA
Tuticorin Grinding Unit- Tamilnadu 1.5 MTPA
Total 10 MTPA
My Home Group Cement Businesses
Management Systems
SJCPL Policies
Energy Review Methodology
Review of Energy Consumption with respect to production in Daily Production Meeting
Energy Committee Cell meeting for Review of Energy Conservation Projects
Setting of Annual Targets for achieving National and International Benchmark
Daily Monthly Yearly
Unit Head
Sr.GM-Engineering Sr.GM-Operations
HOD-Mech HOD-Process HOD-Elect Energy Manager HOD-Inst HOD-Mines HOD-QC HOD-Stores
Section
Incharges-
Mech
Section
Incharges-Elect
Section
Incharges-
Process
Section
Incharges-Inst
Section
Incharges
Section
Incharges
Section
Incharges
Energy Management System Organization Structure
737.70
715.00
697.70 695.10
692.58
670.00
680.00
690.00
700.00
710.00
720.00
730.00
740.00
750.00
2013-14 2014-15 2015-16 2016-17 2017-18
Sp.Thermal energy Consumption -Kcal/Kg Clinker
45 Kcal/Kg cl
6.2% Reduction
Energy Performance From last 5 Years
54.1
52.32 52.06
51.16
49.77
47
48
49
50
51
52
53
54
55
2013-14 2014-15 2015-16 2016-17 2017-18
Electrical SEC: Up to Clinkerisation, Kwh/Ton of Clinker
4.33 Kwh/Ton of cl
8 % Reduction
Energy Performance From last 5 Years
78.80 75.46
78.26 76.35 75.53
55.28 55.84
62.74 64.12 67.44
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
2013-14 2014-15 2015-16 2016-17 2017-18
Electrical SEC : Total Plant ,Kwh/Ton of Cement
Kwh/ton of Cement % of OPC Production
Energy Performance From last 5 Years
1443.56 1428.73 1366.33
750.58 704.14
610.34
0
500
1000
1500
2015-16 2016-17 2017-18
Lakh Units Units cost Rs.Lakhs
Reduction in Electrical Energy Bill
0
0.05
0.1
0.15
0.2
0.25
0.3
2016-17 2017-18
0.05
0.30
TSR %
Thermal Substitution Rate-%
1.73
26.28
3.40
21.87
37.91
2.44 6.37
Crusher Raw Mill
Coal Mill Kiln
Cement Grinding Packing Plant
Utilities
Energy Road Map
72
74
76
78
80
82
2014-15 2015-16 2016-17 2017-18
76.08
77.97 79.13
80.86 CCF
0
20
40
60
80
2014-15 2015-16 2016-17 2017-18
55.84 62.74 64.12 67.44
OPC
0
10
20
30
40
2014-15 2015-16 2016-17 2017-18
33.95
13.42 13.06 12.34
PPC
0
10
20
30
2014-15 2015-16 2016-17 2017-18
10.77
23.84 22.82 20.21
PSC
Blended Cement Ratio
EnCon PROJECT-1
Replacement of Present burner with DUOFLEX burner
Project Description:
Previous burner was designed for lower capacity and consumes more
primary air at around 13-14%. It was decided to reduce the Primary
air consumption for reduction of STEC by installing the FLS Duoflex
burner.
Action Taken:
With management’s approval ,Existing burner was replaced with
New Duoflex Burner to reduce Primary air consumption for
reduction in STEC
Benefits:
Primary Air percentage reduced from 13% to 8%
Sp.Heat Consumption reduced by 3 Kcal/Kg Clinker
Project Description :
Earlier high pressure compressor (6 bar ) was used for fly ash unloading by
regulating the pressure from 6.0 bar to 3.0 bar. It was decided to install a dedicated
Low Pressure compressor for pumping the flyash into Concrete silo to reduce the
Power consumption and safety concerns.
Action Taken :
With management’s approval, LP compressor was installed dedicatedly for flyash
tankers unloading and pumping into the concrete silo.
Benefits:
Annual Power Saving = 1.61 Lakh Kwh
Annual Cost saving = 9.7 Lakhs
Investment = Rs.25.6 Lakhs
Pay back = 2.6 Years Before-6.0 bar After-3.0 bar
EnCon PROJECT-2
Installation of LP compressor for Flyash unloading
EnCon PROJECT-3
Raw Water pump Stopped by Re-routing the water pipe line
Project Description:
In pump house we have used 2 pumps for pumping water for process
requirements to the Raw water tank. This Raw water tank’s water goes to
Process water tank through Multi grade filter for avoiding the contamination.
Our team observed & checked the Mines water before pumping to Raw water
tank. As there is no contamination the raw water pump was by-passed and there
by resulted in reduction of power consumption .
Action Taken:
The water line was Re-routed (from mine water pump to process water tank) and
the water was directly pumped into the Process water tank.
Benefits:
Annual Power Saving = 0.45 Lakh Kwh
Annual Cost saving = 2.79 Lakhs
Investment = Rs.0.46
Pay back = 2 Months
EnCon Project-4
Nitrogen Air Consumption Optimization by arresting the leakages
Project Description:
During compressor air Leakages audit, we have observed some of the leakages at
Nitrogen air compressor area. This compressor air is used for Coal mill bag filters &
Coal mill fine coal bins.
Action Taken:
The leakages across the Nitrogen compressor air system was arrested and there by
resulted in reduction of power consumption
Benefits:
Annual Power Saving = 5.20 Lakh Kwh
Annual Cost saving = 27.05 Lakhs
Investment = Rs.0
Pay back = Immediate
EnCon Project-5 Installation of VFD for Cement Mill Booster fan to avoid damper losses
Project Description:
Earlier Cement Mill booster fan was operated with DOL mode and flow was subsequently controlled with
damper. Our team had observed that damper losses were around 160-185 mmwg across damper, it was then
proposed to install the VFD for Cement Mill booster fan.
Action Taken:
With management’s approval ,VFD was procured & installed to reduce the pressure drop across damper and
there by resulted in reduction of power consumption
Benefits:
Annual Power Saving = 2.34 Lakh Kwh
Annual Cost saving = 14.50 Lakhs
Investment = Rs.35 Lakhs
Pay back = 2.4 Years
Project Description:
9 no's of Cooling fans are in use for cooling the clinker, during flow measurements it
was identified & measured that across cooler fan dampers pressure drop was 20-35
mmwg. Reviewing the pressure drop of Cooler fan dampers, it was proposed to
remove the dampers for all Cooler fan inlets.
Action Taken:
All cooler fan inlet dampers were removed to avoid the pressure drop.
Benefits:
Annual Power Saving = 5.23 Lakh Kwh
Annual Cost saving = 27.20 Lakhs
Investment = Rs.0
Pay back = Immediate
EnCon Project-6 Removal of Cooler fan inlet dampers to avoid damper losses
RTD
TEMPERATURE CONTROLLER
Project Description:
2 no's of Cooling towers are being used for cooling the hot Process water. During internal
energy audit our team members had observed that, these cooling tower fans were operating
continuously even in the idle period. So, it was proposed to provide the interlock with cold
well temperature.
Action Taken:
For providing the interlock with cold well temperature; RTD & Temperature controller
were installed to avoid the idle running of cooling tower fans and there by resulted in
reduction of power consumption
Benefits:
Annual Power Saving = 0.185 Lakh Kwh
Annual Cost saving = 0.96 Lakhs
Investment = Rs.0.10 Lakhs
Pay back = 2 Months
EnCon Project-7 Provided interlock for Cooling tower fan operation with cold well temperature
EnCon Project-8 Installation of Capacitor bank at Switch Yard to improve the Power Factor
Project Description:
Our SJCPL electrical team had observed that, the plant was being operated with 0.97 power factor. In view of
sustainable & energy conservation, it was proposed to install the capacitor bank at switch yard to improve the
power factor.
Action Taken:
With management’s approval, installed 2250 KVAr capacity capacitor bank at switch yard.
Benefits:
Power factor was improved from 0.97 to 0.99
Annual Power Saving = 18.25 Lakh Kwh
Annual Cost saving = 94.90 Lakhs
Investment = Rs.30 Lakhs
Pay back = 4 Months
EnCon Project-9 Star/Delta Panels arranged for all under loaded motors
Project Description:
During internal Energy conservation Audit, the team has identified some under-loaded
motors were running in the plant.
1. Cement Mill Reject bucket elevator
2. Raw Mill Magnetic separator
3. Cement Mill Magnetic separator
4. Raw Mill Cyclone bottom RALs (8 Nos)
Action Taken:
After lot of discussions & brain storming, installed the Star/Delta panels for all
under- loaded motors.
Benefits:
Annual Power Saving = 1.07 Lakh Kwh
Annual Cost saving = 5.59 Lakhs
Investment = Rs.1.20 Lakhs
Pay back = 3 Months
Star/Delta Panel
Project Description:
During In-house lighting audit, our team members had identified that, conventional lights
were in use at plant & colony premises.So,it was planned to replace the conventional lights
with LED lights to reduce power consumption.
Action Taken:
With management’s approval ,495 no's of LED lights were installed at colony & Plant area.
Benefits:
Annual Power Saving = 0.88 Lakh Kwh
Annual Cost saving = 4.56 Lakhs
Investment = Rs.10.50 Lakhs
Pay back = 2.3 Years
EnCon Project-10 Installation of LED light fittings in plant & colony street lighting
Innovative Projects
PROJECT-1
INSTALLATION OF Y-CHUTE FOR GYPSUM FEEDING
Project Description:
In our Cement Mill & Slag Mill section, we have 3 belts conveyors for Gypsum
feeding. At Gypsum Hopper top, spillages was happening daily under the belt
conveyor.so, every day Man Power were deploying for spillage cleaning.
Action Taken:
After Brain Storming, On view of Energy Conservation and to avoid spillages,
our team has decided to install a In-house designed Y-Chute for Gypsum Feeding
at top of the hopper in place of reversible belt.
Benefits:
Annual Power Saving :0.21 Lakh Kwh
Annual Cost Saving :Rs.1.26 Lakhs
Investment :Zero
Pay Back :Immediate
Before
After
Before After
PROJECT-1
INSTALLATION OF Y-CHUTE FOR GYPSUM FEEDING
PROJECT-2
INSTALLATION OF SOLAR LIGHTING SYSTEM IN MINES AREA
Project Description:
Earlier Mobile lighting Diesel generator was used for lighting purpose in our new
Limestone Mining area. Diesel generator consumes more HSD oil at around 493
Lts/Month (5.75 KL/Yr.). On Energy Conservation View and environmental
protection View our team has decided to replace the Mobile lighting Diesel generator
with Solar Lighting System.
Action Taken:
Our team has installed a Solar Lighting System in place of Mobile Lighting Diesel
Generator at New Limestone Mining area.
Benefits:
Annual GHG Reduction :17.25 MT of CO2
Annual HSD Saving :5.75 KL
Annual Cost Saving :Rs.3.74 Lakhs
Investment for Solar Panels :Rs.2.85 Lakhs
Pay Back :9 Months
Mobile Lighting DG Set
Solar Lighting System
PROJECT-3
REMOVAL OF VENTURIES FOR ALL PROCESS FANS
Project Description :
Installed Raw Mill (LM 56.4+4 ), Cement Mill (LM56.3+3), Slag Mill (LM46.2+2) & Coal Mill (LM28.2+2)
for raw materials Grinding. All mill fan inlet ducts are designed with Venturies for online flow indication. It
was identified and measured that Venturi pressure drop was 15-25 mmwg. Reviewing the Venturies Pressure
drop, SJCPL team decided to remove the venturies for all process fan inlet ducts.
Action Taken :
All venturies were removed and hooked up with In- house fabricated same diameter duct at all process fans
inlet ducting to avoid pressure drop across venturies.
Benefits:
Area Annual Electrical
Saving - Lakh Units
Annual Cost Saving Rs.
Lakhs
Investment
Rs. Lakhs Pay Back-Months
Coal Mill 1.56 8.11 2 3
Slag Mill 0.8 4.16 2.2 6
Raw Mill 3.6 18.72 12.5 8
Cement Mill 4.63 24.07 6.76 3
Coal Mill Slag Mill
Raw Mill Cement Mill
Before
Before
Before
Before After After
After After
PROJECT-3
REMOVAL OF VENTURIES FOR ALL PROCESS FANS
Utilization of Renewable Energy
1.2 Mwp Solar Power Plant-Phase-1
0
2
4
6
8
10
12
14
16
18
20
2014-15 2015-16 2016-17 2017-18
0 0
11.65
18.15
Solar Power Generation –Lakh Kwh
Installed in August-2016
Utilization of Waste Oils instead of HSD Oil
Petro Polymer Fuel & Pyrolysis Oils are used for Kiln Light up and
Hot air Generator Light Up.
Pyrolysis Oil is generated from Tyres waste
PPF is generated from Plastic Waste
1MT of HSD oil releases the 3 MT of CO2 Gases.
By using this PPF & Pyrolysis oil, the Carbon emissions are also reduced.
25
31.31
0
10
20
30
40
2016-17 2017-18
Pyrolysis Oil-KL
75
94
0
20
40
60
80
100
2016-17 2017-18
Co2 emissions reduction-MT/Yr
Green House Gases Mitigation
700
710
720
730
740
750
760
770
780
2016-17 2017-18
755.89
731.65
Kg CO2/MT of Cement
Good
Green House Gases Mitigation
Year
Scope 1 emissions Scope 2 emissions Scope 3 emissions Total
Kg CO2/MT Cement Kg CO2/MT Cement Kg CO2/MT Cement Kg CO2/MT Cement
2016-17 687.36 67.75 0.78 755.89
2017-18 665.73 65.19 0.73 731.65
Scope-1 Cement Process-Calcination , Fuel burning in Kiln and HAG
Scope-2 Electricity Consumption form Grid
Scope-3 Raw Material Transport
PAT CYCLE-2 status
GTG SEC- (MTOE/Ton of Eq.Cement) 0.1059
0.1025
0.1007
0.0995
0.1005
0.096
0.098
0.1
0.102
0.104
0.106
0.108
Base Line 2014-15 2015-16 2016-17 2017-18 Target PAT Cycle-2
S.No Project Description Investment Rs.Lakhs
1 Installation of 7 MW Waste Heat recovery System 7000
2 Installation of 10Mwp Solar Power Plant (Phase-2) 3700
3 Improving the TSR 1% to 3 % by installing the AFR System 150
4 Installation of Pfister pumps for pulverized coal pumping system 400
5 Optimize the pressure drop across preheater from cyclone 4 to cyclone 2 80
6 Installation of High efficiency impeller for Cement mill fan 35.20
7 Installation of High efficiency impeller for Raw Mill Bag House fan 33.74
8 Replacement of all conventional lights with LED lights 42.25
Road Map for Achieving the Energy Targets
0
2000
4000
6000
8000
10000
12000
14000
16000
18000
20000
2014-15 2015-16 2016-17 2017-18
15000
18898
11639
9098
Saplings
Green Belt Development
Survival Rate:89%
Area Covered:175 Acres (44%)
Water Conservation Methods
Mines Pit
STP -300 KL
Rain Water Harvesting Pits
(12 No's)
Capacity-1.36 Lakh m3
Online AAQS
Water Sprinkling at Mines Roads Vanam Manam Program Plantation on 44th World Environment Day
Environmental Activities
Employees involvement & Awareness on Energy Conservation
Water & Energy Conservation Pledge on Every Saturday Energy Cell Meeting
Training Programs on Energy Conservation for Employees & Employee’s spouse
Employees involvement & Awareness on Energy Conservation
Awareness Program for Promotion of Blended Cements for reduction of Green House Gases
for Cement dealers, Marketing & Sales department
National Energy Conservation Day-2017 Celebrations
44th World Environment Day-2017 Celebrations
Employees involvement & Awareness on Energy Conservation
INDIA’ S MOST PROMISING BRAND 2015 AWARD
By World Consulting & Research Corporation, LONDON
Awards & Accolades
Awards & Accolades
SEEM National Energy Management Award-2016 SEEM National Energy Management Award-2017
APEX India Excellence Award-2017
QCFI Best Energy Practices Award-2016
CII-National Energy Management Award-2018
