39

Second Prize

Cement (Clinker & Grinding Unit)

THE KCP LIMITED, UNIT-II

Krishna Distt. (Andhra Pradesh)

Unit Profile

The KCP Limited, one of the country's oldest cement producers, has a strong

presence in the south India market. KCP strategically chose this Greenfield plant

located at Ramakrishnapuram, Muktyala Village, Jaggayyapet Mandal in Krishna

District of Andhra Pradesh because of it's close to large limestone reserves and

providing easy access to the key markets of Andhra Pradesh, Tamil Nadu, Karnataka

and Orissa. KHD Humboldt, Germany designed an energy-efficient plant that could

deliver an annual capacity of 1.32 million tonnes of Clinker and 1.52 million tonnes

of Cement.

MAJOR EQUIPMENT INSTALLED

• Hazemag Limestone Crusher: Capacity 850 TPH

• Takraf Stacker & Reclaimer: Capacity 850 TPH

• MPS 4500B Gebr Pfeiffer, Germany Raw Mill: Capacity 350 TPH

• CF blending silo 20m diameter x 45m high: Capacity: 15000 MT

• MPS 2800BK Gebr Pfeiffer, Germany Coal Mill: Capacity 40 TPH

KHD Humboldt, Germany

• ILC 6 Stage Pre-Heater with Pre-Calciner

• 3-support rotary kiln 4.20 m diameter x 64 m long

40

Specific Power Consumption

Specific Thermal Energy Consumption:

ENERGY CONSERVATION MEASURES TAKEN 2013-2014

1) Replacement of Coal crusher RP Feeder with Belt conveyor.

2) Reduction of Pyro & Cement Mill Water Pump capacity (By Installation of Cooling

Tower & Softner) from 75 kW to 22 kW.

3) Coal Crusher By Pass

4) Cement Mill Production Enhancement

5) Modification of Cooler Static Grate inlet by Horse Shoe shape Refractory (To

control the clinker flow in centre and for better Heat Recuperation, which in turn

increased both tertiary and secondary air temperatures)

6) Reduction of capacity of Water Pump for filling of Kiln and Cement mill over

head tanks for Process Requirement from 75 kW to 22 kW

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7) Packer-2 Bag Filter Vent line Modification. Before 2 nos. bag filter fans of 55 kW

and 37 kW operated. After Inter connected both bag filter and operating only

55 kW fan during packer operation.

8) Reduction of Cement Mill Silo extraction Blower from 22 kW to 15 kW

9) Arrangement of Flaps in Place of RAL in Cement Mill Auxiliary Bag Filters.

10) Kiln Feed Bin Aeration Pipe Line Modification (Motor capacity reduced from

55 kW to 37 kW)

11) Optimizing Kiln and cooler by constructing wall at cooler null point.

12) Decreasing the capacity of Compressor in Packing Plant from 75 kW to 37 kW.

13) Optimization of grinding media.

14) Reducing Idle running of Equipments

15) Reducing number of Start/Stop during filling of Raw Material

16) Optimization of Compressed Air

17) Minimizing False Air & Compressed Air Leakages

18) Power Factor Optimization

19) Installation of VFD’s for Auxiliary Bag Filters.

20) Plant lighting Optimization.

A) MODIFICATION OF CALCINER BURNER

KCP INNOVATIVE PROJECTS

� Pre-mixture of fuel and

meal

� Faster ignition

� Avoid peak temp

inside the calciner

�Harmonized temp

across the calciner

� Lower NOx & CO

� No burner Cooling Air

� Specific heat reduced by

4 Kcal/Kg Clinker

� Increased the clinker

output by 100 TPD

� PH Fan power reduced

by 0.50 KWh/T

Coal

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B) ARRANGEMENT OF SPIRAL IN PRE-HEATER EXIT

KCP INNOVATIVE PROJECTS

Arrangement of Spiral� Reduced the dust Loss < 3.50%

� Reduced Specific Heat

Consumption by 5-6 Kcal/Kg

Clinker

C) EXTENTION OF COOLER STACK HEIGHT

KCP INNOVATIVE PROJECTS

Extension of Cooler Stack

height� Increased from 45 Mts to 65 Mts.

� Fan Speed reduced by 200 RPM

� Reduced Power by 32.5 KWh

� Low Fan Maintenance cost

� Reduced CO2 by 270 MT/ Annum

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D) COOLING TOWER FOR LUBRICATION UNIT AND BEARINGS COOLING

KCP INNOVATIVE PROJECTS

Cooling Tower for Lubrication

Unit & Bearings Cooling

� Efficiency of the heat

exchangers has increased

� Temperatures of the

Lubricant oils has come

down by 5-7 Deg C

� Scaling has come down

drastically

� Maintenance cost has come

down by 20%

� Power saving is achieved by

1,700 KW per day due to

reduction in water pumps

run hours

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Energy Policy

45

Second Prize

Cement (Clinker & Grinding Unit)

DIAMOND CEMENTS

PROP. HEIDELBERG CEMENT INDIA LIMITED

Damoh (Madhya Pradesh)

Unit Profile

The Unit is named as Heidelberg Cement India Ltd (HCIL), situated at Damoh in

Madhya Pradesh. Previously HCIL had two production line of Kiln: Line-1 & Line-2

with combined capacity of 1.5 MT clinker production. Line-1 was established in the

year 1983 and Line-2 in the year 1989. HCIL has further enhanced its production

capacity at Narsingarh, Damoh from 1.5 MT to 3.1 MT by initiating commercial

production of newly installed 5000 TPD state of art technology kiln (Line-3) in year

February, 2013.

Damoh unit exclusively a clinker producing plant which uses Indian coal and pet

coke as source of thermal energy for process and grid power is source energy to

cater to the power requirement of the clinker plant.

Energy Consumption

HCIL is committed to optimize the specific heat and power consumption by

implementation of modern technology and practices for reducing its usage of

Energy.

46

The specific energy consumption figures for FY 2012-2013 & 2013-2014 are shown

below.

Description 2012-13 2013-14

Specific Power Consumption (kWh/MT Clinker) 77.64 69.73

Specific Heat Consumption (kCal/kg Clinker) 853 805

Specific Power Consumption Trend

Specific Heat Consumption Trend

Energy Conservation Measures Taken

Below mentioned are the major initiatives which had been taken to achieve

reduction in energy consumption in all activities:

1. Installation and optimization of new production line of kiln of 5000 TPD capacity

having 5 stage, double string pre-heater state of art FLS Technology

2. Installation of water spray in pre-heater Twin Cyclone (Line-2)

3. Dust Settling Chamber Modification in Line-II

4. Speed reduction of calciner Firing Blower in Line-II in Narsingarh

5. Installation of LED light at plant street lights

6. Utilization of Sun light at workshop

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Environment and Safety

HCIL is concerned for clean & green environment and committed to eco-friendly

processing of Clinker manufacturing. HCIL has a well-established integrated Health

and Safety Policy to ensure the optimum safety of the employees, public, plant and

equipment, which are embedded in the core organizational values.

The Unit is complying with ISO 9001:2008, ISO 14001: 2004 and OHSAS 18001:

2007 by integrated management system.

ENERGY POLICY

48

Certificate of Merit

Cement (Clinker & Grinding Unit)

JAYPEE SIDHI CEMENT PLANT

Sidhi (Madhya Pradesh)

Unit Profile

Jaypee group is the 3rd largest cement producer in the country. The groups cement

facilities are located in almost all parts of India; however the first cement plant of

group was installed in Satna cluster (M.P.) which has one of the highest cement

production growth rates in India.

Jaypee Sidhi Cement Plant is one of the modern and energy efficient plant of the

group situated in Sidhi district of Madhya Pradesh, India. Presently, it has two

clinkerization units and its total annual capacity of clinker production is 3.0 MTPA.

The first unit was supplied by L&T (SLC KILN – 4200 TPD) and was successfully

commissioned in January 2009. The Second unit was supplied by FLSMIDTH (ILC

KILN – 4500 TPD) and was also successfully commissioned in January 2013.

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Energy Consumption

The specific power consumption figures for FY 2012-2013 & 2013 – 2014 are

shown below.

KPI FY 2012-2013 FY 2013-2014

Clinker Production 1404840 1753724

Sp. Power Cons./MT Clinker 69.72 65.91

Cement Production 1135755 1340907

Sp. Power Cons./ MT Cement grinding 39.35 38.57

Sp. Power Cons./ MT Cement 90.41 85.92

Energy Conservation Measures Taken

Below mentioned are the major initiatives which had been taken to achieve

reduction in energy consumption in all activities:

1. Modified Kiln String V down pipe i.e. connected directly to the smoke chamber

riser duct towards Kiln side avoiding 3 bends which improved Kiln throughput,

quality of clinker and reduction in power consumption.

2. Modified logic and Installed soft starter for reverse air fan, resulting in energy

saving

3. Replaced coal firing blowers from AMCL to Kay International and also reduced

speed of blower as per requirement. The initial motor kW was 200 kW whereas

present motor is 132 kW.

4. Cement mill transportation group interlocking changed to 20 Min instead of 30

Min.

5. Raw mill & coal mill feed belt magnetic separator was interlocked with the

running of belt resulting in power savings.

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6. Stacker belt take-up was modified for smooth operation & maintenance by

removing 5 no. pulleys also resulting in improved power consumption.

7. 391-AS4 air-slide inclination was increased from 6.5 to 9 degree to avoid

jamming resulting in reduced power consumption by stopping extra air-slide

blower.

8. Interlocking of bag filters with their respective groups.

9. De-energisation of 2 nos. distribution transformers.

10. 3 nos. L.T. motors connections were changed from DELTA To STAR.

11. Installation of 4500 kVAr capacitor bank in switch yard for improving power

factor.

Energy Policy

51

Certificate of Merit Cement (Grinding Unit)

ACC LIMITED, THONDEBHAVI CEMENT WORKS

Chikkaballapur (Karnataka)

Unit Profile

Thondebhavi Cement Works was set up as a Green Field Project in about 120 acres

of land, in the lush green village of Thondebhavi in Karnataka. This cement grinding

plant was commissioned in the month of December 2009; it is the most modern

plant with state of art technology with a capacity of 1.66 million tons of Pozzolona

Portland Cement.

Major raw material for the production of Pozzolona Portland Cement (PPC) is clinker

which is supplied from the ACC’s modern plant in Karnataka situated at Wadi in the

Gulbarga District. For the production of clinker Wadi cement works is burning

alternate fuels like Paint sludge, ETP sludge, waste chemicals etc. By using these

fuels ACC is saving natural fossil fuels like coal & there by reducing CO2 emissions.

This clinker is transported by rail, thus saving on logistics and associated CO2

emissions.

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Energy Consumption

With the implementation of various energy conservation measures as ongoing

practice, there is decline of specific energy consumption since the commissioning of

the plant, the specific energy consumption figures are shown below which depicts

reduction in energy consumption due to plant’s sustained efforts to conserve with

the implementation of various energy conservation measures and ideas to increase

efficiency of equipments.

Description FY 2012-2013 FY 2013-2014

Specific Electrical Energy Consumption

(kWh/T Cem) 34.35 29.89

Specific Thermal energy consumption (Million

kCal /Year) 60.08 0

Specific Electrical Energy Consumption - kWh/T Cement

34.35

29.89

25

30

35

2012-13 2013-14

Major Energy Conservation Measures taken in 2013-2014

Thondebhavi cement works has committed to protect environment by conserving

natural resources; some of the energy conservation activities undertaken by the

team are as given below:

1. Installation of VVVFD for Bag house fan in place of GRR – Achieved savings of

1.2 million kWh

2. Installation of VVVFD for Compressor – Achieved savings of 1.0 million kWh.

3. Installation of VVVFD for Bag filter fans (3 Nos.) – Achieved Savings of 0.1

million kWh

4. Up gradation of Clinker Weigh Feeder from 220 TPH to 300 TPH for improving

TPH in OPC – Achieved Savings of 1.5 million kWh

5. Elimination of Hot Air Generator operation – Achieved savings of 60.08 million

kCal/year & 1.3 million kWh

6. Compressor air optimization study by External Energy auditor – Achieved

savings of 0.3 million kWh

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7. Optimizing the clinker rake unloading time - Achieved savings of 0.08 Million

kWh

8. Modification of bag filter vent line to reduce pressure drop - Achieved savings of

0.05 million kWh

Major Environmental Measures taken in FY 2013-2014

Energy Policy – ISO 50001

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Certificate of Merit Cement (Grinding Unit)

THE RAMCO CEMENTS LIMITED

CEMENT GRINDING UNIT

Valapady (Tamil Nadu)

Unit Profile

Salem Grinding, unit of The Ramco Cements Limited, is set up at Singhipuram

village of Valapadi Taluk. Cement grinding capacity of the unit is 1.6 MTPA.

The grinding unit has the following salient features:

• High-efficiency separator to deliver proper size-distribution of cement.

• Computerized Central Control Room (CCR) to ensure quality assurance.

• Rotary Packers with high-accuracy for packing of cement.

Specific Energy Consumption Details

55

Energy conservation projects implemented in year 2013-14

• Upgraded capacity of plant from 80 TPH to 230 TPH by installing a pre-grinder.

This reduced the specific energy consumption of the total plant.

• Installed SPRS for Separator fan drive (HT) which is circulate the Recirculation

material in the cement mill product circuit.

• Replaced 50 nos. of existing 70 W MH well glass fittings with 42 W LED Well

Glass fittings.

• Replaced 15 nos. of existing 250 W MH street light fittings with 90 W LED Street

Light fittings.

• Converted some motors connection from delta to star connection in packing

plant. Now the packing specific energy reduced from 1.86 to 1.67 kWh per ton of

cement.

Quality, Environment & Safety Policy