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1 of 21
2nd ‘National Workshop cum Technology Exhibition for Promoting Energy Efficient
and Cleaner Production for Sustainable Industrial Growth’
Mr. Sukhwinder Singh(Sr.Eng, Inst.)
Mr. Manish Vijay (Dy. Manager, Pro.)
Mr. Devraj Sharma (Asst.Manager, Mech.)
Mr. Manoj Ubana (Asst.Manager, ELe.)
Brief Introduction of JKLCL – Sirohi, Rajasthan
ISO 9001 ISO 14001 OHSAS 18001 ISO 50001 2
3
Sirohi Clinker Capacity 4.85 MnMT
TOWARDS UPGRADATION
Capacity - 4.75 Mn MT
4
OPC 53 OPC 43 PPC
RMC AAC BLOCK POP
PRODUCTS PRO+
4
SMALL GROUP ACTIVITY (SGA) PROGRAM FOR CONTINUOUS IMPROVEMENT”
under KEP-SPARC Membership Model
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S.No. Group Name No. Of Members No. Of Implemented Projects-
1 Grind Boosters 04 05
2 Lakshya 05 07
3 S.P.A.R.K ian 06 04
4 Urja Sarnkashak Boosters 07 05
5 JEET 07 04
6 Search 04 02
7 Warriors 06 06
Total 39 33
Benefits S.No. Particulars Units Year Wise
1. Total Energy Saving Achieved
a) Thermal Saving Mt of Pet-coke 205
b) Electrical Saving Million KWH 3.61 ( 498 Unit/Hr)
2. Monetary Gain Million INR 18
3. Investment
Million INR 3.5
6
Project1: Reduction in Specific Power of VRM
Observation:
• Pressure Drop across Mill was 892 mmwg.
• Pressure Drop across Nozzle Ring 677 mmwg.
• Pressure Drop across Classifier 215 mmwg.
7
Background: Specific Power Consumption of VRM was 14.2 Kwh/Mt.
Project1: Reduction in Specific Power of VRM
Benefits:
1. Pressure Drop across mill has been reduced by 62 mmwg.
2. Mill fan power has been reduced by 158 Kw.
3. Mill specific Power has been reduced by 0.54 Unit/Mt.
4. Mill reject elevator power has been reduced by 50%.
8
Project Implementation: Installation of Aerofoil Design Louver Ring and Armour Ring.
9
Project 2: Reduction in Specific Heat Consumption of Kiln
Observation:
Studied of coal to air velocity.
Velocity of Conveying Air.
9
Background: Electrical and Thermal Energy Saving by Optmization of Coal Conveying Volume
Project 2: Reduction in Specific Heat Consumption of Kiln
Benefits:
1.Coal Conveying Volume reduced by 12%.
2. Coal Conveying Blower Power has been reduced by 19 kW.
3. Heat Consumption has been reduced by 1 Kcal/Kg.clk.
10
Project Implementation: Installation of VFD in Blower Increased the coal to air ratio by optimizing the speed of Blower .
Project 3: Reduction in Power Consumption of Compressors
Background:
Compressed air distribution system is a major potential area in any Cement plant to reduced the power consumption
11
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S/N Compressor Tag no. Air requirement Loading % Unloading % Motor Rated KW Measured KW by
Analyzer
KILN-1 COMPRESSORS
1 4CP3 (1600 m3/hr.) Pre heater Blaster 65% 35% 150 KW 73
2 5CP3 (500 m3/hr.) Cooler Blaster 58% 42% 55 KW 40
3 5FCP (300 m3/hr.) LAB 31% 69% 37 KW 9
4 4CP4 (150 m3/hr.) Girth Gear 48% 52% 15 KW 10
KILN-2 COMPRESSORS
1 6415 (1800 m3/hr) Pre heater Blaster 62% 38% 180 KW 103
2 4125 (600 m3/hr) Kiln inlet seal 42% 58% 75 KW 39
TCDRI MILL COMPRESSORS
1 361 CP1 Bag House (1800 m3/hr) 17% 83% 160 53
2 36CP3 Raw Mill Bag House
(600 m3/hr.) 0 0 75 0
Observation:
Project 3: Reduction in Power Consumption of Compressors
Project 3: Reduction in Power Consumption of Compressors
13
S/N Compressor Tag
no. Air requirement
(Kiln-1) Loading % Unloading % Motor Rated KW
Measured KW by
Analyzer
KILN-1 COMPRESSORS
1 4CP3 Pre heater Blaster 82% 18% 150 KW 97.51
2 5CP3 Cooler Blaster 0% 0% 55 KW 0
3 5FCP LAB 0% 0% 37 KW 0
4 4CP4 Girth Gear 0% 0% 15 KW 0
KILN-2 COMPRESORS
1 6415 Pre heater Blaster 74% 26% 180 KW 120
2 4125 Kiln inlet seal 0% 0% 75 KW 0
TCDRI MILL COMPRESSORS
1 360CP1 Bag House 0 0 160 0
2 36CP3 Raw Mill Bag House 39 61 75 24
Implementation:
14
Compressor-4
Compressor-1
Compressor-3 Compressor-2
Project Implementation:
1. Interconnection of the Kiln-1 Pre Heater blaster compressors air line with the air line of 3 other compressors.
2. Interconnection of the Kiln-2 Pre Heater blaster compressor air line with air line of inlet seal compressor.
3. Interconnection of the Raw Mill-4 Bag house–compressors air line with air line of Hybrid Bag house Compressor.
Benefits:
1. Power saving achieved in Kiln-1= 34 kW
2. Power saving achieved in Kin-2= 22 kW
3. Power Saving achieved in Raw Mill-4= 29 kW
Total Saving= 85 kW
Project 3: Reduction in Power Consumption of Compressors
15
Project 4: Reduction in power consumption of blaster compressor through optimizing operating Frequency and Unloading Pressure
Background:
The most expensive component in the total cost of compressor air is energy. In efforts
to explore the energy saving opportunity in Blaster compressor of PH-1 and PH-2, an
innovative idea came into mind that we can reduced power consumption of blaster
compressors through optimization of blaster operating frequency and compressor
unloading pressure.
16
Project 4: Reduction in power consumption of blaster compressor through optimizing operating Frequency and Unloading Pressure
Kiln-2 Observations: S.NO. CYCLONE NOS OF
BLASTER
EXISTING OPERATING
FREQ / HR
MODIFIED OPERATING
FREQ / HR
REDUCTION IN
FREQ / HR
1 New Cyclone-2 04 16.5 16.5 NONE
2 New Cyclone-3 05 75 60 15
3 Old Cyclone-3 04 110 40 70
4 New Cyclone-4 05 140 140 NONE
5 Old Cyclone-4 05 72 50 22
6 New Cyclone-5 04 40 40 NONE
7 Old Cyclone-5 03 42 30 12
8 New Cyclone-6 06 60 60 NONE
9 Old Cyclone-6 03 42 30 12
10 Riser Duct 19 68 29 39
11 PC Drop out 07 22.5 22.5 NONE
12 Swan Duct 05 18 10 8
13 PH fan inlet 01 60 12 48
Total 71 766 540 226
17
Project 4: Reduction in power consumption of blaster compressor through optimizing operating Frequency and Unloading Pressure
Kiln-3 Observations: S.NO. CYCLONE NOS OF
BLASTER
EXISTING OPERATING
FREQ / HR
MODIFIED OPERATING
FREQ / HR
REDUCTION IN
FREQ / HR
1 New Cyclone-2 04 15 15 NONE
2 New Cyclone-3 04 40 40 NONE
3 Old Cyclone-3 04 40 40 NONE
4 New Cyclone-4 07 381 140 241
5 Old Cyclone-4 04 80 40 40
6 New Cyclone-5 05 50 50 NONE
7 Old Cyclone-5 02 20 20 NONE
8 New Cyclone-6 10 150 150 NONE
9 Old Cyclone-6 09 81 81 NONE
10 Riser Duct 23 79 79 NONE
11 PC Drop out 07 76 12 64
12 Swan Duct 04 8 8 NONE
13 PH fan inlet 01 12 12 NONE
Total 84 1032 687 345
18
Project Implementation: • Optimization Of Blaster Operating Frequency. • Optimization of Compressor Unloading Pressure from 7kg/cm2 to
6.5 kg/cm2.
Benefits: • Power saving in KILN-2 Blaster compressor 25 Kw. • Power saving in KILN-3 Blaster compressor 30 kw.
Project 4: Reduction in power consumption of blaster compressor through optimizing operating Frequency and Unloading Pressure
19
Project 5: Reduction in Power Consumption of Air Conditioner
Background: Air Conditioner is one of the largest energy consumer in industrial sector. By anticipation the scope of power saving in Air Conditioner , we carried out a study on CCR building centralized Air Conditioner
Observation: Day hours (7.00 AM to 8 .00 PM) power consumption was 1400 kWh Night hours (8.00 PM to 7 .00 AM) power consumption was 1200 kWh
20
CCR Centralized Air Conditioner Flow Diagram of First Floor
AC Comp. 37 KW
AHU Ground Floor 11KW
Chemical LAB ground Floor
Inst LAB
Drawing Office 1 st. Floor
ground floor LAB
SR. GM (Mech.) Off. Area
1 st. Floor
Inst LM Room + SR. GM ( Elect.)
AC Duct
Timer Panel
VFD
Project 5: Reduction in Power Consumption of Air Conditioner
21
Project Implementation: • Installation of Damper in AC Duct • Control of damper through Timer circuit • Installation of VFD in AHU
Benefits: Power saving =26 kW
Project 5: Reduction in Power Consumption of Air Conditioner
22
Total SGA Group Formed
Total Members in 7 Groups
Total Projects Identified
Project Implemented
Electrical Energy Saving Target
Electrical Energy Saving Achieved
Thermal Energy saving Target
Thermal Energy Saving Achieved
Investment Made (in INR)
Monetary Gain per Annum (in INR)
7 39 40 33 617 kW 498 kW (81 % of Target)
1 kCal/kg of Clinker
1 kCal/kg of Clinker (100 % of
Target)
35 Lacs 180 Lacs
Small Group Activities Outcome……
Intangible Benefits:- Increased interpersonal relations between CFT Confidence enhancement Increased motivation of teams Increased team working
This is not end of the journey, This is the beginning of new model