Acc Ltd Laheri Cement Works

7/28/2019 Acc Ltd Laheri Cement Works

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ACC Lakheri Cement Works Strength Performance Passion 22nd 23rd Aug 2012

National Award for Excellence inEnergy Management 2012by CII Sohrabji Godrej Green Business Centre

ACC Ltd - Lakheri

Distt Bundi (Rajasthan)

ACC Lakheri Cement Works

Lakheri, Bundi, Rajasthan


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ACC Lakheri Cement Works 22nd 23rd Aug 2012Strength Performance Passion

Company Profile and Plant History

Process & Business Growth

Energy Conservation Activities

Reduction on Specific energy figures

Global Bench Mark Specific energy

Innovative projects Environmental projects

Involvement of Employees

Team work in ENCON

Monitoring, Reporting and implementation methodologies

Renewable Energy Sources, Utilization of waste

Agenda


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Name of plant : Lakheri Cement Works Year of establishment : 1905

I up-gradation, 1997 : Wet to Dry process 0.48 MTPA

II up-gradation, 2007 : addn 1 PH with calciner string

Present capacity : 1.5 MTPA

Process : Dry

No of Kilns : One (1)

Types of cement produced : PPC and OPC

Captive Power Plant (CPP) : 25 MW

Major suppliers of plant & machinery: Alstom, Pfeiffer, Siemens, ABB,SKF, FLSmidth, BHEL, ELGI, Elecon, MICO, GE, etc.

Company Profile


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Plant History

Plant History 1905 : Foundation of Lakheri started with four cylindrical, pillbox-shaped vertical

Kilns to produce hydraulic lime

1917 : Installation of Indias first cement plant at barren foot hills of Arawali mountaininstalled capacity of 0.32 mtpa using wet process of manufacturing from 3 nos. of kilns.

1997 : Modernization and Expansion by replacing wet process kilns with a single dry process

kiln of capacity 1200 TPD and raising its cement manufacturing capacity to 0.60 MTPA.

2000 : By adopting Kaizens as a way of life, Total productive maintenance (TPM) philosophy,employees innovations and dedications, The plant could achieve production to a level of 0.7mtpa from the same establishment.

2007 : The capacity of the plant is raised by more than two folds to a level of 1.5 mtpa byadding second string of pre-heater with calciner to the existing kiln with replacement of gratecooler and addition of new close circuit cement grinding system.

2007 : Installation of 25 MW capacity Thermal power plant. The manufacturing process issupported by an economical and reliable captive thermal power source.

2009 : Conceived Shikhar Project, In plant R & D with TSS support in Kiln Calciner StringPre heater and cooler modification. Usage of AFR. Transformation of Lakheri.

2011 : No 1 performer in all ACC plants. Winner of National Level energy conservationaward, Green Tech Environment Excellence award and Golden Peacock Environment

Management award. IMEA Award, Green Manufacturing Excellence Award.


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Process Flow

Clinkerproduction

Raw materialpreparation

Raw mealpreparation

Cementgrinding

Shipping

station Shippingstation

Raw materialextraction


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Business Growth

0

200000

400000

600000

800000

1000000

1200000

1400000

1600000

1995-96 1998-99 2002-03 2005 2007 2008 2011

Clinker Total Cement PPC

First Up

gradation

Wet to dry

Second Up gradation

1600 TPD to 3200 TPD


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Energy Policy

Energy Policy

We, at Lakheri Cement works are committed to formulate and implement Total

Energy Management System and in the process continuously strive to improve

the energy performance in all its activities through

Reduction in energy consumption by continuously improving the manufacturing

process, without impairing productivity.

Minimizing the waste and utilize the same for value addition.

To adopt energy efficient technologies and optimize utilization of fuels and otherresources.

To increase the use of renewable sources of fuel and energy and optimization of raw

material by the use of alternative material.

Creating awareness among employees through various forums, upgrade their skills toconserve energy and natural resources, to achieve above goals.

Date: 01.07.2009 (Director Plant)

Place: Lakheri Lakheri Cement Works


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Energy Conservation Cell atcorporate level which act as

facilitator

Energy Communities like

Electrical ,Thermal, Clinkerfactor, MTBF are formed at to

enhance energy efficiency of

all ACC plants.

An Energy Performance Cel l

( Lakhelavya) is formed at

plant level with Energy

Manager as coordinator and

participation of various HODsfor implementation of

identified projects


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Brainstorming for energy conservation conducted every year.

Small group and Energy Circle teams are formed comprising of

workmen and middle management staff which work towards focused

improvements for enhancing the productivity and energy conservation.

The meeting for Energy consumption and analysis is carried out on daily

basis

Variance of energy consumption review weakly dash board meeting for

each module

An unique initiative ofEnergy Observation Tour ( EOT) on daily basis

by staff employees to observe and stop any energy wastages in the plant.

Implementation of ISO : 50001 ( Energy Management System)



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Onl inepower consumption is monitored on daily basis and the analysisof the deviations is discussed in the daily production meeting which isheaded by DGM (Prod) and weekly chaired by Sr GM/ Directo r Plant.

Internal and external training programme conducted for staff as well as

shop floor level. Internal and External energy audits by TERI, CII, Orchid,

Cholamandalam and Techport.

The specific power consumption for all the sections vis-a-vis their

respective targets and the deviations are analyzed and correctiveactions are implemented.

Energy awareness prorgramme like poster, painting, quiz, slogan,nukkad conducted at nearby school and plant level.

Employees are awarded for best innovative projects at plant level, R.Olevel and H.O level

Best Kaizen and best suggestion from SHIKHAR suggestion boxscheme are awarded every month.



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Chairperson

Respective HOD

AE E&I Shift I/C

W/S

Shift I/C

Mines

Shift I/C

Crusher

Shift I/C

Kiln

Shift I/C

CM

S

H

OP

F

L

O

O

R

T

E

A

M

Shift I/C

PP

Shift I/C

VRM

Energy Conservation Cell


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Energy Reporting Format


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Energy Reporting Format


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Energy Review Format


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Daily Production meeting formatEnergy Review Format


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Weekly Dash Board Review Format


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Group Discussion of Energy Circles Nukkad by plant Employee on ENCON

Daily Energy Talk during dash board Training program for employees

Awareness Creation on Energy Conservation


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Specific Energy Consumption

93.81

91.19

84.59

82.27

79.979

70

75

80

85

90

95

2008 2009 2010 2011 2012

YTD

Target

2012

Specific Electrical Energy (Unit/ Ton Cement)


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Specific Energy Consumption

723721

713

717

709 709

700

705

710

715

720

725

2008 2009 2010 2011 2012 YTD Target

2012

Specific Therm al Energy ( Kcal/ Kg Clinker)


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Specific Energy Reduction

1.80 1.781.46

1.30 1.18

0.00

0.50

1.00

1.50

2.00

kWh/ ton

Mat.

2008 2009 2010 2011 2012

YTD

Sp energy Section wise, RMP


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18.92 17.2515.31 14.27

14.02

0.00

3.00

6.00

9.00

12.00

15.00

18.00

21.00

kWh/ ton

Mat.

2008 2009 2010 2011 2012

YTD

Sp energy Section wise,RML


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36.61 37.32 37.2636.04

34.00

30.00

32.00

34.00

36.00

38.00

kWh/ ton

Mat.

2008 2009 2010 2011 2012

YTD

Sp energy Section wise, Clinkering


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38.72 37.8337.93

37.15 36.77

30.00

32.00

34.00

36.00

38.0040.00

kWh/ ton

Mat.

2008 2009 2010 2011 2012

YTD

Sp energy Section wise, Grinding


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Weekly Dash Board Review Format

6765

79.9

0

20

40

60

80

kWh/ ton

Cement

National

Bench Mark

International

Bench Mark

Lakheri Cement

667 660709

0

100

200

300

400

500

600

700

800

kcal/ kg

Clinker

National

Bench Mark

International

Bench Mark

Lakheri

Cement

National & International Benchmark

Comparison of

Specific

Electrical Energy

Comparison of

Specific Thermal

Energy

Ref: Report of the Working Group on Cement Industry for XIIth 5 year Plan 2012-2017 - Department ofIndian Policy & Promotion, Ministry of Commerce & Industry. December 2011


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PAT Obligation ( Gate to Gate )

936.85 938.23854.54 834.93

793.3

970 940

0

200

400

600

800

1000

1200

2008 2009 2010 2011 2012

YTD

Base line

data

Target in

2014-15

Kc

al/KgofCem

en


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0.00

2000.00

4000.00

6000.00

8000.00

10000.00

12000.00

14000.00

2008 2009 2010 2011 2012 YTD

Wind Power Generation, Mwh

Green Energy

7.5 MW Captive Wind Plant at Jodhpur


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Energy Conservation Projects ( Summary for last 3 years)

Excellence in Energy ManagementExcellence in Energy Management

No investment

No of project implemented : 17

Equivalent Kwh : 4.15 Million Kwh

Total Energy Saving : 3569 Million Kcal

Medium Investment

No of project implemented : 32

Equivalent Kwh : 27.077 Million Kwh

Total Energy Saving : 23286 Million Kcal

Net CO2 reduction : 25452 Ts Co2

(Grid Emission factor

0.94 Tco2/MWh)


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Title of the Projects ImplementedAnnual Saving

( Rs Million)

Investment

Rs. Million

Modification in new P.H. lower(C-7)

cyclone inlet ,top cyclone(C-1) inlet & dip

tube height and Cooler IKN Horse shoe

modification)

6.0 3.0

Replacement of low efficiency pumps with

a single high efficiency pump

0.39 0.788

Installation of VFD for DC Fan in VRM,

Packer 4, Primary Crusher0.84 1.05

Install Multi step capacity controller on

selected compressors to optimize

operating pressure

2.03 1.44

Installation VFD drive for cooler fan no3,

fan no -04

0.95 0.7

Energy Conservation Projects in year 2009


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Title of the Projects ImplementedAnnualSaving

( Rs Million)

InvestmentRs. Million

Operate 132 kW compressor and stop 160

kW compressor top reduce operatingload/unload power

0.25 nil

Reduce operating pressure range for

compressors (N0.332CP04,332CP03,442

CP 01)

0.32 nil

Rectify unloading system to reduce unload

power for 160 kW screw compressor no.332

CP O4

0.63 nil

Modify piping and operate coal conveying

compressors at low pressure0.32 0.03

Dilution Air Fan operation, optimization in

compound mode (New VRM running) 0.56 NIL



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( Rs Million)


CFL for colony residence lighting (1500 nos) 0.40 0.135

Mill out put and Sp power optimizationthrough (1) Process optimization (increasing

grinding press) (2) size of mill feed L/S (3)

Usage of Marvel slurry 4) Mill fan inlet

damper removal

8.56 nil

Idle running of dust separation group to be

avoided by interlocking with wobbler group0.14 nil

Energy Saving by reducing damper settingof Clinker silo bag filter fan Drive no.521FN01

0.24 nil

Installation of GRR in E-mill Fan 1.58 0.6



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Title of the Projects Implemented Annual Saving( Rs Million)


Area increased by Removing inlet silencer of

cooler fan ( High pressure drop in cooler

fan3,5 & 8)* Saving=0.25unit/mmWg*3

0.22 nominal

PID control of cooler fan operation 0.92 nil

Reduction of cement-06 mill power by

Optimization of output by chemical dosing2.59 nominal

Power saving by using 556CP01/CP02 air to

old cement mill by providing separate CM-

06 GGLS compressor and stopping one old

cement mill compressor.

0.81 nominal

TOTAL 27.75 7.74



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Major Energy Conservation Projects in year 2010


(Rs. Million)

Investment

(Rs. Million)

Modification in Fan inlet box in order

to minimize the velocity differencebetween duct and fan I/L

0.42 0.03

Replacement of VRM1 main motor

(1200 KW) with 1000 KW motor

(Spare motor)

0.67 Nil

Installation of VFD drive forcooler fan no3

1.346 0.65

Installation of VFD drive for cooler

fan no 041.098 0.7


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(Rs. Million)

Investment

(Rs. Million)

Installation of VFD drive for cooler fan

no -06 1.098 0.8

Installation of VFD for PD Blower of

new high momentum burner0.336 0.75

Installation of GRR for E-mill vent fan 0.623 0.5

E-mill fan casing modification as pernew impeller

2.079 0.65


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(Rs. Million)

Investment

(Rs. Million)

Installation of VFD for cement mill

separator fan 0.123 0.18

Installation of High capacity PD blower

in place of two PD blowers0.673 Nil

Installation of chemical mixing pump to

increase the output of CM6 to 160 TPH

from 154, hence reduce sp. power

consumption

6.57 0.5

Modify piping for low pressure

compressor to reduce pressure drop

and operate compressors at lower

pressure

0.33 0.2


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(Rs. Million)

Investment

(Rs. Million)

Modification of cyclone for

improvement of collection efficiencyand thermal efficiency

72.0 3.0

Replacing kiln inlet seal with the

iteca seal to improve thermal as well

as electrical efficiency

2.0 1.5

Installation of high momentum

burner

2.64 6.0

Total 92.00 14.668



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(Rs. Million)

Investment

(Rs. Million)

Replacement of E.E. Impeller for

cooler Fan No. 4 0.560 0.2

Replacement of E.E. Impeller for

cooler Fan No. 100.120 0.2

Connection of 930 KVAR capacitors

with VRM-2 Main Drive0.30 Nil

Attending false air in graces in TAduct. 3.12 1.2


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Title of the Projects Implemented

Annual

Saving

(Rs. Million)

Investment

(Rs. Million)

Attending to cooler old panel, plategaps, side casting gap and under

grates.

1.81 1.0

Replacing the Conventional chokes

with Electronic Chokes for 30 No'sTube light Fittings.

0.08 0.07

Reduce pressure drop in down comer

duct Preheater

1.19 1.0

1000W halogen replaced with 400W

MH0.41 0.10


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(Rs. Million)

Investment

(Rs. Million)

Installation of VFD for PD blower

no.351PD03 1.01 0.5

optimization of compressed air

system1.05 Nil

Attending false air in graces in TA

duct.3.12 1.2

Regarding of grinding media in

second chamber of close circuitcement mill

5.17 4.5


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(Rs. Million)

Investment

(Rs. Million)

Attended Calciner tertiary air bend - for

flap control open , false air (3%) -Pressure Loss 30-40 mmwg

0.06 0.05

In colony ordinary 100/60w bulb

replaced with CFL1.34 0.05

Improvement in efficiency of VRM2 1.45 4.0

Total 20.79 14.07


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Implemented Projects 2012

Energy saving project :Installation of 18 kw screw compressor in place of 35 kw compressor for

old coal mill bag house and fuel transportation.

Cost benefit analysis:Cost of new compressor = Nil

( used spare in Kiln section)Saving in Power =12 kwh

Run hrs. Per day = hrs. 20

Annual savings in Kwh = 79200

Annual cost savings = 3.56

Lakhs (@ unit cost of Rs.4.50/-)

Simple Pay back period =

Immediate


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Energy saving project :Stoppage of old cement mill compressor during OPC Grinding by

interconnecting with CM6 compressor no 556 CP01/02

Cost benefit analysis:Cost for interconnection = Nil

Saving in Power =20 kwhRun hrs. Per day = hrs. 24


Annual cost savings =

3.24Lakhs (@ unit cost ofRs.4.50/-)

Simple Pay back period =

Immediate



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Energy saving project :Removing the dampers of cooler fan no 3,4,5 and 8 having VFDs to avoid

loss of power through dampers.

Cost benefit analysis:Cost for removing dampers = Nil

Saving in Power = 6.8 kwhRun hrs. Per day = hrs. 24


Annual cost savings = 2.42

Lakhs (@ unit cost of Rs.4.50/-)Simple Pay back period =

Immediate.



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Energy saving project :Installation of Energy Efficient Impeller for cooler fan no 4 ,6,9

and 10.

Cost benefit analysis:

Cost of replacement of impellers = 6.0 Lakhs

Saving in Power =13 kwhRun hrs. Per day = hrs. 24

Annual savings in Kwh = 1.03

Annual cost savings =4.63 Lakhs (@ unit cost of

Rs.4.50/-)

Simple Pay back period = 15 months


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Energy saving project :Installation of power factor improving capacitors in CPP and LC # 3.

Improvement in PF from 0.92 to 0.95

Cost benefit analysis:Cost for installation of APFC =

10 LakhsSaving in Power =15 kwh

Run hrs. Per day = hrs. 24


Annual cost savings = 5.34Lakhs (@ unit cost of Rs.4.50/-)

Simple Pay back period = 6

months



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Energy saving project :Modify piping and to run compressor at lower operating pressure for coal

transportation compressor.


Cost benefit analysis:Cost for Modifying pipe line = Nil

Saving in Power =5 kwh

Run hrs. Per day = 6

Annual savings in Kwh = 59400 kwh

Annual cost savings = 2.67 Lakhs (@ unit cost of Rs.4.50/-)Simple Pay back period = Immediate

Before After


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DescriptionInvestment

Rs Lakh

Unit/ton

cmt

Medium Voltage Drives (HT VFD) for

Calciner Fan - 1200 KW 75.0 1.25

Retrofit impeller of high efficiency (78-80%

at operating parameters) in VRM -1 Fan

for Power saving 20.0 1.48Medium Voltage Drives (HT VFD) for Coal

Mill Vent Fan - 650 KW 50.0 1.40

Installation of Capacitor Banks to improve

the Power factor and hence operatingefficiency of TG

15.0 0.35

TOTAL 160 4.48

Road map to achieve bench mark..

Electrical energy


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Rs Lakh

Unit/ton

cmt

Installation VFD with high efficiency

impeller Retrofitting in Cooler fan no 471

FN06, 471FN07, 471FN09 20.0 0.4

Installation of VFD for Compressors 15.0 0.15

Installation Heavy duty pressureregulating valve for all bag filters.

5.0 0.15

Compressed air management system 35.0 0.10

75.0 0.8

TOTAL235 5.28


Electrical energy


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Rs Lakh

Kcal/

kg clk

Modification of remaining Cyclone for

improvement of collection efficiency and

thermal efficiency 25 8

Utilisation of waste heat from Preheater &

cooler exhaust 3000

(1.5

MW)Installing rotoscale for Calciner coal

feeding system

150 2

TOTAL3175 10

Thermal energy



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Project Title: Optimization of cooler efficiency

Synopsis:

We have observed that clinker cooler and ESP exit temperature is inhigher side 170-180 C and 280-300 C respectively. This is resulting

a direct impact on thermal efficiency and cost of production.

After so many ideation sessions following has been done forimproving the cooler efficiency.

Innovative Projects - 1


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Modification in Cooler IKN

Blocking of two rows of IKN out of eight rows.

Sp. aeration distribution changed 02 rows for Fan No 01 and

04 rows for fan No 02, as against earlier 03 in Fan 01 and

05 in Fan 02. Reduced inlet width of IKN from more than 1200 mm to 1050

mm.

Last 5 rows of cooler grate plate pattern changed from one

moving one stationary to two moving one stationary .Horse shoe & sealing of gaps

Changed in pattern of IKN horse shoe, less width of fines side

and more width of coarse side (E mill), in original design it

was just reverse


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Innovative Projects -1

Reduction of cooler IKN area

Intercompartment sealing

Increasing the number of Static rows in Cooler

last compartment

Benefits: By this cooler modification there is a substantial reduction in clinkertemperature to 150-160 C from 170-180 C and ESP exit temperature decreased to 250-260

C from 280-300 C.

Saving: Finally it is impacted reduction in sp thermal energy by 8 MJ/ton Clinker.Annual saving Rs17.6 Lac.

Other Benefits: Conservation of natural resources by reducing coal consumption and

helps to mitigate CO2 emission


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Project Title: Increasing use of Alternative fuels

Synopsis:

Co-Processing refers to the use as alternative fuels and raw materials(AFR) or disposal of waste materials in industrial processes to recover

energy and material from them. Due to the high temperature (> 1200

degree C) and long residence time in cement kiln all types of wastes

can be effectively disposed without any harmful emissions.Co-processing leaves no residue as the incombustible, inorganic

content of the waste materials are incorporated in the clinker matrix.

Therefore, after the waste is co-processed, it becomes a part of the

product and no liability lies with the waste generators, whatsoever.Respecting the waste management hierarchy Co-processing of waste is

done only when the options of Reduce, Reuse and Recycling have been

addressed. Thus, Co processing ranks higher on the waste disposal

hierarchy and eliminates the need for landfills and incineration.


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Approach and Methodology:

After internal discussion & study of site, it was decided to make

feeding arrangement for Alternative fuels at kiln inlet.

After finalizing the drawings, Procurement of steel, double flap

damper & shut off slide gate had been done.

During plant major shut down, The AFR feeding system has been

installed.

Trials of the various Alternative fuels like Mustard Husk, Saw dust,

Soya Husk, Tire Chips etc. has been taken


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Results: After various trials, it has been found that there is noadverse effect on emissions or kiln operation due to co processing ofAFR materials into Kiln.

Cost benefits:

It has been evaluated that

Basis: Co processing of 100 T of Alternative Fuels

Quantity of AF = 100 T

Cost of AF (Biomass) = 2000 Rs/T

CV of AF = 3000 Kcal/Kg

TSR = 0.33%

Savings = 800 Rs/T

Other Benefit :

Conservation of Natural Resources.

Reduction in CO2 emission


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Project Title : Reduce specific thermal energy consumption bymixing of High VM biomass with low VM pet-coke.

Key Issues:

High cost of conventional fuel

Separate arrangement required for AFR feeding in kiln/calciner

Problem of AF handling

Inadequate availability of AF

Pet coke contains low VM - Difficult to burn

Need fine grindingHas to maintain excess Oxygen for proper burning

High ash of other fossil fuels


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At Lakheri 100% Petcoke is being used in kiln firing. As petcock

contains low VM hence some excess amount of oxygen required

for proper combustion. This excess air leads to reduce thermal

efficiency of the kin system.

Increasing cost of Petcock and conventional coal is also a factor

for considering Alternative Fuel (AF). But again the feeding of

alternative fuel in kiln requires lot of arrangement and modification

to be done. Due to improper availability of AF this capitalexpenditure looks some time unviable

Looking above Lakheri plant after many ideation sessions and

brain storming came with a unique solution to feed Saw dust in theKiln by blending with Petcock itself.



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The methodology used isUse of saw dust To increase VM of firing fuel

Lab scale trial of grinding of pet coke with saw dust

Check availability of saw dust in near by villages

Plant scale trial

Optimum storage of biomass

Optimization of burning operation

After many trials this feeding methodology found very successful

this has resulted reduction in preheater temperatures from 285 c to

274 c and there is considerable amount of power saving due to less

air require for kiln/calciner.

The Saw dust is being grind with petcock in the Ball Mill



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Analysis of Petcoke

Sample

Details

Proximate Analysis CV

cal/gm

(GOD)

% S% Moisture (As

recd.)% VM % Ash

Pet

coke5.2 9.1 0.6 8390 5.4

Analysis of Saw Dust

Sample

Details

Proximate Analysis

CV

cal/gm

(GOD)

% S%

Moisture(As recd.)

%VM % Ash %Fixed C

Saw Dust 17.364.9

0.5 17.3 4440 0.1



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Results :Reduction in %O2 at kiln inlet by 0.4%

(2.4 to 2.0%)

Reduction in %O2 at PH outlet 0.6%

(4.4 to 3.8%)

Increase in AFR TSR from 0.65% to 1.8%

, fuel replacement cost w.r.t Indian gradefuel = 800 Rs/ts (5.0 Lac)

Reduction in sp thermal energy

consumption from 2998 to 2965 ,

equivalent to 7.9 Kcal i.e. 94.6 Rs Lacby considering only 50% = 47.3 L

Total Benefit = Rs 52.3 L


723

721

713

717

709709

700

705

710

715

720

725

2008 2009 2010 2011 2012 YTD Target

2012

Specific Therm al Energ y ( Kcal/ Kg Clinker )


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RABH

ESP

Air Cooling Tower

Sewage Water Treatment

Environmental Projects

RABH Air cooled condenser


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Dust Suppression System Continuous Emission Monitoring System


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Continuous weather monitoring system Environment monitoring Van

Jatropha Plantation 7.5 MW Wind Power


Alternative fuels & Raw Materials


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Alternative fuels & Raw Materials

Marble Slurry Bio mass

Shredded TiresAFR feeding

Alternative Raw

materials

Marble Slurry

Lime Sludge

Coagulation Sludge

Alternative Fuels

Biomass - Mustard Husk,Saw Dust, Rice Husk, tree

pruning etc.

Shredded Tires Industrial Solid Waste

Expired Products

ETP Sludge

Expired ProductsJatropha Plantation


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Thank You

Documents

Acc Ltd Laheri Cement Works