Energy savings at DCL.pdf

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1

Dalmia Cement (Bharat) Limited, Kadapa

Founded in 1935 by Shri Jaidayal Dalmia. The Group established India’s first Cement Plant with 250

TPD in 1939. The Group interests includes Cement, Sugar, Power and

Refractory. Put up Cement Plants in Tamil Nadu and Andhra Pradesh.

Kadapa Unit Commissioned in Mar 2009 with a Capacity

of 2.5MTPA Cement. Overall Cement Manufacturing Capacity 17.9 MTPA.

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• OPC 53

• OPC 43

• SRPC

We Manufacture:

• PPC

ISO 9001:2008,ISO 14001:2004,OHSAS 18001:2007

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We are committed to produce cement of required Quality & Quantity, by Continuous Improvement on Energy Performances through effective implementation of Energy Management System, also by Effective utilization of available Energy resources by

Optimization and alternates. Enhancing the Energy efficiency, Reduction in Energy

Wastage Strive to be a bench marking organization in the Cement

Industry. Abide to all the applicable legal requirements and other

requirements M.C. Gautam Date : 10/07/2013 Executive Director

Plant Ordering Stage – Took Initiative for Energy Efficient Equipments

Plant Execution Stage – Considered Energy Saving Equipments

Commissioning Stage – Developed EMS Software in Plant Automation

Energy Saving by Efficient Eqpt. & Energy Savers: 85.5 Lakhs U/Annum

1st Year Operation Stage – Optimized Startup Time, Idle Run

Solar Heaters & Solar Lights at Mines

Energy Saving by Case Studies : 11.5 Lakhs Units/Annum

2nd Year Operation Stage – Improved the Equipt Perfor.

Energy Saving : 114.77 Lakhs Units/Annum

3rd Year Operation Stage – Improved

Energy Saving : 43.88 Lakhs Units/Annum

Current Plan & Actions

1. EnMS 50001

2. Enhancement of Alternative Fuel Feeding

3. Development of Renewable Power

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MV Drive for Pre Heater Fan & Bag House Fan

Damper less Process Fans with Variable Speed Drive

AC Variable Speed Drive for Coal Mill Main Drive

AC Variable Speed Drive for Kiln Main Drive

Cross Country Belt Conveyor for Lime Stone Transportation

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Expert Optimizer for Efficient Operation

Intelligent MCC for the Motors

Energy Efficiency Series Motors for the Complete Plant

P20 Lighting Energy Saver Panels

Energy Management System in DCS through Digital Meters

Particle Size Analyser

Cross Belt Analyser

Robo Lab

Lowest Pressure Drop for 6 Stage Pre Heater (460 to 480mmwg)

Lowest Specific Power Consumption of PH Fan (4.6 U/T of

Clinker)

Lowest False Air levels

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We do not use any natural mineral resources except Limestone AFR We use Red mud : As corrective in Raw mix Fly ash : As additive in PPC Material Petcoke & AF : As fuel Chemical Gypsum : As Additive in Cement Grinding

Unit Head

Technical Head

Unit Energy Task

Force Leader

Unit Energy Manager

Team Members (from)

Mechanical

Electrical

Process

Instrumentation

Utilities

(Engineers & Technician Categories)

Task Force Leader

Dalmia - Trichy

Task Force Leader

Dalmia - Ariyalur

Task Force Leader

OCL, Rajganpur

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Unit Without

Investment With

Investment

Total No. of Projects No. 35 26

Electrical Energy Saving / Annum

Million Units

6.2 6.84

Fuel Energy Saving / Annum

Million Kcal

6200 100

Cost Saving / Annum Rs.

Million 31.2 33.74

No Investment

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No Investment

Sl. No.

Energy Saving Projects

Annual Electricity

Saving Achieved

Units in Million

Rs. In Million

1 Daily Monitoring and control of Section Wise Idle Power Consumption through DCS

0.35 1.75

2 Cement Mill Transport group stopped during the Mill Heat up.

0.06 0.3

3 Reduction of Cement Heat up Idling time duration from 2 Hours to 45 Minutes

0.84 4.2

No Investment

Sl. No.


Annual Electricity

Saving Achieved Units in Million

Rs. In Million

4 Relocation of VFD for Compressor from Pyro to Cement Mill and avoided the unloading operation of the Compressor

0.16 0.81

5 Increased the Electrical System Power Factor from 0.97 to 0.98 by Auto Operation of HT Bus Capacitors

0.14 0.72

6 Kiln Shell Cooling Fans Operation with Temperature Interlock

0.18 0.9

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No Investment

Sl. No.


Annual Electricity


Rs. In Million

7

Coal Mill Hydraulic Pump Operation interlocked with Oil Temperature after Mill Stoppage and reduced the Idle Running.

0.01 0.015

8 Star Connection for Shell Cooling Fans 0.07 0.36

9 GRR Cooling Fan Stop Interlock at 100% Speed & SPRS Mode

0.38 1.90

No Investment

Sl. No.


Annual Electricity

Saving Achieved

Units in Million

Rs. In Million

10 Reduction of Raw Mill Power Consumption by Dam Ring & Nozzle Ring Modification

1.46 7.31

11 Modification in LS Crusher Wobbler Ribs to reduce the gap and achieved Reduction in Lime Stone Size

1.13 5.63

12 Reduction of Idle Power in RMH Section by No Material Sensors

0.16 0.80

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No Investment

Sl. No.


Annual Electricity

Saving Achieved

Units in Million

Rs. In Million

13 Reduction of Bore well Power by using STP Water for Cement Mill

0.06 0.30

14 Bag House in DP Mode and Reduction of BH Fan & RA Fan Power

0.50 2.52

15 Intermittent Timing Operation for LS Crusher Spillage Conveyor

0.02 0.12

No Investment

Sl. No.


Annual Electricity


Rs. In Million

16

Packing Plant Dust Collector Fans Speed Interlocked with Packer Main Drive. (Reducing Speed to 20% when Packer Stops)

0.11 0.56

17 Conducted Compressor Leak Test & Reducing the Leak of Compressed Air.

0.01 0.05

18 Auto Start Stop Time Interlock for Office Area Centralised AC

0.15 0.73

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No Investment

Sl. No.


Annual Electricity


Rs. In Million

19 Switching Off the Distribution Transformers & Drive Transformers during Plant Shutdown

0.03 0.17

20 Time Delay Interlock for RABH Rotary Air Locks

0.01 0.06

21 Operating of Plant Lighting according to the Seasonal Variations

0.01 0.07

No Investment

Sl. No.


Annual Electricity


Rs. In Million

22 Auto Stop Interlock for Circular Stacker Slew with respect to the Material Flow

0.01 0.05

23 Auto Stop Interlock for Coal Stacker & Additive Stacker Travel with respect to the Material Flow

0.01 0.07

24 Automatic Speed Reduction of Blending Silo Top Bag Filter with respect to the Raw Mill Operation

0.01 0.06

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No Investment

Sl. No.


Annual Electricity

Saving Achieved

Units in Million

Rs. In Million

25 Operating the Raw Mill Hopper Bag Filter Fan with respect to material property

0.13 0.69

26 Auto Start Stop Interlock for Water Fountain Pumps with Office Timing

0.005 0.025

27 Optimized the Wagon Loading Time duration from 15Hrs. to 8 Hrs.

0.01 0.06

No Investment

Sl. No.


Annual Electricity


Rs. In Million

28 Switching OFF Alternative Street Lights at Plant & Colony after late Night

0.01 0.07

29 Reduction of Distribution Transformer Voltage from 435V to 415V by Tap Changing

0.003 0.013

30

Operating the LS Crusher during Day time and minimizing the Lighting requirement. Also, Stopping the Mine Haulage Road Lighting according to the LSC Operation

0.01 0.05

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No Investment

Sl. No.


Annual Electricity


Rs. In Million

31 Intermittent Operation of Truck Tippler Spillage Conveyor

0.02 0.12

32 By reducing the False Air Level (3% Reduced), Coal Mill Fan Power reduced

0.13 0.66

No Investment

Sl. No.


Annual Fuel Saving Achieved /

Annum Fuel Qty.

Rs. In Million

33

Reduction of Fuel Consumption in Pyro Section (False Air, Outlet Temp., O2 Optimization, Exhaust Gas Volume, Insulation Bricks)

17 Kcal/Kg Clinker

2.23

34 Reduction of Specific Diesel Consumption in Cement Mill

450 KL 26.1

35 Reduction of Diesel Consumption during Kiln Start-up.

14 KL/Start

9.75

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With Investment

Sl. No.


Annual Electricity

Saving Achieved

Invest ment (Rs.

Million)

Pay Back

in Mont

hs Units in Million

Rs. In Million

1 Installed VFD for VRM Reject belt & Reduction of Idle Power

0.11 0.53 0.70 16

2 Modification of PH Down comer Expansion Joint and Sustained Lowest False Air

0.32 1.58 0.1 1 1

Kcal/Kg 0.13

3 Silo Aeration Blower Drive Pulley size Reduction

0.04 0.18 0.01 1

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Sl. No.


Annual Electricity

Saving Achieved

Invest ment (Rs.

Million)

Pay Back in Months Units

in Million

Rs. In Million

4 Tower AC Installed for Robo Lab and Optimized Centralised AC Temp.

0.29 1.46 0.20 2

5 Operation of STP Water Pumps through Mobile Phone Starter

0.01 0.03 0.01 4

6 Installed Air Control Module for Flyash Unloading System

0.03 0.15 0.1 8

Sl. No.


Annual Electricity

Saving Achieved

Invest ment (Rs.

Million)

Pay Back in Month

s Units in Million

Rs. In Million

7

Raw Mill Inlet duct modification with chute and improved productivity

0.66 3.3 0.1 1

8 Packing Plant Blower Capacity Reduced from 30KW to 22 KW

0.07 0.35 0.04 2

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Sl. No.


Annual Electricity

Saving Achieved

Invest ment (Rs.

Million)

Pay Back in Months Units

in Million

Rs. In Million

9 Installed HT Bus Capacitor and Improved the PF from 0.98 to 0.992

1.5 7.3 0.7 2

10 Speed Reduction of Coal Crusher Belt Conveyors

0.05 0.25 0.08 4

11

Replacement of Low Efficient old Pumps with Efficient Pumps in Centralised AC System

0.07 0.35 0.04 2

Sl. No.


Annual Electricity

Saving Achieved

Invest ment (Rs.

Million)

Pay Back in Month

s Units in Million

Rs. In Million

12 Optimization of Cement Mill Power by rebuilding the Rollers & Table

2.80 14.00 0.30 1

13 Decentralised 30KW Compressors for Individual Packers

0.39 1.96 2.80 18

14 Installed LED Street Lights in Colony

0.01 0.03 0.19 80

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Sl. No.


Annual Electricity

Saving Achieved

Invest ment (Rs.

Million)

Pay Back in Month

s Units in Million

Rs. In Million

15

Installed Hydraulic Scrapper for unloading of Raw Material in Truck Tippler and reduced the Truck unloading Time & Truck Tippler Group Operating Hours

0.02 0.1 0.25 30

16

Converted of 200W Incandescent to 70W HPSV Lamp in the SF Cooler Inspection Chamber

0.03 0.13 0.02 2

Sl. No.


Annual Electricity

Saving Achieved

Invest ment (Rs.

Million)

Pay Back in Month

s Units in Million

Rs. In Million

17 Manual Switch Control for Packing, Workshop, Silo Lightings

0.02 0.04 0.01 3

18 Permanent Speed Reduction of Raw Coal Hopper BF Fan

0.06 0.3 0.05 2

19

Interconnected Bag Filter Suction & Stopped 2 Nos. of 11KW BF Fan (491FN8 & 391FN9)

0.14 0.66 0.04 1

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Sl. No.


Annual Electricity

Saving Achieved

Invest ment (Rs.

Million)

Pay Back in Month

s Units in Million

Rs. In Million

20

Usage of Hand Driven LED Torch Light for Securities, in place of Inspection Hand Lamp for Maintenance

0.006 0.03 0.03 12

21 Installation of Solar Water Heaters for Athiti & Swagath Guest Houses

0.04 0.18 0.20 12

22 Installation of Solar Street Lights with LED Light Fittings at Mines Magazine

0.01 0.04 0.15 45

Sl. No.


Annual Electricity

Saving Achieved

Invest ment (Rs.

Million)

Pay Back in Month

s Units in Million

Rs. In Million

23

Installed Chute at Pre Heater to shift the Scrap Material from 3rd /2nd /1st Floor to Ground. Hence, Lift Operation reduced.

0.0005 0.0025 0.05 240

24 Occupancy Sensor for Load Centre Lighting Auto Control

0.04 0.19 0.01 1

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Sl. No.


Annual Electricity

Saving Achieved

Invest ment (Rs.

Million)

Pay Back in Month

s Units

in Millio

n

Rs. In Million

25

Replacement of 60W Incandescent Lamp with 11W CFL Lamps at Colony & Guest Houses

0.04 0.2 0.05 4

26

Replacement of 36W Fluorescent Lamps to T5 Lamps & CFL Lamps at Offices

0.08 0.4 0.05 2

690

695

700

705

710

715

720

725

730

2010-11 2011-12 2012-13 2013-14

725

721

707

702

Kcal / Kg Clinker

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64

66

68

70

72

74

76

78

80

82

84

86

2010-11 2011-12 2012-13 2013-14

84.45

82.64

76.5

72.14

Overall Units / Ton of Cement

50

51

52

53

54

55

56

57

2010-11 2011-12 2012-13 2013-14

56.02

55.25

54.20

52.00

KWH/T of Clinker

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70

72

74

76

78

80

82

84

86

88

90

2010-11 2011-12 2012-13 2013-14

88.70

86.10

80.10

77.12

KWH/T of Cement (OPC)

60

61

62

63

64

65

66

67

68

69

2010-11 2011-12 2012-13 2013-14

68.2

66.3

63.4 63.2

Kwh/Ton of Cement (PPC)

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5

10

15

20

25

2009-10 2010-11 2011-12 2012-13

10.50

16.50

20.80

23.50

Energy Savings (Million Units / Annum) Cumulative Trend

0

0.02

0.04

0.06

0.08

0.1

0.12

0.14

0.16

0.18

2008-09 2009-10 2010-11 2011-12 2012-13 2013-14

0.17

0.15

0.11 0.1

0.09 0.08

Explosives Kg/MT of Limestone

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SEC DCBL Actual (FY 2012-13)

National Benchmark

***

International Benchmark

***

Specific Energy Consumption – Thermal (KCal/Kg of Clinker)

707* 667 660

Specific Energy Consumption – Electrical (KWh/T of Cement)

76.5 67 65

*** Source of Information : 12th Planning Commission Report

*Specific heat consumption is : 686 Kcal/Kg Clinker

60

61

62

63

64

65

66

67

68

69

2010-11 2011-12 2012-13 2013-14

68.2

66.3

63.4 63.2

Kwh/Ton of Cement (PPC)

NB

INB

NB – National Benchmark INB – International Benchmark

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1

• Installation of Waste Heat Recovery Power Plant. Generation Potential : 4.3 MW/Hr.

•Ordered to M/s Techpro Systems Ltd.

•Target : September 2014

2

•Retrofitting of Cement Mill Fan Impeller for Energy Efficiency Improvement

•Study Completed. Saving Potential 250KW/Hr. Ordering Stage, Target : March 2014

3

•Replacement of High Pressure Compressor to Energy Efficient Turbojet Blower for Flyash Handling

•Ordering Stage. Target : March 2014

4

•Reduction of Pressure Loss b/w Raw Mill Cyclone to Raw Mill Fan duct. Saving Potential 100mmwg.

•Study Completed. Saving Potential is 60KW/Hr. (Rs. 24 Lakhs / Annum) Target : September 2014

5

• Improving the PPC Cement Dispatches

•Launched New PPC Product “Dalmia Ultra” to boost the PPC Sales. Shall reduce the SEC. 6

•Retrofitting of RABH Fan Impeller for Energy Efficiency Improvement

•Study Completed, Savings Potential 50KW/Hr. (Rs. 20 Lakhs / Annum) Target : June 2014

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Objective: Reduction of Fuel Consumption from 721 kcal/kg to 700 kcal/kg

Approach: 2R principle that is

Reduce

Replace

IP - 1

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Variation in Kiln Feed Process

Operation

Limestone

Limestone size 90mm >5%

Segregation of material in Pile

Low Burnability

High False Air

High Loss through PH Exist Gases

High Silica

Secondary Temp. Variation

High Clinker Temp.

Reduction of K.Cal/kg of Clinker

Coal

Silo Blending Efficiency

Uneven Flow Of Correctives

IP - 1

Mines

•Control the Fragmentation Size in Blast Muck Pile

•Two point Loading for better blending

Crusher

• Reduction of output size less than 90mm

• Remove the clay in the Limestone to reduce Silica Variations

Stock Pile

• Height of Fall in Limestone Stocking

• Pile Sequencing in Limestone Stocking

• Pile formation in Coal and correctives

IP - 1

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Raw Mill

•Desired Flow of corrective material that is Red Mud.

•Optimum residue for good Burnability.

Pre Heater

•Proper dispersion of raw meal into Pre-Heater

•False Air Management

IP - 1

Challenges:

High moisture up to 30% in the Red mud the corrective material affect the material flowability in the system.

Circular Stock Pile for Limestone which is having less blending efficiency

Limestone with relatively High Bond Index

Used varieties of coal of origin Indonesia, South Africa, US and Petcoke

IP - 1

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Sl. No.

Area Problem Improvement Actions

1 Mines Control the Fragmentation Size in Blast Muck Pile

Optimising the Powder Factor (Explosive Energy Consumed per MT of Limestone)

2 Crusher

Remove the clay in the Limestone To reduce Silica Variations

Installation of Screening Plant in the Limestone crushing Circuit

Reduce the crusher output size less than 90mm

Wobbler Feeder Gap reduced from 85mm to 60mm by introducing the additional rib on the rollers

IP - 1

Sl. No.


3 Stock Pile

Height of Fall in Limestone Stocking

Maintaining the Luffing Action of Limestone Stacker

Pile Sequencing in Limestone Stocking

Interlocking the horizontal movement of Limestone Stacker with respect to the Material

Pile formation in Coal and correctives

Linear Pile system for correctives and coal instead of point stocking

IP - 1

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Sl. No.


4 Raw Mill

Desired Flow of corrective material that is Red Mud.

• Additional Hopper for Red mud for quick change over and continuity of flow. • Polymer Lining to the storage hoppers

Optimum residue for good Burnability.

Conducted the Burnability studies and fixed the optimum residue for good burnability

Raw mix residue optimized to 23% on 90 µ and 2.5% on 212 µ

IP - 1

Sl. No.


5 Blending Silo

Blending Efficiency

Raw Meal silo extraction cycle pattern changed from normal to alternate cycle and timer changed from 3 minute to 2 minutes

Blending Silo extraction Air Slide Cloth Changed

Raw Meal silo top filling timer changed from 7 minutes to 3 minutes

Filling of Silo more than 70%

IP - 1

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Sl. No.


6 Pre Heater

Proper dispersion of the raw meal into the Pre Heater

Adjustment of the dispersion plate in the feed box of cyclone 4 and 5 to optimize the Heat Transfer Profile

IP - 1

IP - 1

Retrofitting of Screening Plant in the Existing Crusher Circuit

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Benefits of Screening Plant Improved quality of limestone by separating the clay

from limestone. Reduction in Reject of low grade limestone, hence the

cost saving is Rs. 0.60/ton of material. (Saving Rs. 12 Lakhs / Annum) Life of the limestone mine increased. (Mineral

Conservation)

IP - 1

Optimization of Preheater Exit Oxygen level from 3.0 %to 2.5% despite of using Petcoke by close & regular monitoring of all major expansion joints.

Preheater down comer duct modified with telescopic design expansion joint to avoid thermal losses.

Calciner Exit temperature optimised to the range of 880 to 885 deg C as against earlier of 900 deg C by consistent Raw mix quality.

Installed Insulation Bricks (Alite – Dalmia Refractory) in Calcination zone of kiln to reduce Kiln radiation.

IP - 1

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Because of all these actions, remarkable reduction in Preheater Exit temperature from 270 to 250 C to reduce the heat losses through PH exit gases.

Cooler bed height increased from 600 to 720 mmwg, for better heat recuperation.

Physical inspection and false air measurements every week in each section. • Achieved Best Figure for False Air %, which is

witnessed by CII Energy Audit Team during their visit in May-2013 Raw Mill : 7.2% Coal Mill : 6.2% Cement Mill : 7.4%

IP - 1

Improved the reliability and availability of kiln inlet analyser by increasing the probe length and by changing the angle.

Reduction in diesel consumption for kiln light up from 12 KL to 4 KL per each light up.

(Cost Saving 557 Lakhs / Annum)

IP - 1

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Our Focus are

Liquid Alternate Fuel

(from Pharmaceutical Industry)

Dolachar (from Steel Rerolling Mills)

Spent Carbon (from Pharmaceutical Industry)

IP - 1

Developed Inhouse system for the feeding of Liquid Alternative fuel.

IP - 1

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0

0.5

1

1.5

2

2.5

2012-13 2013-14

2.01 1.86

Alternative Fuels in TSR%

IP - 1

Installed VFD for Alternative Fuel Pump for effective combustion. Separate Feeding arrangement for Solid alternate fuel. Spent Carbon utilization by spreading in Raw Coal Pile.

IP - 1

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35

690

695

700

705

710

715

720

725

730

2010-11 2011-12 2012-13 2013-14

725

721

707

702

Kcal / Kg Clinker

IP - 1

Result:

Current Status of Heat Consumption in Pyro

Heat of Formation 410 Kcal/Kg Clinker

Heat loss through PH Exit gases 114 Kcal/Kg Clinker

Heat loss through Cooler Exit Gases 88 Kcal/Kg Clinker

Heat Loss through Clinker 31 Kcal/Kg Clinker

Heat Loss through Radiation 43 Kcal/Kg Clinker

Total Heat Consumption 686 Kcal/Kg Clinker

IP - 1

Result:

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59.8 16.6

12.8

4.5 6.3

Formation PH Exit Cooler Exit Clinker Radiation

IP - 1

Objective: Improve the Raw Mill Productivity from 370 to 400 TPH

Background:

To maintain kiln feed quality consistently it is desirable to maintain the Raw Meal silo level more than 70%. To achieve this raw mill output requires 400MT per Hour for the Kiln output of 5200TPD.

Achieved 6000TPD as highest Clinker Production, but optimized at 5200 TPD, keeping in view of Power & Fuel Economy

IP - 2

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Challenges: To maintain the Raw Meal residue 23% on 90 micron and 2.5% on 212 micron for better burnability.

Designed capacity of mill is 375TPH at

23% residue on 90 microns

Limestone with relatively High Bond Index

Maximise the Alternative Raw Materials in place of minerals as correctives

To avoid Running of Raw Mill in Peak Hrs

IP - 2

Lime Stone size is higher (5% more than 90mm Size)

High Reject from the Raw Mill

High Mill Main Drive load while increase Mill feed.

Heavy Material deposition at Mill Inlet Duct.

IP - 2

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Reduction of Lime Stone Size

Increase the Raw Mill Grinding Pressure

Increase of Nozzle Ring Velocity

Optimization of Dam Ring Height

Optimization of Water Spray

IP - 2

Consistent feeding of Red mud.

Solution for material accumulation at Mill inlet duct

Optimization of Classifier Operation

IP - 2

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39

To reduce the Lime stone Crusher output size less than 90mm

• Blow Bar gap reduced from 90 mm to 80 mm.

• Extra Ribs provided in Wobbler Rollers to avoid any

escape of higher size Lime Stones.

IP - 2

Additional Wobbler Ribs Provided to reduce the sieve size.

Additional Ribs

IP - 2

Before After

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40

To maintain the consistent flow of Red Mud

• Stacker operation converted to auto linear stacking instead of point stacking.

• Iron ore hopper converted to stand by Red mud hopper for quick change over in case of jamming.

• Provided Vibrator and Blasters for better flow of high moisture Red mud.

• Polymer lining provided for better flow.

• Extra hopper for Red mud feeding, provided at reclaimer belt for dry Red mud during critical condition.

IP - 2

Optimized Nozzle Ring Velocity

• Nozzle Ring area between two Rollers of Raw Mill blocked.

• Total Nozzle ring area 7.99 M2

• Blocked nozzle ring area 1.83 M2 (23%)

• Nozzle Ring Velocity : 36.21 M/Sec

IP - 2

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Nozzle Ring Blocked

IP - 2

Nozzle Ring Blocked

Dam Ring reduced from 65 mm to 25 mm in two phase, which reduced Mill Main Drive load from 3700 to 3400 KW.

Optimized the Grinding Pressure.

Raw Mill Separator Seal gap reduced by applying felt to avoid escaping of raw meal from separator seal.

After increasing grinding pressure & applying felt for Separator, Separator speed optimized from 63% to 59% to achieve Raw Meal residue 22-23% on 90 µ & 2.8% on 212 µ.

IP - 2

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42

Raw Mill Feed chute length extended by 200 mm to avoid material rejection due to centrifugal force.

Raw Mill water spray nozzle location optimized to minimize the water consumption from 6 M3/Hr. to 2.5 M3/Hr.

IP - 2

Extended Chute

IP - 2

Feed Chute Extended 200mm

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Heavy Material Deposition

Inlet Duct Outer View

IP - 2

Installed Chute below the Inlet Duct to drain the deposition

No Material Deposition

IP - 2

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44

382

388

406

360

365

370

375

380

385

390

395

400

405

410

2011-12 2012-13 2013-14

Raw Mill TPH

Design Capacity 375 TPH

IP - 2

18 17.7

16.7

14

15

16

17

18

19

20

2011-12 2012-13 2013-14

Raw Mill Specific Power

OEM Guaranteed 19 Units/Ton of Material

Units / Ton of Material

IP - 2

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45

1.5

2

2.5

3

3.5

4

2011-12 2012-2013 2013-2014

3.5

3.0 2.8

% Residue on 212µ

IP - 2

Objective: Capacity Utilization of VRM (Raw Mill & Cement Mill) at all the Times and Reduction of VRM Power due to unexpected Tripping.

IP - 3

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46

Problem Faced:

After the Unexpected Tripping of VRM, Mill unable to Operate at rated capacity due to Reject Bucket Elevator Overloading. (Due to Handling of Reject Hopper Material & VRM Reject Material).

Hence, Mill Idle Power is High due to Operating at Under Capacity.

IP - 3

Action Taken :

Installed the Variable Frequency Drive for the Reject Handling Belt Conveyor.

Reject Material in the Hopper is handled to the VRM at

10% Speed of the Reject Belt with the help of VFD.

IP - 3

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47

Benefits:

Overloading of Reject Belt Conveyor and Jamming of Reject Bucket Elevator avoided. Hence, avoided Mill Stoppage.

VRM shall Operate at Rated Capacity with in a very short period.

Idle Run Time, Productivity, Idle Power Consumption and Mill Performance were improved.

IP - 3

Summary:

Investment : 3.5 Lakhs / VRM

Unexpected Tripping : 2 Tripping per month / VRM

Production Loss : 70 Tons Prod. / Trip / VRM i.e. 140 Tons Production Loss / Month in Raw Mill 140 Tons Production / Month in Cement Mill Idle Power Loss:

Raw Mill : 1600 Units Loss / Trip

Cement Mill : 1700 Units Loss / Trip

Tentative Power Loss : 6600 Units Loss / Month

IP - 3

8/29/2013

48

Results Achieved: Savings:

Power Cost Saving : 6600 Units X Rs. 5.00 : Rs. 33,000 per Month Total Power Cost Saving : Rs. 4 Lakhs / Annum Payback : 2 Years Note: Savings excluding the Truck Handling Charges

IP - 3

IP - 4

Objective: Optimizing the Cement Mill Operation with Minimum Hot Gas and Smooth Operation. Actions Taken:

1. Optimized the Temperature of Cement Mill VRM during Startup

2. Optimized the Water Spray able to retain the Temperature generated during the Grinding.

8/29/2013

49

Action Taken :

3. Optimizing the Recirculation Damper to avoid the heat

loss.

4. Reducing the Start-up Idle Operation Time by One Hour due to Optimized with low temperature

5. Eliminated the requirement of Hot Gas during Operation (after Start up)

6. Stopped the Booster Fan Operation after Start up

IP - 4

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

2

2009-10 2010-11 2011-12 2012-13

1.98

1.4

0.21 0.15

0.6

Specific DieselConsumption(Ltr./Ton of Cement)

Cluster Specific DieselConsumption(Ltr./Ton of Cement)

IP - 4

8/29/2013

50

IP - 5

Objective: Optimizing the KVAH Consumption by Improving the Power Factor from 0.975 to 0.990. Actions Taken:

1. Measured the Capacitor Requirement at the Individual Load Centres with the Help of Digital Multi Function Meter available in all the Feeders.

IP - 5

Actions Taken:

2. Provided Auto Start Stop Interlock for the HT Bus Capacitors through DCS

3. Arrived the Capacitor Requirement and Installed the additional HT Bus Capacitor

4. Controlled the HT Bus Capacitors operation through DCS as per the Mills Operation.

5. Ensured No Leading Power Factor all the Conditions

8/29/2013

51

0.965

0.970

0.975

0.980

0.985

0.990

0.995

0.97

0

0.97

0

0.97

2

0.98

0

0.98

0

0.98

7 0.99

0

0.99

1

0.99

2

0.99

1

0.99

1

0.99

2

0.99

0

0.99

0

Grid Power Factor

IP - 5

0.97

0.98

0.99

0.96

0.965

0.97

0.975

0.98

0.985

0.99

0.995

2010-2011 2011-2012 2012-2013

Continual Power Factor Improvement

IP - 5

8/29/2013

52

IP - 6

Objective: Reduction of Packing Plant Specific Power Consumption from 3.0 U/T of Cement to 1.2 U/T of Cement Actions Taken:

1. Installed & Operating 30KW Individual Compressor for Individual Packer instead of Operating 160KW Centralised Compressor

IP - 6

Actions Taken:

2. Arrested the Compressed Air Leakages & Optimized the Bag Filters Purging Frequency & Time

3. Monitoring & Controlling of Idle Power Consumption on daily basis

4. Reduced the Idling Time by Training given to Truck Loader Operators.

5. Optimised the Operating Speed of Bag Filter Fans through VFD.

6. Automatic Speed Interlocking to Bag Filter Fan with respect to Packer Main Drive Operation

7. Operation Interlock for Bag Cleaning Fans

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Result:

Specific Power Consumption of Packing Plant reduced from 3.0U/T to 1.2 U/T of Cement

Energy Saving of 2.5 Lakh Units / Annum

IP - 6

Sp. Power Reduction in Packing Plant

IP - 6

8/29/2013

54

• Reuse of STP water

• Water Conservation Task Force

• Rain Water Harvesting and Use of Mine Pumped out Water

Water

• Energy Conservation Projects Energy

• Solar Power

• Bio-Diesel

• Wind Power

Non-Convention

al Energy

• Jetropa Plantation

• Mass Tree Plantation on June 5th & providing sapling to neighbouring

• Department wise ownership

Plantation

8/29/2013

55

• Stack Emissions

• Recycling of Floor Spills

• Gypsum Un loader

• Reuse of Waste

Environment

• Vermi-compost

• Common Vehicle for commuting in Plant & Colony

• Use of Bicycles by movement in the Plant

• Form pond

• Rain water harvesting structures

• Distribution of Solar lamps

• Practice of integrated Pest Management

• Awareness on Environment

Community

• Installation of Waste Heat Recovery Power Plant at Pyro Section Vent

CDM Project

Green Development

Neerium Neem

Pungam Pungamia

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Konocarpus

Tacoma

Yellow

Green Development

Green Development

8/29/2013

57

Green Development

Green Development

8/29/2013

58

Involvement of Employees, Families & Children

Involvement of Employees, Families & Children

8/29/2013

59

10000

15000

15000

16000

2010-11 2011-12 2012-13 2009-10

20000

TARGET

(2013-14)

Green Development in the Plant & Colony

1. Celebrated Energy Conservation Week during the National Energy Conservation Day 14th December 2012

2. Conducted Campaign at nearby Villages about the Energy Conservation and Methods to Save Energy

3. Sharing Energy Conservation Tips for the day during Energy Conservation Campaign

http://www.potato2008.org/images/plant-t.jpg




8/29/2013

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8/29/2013

61

1. Utilizing 100% STP Generated Water to the Plant for VRM Water Spray.

2. Generated water storage pond for capacity 180000 M3 with an Investment of Rs.20.0 lakhs (Mines Pond Water)

3. Reduced Water Consumption in Clinker Cooler by improving the Heat recuperation from Cooler Fans (Fan No. 1, 2 & 3) and Optimized the fresh air entry by installing Fresh Air Damper at cooler ESP duct. Reduced Water consumption from 16 M3 to 3.5 M3.

Water Management Award received from CII

0

2

4

6

8

10

12

14

16

Before At Present

Cooler Water Consumption (M3/Hr.)

16

3.5

8/29/2013

62

CII’s National Excellence in Water Management Award - 2012

Electrical Energy Saving Projects 19505 Ton of CO2

Reduction / Annum

Thermal Energy Saving Projects 640 Tons of CO2

Reduction / Annum

Greenary Development 56,000 Nos. of Plantation

(Survived)

Summary

Major Future Plan Waste Heat Recovery Plant Installation & Commissioning.

Ordering Completed. Target for Commissioning : September 2014

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Employee Involvement & Opportunities for sharing Encon Ideas

1. Employee Suggestion Scheme from Workmen to Management Staff

2. Section wise Monthly Performance Meeting from Workmen to HOD

3. Employee Communication for Suggestions & Ideas to Corporate Management & Unit Management

4. Selection of Monthly Campaign for Energy Conservation, Environment, Health, Safety…ggestion to Managing Director

Employee Involvement & Opportunities for sharing Encon Ideas

5. Capturing of Essays, Slogans, Essays from Workmen and awarding during Monthly Gate Safety Meeting

6. Weekly Section Wise Plant Review Meeting with Engineer Level to Top Management for the Improvement Jobs

7. Hotline Mail ID for Ideas & Suggestion to Managing Director

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Total No. of Suggestions (from Employees to Workmen)

No. 231

Suggestions Related to Energy Conservation

No. 79

Validated Suggestions related to Energy Conservation

No. 72

Total No. of Energy Conservation Suggestions Implemented

No. 69

Note : Including Minor Suggestions

Sl. No.

Name of the Training Programme

No. of Employees

Participated

Training days

Total Man Days

1 Energy Management Systems

39 1 39

2 Energy Conservation & Audit Methods

18 1 18

3 ENCON mission to world class energy efficient cement industries

4 1 4

4 Energy Management Systems

2 2 4

5 Training Program On Energy Management

2 5 10

8/29/2013

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Sl. No.

Name of the Training Programme

No.Of Employees Particpated

Training days

Total Man Days

6 Energy Conservation & Management in Cement Industry

5 2 10

7 Energy Conservation & Energy Audits in Cement Plants

2 3 6

8 Energy Management in Cement Industry 2 2 4

Sl. No

Source of EnCon idea * Idea

originated in FY

Extent of man-power

involved

Progress of implementation

1 Power Factor Improvement from 0.975 to 0.992

2012-13 Shift

Technicians & Engr.

Completed & Achieved

2 Conversion of Delta Conn. to Star Conn. for Shell & Tyre Cooling Fan

2012-13 Elect.

Technician & Engineer

Completed. Project Identified during Section Review Meeting

3 Silo Aeration blower Speed Reduction by Changing Pulley

2012-13 Encon Team

& Section Engineer

Completed. Project Identified during Encon Team Rounds & Reviewed with Section Meeting involved Foreman, Supervisor, CCR Operator & Engineers

8/29/2013

66

Sl.

No Source of EnCon idea *

Idea

originated

in FY

Extent of

man-power

involved

Progress of

implementation

4

Relocated VFD from Pyro

Comp. to Cement Mill

Comp.

(Avoided Unloading Operation of Comp.)

2012-13 Section

Engineer &

Section Head

Completed. Project

Identified during Encon

Team Rounds &

Reviewed with Section

Meeting involved

Foreman & Supervisor

5 Installed VFD for VRM

Reject Belts and Improved

Equipment Availability 2012-13

Fitter,

Engineer &

Management

Completed. Project

Identified during Section

Review Meeting involved

Foreman, Supervisor,

CCR Operator &

Engineers

Sl. No


originated in FY

Extent of man-power

involved


6 GRR Cooling Fan Stop

Interlock with 100% Speed 2011-12

Elect.

Techncian &

Engr.

Completed. Project

Identified through

Employee Suggestion

Scheme

7 Operation of Bag Filter in DP mode instead of Timer Mode

2011-12

Section Engineer &

Section Head

Completed. Suggested by Section Engineer

8 Regular Monitoring of False Air Level in the Mills & Pyro section

2011-12

Fitters, Attenders, Welders & Engineers

Continuous Process.

8/29/2013

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Sl. No


originated in FY

Extent of man-power

involved


9 Plant Lighting Time tuning as per the Seasonal Variation

2010-11 Electrical

Technician

Completed. Project Identified During Daily Morning Meeting with Technicians

10 Coal Crusher Belt Conv. Speed Reduced & Improved Belt Life

2012-13

Fitter, Welder, Engr. & HOD

Completed. Identified & Proposed the Workmen Team from RMH Section

Sl. No.


Investment in

Rs. Million

Energy Saving

Potential (Million

Units/Annum)

1 Installation of Waste Heat Recovery System for Pre Heater Exit Gas

40 18.08

2 Retrofitting of Cement Mill Fan to Save the Power of 250KW/Hr.

4 1.34

3 Lower Cyclone Dispersion Box height in riser duct and increase heat transfer

4 0.80

8/29/2013

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Sl. No.


Investment in

Rs. Million

Energy Saving

Potential (Million

Units/Annum)

4 Reduce Pressure drop across Cyclones outlet to fan inlet duct in Raw Mill

1.5 0.56

5 Cooler Fan Silencer Pressure Drop is more hence Replace with Less Pressure Drop silencer

0.5 0.27

6 Load Center A/C Chillier Thermostat to be replace with Electronic Thermostat

0.5 0.12

Sl. No.


Investment in

Rs. Million

Energy Saving Potential (Million

Units/Annum)

7 Replacement of High Pressure Compressor with High Eff. Turbojet Blowers for Flyash Handling

0.8 0.09

8 Avoid air venting in packer Aeration blower by Providing VFD and Common Header

0.5 0.02

9 Install New efficient Process Flow Pump Pumps at Water Treatment Plant

0.2 0.02

10 Installation of Wind Power Generator at Pre Heater

1 0.01

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Non Conformities – 3 Nos.

SL.

NO NON CONFORMITIES CORRECTIVE & PREVENTIVE

ACTION

1.

Senior Engineer position defined

but the authorities &

Responsibilities not defined in the

process manual reference doc no:

F-1(SP-5, AM-5) Issue 02, Rev

no:00 dated 12.08.11

CORRECTIVE: Amend the format with

respect to the responsibilities of Senior

Engineer

PREVENTIVE: Periodical Review

Mechanism developed

2.

Chain pulley 3 MT capacity

(equipment id no: BR 60068)

periodical testing details not

evidenced

CORRECTIVE: The Chain Pulley will be

tested.

PREVENTIVE: List of Equipment's with their

schedule to be made.

3.

Aspect of Generation and disposal

of E wastes during the Maintenance

of Instruments found not identified

and evaluated.

CORRECTIVE: Aspects of generation &

disposal of E waste will be identified

PREVENTIVE: Periodical Review of Aspect

Register shall be followed.

8/29/2013

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Dalmia Cement (Bharat) Limited. Kadapa Project Daily Power Consumption Report

132Kv Main Incoming Units 374595 Kwhr Avg PF: 0.990 Report Date: XX.06.2013

DG Generation Units 0 Kwhr Consumption Date: XX.06.2013

Peak Hour Consumption 20715 Kwhr (MD) KVA 22500 OLTC Opn. Count 9

Sl. No.

Section Description Units Consumption Running

Hrs Prodn.

Production Rate

Avg Kw Guaranteed U/T of Matl.

Actual U/T of Matl.

1 LS Crusher 16.17 11445 707.79 628

LS Crusher Main Drive 3771 233 0.38 0.33

LS Crusher Auxiliaries 1938 120 0.46 0.17

211BC2 Long Belt 2386 148 0.42

0.21

211BC2A Long Belt 2060 127 0.18

LS Crusher & Transport-Total 10155 1.25 0.89

2 Raw Mill 16.92 7105 419.92 7106

Raw Mill Main Motor 63158 3733

17.42

8.89

Raw Mill Fan Motor 44628 2638 6.28

Raw Mill Classifier 1523 90 0.21

MCC - 02 (LS Transport) 1957 116

2.07

0.28

MCC - 03 (RM Grinding Aux.) 6936 410 0.98

Additive Reclaimer 327 19 0.05

LS Stacker & Reclaimer 1706 101 0.24

RM Fan SPRS Recovery 0 0 0.00

Total 120235 19.49 16.92

3 Coal Mill 14.33 577 40.27 877

Coal Mill Main Motor 5197 363

25.51

9.01

Coal Mill Fan Motor 3577 250 6.20

Coal Mill Classifier 272 19 0.47

MCC - 07 (Coal Mill Grinding Aux.) 2169 151 16.73

3.76

RMH & Coal Crusher 1349 94 2.34

Total 12564 25.51 21.77

Daily Power Consumption Report

4 Kiln & Cooler 24.00 5282 220.08 4175

Kiln Main Drive 9244 385

15.60

1.75

Pre Heater Fan 25092 1046 4.75

Cooler Fans & PA Fan VFD 32221 1343 6.10

Bag House Fan 5208 217 2.61 0.99

MCC - 04 (RABH Dust Tpt.) 960 40

9.33

0.18

MCC - 05A (CF Silo Ext. & Kiln Feed BE) 15257 636 2.89

MCC - 05B (Kiln Shell Cool & Lub) 2092 87 0.40

MCC - 08 (Coal Firing) 2597 108 0.49

MCC - 09 (SF Cooler, ESP & DPC) 5057 211 0.96

Utilities (Water Treatment) 2461 103 0.47

Total 100189 27.54 18.97

5 Cement Mill OPC PPC OPC RH 11.33 OPC KW PPC KW OPC U/T PPC U/T

Cement Mill Main Drive 52877 17305 OPC Prod. 3739 4667 5197

27.00

14.14 16.74

Cement Mill Fan Drive 26340 5945 Prod. Rate 330 2325 1785 7.04 5.75

Cement Mill Classifier Drive 1296 701 114 211 0.35 0.68

MCC - 10 (Clinker Silo Ext.) 909 450 PPC RH 3.33 80 135

5.20

0.24 0.44

MCC - 11 (Fly Ash Aux. & Comp.) 0 257 PPC Prod. 1034 0 77 0.00 0.25

Compressors 1314 1303 Prod. Rate 311 116 391 0.35 1.26

MCC - 12 (Mill Grinding Aux.) 3841 963 339 289 1.03 0.93

CM Fan Recovery Power -2942 0 Total RH 14.66 -260 0 -0.79 0.00

Total 83635 26924 Total Prod. 4773 7382 8085 32.20 22.37 26.04

6 Packing Plant 24.00 4672.00 194.67 208

MCC - 13 (Silo Extraction & Comp.) 2343 98

1.33

0.50

Compressors 0 0 0.00

MCC - 14A (Packer - 1) 831 35 0.18

MCC - 14B (Packer - 2) 797 33 0.17

MCC - 14C (Packer - 3) 1026 43 0.22

Total 4997 1.33 1.07


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71

7 Plant Services: 24.00 5282 220.08 465

Plant Lighting 1469 61

2.50

0.28

Plant Aux. Power (Welding) 2140 89 0.41

RMBH AC Power 2082 87 0.39

CCR AC Power 4327 180 0.82

CMBH AC Power 1153 48 0.22

Total 11171 2.50 2.11

8 Distribution Losses 2452 24.00 5282 220.08 102 0.46

Gross Units Consumption 372143

Total for Pre - Clinker 243143 24.00 5282 10131 73.79 60.67

Total for Post - Clinker 115556 0.00 0 #DIV/0! 24.23


ENERGY CONSERVATION (IDLE POWER CONSUMPTION REPORT)

SECTION SECTION DESCRIPTION OPTIMUM

SATRT UP

TIME

ACTUAL

RUNNING

HOURS

XX.06.2013 ENERGY IN KWH

IDLE

RUNING

TIME

IDLE /SHUT

DOWN UNITS ACTUAL

U/Ton

WITHOUT

IDLE

RUNNING

U/Ton

Kwh

LS CRUSHER

APRON FEEDER 0.00 16.17

0.89 0.86

CRUSHER MAIN DRIVE 0.17 17.67 1.33 106.40 80.00

211BC2 0.50 17.92 0.00 0.00 145.00

211BC2A 0.50 17.92 1.25 181.25 145.00

MINES DEWATERING PUMP 66.00

IDLE/SHUT DOWN POWER 287.65

No of Start/ Stops 3.00

16.92 16.88

Raw Mill

WEIGH FEEDER 0.00 16.92

MAIN DRIVE 0.03 16.90 -0.05 0.00 150.00

FAN 0.30 16.90 -0.32 0.00 2600.00

LS RECLAIMER FEED GROUP 12.20 16.50 4.30 335.40 78.00

AD. RECLAIMER FEED GROUP 10.10 12.70 2.60 0.00 49.00

TOTAL DCS IDLE / SHUT DOWN POWER 335.40

No of Start/ Stops 0.00 Dcs Idle Power 331.00

19.44 19.06

Coal Mill

WEIGH FEEDER 0.00 14.33

MAIN DRIVE 0.03 14.40 0.04 2.00 50.00

FAN 0.17 14.70 0.13 32.50 250.00

COAL STACKER FEED GROUP 3.30 3.30 0.00 0.00 54.00

COAL RECLAIMER FEED GROUP 3.80 5.30 1.50 180.00 120.00

RAW MATERIAL HANDLING 1349.00



Daily Idle Power Consumption Report

8/29/2013

72

KILN

KILN 24.00

18.50 18.50

COMPRESSOR 24.00 0.00 0.00 160.00

ALL DRIVES 0.00 -24.00 0.00


No of Start/ Stops 0.00

CEMNT MILL

WEIGH FEEDER 0.00 14.66 1.24

MAIN DRIVE 0.08 14.90 0.00 0.00

23.16 23.14

250.00

FAN 1.00 15.90 -1.00 0.00 2449.00

CLASSIFIER 1.00 16.00 0.34 71.06 209.00

SILO FEEDG ROUP 1.00 15.30 -0.60 0.00 185.00

COMPRESSERS 1.00 16.60 0.30 52.80 176.00

BOOSTER FAN 1.00 2.00 0.00 0.00 45.00

IDLE /SHUT DOWN POWER 123.86


PACKING PLANT

PACKER-1 12.64 0.00 0.00

1.07 1.00

621MD1 18.75 6.11 61.10 10.00

641FN1+641FN2 18.75 6.11 183.30 30.00

PACKER-2 10.27 0.00 0.00 6.00

622MD1 13.55 3.28 32.80 10.00

642FN1 13.55 3.28 65.60 20.00

PACKER3 12.06 0.00 0.00

BULK LOADING 1212.04 12.15 0.00 0.00

623MD1 TON 20.00 -4.21 0.00 10.00

643FN1+643FN2 20.00 -4.21 0.00 20.00

PACKING PLANT COMPRESSOR-CP1 0.00

-2.42 0.00

38.00




CEMENT MILL COMPRESSOR 0.00 0.00 0.00

IDLE/SHUT DOWN POWER 342.80

UTILITIES UTILITIES 11171.00

TOTAL UNITS

FLY ASH 331.52 U/T 3.17


Compressor R Hours Units Consumption Avg. KW % Loading

441CP1 0.00 0.00 #DIV/0! #DIV/0!

441CP2 0.00 0.00 #DIV/0! #DIV/0!

441CP3 24.00 4171.00 173.79 98.47

441CP4 0.00 0.00 #DIV/0! #DIV/0!

421CP1 0.00 0.00 #DIV/0! #DIV/0!

421CP1 A 0.00 0.00 #DIV/0! #DIV/0!

K21CP1 0.00 0.00 #DIV/0! #DIV/0!

K21CP2 16.60 1733.00 104.40 59.15

K21CP3 0.00 0.00 #DIV/0! #DIV/0!

K21CP4 9.30 1050.00 112.90 63.97

K21CP5 0.00 0.00 #DIV/0! #DIV/0!

K21CP6 0.00 0.00 #DIV/0! #DIV/0!

621CP1 0.00 0.00 #DIV/0! #DIV/0!

621CP2 20.90 249.00 11.91 6.75

621CP3 21.40 708.00 33.08 18.74

621CP4 2.40 81.00 33.75 19.12

Units Run Hours Avg. KW

Comp. Energy Consumed for Pyro 4171.00 24.00 173.79

Comp. Energy Consumed for Cement Mill 1733.00 16.60 104.40

Comp. Energy Consumed for Fly Ash 1050.00 9.30 112.90

Comp. Energy Consumed for Packing Plant 1038.00 44.70 23.22

Total Compressed Air Energy Consumption 7992.00 24.00 333.00


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Power units / MT of Material

Description XX-XX-13 XX-XX-13 XX-XX-13 XX-XX-13 XX-XX-13 XX-XX-13 XX-XX-13 XX-XX-13 Month Total Pvs mnth May

L S Crusher 0.97 1.07 0.88 0.89 0.87 0.91 0.93 0.84 0.94 0.95

Raw Mill 17.21 17.04 16.11 17.09 16.19 16.88 16.66 17.03 17.37 16.43

Coal Mill 20.07 22.29 20.51 21.60 19.05 20.80 18.89 19.78 20.84 19.89

Coal Crusher 1.83 2.11 2.14 1.67 2.13 2.09 1.93 2.01 3.37 2.89

Kiln & Cooler 19.00 18.98 18.20 18.52 18.51 18.40 18.82 18.77 20.35 18.48

Power units / MT of Clinker

Description 6-17-13 6-18-13 6-19-13 6-20-13 6-21-13 6-22-13 6-23-13 6-24-13 Month Total Pvs mnth May

L S Crusher 1.36 1.50 1.24 1.25 1.22 1.28 1.30 1.18 1.32 1.33

Raw Mill 26.16 25.91 24.49 25.98 24.61 25.66 25.32 25.89 26.41 24.98

Coal Mill & Crusher 2.41 2.66 2.60 2.58 2.37 2.48 2.30 2.50 2.69 2.68

Kiln & Cooler 19.00 18.98 18.20 18.52 18.51 18.40 18.82 18.77 20.35 18.48

Utilities & Others 2.16 2.17 2.28 2.09 2.24 2.29 2.17 2.13 3.23 3.10

Power Upto Clinkerization 51.09 51.21 48.82 50.42 48.96 50.11 49.90 50.47 54.01 50.57

Cement Mill 26.11 23.84 24.16 24.74 27.37 25.40 26.37 25.53 25.50 25.23

OPC 27.07 23.73 24.66 24.67 28.28 24.92 26.13 21.86 25.37 24.72

PPC 23.65 0.00 23.27 0.00 26.78 26.36 0.00 26.12 26.05 26.79

Packing Plant 1.15 1.21 1.07 1.17 1.12 1.15 1.24 1.20 1.17 1.27

Cement - Overall

OPC 77.51 74.53 72.93 74.70 76.66 74.54 75.60 71.75 78.59 74.65

PPC 61.88 0.00 59.52 0.00 63.31 63.70 0.00 63.63 66.17 64.14

Overall 73.12 74.63 68.15 74.77 68.59 70.92 75.84 64.76 76.13 72.09

Monthly Energy Monitoring Report

Plant DCS Report Formats Idle Run Report Section Specific Energy Consumption Data

Online Specific Energy Consumption

Online Electrical SEC

Online Thermal SEC

8/29/2013

74

Type of Renewable

Energy Source

Installed Capacity

in KW

Savings (Last 3 Years)

Energy Generated

(Lakhs Unit)

Cost Saving (Rs. Lakhs)

* Wind Power 16525 884 4420

Portable Wind Power

1.5 0.03 0.15

Solar Power 2 0.044 0.22

Solar Water Heater

36 0.15 0.75

Note: * Wind Power Generation from the Dalmia Group (Dalmia Bharat Power)

Solar power Pack

Solar Water Heater

Wind Power Generator

Solar Street Lights

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Wind Power Generator

Slogans

Reminders

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76

Pet Coke Using 100% Petcoke for Clinkerization

Red Mud Waste From Alumina Industry as the Additive for Raw Mix, Which boost up utilization of Pet coke 100%

Chemical Gypsum

Chemical Gypsum for Additive for Cement Grinding ( 2%)

Alternate Fuels

2 % of Alternative Fuel for Clinkerization. By using the Hazardous Waste of Pharmaceutical Industry

Flyash Utilization of Flyash 32% for Cement Grinding

STP Water Utilizing the STP Water for the Cement Mill Water Spray

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Sewage Water

Installation of Sewage Water Treatment Plant at Jammalamadugu (Near by Town) and Pumping the Treated water for Process Feasibility Study Completed. Under Engineering Stage

Municipal Waste

Collection of Municipal Waste and use as alternative fuel in Pyro Under Process with Pollution Control Board

Other Industry

Waste

Identification of Waste (Agro Waste and Other Waste Generating from Industries). Identified Waste & Pollution Control Board Obtained

Vendor : Sri Sai Devine Mining Pvt. Ltd.

Service: Supply of Lime Stone from Mines to Crusher

Prior to Encon: Specific Fuel Consumption : 0.42/T of Lime Stone

After Encon: Specific Fuel Consumption : 0.40/T of Lime Stone

Improvement: 4.7% of Fuel Consumption Reduced.

Encon Efforts : Reduced the Hauling distance by making straight haul road Controlled the Idle time of Loading Machine and Dumper

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Vendor : RR Transport & Sri Subramaniswar Transport

Service: Logistics Services for Cement Dispatch by Road

Prior to Encon: Specific Fuel Consumption : 0.33 Ltr./KM

After Encon : Specific Fuel Consumption : 0.29 Ltr./KM

Improvement: 14% of Fuel Consumption Reduced.

Encon Efforts : Training to all Drivers on Defensive Driving Educating Drivers on Clutch / Brake Usage, Ramp up,

Ramp down & Free Running Speed Utilization of Vehicle arriving with Red Mud for

dispatching the Cements

Vendor : Meen Bahadhur Thakur

Service: Maintenance of Guest House

Prior to Encon: Consumption of LPG Cylinders 25 Nos. / Month

After Encon : Consumption of LPG Cylinders 20 Nos. / Month

Improvement: 20% of LPG Consumption Reduced / Month.

Encon Efforts : Educated for avoiding the Idling of Gas Stove Educated on Preheating by Keeping the Vessels on the Vessels Usage of Pressure Cooker

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Distribution of Solar Lamps to the Surrounding Communities

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Won the following Mines Zonal Safety Competitions 2012

Drilling & Blasting 1st Prize

Overall Performance 1st Prize

Mines Lighting & Electrical 1st Prize

Hazard Identification & Risk Assessment 1st Prize

Mine Working 2nd Prize.

Photographs of Mines Award Ceremony – Year 2012

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CII’s 5S Excellence Award - 2012

CII’s EHS Award - 2012

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Group Award

Safety, Environment & Housekeeping Award

Go Green Award

360° Value Feedback Award

CSR Award

Group Award

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Save Energy - Save Money - Save the Planet.

Documents

Energy savings at DCL.pdf