Kapilas Cement Manufacturing Works (A Unit of OCL …greenbusinesscentre.com/energyaward2017presentations...Kapilas Cement Manufacturing Works (A Unit of OCL India Limited) Dalmia

Kapilas Cement Manufacturing Works

(A Unit of OCL India Limited)

Dalmia Bharat Group Co.

KCW1.70 MTPA

Fourth largest cement group in India

with 27 Million Tons of installed

cement capacity 186 MW of captive

power capacity

3 plants in 2 states serving 4 states

27 MnT

14 plants in 9 states serving 21 states

Pan India Footprint Of Dalmia Cement

Kapilas Cement Manufacturing Works 2

KCMW AT A GLANCE


➢ Kapilas Cement Manufacturing Works (here-in-after referred to as KCMW), a Dalmia Bharat GroupCompany, is operating a Cement Grinding Unit having installed capacity of 1.35 MTPA, later up-gradedto 1.7 MTPA, situated at the border of Cuttack and Jajpur Districts in Odisha.

➢ Cement Plant commissioned on 28th March, 2008.

➢ A Solar PV Power Plant of 2.5 MW capacity commissioned on 28th March, 2014.

➢ Certified for Integrated Management System of ISO 9001,14001 & 18001 ( Quality , Environment & OHSAS ) and Energy Management System ISO 50001 by TUV .

➢ Presently operating a LOESCHE VRM (LM 56.3+3 CS) with 1.70 MTPA capacity for Clinker and Slaggrinding separately.

➢ Predominantly manufacture Portland Slag Cement (PSC) and catering to the coastal belt as well assouthern, northern & central part of Odisha with 100% road dispatches.

Process Flow Diagram


Cement Silos

2 x 7,500 t

Roto Packers2 X 180 tph

8 Nos, 90 tph Truck loaders

Dispatch to Customers

Gypsum Stockpile 2 x 2,500

t

C VRM

4 Compartmen

t Silo

Slag Stock Pile 2

x 12,500 t

Coal Stockpile

1 x 4,000 t

Clinker Silo 25,000 t

Clinker from

Wagon Tippler

Coal crushe

r

To HAG & Coal Mill

Paddle Mixer

Bag House

MAJOR PLANT & MACHINERY


CVRM

LM 56. 3+3 C/S

COAL MILL

Alstom BRM 85 (10)

WAGON TIPPLER

LARSEN & TOUBRO LIMITED

HAG

Singhania- 2 x

15 M Kcal/Hr

RECLAIMER

Side Scraper Reclaimer

ROTO PACKER

16 SRPE Enexco Technologies India Ltd

TRUCK LOADER

ENTL 2000-T (12 M)

TRUCK TIPPLER60 Tons Hydraulic Truck Unloader

6

CERTIFICATIONS


6ISO 9001: 2008 ISO 14001: 2004 EN ISO 50001: 2011

6

OSHAS 18001: 2007ISO 9001: 2008 ISO 14001: 2004 EN ISO 50001: 2011ISO 9001: 2008 ISO 14001: 2004 EN ISO 50001: 2011

Certification for IMS (QMS, EMS & OHSAS) and Energy Mgt System ISO 50001 from TUV NORD

EnMs & IMS POLICY


EnMs Policy IMS Policy

8

Awards & Accolades


8

8

State Safety Award in the year 2009 & 2012 and International safety AwardNational Energy

Conservation Award

9

Awards & Accolades


9

09

Pollution Control Appreciation Award 2016 by OSPCB

Living Legend Award 2016

Green Homes Platinum Award from IGBC

10Kapilas Cement Manufacturing Works 10

SPECIFIC ENERGY CONSUMPTION

105.81 101.42

77.6971.02 65.96

0

20

40

60

80

100

120

14-15 15-16 16-17 17-18 Benchmark

SPECIFIC THERMAL ENERGY CONSUMPTION Kcal/Kg OF CEMENT

32.88%

44.45 42.88 39.935.6 33.0

0

10

20

30

40

50

2014-15 2015-16 2016-17 2017-18 Benchmark

SPECIFIC POWER CONSUMPTION (KWH/TON) ON CEMENT

19.91%

Goal 33 SPC

Goal 65.9 SHC


Roadmap To Achieve Target SEC ( KWH/T)

ENERGY CONSERVATION PROJECT IMPLIMENTED


No of Project Completed

Cost Saving Achieved

Electrical Energy Saved

Thermal Energy Saved

Project With Nil Investment

Investment Made61.77

Million

41 Nos

60.59 Million

9.80 MkWh

44947 MKcal

23 Nos

13

ENCON Actions : Without Investment


No Title of Project Year

Annual

Electrical

Saving

(Million kWh)

Annual

Electrical

Cost Saving

(Rs million)

Annual Thermal SavingTotal Annual

Savings (Rs

million)Quantity

Unit of

Measuremen

t

1 Stopping of Auxiliary bag filter fan of feeding section during slag transport 2014-2015 0.176 1.056 0 1.056

2 HAG is to be stopped during CCR grinding 2014-2015 0 0 2250000 kilocalorie 1.6698

3 After rain water harvesting, stop all pump for pumping water from ground

for about 10 months.

2014-2015 0.1 0.6 0 0.6

4 Stopping P&V , panel fans while plant stoppage 2014-2015 0.0168 0.1008 0 0.1008

5 Aux bag filter purging off delay time increases from 15 sec. to 30 sec. 2014-2015 0.0384 0.23 0 0.23

6 CVRM main drive motor starting delay time reduced from 15 min to 7 min. 2014-2015 0.27 1.62 0 1.62

7 Ventury removal from Coal Mill ID Fan 2016-2017 0.0405 0.243 0 0.243

8 Reduced power consumption during CVRM mill heat-up & cooling time 2016-2017 0.0054 0.0324 0 0.0324

14




Annual Electrical

Saving (Million kWh)

Annual

Electrical

Cost Saving

(Rs million)


Savings (Rs

million)Quantity

Unit of

Measuremen

t

9 Both Packer bag cleaning blower stop when respective radial/tangential

belt not running

2015-2016 0.198 1.188 0 1.188

10 Switching of 2 nos of transformer of solar power plant during night hrs 2016-2017 0.0292 0.18 0 0.18

11 Replacement of 531BC3 and 531BC4 motor from 45 KW to 37 Kw 2016-2017 0.034363 0.206 0 0.206

12 Replacement of 491BC3 motor from 45 KW to 37 KW 2016-2017 0.011781 0.07 0 0.07

13 To stop the Compressor of Packing plant and utilize compressor of CVRM 2016-2017 0.27 0.243 0 0.243

14 Cooling tower fan to be stopped and Temperature sensor installed to

reduce running hour of fan.

2016-2017 0.021 0.126 0 0.126

15 Packer Interlock logic modified for reduction of idle running 2016-2017 0.216 1.296 0 1.296

16 Installation of belt starvation switch and development of logic to minimize

idle run of belt conveyor

2016-2017 0.027 0.162 0 0.162

15




Annual Electrical

Saving (Million kWh)

Annual

Electrical

Cost Saving

(Rs million)


Savings (Rs

million)Quantity

Unit of

Measuremen

t

17 Packing House Compressor & MC Silo compressor to be connected with

Bag House compressor

2016-2017 0.11 0.66 0 0.66

18 Reduction of False air Across the system limited to 12% On going process

0 0 44947 MKcal 36.97

19 Master roller sealing arrangement for restriction of false air 2016-2017 0 0

20 Reduction on coal mill residue on 90 Micron 2016-2017 0 0

21 Reduction in mill inside water spray 2016-2017 0 0

22 Slag to be stored in shed in rainy season & to be stored in outside shed in summer season for reduction in heat consumption

On going process

0 0

23 Removal of damper of ID fan motor 2017-2018 0.405 UnderObservation

Under

Observation

ENCON Actions : With Investment



Annual Electrical

Saving (Million

kWh)

Annual

Electrical

Cost

Saving (Rs

million)

Annual Thermal

Saving

Annual

Thermal

Cost

Saving (Rs

million)

Total

Annual

Savings

(Rs

million)

Investmen

t Made

(Rs

million)

Payback

(Yrs)Quantity

Unit of

Measure

ment

1 To reduce the minimum coal firing to below 1.5 tph 2014-2015 0 0 240 ton 0 0.67 0.8 1.19

2 By installing VFD for stacker belt conveyor 2014-2015 0.06 0.36 0 0 0.36 0.45 1.25

3 To Stop 591FNB air slid fan by modifying bag filter discharge

chute

2015-2016 0.033 0.198 0 0 0.198 0.025 0.126

4 Classifier bottom bearing cooling arrangement modification 2015-2016 2.599 15.59 0 0 15.59 0.15 0.01

5 Cooling tower one no of pump stop by modify CVRM

motor O/L water direct discharge to Tower

2015-2016 0.222 1.332 0 0 1.332 0.075 0.56

6 Three nos of 50KVA lighting energy saving device installation 2015-2016 0.41975 2.518 0 0 2.518 0.45 0.18

7 Installation of VFD for L21BC1 2015-2016 0.0352 0.212 0 0 0.212 0.35 1.65

8 Installation of new GRR under buy back scheme with better

speed regulation

2015-2016 0.675 4.05 0 0 4.05 0.8 0.2

9 Installation of VFD for coal conveying blower 1 2016-2017 0.0288 0.175 0 0 0.175 0.2 1.14

10 Installation of VFD for coal conveying blower 2 2016-2017 0.0288 0.175 0 0 0.175 0.2 1.14

16

17

ENCON Actions : With Investment



Annual

Electrical

Saving

(Million

kWh)

Annual

Electrical

Cost

Saving (Rs

million)

Annual Thermal

Saving

Annual

Thermal

Cost

Saving (Rs

million)

Total

Annual

Savings

(Rs

million)

Investmen

t Made (Rs

million)

Payback

(yrs)Quantity

Unit of

Measure

ment

11 Replacement of 300 nos of 70watt HPSV lamp with 32watt LED

lamp

2016-2017 0.04161 0.25 0 0 0.25 0.393 1.57

12 Up-gradation of mill classifier and replacement of new design tire and liner along with Optimisation of Mill

2016-2017 2.7 16.2 0 0 16.2 46 2.84

13 Installation of VFD for Packing plant bag filter fan 1 and 2 2016-2017 0.432 2.6 0 0 2.6 0.9 0.4

14 Installation of SPRS FOR 2500KW ID fan motor 2016-2017 2.025 12.15 0 0 12.15 8.6 0.7

15 Star feeder up-gradation 2017-2018 0.405 2.43 0 0 2.43 1.0 0.41

15 Replacement of existing pump by Grundfos Energy efficient

pump as per pump energy audit

2016-2017 0.088 0.528 0 0 1.6 1.036 0.65

16 Multi-compartment slag bin extraction air slide sized changed

from 300 mm to 400 mm (To increase the TPH & power

reduction).

2016-2017 0.014 0.084 0 0 0.084 0.35 4.1

17 Packer Bin to packer hopper- Single discharge to be modified

to double discharge

2016-2017 0 0

18 Blower Installation at Packing Plant for body cleaning purpose

& reduction in compress air consumption

2016-2017 0 0


ENERGY CONSERVATION INITIATIVES

No Title of Project YearAnnual Electrical Saving

(kWh)Annual Thermal Saving

(Ton/year)

1 Switching of Colony transformer and providing separate supply 2017-2018 43800 0

2 Replacement of 400 nos of 70watt HPSV lamp with 32 watt LED lamp 2017-2018 55480 0

3 Installation of VFD for 531FN1 and 531FN2 2017-2018 54000 0

4 Replacement of L21BC4 motor from 200KW to 160KW 2017-2018 23563 0

5 Replacement of scrapper motor from 75KW to 55KW 2017-2018 26509 0

6 replacement of 511BC2 from 110KW to 90KW 2017-2018 17673 0

7 Replacement of L21BC2 from 55KW to 37KW 2017-2018 43200 0

9 Installation of VFD for mill feed circuit bag filter fans 2017-2018 67500 0

10 Uniform distribution of temperature at mill inlet by providing baffle plate 2017-2018 0 0

11 Replacement of existing RAL by 400x400mm against 300X300mm. 2017-2018 32400 0

12 Drag link feeder to be replaced by 25 TPH Weigh Feeder 2017-2018 28350 0

13 FRB Blade installation in cooling tower fan 2017-2018 8910 0

14 Coal mill BH compress air line to be automated by providing solenoid valve 2017-2018 27000 0

TOTAL 428385

18


Approach For Energy Conservation Initiatives towardsExcellence

Core Committee Team

Daily Monitoring

Energy Conservation Monthly Review Meeting

Analyzing & Brain Storming to evolve Energyimprovement projects

Action Plan & Implementation

Achieving Goals

Rewards


Core Committee Team-Energy Cell

Unit Head

Tech Head

Raw Material Handling

CVRM, Coal Mill, HAG

Packing Plant

Utility & Compressors

Solar Plant

Total Nos of Project Proposed :- 63Total Nos of Project Accepted :- 55Nos of Project Executed :- 41Nos of Project WIP :- 14


Daily EnCon, Production, EHS Discuission meeting

22

ENCON Methodology: Energy Levers


VRM POWER OPTIMIZATION

1. Dam ring

2. False air

3. Feed size control

4. Separator efficiency Power factor

& efficient silo management to avoid peak hour

usage

Fans & blowers efficient running

1. As required convert delta to

star connection of motor

Compressor power minimization

1. Stopping auxillary

compressor

Equipment idle run minimization

1. Stop interlocks

2. starvation stop

3. Shop stoppage power

Solar power

22

69.56, 69%

14.01, 14%

10.14, 10%

4.63, 5%

1.66, 2%

Effective use of Energy Levers in 2017-18

VRM & Process Optimization

VFD Installation & poweroptimization

Motor load study & optimaztion

Compressor power minimazation

Equipment Idle running

23

ENCON Methodology: Power reports


DAILY PERFORMANCE REPORT OF 2.5 MW PV SOLAR POWER PLANT

DATE: 3-Apr-17 MONTH: April

SL NO PARTICULARS UNIT TODAY MTD YTD

A COMMITTED:

1 SOLAR IRRADIATION kwh/m2/d 6.17 6.17 6.17

2 NET GENERATION KWH 11387 34161 34161

3 PLANT LOAD FACTOR % 19.0% 19.0% 19.0%

4 PERFORMANCE RATIO % 69.1% 69.1% 69.12%

B ACHIEVED:

1 GENERATION DETAILS

1.1 AT INVERTER OUTPUT- 1A KWH 3241 8889 8889

1.2 AT INVERTER OUTPUT- 1B KWH 3291 9142 9142

1.3 AT INVERTER OUTPUT- 2A KWH 3228 8864 8864

1.4 AT INVERTER OUTPUT- 2B KWH 3266 8953 8953

1.5 TOTAL- INVERTER GENERATION KWH 13026 35848 35848

2 GROSS GENERATION KWH 12883 35456 35456

3 AUXILLIARY CONS. (Net of Import) KWH 72 210 210

4 IMPORT FROM GRID (FOR AUX. CONS.) KWH 10 90 90

5 ACTUAL GENERATION/ INJECTION TO GRID (ELIGIBLE FOR REC) KWH 12740 35050 35050

6 CAPTIVE CONSUMPTION KWH 12740 35050 35050

7 PASSED ON TO GRID KWH 0 0 0

8 REC APPROVED BY NLDC NOS 0

9 DIFFERENCE- COMMITTED VS ACTUAL KWH 1353 889 889

10 PERFORMANCE RATIO % 81.3% 78.4% 78.5%

C OPERATING PARAMETERS:

1 SOLAR IRRADIATION kwh/m2/d 5.87 5.58 5.58

2 PLANT LOAD FACTOR % 21.2% 19.5% 19.5%

3 AMBIENT TEMP- MAXM 0C 36.75 36.75 36.75

4 AMBIENT TEMP- MIN 0C 23.28 23.28 23.28

5 MODULE TEMPERATURE 0C 44.26 47.70 47.70

6 OPERATING TIME HRS 11.30 34.60 34.60

7 DOWNTIME:

7.1 GRID FAILURE HRS 0 0 0.00

7.2 INVERTER MALFUNCTIONING HRS 0.00

7.3 OTHER REASONS HRS 0.00

7.4 TOTAL DOWNTIME HRS 0 0 0.00

28-Jun-16 Jun-16

CESU POWER CONSUMPTION kWh -4237 -193201

OPEN ACCESS POWER AVAILED kWh 181237 4637161

SOLAR POWER CONSUMPTION kWh 10600 276750

TOTAL UNIT AVAILED AT KCMW FROM CESU (OA+GRID) kWh 177000 4443960

DG POWER CONSUMPTION kWh 0

TOTAL POWER CONSUMPTION AT KCMW(OA+SOLAR+GRID) kWh 187600 4720710

Power Cons.in KCW (Without Distribution Loss) kWh 190379 4749145

MAXIMUM DEMAND (MD) MD 9360 9792

Distribution Loss kWh -2779 -28435

Distribution Loss % -1.5 -0.6

Total Power drawn kWh 187600 4720707

Power Consumed With Distribution Loss

STACKER RECLAIMER

STACKER & RECLAIMER kWh

WAGON TIPPLER kWh 542 14212

TRUCK TIPPLER kWh 0

CLINKER SILO FEEDING kWh 638 5440

CVRM-IV

CVRM MAIN DRIVE kWh 103467 2649520

BAG FILTER FAN kWh 38440 956044

CVRM CLASSIFIER kWh 5075 116734

CVRM Aux. as per Loesche kWh 2090 51326

CVRM AUX-1 kWh 2123 50229

CVRM AUX-2 kWh 1675 43636

CVRM COMPRESSOR -1 kWh 2454 65233

CVRM COMPRESSOR -2 kWh 2779 67238

HOPPER FEEDING BELTS kWh 6079 148119

WATER SUPPLY kWh 1569 38533

SILO FEEDING kWh 3356 37252

LIGHTING kWh 0 0

HAG kWh 2838 76493

Total Power consumed for CVRM kWh 173124 4320010

COAL MILL

COAL MILL MAINDRIVE kWh 808 19806

COAL MILL FAN kWh 325 12406

COAL MILL AUX. kWh 91 1994

RAW COAL HOPPER FILLING kWh 0 0

Total Power consumed for COAL MILL 1224 34207

INTERMIXING (MULTICOMPARTMENT)

SILO FEEDING & INTERMIXING kWh 0 50490

PACKING HOUSE

ROTOPACKER -1 kWh 4117 83940

ROTOPACKER -2 kWh 3242 74406

LIGHTING kWh 0 9023

COMPRESSORS & BAGFILTERS ETC. kWh 0

Total Power consumed for PACKING HOUSE kWh 7359 167369

SERVICESkWh 0

GARAGE , STREET LIGHT,STORE AND CANTEEN kWh 515 14469COLONY LIGHTING kWh 1375 37326

FACTORY LIGHTING (DG) kWh 0PLANT OUTSIDE kWh 281 10761

WATER SUPPLY AND PLANT LIGHTING kWh 3723 86076Total Power consumption for SERVICES kWh 5893 148631

TOTAL POWER CONSUMED IN KCW 187600 4720707TOTAL PSC PRODUCTION t 3944.90 103802.60

CEMENT VRM PRODN (PSC) t 1737 45886CEMENT VRM PRODN (CCR) t 0 17994

CEMENT VRM PRODN (SLAG) t 0 27026CEMENT VRM PRODN (DSP) t 2208 16296

TOTAL MATERIAL GROUND (CVRM) t 3945 107202COAL MILL PRODUCTION t 58 1812

PSC PRODUCTION (INTERMIXING) t 0 41621PSC PACKING (DESPATCH) t 4478 102091

CEMENT VRM (PSC) hrs 8.68 227.23CEMENT VRM (CCR) hrs 0.00 83.06

CEMENT VRM (SLAG) hrs 0.00 140.77CEMENT VRM (DSP) hrs 13.67 93.89

TOTAL RUNNING HRS.OF CVRM hrs 22.35 544.95COAL MILL hrs 5.98 130.44

INTERMIXING hrs 0.00 197.91PSC PACKING (DESPATCH) hrs 0.00 0.00

CVRM-IVCVRM MAIN DRIVE kWh/ton 26.23 24.72

BAG FILTER FAN kWh/ton 9.74 8.92CVRM CLASSIFIER kWh/ton 1.29 1.09

CVRM Aux. as per Loesche kWh/ton 0.53 0.48CVRM AUX-1 kWh/ton 0.54 0.47CVRM AUX-2 kWh/ton 0.42 0.41

CVRM COMPRESSOR -1 kWh/ton 0.62 0.61CVRM COMPRESSOR -2 kWh/ton 0.70 0.63HOPPER FEEDING BELTS kWh/ton 1.54 1.38

WATER SUPPLY kWh/ton 0.40 0.36SILO FEEDING INTG kWh/ton 0.85 0.35

LIGHTING kWh/ton 0.00 0.00WAGON TIPPLER kWh/ton 0.14 0.13

HAG kWh/ton 0.72 0.71CLINKER SILO FEEDING kWh/ton 0.16 0.05

Total Power consumed for CVRM kWh/ton 43.89 40.30

COAL MILLCOAL MILL MAINDRIVE kWh/ton 13.93 10.93

COAL MILL FAN kWh/ton 5.61 6.84COAL MILL AUX. kWh/ton 1.6 1.10

RAW COAL HOPPER FILLING kWh/ton 0.0 0.00Total Power consumed for COAL MILL kWh/ton 21.10 18.87

INTERMIXING (MULTICOMPARTMENT)(A) SILO FEEDING & INTERMIXING kWh/ton 0.00 1.21

PACKING HOUSETotal Power consumed for PACKING HOUSE kWh/ton 1.64 1.64

CEMENT VRM PRODN (PSC) kWh/ton 39.0 39.57CEMENT VRM PRODN (CCR) kWh/ton 0.0 36.9

CEMENT VRM PRODN (SLAG) kWh/ton 0.0 41.6CEMENT VRM PRODN (DSP) kWh/ton 48.29 46.04

( B )POWER FOR PRODUCTION. kWh/ton 44.20 40.62( C )POWER FOR PACKING kWh/ton 1.64 1.64

POWER CONSUMED ON CEMENT (A+B+C) kWh/ton 45.84 43.47

24

ENCON Methodology: Idle Running Hr Monitoring


Idle Hour Counter On main PLC screen

25

ENCON Methodology: Digitization in Monitoring


Ewatch system access from Computer

Ewatch system access from Mobile

Innovative Project: 1


❖ Project: Mill up gradation by replacing the original Classifier of LSKS 92 CS model with latest Vortex based LSVS 97 CS Classifier with modified bigger dia tires & flat liners of Sinter cast and subsequent Mill optimization measures.

❖ Objective: Reduction of Specific Power Consumption & increase in Mill Output.

26

✓ Scope: KCMW was equiped with Loesche Mill LM 56. 3+3 C/s Millwith LSKS 92 CS model classifier

✓ Action taken :

1. Replaced the old design classifier with latest vortex classifier LSVS97 CS alongwith bigger diameter tire & flast table liner.

2. Replaced old GRR with new one along with SPRS installation

3. Damring & louvrering optimization.

4. Reduction of False air across the mill.

5. Water spray nozzle angle change.

Benefits :▪ Sp power on cement reduced by 2.5 kWh /Ton

▪ Annual Electrical Cost Saving Rs. 18.85 Million

▪ Mill output increased from 210 TPH to 252 TPH



❖ Project: CVRM main bag filter capacity 750000 m3/hr inlet Damper removal.

❖ Objective: Power saving

27

✓ Scope: CVRM main bag filter fan is operated with inletmotorized damper, the pressure drop across the damper is45 MMWC.

✓Action taken :

▪ Removed damper & provided transition piece forelimination of any pressure drop.

Benefits :▪ Saved 105 KW by removal of damper.

▪ Sp power on cement reduced by 0.3 kWh/Ton

▪ Annual Electrical Cost Saving Rs. 2.26 million



❖ Project: Increase in KW & RPM of Mill Feed star feeder

❖ Objective: Reduction of idle running & Power saving due to star feeder tripping.

28

✓ Scope: CVRM is equipped with two star feeders for mill feed.Star feeder tripping was on an average 48 times/Month with anaverage stoppage of 9.43 hrs/ month

✓Action taken :

▪ Replaced old starfeeder geared motor of 7.5 KW & 8 RPMwith higher capacity geared motor of 11KW & 12 RPM

Benefits :▪ Sp power on cement reduced by 0.325 kWh/Ton


▪ Stoppage frequency reduced to 8times/Month, i.e. 2 hrs/Month



❖ Project: Providing compress air line to various location for stopping auxiliary compressor & running the

whole plant with one main BH compressor.

❖ Objective: Reduction of specific power consumption.

29

✓ Scope: For plant operation we were running one Main BHcompressor with 3 nos of auxillary compressor

✓Action taken :

▪ Provided compress air line to different locationsin CoalMill & Packing House and stopped all auxillarycompressors

Benefits :▪ Sp power on cement reduced by 0.32kwh/Ton


Month CVRM Prod(Mt)

Power Consumed By

B/H Compressor

(KWH)

Sp.Power CVRM

Prod. (KWH/T)Dispatch (Mt)

Power Consumed

By P/H Compressor

(KWH)

Sp.Power for

Packing (KWH/T)

Nov'16 80610.4 68879 0.85 85803 22979 0.27

Dec'16 110530.8 91083 0.82 109034 19440 0.18

Total 191141.2 159962 0.84 194837 42419 0.22

1.05 KWH/T

Month CVRM Prod(Mt)

Power Consumed By

B/H Compressor

(KWH)

Sp.Power CVRM

Prod. (KWH/T)Dispatch (Mt)

Power Consumed

By P/H Compressor

(KWH)

Sp.Power for

Packing (KWH/T)

Jan'17 (Ti l l 27th) 111547.6 99290 0.89 112200 13193 0.12

1.01 KWH/T

KWH/T 0.05

Rs/KWH 6.00

Rs/T 0.28

Rs/Yr 365789

Power Cost

Cost Saved/T of Cement Production & Dispatch

Cost Saved for 13 LMt Production & Dispatch

Before Modification

After Modification

For 1 Mt of Production & Dispatch, Sp. Power required

For 1 Mt of Production & Dispatch, Sp. Power required

Power Saved/T of Cement Production & Dispatch



❖ Project: Conducted Motor load study and undertook replacement of under loaded motors across the plant.

❖ Objective: Reduction of specific power consumption.

30

✓ Scope: During project time belt conveyor was

designed for higher capacity with higher KWMotor.

✓Action taken :

▪ Studied the motor running load & replaced withsuitable lower KW motor as available in plant

Benefits :▪ Sp power on cement reduced by 0.7kWh/Ton


511 BC-1 Current Reading with 110 KW motor

SL No Date Current KW=Current*415*0.8/1000, PF=0.8

1 11.04.2017 115 66.127762 11.04.2017 117 67.277808

3 12.04.2017 118 67.813656

4 12.05.2017 116 66.702784

5 13.05.2017 110 63.252646 13.05.2017 118 67.852832

7 15.05.2017 112 64.365504

8 15.05.2017 118 67.813656

9 24.05.2017 114 65.51488810 25.05.2017 110 63.25264

11 26.05.2017 115 66.12776

Total 726.101Avg 66.009

511 BC-1 Current Reading With 90 KW Motor1 29.05.2017 98 56.352352

2 30.05.2017 96 55.202304

3 31.05.2017 99 56.927376

4 01.06.2017 97 55.7773285 01.06.2017 96 55.202304

6 02.06.2017 100 57.5024

7 02.06.2017 96 55.202304

8 03.06.2017 97 55.777328

9 05.06.2017 99 56.927376

Total 336.389Avg 56.065

Average KW saving in 511 BC1= 66 KW - 56 KW=10 KWKWH Saving/hr= 10 KWHAverage running Hour /day= 8 hrsTotal running hour in a year considering 320 days=8X320= 2560 HrsTotal Energy saving will be= 2560*11=25600 unitsCost saving in terms of energy @ Rs6/- per unit=25600*6= Rs 153600/-

Renewable Energy Usage From 2.5MW Solar PV Power Plant


Initiatives taken to optimize Generation despite degradation of Modules as committed by OEM:

✓ Tilting solar module two times in a year with trials at different angle on every season.

✓ Cleaning entire solar modules in 4 cycles in a months for summer and winter season instead of 2 Cycles suggested by OEM.

✓ Regularly checking VOC of solar modules on every month and replacing faulty modules.

✓ Condition monitoring of transformer, HT and LT switch gear and all the repairs or rectification done in the evening hrs with out effecting plant performance . Thus 100% up-keep achived in last year.

✓ Cleaning and replacing air filters of Inverter as regular interval and also arrangement done for better cooling . Thus increased efficiency of inverters.

✓ Planting tress like water melon, pineapple, aloe-verra for cooling of solar modules during summer season.

✓ Water spraying system arrangement done for one inverter on top of the module for cooling purpose.

✓ Switching of power transformer of solar power plant from 06.00PM to 06.00AM . Thus saving 80Kwh everyday.

3330 3302 3278

1123

3250

3765 3823 3866

1285

0

500

1000

1500

2000

2500

3000

3500

4000

4500

2014-15 2015-16 2016-17 2017-18 Benchmark

Solar Power Utilization

Committed Generation in MWH Actual Generation in MWH

9/2/2017 32Kapilas Cement Manufacturing Works

Clean Energy Solutions (Solar study lamps) & Clean cooking Households (Fuel efficient stove) distributed to nearby village

to promote use of renewable Energy

Renewable Energy Usage Continues…..

32

33

Carbon Foot Print Reduction


❖ Initiatives to reduce carbon emission :

1. Reduction of thermal energy (Kcal/Kg) by process optimization

2. Installation of 2.5 MW solar PV power plant to utilize renewableenergy and Reduction of total KWH consumption through variousinitiatives.

3. Improving clinker factor by higher addition of slag for cementupto70% & Reduction of Fuel oil consumption by improvingreliability

33

28393.3

43553.9 41748.2

26166.2

0

10000

20000

30000

40000

50000

2013-14 2014-15 2015-16 2016-17

Scope 1. Direct Co2 Emission in Ton

48232

52079

45837

420004300044000450004600047000480004900050000510005200053000

2014-15 2015-16 2016-17

Scope 2. Indirect Co2 Emission in Ton by purchase of electricity

524594488774

446412404901

0

100000

200000

300000

400000

500000

600000

2013-14 2014-15 2015-16 2016-17

Co2 Emission in Ton

34

Carbon Foot Print Reduction


❖ Initiatives to reduce carbon emission :

▪ Increase in use of B F Slag %

▪ Journey started with 43.5% in year 2013 to 70% in Year 2017

34

43.5

54.9

64.566.1 69.1

0

10

20

30

40

50

60

70

80

2013-14 2014-15 2015-16 2016-17 2017-18 (4M)

% Usage of Slag

450895396988

352584 332898

0

100000

200000

300000

400000

500000

2013-14 2014-15 2015-16 2016-17

Scope 3. Indirect Co2 Emission in Ton by Cement Grinding

612

579

395

322

Net CO2 Emission in Kg/T of Cement (2016-17 estimated)

Global Average

Indian Average

Dalmia Bharat Group Average

KCMWAverage

Carbon Footprint Scenario in cement sector

Green Supply Chain


Best Practices1. Office order issued for procurement of material considering Energy

Efficiency2. Procurement of Energy efficient motor Only, calculating the landed

cost considering the energy efficiency.3. Requesting Quotation/ Offers from various suppliers, energy

efficiency criteria must be mentioned on the quotation request from.4. Idle Running of Equipment, wastage of water, air, fuel etc will impact

performance rating of contractor & the unit will impose penalty on observing such incidence.

35

36

Water Positive Plant


0.0330.029

0.0250.027

0.0220.02

0

0.005

0.01

0.015

0.02

0.025

0.03

0.035

2012-13 2013-14 2014-15 2015-16 2016-17 2017-18

Specific water consumption KL/Ton

Particulars Earlier Present Annual

Rain water harvesting capacity (KL) 85,467 1,03,767 1,03,767

Direct use of Rain water (KL) Thru WTP-For 3 months- estimated

23,600

STP Treated Water Consumption Pattern (KL/Day) – Used for Horticulture & Dust Suppression

70 100 1200

Rain water harvesting Structures developed - outside Plant

14,607 30,107 30,107

Total-1,58,674Fresh Water Consumption Pattern (KL/DAY)

Actual Target Annual Target

1 Process Water Consumption 71 90 26,250

2Sanitation-Plant, Colony & Truck Parking

261 200 73,000

3 Horticulture 0 0 0

4 Dust Suppression 1 0 0

5 Solar PV Cleaning 1 5 1700

6 Drinking- RO & Truck Parking 12 10 3650

Total Fresh Water Cons (KL/DAY) 346 305 1,04,600

100% treated STP water being used for Dust suppression & Horticulture. Targeted to achieve 150% Water positive status by this year, i.e. Dec-17

❖ Systematic green belt development initiative :▪ Total 105435 nos of survived saplings till Date out of 126865 saplings

planted inside plant premises. Survival rate is around 83%.▪ 33% of total acquired area is developed as a green belt▪ 150 types of different species is planted through out the plant area.▪ Quick growing forest tree plantation initiative along boundary line

having wood value & dust prevention potential.▪ Landscaping garden development at around 16 acre area for

beautification.

22,696 22,226

20,003

14,424

18,838 18,448

16,602

11,972

-

5,000

10,000

15,000

20,000

25,000

2014-15 1015-16 2016-17 2017-18 (4M)

PLANTED SAPLINGS PLANTED SAPLINGS (SURVIVED)

24,378 28,476

36,892

15,591

-

5,000

10,000

15,000

20,000

25,000

30,000

35,000

40,000

2014-15 1015-16 2016-17 2017-18 (4M)

PLANTED SAPLINGS (Out side Plant Premises)

Valuables Trees with Big Trunks,

71.80%

Flowers, 10%

Fruits, 1.20%

Meditional, 2%

Ornamental, 15%

DEVELOPMENT OF GREEN BELT

Greenbelt Development Initiative


❖ Systematic green belt development initiative :

▪ Organic farming vegetable cultivation through out 43560 Sq Ft area.▪ Canteen waste ,other agriculture & garden waste are used to prepare vermin compost

along with cow dung- received from distributed cows to near by villagers. This eliminatesthe hazard of chemical fertiliser usage. Also ground water contamination is prevented.

▪ Development of green house & Poly house around 360 Sq Mtr for seedling development▪ 10000 nos of pineapple planted below solar panel for solar panel effective cooling.

Greenbelt Development Initiative


Plant LandscapeTotal Plant Area:- 347 Acre

Plantation Area:- 114 Acre (33%)

Greenbelt Development InitiativeRaw material Storage yardCCR Side Area

Colony area Arial View of the plantNear Packing House area

Greenbelt Development InitiativePlant Canteen Front AreaCCR Front Area

Colony Gate AreaColony Area


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