Welcome You All Dalmia Cements (B) Ltd-Ariyalur Plant · Welcome You All Dalmia Cements (B) Ltd-Ariyalur Plant . Dalmia Bharat Group Human Resources Department Building Culture Nurturing

Dalmia Bharat Group

Human Resources Department Building Culture Nurturing Talent 1

Welcome You All Dalmia Cements (B) Ltd-Ariyalur Plant

Dalmia Bharat Group


WORLD CLASS CEMENT MANUFACTURING FACILITY

Dalmia Bharat Group

Human Resources Department Building Culture Nurturing Talent

Group Profile

Cement Power & Energy Refractory Sugar

Founded in 1935 by Shri Jaidayal Dalmia.

Dalmia’s first plant started in 1939 with

250 TPD capacity and celebrating

Platinum jubilee with 24 Million TPA

capacity.

Manufacturing of Special cements like

Oil well, Air strips & Railway sleeper

grade cement.

ISO certified company

Group Turn over 7000 Crores

Diversified business in to Sugar, Power

and Refractory provides growth

opportunities & reduced risk

Dalmia Bharat Group


3rd

Dalmia Bharat Group


Our Vision

Dalmia Bharat Group


Our Mission

Dalmia Bharat Group


Values

Dalmia Bharat Group


ENERGY POLICY

Dalmia Bharat Group


Salient features of the Plant

The above facilities serve the major purpose of

Zero manual intervention

High degree of consistency in Operations and product quality

ROBOT lab with online

sampling

Green Belt

Development

Online particle size

distribution analysis

World Class Power Saving

Equipment's

Dalmia Bharat Group


Dalmia Bharat Group


Cement Dispatch - Lacs MT

14.44

15.15 14.88

2013-2014 2014-2015 2015-2016

Dalmia Bharat Group


Specific Power Consumption –Section wise (Kwh/Mt)

2013-14 2014-15 2015-16

0.89 0.91

0.89

2013-14 2014-15 2015-16

15.66

15.14

14.47

2013-14 2014-15 2015-16

37.68 45.69

37.51

2013-14 2014-15 2015-16

4.25 4.14

3.71

Dalmia Bharat Group


Kiln Performance

2013-14 2014-15 2015-16

16.29

17.06 17.07

2013-14 2014-15 2015-16

4676 4643

5018

Dalmia Bharat Group


2013-14 2014-15 2015-16

49.45

50.99

47.59

Due to Lignite Usage

Specific Power Consumption up to Clinkerization

Dalmia Bharat Group


Specific Power Consumption for Cement Grinding

2013-14 2014-15 2015-16

26.08 24.96

26.41

2013-14 2014-15 2015-16

31.25

30.01 29.80

Due to Wet Fly Ash Usage

increased from 48 to 62 %

Dalmia Bharat Group


Overall Power Consumption of Cement Grinding

2013-14 2014-15 2015-16

79.27 79.66

75.99

2013-14 2014-15 2015-16

60.33

59.06

57.74

Dalmia Bharat Group


Overall Power Consumption of Cement Grinding

2013-14 2014-15 2015-16

67.17

66.54

63.89

Dalmia Bharat Group


Reduction of Clinkerization Power (Kwh /Mt)

Primary Crusher modified to avoid the ACB tripping & Jamming leads to saving 0.05Kwh/MT

0.5 Kwh/MT sp. power reduction achieved in RVRM by Nozzle ring seal gap arresting modification

RVRM inlet duct modified to reduce the Pressure drop leads to savings of 0.3 Kwh/MT

RVRM internal modification -0 dam ring and nozzle ring optimization

RVRM False Air reduction from 11.2 to 7 %

Coal mill dam ring reduced according to the fuel combination

PH outlet O2 maintaining from 3.5 to 2.8 % and achieved Lowest PH Fan power – 3.8 Kwh /MT

Lowest PH False Air maintaining at 3.8 %

Dalmia Bharat Group


49.45

50.99

47.59

2013-14 2014-15 2015-16

19

Reduction of Clinkerization Power (Kwh /MT)

Due to Lignite usage

Dalmia Bharat Group


714

710

699

2013-14 2014-15 2015-16

20

Reduction of Specific Fuel Consumption(KCal /Kg Clinker)

Achieved Lowest Sp. Heat consumption – 690 Kcal / Kg clinker

during Higher TPD Model

Clinker LSF reduction from 97 % to 95% to reduce the Heat of

Reaction

Cooler first three fans flow increased to 110% to get higher

recuperation

Continuous monitoring of false air and sustaining at 4.5% of

false air

PC coal conveying blower VFD installed to reduce conveying

air flow

Cooler Re- cuperation Efficiency increased from 64 to 65%

Online Burner Tip cleaning arrangement was made

Dalmia Bharat Group


Dalmia Bharat Group


Energy Saving For last 3 years

Year (April - March)

Annual Energy consumption Cement Prodn.

in tons

Specific Energy Consumption

Redn. in Specific Energy consn. Over previous year **

Electrical Thermal Electrical Thermal Electrical Thermal

kWh * Million Rs Million Type of major

fuel Tons Rs Million

kWh / Ton of Actual Cement

KCal/kg of

clinker % %

2013-14 97.09 588.14 Coal 122010 803.97 1440190 67.17 714 3.8% 0.6%

2014-15 101.01 634.37 Petcoke 132705 766.48 1518095 66.54 710 0.9% 0.6%

2015-16 95.11 559.26 Petcoke 102257 515.80 1488680 63.89 699 4.0% 1.5%

Dalmia Bharat Group


National & International Benchmarks with 5 Stage preheater

Description Achieved National

Benchmark **

International Benchmark

***

Specific Energy Consumption -

Thermal (kCal/kg of clinker) 695 690 681

Specific Energy Consumption -

Electrical kWh/T of cement (Actual) 63.89

63

60

***http://ietd.iipnetwork.org/content/cement#benchmarks (International Benchmark)

**http://www.indiaenvironmentportal.org.in/files/Cement.pdf (National Benchmark)

Due to Start stop the Specific Heat Consumption – 699 Kcal /Kg Clinker

Dalmia Bharat Group


Energy Conservation Projects Implemented During 2013-14

Sl No Year of

Implementation

Title of Energy Saving project implemented

Annual Electrical Savings achieved

Annual thermal savings

Total Annual Savings

Invest. Made Pay back

months Units Million

Rs Million Tons of

Fuel Rs Million Rs Million Rs Million

1 2013-14 Reduction of specific power and fuel

consumption in pyro section 0.8 4.3 2516.6 16.6 20.9 2.1 3.0

2 2013-14 RVRM internal modifications 1.8 10.2 - - 10.2 1.0 -

3 2013-14

Reduction of coal and diesel consumption in

RVRM by increased heat availability through

dilution damper and high volume booster fan

- - 1226.2 10.6 10.6 9.0

8.0

4 2013-14 Re-design of CVRM internals and modification

of material handling circuit 1.2 6.6 - - 6.6 0.2 <1

5 2013-14 Reduction of diesel consumption in CVRM by

using coal fired RVRM HAG - - 14.8 29.6 29.6 16.0 10

6 2013-14 Reduction of Packing house power by new logic

of VFD to BF fan and reduced idle run hours 0.3 1.7 - - 1.7 - -

Sub Total 4.0 22.8 3757.6 56.8 79.6 28.3

Dalmia Bharat Group


Award for the Year 2013

National Energy Conservation award from Ministry of Power Consecutively for the second year

Only one award in this year from the Cement sector in India

Dalmia Bharat Group



Sl. No. Title of Project Annual

Electrical Saving (kWh)

Annual Electrical

Cost Saving (Rs

million)

Annual Thermal Saving

(Ton/year)

Annual Thermal

Saving (Rs million)

Total Annual

Savings (Rs million)

Investment Made

(Rs million)

Payback

(Months)

1 RVRM internal dam ring and scatter ring modification

931,309 4.7 0 0.0 4.7 0.1 0.3

2 Clinker LSF reduction - specific heat reduction by 3 kcal/kg clinker

0 0.0 552 3.0 3.2 0 0

3 Calcination optimisation - 2 Kcal/kg clinker 0 0.0 368 2.0 2.2 0 0

4 CVRM central feed chute modification 531,333 2.7 0 0.0 2.7 0.1 0.5

5 CVRM Fan optimization 607,238 3.0 0 0.0 3 0.2 0.8

6 CVRM internal modification 607,238 3.0 0 0.0 3 0.1 0.4

Dalmia Bharat Group



Sl. No. Title of Project

Annual Electrical

Saving (kWh)

Annual Electrical

Cost Saving (Rs

million)


(Ton/year)

Annual Thermal

Saving (Rs million)


(Rs million)

Investment Made

(Rs million)

Payback

(Months)

7 CVRM HAG diesel consumption reduction

0 0.0 84 4.0 3.5 0.1 0.3

8 To stop the bag filter fan by connection of venting line with ESP inlet

115,200 0.6 0 0.0 0.6 0 0

9 Reduction of Fire hydrant Pump 55kw running hours

44,798 0.2 0 0.0 0.2 0 0

10 Reduction of Lighting Power in RMBH LC and Cellar room.

36,840 0.2 0 0.0 0.2 0.1 6.5

11 Reduction of process pumps running during shut down days by installation of a small pump

46,080 0.2 0 0.0 0.2 0 0

Total 2920036 14.6 1004 8.93 23.5 0.7 0.36

Dalmia Bharat Group


Award for the Year 2015

Excellent Energy Efficient Unit Award for the year 2015 From CII, Hyderabad

Dalmia Bharat Group



Annual Electrical

Saving (kWh)

Annual Electrical

Cost Saving (Rs

million)


(Ton/year)


(Rs million)


(Rs million)

Investment Made

(Rs million)

Payback

(Months)

1 RVRM inlet duct Modification 518,400 2.59 2.6 1.4 6.5

2 RVRM Grit Cone Modification 129,600 0.65 0.6 1 18.5

3 RVRM Silo Feed Elevator Discharge Chute Modification

108,000 0.54 0.5 0.1 2.2

4 RVRM HAG Root Blower Installation instead of Compressor Air

64,800 0.32 0.3 0.25 9.3

5 HAG Coal Blower VFD Installation 51,840 0.26 0.3 0.2 9.3

6 False Air Reduction 129,600 0.65 0.6 0.1 1.9


Dalmia Bharat Group



Annual Electrical

Saving (kWh)

Annual Electrical

Cost Saving (Rs

million)


(Ton/year)


(Rs million)


(Rs million)

Investment Made

(Rs million)

Payback

(Months)

7 Reclaimer Output increased from 400 to 500 TPH

108,000 0.54 0.5 0.2 4.4

8 Sp. Heat Consumption reduction by Kiln TPD increased 6500 TPD

1511 8.0 8.0 0 0.0

9 Reduction of Crusher Sp. Power by modificaiton of Start & Stop sequence

43,200 0.22 0.2 0 0.0

10 Compressor Power Reduction 108,000 0.54 0.5 0 0.0

11 Coal Mill Sp. Power Reductin by output increased

864,000 4.32 4.3 1 2.8

12 CVRM Sp. Power Reduction in OPC 103,680 0.5184 0.5 1 23.1

Total 2229120 11.15 1511 8.04 19.19 5.25 3.3


Dalmia Bharat Group


Pulse Radar animation

Dalmia Bharat Group


Best Practices

Cross Functional Teams – CFT

Gate Meeting every month

Training Programs

Daily Pep Talks & Awareness about Energy Conservation

Coordination Meeting every day

Why- Why Analysis For the every Break Down

Break Down Analysis Meeting on Monthly

Optimization of Specific power Consumption in all sections

Maximum Usage Of Low Cost Fuel as like Pet-coke

Usage Of Alternate Fuels & Raw Material

Dalmia Bharat Group


Cross Functional Team - CFT

Cross Functional Teams - CFT (Factory within factory concept):-

CFT operates as an autonomous group.

Areas focussed are

Productivity improvement, Quality, Plant availability, Energy conservation, Cost optimization

and SHE initiatives(Safety, Health & Environment).

For any technical issues CFT arrives at solutions through QC tools /SGA approach.

Quarterly rewards and recognitions for CFTs based on Comprehensive Zone award Evaluation

criteria results.

Dalmia Bharat Group


Daily Co-ordination Meeting

Dalmia Bharat Group


Monitoring and Reporting Systems

Daily Comparison Monthly Comparison

Dalmia Bharat Group


Monitoring and Reporting Systems

Dalmia Bharat Group


Daily Production & Power Report

Material On Date (KWh/Te) M to Date (KWh/Te) Y to Date (KWh/Te)

Matl Clkr OPC PPC Matl Clkr OPC PPC Matl Clkr OPC PPC

Crusher 0.79 1.21 1.15 0.76 0.79 1.19 1.13 0.73 0.89 1.35 1.28 0.86

Raw Mill 14.97 22.84 21.70 14.39 14.09 21.50 20.42 13.30 14.47 22.09 20.95 14.04

Coal Mill 38.77 3.49 3.31 2.20 34.76 3.13 2.97 1.94 37.51 3.38 3.20 2.15

Kiln 15.80 15.80 17.23 11.42 18.09 18.09 20.22 13.17 17.07 17.07 19.70 13.21

Sub Total 43.34 43.90 43.88

Utilities 2.33 3.20 3.71

Cement Mill 26.96 29.65 24.81 27.34 29.66 26.10 27.55 29.80 26.41

Packing 0.89 0.89 0.89 0.98 0.98 0.98 1.07 1.07 1.07

Total 45.67 73.92 54.47 47.10 75.38 56.22 47.59 75.99 57.74

Weighted Average 63.11 62.91 63.89

Daily Production Reports 31-03-2016

Section On Date Month To Date Year To Date

Running Hours

Production TPH Kwh/MT Running

Hours Production TPH Kwh/MT

Running Hours

Production TPH Kwh/MT

Crusher 12.5 7915 632 0.79 241.7 168474 697 0.79 2671.6 1672385 626 0.89

Raw Mill 24.0 7560 315 14.97 453.0 180327 398 14.09 5033.8 1669090 332 14.47

Coal Mill 17.0 402 24 38.77 428.1 11111 26 34.76 4114.1 102143 25 37.51

Kiln 24.0 5220 218 15.80 479.5 116118 242 18.09 5228.2 1093198 209 17.07

OPC-43 7.5 1901 255 29.65

111.3 28026 252 29.66

675.2 175328 260 29.80

OPC-53 2.5 638 255 97.2 24484 252 1252.4 326504 261

PPC 10.4 3177 305 24.81 342.2 97968 286 26.10 3360.4 986848 294 26.41

Total Cement 20.4 5716 281 26.96 550.7 150478 273 27.34 5288.0 1488680 282 27.55

Dalmia Bharat Group


Utility Power Report Monitoring Utility Power Consumption Date 27-Apr-16

Description On Date MTD Running Hrs / Remarks TARGET WHILE

PLANT RUNNING

TARGET WHILE PLANT STOPPAGE

RESPONSIBILITY

Lighting, A/c & Water supply ON DATE MTD Plant Lighting-CCR 618 16565 650 650 Mr.Upadhyay

Plant Lighting-RMBH, Stacker & Reclaimer 625 16225 710 710 Mr.Sudhakar Plant Lighting-CMBH & Packing Plant 741 20418 800 800 Mr.Nagaraj

Air Conditioning- CCR 4031 71945

CH1-C1 CH1-C2 CH1-C3 CH1-C4 CH2-C1 CH2-C2 CH2-C3 CH2-C4

2700 1500 Mr.Rajendran 0 0 0 0 24 0 24 24

CH3-C1 CH3-C2 CH3-C3 CH3-C4 Total

18.8 20.1 2.8 11.4 125.1

Air Conditioning- RMBH 1611 23833

CH1-C1 CH1-C2 CH1-C3 CH1-C4 CH2-C1 CH2-C2 CH2-C3 CH2-C4 1400 0 Mr.Rajendran 0 0 0 0 19.5 19.6 19.5 0

Load centre A/c running

Air Conditioning- CMBH 1582 25048

CH1-C1 CH1-C2 CH1-C3 CH1-C4 CH2-C1 CH2-C2 CH2-C3 CH2-C4 1500 0 Mr.Rajendran 18.4 13.6 18.1 9.3 7 0.1 0 0

Load centre A/c running

MCC- 15 (Water Supply) 1471 30749

Process Water Pump 45.97 Hr Fire Hyd. (Hr)

1600 600 Mr.Sathish Kumar 5A 5B 5C 5D 5E 6A 6B Total 24 21.97 0 0 0 2.95 0 2.95

Plant requirement RMBH APDB - 1 & Crusher Stand by Utility 790 16971 650 450

Mr.Sudhakar RMBH APDB - 2, Stacker & Reclaimer 276 7060 250 600

CCR APDB - 1 43 1421 80 80 Mr.Upadhyay

CCR APDB - 2 113 2316 120 120

CMBH APDB - 1 & RMHS APDB 779 17821 450 450 Mr.Nagaraj

CMBH APDB - 2 78 1318 90 25

Total 12758 251690 10760 5305 DISTRIBUTION TRANSFORMER LOSS 205 21892 DISTRIBUTION TRANSFORMER - % OF LOSS 0.04% 0.32% POWER TRANSFORMER LOSS 2213 43958 POWER TRANSFORMER - % OF LOSS 1.55% 1.31%

COMPRESSOR CONSUMPTION ON DATE MTD Running Hrs Remark

441CP1 4158 25186 24 4300

Mr.Sankarappa/Sathish Kumar

441CP2 (VFD Compressor) 0 0 0 For Plant operation 1200 2200

441CP3 151 38975 1.12 For Plant operation 441CP4 0 39234 0 For Plant operation 441CP5 (Robo Lab compressor - 45KW) 0 4242 0

Total 4309 107637 20815.12 5500 2200

DENSE PHASE COMPRESSOR 1571 13399 Running Hrs 12.08

CEMENT MILL COMPRESSORS (K21CP1 & CP2) 2297 39319

K21CP1 K21CP2 Total 2280

Mr.Narasimma Sai/Mr.Sathish Kumar

0 24 24

Cement Mill running Hr 23.53 Hrs 96 Unit/hr FLY ASH COMPRESSORS (K21CP3 TO CP5) 1039 26442 DFA Receipt 238 Tons 2.5 Kwh/Ton Mr.Narasimma Sai

Dalmia Bharat Group


Monthly Performance Indicators Section wise Unit/Ton

Dalmia Bharat Group


EnMS Reporting System

Dalmia Bharat Group


Approach For Energy Conservation Initiatives Towards Excellence

Rewards

Achieving Coals

Action Plan & Implementation

Daily Monitoring

Analyzing & Brain Storming to evolve Energy improvement projects

Responsibilities of Designated Energy Manager

Energy Conservation Monthly Review Meeting

CFT Based Energy Team

Dalmia Bharat Group


Energy Conservation Initiatives

All the nuisance bag filters are taken into DP mode operation instead of Timer mode to reduce the

compressor air consumption

VFDs taken in line for energy conservation and optimization (More than 65Nos of VFDs Installed for

Fans, Pumps etc..)

VFD for Compressors

Continuous monitoring of false air in each section and reduction activities (Raw mill circuit -7%

including seal Air and Kiln 3.8%)

All major drives like Process Bag filter Fans , PH Fans, Coolers Fans, Kiln etc. are running in VFD

Expert Optimizer (EO) implemented for Raw Mill, Cement Mill, Coal Mill & Pyro

Dalmia Bharat Group


Energy Conservation Initiatives

Periodical Visit to Cement plants for Bench Marking, Learning and Effective implementation.

Continuous up gradation of Process Logic in DCS to reduce the Power Consumption.

Auto start / stop logic developed for compressors, belt conveyors and fans to avoid the idle running

hrs

Operation & Optimization of Air Blasters in Kiln inlet raiser duct & cooler to reduce the compressor

air consumption

Going for LED lights to save the power consumption

Dalmia Bharat Group


Employee Involvement on Encon Projects

Dalmia Bharat Group


Employee Involvement on Encon Projects

Dalmia Bharat Group


Dalmia Bharat Group


In-House Modification of Primary Crusher Gear Arrangement

Primary Crusher ACB Tripping frequently due to Jamming

To reduce the tripping frequency and jamming

In order to find the actual problem inside the Crusher we decided to fix the overhead surveillance camera

above the crusher hood top

we found that the tripping was happening whenever the big boulders gets trapped in between the tooth

By shifting spur gear timing in gear camper, resulting that Gap between Taper tips of two rotors was

reduced from 1000 mm to 800 mm.

we have eliminated ACB trippings and simultaneously reduced the start & stop frequency as

well as specific power consumption reduced to 0.05 Kwh/MT

Dalmia Bharat Group


In-House Modification of Primary Crusher Gear Arrangement

Dalmia Bharat Group


Raw Mill output increased from 375 to 450 TPH with Modification of Silo Feed Elevator discharge chute and VFD installation

Silo Feed Elevator current high, due to material recirculation because of “vacuum” created in

top portion around -500mmwg

To reduce the material recirculation as well as current

Silo feed elevator discharge chute was modified and Vacuum pressure came down from 500 to

90mmwg simultaneously reduced the material recirculation.

Silo feed elevator motor changed from DOL to VFD.

Raw Mill output can able to increase from 375 to 450 TPH and Power saving of 0.3 Kwh/MT

Dalmia Bharat Group


Before Modification After Modification

-505mmwg -90mmwg

Draft after chute modification

Recirculation Material

Dalmia Bharat Group


In-House Modification of RVRM Hot Gas Inlet Duct

To reduce the Pressure drop across the system and To

reduce the Specific Power Consumption

Dalmia Bharat Group


Main Drive

BEFORE


Raw Mill inlet Duct

Dalmia Bharat Group


Main Drive

AFTER


Raw Mill inlet Duct

Dalmia Bharat Group


Higher Pressure drop across the Mill inlet duct

To reduce the Pressure drop across mill inlet duct –Scraper chamber entry area (150 mmwg)

Team decided to increase the mill inlet duct area to reduce the pressure drop in the circuit.

Mill inlet duct area was increased from 6 m2 to 18 m2 .

Pressure drop got reduced by 80 mmwg and RVRM Sp.power consumption got reduced by 0.3 Kwh/MT

RVRM Hot Gas Inlet Duct In-House Modification

Dalmia Bharat Group


Less heat availability in the raw grinding circuit since beginning. As the raw material was

high in moisture, it reduces the output of the mill

To enhance the production, we are running HAG in raw grinding circuit, which consumes

coal and diesel and hence leads to increase in cost of production

As a part of energy conservation reduction initiative, the unit decided to utilize the maximum heat

from cooler vent gases whenever CVRM is stopped or OPC running condition

Introduced the dilution air damper in place of cooler water spray for better utilization of cooler exit

heat to RVRM as well as reduction of water consumption

Through this modification Heat availability got increased by 3.5 MKcal/hr

Reduction of Coal and Diesel consumption in RVRM by increased heat availability through dilution damper

Dalmia Bharat Group


Reduction of Coal and Diesel consumption in RVRM by increased heat availability through dilution damper

Before After

Dalmia Bharat Group


Clinker Cooler Breaker Modification

We had been facing frequent Kiln coating collapse and snow men formation in Cooler which

leads Clinker Breaker jam.

Enhanced the area of Clinker Breaker discharge chute

Increased Kiln Availability & Reduce the stoppages and Power saving 0.2 Kwh/Mt

Dalmia Bharat Group


KILN COOLER WITH CLINKER BREAKER

Dalmia Bharat Group


KILN COOLER WITH CLINKER BREAKER

Dalmia Bharat Group


Clinker Breaker Jam

BEFORE AFTER

Dalmia Bharat Group


Utilize Raw mill HAG for Cement mill during kiln stopped condition

HSD is used for CVRM heat requirement, during kiln not running condition, as there is no

coal fired Hot Air Generator. The proposal was to use the existing coal fired Raw Mill HAG to the

Cement Mill. This involves the ducting rearrangement and the isolation dampers

Reducing the diesel consumption in CVRM

Conserving the natural resources

A core cross-functional team formed with five Executives including Head of the departments, were

assigned to this ambitious project

Dalmia Bharat Group



Raw mill HAG located more than 250 meter away from Cement mill

Maintaining < 350 0 C gas temperature before it reaches ducting is difficult

Planned to use the existing both CVRM as well as RVRM booster fans ducting for using Raw mill HAG

hot gases to Cement mill

Run the CVRM booster fan and bypassed the RVRM booster fan to take the hot gas from RVRM HAG

through the new ducting arrangement

Utilization of Dilution air to maintain the temperature at the duct

Dalmia Bharat Group


Bypass duct

Coffee pot damper

Soot blaster system


Dalmia Bharat Group


Utilize Raw mill HAG for Cement mill during kiln stopped condition 32

0.85 0

5.1

Before After

Diesel Cost INR /MT of cement Coal Cost INR/MT of Cement

Wet Flyash increased from 40% to 70% during kiln

stopped condition

Dalmia Bharat Group


TT-8 Dust Emission Reduction ( CVRM Feeding Belt Transfer Tower Aux Bag Filter)

Due to wet fly ash usage along with high temperature clinker in the same feeding belt,

condensation happening in the bag filter vent line. So bag filter DP increased and it leads to dust

spillage around the area

Hot gas supplying booster fan was installed and it connected to the bag filter venting line.

To handle higher volume BF capacity increased

By increasing the bag filter inlet temperature Condensation was avoided

It ensures Bag filter 100% operation and reduction in dust spillage

Dalmia Bharat Group


. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .

. .

. . . . . . . . . .

. .

TT-8 Dust Emission Reduction

Dalmia Bharat Group



531BC1

531BC2

Chimney

Transfer Tower bag

filter 531BF2

Hot air

given from

Hot air given to the inlet of the

suction line

Hot air

given to the inlet of

the suction

Dalmia Bharat Group



Before After

Dalmia Bharat Group


Wet Fly Ash Feeding Dump Hopper

Insufficient wet fly ash feed, due to material jam in dump hopper

WFA Requirement for cement mill = 96 TPH

Actual WFA feed rate = 36 TPH

To increase the Wet Fly Ash Consumption

M.S Angle fabricated grill was replaced by 12 mm TK M.S flat bar used with spring suspension

system

WFA feed rate increased from 36 to 120 TPH and reduced the idle running hours as well as

Power saving -30Kwh

Dalmia Bharat Group



Before After

• Instead of M.S Angle, we replaced 12mm M.S flat.

Dalmia Bharat Group


Dump Hopper

Belt Conveyor


Dalmia Bharat Group


Dump Hopper

Belt Conveyor


Dalmia Bharat Group


CVRM central feed chute modification

CVRM main drive load around 5200 Kwh/hr unable to

reduce the mill load

Discussed the same in CFT (Cross functional team) meeting to

increase the length of the center chute.

Reduced the center chute pipe diameter by 400 mm

Minimize the gap between Table to center chute from 1500 to

700mm.

Due to the above modification, Mill main drive load got reduced

by 120 Kwh and Mill DP got reduced by 20 mmwg.

Dalmia Bharat Group


CVRM central feed chute modification

Dalmia Bharat Group


Kiln Burner Tip cleaning

Dalmia Bharat Group


After started to use petcoke in the kiln firing, we faced frequent coating formation in the face of the burner tip due to high sulphur content

Due to this coating in the face of the burner tip, flame was getting disturbed and started to hit on the refractories

Refractories started to fail frequently and the production was affected

Normal Flame Disturbed Flame

Coating

Kiln Burner Tip cleaning

Dalmia Bharat Group


UT pump water Line

In order to clean the burner face online we had tried from the Inspection door. But we could not able to do it since the burner was far away from the door

While searching for the solution suddenly innovative idea has raised to use the burner diesel firing line to clear the coating. Trial taken by using UT pump water in the diesel line.

Strategic Plan

Dalmia Bharat Group


Challenges : While using the UT pump for clearing we could not exactly reach the burner tip since there was no

any reference for distance

During Shutdown we exactly measured the distance of the burner tip from the starting point of diesel line.

Then we had started to clear the coating in the burner online successfully

Accomplishments

After this innovative implementation , refractory failure has been totally eliminated because of the coating in the Burner tip

In the last 5 month there is no any refractory failure in the kiln and also the consumption of refractory has come down considerably.

Dalmia Bharat Group


Cement Sustainability Initiative (CSI)

WBCSD

CSI - Charter

CSI in India

CSI in DCBL

MD Signing the new Charter at Seoul , Oct 2012

Dalmia Bharat Group


BEE - Energy Awards

National Energy Conservation award from Ministry of

Power FY 2013

National Energy Conservation award from Ministry of

Power FY 2012

Dalmia Bharat Group


CII - Energy Awards

4 Consecutive Years

2011-2012

2014-2015 2013-2014

2012-2013

Dalmia Bharat Group

Human Resources Department Building Culture Nurturing Talent 82 82

Ariyalur unit –Usain Bolt of Cement Industry But believes in perfection has no limits

Dalmia Bharat Group


Dalmia Bharat Group

Human Resources Department Building Culture Nurturing Talent 84 84

Documents

Welcome You All Dalmia Cements (B) Ltd-Ariyalur Plant · Welcome You All Dalmia Cements (B) Ltd-Ariyalur Plant . Dalmia Bharat Group Human Resources Department Building Culture Nurturing