best practices in energy efficiency j.k. cement works ...j.k. cement works, nimbahera from:-team...

Best Practices in Energy Efficiency

J.K. Cement Works,

Nimbahera

From:-Team J.K. Nimbahera

CFD Study and Implementation in Preheater cyclone ducting

Computational fluid

dynamics (CFD) modelling

To reduce pressure drop

across cyclones & inlet ducting

Analysing the results and

locating the problematic areas

in the existing design

Iteratively modify the design so

as to remove the problematic

areas

2

CFD Study and Implementation in Preheater cyclone ducting

Conclusion for PH-III system

By small modification in 4th stage cyclone inlet duct, the reduction in

pressure drop by 45mm WC in the system

To get the exact flow in the 4th cyclone to capture the centre core (vortex)

there is need to increase the dip tube height to 2500 mm.

Conclusion for PH-IV system For the trail modification by increasing the width of the inlet of 4th stage

cyclone at the riser duct, pressure drop reduction by 20 mmWC , which is

optimum without affecting the efficiency of the cyclones

KILN-3: Total Annual Saving is 30.6 Lakh kWh (Approx..)

KILN-2: Total Annual Saving is 6.4 Lakh kWh (Approx..)

3

PC 4th Cyclone inlet Before Modification

4

4th cyclone inlet after modification

5

Kiln-3 String, 4th cyclone inlet After Modification

6

PH-2, 3rd cyclone inlet duct after modification.

7

8

PH-2 4th cyclone inlet duct

PREHEATER NO.-3

PRESSURE DROP (BEFORE)

PRESSURE DROP (AFTER)

CYCLONE (mmWG) (mmWG)

I 78 60

II 80 145

III 175 155

IV 225 215

9

PREHEATER NO.-4




I 20 70

II 115 90

III 118 110

IV 102 120

V 215 125

STATUS OF PRESSURE DROP BEFORE AND AFTER MODIFICATIONS

10

PREHEATER NO.-2




I 55 79

II 185 85

III 70 98

IV 205 179

STATUS OF PRESSURE DROP BEFORE AND AFTER MODIFICATIONS

Cost reduction By using Carbon black 2014-15

11

Quantity of Carbon

Black/Charcoal Dust

GCV Indian

Coal Avg. GCV

Equivalent Quantity of Indian

Coal

Quantity of Indian Coal Saved

MT kcal/kg kcal/kg MT MT

430.98 5898.76 4948.17 513.7 82.80

We are planning to consume 30-40 MT/Day carbon black in 2015-16:-

Power reduction in compressors

12

S.No. Section Existing compressor Compressor Replaced

1. CM 2 in silo 2 & 4.

Compressor Z2X11 (52

M3/min, 340 kw)


M3/min, 225 Kw )

2. CM 2 in Silo 6


M3/min, 615 Kw)


M3/min, 340 kw )

3. Packing dust filter Compressor P1X06 (19

M3/min, 160 kw )


M3/min, 55 Kw)

4. When CM-3,CM-4

and packer-1,2& 3

is only running

2 compressors (10

M3/min,55 kw)

1 compressor (10 M3/min, 55

kw) for dust filters in both

cement mill and packing

plant

Power reduction in Return water tank due to installation of level sensor & automation

• Total saving per year ( assume 300 days)

= 318.52 X 300

=95556 kWh (Approx.)

13

S.No. Section Running KW

Before KWH( Unit)/ day

After automation KWH( Unit)/ day

1. V3KO1 (25 HP) 16 225.6 304

2. V3KO2 (25 HP) 15 276.5 292.5

3. V3KO3 ( 30 HP) 19.91 421.67 384.263

4. V2K01 (25 HP) 15.8 79 37.92

5. V2K03 (25 HP) 16 376 41.6

Total KWH( Unit)/ day 1378.80 1060.80

Modification of cooler fan

Modification of cooler fan K17 inlet (Narrow cylindrical to bell mouth)

Total Saving is 1.6 Lakh kWh (Reduction in Fan Load by 20 kW)

Replacement of (50 No's & 250 W each ) HPSV lights with 90 watt LED lights Total

Saving is 0.31 Lakh kWh

Replacement of (25 Nos & 125 W each ) HPMV lights with 70 watt Metal Helide

lights Total Saving is 0.054 Lakh kWh

14

Saving with replacement of lights

15 Other Savings in 2014-15

Project/Program Investment Electricity Saving,

Lakh, kWh)

Coal Saving, in

MT

Implementation of CFD suggestion in Preheater No-2 8 6.4 220

Use of Alternative fuel (Carbon Black & Char Dust) in Kiln 0 82.8

Modification in CF Silo for bin and Silo aeration 1.93

Modification of cooler fan K17 inlet (Narrow cylindrical to bell mouth)

0.25 1.6

Installation of VFD in GCT-1 water pump 2.5 1 Installation of VFD in GCT-2 water pump 2.6 0.96 Installation of VFD in GCT-3 water pump 3.9 1.2 Installation of PID in Booster fan-1 0.25 0.96 Installation of PID in Booster fan-2 0.25 1.2 Installation of PID in Booster fan-4 0.25 3.6 Insttalled of SPRS in Raw Mill-4 fan 100 12.68 Insttalled of SPRS in SG FAN-4 60 15.84 Replacement of (50 Nos & 250 W each ) HPSV lights with 90 watt LED lights

0.32

Replacement of (25 Nos & 125 W each ) HPMV lights with 70 watt Metal Helide lights

0.05

Thanks For further information, please contact:

Mr. Narpat Anjana, Astt Manager (Process), J K Cement, Nimbahera Plant

[email protected]

Mr. M P Malav , Astt Manager (Process), J K Cement, Nimbahera Plant [email protected]

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best practices in energy efficiency j.k. cement works ...j.k. cement works, nimbahera from:-team...

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