39
Second Prize
Cement (Clinker & Grinding Unit)
THE KCP LIMITED, UNIT-II
Krishna Distt. (Andhra Pradesh)
Unit Profile
The KCP Limited, one of the country's oldest cement producers, has a strong
presence in the south India market. KCP strategically chose this Greenfield plant
located at Ramakrishnapuram, Muktyala Village, Jaggayyapet Mandal in Krishna
District of Andhra Pradesh because of it's close to large limestone reserves and
providing easy access to the key markets of Andhra Pradesh, Tamil Nadu, Karnataka
and Orissa. KHD Humboldt, Germany designed an energy-efficient plant that could
deliver an annual capacity of 1.32 million tonnes of Clinker and 1.52 million tonnes
of Cement.
MAJOR EQUIPMENT INSTALLED
• Hazemag Limestone Crusher: Capacity 850 TPH
• Takraf Stacker & Reclaimer: Capacity 850 TPH
• MPS 4500B Gebr Pfeiffer, Germany Raw Mill: Capacity 350 TPH
• CF blending silo 20m diameter x 45m high: Capacity: 15000 MT
• MPS 2800BK Gebr Pfeiffer, Germany Coal Mill: Capacity 40 TPH
KHD Humboldt, Germany
• ILC 6 Stage Pre-Heater with Pre-Calciner
• 3-support rotary kiln 4.20 m diameter x 64 m long
40
Specific Power Consumption
Specific Thermal Energy Consumption:
ENERGY CONSERVATION MEASURES TAKEN 2013-2014
1) Replacement of Coal crusher RP Feeder with Belt conveyor.
2) Reduction of Pyro & Cement Mill Water Pump capacity (By Installation of Cooling
Tower & Softner) from 75 kW to 22 kW.
3) Coal Crusher By Pass
4) Cement Mill Production Enhancement
5) Modification of Cooler Static Grate inlet by Horse Shoe shape Refractory (To
control the clinker flow in centre and for better Heat Recuperation, which in turn
increased both tertiary and secondary air temperatures)
6) Reduction of capacity of Water Pump for filling of Kiln and Cement mill over
head tanks for Process Requirement from 75 kW to 22 kW
41
7) Packer-2 Bag Filter Vent line Modification. Before 2 nos. bag filter fans of 55 kW
and 37 kW operated. After Inter connected both bag filter and operating only
55 kW fan during packer operation.
8) Reduction of Cement Mill Silo extraction Blower from 22 kW to 15 kW
9) Arrangement of Flaps in Place of RAL in Cement Mill Auxiliary Bag Filters.
10) Kiln Feed Bin Aeration Pipe Line Modification (Motor capacity reduced from
55 kW to 37 kW)
11) Optimizing Kiln and cooler by constructing wall at cooler null point.
12) Decreasing the capacity of Compressor in Packing Plant from 75 kW to 37 kW.
13) Optimization of grinding media.
14) Reducing Idle running of Equipments
15) Reducing number of Start/Stop during filling of Raw Material
16) Optimization of Compressed Air
17) Minimizing False Air & Compressed Air Leakages
18) Power Factor Optimization
19) Installation of VFD’s for Auxiliary Bag Filters.
20) Plant lighting Optimization.
A) MODIFICATION OF CALCINER BURNER
KCP INNOVATIVE PROJECTS
� Pre-mixture of fuel and
meal
� Faster ignition
� Avoid peak temp
inside the calciner
�Harmonized temp
across the calciner
� Lower NOx & CO
� No burner Cooling Air
� Specific heat reduced by
4 Kcal/Kg Clinker
� Increased the clinker
output by 100 TPD
� PH Fan power reduced
by 0.50 KWh/T
Coal
42
B) ARRANGEMENT OF SPIRAL IN PRE-HEATER EXIT
KCP INNOVATIVE PROJECTS
Arrangement of Spiral� Reduced the dust Loss < 3.50%
� Reduced Specific Heat
Consumption by 5-6 Kcal/Kg
Clinker
C) EXTENTION OF COOLER STACK HEIGHT
KCP INNOVATIVE PROJECTS
Extension of Cooler Stack
height� Increased from 45 Mts to 65 Mts.
� Fan Speed reduced by 200 RPM
� Reduced Power by 32.5 KWh
� Low Fan Maintenance cost
� Reduced CO2 by 270 MT/ Annum
43
D) COOLING TOWER FOR LUBRICATION UNIT AND BEARINGS COOLING
KCP INNOVATIVE PROJECTS
Cooling Tower for Lubrication
Unit & Bearings Cooling
� Efficiency of the heat
exchangers has increased
� Temperatures of the
Lubricant oils has come
down by 5-7 Deg C
� Scaling has come down
drastically
� Maintenance cost has come
down by 20%
� Power saving is achieved by
1,700 KW per day due to
reduction in water pumps
run hours
44
Energy Policy
45
Second Prize
Cement (Clinker & Grinding Unit)
DIAMOND CEMENTS
PROP. HEIDELBERG CEMENT INDIA LIMITED
Damoh (Madhya Pradesh)
Unit Profile
The Unit is named as Heidelberg Cement India Ltd (HCIL), situated at Damoh in
Madhya Pradesh. Previously HCIL had two production line of Kiln: Line-1 & Line-2
with combined capacity of 1.5 MT clinker production. Line-1 was established in the
year 1983 and Line-2 in the year 1989. HCIL has further enhanced its production
capacity at Narsingarh, Damoh from 1.5 MT to 3.1 MT by initiating commercial
production of newly installed 5000 TPD state of art technology kiln (Line-3) in year
February, 2013.
Damoh unit exclusively a clinker producing plant which uses Indian coal and pet
coke as source of thermal energy for process and grid power is source energy to
cater to the power requirement of the clinker plant.
Energy Consumption
HCIL is committed to optimize the specific heat and power consumption by
implementation of modern technology and practices for reducing its usage of
Energy.
46
The specific energy consumption figures for FY 2012-2013 & 2013-2014 are shown
below.
Description 2012-13 2013-14
Specific Power Consumption (kWh/MT Clinker) 77.64 69.73
Specific Heat Consumption (kCal/kg Clinker) 853 805
Specific Power Consumption Trend
Specific Heat Consumption Trend
Energy Conservation Measures Taken
Below mentioned are the major initiatives which had been taken to achieve
reduction in energy consumption in all activities:
1. Installation and optimization of new production line of kiln of 5000 TPD capacity
having 5 stage, double string pre-heater state of art FLS Technology
2. Installation of water spray in pre-heater Twin Cyclone (Line-2)
3. Dust Settling Chamber Modification in Line-II
4. Speed reduction of calciner Firing Blower in Line-II in Narsingarh
5. Installation of LED light at plant street lights
6. Utilization of Sun light at workshop
47
Environment and Safety
HCIL is concerned for clean & green environment and committed to eco-friendly
processing of Clinker manufacturing. HCIL has a well-established integrated Health
and Safety Policy to ensure the optimum safety of the employees, public, plant and
equipment, which are embedded in the core organizational values.
The Unit is complying with ISO 9001:2008, ISO 14001: 2004 and OHSAS 18001:
2007 by integrated management system.
ENERGY POLICY
48
Certificate of Merit
Cement (Clinker & Grinding Unit)
JAYPEE SIDHI CEMENT PLANT
Sidhi (Madhya Pradesh)
Unit Profile
Jaypee group is the 3rd largest cement producer in the country. The groups cement
facilities are located in almost all parts of India; however the first cement plant of
group was installed in Satna cluster (M.P.) which has one of the highest cement
production growth rates in India.
Jaypee Sidhi Cement Plant is one of the modern and energy efficient plant of the
group situated in Sidhi district of Madhya Pradesh, India. Presently, it has two
clinkerization units and its total annual capacity of clinker production is 3.0 MTPA.
The first unit was supplied by L&T (SLC KILN – 4200 TPD) and was successfully
commissioned in January 2009. The Second unit was supplied by FLSMIDTH (ILC
KILN – 4500 TPD) and was also successfully commissioned in January 2013.
49
Energy Consumption
The specific power consumption figures for FY 2012-2013 & 2013 – 2014 are
shown below.
KPI FY 2012-2013 FY 2013-2014
Clinker Production 1404840 1753724
Sp. Power Cons./MT Clinker 69.72 65.91
Cement Production 1135755 1340907
Sp. Power Cons./ MT Cement grinding 39.35 38.57
Sp. Power Cons./ MT Cement 90.41 85.92
Energy Conservation Measures Taken
Below mentioned are the major initiatives which had been taken to achieve
reduction in energy consumption in all activities:
1. Modified Kiln String V down pipe i.e. connected directly to the smoke chamber
riser duct towards Kiln side avoiding 3 bends which improved Kiln throughput,
quality of clinker and reduction in power consumption.
2. Modified logic and Installed soft starter for reverse air fan, resulting in energy
saving
3. Replaced coal firing blowers from AMCL to Kay International and also reduced
speed of blower as per requirement. The initial motor kW was 200 kW whereas
present motor is 132 kW.
4. Cement mill transportation group interlocking changed to 20 Min instead of 30
Min.
5. Raw mill & coal mill feed belt magnetic separator was interlocked with the
running of belt resulting in power savings.
50
6. Stacker belt take-up was modified for smooth operation & maintenance by
removing 5 no. pulleys also resulting in improved power consumption.
7. 391-AS4 air-slide inclination was increased from 6.5 to 9 degree to avoid
jamming resulting in reduced power consumption by stopping extra air-slide
blower.
8. Interlocking of bag filters with their respective groups.
9. De-energisation of 2 nos. distribution transformers.
10. 3 nos. L.T. motors connections were changed from DELTA To STAR.
11. Installation of 4500 kVAr capacitor bank in switch yard for improving power
factor.
Energy Policy
51
Certificate of Merit Cement (Grinding Unit)
ACC LIMITED, THONDEBHAVI CEMENT WORKS
Chikkaballapur (Karnataka)
Unit Profile
Thondebhavi Cement Works was set up as a Green Field Project in about 120 acres
of land, in the lush green village of Thondebhavi in Karnataka. This cement grinding
plant was commissioned in the month of December 2009; it is the most modern
plant with state of art technology with a capacity of 1.66 million tons of Pozzolona
Portland Cement.
Major raw material for the production of Pozzolona Portland Cement (PPC) is clinker
which is supplied from the ACC’s modern plant in Karnataka situated at Wadi in the
Gulbarga District. For the production of clinker Wadi cement works is burning
alternate fuels like Paint sludge, ETP sludge, waste chemicals etc. By using these
fuels ACC is saving natural fossil fuels like coal & there by reducing CO2 emissions.
This clinker is transported by rail, thus saving on logistics and associated CO2
emissions.
52
Energy Consumption
With the implementation of various energy conservation measures as ongoing
practice, there is decline of specific energy consumption since the commissioning of
the plant, the specific energy consumption figures are shown below which depicts
reduction in energy consumption due to plant’s sustained efforts to conserve with
the implementation of various energy conservation measures and ideas to increase
efficiency of equipments.
Description FY 2012-2013 FY 2013-2014
Specific Electrical Energy Consumption
(kWh/T Cem) 34.35 29.89
Specific Thermal energy consumption (Million
kCal /Year) 60.08 0
Specific Electrical Energy Consumption - kWh/T Cement
34.35
29.89
25
30
35
2012-13 2013-14
Major Energy Conservation Measures taken in 2013-2014
Thondebhavi cement works has committed to protect environment by conserving
natural resources; some of the energy conservation activities undertaken by the
team are as given below:
1. Installation of VVVFD for Bag house fan in place of GRR – Achieved savings of
1.2 million kWh
2. Installation of VVVFD for Compressor – Achieved savings of 1.0 million kWh.
3. Installation of VVVFD for Bag filter fans (3 Nos.) – Achieved Savings of 0.1
million kWh
4. Up gradation of Clinker Weigh Feeder from 220 TPH to 300 TPH for improving
TPH in OPC – Achieved Savings of 1.5 million kWh
5. Elimination of Hot Air Generator operation – Achieved savings of 60.08 million
kCal/year & 1.3 million kWh
6. Compressor air optimization study by External Energy auditor – Achieved
savings of 0.3 million kWh
53
7. Optimizing the clinker rake unloading time - Achieved savings of 0.08 Million
kWh
8. Modification of bag filter vent line to reduce pressure drop - Achieved savings of
0.05 million kWh
Major Environmental Measures taken in FY 2013-2014
Energy Policy – ISO 50001
54
Certificate of Merit Cement (Grinding Unit)
THE RAMCO CEMENTS LIMITED
CEMENT GRINDING UNIT
Valapady (Tamil Nadu)
Unit Profile
Salem Grinding, unit of The Ramco Cements Limited, is set up at Singhipuram
village of Valapadi Taluk. Cement grinding capacity of the unit is 1.6 MTPA.
The grinding unit has the following salient features:
• High-efficiency separator to deliver proper size-distribution of cement.
• Computerized Central Control Room (CCR) to ensure quality assurance.
• Rotary Packers with high-accuracy for packing of cement.
Specific Energy Consumption Details
55
Energy conservation projects implemented in year 2013-14
• Upgraded capacity of plant from 80 TPH to 230 TPH by installing a pre-grinder.
This reduced the specific energy consumption of the total plant.
• Installed SPRS for Separator fan drive (HT) which is circulate the Recirculation
material in the cement mill product circuit.
• Replaced 50 nos. of existing 70 W MH well glass fittings with 42 W LED Well
Glass fittings.
• Replaced 15 nos. of existing 250 W MH street light fittings with 90 W LED Street
Light fittings.
• Converted some motors connection from delta to star connection in packing
plant. Now the packing specific energy reduced from 1.86 to 1.67 kWh per ton of
cement.
Quality, Environment & Safety Policy