ENERGY EXCELLENCEIN

J.K.WHITE CEMENT WORKS, GOTAN

Presented by (Virendra Singh Rathore)Date of Presentation (15/10/2018)

Place of Presentation (QCFI, Hyderabad)

J. K. White Cement Works & J.K.Cement Works, Gotan (Unit of J.K. Cement Ltd.) is committed to –

Provide Quality products at optimum cost & services to the satisfaction of our customer with due consideration to legal andother requirements.

Continually improve the effectiveness of Integrated Management System, which includes quality, environment, Occupational health & safety and Energy Management system.

Eliminate/ minimize and control the environmental impacts and OHS hazards of our activities and Prevent ill health & injury.

Measure, Monitor, Control and analyse the energy consumption and take appropriate action to reduce the energy consumption.

Support the energy efficient products, services and design for energy performance improvement.

The resources required for the implementation of this policy are made available on priority by Unit head.

Management policy, objectives and targets are established and reviewed for continuing suitability during management review meetings.

Management policy is communicated and explained to the persons working in the organization and working on behalf of the organization.

Ensure that policy is made available to all employees and stakeholders.

Ensure that Policy is regularly reviewed and updated as necessary.Y.P.SINGHANIAManaging Director

ENERGY POLICY UNDER IMS POLICY

ENERGY MANAGEMENT TEAM

J.K.White Cement Works, Gotan is ISO 50001 certified unit and the unit has a dedicated Cross functional energy management team –

1. Technical Head- Head of the EnMGMT Team2. Management representative- ISO 50001 3. Electrical Head4. Instrumentation head 5. Process Head6. Mechanical Head 7. Project Head

Head of the Energy management team reports to Unit Head

ISO 50001 CERTIFICATION

HIGHLIGHTS

CERTIFICATION DONE ON : 19 MARCH 2015

CERTIFYING BODY : LRQA , UK

AUDIT SCOPE :

1. Manufacturing of White Cement & Dry Mix Mortars .

2. Thermal Power Generation Capacity 7.5 MW

S.No. Title of EnMP Annual savings (KWH)

Savings in Rs. tCO2

1 Installation of energy efficient Screw Blower in place of Low pressure KG khosla Reciprocating compressor 284700 2027064 256.23

2Installation of 1.1kw (1.5HP) SHAKTI make energy efficient inline vertical multistage pumps in place of horizontal multistage pumps ( 1.5 kw-2 HP)

8832 62883.84 7.95

3 Replacement of CFL/Metal Halide/Fluorescent tube lightings by LED lights 136583 972470.96 122.92

4 Replacement of Oversize motors 22162 157793.44 19.95

5 Installation of 25 HP Shakti Submersible pump in Mines Tube Well. 35260 251051.2 31.73

Energy Saving Projects Implemented in 2017-18

Energy Saving Projects Implemented in 2017-18

S.No. Title of EnMP Annual savings (KWH) Savings in Rs. tCO2

6 Energy saving by replacing RAL and installing gravity flap at RM inlet 10800 76896 9.72

7 Installation of variable frequency drive(VFD) for bag house fan for Petro coke Mill-1. 10333 73570.96 9.30

8 Operation interlocking of hopper filling conveyor belt in order to avoid idle running of belt conveyor. 33333 237331 30.00

9 Operation interlocking of hopper filling conveyor belt conveyor. 29747 211798.6 26.77

10 Installation of occupancy Sensor in Office & Conference Hall. ------- ------- -------

TOTAL 571750 4070860 514.58

Installation of Solar Power System at Mines Weigh Bridge

Solar system consists of 10 PV solar panels, each with a capacity of 255 W, totalling2.5 KW. The solar panel is connected to a solar charging controller which chargesthe battery bank. The battery bank is connected to a 3 KVA UPS which gives a 220V AC single phase output; the UPS is also connected to a 2 KVA generator set foremergency power supply.

Non-availability of power supply at

Weigh Bridge

Grid supply not available

Remote area

DG not available

No other source of power

Average Generation/Month – 30kwh

Innovative ideas implemented

Innovative ideas implemented

Installation of occupancy Sensor in Office & Conference Hall

Office lightings of 4 major areas of plant – Technical Building conference hall, New admin building –commercial and accounts department , Production Office and Maintenance building , on /off control fully of lights were manually operated due to which there are chances of wastage of electrical energy may happened if lights are not switched off while leaving the office. We have installed the Occupancy sensors in these major office areas which has automatically switch off the lights when there is no one in the office.

USE OF CINDER AS AN ALTERNATIVE FUEL

PROBLEM - Cinder was a product which was generated at our own thermal power plant at the rate of approximately 35 MT/day The existing layout of Petcoke grinding mills does not allow us to mix Petcoke and Cinder at grinding stage. IMPROVEMENT – At Petcoke storage yard we have installed three separate hoppers for Petcoke, Cinder and TDI tar. The controlled mixing will be done by three separate belt feeders which will be running with VFD at different feed rates.

Innovative ideas implemented

MAXIMISING USE OF VFD

Optimizing motor control system by installing or upgrading to VFDs to reduce energy consumption . Accordingly VFD installed at selected equipments where we found process variations .

S.NO. SEGMENT NO. OF VFD'S

1 WHITE CEMENT 104

2 PUTTY PLANT 34

3 CAPTIVE POWER PLANT 16

S.NO. KEY LOCATIONS WHERE VFD INSTALLED AREA

1 RAW MILL SEPARATOR RAW MILL

2 RAW MILL DRYER FAN RAW MILL

3 STEAM EXHAUST FAN KILN

4 HOT AIR FAN KILN

5 NEW ESP FAN KILN

6 CEMENT MILL-1 & 2 SEPARATOR FAN CEMENT MILL

7 CEMENT MILL-3 AIR VENT FAN CEMENT MILL

8 PETROCOKE MILL BAGHOUSE FAN PC MILL

9 BOILER FEED PUMP THERMAL POWER PLANT

10 FD FAN THERMAL POWER PLANT

11 ID FAN THERMAL POWER PLANT

12 ACC FAN THERMAL POWER PLANT

MAXIMISING USE OF VFD

Optimizing motor control system by installing or upgrading to VFDs to reduce energy consumption . Accordingly VFD installed at selected equipments where we found process variations .

Innovative energy conservation projects/Renewable Energy projects under implementation-

Organization has plan to install the 150 KW Solar Power Plant on Roof of NewAdmin Building of J.K.White Cement works, Gotan which will run insynchronization with grid. Power generated from this plant will be used in newADM building. Cost of electricity from grid is increasing constantly which forces usto think for renewable energy sources of electricity.

KNOWLEDGE SHARINGOrganization has a tradition of sharing the energy savings related case study ,published in the KEP newsletter for sharing it to all over India . J.K.White cementworks , Gotan ’s 4 case study has been published in KEP Newsletter-

CASE STUDY PUBLISHED IN ISSUE-2, JUNE, 2015 NEWSLETTER

1. Implementation of ISO 50001 at J.K.White Cement Works2. Reduction in specific energy consumption of limestone crusher by increasing its per hourtonnage

CASE STUDY PUBLISHED IN ISSUE-4, SPECIAL EDITION-NECA 2015

1. Installation of VFD at CPP Coal Crusher2. Installation of VFD at CPP Primary Air (PA) Fan

CASE STUDY PUBLISHED IN ISSUE -7, JULY 2017

1. Installation of Solar power system at Mines weigh Bridge of Dhannapa Limestone Mines of JK White Cement Works, Gotan

Sl. No Description Units 2016-17 2017-18

1 MTOE reduction MTOE 0.000033 0.000049

2 Kiln Thermal SEC kCal/kg clinker 1024.7 989.46

3 Specific Electrical Energy - clinkering kWh/T of clinker 55.44 57.45

4 Specific Electrical Energy – Grinding kWh/T of cement 39.93 39.30

5 CPP Heat rate kCal/kWh 4018 4114

6 CPP auxiliary consumption % 9.55 % 9.67 %

7 Thermal Substitution Rate % 0 0.71%

8 Clinker factor % 0.916 0.892

9 Blended cement *%) of total cement % ---- ----

10 Renewable Energy (RPO)

11 REC Purchased – Solar REC 1347 1737

12 REC Purchased – Non Solar REC ---- ----

13 Specific CO2 emission Kg CO2/ kg cement 0.5653 0.5003

ENERGY PERFORMANCE

Remarks- REC- solar purchasing is done at group level of J.K.Cement Ltd.

Energy Monitoring Methodology

Online Energy monitoring System

(EMS System)

Energy monitoring through Daily Power

report

Communication of Electrical Energy(KWH/Ton of cement) &

Thermal Energy(Kcal/Kg of clinker)to Process & Maintenance

Dept. on daily basis

Daily Review By

Concerned Process

Departments

Reviewed by Technical Head &

Unit Head on daily basis

RCA of Energy Deviation by

concerned Process Department

Energy saving Potentials/

Management Programme proposed

by Process & Maintenance Department

Feasibility Testing & approval of Energy

Management Programme

Documentation and Implementation

Observation and Monitoring of Energy

Management Programmes &

Savings

387580

571750630000

0

100000

200000

300000

400000

500000

600000

700000

2016-17 2017-18 2018-19

KW

H

YEAR

ENERGY SAVINGS (KWH)

ENERGY SAVINGS ACHIEVED

10

1719

0

5

10

15

20

25

2016-17 2017-18 2018-19

No.

Of E

nMP

YEAR

ENERGY MANAGEMENT PROGRAMMES

ENERGY MANAGEMENT PROGRAMMES (EnMP)

109.31108.54 108.87

100.00

102.00

104.00

106.00

108.00

110.00

112.00

2015-16 2016-17 2017-18

KW

H/T

on o

f Cem

ent

YEAR

ELECTRICAL ENERGY - KWH/TON OF CEMENT

ELECTRICAL ENERGY PERFORMANCE

953.12

934.72

881.25

800

820

840

860

880

900

920

940

960

980

1000

2015-16 2016-17 2017-18

Kca

l/Kg

of C

emen

t

YEAR

THERMAL ENERGY

THERMAL ENERGY PERFORMANCE

1379

1365

1355

1360

1365

1370

1375

1380

1385

TARGET ACHIEVED

Kca

l/K

g of

Cem

ent

PAT FIRST CYCLE - TARGET V/S ACHIEVED

PAT Ist Cycle - TARGET V/S ACHIEVED

ENERGY PERFORMANCE – PAT CYCLE-1

431

0

50

100

150

200

250

300

350

400

450

500

2012-15

No.

Of E

scer

ts

PAT FIRST CYCLE

No. Of Escerts Earned

PAT Ist CYCLE – EsCERTS EARNED

TOTAL ENERGY CONSUMPTION- Kg CO2/ kg cement

0.56530.5003

0

0.25

0.5

0.75

1

2016-17 2017-18

Kg

CO

2/ k

g ce

men

t

YEAR

SPECIFIC Kg CO2/ kg cement

MAINTAINING THE POWER FACTOR

0.99 0.99 0.99 0.99 0.99 0.99

0.80

0.90

1.00

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

POW

ER F

AC

TOR

YEAR

POWER FACTOR

Use of High Efficiency Motors(IE3)

Operation of Fans with Variable Frequency Drives

Use of LED Lights

Energy consumption tracking by Energy Management System

High efficiency fans

Mechanical transport in place of pneumatic

High efficiency separators

Use of Renewable energy sources as a means of installing Solar Power Panels for office lighting

Air Heater for Thermal Energy

BEST PRACTICES – ENERGY

BEST PRACTICES -ENERGY Online Power monitoring through EMS system

High efficiency Screw Compressors

Capacitor installation to achieve high Power Factor of Grid Supply

Purchase Power from Open access to reduce the cost of power.

In-house development and modification of burner to use petro coke and fuel oil

RMP control through QC X-Ray Analyser With XRF and XRD Features

Automation of RM tunnel extraction system

Small packing automation with high-speed packing machines

Ultra-sonic level sensor installation for silo level / material balance

JK White Cement Works, Gotan was awarded Certificate of “Recognition award” for the conscious and systematic efforts put in for efficient utilisation and measurable conservation of energy during the year 2014-15 compared to the preceding year (2013-14). Award was given by Mr Sanjay Malhotra, Principal Secretary (Energy), energy department, government of Rajasthan. Ceremony was organized by Rajasthan renewable energy corporation limited (RRECL) on 14-12-2015 at Indralok Auditorium, Sawai Mansingh Rd, Rambagh, Jaipur.

ENERGY CONSERVATION AWARD BY RRECL

JOURNEY CONTINUES………….

THANKS!