shree cement ltd. beawar, india - cii award... · shree cement ltd. beawar, ... preheater kiln raw...

An Energy & Environment Conscious, Sustainable & Prosperous Organization

Shree Cement Ltd. Beawar, INDIA

National Award for Excellence in Energy Management 2009

Presented by Sanjay Singh


Presentation Sequence

Shree Cement Profile

Cement Manufacturing Process

Energy Performance

Energy Saving Projects

Innovative Projects: case studies

Energy Management Practices in SCL

Climate Security

Recognitions



Among the Top Five Cement Groups in India.

Operating at Beawar, Ras, Khushkhera, Suratgarh & Roorkee.

Largest Cement Player of North India.Entered into Merchant power business.One of the Highest Operating Profit Margins.Turnover- US$ 773 Million


Rising Trend in Cement capacityShree Cement Profile


Rising Trend in Power generationShree Cement Profile

Shree Power Gen Capacity (MW)


Vision & Guiding PrinciplesShree Cement Profile

“To drive and sustain industry leadership of the company within aglobal context- by developing individual leadership competencies at every level, through a robust back bone of Trust, Support, Innovation and Reward.”

Vision

Guiding PrinciplesEnforce good corporate governance practices

Encourage integrity of conduct

Ensure clarity and unambiguity in communication

Remain accountable to all stakeholders

Encourage socially responsible behavior


Management Systems

ISO-14001 – Environmental Management System

OHSAS-18001 – Occupational Health & Safety

SA- 8000 – Social Accountability

ISO-9001 Quality Management

BS-EN 16001 – Energy Management System


MANAGEMENT SYSTEMS


SHREE ULTRA

BANGUR CEMENT

ROCK STRONG

Marketing Strategy Shree Cement Profile

Market Leader in Rajasthan, Delhi and Haryana

Convey social messages along with brand building such as ‘Save Water’, ‘Blood donation’, ‘Swatantarta keRakshak’ etc.


First Indian Cement Company to join Cement Sustainability Initiative of WBCSD.

Global Reporting Initiative to improve information sharing on Environment and Social issues.

Endorsed the Global Roundtable Joint Statement on Climate Change to discuss issues for shaping public policy on climate change..

Shree Cement ProfileGlobal Partnership

Member of Cement Sector Task Force of APP-7, formed by Govts. of India, USA, China, Japan, Korea, Canada and Australia.


Appointed Leader of Cement Sector Task Force for the 7th

consecutive year by Bureau of Energy Efficiency, Ministry of Power, Government of India.

One of the lowest Power & Fuel Consumption in the industry.

Shree remains the benchmark for other companies in terms of overall energy efficiency.

Recognized R&D Centre by Govt. of India

Shree Cement ProfileAchievements

Highest 4 star rating for 9th consecutive year by Whitehopleman U.K.


Plant in India to develop process for production of synthetic gypsum.

Cement company of the World to receive 4.5 LacsCertified Emission Reductions (CER’s) on its Clean Development Mechanism project “Optimal Utilisation of Clinker”.

Company in the World to utilize 100% petcoke in its operations.

Shree Cement ProfilePioneer Activities

Indian cement company to issue Corporate Sustainability Report according to GRI guidelines.

Clinkerisation Unit (U-VII) of 1 MTPA capacity commissioned in record time of 367 days .

An Energy & Environment Conscious, Sustainable & Prosperous Organization 12

Cement Manufacturing Process

PackingWagon & trucks

Cement silo Roller press cum Cement mill

Cement Millhopper

Clinker stock yard

KilnPreheater

Raw millsilo

Raw mill Raw mill hopper Reclaimer

StackerMines


Annual Comparison of Power Consumption

Annual comparison of Thermal Consumption

Energy PerformanceDecreasing Trends & Targets

2009-10 NCBM Avg. Benchmark

84


AverageShree

Cement Best

Aux

Packing

Cement Grinding

Kiln

Raw Materials Grinding

Total

0.00

20.00

40.00

60.00

80.00

100.00

120.00

kwh/t

Power Consumption

The graph shows Shree power consumption is well below the average

BenchmarkingEnergy Performance


Energy Saving ProjectsImplemented during 2007-08 & 08-09


SN

Title of Project Annual Electrical Savings Investments Rs. Million

Units Million Million Rs.

1. Installation of SPRS in Raw Mill Fan 0.48 2.92 6.8

2. Installation of SPRS in (SKS) Fan0.12 0.72 2.4

3. Implementation of Slip Power Recovery System in Raw mill ESP fan 0.43 2.59 2.5

4. Installation of VFD in damper controlled Cooler fan (4Nos) 0.36 2.16 1.94

5. Replacement of Cooler ESP fan HT Motor with LT motor and VFD 0.45 2.7 2.0

6. Increase the stack Height of Cooler ESP Fan 0.12 0.72 0.2

Energy Saving ProjectsImplemented during 2009-10


Innovative Projects - Case Study - I

Installation of flame analysis system from Powitech for reduction of fuel consumption in Kiln

Before the installation of Powitech system = 741 kcal/kg.cl

Annual Saving in Coal consumption = 2460 MT

After the installation of Powitech system = 720 kcal/kg.cl

Annual saving in Rs = 19.7 million

Cost involved in this project = 20 million

Simple pay back = 12.17 months

Reduction of CO2 Emission = 8019.6Ton / Annum* As per clinker production for 2008-09


Increase the stack Height of Cooler ESP Fan by 7.8 meters

Before the increase of stack height After the increase of stack height

Fan Efficiency* measured before

= 35.33%

Fan Efficiency measured after

= 57.53%

Saving in Power Consumption of ESP fan = 16kWh

*Reduction of CO2 Emission = 108 Ton / Annum

* As per clinker production for 2008-09

Innovative Projects - Case Study - II


Innovative Projects - Case Study - III

Waste Heat Recovery at Six Stage Preheater – A Milestone

Flue gases are released from preheater andCooler. WHR installed for the recovery ofthe waste heat from exit gases.

Barriers:vLow heat content in gases that exit from 6 stage PHvHigh Dust ContentvHigh cost of installation

Solution:vSpecific design of boiler in view of high dust load

and low enthalpy in waste gasesvHammering system

8 MW WHR resulted in 349916 tons/ annum CO2 emission reductions


Pre-

Heater (PH

)

Air Quenched Cooler (AQC)

GCT

KilnESP

Kiln Feed

Coal Mill

Clinker from Kiln

Hot Gas to Kiln

Hot Gas to TAD

Pre-heated Kiln feed Hot

gas

Clinker

Pre-heater Exit gases

(300ºC)

Exit gases(150ºC)

Fuel

Exit gases

Innovative Projects - Case Study – III cont.

Pre-Heater

(PH)

Air Quenched Cooler (AQC)

GCT

Kiln

ESP

Kiln Feed

Coal Mill

Clinker from Kiln

Hot Gas to Kiln

Hot Gas to TAD

Raw mill and Vented out

Pre-heated Kiln feed

Hot gas

Vented out

Clinker

AQC Boiler

PH Boiler

HP, LP header & Flusher Turbine

Pre heater

Exit gas (300ºC)

Pre heater Exit gas (300ºC)

Exit gas (150ºC)

AQC gas (400ºC)

Air

Air


SR.V P (Works)

Energy Monitoring CELL Headed by Energy Manager Engineer Utilities

(Steam, Power & Water)

Energy Audit Benchmarking Contact Process Equipment Supplier

Energy MonitoringMeasure Identification& Implementation

Investment & Return Analysis

Idea Generation Activities Small Group Activities

Chemical Engineer

Electrical EngineerPower Utilization

Managers(Process & Engg)

UnitsHead

Energy Management Practices in SCL Monitoring and Reporting System


To communicate ideas

To bring all the members into the mainstream

To encourage active participation

To tap into the latent potential of employees, reduce costs, increase productivity and ultimately, profits.

Idea Generation Activities Energy Management Practices in SCL

Implementation of Suggestion Scheme Measures adopted in SCL

“Jo Soche Who Paave”

Employees to think like leaders by providing them a platform

Resulted in


Identification of Energy conservation areas in the plant.

Prioritization of identified energy conservation areas.

Finding out of technical feasibility including, market availability and cost benefit analysis.

Renewable energy identification

Benefits :Implementation of Energy Monitoring

Plan and energy analysis thereby optimizing energy consumption.

Benefits through cost reduction.

Adoption of BS-EN 16001

Development Without Destruction

Commitment for Climate Security


Initiatives for Carbon Emission ReductionCommitment for Climate Security

S.N Title of project implemented Year of Implementation

Total CO2 Reduction

1 Optimal utilization of clinker by using fly ash in cement 2001-02

293818(Project completed

in July-2010)

2 *Waste heat recovery from Preheater & Cooler for power generation 2008-09 51051

3 **Utilization of Biomass fuels for Pyro processing in Cement plant 2006-07 33232

*Project is under validation for CDM. **Registered at UNFCC


CO2 Reduction as per CSI Protocol

When We Put the Environment First, Development Will Last



“Use of 100% Petcoke, a waste from Oil Refineries, thereby conserving Fossil Fuels.

Maximized use of slag, a waste from smelting plant, thereby conserving iron ore.

Developing new environment friendly alternative raw materials & conserving natural resources.

Optimal Utilization of ResourcesCommitment for Climate Security


Alternatives Percentage

46 MW Green Power Plant (WHR based) 49.5 % of total power used

Fly ash 30 – 32 % replacement of clinker

Petcoke 100 % replacement of coal

Slag from Smelter 2.4 % of Raw Material

Use of AlternativesCommitment for Climate Security


Cultivation of micro algae for 5% replacement of petcoke.

Installation of 50 MW Solar Power Plant.

LED and Solar power for lighting.

Installation of Flue Gas Desulphurization Unit at Power Plant.

Adoption of Powitech Process Optimization with Intelligent Technologies.

Development of system design for use of pond fly ash.

Futuristic Approach to Mitigate CO2 Emissions

Our Earth - Our Future - Just Save It



Recognitions

µFirst prize for Energy Conservation by Bureau of Energy Efficiency.

µFICCI SEDF Corporate Social Responsibility Award.

µ CII Sustainability Award

µQuality Excellence Award –By NCCBM

µGolden Peacock Award for Climate Security

µExcellent Water Efficient Unit –Awarded by CII


µEnergy Efficiency Award -Awarded by CII

µGreen Business Award by Emergent Venture India & Financial Express

µNational Award for Excellence in Cost Management

µ Energy Conservation Award by Bureau of Energy Efficiency.

Recognitions


May our earth with all its beauty produce a harvest of PEACE and PROSPERITY

- Rigveda

Thank you

Visit us at: www.shreecementltd.com

shree cement ltd. beawar, india - cii award... · shree cement ltd. beawar, ... preheater kiln raw...

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