19 National Award For Excellence In Energy Management-2018 ... … · cement mill-1 (60 kW) 3.39 02 07 Re-Routing of dry fly ash transportation line. (60 kW) 1.84 2.9 08 Kiln inlet

J K LAKSHMI CEMENT, SIROHI, RAJASTHAN

19TH National Award For Excellence In Energy Management-2018

Presented By:-

Pradip Kr. Ghara, Sr. Mgr. (Elect.)

Kanish Kr. Singh, Asst. Mgr (Process)(EM-13473)

Brief Introduction of JKLCL – Sirohi, Rajasthan

19TH National Award For Excellence In Energy Management-2018

ISO 9001 ISO 14001 OHSAS 18001 ISO 50001

53 GRADE 43 GRADE PPC GRADE

RMC AAC BLOCK POP

Products Manufactured Here .

PRO+ GRADE

PLANTYEAR OF

COMMISSIONING

INSTALLED CAPACITY

(TPD)

PRESENT

STATUS

(TPD)

KILN-1 1982 1500 4500

KILN-2 1995 2500 5000

KILN-3 1996 2500 5000

Journey Towards Up gradation……..

Established

in Aug1982

with 0.5

MTPA

capacity.

Unit – II

Commissioned

in 1995 with

0.9 MTPA

capacity.

Unit – III

Commissioned

in 1996 with 0.9

MTPA capacity.

Present Cement

Production

Capacity 4.64

MTPA.

Year(April March)

Specific Energy ConsumptionRedn. in SEC Over

previous years

ElectricalThermal Elect. Thermal

Kwh/Ton of Cement(excl. Crusher)

KCal/kg of clinker

% %

2014-2015 76.46 704 3.03

2015–16 77.62 677* (- 1.52)** 3.84

2016–17 77.73 699 (- 0.14) ** (- 3.25)

2017-18 75.87 697 2.39*** 0.286

** Increased because of Less PPC production and increase in Ball Mill run hrs

* Reduced due to easy burning material from mines

*** SEC up to clinker reduced for energy saving in SPRS, VRM & more PPC

production

Energy Performance Since 2014……

A Comparison with National & International Benchmark

Thermal Energy Consumption (Kcal/KG Clinker)

600

650

700

750

660684

704677

699 697

Kca

l/

Kg

C

LIN

KE

R

• Reference : CII Energy Benchmarking study carried out at JKLC in May,2018

A Comparison with National & International Benchmark

Electrical Energy Consumption(Unit/ton cement )

60

65

70

75

80

International

Benchmark

National

Benchmark

2014-15 2015-16 2016-17 2017-18

65

65.67

76.4677.62 77.73

75.87

KW

H/

MT

C

EM

EN

T


Electrical Energy Consumption(For Raw Grinding Section)

0

5

10

15

20

JKLC

U-I VRM

JKLC

U-II VRM

JKLC

U-III VRM

COUNTRY

BEST

12.21 9.87 9.6713.3

KW

H/

MT

M

AT

ER

IAL


Incl: Main drive, Mill Fan, Classifier & Reject Elevator Power

Electrical Energy Consumption(For Clinkerization)

• Due to High PH Fan Power due to High Pressure Drop Across PH

0

5

10

15

20

2523.09 22.2 21.61 24.5

16.92

KW

H/

MT

C

LIN

KE

R


Electrical Energy Consumption(Up to Clinkerization)

0

10

20

30

40

50

60

JKLC U-I JKLC U-II JKLC U-III OVERALL

JKLC

COUNTRY

BEST

52.45

44.85 44.61 47.143.32

KW

H/

MT

C

LIN

KE

R

Kca

l /

Kg

of

Clin

ker

A Comparison Thermal Energy Consumption with Plants in same

cluster (Kcal/Kg of Clinker)

650

660

670

680

690

700

710

720

JKLC CII

CLUSTER

FIGURE

A B C

697694

720

687

676

Kca

l/

Kg

C

LIN

KE

R

A Comparison Electrical Energy Consumption with Plants in

same cluster (Unit/ton cement )

73

74

75

76

77

78

JKLC A B C

75.87

77.38

75.53

74.73

KW

H/

MT

C

EM

EN

T

• To Reduce Pressure drop From Mill O/L to Fan I/L In

VRM(0.2Kwh/t of material)

• To reduce Pressure drop across Cyclone of VRM(1 Kwh/T material)

• Installation of Pre-Grinder in Cement Mills.

• To reduce pressure drop by 40 mmWc across down comer duct(0.5

Kwh/t of Clk)

• PH fan efficiency improvement by 5 %.(0.5 Kwh/t of Clk)

• Top cyclone efficiency improvement (3 kcal/Kg clk)

• Improving separator efficiency of Cement mill-1(0.3 Kwh/T cement)

Road Map to achieve the National / International Benchmark

Energy Benchmark study through CII-GBC, Hyderabad, May18.

❖Replacement of AQC fan with high efficient fan.

❖Installation of AQC boiler in Line-3

❖Reduce the pressure drop across Mill body in Raw mill-4

❖Replacement of conventional lights with Led(Ongoing).

❖ Installation of New Louver Ring in RM-2 in upcoming shut down

Road Map to achieve the National / International Benchmark

Energy saving Proposals based on Internal Audits

(SGA/CFT/KAIZEN/Technical cell

0.0877

0.0833

0.0747

0.09880.0940

0.06

0.07

0.08

0.09

0.1

0.11

0.12

Base Line (On PPC)-

PAT cycle-1

Target (On PPC)-PAT

cyce-1

Achieved(On PPC) PAT

cycle-1

Base Line(On OPC)-

PAT Cycle-2

Target(On OPC) PAT

cycle-2

MT

OE

/to

n p

rod

uct

PAT Performance

Target

Reduction

4.91%

Achieved

Reduction

14.82%

Target

Reduction

4.86%

PAT (Performance, Achieve & Trade)

Energy Conservation projects since 2015……

Sr.

No.DESCRIPTION UNITS

ZERO

INVESTMENT

WITH

INVESTMENT

ATOTAL PROJECT

IMPLEMENTEDNO.S 36 19

BTOTAL ELECTRICAL ENERGY

SAVINGS

MILLION

KWH6.23 7.33

CTOTAL THERMAL ENERGY

SAVING

MT OF

COAL16822 0

D TOTAL SAVING

I ELECTRICAL RS MILLION 47.69 60.98

II THERMAL RS MILLION 98.9 0

E TOTAL SAVINGS RS MILLION 146.59 60.98

F TOTAL INVESTMENT RS MILLION NIL 42.13

*All savings calculation is on per annum basis

Energy Efficiency Improvement Activities

Last Three Years Project ( 2015-16, 2016-17, 2017-18)

S.

No

List of Major Energy Saving Projects

(2015-2016)

Annual Saving Rs.

Million

Invest.

Made

Elect. ThermalRs.

Millions

01

Optimization of VRM by modification of

Nozzle ring and optimization of mill bed

height. (133 kW)

7.241 - -

02

Optimization of Coal Mill by grinding

media and modification of intermediate

diaphragm. (61 kW)

3.308 - -

03

Optimization of Kiln-3 Compressors

Operation by reducing the operating

pressure of Compressor. (15 kW)

0.89 -

04Modification in discharge circuit of Ball

mill and TCDRI VRM. (6.88 kW)0.374

Major Energy Saving Projects Zero Investment (2015-16)

S.

No


(2015-2016)

Annual Saving Rs.

Million

Invest.

Made

Elect. Thermal Rs.

Millions

05Replacement of 2 nos. of screw conveyors

with chain conveyors. (8 kW)0.494 - -

06Optimization of kiln operation.

(16630 MT Coal Saving /Annum)97.37 -

07

Replacement of 18 KW Analyzer water

pump with 5.5 KW water pump

(8 kW)

0.356 - -


S.

No


(2016-2017)

Annual Saving Rs.

Million

Invest.

Made

Elect. Thermal Rs.

Millions

08

Optimization of Dam Ring Height in China VRM

(70 mm to 56 mm)

(110 kW )

6.19 -

09

Arresting of false air in pre-collector and

replacement of expansion joint in china VRM

(22 kW)

1.24 - -

10

Reduction in PH fan power consumption in Kiln-3

by arresting false air ingress

(30 kW )

1.84

11

Remove 35 BE1 Bucket elevator in precrusher

(Feeding belt discharge in vibrating screen instead

of bucket elevator)

(15 kW )

0.84


S.

No


(2016-2017)

Annual Saving Rs.

Million

Invest.

Made

Elect. Thermal Rs.

Millions

12

One air slide blower stopped in PH-1 VRM

(To be remove from group and interlock air

slide blower made it stand by for 2606 )

(7 kW)

0.41 - -


S.

No


(2017-2018)

Annual Saving Rs.

Million

Invest.

Made

Elect. Thermal Rs.

Millions

13Blended appron feeder and spillage conveyor

removal from the circuit (5 KW)0.28 - -

14Reduced power consumption in 10FN-1 Dust

collector Fan (18 KW)1.02 - -

15Reduce power consumption in Kiln-1 cooler

fans through optimization (15 KW)0.92 -

-

16

Saved Power consumption by reducing the

pressure drop across the dampers of Silo Top

Bag Filter Fan in Kin-2 (9 KW)

0.55 --

17

Reduced Power consumption in Kiln-1 CV

Fan by removing the damper as fan always

runs with VFD (10 KW)

0.62 --

18Optimization of cooling air in kiln-1 by

cleaning of grate plates (46 KW)2.82 - -


S.

No


(2017-2018)

Annual Saving

Rs. Million

Invest.

Made

Elect. Thermal Rs.

Millions

19Removal of Bag filter fan from dry fly ash

Circuit in CM-2 (9 KW)0.31 - -

20 False air Arresting in RM-4 (5 KW) 0.28 - -

21Optimization of separator BH DP in CM-1,

CM-3,CM-5,CM-6 (16 KW)0.91 - -

22Sphere slot of outlet diaphragm has been

blocked in cement mill-1 (25 KW)1.42 - -

23Modification Of Cheek Plate in CM-2 HRC

(10 KW)0.57 - -


S.

No


(2017-2018)

Annual Saving

Rs. Million

Invest.

Made

Elect

.

Thermal Rs.

Millions

24Modification in Pre crusher Circuit by removal of

Belt Conveyor 35-BC-3 (11 KW)0.56 - -

25Booster Fan Inlet Damper replaced by Distance

Piece in coal mill-1(3 KW)0.17 - -

26Pre crusher dust collector fan damper

Removal(35-FN-1 & 35-FN-2) (10 KW)1.02 - -

27Apron Feeder DC Drives replace with AC drives

in RM-2 (3 KW)0.17 - -

28

Reduction in Electrical & Heat Consumption by

Optimizing the Coal Conveying Volume in Kiln-

1(18 KW & 1 Kcal/Kg Clk)

1.11 1.53 -

29 VFD Installation in Tippler Bag filter fan (9 KW) 0.31 - -

30

Interconnection of RM-1 Compressor 36CP-3

with Raw Mill-4 Bag House Compressor 361CP-

1 (29 KW)

1.64 - -


S.

No


(2016-2017)

Annual Saving Rs.

Million

Invest.

Made

Elect. Thermal Rs.

Millions

31Reduce pressure drop across Bag House Fan

inlet damper in Raw Mill-4 (12 KW)0.68 - -

32

Reduce power consumption of Kiln-2

andKiln-3 Blaster compressor by optimization

of Blaster Operating freq. & compressor

loading-unloading pressure (55 KW)

3.38 - -

33Interconnection of Kiln-2 PH blaster compr

with Kiln-2 inlet seal compr (22 KW)1.35 - -

34

Interconnection of Kiln-1 PH Blaster compr

with 3 nos. of other compr (KGG; Cooler

Blaster & Chemical Lab) (25 KW)

1.54 - -

35Optimization of CM-1,CM-3,CM-5,CM-6 Bag

house system (34 KW)1.91 - -

36 CM-1 CA Fan I/L Damper Removal (22KW) 1.25 - -


*All savings calculation is on per annum Basis

Major Energy Saving Projects With Investment

Since 2015…..

Total Projects Implemented : 19

Total Electrical Energy Saving : 7.33 Million KWH

Total Thermal Saving : 0 MT of Coal

Total Savings in Rs :

Electrical : Rs. 60.98 Million

Thermal : Rs. 0 Million

Total Savings : Rs. 60.98 Million

Total Investment : Rs. 42.13 million

S.

No


(2015-2016)

Annual Saving Rs.

Million

Invest.

Made

Elect Thermal Rs.

Millions

01Installation of 02 Nos. of 75 KW VFD’s in Pre

Crusher Bag filter Fans. (10 kW)0.54 0.50

02Installation of 650 KW SPRS in Fly Ash Drier

Fan. (10 kW)0.30 1.05

03Modification in 465 KW Kiln-2 CV Fan SPRS

system. (42 kW )2.47 0.80

04Replacement of 50 Nos. CFL 15 W to LED

lamp 7W in colony (0.17 kW )0.01 0.0035

Major Energy Saving Projects With Investment (2015-16)

S.

No


(2016-2017)

Annual Saving Rs.

Million

Invest.

Made

Elect Thermal Rs.

Millions

05Replacement of 27 Nos. 40W Tube lights to 20

nos. LED 7 in ADM Building (0.94 kW )0.003 0.002

06Installation of high efficient fan with VFD in

cement mill-1 (60 kW)3.39 02

07Re-Routing of dry fly ash transportation line.

(60 kW)1.84 2.9

08Kiln inlet riser duct modification in kiln-1

(60 kW)3.68 1.2

09Modification of Raw Mill -2 by CFD of

Cyclones and duct (60 kW)3.38 0.6


S.

No


(2016-2017)

Annual Saving Rs.

Million

Invest.

Made

Elect Thermal Rs.

Millions

10Modification of Raw Mill -3 by CFD of

Cyclones and duct. (60 kW)3.38 0.6

11

Installation of IGBT based digital SPRS in

place of thyrister based analolouge SPRS in

raw mill-3 (50 kW)

2.81 2.7

12Installation of recirculation damper in CM-2

Stack (12 kW)0.68 0.2

1323 nos 150 watt HPSV street light lamp replace

with 40 watt LED lamp. (2.5 kW)0.072 0.1


S.

No


(2016-2017)

Annual Saving Rs.

Million

Invest.

Made

Elect Thermal Rs.

Millions

14735 nos. 36 watt fluroscent tube rod replace

with 22 watt LED tube rod. (10.2 kW)0.291 0.3

1520 nos. 150watt HPSV street light lamp replace

with 60 watt LED lamp. (1.8 kW)0.051 0.1


S.

No


(2017-2018)

Annual Saving Rs.

Million

Invest.

Made

Elect Thermal Rs.

Millions

16417 Nos. Conventional HPSV Lights replaced

with Energy Efficient LED lights (33 KW)1.13 - 2.2

17

Installation of HOT Air Recirculation in Kiln-2

to increase the Green Power Generation

(Through WHRS) (9500 Units/Day)

24.36 - 22.2

18Installation of Active Harmonic Filter (AHF) for

Power Factor improvement 4.14 - 4

19Installation of New Louver Ring in RM-3

(150 KW)8.46 - 0.5


at JK Lakshmi Cement

Reduction in Raw mill fan power consumption by installation of aerofoil design louver ring in VRM-III

Innovative Project-I

Background: Pressure drop across Mill

(892 mmwg)

Probable reason : Non uniform distribution

of air across louver ring

Action taken : Thorough study and replacement of louver ring

aerofoil louvers

Reduction in Raw mill fan power consumption by installation of

aerofoil design louver ring in VRM-III

Innovative Project-I

•This modification helped us to reduce

pressure drop by 62 mmwg.

• Production Increased by 3 Tph.

• Total units saved : 1089000 KWH/Year

• Total Savings : 5.98 Million/Annum (@5. 5Rs/Unit)

• Total Investment : 0.35 Million

• Payback Period : 1 Month

Savings in terms Power Consumption

•There is saving of 150 units/hour

in Raw mill fan Power

Installation of Hot Air Recirculation in Kiln-II to generate

more green power

Innovative Project-II

➢ Hot Air Recirculation in Fan Nos.6 , 7 & 8.

➢ Gross Power Generation Increased by 9500 Units/Day.

➢ Commissioned in January,2018.

➢ Reduction in Green House gases 12085 Kg CO2/Day.

Duct From CV Stack Entry At Fans

Innovative Project-II

Cost Benefit Analysis

• Total units generated : 3135000 KWH/Year

• Total Savings : 17.24 Million/Annum (@5.5 Rs/Unit)

• Total Investment : 22.2 Million

• Payback Period : 15 Months

Benefit & Savings

Particulars Units/Day

Increase in Power Generation from WHR

System

KW 9500

Reduction in Green House Gases Kg of CO2 12085

Reduction In Numbers of Hammers in Pre Crusher

Innovative Project-III

Background :Heavy Wear pattern of Hammers &(40%) of Hammers running Idle.

:Total No. Of Hammers : 102

: To reduce Maintenance time

Idea Generation: Study of the wear pattern

Action Taken : Decision to eliminate alternate row of Hammers

: Keeping 54 Hammers in line in 9-9-9 combination first

: Later on 51 Hammers in line with 9-8-9 combination

Reduction In Numbers of Hammers in Pre Crusher

Innovative Project-III

Results :

• Vibration of Rotor Bearing reduced by 1 mm/sec.

• Power saving by 40 Kw at same output

• Maintenance period reduced from 3 days to 1 day

Power saving : 40 KW

Annual Power Savings : 0.95 Million Rs

Annual Mechanical maintenance saving : 3.45 Million Rs

Total Savings : 4.4 Million Rs

Savings

Renewable Energy

Use of Bio Mass Such as Mustard, Moong, Mahendi,

Soyabean husk, Sarason to replace some quantity of Coal

used in PC firing of the kiln section.

Conservation of natural Resources.

Reduction in net CO2 emission in the atmosphere.

Low Cost.

Year 2015-16 2016-17 2017-18

Used Quantity

(MT)704** 2223** 11009.79

** Less due to Unavailability

Bio-Mass As A Renewable Energy

Benefits

Utilization Of Waste Material as Fuel

S No Fuel Used 2015-16 ( MT) 2016-17( MT) 2017-18 (MT)

1 Waste Mix Solid 0 0 714

2 TDI Tar 0 0 469

3 TPP Fly Ash 22836 23180 32795

4 De Oil Cake 0 287 3705

5 Pulp Waste 101 33 0

6 RDF Fluff 4323 2590 842

Total 23370 26090 38525

5.5 % TSR

Bio Mass Handling System

Renewable Energy From WHRS and GHG Reduction

0.00

50.00

100.00

2015-16 2016-17 2017-18

78.3790.08 92.46

21.63 23.55 24.63

WH

R G

en

era

tio

n (

Mil

lio

n K

WH

/An

nu

m

Co

2 R

ed

ucti

on

(K

g C

o2

/T

Clk

)

YEARS

JK LAKSHMI CEMENT, JAYKAYPURAM

Co2 Reduction (Kg Co2/T Clk)

WHR Generation Kg CO 2 / T Clk Reduction

660

665

670

675

680

214-15 2015-16 2016-17 2017-18

675 674 676 677

Kg Co2 / T Major Product

Co

2 R

edu

ctio

n (

Kg

Co

2/T

Cem

ent

GHG Inventorisation

BENEFITS

Saving of 25000 units/ year

CO2 emission reduction 40 Tonne/ Year

Solar Water Heater At Transit House

Solar Power Plant At Village Lumbaniya, District Jodhpur

(RAJ.)

Capacity-: 6.12 MW

Solar Power Plant At Jaykaypuram Colony

Capacity- 232 KW

Green Supply Chain

http://jklakshmicementsrm.com/srm/

Energy Management Policy

(Integrated Management System)

Employee Association In Encon Activities

CFT

KAIZEN

QUALITY CIRCLE

TECH CELL

SHOP FLOOR ENCON TEAM

Feasibility Test

Suggestion at

[email protected]

Concerned Section

reviewCommittee review

Suggestion

Approval

Trail

Successful

Documentation

&

Implementation

of Suggestion

Review Of

Implemented Idea for

benefits &

Sustainability

Audit Team

Confirmation

Rewards,

Recognition &

Appreciation

Employee Association In ENCON Activities Suggestion Scheme

Methodology

❖Daily, weekly& monthly monitoring & analysis of SEC.

❖Online display of SEC in DCS

❖Inter-firm comparison for SEC.

❖Adoption of best practices.

❖ Attending task force meeting with BEE

❖Internal & external audits .

❖Regular training programmes.

❖CFT , SGA, Kaizen, Quality circle

Sustainability

Monitoring

And

Analysis

Decision Making

Management Level

Decision Making

Operations Level

Decision Making

Real Time

Action

Feedback

Feedback

Off Line

On Line

Data

Action

ActionOperator

Real Time

Information System

Plant

Data

Energy Management Tool

Plant Head

Departmental

Heads

Energy Manager

(Process)Energy Manager

(Electrical)

Section In charge / CFT

Plant Operator

WTD

JKLC HAS DEDICATED ENERGY

CELL WITHIN

TECHNICAL SERVICES

Energy Management Team

❖Energy management cell with clear cut responsibilities.

❖Daily monitoring of Energy Deviation report.

❖ Benchmarking National/International/group wise/Cluster units.

❖ Regular study of equipments on deviation and their analysis.

❖ Process evaluation & identification of energy conservation scope.

❖ Feasibility study of suggestions and designing proposals for sanctions.

❖ Taking corrective and preventive measures and ensuring

implementation.

❖ Organizing internal and external Energy Audit survey.

Energy Monitoring Methodology

Certificate Observations Actions Taken

OHSAS 18001:2007

1. White wash of Canteen may be considered.

2. Better housekeeping near Electrical Panels by removing unwanted items

Implemented.

ISO 9001:2015

Monitoring of inter locking system may be recorded

The new record sheet made & system implemented.

Doc No: DSP/07/F/16 Rev: 00 25th Oct 2017

ISO 14001:2015

Energy Efficiency criteria in

the procurement process is

already implemented to be

recorded properly.

Implemented

Implementation of Integrated QEnHSE

Management System External Audit Report: Stage2

Note- There was no any non-conformity but observations for

opportunity to improvement

Environment

Greenery in Plant, Colony and nearby area

Environment

Cap

. 16500

m3

Cap

. 12500

m3

Rain Water Harvesting in Pond

Surface and Roof Top Water Harvesting

Watershed Management in Mines Hills

Environment

KFP Patented Rain Water Harvesting Systems to augment ground water recharge.

Environment

4NH3+4NO+O2→4N2+6H2O

NOX (mg/Nm³)@ 10 % O2 < 800

SNCR System In All Three Kilns.

NOX (mg/Nm³)@ 10 % O2 < 1000

Inauguration on 29Th November 2017

Safety Innovation

65

National Safety MonthRoad Safety Week

Fire Service Week

Safety Celebration

Corporate Social Responsibility (CSR)

Adopted Primary Health Centre

Swatch Bharat Mission – Ek Abhiyaan


Literacy Projects Reward and recognition to academically

bright children and talented sportspersons

Free Medical Services to Nearby

Villages

Family Welfare Programs in

Nearby Villages


Blood Donation Camp At Jaykaypuram

One of Top 25 Most Innovative Companies

Rewards and Recognition

CII “Excellent Energy Efficient Unit Award -2016 & 2015”

CII “Excellent Energy Efficient Unit Award -2014 & Most Innovative Project Award”


CII “Energy Efficient Unit

Award -2013

CII “ExcellenceEnergy

Efficient Unit Award -2012

National award for energy efficiency in cement industry (2013-14)


Energy Concervation

Award -2011 By StateEnergy Consevation

Award by BEE -2011

National award for excellence in

energy management 2010-energy

efficient unit ”

Best Energy Efficient Practice

Exhibitioner- 1st Prize


International Safety

Award -2016 from British

Safety Council London

FAME-Excellence Award 2016

“Best Innovative CSR Project

GOLD AWARD"


[email protected]

[email protected]]

Documents

19 National Award For Excellence In Energy Management-2018 ... … · cement mill-1 (60 kW) 3.39 02 07 Re-Routing of dry fly ash transportation line. (60 kW) 1.84 2.9 08 Kiln inlet