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About the Organisation
CII National Energy Efficiency Circle Competition 2
A. About JK Cement :-❖ JK Cement has an installed grey cement capacity is 10.5 MnTPA and 103 MW CPP & 23 MW WHR power generation
Capacity. ❖ JK Cement has 7 integrated grey Cement Plant and 01 white cement plant
(India’s 2nd largest white cement producer)❖ We have complete low cost of production and high efficiency among the industry.❖ JK Cement believe to have maximum Cement volume from energy efficient location like Mangrol and to improve
company’s profitability.
B. Certifications it possesses :- JK Cement Works, Mangrol is certified with❖ ISO 9001:2008 - Quality Management System❖ ISO 14001:2004 - Environment Management system❖ OHSAS 18001:2007 - Occupational Health and Safety Management System❖ ISO 50001:2011 - Energy Management System
C. Highlights of JK Cement Mangrol.:-❖ Two integrated lines (Line-1 and Line-2)❖ Lower Manufacturing cost of production of Clinker and Cement.❖ Strong capability of loading of cement by rail as well as by road❖ Line-2 efficiency is the best among the other cement industries.
3
• Recently JK Cement Mangrol won the SEEM National Energy Management Awards 2017
• Category :- Industries
• Sector & Organization :- Cement - JK Cement works, Mangrol
• Position :- PLATINUM
Awards Achieved in 2017-18
4
One of the most prestigious award amongst the Industries i.e. “Golden Peacock Awards” Won by “JK Cement Works Mangrol” under the leadership of our Unit Head Sh. S. K. Rathore Sir, in the Category “Eco-Innovation Award” at Institute Of Directors (IOD), India’s 19th World Congress on ENVIRONMENT MANAGEMENT and Golden Peacock Awards Presentation Ceremony at The HICC - Novotel in Hyderabad (India) on 07th – 08th July’17.
Awards Achieved in 2017-18
5
Private Sector waste Management Award :- JK Cement Works, Mangrol Best Waste Management Officer :- S.K. Rathore (Unit Head)
Awards Achieved in 2017-18
• Ever Highest Clinker Production 2.42 million Ts. (2.25 million Ts. in 2016-17)
• Ever Highest Fly Ash Consumption – 30.94% (30.69% in 2016-17)
• Ever Lowest Thermal consumption of Line-1– 753 kcal/kg of clinker. (771 kcal/kg of clinker in 2016-17) and Line-2 of 681 Kcal/Kg of Clinker (5 stage Preheater).
• Ever Lowest clinker consumption (Overall clinker factor) – 76.6 % (80.47% in 2016-17)
• Ever Lowest PPC clinker factor – 62.85%. (63.68% in 2016-17)
• Ever Lowest OPC clinker factor Line-1 – 89.69%.(94.13% in 2016-17)
• Ever Lowest OPC clinker factor Line-2 – 90.35%.(95.53% in 2016-17)
• Ever highest TSR% achieved in Line-1 – 4.9%.(4.3% in 2016-17)
• Ever highest TSR% achieved in Line-2 – 8.5%.(8.0% in 2016-17)
• Ever Highest AFR consumption: 57744 MT (30405 MT in 2016-17)
• Ever Highest Clinker Movement – 0.75 million Ts. {0.62 million Ts. (Jajjhar-Grinding Unit) and 0.13 million Ts. (Sold)} (0.46 million Ts. in 2016-17)
Executive Summary FY 2017-18
• Ever Highest WHR Gross Generation – 580.53 Lakhs KWH. (428.70 Lakhs KWH in 2016-17)
• Ever Highest WHR Generation Capability – 24.61 KWh/MT Clinker. (20.2 KWh/MT Clinker in 2016-17)
• Ever Highest WHR PLF% - 73.02%. ( 60.91 % in 2016-17)
• Ever Highest WHR Average Load – 7.01 MW. (5.84 MW in 2016-17)
• Ever Lowest WHR Auxiliary Consumption – 4.51%. ( 4.94% in 2016-17)
• Ever Highest CPP Generation 1550.31 Lakhs KWH. (1467.99 KWH in 2016-17)
• Ever Highest CPP PLF% - 82.81% ( 72.99 % in 2016-17)
• Ever Lowest CPP Auxiliary Consumption – 8.70%. (10.97% in 2016-17)
• Ever Lowest CPP Station Heat Rate – 3213 Kcal/KWh. (3229 Kcal/KWh in 2015-16)
Executive Summary FY 2017-18
The types of AFR are using at JK Cement Works, Mangrol
Alternative Fuels:-
• Solid Mix Waste.
• Waste Mix Liquid.
• Carbon Black.
• Fiber Mass.
• Agro Waste.
• ETP Sludge.
• Plastic Waste.
• Plastic and Resin Waste.
• Pyrolysis Oil.
Alternative Raw Materials:-
• Chemical Gypsum.
• Slag/Zinc Slag.
• Iron Sludge.
• Marble Khanda
8
• We are committed to use alternative materials and fuels for clinker and cement production when technically, ecologically and economically feasible.
• We developed this policy to define the conditions and criteria for a safe and secure way to use waste-derived materials and fuels or byproducts coming from society or other industries
• The burning processes used for clinker production – high temperatures and long residence times under controlled conditions – make it feasible to use alternative fuels completely without any ash.
• The quality of our products is of the highest importance to us and our customers.
• Health and Safety of our employees, neighbors and customers is important for us.
• Our production processes are characterized by the use of modern technology, appropriate safety and environmental measures and rules.
• We are aware of our responsibility to our employees, the public and the environment.
• The dialogue with our employees, neighbors and other stakeholders is of high value for us.
AFR Policy
Solid AFR Feeding System in Line-1
10
Hopper Mesh Hopper & Screw Conveyor Feeding Belt Conveyor
Feeding system in Calciner
Solid AFR Feeding System in Line-2
11
AFR Yard Feeding Belt Conveyor
Solid AFR Feeding in Calciner
Hopper & EOT Crane
12
1212
0.00
470.00
1128
361
79 810
23470
296.68
665
8.03
0.00 5.16
7.12
2.610.85 0.76 0 4.96 1.61
4.19
12.6
01234567891011121314
0
200
400
600
800
1000
1200
1400
Apr-16 May-16 Jun-16 Jul-16 Aug-16 Sep-16 Oct-16 Nov-16 Dec-16 Jan-17 Feb-17 Mar-17
Quantity (Ts) TSR %
Usage of AFR in Line-1&2 (2016-17)
0409.00
1080.001553
1062
25263081
1463
3114
3945 3844
4891
01.40 3.64
6.043.53
9.60 9.847.73
10.212.13 13.4
15.16
0
2
4
6
8
10
12
14
16
0
1000
2000
3000
4000
5000
6000
Apr-16 May-16 Jun-16 Jul-16 Aug-16 Sep-16 Oct-16 Nov-16 Dec-16 Jan-17 Feb-17 Mar-17
Quantity (Ts) TSR %
Line-2
Line-1
Major Challenges faced by JK Cement, Mangrol 2016-17
13
1. Process Stabilization: We have installed In house made Liquid waste firing system with the available old pumps etc. Stabilization to be done in line-1 with liquid waste as kiln stopped just after trial in the calciner firing and now kiln running with restricted output. Solid waste feeding system is not available in line-1 where only agro waste feeding system is installed. We have stabilized our process in line-2 with approximately 100TPD of solid waste and 20 TPD of Liquid waste firing. For stabilization we have used the installed AFR Feeding system for solid waste firing while for liquid waste firing we have developed in house firing system.
2. Process Equipment:For Further stabilization with increased usage of AFR in Line-2 refractory of the calciner has to be upgraded with higher version compatible with HW firing. With the usage of HW firing we have observed deterioration in our main Bag house like corrosion problem in main body.
3. Quality and Supply: Consistency in the supply of HW is hampering utilization percentage even after close monitoring and follow up for consistent supplies with satisfactory Heat value.
4. Environmental Aspects:With the usage of Liquid AFR potential risk of undesirable emissions are yet to be assessed in terms of concentration and quantity.
Action taken to overcome Co-Processing Challenges in 2016-17
14
1. Process Stabilization: Trial of Solid and Liquid waste to be taken after kiln-1 Tyre replacement at normal output.
2. Process Equipment:Planning for the replacement of Calciner refractory with higher version is under process. Anti-corrosion coatings applied by different agencies to observe suitability w.r.t anticorrosion.To find out root cause for corrosion suitable sample submitted to external agency for study.
3. Quality and Supply: For consistent supplies follow up with supplier on daily basis. Besides follow up preplanned usage are also intimated to supplier.Joints Sampling and checking of Heat value done and supplier intimated to take actions accordingly to improve heat value.
4. Environmental Aspects: To minimize the undesirable emissions stack monitoring done by external agency and doses of liquid reduced as a precautionary measure.
5. Handling & storage:AFR Yard Flooring to be done as per CPCB norms in Line-2 (Concrete flooring with PVC base).Skilled Manpower engaged for feeding and storage.Hazardous Waste handling compatible suits provided to workmen.Regular safety Tool Talk and training started
15
0
620.0
1965.8
1169.3
709.68879.34
1413.53
1097.20
357545.56
93.23
2279.46
0
8.3
9.26.9
23.1
3.94.35
7.260.23 0
12.3
0123456789101112131415
0
500
1000
1500
2000
2500
Apr'17 May'17 June'17 July'17 Aug'17 Sep'17 Oct'17 Nov'17 Dec'17 Jan'18 Feb'18 Mar'18
Quantity (Ts) TSR %
Usage of AFR in Line-1&2 (2017-18)
4965.24514.74 4301.51
3995.92
2764.272425.76
3853.88
4599.38 4843.11
3481.37 3641.913207.10
14.06
10.948.62
7.889.61 7.92 7.7 9.34 9.04 5.7
4.7
5.5
0
2
4
6
8
10
12
14
16
0
1000
2000
3000
4000
5000
6000
Apr'17 May'17 June'17 July'17 Aug'17 Sep'17 Oct'17 Nov'17 Dec'17 Jan'18 feb'18 Mar'18Quantity (Ts) TSR %
Line-1
Line-2
New EOT crane Of Line-1 Commissioned Successfully On
09.12.17
Small Feeding hopper at D/C of 261WF350
Additional hopper installed for feeding of Plastic waste.
Initiatives to increase AFR consumption
Contaminated water sewage pit First Aid Box
Dispensary at Mangrol Fire Brigade
Working with safety PPEs
Ambulance
Activities Done in Line-1 (2017-18)
S.NO DESCRIPTION EFFECT OF MODIFICATION RESPONSIBILITY STATUS
1Blaster installation at Solid waste
feeding RBC D/C Reduction in Jamming Frequency. Process Completed
2Solid waste Quality check Before Entry
in gateOnly suitable lot will be Recieved Quality Control
Completed/
Running
3 Menpower UtilizationIncrease AFR consumption with SWP &
Better HousekeepingProcess Completed
4 Secondary access Nearby hopper For Emergency evacuation Civil completed
5 New ECS selection for Screw conveyor Smooth Feeding of AFRProcess/
InstrumentCompleted
6 Poking window created at Solid waste
D/C To decrease jamming removal time Process Completed
Activities Done in Line-1 (2017-18)
S.NO DESCRIPTION EFFECT OF MODIFICATION RESPONSIBILITY STATUS
1A secondary passage near AFR
hopper construction doneFor safe evacuation in Emergency Mechanical Completed
2Liquid firing Pump Teflon Seal
replaced by Brass seal
Seal leakage Frequency reduced resulting
Reduced Downtime Of pump. Mechanical Completed
3 EOT crane commisioning done AFR consumption will improve All Dept. Completed
4Discharge Airsluice LPB Location
change
During jamming Airsluice operation in
local mode can be done easily
Process/
ElectricalCompleted
Activities Done in Line-2 (2017-18)
S.NO DESCRIPTION EFFECT OF MODIFICATION RESPONSIBILITY STATUS
1Solid waste Quality check Before
Entry in gateOnly suitable lot will be Recieved Quality Control Completed/ Running
2 Menpower UtilizationIncrease AFR consumption with SWP &
Better HousekeepingProcess Completed
3 261BC650 Guide Roller installed Belt out Problem solved Mechanical Completed
4Stand by liquid feeding pump
installed
To continue liquid firing if seal leakage
in main pumpMechanical Completed
5Small Feeding hopper at D/C of
261WF350
To feed Plastic waste from outside to
increase consumption Process Completed
6New source Shredded plastic trial
conducted successfully
suitable AFR will support to increase
TSR%Process Completed
Activities Done in Line-2 (2017-18)
S.NO DESCRIPTION EFFECT OF MODIFICATION RESPONSIBILITY STATUS
1Used solid waste plastic bag heap
relocated
Agrowaste/Fibermass stored under the heap is
utilizedProcess Underprogress
2A concrete wall is made surrounding
of Liquid Firing at P.H. 2nd floor
To isolate surronding area from Haz. Liquid in
case of spillage /Leakage / OverflowProcess/civil Completed
32 Nos. of Exhaust Fan Installed in
AFR yard Better ventillation
Process/
ElectricalCompleted
4 Trial Of Biowish Odour Control Making AFR area Odour less As well as
Compliant with OH&S requirement Process Completed
5Installation of Blaster at AFR D/C
bend to avoid jamming
Frequency of Chute jamming as well as
probability of Fire will be eliminated
Process/
Mechanical
underprogress
complete by
25.02.18
Future Plan in Line-1
S.NO DESCRIPTION EFFECT OF MODIFICATION RESPONSIBILITY
1 AFR D/C modification in line-1 Jamming will be reducedProcess/
Mechanical
2 AFR feeding system to run in auto mode in line-1 smooth Feeding of AFRInstrument/
Process
3Magnetic seal Liquid Firing pump to be installed If
Successfully run in Line-2
Downtime due to frequent sealing
leakage will be removedMechanical
4 New Line-1 EOT crane operation will start Increase AFR consumption Process
Future Plan in Line-1
S.NO DESCRIPTIONEFFECT OF
MODIFICATIONRESPONSIBILITY STATUS
1 AFR D/C modification in line-1 Jamming will be reducedProcess/
Mechanical
Next Planned
shutdown
2Antistick Coating to be done in AFR D/C to
reduce JammingJamming will be reduced
Process/
Mechanical
Next Planned
shutdown
3Magnetic seal Less Liquid Firing pump to be
installed If Successfully run in Line-2
Downtime due to frequent
sealing leakage will be
removed
MechanicalLine-2 pump perf.
Under observation
Future Plan in Line-2
S.NO DESCRIPTION EFFECT OF MODIFICATION RESPONSIBILITY
1New AFR Additional Hopper & BC600 length increase will be
commisioned Increase Plastic waste consumption Civil/ Mechanical
2 Magnetic seal Liquid Firing pump to be installed & evaluate Perf.Downtime due to frequent sealing leakage
will be removedMechanical
3261SC300 Main conveyor will be remove & WF350 will be extended
backwardScrew conveyor jamming will be eliminated Mechanical/ Process
4 Shock Proof Exhaust fan will be Installed AFR yard Environment More suitable for
Human workingElectrical/ Process
5 To install Blaster at AFR D/C bend to avoid jamming line-2 Jamming will be reduced Process/ Mechanical
6 Flexco Scrapper to be install in 261BC650Roller coating will be avoided so downtime
will reduceMechanical
7 ODC-50 Odour control fogging System to be install in AFR yardTo make Yard area Compliance with OH&S
standard Process
Future Plan Line-2
S.NO DESCRIPTIONEFFECT OF
MODIFICATIONRESPONSIBILITY STATUS
1New AFR Additional Hopper & BC600
length increase will be commisioned
Increase Plastic
waste consumption
Mechanical/
Electrical
Hopper and Length Increase
Arrangement Erected ,
Agitator’s Erection And Power
Source Awaiting.
2
261SC300 Main conveyor will be
removed & WF350 will be extended
backward
Screw conveyor
jamming will be
eliminated
Mechanical/
Process
Under Discussion Due to safety
reasons
3 Installtion Of Fire Hydrant systemFire Emergency
PlanningSafety
Procurement of system
Initiated
4ODC-50 Odour control fogging System
to be install in AFR yard
To make Yard area
Compliance with
OH&S standard
Process Trial done
Shredder
We installed one shredder ( Capacity 3-4 TPH) , to shred in house waste like tires , wooden blocks and bags of solid waste
Summary
Quantity of Alternative Fuel used (Ts.)
Quantity of Alternative Raw Material used (Ts.)
TSR% in Line-1
TSR% in Line-2
Quantity of Fuel Saved (Ts.)
FY 2016-17 30405 13821 4.3 8.0 15454
FY 2017-18 57744 51110 4.9 8.5 17378