Birla Corporation Limited, Chittorgarh (Units: Chanderia Cement Works)

Energy Excellence Award

Energy Roadmap

Chanderia Cement Works, Chanderia

KPI UOMData for 2017-18 Aspiration for 2018-19 Annual Saving

TPH/TPD kWh/T TPH/TPD kWh/T Lakh Rs.

KILN-1 TPD 3842 34.73 3950 33.8 59

KILN-2 TPD 3996 30.23 4250 28.4 126

CM-1

43 G, TPH 220 34.86 240 32 52

53 G, TPH 185 41.0 200 38 40

PPC, TPH 259 29.3 280 27

CM-243 G, TPH 227 29.32 250 27

PPC, TPH 282 26.50 300 25 213

Raw Ball Mill TPH 178.5 26.5 182.1 25.98 19

RVRM TPH 173 19 176.46 18.6 22

Roller Press TPH 310 17.3 316.2 16.9 37

Fly Ash Absorbtion % 30.9 33.0 576

AFR,TSR CCW1 % 2.25 6.0700

AFR,TSR CCW2 % 9.94 10.6%

Thermal Energy, Kiln-1 Kcal/kg clinker 740 725 225

Thermal Energy, Kiln-2 Kcal/kg clinker 736 721 236

Reduce lime stone PILE LSF 112 107 744Total Saving Potential (Lakh Rs.) 3048

Energy Performance Improvement:- highlights

• Reduced 4.57 kWh/T power in 2017-18 as compared with 2016-17

• Reduced 4.0 kWh/T cement grinding power in 2017-18 as compared with 2016-17

• Clinkerisation power reduced after kilns shutdown(in Oct-2018) as various modifications carried out during shutdown

• Fly ash absorption increased by around 3.0% in 2017-18 as compared with 2016-17

• Thermal energy reduced after kilns shutdown(in Oct-2018) as various modifications carried out during shutdown

Energy Performance Improvement

Sl. No Description Units 2016-17 2017-18

1 MTOE reduction MTOE 0.0748 0.0763

2 Kiln Thermal SEC kCal/kg cli 733 738

3 Specific Electrical Energy - clinkering kWh/T of clinker 64.32 65.81

4 Specific Electrical Energy – Grinding kWh/T of cement 34.30 30.38

5 CPP Heat rate kCal/kWh 3448 3921*

6 CPP auxiliary consumption % 9.92 10.55

7 Thermal Substitution Rate % 2.41 6.14

8 Clinker factor % 0.748 0.715

9 Blended cement (%) of total cement % 65.58 73.56

10 Renewable Energy (RPO) 20980819 26558578

11 REC Purchased – Solar REC NA NA

12 REC Purchased – Non Solar REC NA NA

13 Specific CO2 emission Kg CO2/ kg cement 0.925 0.838

*CPP Heat rate increased due to change in coal mix (Ban on pet coke). We are doing further optimization to

reduce it.

Energy Performance Improvement

Remarks:- Power consumption increased in Mar-18 due to stoppage of our Line-2 Kiln which is most

energy efficient line

Energy Performance Improvement

Remarks:- Power consumption increased in Mar-18 due to stoppage of our Line-2 Kiln

which is most energy efficient line

Energy Performance Improvement

Energy Performance Improvement (Cement Mill-1)

Energy Performance Improvement (Cement Mill-2)

Energy Performance Improvement (Kcal/kg clinker)

Energy Performance Improvement (Fly Ash Absorption)

Remarks:- After Mar-18 it is continuous 34.5% as monthly average

Implemented Energy Projects

Sl. No.Description of energy efficiency improvement

measure

Investment

(Rupees) Lakhs

Verified savings4 (Rupees)

Lakhs

Verified energy savings

Units5 Fuel MTs Remarks

1 AFR Feeding System to NCCW 950 844.73 10402.18 MT Pet coke Completed

2 Feeding of Carbon Black to CCW Coal VRM 250 18.76 231.00 MT Pet coke Completed

3Power saving by Optimization of Roller Press-1 after RP-2 breakdown

0 59.60 778.01 MWH - Completed

4Replacement of existing Swirlex burner with low NOx Pyrojetc burner for kiln firing in CCW.

187 17.30 380.43 MT CoalCommissioned in

Dec.2017

5Fuel saving by Installation of liquid Waste firing system

10 9.13 112.49 MT Pet cokeCommissioned in

Oct.2017

6Energy saving by Replacement of existing kiln inlet & outlet seal with double lamella seal in CCW.

90 12.36 271.74 MT Mix CoalCommissioned in

Dec.2017

7 Power saving by Implementation of CFD analysis recommendation in CCW Pre heater & TAD

15 105.76 1380.71 MWHCommissioned in

Dec.2017

8Power saving by Increase in production of Cement Mills by regradation of Grinding media, optimization and roller profiling

215 830.01 10835.70 MWH Completed

9Power saving by avoiding suction side loss in all cooler fans in CCW by removing of cooler fan dampers

0 52.56 686.22 MWH Completed

Implemented Energy Projects

Sl. No.

Description of energy efficiency improvement measure

Investment (Rupees)

Lakhs

Verified savings4 (Rupees)

Lakhs

Verified energy savings

Units5 Fuel MTs Remarks

10Power saving by Optimization of raw Ball Mill ,and grinding media regradation

32 12.065 157.5114 MWH Completed

12Power saving by CCW Kiln-1 Optimization, false air reduction and raw mix optimization

0 84.099 1097.904 MWH Completed

13Power saving by CCW Kiln-2 Optimization, false air reduction and raw mix optimization

0 43.199 563.958 MWH Completed

14Fuel saving by Increased Fly ash absorption in PPC from 28.05 % to 30.86 % by mills optimization, use of proper grinding aid and proper raw mix design

242.0 301.64 6632.1 MT Fuel Mix Completed

14 Power saving by arresting of false air leakage 0 211.738486 2764.21 MWH Completed

Innovative Ideas Implemented

• Cement mills (Polysius Combi circuit Polycom) optimization and achieved highest TPD and

lowest power consumption among the industry

• Optimization of Raw grinding roller press-1 after roller press-2 breakdown and achieved

highest throughput with roller press-1 running only

• Raw Grinding VRM output increased and stoppages reduced (due to vibration high) by in-

house modification

• Fly Ash absorption in PPC increased up to 34% from 28% of 2016-17 by optimization of raw mix

& usage of grinding aid.

• CCW Line-1 Clinker throughput (TPD) increased up to 4100 TPD from 3626 TPD in FY2016-17 by

in-house optimization

• CCW Line-2 Clinker throughput (TPD) increased up to 4342 TPD from 3543 TPD in FY2016-17

• AFR consumption increased up to 16% as TSR in CCW Line-2 by circuit and AFR mix

optimization

• LSF of lime stone pile reduced from 112 to 107 by raw mix optimization & introduction of

Bauxite

Innovative Energy Conservation Projects

S.N. Project title Status

1Installation of Double Lamella sealat Inlet & Outlet of CCW kiln.

05.12.17

Benefits Achieved

S.N. Description Benefits

1 Saving in fuel consumption 5.0 Kcal /Kg clinker

2 Expected Annual saving Rs. 90.0 Lacs

3 PAT Benefits* Rs. 6.0 Lacs

4 Total Benefits Rs. 96.0 Lacs

5Reduction in kiln stoppage on account of outlet seal

problem.

Outlet Lamella seal

Innovative Energy Conservation Projects

S.N. Project titleDate of

commissioning

2Installation of Pyro-jet burner atCCW Kiln.

05.12.17

Benefits

S.N. Description Benefits

1 NOx level reduced 150 mg/Nm3

2Reduction in preheater fan power consumption

65 KWH

3 Expected annual saving Rs. 39.0 Lacs

4 PAT Benefits Rs. 1.27 Lacs

5 Saving in specific heat consumption 5 Kcal/Kg. clinker

6 Annual saving Rs. 90.0 Lacs.

7 PAT Benefits Rs. 7.2 Lacs

8 Total Benefits Rs. 137.47 Lacs.

Pyro-jet burner

Innovative Energy Conservation Projects

S.N. Project titleDate of

commissioning

3Implementation of CFD analysisresult in CCW preheater.

05.12.17

Benefits

S.N.

Description Benefits

1Reduction in pressure drop >35 mmWgand saving in preheater fan power consumption

65 -70 KWH.

2 Expected Annual saving Rs. 39 lacs

3 PAT Benefit Rs. 1.16 lacs

4 Total Benefits Rs. 40.16 Lacs.

Modifications across PH system

Thank You