best practices adopted by gujarat cement works

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Gujarat Cement Works

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Units

Symbol Number of Units

Integrated Plants 12

Grinding Units 12

Bulk Terminals 5

Presence in India

Hirmi Cement Works

Jafrabad Cement Works

Magdalla Cement Works

Ratnagiri Cement Works

Andhra Pradesh Cement Works

Arrakonam Cement Works

Awarpur Cement Works

Jharsuguda Cement Works

West Bengal Cement Works

Bathinda Cement Works

Aditya Cement

Vikram Cement

Gujarat Cement Works

Kotputli Cement Works

Hotgi Cement Works

Rajashree Cement Works

Ginigera Cement Works

Panipat Cement Works Dadri Cement Works

Aligarh Cement Works

Location of Integrated Plants,

Grinding Units and Bulk Terminals

RWCW

Reddipalayam Cement Works

Integrated plant

Grinding unit

Bulk terminals Mangalore Cement Unit

BSBT- Dodballapur

Shankarapally Bulk Terminal

Navi Mumbai Cement Unit

Cochin Bulk Terminal GCW

GCW is Country’s largest Exporter of Clinker.

• Largest producer of grey cement

in India

• Among the leading producer in

world

• Customized high quality Ready

Mix Concrete

• Units in India, Sri Lanka, UAE,

Bangladesh and Bahrain

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Gujarat Map

Overview

Cochin ─ 799 nautical miles

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GC

W

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GCW - Distances

Overview

Cochin ─ 799 nautical miles

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Cochin ─ 799 nautical miles

Rajkot ─ 210 km

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System Year of commissioning Installed Capacity Remarks

Kiln-1 Apr-96 6500 TPD Present – 8000 TPD (peak production)

Kiln-2 Apr-97 6500 TPD Present – 8000 TPD (peak production)

Cement mill-1&2 Cementmill-4

Apr-96

Apr-98

133TPH

Close circuit

Upgraded to 230TPH by installing Roller press

Cementmil-3 Apr-98 161TPH

Close circuit

Jetty Oct-97 45000 DWT Jetty Expansion is in progress

Thermal Power Plant Apr-08 to Feb-09 4 x 23 MW CFBC Boilers, China

DG Sets Oct-97 2 x 6 MW For Emergency Use

CPP - Combined Cycle – GT 1997 53 MW De-commissioned in 2008

Desalination Plant Sep-99 2040 m3 / day From Waste heat of Cooler-1

RO Plant Apr-08 2 x 50 m3 / Hour Zero Ground water drawl

Plant History

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Gujarat Cement Works

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Area : Coal mill -1 & 2

Problem : With two different fuels grinding in same mill was impacting

overall output of mill due to fixed gap kept between static

guide vanes during SA & Pet coke grinding

Action taken : Online arrangement made for adjusting separator louvers

gap which facilitate to maximize output in both mills

Benefits : 1. Reduction in mill run hours

2. Increased output rate during SA coal grinding

from Average 60 to Average 74 TPH

Replication : Group units in UTCL

Best Practice at GCW

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Best Practice at GCW

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Modified in both the coal mill Air Separator

ARM LINK

LINIEAR

ACTUATOR

LINK , PIN & BUSH

RING

Guide & Support

Rollers

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Best Practice at GCW

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Area : Coal Mill 1 & 2

Problem : Higher main motor specific power

KM-1 :-16.08 kWh /t , KM-2:- 16.22 kWh / t

Action taken : 1.Reduced dam ring height by 20 mm in both the mill

2.Installed GRR in mill motor to change table speed

as required for SA & Pet coke

Benefits : Main motor specific power reduced by 0.71 and

1.22 units / t in KM-1 & KM-2 respectively.

Saving Rs. 8.50 Lac ( Sep-14 to Mar-15 )

Replication : --

Best Practice at GCW

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Area : Kiln -2

Problem : Higher fuel cost by use of SA - Imp coal

Action taken : Modified Raw mix design for 100 % utilization of

pet coke

Benefits : 1. Reduction in fossil fuel consumption

2. Reduction in fuel cost

Replication : Group units in UTCL

Best Practice at GCW

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Area : Raw Mill

Problem : Requirement of costlier additives iron ore in Raw mix

Action taken : Partial replacement of Iron ore by Iron sludge

Benefits : 1. Reduction in Raw material cost

2. Conservation of natural resources

Replication : Group units in UTCL

Best Practice at GCW

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Area : Cement mill

Problem : Fly Ash utilization less than Cluster and Group units

Action taken : Trial taken with different grinding aid & Established for

31% absorption.

Benefits : 1. Waste material utilization of thermal power plant

2. Conservation of natural resources

Replication : Group units in UTCL,

Best Practice at GCW

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Area : Kiln -1 & 2

Problem : No facility for Liquid firing in both the line.

Action taken : Installed Liquid firing system in both the line

Benefits : 1. Disposal of Hazardous waste .

2. Available with negative cost

Replication : Group units in UTCL,

Best Practice at GCW

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Area : Kiln

Problem : Less TSR %

1. Solid waste cons. Low due to freq jamming problem in Line-1

2. No facility for feeding in Line-2

Action taken: 1. Modified solid waste firing bin design in Line-1

2. Installed in house system for feeding Plastic waste

in Calciner at Line-2

3. Solid waste firing system erection in final stage in Line-2

Benefits : 1. Clean environment

2. Disposal of Hazardous waste .

Replication :Group units in UTCL

Best Practice at GCW

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Area : Kiln

Problem : Kiln tip casting castable life max 6 months due to wear.

Required 6-7 days for Castable replacement

Action taken : Explored possibility for new product and Changed the

Castable type .

Benefits : Tip casting castable Life enhanced one year.

Replication : Group units in UTCL,

Best Practice at GCW

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Area : Kiln / Raw Mill / Coal Mill

Problem : High False Air across the system

Action taken : 1.Started practice for weekly tracking & Leakage arresting.

2.Pre heater Cyclone shell thickness measurement &

Schedule replacement of weak part in shutdown

Benefits : Electrical & Thermal energy saving

Replication : Group units in UTCL

Best Practice at GCW

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False Air

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Area : Kiln

Problem : High specific power consumption

Action taken : Study kiln operation at different output to establish

optimum operating parameters for optimum power

consumption.

Benefits : Reduction in kiln specific power consumption

Replication : Group units in UTCL

Best Practice at GCW

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Kiln Specific Power

20 # Fig in kWh/T of material

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Area : Cement mill

Problem : Higher specific power consumption ( 31-32 units / ton )

Action taken : Installed Roller press in existing cement grinding circuit

for Cement mill-1,2 & 4

Benefits : 1. Increased cement grinding capacity

2. Reduction in Specific Power consumption. ( 30 units / t )

Replication : Group units in UTCL,

Best Practice at GCW

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Area : Kiln-1 & 2

Problem : Process disturbance due to frequently outages of

SPRS system

Action taken : 1. Increased frequency of calibration and testing of SPRS

2.Strengthen LRS / GRR tracking system

Benefits : 1. Availability of SPRS system increased.

2. Recovered Electrical energy 178 LkWh in FY 14-15

Replication : Group units in UTCL,

Best Practice at GCW

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SPRS Saving – LkWh

# Fig in Lac kWh 23

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Best Practice at GCW

Area : Kiln -2 Calciner Fan

Problem : 1. Unable to operate SPRS below 71%

2. Freq outage & component failure in voltage dips

3. Low reliability of system

Action taken : Upgraded with IGBT based SPRS

Benefits : 1. IGBT SPRS can sustain voltage dips up to 40%

2. Vast speed range ,i.e. 67 % to 93% hence fan operation

is possible at lower side

Replication : Group units in UTCL,

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Saving with new SPRS

# Fig in Lac kWh 25

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Area : Kiln -1 & Kiln -2

Problem : Burner castable life 2 to 3 months max

Action taken : Pre heating of burner pipe castable as per the heat up

curve suggested by castable supplier.

Benefits : Castable life enhanced from 2 to 6 months

Replication : Group units & Other than group units

Best Practice at GCW

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Castable failure After 45 - 90days

Heat blanket

Best Practice

Old Practice

Best Practice at GCW

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Area : Raw Mill 1 & 2

Problem : Higher main motor specific power

RM-1 5.22 kWh /t , RM-2 5.17 kWh / t

Action taken : Reduced dam ring height by 20 mm in both the mill

Benefits : Main motor specific power reduced by 0.05 units / t / mill

Saving Rs. 7.48 Lac ( Sep-14 to Mar-15 )

Replication : --

Best Practice at GCW

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Area : Cement mill

Problem : Fines proportion higher in Separator reject material

( 4 to 7 % R on 45 micron sieve in finished product )

Action taken : Installed Additional Static guide vanes in SKS separator

for Cement mill-1,2 & 4

Benefits : 1. Reduction of fines in Separator reject

(Achieved 15-18 % R on 45 micron sieve)

2. Reduction in specific power

Replication : Group units in UTCL

Best Practice at GCW

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Area : Cement mill

Problem : Higher pressure drop at Separator fan inlet

Action taken : Modified inlet static part of separator fan for

Cement mill-1,2

Benefits : Reduction in fan power by 25 & 50 kW for

Cem-2 and Cem-1 respectively.

Replication : Group units in UTCL

Best Practice at GCW

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Area : Cement mill

Problem : Frequent jamming of Gypsum & Lime stone hopper

Action taken : Installed SS 304 2B finished liner in Gypsum hopper

& Polymer liner in Lime stone hopper.

Benefits : Reduced Gypsum jamming frequency

Increased addition of Performance improver in OPC

Replication : Group units in UTCL

Best Practice at GCW

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Area : Cement mill -2 & 4

Problem : Separator power high

Action taken : Installation of vortex plate in separator rotor

Benefits : Reduction Separator power from 180KW to 150KW

and 250 KW to 200KW in CM-2 & CM-4 respectively.

Replication : Group units in UTCL

Best Practice at GCW

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Area : Cement mill -2 & 4

Problem : 1. Separator speed required to keep on higher side.( 85-90 ) %

2. Process bag house DP remains on higher side. ( 180 mm )

Action taken : Modification in V –separator by pass duct

Benefits : 1. Separator speed reduced to 75-80 %

2. Bag house DP reduced to 110-120 mm wg.

Replication : Group units in UTCL

Best Practice at GCW

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Area : Packing Plant

Problem : Higher Bag weight variation

Action taken : Converted all mechanical Packers to electronic Packers

Benefits : Bag weight variation within specified limit

Replication : Group units in UTCL

Best Practice at GCW

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Best Practice at GCW

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Area : Plant Lighting

Problem : Poor life & required Frequent Maintenance

Action taken : Started to replacement of conventional lighting with LED

Benefits : 1. Reduction in energy consumption

2. Longer life & Maintenance free

Replication : Group units in UTCL,

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LED lighting in different area

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Best Practice at GCW

Sr

no Old Fitting LED fitting Qty

Saving in kWh / Year

( Qty x Diff in W x 10H

x 365 Days )

1 Well glass 70 Watt HPSV 24 Watt 25 3194

2 HPSV Flood -150 Watt 85 Watt 54 12811

3 Florescent T/L 40 Watt 18 Watt 1070 85921

4 Well glass 70 Watt HPSV 45 Watt 835 76193

5 Street light 150 W HPSV 90 watt 58 6774

Total 2042 184893

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For more information, please contact:

Shri Ashok Masrani, Sr. Manager (Process), Gujarat Cement Works

ashok.masarani@adityabirla.com