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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