energy excellence award
TRANSCRIPT
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