energy excellence shree cement ltd., unit-i,...
TRANSCRIPT
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Energy Excellence
Shree Cement Ltd.,
Unit-I, Beawar
National Awards for Cement Industry and Conclave on Sustainability
Excellence of Indian Cement Industry
15th & 16th Oct 2018, Hyderabad
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Contents
• Overview
• Energy Conservation Awareness
• Energy Management System
• Energy Peformance Improvement
• Targets & Achievements
• Conclusion
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Shree Cement Limited is a rapidly growing as one of the most efficient and
environment friendly cement company in India.
41.9 MTPA Cement
production capacity till
date
646 MW power generation capacity till
date
Among the top 3 cement
groups in India
Largest WHRP producer in the global cement
industry excluding china
86,117 ESCertsissued to
Beawar plant for WHRP generation
5 star rating for Beawar and
Ras limestone mines for
sustainable development
by IBM
An Energy & Environment Conscious Sustainable Organization
Shree Cement Profile
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25245
3950943270
5067059293 59557
30/06/14 30/06/15 31/03/16 30/06/16 31/03/17 31/03/18
Market Capitalization (Rs. in Crore)
Financial Performance
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“Lead in Creating Prosperity & Happiness for all Stakeholders through Innovation
& Sustainable Practices”
Our Vision
Guiding Principle
Enforce good corporate
governance practices
Encourage integrity of
conduct
Ensure clarity and un-
ambiguity in communication
Remain accountable to
all stakeholders
Encourage socially
responsible behavior
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Total Prosperity
Sustainability
Total
Prosperity
Profit
Stakeholder
+Happiness
Workforce
+
Innovations
Ethics
+
Integrity
Clean
+
Green
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1985: 0.6 MTPA
Energy Cons.- 118 Kwh/t Cement
Heat Cons.-902 Kcal/Kg Clk
1995 : 1.0 MTPA
Energy Cons.- 110 Kwh/t Cement
Heat Cons.-860 Kcal/Kg Clk.
2018: 1.2 MTPA
Energy Cons.- 74.57 Kwh/t Cement
Heat Cons.-705 Kcal/Kg Clk.
Unit-I in 1985 Unit-I in 2018
Shree Cement’s Journey
780
718
705
640
660
680
700
720
740
760
780
800
2015-16 2016-17 2017-18
Specific Thermal Energy (kCal/Kg Clk.)
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81.85
80.91
74.57
2015-16 2016-17 2017-18
Specific Power Consumption (KWh/t Cement.)
Shree Cement’s Journey
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SCL Approach
Adopted 7 ‘R’ philosophy to ensure energy and resource conservation
Reduce: Energy & water consumption
Release: Lesser emissions
Reuse: Waste gases
Replace: Conventional fuels
Restore: Natural resources
Raise: Green Power generation
Research: Capacity enhancement
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ISO-50001• Energy Management System
ISO-14001• Environmental Management System
SA-8000• Social Accountability
ISO-9001• Quality Management System
OHSAS-18001
• Occupational Health & Safety Assessment Series
Management Systems
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Energy Conservation Awareness
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Energy Conservation Awareness
Sharing of Information
• Awareness program in association with BEE since 2002.
• SCL has been identified as a cement Stock Task Force Leader.
• First awareness program regarding energy efficiency and target setting process
was held at Shree Cement Unit.
• “Best Energy saving initiatives are Awarded in every Monthly
safetymeeting”
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Dedicated Team
Energy Task Force Team formed with cross functional team members and best energy saving
initiatives discussed and implemented.
Energy Conservation is the foundation of Energy Independence
Energy Management System
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Energy Professionals
Shree Cement Ltd. encourages employee to become
CEM & CEA by reimbursing the BEE Exam fee. Till
date SCL have more than 50 Nos. BEE Certified
Energy Managers and EnergyAuditors.
SCL is also engaged various external energy
professionals and experts from agencies.
Energy Saved is Energy Produced
Energy Management System
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Monitoring of Energy Consumption:
• Daily monitor energy consumption and discuss in production / power meeting
• False air study of Preheater, Raw Mill Section & Coal Mill Section
• Identification of Compressed air leakages
• Thermography of Electrical Panels & Plant
• FAD test of Compressors
• Performance evaluation of efficiency of Pumps, Fans
Energy Efficiency leads to Lower Monthly Bills & a Lower Carbon Footprints
Energy Management System
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Power quality analyzer
Compressed air flow meter
Ultrasonic water flow meter
Hot wire anemometer
IR-Temperature indicator
Thermal imager
Compressed Air leak detector
Digital pressure manometer
Digital pressure gauge
Power Packed with latest Instruments for Energy Audit
Energy Management System
Energy Management team is equipped with following list of calibrated instruments
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Energy Management Certificate- ISO 50001-2001
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Energy Management Certificate- ISO 50001-2001
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CSI has developed roadmap to reduce energy consumption of Indian cement industry which
was co-chaired by Shree Cement.
To meet the CSI roadmap and the PAT targets SCL has develop its own roadmap.
0.08130.0776
0.0585 0.0562 0.0541
0
0.02
0.04
0.06
0.08
0.1
FY 07-10
Baseline
SEC
FY 12-15
PAT Cycle-1
Target SEC
FY 14-15
Achieved
SEC
FY 14-15
Baseline
SEC
FY 16-19
PAT Cycle-2
Target SEC
SCL Specific Energy Consumption (Gate to Gate)
844
549 555
828
547 553
0
100
200
300
400
500
600
700
800
900
Per ton of clinker Per ton of cement Per ton of cementious
material
Specific Net CO2 (Kg.) Emissions
2016-17 2017-18
Energy Performance Improvement
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0.3660.350
0.264
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
Present Target AchievedEn
erg
y C
on
su
mp
tio
n (
MT
OE
)
• Energy reduction target = 4.55%
• Target achieved = 29.16%
• Target overachieved = 24.61%
• ESCerts Issued = 86117Nos.
PAT Performance
Energy Performance Improvement
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Energy Saving Projects Implemented in FY 17-18
Sl No. Energy Efficiency Improvement Measures Category
Investment
(Lakh
Rupees)
Savings
(Lakh
Rupees)
1 Up-gradation of Preheater Unit-I Thermal 5600.00 1112
2 Additional cyclone 3rd in raw mill circuit at U-1 Electrical 154.17 64.80
3 Installation of SPRS in SG fan Unit-1 Electrical 1.00 25.20
4Modification of down comer duct and removal of gct of ph
U-1Electrical 136.83 22.81
5 Installation of LED lights in place of conventional light Electrical 7.83 1.51
6Modification of kiln outlet shell, hood & graphite seal in
U-1
Thermal &
Electrical148.39
Under
Evaluation
7Replacement of GPP Boilers PH-1 and AQC-1 of Kiln-1
BeawarElectrical 3894.00 -
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Energy Performance Improvement - Energy Saving Projects
Sl. No Description Units 2016-17 2017-18
1 MTOE reduction MTOE 1877
2 Kiln Thermal SEC kCal/kg clinker 718 705
3 Specific Electrical Energy – clinkering kWh/T of clinker 60.35 53.5
4 Specific Electrical Energy – Grinding kWh/T of cement 92.03 84.35
5 CPP Heat rate kCal/kWh 3007 2998
6 CPP auxiliary consumption % 8.4 7.2
7 Thermal Substitution Rate % 0.063 0.0923
8 Clinker factor % 0.739 0.73
9 Blended cement *%) of total cement % 48.17 51.08
10 Renewable Energy (RPO) NA NA
11 REC Purchased – Solar REC NA NA
12 REC Purchased – Non Solar REC NA NA
13 Specific CO2 emission Kg CO2/ kg cement 0.549 0.547
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Daily Power Report
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Installation of High Efficiency Classifier with Additional Triplet
Cyclone In Raw Mill
New high efficiency classifer along
with additional triplet cyclone have
been installed in Unit 1 Raw Mill as a
result specific power consumption of
raw mill has reduce due to reduction in
pressure drop and increase in
production.
Approx. saving of 14.9% achieved.
Achievements - Innovative Projects
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Up-gradation of Pre-heater from 4-stage to 6-stage with WHRB
Achievements - Innovative Projects
• Replacement of 4 stage preheater with 6 stage preheater without affecting the
WHRB generation.
• Reduced temperature of gases leaving from top stage cyclone of preheater to
280oC-290oC from around 400oC.
• Saving of approx 12% achieved in coal consumption.
Before After
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• Installation of centrifugal compressor in place of reciprocating compressor first
installation in cement industries
• Formation of Computational fluid dynamics (CFD) Cell for plant operations
• Coal Mill Classifier modification and modication of ducts.
• Enlargement of Kiln riser orifice area.
• Removal of Dust Settling Chamber.
• Clinker cooler grate area enlargement.
Achievements - Innovative Projects Under Implementation
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Investments made in Energy Saving Projects
• Total investment by 65 DCs = 2568 Crore
• Total investment by Shree Cement Ltd = 250.9 Crore
• Overall paypack period = <3Years
• % Share by Shree Cement = 9.7 %
250.9, 9.7%
2568.0, 90.3%
Investment in Cement Sector
Total investment by SCL Total Investment by 65 DC's
Achievements
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15.01
14.20
13.53
12.5
13
13.5
14
14.5
15
15.5
Present Target Achieved
En
erg
y C
on
sum
pti
on
(M
TO
E)
Cement Sector Performance
0.3660.350
0.264
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
Present Target Achieved
En
erg
y C
on
sum
pti
on
(M
TO
E)
SCL Beawar Performance
Achievements
Cement Sector
• Energy reduction target = 5.74%
• Target achieved = 10.43%
• Target overachieved = 4.68%
SCL Beawar plant
• Energy reduction target = 4.55%
• Target achieved = 29.16%
• Target overachieved = 24.61%
• ESCerts Issued = 86117Nos.
Saving energy saves you money
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Shree Cement has been awarded Best performer in Cement sector by BEE,
Ministry of Power. On occasion Shree Cement delivered presentation on Energy
Efficiency in Industrial Sector on National Energy Conservation day 14-12-2017
at Vigyan Bhawan, Delhi.
Outcome of Our Best Practices
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Shree has been entitled for following awards by NCCBM-
• Best Improvement in Thermal Energy Performance in the year 2015-16.
• Award for Best Quality Excellence for the year 2016-17
• Award for Best Quality Excellence for the year 2015-16
Outcome of Our Best Practices
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Conclusion
• Dedicated energy audit team to reduce energy
consumption of plant
• Small-small activities and efforts results in huge
saving to achieved targets
• R&D and Innovation is the zest of achieving goals.
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