excellent energy efficient unit -...

Excellent Energy Efficient Unit

JK Cement Works, Mangrol

S.K. Rathore - Unit Head ([email protected])

Company ProfileA. About JK Cement Ltd.:-

❖ JK Cement has an installed grey cement capacity is 10.5 MnTPA and 103 MW CPP & 23 MW WHR power generation Capacity.

❖ In India, JK Cement has 7 integrated grey Cement Plant & 01 white cement plant (India’s 2nd largest white cement producer) and In abroad (Fujairah) - 1 White cement plant.

❖ We have complete low cost of production and high efficiency among the industry.❖ JK Cement believe to have maximum Cement volume from energy efficient location like Mangrol and to

improve company’s profitability.

B. Certifications it possesses :- JK Cement Ltd., Mangrol is certified with❖ ISO 9001:2008 - Quality Management System❖ ISO 14001:2004 - Environment Management system❖ OHSAS 18001:2007 - Occupational Health and Safety Management System❖ ISO 50001:2011 - Energy Management System

C. Some interesting facts about our organisation:-❖ Lower Manufacturing cost of production of Clinker and Cement.❖ Strong capability of loading of cement by rail as well as by road❖ Line-2 efficiency is the best among the other cement industries.

Company Profile - JK Cement Works, Mangrol

JK Cement Works, Mangrol at a glance:- year of commissioning Sept-2014With a capacity of productionClinker:- 2.15 MTCement:- 2.50 MT

Major Machineries:-Crusher: (Thyssen Krupp) – 800TPH

Raw Mill grinding for roller press in grinding mode (Thyssen Krupp) – 420TPH

Pyro-Process : Supplied by FLSmidth5 Stage single stage In line calcinerRotary Kiln (5000 TPD) 67*4.35m, 4% SlopeModern generation Cross bar cooler.

Fuel grinding Atox vertical mill supplied by FLSmidth – 32TPH

Cement Grinding: (Thyssen Krupp) – for OPC 250-260 TPH and for PPC 260-280 TPHCombi-Circuit (Roller press and Ball Mill for both OPC and PPC production).

Packing Plant : 120TPH*4 Packer (Roto-Packer FLSmidth)

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Awards Achieved in 2016-17

Private Sector waste Management Award :-JK Cement Works, Mangrol

Best Waste Management Officer :-S.K. Rathore (Unit Head)

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JK Cement Woks, Mangrol recently won “CII - National Energy Efficiency Circle (EC)Competition”on 18-19 May’2017 in New Delhi and awarded the Second Best prize for “Best Energy Efficiency Organization” by Confederation of Indian Industry.


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One of the most prestigious award amongst the Industries i.e. “Golden Peacock Awards” Won by “JK Cement Works Mangrol” under the leadership of our Unit Head Sh. S. K. Rathore Sir, in the Category “Eco-Innovation Award” at Institute Of Directors (IOD), India’s 19th World Congress on ENVIRONMENT MANAGEMENT and Golden Peacock Awards Presentation Ceremony at The HICC - Novotel in Hyderabad (India) on 07th – 08th July’17.


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• JK Cement Woks, Mangrol won the SEEM National Energy Management Awards 2016

• Category :- Industries

• Sector & Organization :-

Cement - JK Cement works, Mangrol

• Position :- GOLD


JK Cement Woks, Mangrol has received Rajasthan Energy Conservation Award 2016 on 14th

Dec 2016.

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▪ JK Cement was awarded the 2nd Fastest Growing Cement Company in India in the medium category at the Indian Cement Review Awards 2016.

▪ Best CSR Campaign Award at Business Rankers Award 2016 for the Baal Sabha campaign conducted in Tonk, Rajasthan.

▪ No. of awards won in Mines, Environment & mineral conservation week.(Under the aegis of Indian bureau of mines, Udaipur) .

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Energy Mapping

Major Steps taken for Excellent Energy Efficient Unit :-

❖ Optimization of Power mix (Daily Basis).

❖ Analysis of Electrical Energy consumption (Daily Basis).

❖ Optimization of Fly ash addition in PPC to minimize Cement grinding power.

❖ PSD Monitoring.

❖ Optimization of process parameters in Grinding as well as in Pyro-section to optimize thermal and electrical energy consumption.

Crusher2%

Raw Mill23%

Kiln29%

Cement Mill43%

Packing Plant3%

KWH/TON OF CEMENT

Total 65.80 kWh/T Cem

Initiatives To Be Excellent Energy Efficient UnitS.

NoMajor Initiatives Impact (for FY 16-17)

1Replacement of Dry Fly ash by cheaper Pond Fly ash up to

38.3%Total saving achieved - Rs 6.37 Cr.

2 Hot Air furnace installed in Cement Mill. Increase Pond Ash Consumption

3 Optimized usage of In-house grinding Aid in Cement grinding. Total saving achieved - Rs. 1.39 Cr

4Energy Saver Panel installed at different locations of Plant for Saving Lighting Load

Approx. Rs.64 Lakh Per Year Saved.

5 Usage of AFR in Kiln TSR up to 8.01% achieved with a saving of Rs. 8.58 Cr

610 Nos. of Motors (From 37 Kw To 132 KW Range) converted into VFD Type

Energy saving of approx. 2000 KWH unit per day and cost saving is Rs.32.85 Lakh

7662 Nos. of LED Lights (From 70 Watt To 250 Watt Lights Changed In Lower Watt LED) installed

Saving of KWH is 1242 per day and cost saving is Rs.20.13 Lakh per year.

8 Energy management system implementation and certification.For becoming best energy efficient organisation JK Cement ,

Mangrol is now certified with ISO 50001:2011.

9For the best excellence in energy JK Cement, Mangrol has Manufacturing Excellence Program called ‘UDAAN’ .

Various KPIs achievements and reduction in thermal and electrical energy of the plant.

Initiatives To Be Excellent Energy Efficient Unit

S. No

Major Initiatives Impact (for FY 16-17)

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Optimization of Heat Consumption of Kiln by various steps:-(a) Optimization of Burner Momentum(b) Optimization of excess Air(c) Optimization of Raw Mix chemistry with mineralizer(d) Optimization of Process Parameters(e) Optimization of PID Controls

Thermal energy is reduced from 703 Kcal/Kg of Clinker to 682 Kcal/Kg of Clinker.21 Kcal/Kg of Clinker is saved.

12Allocation of additional budget for the implementation of energy saving measures.

Budget sanctioned for additional weigh feeder for pond ash, additional furnace, CBA installation, etc.

13 Installation of Additional Pond Ash Weigh Feeder for Feeding Pond ash Consumption increased.

14External energy audit for further improvement in energy efficiency.

Implementation in the recommendations resulted in thermal, electrical energy consumption along with CPP and WHR

15 Training for energy conservation.

Employees are trained for in-house energy conservation and also sent outside for such trainings like CII etc. Also energy audits done by BEE approved auditor & CEMCON Switzerland for identifying areas of improvement

Year Project description

Achievement of energy savings

per year basisInvestment

incurred on

the project

Rs. Lakhs)

Electricity Fuels*Total savings

in (Rs. Lakhs)(Lakhs

kWh)

Coal

(tonnes)

2015-16

Use of In House Grinding aid for optimization of cement grinding

12.82 58.5 10.8

Installation of VFD & Removing of damper in Ball mill vent fan -228 will help in avoiding damper loss & improve performance of fan.

1.0 4.7 6.3

Installation of cross belt analyser for controlling the pile quality

178.0 9.9 215.0

Increase in Usage of pond ash by installation of Hot air furnace in Cement Mill at Ball mill Inlet

80.0 0.0

Replacement of 123Nos. 250Watt HPSV Light by 90 Watt LED Street Light

0.9 3.8 9.5

Replacement of 110Nos. 250Watt HPSV Light by 30 Watt LED Street Light

1.1 4.7 2.1

Energy Conservation Projects


Achievement of energy savings per

year basisInvestment incurred on

the project Rs. Lakhs)Electricity Fuels* Total

savings in

(Rs. Lakhs)(Lakhs

kWh)

Coal

(tonnes)

2015-16

Replacement of 65Nos. 250Watt HPSV Light by 150 Watt High Bay LED

0.7 1.3 6.7

Replacement of 113Nos. 250Watt HPSV Light by 150 Watt Halogen LED

1.2 5.5 15.2

Replacement of 175Nos.70Watt HPSV Well Glass light by 40 Watt LED Well Glass

0.2 1.0 6.2

Replacement of 26Nos. 2X36Watt false Ceiling CFL Light by 2X18Watt LED

0.04 0.2 0.8

Replacement of 50Nos. 250Watt HPSV Light by 70Watt LED Street Light

0.4 1.7 3.0

Installation of 150KVA Energy Saver Panel(Implemented in month of Feb-16)

0.04 0.2 3.4



Achievement of energy savings

per year basis Investment

incurred on

the project

Rs. Lakhs)

Electricity Fuels* Total

savings in

(Rs. Lakhs)

(Lakhs

kWh)

Coal

(tonnes)

2015-16

Installation of 225KVA Energy Saver Panel(Implemented in month of Feb-16)

0.1 0.3 4.5

Installation of 25 KVA Energy Saver Panel Qty-2 Nos(Implemented in month of Feb-16)

0.01 0.1 1.6

Installation of 90 KVA Energy Saver Panel(Implemented in month of Feb-16)

0.01 0.1 2.4

Optimization of Fuel Mix design 3174.0Stablization & Optimization of process parameters, excess air Reduction, burner momentum Increase, kiln rpm Optimization etc. Thermal energy reduced from 722.4 Kcal/Kg Clinker (2014-15) to 703.3 Kcal/Kg Clinker(2015-16)

3542.0 224.2 2.0

Installation of VFD in Condensate Extraction Pump - 2. 1.65 7.52 2.6

ACC putted on AUTO mode. 1.16 5.27 -


Year Description of energy efficiency improvements measureMillion

investmentMillion Saving

Verified energy savings

Units

2016-17

Regulation of grinding aid dosage in Cement mill Rebuilding of roller surface profiling periodically, Grinding media composition optimization, Improved separator maintenance, PSD analysis of product, Improvement in Clinker chemistry

1.24 20.64 5318402.5 Kwh

Modification of interlocks to reduce idle running hrs. of equipments, Improvement in PRI in Raw mill and kiln, VFD installation in kiln feed elevator and rotary air lock, Improved maintenance of Kiln, Cross bar cooler, Raw mill separator vanes modification.

4.16 8.42 2171054.102 Kwh

Replacement of main fuel by various kinds of AFRs like Agrowaste, Liquid mix waste, Solid mix waste, Fiber mass, ETP sludge, Carbon black

6.23 88.81 107591880191 KCal

Optimization of Burner Momentum, Optimization of excess Air, Optimization of Raw Mix chemistry, Optimization of Process Parameters, Optimization of PID Controls.

4.96 31.05 37617490356 Kcal

Installation of Energy Saver Panel at Cement Mill, ADDITIVE LOAD CENTRE and DISPATCH GATE

0.88 0.29 65700 kwh


YearDescription of energy efficiency improvements

measureMillion

investmentMillion Saving

Verified energy savings

Units

2016-17

Replacement of 100Nos.70Watt HPSV Well Glass light by 40 Watt LED Well Glass and Replacement of 26Nos. 2X36Watt false Ceiling CFL Light by 2X18Watt LED

0.48 0.08 17280 kwh

Installed load tap changer at lighting transformer 0.18 0.20 52600 Kwh

Raw mix feeding system modification in house 0.08 0.28 73200 Kwh

DM water make up in CST through gravity 0.05 0.01 2124 Kwh

LED lights provided 0.04 0.02 4452 Kwh

ACC fan running methodology changed 0.00 0.04 10850 Kwh

Cooling tower make up done by ACF feed pump 0.01 0.01 2100 Kwh

Installation of zero air loss drain valve 0.05 0.01 2630 Kwh

Insulation work on condensate system 0.79 0.21 286463160.0 Kcal

VFD Installed in CEP NO. 2. (Old VFD shifted from Baminia power plant)

0.24 62000.0 Kwh

Insulation work of CST and its connected lines 0.44 140929300.8 Kcal


The Major Energy Conservation Projects

Title of the Project

Brief Description of the projectAnnual Savings, Rs

million/year

Investment, Rs

million/year

Saving Potential (Electrical SEC)

Thermal potential (Thermal SEC)

Amelioration in Cement Grinding

Regulation of grinding aid dosage in Cement mill Rebuilding of roller surface profiling periodically, Grinding media composition

optimization, Improved separator maintenance, PSD analysis of product,

Improvement in Clinker chemistry

20.6 1.24

Electrical Power consumption for cement grinding

reduced from 30.5 to 27.52 kwh/ Ton of

cement

-

Usage of AFR instead of Petcoke

Replacement of main fuel by various kinds of AFRs like Agrowaste, Liquid mix waste, Solid mix waste, Fiber mass, ETP sludge, Carbon

black

85.8 6.23

Utilization of AFR with 8 % TSR i.e. replacing 54.62

Kcal/Kg of clinker thermal energy.

Amelioration in Kiln

Optimization of Burner Momentum, Optimization of excess Air, Optimization of

Raw Mix chemistry, Optimization of Process Parameters, Optimization of PID Controls.

31.1 4.96

Thermal energy consumption

reduced from 703 to 682 Kcal / kg clinker

Road Map of Energy Conservation for Coming years

(A). Optimization of Cement mill by grinding media re-gradation.

(B). Optimization of OPC Clinker factor from 95 % to 90%

(C). Reduction in false air of raw mills and pyro section circuit to reduce power consumption of circuit

(D). Reduction in idle running of various small drives or circuit.

(E). Profiling of both roller press rollers along with grinding media re-gradation to reduce grinding power consumption in Raw mill and Cement mill.

(F). Increase in usage of Dry fly ash upto 32% in PPC production.

(G). Exhaustive energy audit of the Plant to find out various potentials for energy saving

(H). Installation of VFDs in various drives to save electrical energy.

(I). Burner replacement of old burners to low NOx Pyrojet Burner to reduce upto 3 kCal/Kg Clk.

Daily review meetings snaps

GHG Inventorisation

CO2 2016-17 2015-16 2014-15

Total CO2/Ts of Cement 0.579 0.618 0.673

CO2 reduction by WHR generation (Ts./annum) 60416 56959 8832

% investment for Energy Conservation projects on turnover

Total turnover of the plant FY 2016-17 (Rs. Million) 9759.47

Amount invested in EnCon Projects FY 2016-17 (Rs. Million) 19.13

Investment % 0.20

Results AchievedManufacturing Excellence Drive Score Card Over Aspiration

JK Cement Works, Mangrol

KPIs Unit Aspiration YTD 2016-17 YTD 2015-16

Specific Thermal energy consumption kCal/kg Clinker 700 682 703Specific Power consumption Up to Clinkerisation kWh/Ts Clinker 46 45.4 46.6

Specific Power consumption Cement Grinding kWh/Ts Cem 29 27.5 30.5PPC Clinker Factor % 64 63.7 65.1

MTBF Raw Mill HR 75 63.2 29.6MTBF Kiln HR 500 135.2 64.8

MTBF Cement Mill HR 150 31.6 7.9TSR (AFR) % 10 8.0 0

Pond ash in Total Fly ash Mix % 50 38.3 15.7Plant Availability Factor % CPP 93 92.7 89.3

Station Heat Rate (kCal/kwh) CPP 3250 3309.0 3229Auxiliary Consumption % CPP 12 11.0 12.5

Plant Availability Factor % WHR 99.6 99.8 99.4Generation Capability WHR 25 20.2 18.1

Auxiliary Consumption % WHR 5.5 4.9 5.8

Results Achieved

1Electrical energy reduction done during the year

2015-16 2016-17 KWh/Ts Cement Saving in Crore71.69 65.8 5.89 Rs 4.08

2Thermal energy reduction done during the year.

2015-16 2016-17 Kcal/Kg Clinker Saving in Crore703 682 21 Rs 3.02

3 Within a year very high TSR% achieved.2015-16 2016-17 Petcoke saved (Ts) Saving in Crore

0 8.01 12300 Rs 8.58

4Utilization of Pond ash % achieved by In-house modification and optimization.

2015-16 2016-17 % Increased Saving in Crore16.1 38.3 22.2 Rs 6.37

5VFD installation, Motor replacement, LED installation, etc.

Savings in KWh Saving in Crore1002885 Rs 0.39

Unique features for Excellent Energy Efficient Unit

❖ Running in house manufacturing excellence program , name – “ UDAAN “

❖ Electrical energy consumption was 65.80 Kwh/Ts. cement (One of the best in cement industry)(Saved 5.89 Kwh/Ts. cement over last year)Power generation from WHR 20.20 Kwh/Ts. clinker Or 15.38 Kwh/Ts. of Cement.Therefore, Net Power consumption Kwh/Ts. Cement = 65.80 – 15.38 = 50.42 Kwh/Ts of Cement only

❖ Thermal Energy consumption was 682 Kcal/kg of clinker. (One of the best for this design of plant)(Saved 21 Kcal/Kg of clinker over last year)

❖ Utilisation of AFR with 8 % TSR i.e. replacing 54.62 Kcal/Kg of clinker thermal energy.Therefore, Net fossil fuel Utilisation in Kcal/Kg of clinker = 682 – 54.62 = 627.37 Kcal/Kg of clinker onlyFinally, reducing emissions of GHG as well as saving natural resources (fossil fuels).

❖ In WHR, Auxiliary consumption minimized – 4.9 % (One of the best)

Thank you !

excellent energy efficient unit -...

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