jhansi, india 19th national award for “excellence …...jhansi, india mr gnb rao,plant head mr...

JHANSI, INDIA

Mr GNB Rao,Plant Head

Mr Deepak Kakkar, SGM( E&I)

Mr Manoj Vaish, GM( Production)

19th National Award for “Excellence in Energy

Management 2018” CII Hyderabad,

29 Aug - 31 Aug 2018

Contents

Company Profile & major process equipment specifications

Specific energy Consumption for last three years

Information of competittors / benchmark in SEC & road map

List of Energy Saving Projects of last three years

Innovative Projects Implemented

Utilization of Renewable Energy sources

Utilization of Waste material as fuel

GHG Inventorisation in HCIL Jhansi

Green Supply Chain

Team work , Employee involvment and monitoring

Implementation of ISO 50001/Green Co/IGBC rating

Employee involvement & Awarness Tool (CIP)

Environmental , Green Projects & Best Practices

HeidelbergCement Group

▪ Largest Integerated manufacturing Co.

Of Building material

▪ 59,000 employees

▪ Core Business

– Aggregates

– Cement

– Downstream activities: ready-mixed concrete and asphalt

▪ 3,030 locations in around 60 countries (incl. Joint Vntures)

– 616 Production sites for sand, gravel and crushed rock

– 159 Cement and Grinding plants

– 1,735 ready – mixed concrete plants

– 112 asphalt plants

– Cement Capacity 195 Million Tonnes (incl. Joint Ventures )

▪ Aggregates reserves & resurces 20 Billion Tonnes

HeidelbergCement in the world & IndiaNumber 1 in aggregates,

Number 2 in cement, Number 3 in ready-mixed concrete

Plant Profile – Jhansi Unit

▪ Jhansi Plant having Cement Grinding and Packing facility with installedcapacity of 0.5 MTons/annum was set up in the vicinity of Parichha ThermalPower Project with a view to manufacture PPC by using the waste Fly Ashfrom PTPP, at Village: Madora, District: Jhansi, Uttar Pradesh, which came inproduction during April, 1989.Plant capacity was expanded to 2.7 MTPA byinstalling VRM & packing plant and material handling equipment in 2013.

Milestones – Jhansi Unit

Process Equipment

Major Equipment Capacity

Cement Mill-1 (Ball Mill)Capacity-105 TPH

Make: KHD Humboldt

Cement Mill-2(VRM)Capacity-215 TPH

Make: Loesche

Packer- 4 Nos.Capacity- 4* 240 TPH

Make: EEL

Wagon TipplerCapacity: 1000 TPH

Make: Metso

Over all Cement Grinding Specific Energy Consumption (SEC) KWH/Ton

23.00

24.00

25.00

26.00

27.00

28.00

29.00

30.00

VRM 2014-15 VRM 2015-16 VRM 2016-17 VRM 2017-18

25.90

24.45 24.3623.93

2.25

2.13 2.041.99

1.65

1.55 1.581.62

Cement Grinding Sp. Power Consumption Vertical Roller Mill (KWH/Ton)

Cement Grinding

RMH

Packing Plant

29.8

28.1327.98

27.54

Cement Grinding Sp. Power Consumption Ball Mill ( KWH/Ton)

29.67

28.0127.82

Cement Grinding

RMH

Packing Plant

28.62

Sp. Power Comparison with Benchmark

23.9325.0

Main Drive Mill Aux.Mill Fan

VRM Best in Industry Ball Mill Best in Industry

HCIL ZCL

Year 2018 2019 2020 2021 Remarks

BM Power reduction

25.7 25.5 25.2 24.75- Airlift replacement by BE- High efficiency separator fan

VRM Power reduction 26 25.5 25 24.5

- Optimization of Bag Filters- Monitoring usage of HAG- Increasing productivity

Packing plant Power

reduction1.65 1.6 1.5 1.4

- Monitoring Idle running of Packer

- Optimization of Compressor- Additional wagon loading point

Aux Unit reduction

0.75 0.7 0.65 0.55

- Installation of Led light in place of conventional fittings

- Monitoring idle running of equipment

- Optimization of compressor & Air conditioners

Long term Target SEC ( Units / Ton)

HCIL ZCL

Capex Fund Allocation 2018 & 2019

S.NO. NATURE OF JOB FUND ALLOCATED

1. New High Efficiency separator for CM 51500 KINR

2. Refrigerated Air-dryer for old packing plant compressor

1000 KINR

3. Soft starter for airlift blower 160 KW motor

600 KINR

4. Replacement of existing light fitting with LED lights

4400 KINR

5. Truck Loading Machine Hydraulic System 2500 KINR

Energy Saving Project 2015-16 ( without major Investment)

SI NO. Description of ProjectTotal Annual Savings (Rs.

Million)

1.Stopped 15 KW air compressor of wagon tippler by connecting compressed air from other compressor

0.16

2.Stopped one Bag Filter Fan with RAL of VRM clinker hopper top by connecting venting line from other Bag filter

0.63

3.Installed Flap gate in place of rotary airlock of Bag Filter of Silo Top

0.11

4.Power saving by monitoring idle running & other power saving corrective action

23.38

5. Diesel saving by process optimisation (diesel saving) 23.67



Million)

1.Installation of VFD in place of DOL starter for Bag filter fan

1.8

2.Bag Filter fan of 37 KW has been stopped by optimisation of bag filter circuit

1.8

3.Stopping of Idle running dust transport group during preheating with HAG

1.1

4.Optimisation of Plant compressors by using air pressure interlock & adjustment in sump air pressure

6.0



Million)

1Installation of LED lights in Place of Conventional lights

1.28

2Reduction in 40 mmwg Pressure Drop Across Damper by Removing inlet Damper of VRM Bag House Fan

5.79

3Optimisation of Dust Collectors in VRM section by stopping 2 nos. Dust Collectors Fan of Capacity 55 KW each

2.63

4Installation of Soft Starter and SQIM in Place of Slipring Motor with LRS

0.93

5Optimisation of Ball Mill Operation by Modification in Ball Mill Liners and Tipping of Discharge Elevator by 20 mm to increase the productivity

7.2

Innovative Project 1 – Optimisation of Ball Mill

Abstract :Year 2015 and Year 2016 annual average TPH of Ball Mill achieved 127.5MT.Targeting to achieve this up to 130-135 TPH.To achieve this target mill optimisation plan drafted and implemented theplan step by step. During optimisation process different hurdles identifiedwhich has been rectified in sequential manner.Following bottlenecking recorded in system:-1. Poor grinding in first chamber due to coarse grinding 2. Poor classification of grinding media in second chamber3. Load fluctuation in mill discharge elevator.4. Material back flushing from elevator with the increase of elevator load.

Above hurdles come-across during the optimisation process which rectified and finally results achieved in increase of TPH, reduction in Power consumption and improve in housekeeping at Ball mill area.

Innovative Projects- 1. Optimisation of Ball mill

Problem:

1. To improve Mill productivity to achieve SPC 26.0 kwh/t_cement

2. To identify and eliminate bottlenecks for dry flyash feeding point at mill

discharge bucket

elevator – material flushing out due to surge, restricting flyash feed

3. Mill discharge bucket elevator running on full load due to over filled

material at boot and bucket as well thus restricting increase in total mill

feed.

Idea/Solution:

1. Replaced 2nd chamber liners with new design semi boltless thin

classifying liners for better classification and improved grinding

2. Relocating the flyash feeding point at mill discharge bucket elevator

to resolve the material flushing problem

3. Tipping of buckets by 20 mm leading to increase in bucket volume

eliminating the boot filling due to material spillage thus resulting in

smooth operation of bucket elevator also drawing less power.

Optimisation of Ball Mill

Innovative Project 1 – Ball Mill Optimisation

Improvement in grinding efficiency of mill :

• Thin Classifying semi-

boltless liners have been

installed in second chamber

to improve classification.

• Bigger size (90 mm) grinding

media introduced in first

chamber to improve grinding

efficiency in first chamber.

• This resulted in increase of

mill feed.

• But due to problem of back

flushing and overload

tripping of mill discharge

elevator target could not be

achieved.


To rectify this problem some series of modification were done

Modification – 1➢ De-Bottlenecking in Bucket elevator feed chute which was not able to

handle feed more than 125 TPH.➢ To rectify this bottleneck feed chute modification carried out.

Before After


Modification – 2

➢ Crash stopped the elevator to inspect bucket filling and observed that elevator bucket filling was more than 90%.

➢ To increase the bucket filling capacity,20 mm bucket tipping was done.

Before After

20 mm bucket

tipping


Modification and spare change – 3➢ Elevator head shaft traction wheel segments replaced with OEM (Rexnord )

supplied segments and discharge lip seal plate replaced with minimum gapas recommended by OEM.

➢ This help to maintain optimum carrying capacity of bucket elevator whichprevented back flushing and overload tripping problems.

Lip Plate

adjustment

Traction wheel segment

2016 2017 2018

Month TPH Month TPH Month TPH

Jan 128.15 Jan 127.25 Jan 135.17

Feb 131.23 Feb 125.53 Feb 136.06

Mar 130.35 Mar 128.10 Mar 137.15

Apr 129.48 Apr 127.41 YTD 136.18

May 128.03 May 131.63

Jun 125.05 Jun 132.66

Jul 128.23 Jul 130.99

Aug 129.20 Aug 126.21

Sep 124.93 Sep 128.44

Oct 127.45 Oct 128.46

Nov 124.16 Nov 131.84

Dec 128.35 Dec 134.61

YTD 127.9 YTD 129.51

Results Achieved ➢ The optimisation process was over in Nov 2017 and finally 5~6% increase in

productivity has been achieved.➢ General cleanliness and housekeeping has been improved substantially in and

around Ball mill area.➢ Following are the annual average figures of 2016, 2017 and 2018 till March

2018.



120125130135140

TPH

Aug-17 Sep-17 Oct-17 Nov-17 Dec-17 Jan-18 Feb-18 Mar-18 Apr-18

TPH 126 128 128 132 135 135 136 137 137

Increase in Production Rate

2425262728

kWh

/MT

Aug-17 Sep-17 Oct-17 Nov-17 Dec-17 Jan-18 Feb-18 Mar-18 Apr-18

SPC 27.42 26.93 27.06 26.71 26.51 26.42 26.12 25.97 25.65

Reduction in Power Consumption

Financial savings achieved : 3,353,960 INR (till Mar-2018) ie 3.35 MINR

Innovative Project 2 – Optimisation of Bag filter in VRM area

Problem-In VRM feeding and reject circuit there were 04 nos. of bag filters having cumulative capacity of 58,000 m3/Hr and installed Power 222 Kwh. Two Bag filters were running with very less DP across tube sheet although suction was controlled through damper valves.

Solution –Step by step dust collector operation parameters checked and found that DP across tube sheet was in the range of 40~60 mm wg even though suction ducts were regulated through damper valves. Lay out of all bag filters studied and modification plan finalised as follows:-1. Bag Filter 201BF10 inlet pipelines modified and suction lines of 205BF10 connected to this Bag Filter.2. Bag Filter 201BF20 inlet pipe lines connected to suction pipelines of 201BF30 Bag Filter.3. Stop the Bag Filters 205BF10 and 201BF20.4. Total power saved 61 kwh/ Hour without any adverse effect in fugitive dust emissions.

Innovative Project 2 – Optimisation of Bag filter in VRM area

Modification in Bag FiltersAfter modification - 61 mmwg DP of combine Bag Filter

Innovative Project 3 – in-house arrangement of Incinerator from scrap for heat generation

Abstract :

▪ Nearby Power plant getting stopped due to low power demand▪ It Results in non availability of Dry fly ash and subsequently results in

use of wet fly ash above 20-40 tons per hour) and dry fly ash both to run the VRM

▪ Fuel 250-400 litres per hour fuel were required to maintain the VRM outlet temperature (At low temperature VRM feed rate decreased).

▪ Another Challenge - Big issue of disposal of fallen Leaves & Wood and partially / fully rotten trees specially in summer season as creates unsafe condition ( fire incidents) & housekeeping problem in Colony & Plant area

Solution :• Make in-house arrangement of Incinerator (already old scrap

Incinerator available which was not used since a long time) for burning of bio mass / waste material and generated heat use as a fuel in VRM.

Innovative Project 3 – in-house arrangement of Incinerator from bio mass/ scrap for heat generation

Action Implemented:▪ Engineering drawing made for installation ▪ Fixed the insulated bricks & castable inside the incinerator to reduce

the heat loss▪ Insulated the outlet duct of Hot Air generator. ▪ Adjusted the Process Parameters after installation of Hot Air generator▪ Commissioned the Burning System ▪ Feeding arrangement made for waste leaves

Result:Increase of • VRM outlet temperature by 5-10 ºC

• VRM feed rate by 5 to 10 tons per hour • Addition of wet fly ash around 20-40 Tons/Hrs. without using HSD or

Pyro oil.

• Saving of 1778 KINR in 2017-18

Innovative Project 3 – in-house arrangement of Incinerator from bio-mass for heat generation

Renewable Energy - Practices

Transparent sheets installation at packer floor and truck loading area to get natural light during day hours.

Total Cost – 4.5 KINR, Saving – 1.5 KINR

Before After

Packer- 1,2 floor with Electric Lights

Solar 7.5 KW plant for SVK Building▪ Independent Unit for New

SVK Building▪ Zero Power consumption

Renewable Energy - Practices

Uses of Renewable energy

▪ Use of Turbo Vent to Improve the Air circulation

Energy Saving =5.23 Lakhs

▪ Use of Day light in workshop area

Energy Saving =11.30 Lakhs

▪ Use of solar Energy for street Illumination.

Energy Saving=2.5 Lakhs

▪ Use of Solar Water Geyser in Plant Colony and

Guest House.

Energy Saving=3.0 Lakhs

TOTAL SAVING: 22.03Lakhs

Proposed solar roof top plant – 0.75 MW

UTILISATION OF WASTE MATERIAL - HEAT GENERATION (

THERMAL ENERGY)

Problem –

- Non availability of Dry fly as per daily requirement

- Use of wet fly ash by 10-20%

- Fuel 250-400 litres per hour is required to maintain the VRM outlet

temperature in case of wet fly ash

Solution -

- Make in-house arrangement of Incinerator (already old scrap

Incinerator available which was not used since a long time) for

burning of bio mass / waste material and generated heat use as a

fuel in VRM.

Action Taken –1. Made the engineering drawing for installation2. Fixed the insulated bricks & castable inside the incinerator to reducethe heat loss.3. Insulated the outlet duct of Hot Air generator.2. Adjusted the Process Parameters after installation of Hot Air

generator

Burning waste material

in generator to increase the VRM

outlet temperature & this has

increased the VRM feed rate by 5 to

10 tons per hour and also able to

absorb around 20-25 Tones of wet fly

ash without using HSD/Pyro oil.

Saving

Utilisation of bio mass / waste material - Heat Generation ( Thermal

Energy)

GHG Inventorisation

➢10 % Reduction in GHG emission in Kgof CO2/Ton of Cement produced byyear 2020.➢To achieve Carbon sequestration

through plantation (3000 plants/year)➢Specific energy consumption

reduction➢Roof saving Target➢Sharing vehicles for commute

Year 2018 2019 2020 2020

GHG emission in Kg of CO2/Ton of Cement

produced28.0 27.0 26.50 26.0

Total GHG emission in Tons

71378 72900 71550 70200

GHG Inventorisation

❖ Daily monitoring of Power consumption

❖ Power consumption reduction ideas implementation

❖ Monthly monitoring & review of GHG emission

❖ Fuel consumption optimization in VRM

❖ Maximize the use of Fly ash as per rules & regulations

❖ Avoid idle running of equipments

❖ Optimization of Bag filters operation

❖ Ball Mill & VRM optimization

❖ Optimization of Air compressors

❖ Replacement plan of low efficiency motors with high efficiency motors in phase manner

❖ Replacement of Air lift by Bucket elevator in Ball Mill

❖ Installation of High efficiency Separator in Ball Mill

❖ Installation of Bucket elevator in place of Air-lift

❖ Installation of VFD in Bag filter fan motor

❖ Installation of Solar panels

GHG Inventorisation - Monitoring

Direct GHG Emission S.No. SourceTons of CO2 per

annum

Kg CO2 / MT

Cement

1 DG set 0.00 0.0000

2 Fuel for HAG 9.92 0.0418

3

Own vehicles(Fork-Lift, Sweeping

Machine, Hydra & Clamshell

machine usage)

25.29 0.107

4 Fabrication 0.00 0.000

5 R & AC 105.40 0.444

6 Fire Extinguisher 0.01 0.00

7 Mess 0.15 0.001

Sub Total 141 0.593

Energy Indirect GHG

EmissionS.No. Source

Annual CO2

emissions (MT)

Kg CO2 / MT

Cement

1 Electrical Power Consumption 5522 23.26

Other Indirect GHG

EmissionS.No. Source

Annual CO2

emissions (MT)

Kg CO2 / MT

Cement

1 Cement Dispatch - Road 658 2.773

2 Cement Dispatch - Rail 15 0.063

3 Fly Ash - Road 56 0.2354 Gypsum - Rail 1 0.005

5 Clinker Receipt by Road 207 0.873

6 Clinker Receipt by Rail 4 0.018

7 Contract vehicles at plant 8 0.033

Sub Total 950 4.00

SAP Implemented for paper less procedure.

Bravo Portal Implemented for paper less inquiry system for

procurement

Procurement of LED lights and Energy Efficient motors.

Installation of thin classifying liners for ball mill.

47

Green Supply Chain – Raw material procurement

Green Supply Chain – Raw material procurement

▪ Fly ash

▪ Maximisation of fly ash blending @ 34.83%

▪ Contract with Power plant to ensure for sustained dry fly ash supply

to ensure high blending ration

▪ Mineral conservation due to usage of fly ash

▪ Machinery & spare procurement

• Encouraging local vendors to reduce carbon foot print & inventory

• Vendor Stocking to have just in time concept ie. Lubricants , PP Bags,etc

• ARC contract for fast moving spares

• LED lights installation and solar panel procurement

• Drip irrigation to reduce water consumption

▪ Scrap Disposal – E-auction

▪ Inbound Logistic

- Two way transportation (from one unit to other unit ie Clinker from

one plant and return with fly ash

- Transport pooling to reduce carbon foot print

48


Continuous improvement program

( Employee Involvement)

▪ Tool for idea generation process

and its implementation.

▪ Ideas generation by all level of

employees through idea card.

▪ Discussion on ideas by Energy

Management cell

meeting.(Monthly)

▪ Energy Consumption review

through power report.(Daily)

- Key Performance Indicators i.e. Specific power & Fuel consumption are being monitored on daily basis and deviation is being highlighted.

- Review is being done on monthly basis by top management in monthly MRMs.

ANNUAL TECHNICAL MEET 2018 / 2017/ 2016/2015

Annual Technical convention to discuss

new innovative ideas implemented at

different units of Heidelberg cement

Benchmarking & best practices sharing

Platform to share ENCON projects

implemented and energy targets.

For benchmarking , innovation & best practice sharing among HCIL- ZCL in the presence of higher management


Training for shop floor employees on

energy conservation.

ENCON Extempore was organized.

Shop floor employees were asked to

explain the understanding of ENCON in

their respective areas.

Quick & Direct feedback about ENCON.

Monthly energy saving awards.

Installed Performance Boards at different

locations of plant to highlight the present

condition and target for SEC and energy

saving Projects.

Discussion with Unit Head on ENCON Projects

ENCON motivational training program & & mega knowledge fair

Meeting of Energy Management Cell

Extempore on Energy Saving

Idea Presentations were given by Employees


Green CoGreen Co presentation has been submitted for different modules and initial assessment has been done. Final assessment is expected in September 1st week.

Implementation of ISO 50001/Green Co/IGBC rating –

Self assessment


Team Members List for Green CO Rating

S.No.

ParticularActive

MemberJhansi Dy. Owner

1 Energy Efficiency Deepak Kakkar Javed Alam2 Renewable Energy Deepak Kakkar Javed Alam

3 Water Conservation Akhilesh Tamrakar DK Sharma

4 GHG Reduction Manoj Vaish Anil Sharda

Javed Alam, Ankur, Juneja

5 Waste ManagementBalraj Bharti/BR Yadav

Sushil Pathak

6Material Conservation, Recycling & Recyclables

Saurav Singh G.Kasana

7 Green Supply Chain Nipun Beri /Arun Rai Arvind Srivastava

8 Product StewardshipSaurav Singh/Arun Rai

Gajendra Kasana

9 Life Cycle Assessment Mayank Bajpai Rohit Pandey

10Others (Ventilation, Site Selection, Green Belt & Innovation)

Vikas Chand Jain Rama shankar Sen


ISO 50001

We have applied ISO 50001 certification and will be under audit in Dec 2018.

HCIL ZCL

Certification•Certified to ISO 9001 / ISO 14001 / OHSAS 18001 since 2013.

•External & Internal Yearly audit from Certified agencies ( TUV) & trained

auditors

Target Audit 2018

HCIL ZCL

Energy Policy

➢ Policies and program to create awareness towards energy conservation

➢ Collection of Innovative ideas from all level of workforce through idea generation

➢ Investment in energy conservation projects

➢ Continuous EnPI monitoring with Benchmark data.

Prime Driving factor for

Energy conservation in

organisation

HCIL ZCL

Sustainability Commitments 2030

(SC2030) : Covers six areasOur Sustainability Priorities Include:1. Energy & Climate Protection2. Resource Conservation3. Health & Safety of employees4. Social responsibility in our communitiesRoad Map –a. Driving Economic Strength and Innovation - through the effective management of all processes and resources and the continuing innovation of products and services. b. Achieving excellence in Occupational Health and Safety by continuously enhancing the occupational health and safety conditions of our employees, contractors and third parties.c. Reducing our Environmental Footprint by reducing our impacts on air, land and water.d. Enabling the Circular Economy by continuously increasing the use of alternative resources as substitutes for natural raw materials.e. Being a Good Neighbour by supporting the social and economic development of our neighbouring communities and ensure transparent communication to all our stakeholders.f. Ensuring Compliance and creating Transparency as adhere to human rights, anti-corruption and labour standards and co-operate pro-actively in an open and transparent manner with all our stakeholders

HCIL ZCL

Energy Management Team

Plant Head Jhansi – Mr GNB

Rao

Process In charge

(Grinding & MH)-Mr Manoj Vaish

Maintenance &

Utility In charge-Mr AK Tamrakar

Packing &

Dispatch In charge – Mr BR Yadav

ENCON PROJECT HOD (E&I) –

Mr Deepak Kakkar

HCIL ZCL

ENERGY MANAGEMENT CELL

Roles & Responsibilities

➢ Plant Head– Responsible for total Plant operation & Performance. Chairs the

Plant Energy Review meetings (weekly & Monthly) and Takes the decisions as and

when required. Gives instructions to concerned on targets & action plans.

➢ ENCON PROJET HEAD– Co-ordinates the Plant Energy Review meetings.

Analyses the Section wise Plant Energy details and performances. Discuss and

collects the improvement ideas and monitors their implementation. Supports section

heads to improve awareness &Training.

➢ General Manager- Reviews the overall Energy Performances and

improvements, benchmarking with the best figures, Gap analysis and their

implementations. Energy Improvement project presentation and approval with the

senior management and their effective and timely implementation.

➢ Section Heads - Reviews the respective section Energy Performances and

improvements and their implementations. Collects the ideas and their

implementation. Presents their section performance to Plant Head in Energy review

Meetings.

HCIL ZCL

PARTICULARS Jan-18 Feb-18 Mar-18 Apr-18 May-18 Jun-18 Jul-18 Aug-18 Sep-18 Oct-18 Nov-18 Dec-18 YTD

Power

Power-Cement Grinding

PPC-Ball Mill Kwh/t 27.10 27.10 27.10 27.10 27.10 27.30 27.30 27.30 27.30 27.10 27.10 27.10 27.17

PPC-VRM " 26.30 26.30 26.30 26.30 26.30 26.30 26.60 26.60 26.60 26.40 26.30 26.30 26.38

Avg " 26.59 26.59 26.59 26.59 26.59 26.67 26.86 26.86 26.86 26.66 26.60 26.60 26.67

Power-Cement Packing

-Packing-ball Mill Kwh/t 1.64 1.64 1.64 1.64 1.64 1.64 1.68 1.68 1.68 1.64 1.64 1.64 1.65

-Packing-VRM " 1.55 1.55 1.55 1.55 1.55 1.55 1.58 1.58 1.58 1.54 1.54 1.54 1.55

Avg " 1.58 1.58 1.58 1.58 1.58 1.58 1.62 1.62 1.62 1.58 1.58 1.58 1.59

Auxilary

-Auxilary-Ball Mill Kwh/t 1.02 0.90 0.95 0.98 0.98 0.92 1.02 1.28 1.20 1.00 0.97 0.90 1.01

-Auxilary-VRM " 0.81 0.72 0.76 0.78 0.79 0.74 0.98 0.99 0.77 0.80 0.77 0.72 0.80

-Auxilary-avg. " 0.89 0.79 0.83 0.85 0.86 0.81 0.99 1.10 0.93 0.87 0.84 0.79 0.88

Total Power 29.06 28.96 29.01 29.03 29.03 29.06 29.46 29.57 29.41 29.11 29.01 28.97 29.14

Targets Setting:The key to performance-driven energy management is setting Short term & long

term goals. Specific, measurable, assignable and realistic targets are only being

set.

- Annual specific energy targets are being set on the basis of previous year best

power achieved and energy Project considered for the specific year.

- Long term ( 3 to 5 year ) targets are being set on the basis of Capital expenses

plan for the coming years, statutory guidelines for environment , availability of

raw material, process related change etc..

Annual specific power Target - Operating Plan -2018 (Power Target)

Energy Management system

➢ Energy management system is installed for online monitoring of power.

➢ Trivector meter and Multifuctional meters are installed for the purpose

➢ EMS SCADA for operator to monitor online

Trivector Meter Multifunctional Meter

EMS software for SCADA

HCIL ZCL

Heidelberg Cement India Limited

Unit: Jhansi

26,859 42,327

Actual Q1

2017

Actual Q2

2017

Actual Q3

2017

Actual Q4

2017Total FA 2018 PL2018 PL 2019 PL 2020

ENVIRONMENT / SAFETY & LEGAL

55 Jhansi Replacement 182674 Truck Loading Machine Hydraulic System - - 2,500 5000 2500

Currently its Winch machine with rope.

There have been incidence of rope

breakage. This can lead to fatal

To avoid fall of existing truck loading 57 Jhansi Replacement 183117 Replacement of existing light fitting with LED - - 4,400 4,400 7,500

77 Jhansi Improvement MYSHDO.15.0172 Soft starter for airlift blower 220 KW motor - - 600 6001. To reduce the starting current

2. Power saving

3. Reduction in frequent plantstoppage

79 Jhansi Improvement MYSHDO.15.0174

Standby development - LT motors for VRM

section (Bucket elevator,LP Pump/CA &DA fan,FK

Pump,Zypsum Crusher,Filter Pump)

- - 1,000 1000

These motors are special designed and

generally take high delivery time, to

save high downtime these motors are to

be kept as critical spares

80 Jhansi Improvement MYSHDO.15.0175Referigerated Airdryer for old packing plant

compressor - - 1,000 1000

Currently we are running old plant

without dryer. Jamming of packing

spouts.ROI - 1.3 YRS

94 Jhansi Expansion 182692 New High Efficiency separator for CM - - 836 2,500 43,000 2,500

Sr.

No.Plant Category NEW AFE No.'s Projects Description

Actual

Reasons Y

2017+2018+2019+2020

MECHANISM FOR RESOURCE ALLOCATION: 1. OPEX – Department Budget is being allocated on the basis of previous year consumption,

Major expenses forecast for the year and energy efficient improvement project considered.

2. Capex - All major planned / unplanned non operational investments are being made through

Capex Process. Capex plan is being prepared for each of three operating plan years. Approval

process is following:

Major Future Capex For Energy Saving 2018-2020

HCIL ZCL

Review Of EnMS

MINUTES OF WEEKLY MEETING OF HODs

Meeting Date: 4th April 2018

Headed By : Plant Head, Jhansi

Participants:- Mr AK Tamrakar (AKT) Mr D Kakkar (DK) Mr M Vaish (MV) Mr M Bajpai (MB) Mr BR Yadav (BRY) Mr Arun Rai (AR) Mr VK Mishra (VKM) Mr Pradeep Hastwala (PH) Mr Balraj Bharti (BB)

PPAAPP PP A

Mr Kuldip Singh (KS) Mr Vivek Dev (VD) Mr Nipun Beri (NB) Mr Vikas Chand Jain (VCJ) Mr Saurav Singh (SS) Mr Gauri Sharma (GS)

A P P P P P A

PREVIOUS PENDING POINTS: Responsibility

Target Date Present Status

1. Following 5 Important Projects, this is the responsibility of Mr. Manoj Vaish. Co-operation of all concerned is must to complete these projects: - New HAG, BC6 Speed, Motor D rating, TOD

(Point raised on 7.7.17).

MV Continuous

1. TOD: 1.69 % reduced in peak hour’s operation over June17 month. 2.New HAG : Functioning. 3.Motor D rating: Identified 6 motors for D-rating, For trial we will replace 75 Kw motor with 55 Kw motor 4. BC6 speed: Gearbox internals replaced trial to be taken.

2. Railway office record in Office/Building is not being maintained properly, which has to be attended by Mr. Arun rai and as per guideline of Mr Arun and Mr. Deepak Kakkar Civil Deptt has modified the office (Point raised by Mr. Deepak Kakkar on 7.7.17). Mr. Mayank Bajpai has been advised to visit the area along with AR , DK and VCJ to ascertain the correct situation to take a final decision based on their feed-back.

DK Immediate

Concern has visited & found separate room for record purposed would be given along with renovation in existing rooms. It is recommended to give a new building if possible: Arun Rai

3. All lacunas in Admn Building and its surroundings are the sole responsibility of Mr. KS and Mr. VCJ. Mr. M Bajpai is made responsible for preparation of an estimate for removal /renovation of the Kitchens in Admn Building (Point raised on 18.8.17).

MB/KS/VCJ

Immediate

The plan has to be finalising for estimation at the end of VCJ.

4. A list needs to be prepared by Mr. Mayank Bajpai for all the items to be discarded as well

DK/MB.KS/VCJ

Immediate Inspection has been done, submitted and

Power quality analysis and harmonic study is being done on regular basis. Optimization of compressed air and running of compressor has been done with the help of

OEM engineers Optimization of Mill productivity with OEM consultation in regular basis.

Distribution of Portable Solar Lamps to 1000 Students & Energy awareness Program for local community

▪ To Promote use of Solar Energy

& Power Saving village temple

illuminated by solar light

▪ HCIL arranged for portable solar

lamp to each 1000 girl student of

Kasturba Gandhi Balika

vidyalaya to support their study

not being interrupted by power

Jan Jagran Rally on World Environment Day (5th June 2018 )

For Awareness on Energy Saving & Tree Plantation

▪ This rally marched

with a motive to

create awareness for

energy conservation

and green

environment

protection.

Rally start by Jhansi District Magistrate

Tree Plantation by Jhansi SSP

Jan Jagran Rally on World Environment Day (5th June 2017)

For Awareness on Energy Saving & Poster making

▪ Members of HCIL family have

participated in this rally.

▪ This rally marched with a motive

to create awareness for energy

conservation and green

environment protection.

BEST PRACTICES

Display of Monthly ENCON

themes

▪ Increase the awareness

regarding energy conservation

theme.

▪ To increase Participation of all

the employees.

Use of Polymer liners on the

Wagon Loading Chutes and all

other places

▪ Reduction in Bag Jamming thus

reduction in idle running of

equipment in Packing plant

Awards

CII award -Energy Efficient Unit 2017 CII award - Excellent Energy Efficient Unit 2016

Jhansi Unit, home for many beautiful distinct species.

Some of the birds seen in the campus are:

Grey Hornbill

Black Drongo

BIODIVERSITY

Little Egret

White Throated Kingfisher

FLORA & FAUNA Some of the plants seen in the campus are:

Emblic

Lenthra

Himelya

Berigeta

Rose

Uforviya

Thank you

for better building

Energy Conservation is

our Foremost priority

CII Benchmarking 2018

jhansi, india 19th national award for “excellence …...jhansi, india mr gnb rao,plant head mr...

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