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Presentation on Innovations and energy savings activities Carried out atJ K LAKSHMI CEMENT, SIROHI ,RAJASTHAN
During last 3 years (2014-2017)
1 of 21
18TH NATIONAL AWARD FOR EXCELLENCE IN ENERGY MANAGEMENT-2017
Mr. Pankaj Kumar Tiwari (Manager, Process)
Mr. N K J Panchal(DGM, Electrical)
Brief Introduction of JKLCL – Sirohi, Rajasthan
ISO 9001 ISO 14001 OHSAS 18001 ISO 50001 2
OPC 53 OPC 43 PPC
RMC AAC BLOCK POP
PRODUCTS MANUFACTURED..
PRO+
3
4
Sirohi Clinker Capacity 4.75 MnMT
Kiln-1 4550 TPD
Kiln-2 5050 TPD
Kiln-3 5050 TPD
Total Clinker Production
Capacity 4.75 MTPA.
TOWARDS UPGRADATION
Capacity - 4.75 Mn MT
VRM
BLENDING SILO
PRE-HEATER
CLINKERISATION
CLINKER COOLINGCLINKER SILO
CEMENT MILL
CEMENT SILO
PACKINGCLINKER , GYPSUM
& Fly Ash
Coal Mill..
Cement Manufacturing Process
RECLAIMER
5
Engineering Innovations since 2014……
6
LAST THREE YEARS PROJECTS
Sr.
No.DESCRIPTION UNITS
ZERO
INVESTMENT
WITH
INVESTMENT
A TOTAL PROJECT IMPLEMENTED NO.S 17 23
B TOTAL ELECTRICAL ENERGY SAVINGS MILLION KWH 4.954 3.91
C TOTAL THERMAL ENERGY SAVING MT OF COAL 29239 200
D TOTAL SAVING
I ELECTRICAL RS MILLION 34.49 28.49
II THERMAL RS MILLION 161.45 1.40
E TOTAL SAVINGS RS MILLION 195.94 29.89
F TOTAL INVESTMENT RS MILLION NIL 29.78
*All savings calculation is on per annum basis
ENERGY EFFICIENCY IMPROVEMENT ACTIVITIES/PROJECTS
7
*All savings calculation is on per annum basis
ZERO INVESTMENT PROJECTS SINCE 2014....
Total Projects Implemented : 17
Total Electrical Energy Saving : 4.95 Million KWH
Total Thermal Saving : 29239MT of Coal
Total Savings in Rs :
Electrical : 34.49 Rs. Million
Thermal : 161.45Rs. Million
Total : 195.94 Rs. Million
8
S.
No
List of Major Energy Saving Projects
(2014-2015)
Annual Saving Rs. MillionInvest.
Made
Elect. Thermal Rs.
Millions
01Modification of Cone portion of New Cyclone 4 in Kiln-2
& Kiln-3 (60 kW saving)2.831 - -
02Modification in final discharge circuit of cement mill 5 &
6(12 kW saving)0.572 - -
03Optimization of Kiln
(1592 kg/Hrs Coal saving)88.28 -
04Conversion of cement mill-1 separator drive DC to AC
(16.87 kW saving)0.68
05Optimization of process parameter to improve Chinese
mill rate from 210 tph to 220 tph (167 kW saving)7.224 - -
MAJOR ENERGY SAVING PROJECTS ZERO INVESTMENT
(2014-15)
9
S.
No
List of Major Energy Saving Projects
(2015-2016)
Annual Saving Rs. MillionInvest.
Made
Elect. ThermalRs.
Millions
06Optimization of VRM by modification of Nozzle ring
and optimization of mill bed height. (133 kW saving)7.241 - -
07Optimization of Coal Mill by grinding media and
modification of intermediate diaphragm. (61 kW saving)3.308 - -
08Optimization of Kiln-3 Compressors Operation by reducing
the operating pressure of Compressor. (15 kW saving)0.89 -
09Modification in discharge circuit of Ball mill and TCDRI
VRM. (6.88 kW saving)0.374
10Replacement of 2 nos. of screw conveyors with chain
conveyors. (8 kW saving)0.494 - -
MAJOR ENERGY SAVING PROJECTS ZERO INVESTMENT (2015-16)
10
S.
No
List of Major Energy Saving Projects
(2015-2016)
Annual Saving Rs.
Million
Invest.
Made
Elect. Thermal Rs.
Millions
11Optimization of kiln operation.
(16630 MT Coal Saving /Annum)73.17 -
12
Replacement of 18 KW Analyzer water pump with 5.5
KW water pump
(8 kW saving)
0.356 - -
MAJOR ENERGY SAVING PROJECTS ZERO INVESTMENT
(2015-16)
11
S.
No
List of Major Energy Saving Projects
(2016-2017)
Annual Saving Rs.
Million
Invest.
Made
Elect. Thermal Rs.
Millions
13
Optimization of Dam Ring Height in China VRM (70 mm
to 56 mm)
(110 kW saving)
6.19 -
14
Arresting of false air in pre-collector and replacement of
expansion joint in china VRM
(22 kW saving)
1.24 - -
15
Reduction in PH fan power consumption in Kiln-3 by
arresting false air ingress
(30 kW saving)
1.84
16
Remove 35 BE1 Bucket elevator in precrusher (Feeding belt
discharge in vibrating screen instead in bucket elevator)
(15 kW saving)
0.84
MAJOR ENERGY SAVING PROJECTS ZERO INVESTMENT (2016-17)
12
S.
No
List of Major Energy Saving Projects
(2016-2017)
Annual Saving Rs.
Million
Invest.
Made
Elect. Thermal Rs.
Millions
17
One air slide blower stopped in PH-1 VRM (To be remove
from group and interlock air slide blower made it stand by
for 2606 )
(7 kW saving)
0.41 -
MAJOR ENERGY SAVING PROJECTS ZERO INVESTMENT (2016-17)
13
*All savings calculation is on per annum Basis
MAJOR ENERGY SAVING PROJECTS WITH INVESTMENT
SINCE 2014…..
Total Projects Implemented : 23
Total Electrical Energy Saving : 3.91 Million KWH
Total Thermal Saving : 200 MT of Coal
Total Savings in Rs :
Electrical : Rs. 28.49 Million
Thermal : Rs. 1.40 Million
Total Savings : Rs. 29.89 Million
Total Investment : Rs. 29.78 million
14
S.
No
List of Major Energy Saving Projects
(2014-2015)
Annual Saving Rs.
Million
Invest.
Made
Elect Thermal Rs.
Millions
01Innovative Brick arrangement in kiln to improve run factor
(200 Ton Coal/Annum)0.358 1.4 15
02
Installation of 90kva rating energy saving devise in the light
circuit of load centre 1 & 1A of crusher section (10 kW
saving)
0.471 0.25
03Installation of 10no.s of 56 watt energy saving LED lights
(0.49 kW saving)0.024 0.05
04Installation of VFD in cements mill 1 vent fan
(33 kW saving)1.579 0.30
Major Energy Saving Projects with Investment (2014-15)
15
S.
No
List of Major Energy Saving Projects
(2014-2015)
Annual Saving Rs. MillionInvest.
Made
Elect Thermal Rs.
Millions
05Installation of VFD in cements mill-3 separator vent fan (22 kW
saving)1.05 0.25
06Installation of VFD in cements mill-5 separator vent fan (20 kW
saving)0.96 0.25
07Installation of VFD in cements mill-6 separator vent fan (8 kW
saving)0.38 0.25
08Installation of VFD in coal mill booster fan
(12 kW saving)0.78 0.20
Major Energy Saving Projects with Investment (2014-15)
16
S.
No
List of Major Energy Saving Projects
(2015-2016)
Annual Saving Rs. MillionInvest.
Made
Elect Thermal Rs.
Millions
09Installation of 02 Nos. of 75 KW VFD’s in Pre Crusher Bag
filter Fans. (10 kW saving)0.54 0.50
10Installation of 650 KW SPRS in Fly Ash Drier Fan. (10 kW
saving)0.30 1.05
11Modification in 465 KW Kiln-2 CV Fan SPRS system. (42 kW
saving)2.47 0.80
12Replacement of 50 Nos. CFL 15 W to LED lamp 7W in colony
(0.17 kW saving)0.01 0.0035
MAJOR ENERGY SAVING PROJECTS WITH INVESTMENT (2015-16)
17
S.
No
List of Major Energy Saving Projects
(2016-2017)
Annual Saving Rs. MillionInvest.
Made
Elect Thermal Rs.
Millions
13Replacement of 27 Nos. 40W Tube lights to 20 nos. LED 7 in
ADM Building (0.94 kW saving)0.003 0.002
14Installation of high efficient fan with VFD in cement mill-1 (60
kW saving)3.39 02
15Re-Routing of dry fly ash tranportation line.
(60 kW saving)1.84 2.9
16Kiln inlet riser duct modification in kiln-1
(60 kW saving)3.68 1.2
17Modification of Raw Mill -2 by CFD of Cyclones and duct (60
kW saving)3.38 0.6
MAJOR ENERGY SAVING PROJECTS WITH INVESTMENT (2016-17)
18
S.
No
List of Major Energy Saving Projects
(2016-2017)
Annual Saving Rs. MillionInvest.
Made
Elect Thermal Rs.
Millions
18Modification of Raw Mill -3 by CFD of Cyclones and duct.
(60 kW saving)3.38 0.6
19Installation of IGBT based digital SPRS in place of thyrister
based analolouge SPRS in raw mill-3 (50 kW saving)2.81 2.7
20Installation of recirculation damper in CM-2 Stack (12 kW
saving)0.68 0.2
2123 nos 150 watt HPSV street light lamp replace with 40 watt
LED lamp. (2.5 kW saving)0.072 0.1
MAJOR ENERGY SAVING PROJECTS WITH INVESTMENT (2016-17)
19
S.
No
List of Major Energy Saving Projects
(2016-2017)
Annual Saving Rs. MillionInvest.
Made
Elect Thermal Rs.
Millions
22735 nos. 36 watt fluroscent tube rod replace with 22 watt LED
tube rod. (10.2 kW saving)0.291 0.3
2320 nos. 150watt HPSV street light lamp replace with 60 watt
LED lamp. (1.8 kW saving)0.051 0.1
MAJOR ENERGY SAVING PROJECTS WITH INVESTMENT (2016-17)
20
Year(April March)
Specific Energy ConsumptionRedn. in Specific Energy consn. Over
previous years
ElectricalThermal Elect. Thermal
Kwh/Ton of Cement(excl. Crusher)
kCal/kg of clinker % %
2013-2014 72.58 726
2014–15 74.00** 704 (1.96) 3.03
2015–16 74.66** 677* (0.89) 3.83
2016-17 74.48 699 0.24 (3.25)
** Increased because of Less PPC production and increase in Ball Mill running hours* Reduced due to easy burning material from mines
Energy Reduction Since 2013……
21
A Comparison with National & International Benchmark
620
640
660
680
700
720
740
660667
726
704
677
699
Kca
l/K
g cl
k
Thermal Energy Consumption (Kcal/KG Clinker)
22
600
650
700
Average of Top 3 Best Plant
Average of Top 10 Plant
JK lakshmi cement Ltd
690704 699
Kcal
/ Kg
of C
lk
Thermal SEC for the Kiln Having 6 Stage Pre-Heater
Energy Benchmarking by CII-May-14 for Cement Industry
23
A Comparison with National & International Benchmark
60
65
70
75
6567
72.5874 74.66 74.48
UN
IT/T
ON
CEM
ENT
Electrical Energy Consumption(Unit/ton cement )
24
40
45
50
55
60
Average of Top 3 Best Plant
Average of Top 10 Plant
JK lakshmi cement Ltd
49.77
59.27
47.71
KW
H/M
T C
LIN
KER
ELECTRICAL SEC UPTO CLINKERISATION
Energy Benchmarking by CII-May-14 for Cement Industry
25
60
65
70
75
80
Average of Top 3 Best
Plant
Average of Top 10 Plant
JK lakshmi cement Ltd
67
75 74.48
KWH
/T C
EMEN
TOVERALL ELECTRICAL ENERGY CONSUMPTION
Energy Benchmarking by CII-May-14 for Cement Industry
26
68
70
72
74
76
78
80
82
84
86
JK Lakshmi cement
A B C
74.48
78.28
74.43
85.8
A Comparison Electrical Energy Consumption with Plants in same cluster(Unit/ton
cement )
27
665
670
675
680
685
690
695
700
705
JK Lakshmi cement A B C
699
688
680
704
Kca
l /
Kg
of
Clin
ker
A Comparison Thermal Energy Consumption with Plants in same cluster (Kcal/Kg of Clinker)
28
0.0877
0.0833
0.0747
0.0988
0.0940
0.06
0.07
0.08
0.09
0.1
0.11
0.12
Base Line (On PPC)-PAT cycle-1
Target (On PPC)-PAT cyce-1
Achieved(on PPC) PAT cycle-1
Base Line(on OPC)-PAT Cycle-2
Target(ON OPC) PAT cycle-2
MTO
E/to
n pr
oduc
t
PAT Performance_____ ___ __ __ _
Target Reduction
4.91%
Achieved Reduction
14.82%
Target Reduction
4.86%
“PAT” Performance
29
45.83
1.4
7.26
3.07
24.39
4.43
Percentage Contribution of Activities in Achieving Target
WHR Hot Air Recirculation IKN cooler
CHINA VRM Kiln optimisation Bio Mass
Energy Performance Improvement (%)
14.82 % (for PAT cycle-1)
Annual energy cost savings Rs 903 Millions (for PAT cycle-1)
Cost to implement Rs 2831 Millions (for PAT cycle-1)
Payback period 38 Months
Escerts to be issued 38987
Contribution of Activities in Achieving “PAT” Target
30
➢ Monitoring & analysis of specific energy consumption on daily, weekly and monthly basis andtake corrective action as per requirement.
➢ Display of online specific energy consumption data in DCS
➢ Participated in CMA benchmarking exercise
➢ Inter-firm comparison for specific energy consumption
➢ Analysis & implementation of best practices adopted by other plants
➢ Participation in BEE cement sector task force meetings & discussion with other plant officialsfor improvement
➢ Regular energy auditing by in house energy audit team and BEE accredited energy auditors .
SUSTANABILITY
31
➢ Regular training programs (In house as well as by external experts)
➢ Suggestion and rewarding scheme for energy conservation
➢ Cross functional teams (CFT’s)
➢ Purchase of energy efficient equipment.
➢ Carrying out CFD analysis
➢ Installation of energy saving devices (i.e. SPRS, VFD etc.).
➢ Involvement of quality circles (QC’s) for energy efficiency improvement
➢ Small Group Activity under KEP- SPARC membership
SUSTANABILITY
32
Energy Management Policy
33
MonitoringAnd
Analysis
Decision MakingManagement Level
Decision MakingOperations Level
Decision MakingReal Time
Action
Feedback
Feedback
Off Line
On Line
Data
Action
ActionOperator
Real Time
Information System
Plant
Data
Energy Management Tool
34
Plant Head
Departmental Heads
Energy Manager (Process) Energy Manager (Electrical)
Section In charge / CFT
Plant Operator
WTD
JKLC HAS DEDICATED ENERGY CELL WITHIN
TECHNICAL SERVICES
Energy Management Team
35
❖Energy management cell with clear cut responsibilities.
❖Daily monitoring of Energy Deviation report.
❖ Benchmarking National/International/group wise/Cluster units.
❖ Regular study of equipments on deviation and their analysis.
❖ Process evaluation & identification of energy conservation scope.
❖ Feasibility study of suggestions and designing proposals for sanctions.
❖ Taking corrective and preventive measures and ensuring implementation.
❖Organizing internal and external Energy Audit survey.
Energy Monitoring Methodology
36
24-hrs paramers for the month of AUG-2010 (KILN NO -1)
S No. Parameters 1-Jun 2-Jun 3-Jun 4-Jun 5-Jun 6-Jun 7-Jun 8-Jun 9-Jun 10-Jun 11-Jun 12-Jun 13-Jun 14-Jun 15-Jun 16-Jun 17-Jun 18-Jun 19-Jun 20-Jun 21-Jun 22-Jun 23-Jun 24-Jun 25-Jun 26-Jun 27-Jun 28-Jun 29-Jun 30-Jun Avg
1 kiln feed
2 B.E.KW
3 pan con kw
4 kiln coal
5 pc coal
6 PH FAN RPM
7 PH FAN KW
8 water spray
9 TOP TEMP
10 Cy-6 gas temp
11 Cooler o/L T
12 clinker temp
13 kiln amp
14 B.Z temp
15 PH fan o/l o2
16 NCV
17 Coal con
18 Heat con
19 Available hrs
20 Running hrs
21 Run factor
22 production
23 Rate
24 PH fan KW
25 CV Fan KW
26 K/F&SiloKW
27 cooler fan
28 L T drives
29 Tottal
30 Power
Daily process parameters Report
Energy Monitoring reports
38
WEEKLY POWER LOSS ANALYSIS.(FROM …………….TO……………..)
UNITS PER TON. POWER LOSSES
(MATERIAL) 1 2 3 4 5 6
S.NO. SECTION TARGET ACTUAL LOSS IN SPECIFIC POWER CONSUMPTION DUE TO :- TOTAL TOTAL REMARKS
STOPPAGES IDLE RUNNING HIGH KW. LOW TPH LOSS LOSS IN
DEPTT. STOP.DETAILS LOSSES EQUIPMENT U/Ton U/Ton U/Ton U/Ton Rs./=
FREQ. Hrs. Min. Units U/Ton cem. cem. cem. cem.
1 CRUSHER
PROD. MECH.
AVR.PROD./ DAY ELECT.
AVR. R.HRS/ DAY INSTMN.
TPH PROCESS.
CR. < DR.KW OTHERS.
STACKER KW POW. INTR.
TOTAL KW TOTAL
UNITS/TON
2 VRM-1
MECH.
PROD. ELECT.
AVR.PROD./ DAY INSTMN.
AVR. R.HRS/ DAY PROCESS.
TPH OTHERS.
AVR.B.H. D.P. POW. INTR.
AVR.BHF.RPM MINES
AVR.RMF.RPM TOTAL
RM DRV KW
RM FAN KW
BH FAN KW
RECLAIMER KW RESIDUE AT 90 MIC. =
L.T. DRIVE KW RESIDUE AT 212 MIC. =
TOTAL KW
UNITS/TON
Energy Monitoring reports
Weekly Power Analysis report
39
Energy Management Software (In
House Developed)
Energy Monitoring reports
40
Energy Management Software
(In House Developed)
Energy Monitoring reports
41
at JK Lakshmi Cement
42
Reduction in Raw mill fan power consumption by modification of VRM cyclone
Background-Pressure drop across VRMcyclone was high. (205-215 mmwg)
Probable Reason-:
1. High velocity in duct and bends
2. High dust loading
3. Turbulence & dead zone in the flow
Action Taken-: CFD has been carried out
43
Reduction in Raw mill fan power consumption by modification of VRM cyclone
Cyclone inlet height increased by 300 mm
Guide van has been installed at fan inlet.
Investment: Total Rs. 11 lakhs
Savings:
❖Units in VRM section: 60 units /HrTotal Units: 435600 KWH/Year
❖Monetary Gain: Rs. 23.96 lakhs / Year@ Rs 5.5 /unit
❖Productivity improved by 05 tph
44
Pressure drop
reduced by 40mmwg
Innovative Project-2Increase in Riser duct length & Shifting Of PC coal firing in Kiln-1”
Old Firing
Position
New Firing
Position
➢Concept of Low Nox Calciner.
➢Shifting of PC coal firing position by 550 mm.
➢CO Reduces NOx generated In Kiln.
➢Reduction in pressure drop by 60 mmwg
Result : NOX reduced by 60 mg/Nm³.
•Ammonia Saved = 0.061 M³/hr.= 1.33 Tpd( 440 Ton/annum)
Price Of 24.9% NH3 Sol. = Rs.12500/MT.
Annual Saving = Rs.5.5 million.
Savings in terms of Ammonia Consumption
45
60 Units/Hr
Innovative Project-3
Installation of Mid-Frequency Power Supply (MFPS) Micro Processor based controller
Key Features
• 1st installation in India
• Operating frequency range 0-400 HZ
• ( 8 times of earlier version)
• Based on IGBT technology
• No shut down is required
• Cheaper than other alternatives ( New bag filter for drier orModification of existing ESP)
To reduce the dust emission from Kiln-3 ESP stack
Cost economics:
• Installation cost-: Rs. 45 Lacks (for 3 field)
• Reduction in Dust emission-: 60-70 %
46
660
665
670
675
680
2014-15 2015-16 2016-17
676 676678
Co2
Redu
ctio
n (K
g Co
2/T
Clk)
YEARS
JK LAKSHMI CEMENT, JAYKAYPURAM
Co2 Reduction (Kg Co2/T Clk)
Kg CO 2 / T Clk Emission
GHG REDUCTION
47
Employee Association In Encon Activities
EnconActivities Through
Cross Functional Team (CFT)
Kaizen Activity
Quality Circle
Quality Improvement
Team
Shop Floor Energy
Conservation Team
Small Group Activity (SGA)
Projects
under
KEP- SPARC membership
48
Feasibility Test
Suggestion at [email protected]
Concerned Section review Committee reviewSuggestion Approval
Trail Successful
Documentation & Implementation of
Suggestion
Review Of Implemented Idea for benefits & Sustainability
Audit Team Confirmation Rewards, Recognition & Appreciation
EMPLOYEE ASSOCIATION IN ENCON ACTIVITIES SUGGESTION SCHEME METHODOLOGY
49
Certificate Observations Actions Taken
OHSAS
18001:2007
The color coding of various types of
pipeline to be displayed.
The color coding of various type of pipe lines was
displayed at appropriate location.
ISO 9001:2008Earth pits needs to be properly
identified.
All Earth pits were identified with unique
identification No.
ISO
14001:2004
The monitoring of 12 parameters to
be restarted as per reference
National Ambient Air Quality
emission standards 2009.
In 2013-14 monitoring of parameters was reduced
from 12 to 5 parameters, relevant to cement plant,
but as per observation report, monitoring of 12
parameters restarted.
Implementation of IMS
Some Of Corrective/Preventive action taken based on IMS Audit
Note- There was not any non-conformity but observations for opportunity to improvement
50
Sr.
no.Title Of Project
Name of the
Associate/
Vendor
Name of
service
Provided to
vendor
Annual Energy
Consump. Before
implementing
Project (in KWH)
Annual Energy
Consump. after
implementing
Project
in (KWH)
Saving in
KWH)
Type of inputs/
services/
training
provided to the
vendor/
associate
1
Optimization of Lighting
through Re-location of
Lights as per illumination
level and removed 40 nos.
70 watt lights by providing
12 nos. 36 watt LED lights
M/s. Nirman
Electricals
Electrical
Dept.12264 1892 10372
Training
Provided
2.
Energy saving through
Conventional 40W
Fluorescent Tube Light
replaced with LED Tube
Light (22W)
M/s. Raju
Electricals
Electrical
Dept.14016 7708 6308
Training
Provided
Replication arising out of Best Practices Implemented
51
➢ Installation Of Pre-Grinder in cement mill
➢ Modification of BH fan inlet box to reduce pressure drop
➢ Installation of Low Nox Burner
➢ Installation Of VFD for belt Conveyor
➢ Replacement of D.C. Motors with A.C. Drives in VRM section
➢ Efficiency improvement in compressors, fan and blower in mining area
➢ Improvement in motor efficiency by study of % loading of LT motors in Kiln-1 areaand study of raw mill area compressors
52
Renewable Energy
53
Use of Bio Mass Such as Mustard, Moong, Mahendi, Soyabean husk, Sarason to replace some quantity of Coal
used in PC firing of the kiln section.
Conservation of natural Resources.
Reduction in net CO2 emission in the atmosphere.
Low Cost.
Year 2014-15 2015-16 2016-17
Used Quantity
(MT)9390 704** 2223**
**- Less due to Unavailability
BIO-MASS AS A RENEWABLE ENERGY
54
BIO MASS HANDLING SYSTEM
55
BENEFITS
• Saving of 25000 units/ year
• CO2 emission reduction 40 Tonnes/ Year
SOLAR WATER HEATER AT TRANSIT HOUSE
56
SOLAR POWER PLANT AT VILLAGE LUMBANIYA, DISTRICT JODHPUR (RAJ.)
Capacity-: 6.12 MW
57
SOLAR POWER PLANT AT JAYAYPURAM SCHOOL
Capacity- 34.8 KW
58
0.00
20.00
40.00
60.00
80.00
100.00
2014-15 2015-16 2016-17
90.62
78.37
90.08
24.56 21.63 23.55
WHR
Gen
erat
ion
(Mill
ion
KWH/
Annu
m
Co2
Redu
ctio
n (K
g Co
2/T
Clk)
YEARS
JK LAKSHMI CEMENT, JAYKAYPURAM
Co2 Reduction (Kg Co2/T Clk)
WHR Generation Kg CO 2 / T Clk Reduction
WHR generation and GHG reduction
59
S. No. Type of Fuel
Used (MT)
2014-15 2015-16 2016-17
1 Bed Material PC 15499 22836 23180
2
RDF Fluff 633 2591
3 PULP waste 101 334
Doil Cake 287
Utilization Of waste Fuel
60
Environment
61
Greenery in Plant, Colony and nearby area
Environment
62
Cap
. 16500
m3
Cap
. 12500
m3
Rain Water Harvesting in Pond
Surface and Roof Top Water Harvesting
Watershed Management in Mines Hills
Environment
63
Environment
64
Aqu. Ammonia acting as reagent to Control NoX
4NH3+4NO+O2→4N2+6H2O
System designed for NoX Reduction from 1650 to 500 mg/Nm³.
NOX (mg/Nm³)@ 10 % O2 < 800.( w.e.f 1st jan-18)
65
SNCR System Basic Design
PU
IM INJECTORSPMRPMFTANKER
NH3
TANK
➢ PMF = 1 W+1S Pump For Kiln-1.
➢ 150M³ Storage Tank.
➢PMR = 1 W+1 S Pump for Kiln-1.
➢ PU = Process Unit.
➢ Nozzles = For Ammonia Spray.
66
67
Safety
68
Safety
National Safety MonthRoad Safety Week
Fire Service Week
69
Corporate Social Responsibility (CSR)
70
Adopted Primary Health Centre
Swatch Bharat Mission –EK ABHIYAAN
Corporate Social Responsibility (CSR)
71
Corporate Social Responsibility (CSR)
Dental Check up and Treatment Camp in nearby villages
72
Corporate Social Responsibility (CSR)
Adoption of Aanganwadi Centres Under Nand Ghar Yojana
Project “Aarambh” Enrollment of dropout & un enrolled children in Govt. Schools
73
Corporate Social Responsibility (CSR)
Materials distribution in nearby schools
74
Corporate Social Responsibility (CSR)
Materials distribution in nearby schools
75
Literacy Projects Reward and recognition to academically bright children and talented
sportspersons
Free Medical Services to Nearby Villages Family Welfare Programs in Nearby Villages
Corporate Social Responsibility (CSR)
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BLOOD DONATION CAMP AT JAYKAYPURAM
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One of Top 25 Most Innovative Companies
Rewards and Recognition
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CII “Excellent Energy Efficient Unit Award -2016 & 2015”
Rewards and Recognition
CII “Excellent Energy Efficient Unit Award -2014 & Most Innovative Project Award”
79
CII “Energy Efficient Unit Award -2013
Rewards and Recognition
CII “ExcellenceEnergy Efficient Unit Award -2012
National award for energy efficiency in cement industry (2013-14)
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Rewards and RecognitionEnergy Concervation Award -2011 By State Energy Consevation Award by BEE -2011
National award for excellence in energy management 2010-energy efficient unit ”
Best Energy Efficient Practice Exhibitioner- 1st Prize
81
Rewards and Recognition
International Safety Award -2016 from British Safety Council London
FAME-Excellence Award 2016 “Best Innovative CSR Project
GOLD AWARD"
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