COMPARISON WITH GLOBAL AND NATIONAL BENCHMARKS (SPECIFIC ENERGY CONSUMPTION)
r e k n il C n o T / h w K
768
91 85 79
650
73 67
667
80.25
800 733 80
69
750 700
600
65
550
61
500
55
450 Global
National
JKLC
Kwh/Ton Cement
r e k n il g K /l a c K
Target (2009-2010)
Kcal/Kg Clinker 7
ROAD MAP TO ACHIEVE BENCHMARK S NO
DESCRIPTION
EXPECTED SAVING Electrical Thermal U/T Cement
Kcal/Kg Clinker
1
To increase production of blended Cement
2.00
-
2
Installation of pre grinder for cement mills
5.00
-
3
To increase % of Pozzolonic material in production of blended cement
0.50
-
4
Retrofitting of major process fans
1.00
-
5
To upgrade cooler of kilnkiln-2 & kiln kiln--3
6
Optimisation of compressed air system TOTAL
10 0.25 8.75
10 8
SUSTAINABILITY
Monitoring & analysis of specific energy consumption on daily, weekly and monthly basis and take corrective action as per requirement
Going for WHR Systems
Display of online specific energy consumption data in DCS
Participation in CMA benchmarking exercise
Interfirm 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 officials for improvement
9
SUSTAINABILITY
Regular energy auditing by in house energy audit team and BEE accredited energy auditors
Regular training programs (In house as well as by external experts)
Participation in national & international seminars
Suggestion and rewarding scheme for energy conservation
Cross functional teams (CFT’s)
Purchase of energy efficient equipment
Installation of energy saving devices (i.e. SPRS, VFD etc.)
Involvement of quality circles (QC’s) for energy efficiency improvement
10
ENERGY MANAGEMENT POLICY JK LAKSHMI CEMENT LTD. JAYKAYPURAM
Energy Management Policy The management of M/s JK Lakshmi Cement Ltd stands committed to continual improvement in Energy Conservation in accordance with Energy Conservation Act – 2001, by taking the following steps :
Closely monitor, control and analyze the equipment and process performance for spec c nergy consump on roug nergy anagemen e an a e corrective action. Explore the possibility of the use of cheaper alternative fuel and waste products with a view to protect Environment and Natural Resources. Create awareness for energy conservation and disseminate information to the grass-root level by conducting training and motivational programs. Conduct Energy Audit through accredited auditor and prepare an annual activity plan to reduce energy consumption.
Place
: Jaykaypuram
(GANPAT SINGH) CHIEF EXECUTIVE (WORKS) 11
JK LAKSHMI CEMENT LTD,JKPURAM FLYASH CONSUMPTION M.T. / YEAR
MAJOR INNOVATIVE PROJECT – 1 INSTALLATION OF FLY ASH DRIER (2008 – 09) Background : Domestic
demand of PPC has increased during last few years. Non availability of Dry Fly, forced us for wet fly ash usage to . Specific power consumption of Cement Mill section has increased because of wet fly ash usage Above 20% usage of Wet Fly Ash has resulted in Operational trouble. Hence, the need of wet fly ash drying system has arisen
14
MAJOR INNOVATIVE PROJECT – 1 INSTALLATION OF FLY ASH DRIER
Activities carried out : Connection
from cooler exhaust duct
Installation
of Fly ash Drier system.
Installation
of wet Fly ash Unloading system.
Installation of Dry Fly Ash Conveying system.
Problem Facing in Dry Fly Ash System
Separation of clinker dust from cooler hot air.
Transportation of Dry Fly Ash.
Dedusting problem.
Separation of Foreign material from wet fly ash. 15
MAJOR INNOVATIVE PROJECT – 1
INSTALLATION OF FLY ASH DRIER
CONCEPT OF FLY ASH DRING Available Heat at Cooler O/L
8.72 x 106 Kcal/hr
Water Evaporation Rate from available heat
13.47 Ton/hr
Cement Grinding Capacity ( when idea was conce ve
500TPH
For 100% PPC Production, Wet Fly Ash Requirement
100TPH (22%dry Fly Ash)
Capacity of FLY ASH DRIER Moisture content in Fly Ash (%)
20
18
16
14
12
11
Wet Fly Ash (TPH)
67
75
84
96
112
122
Dry Fly Ash (TPH)
55
62
72
84
100
110 16
MAJOR INNOVATIVE PROJECT – 1 FLY ASH DRIER FLOW SHEET WFA BELT
CYCLONE Wet fly ash hopper
WEIGH FEEDER
DRIER DRY FLY ASH HOPPER
DRIER FAN WASTE HOT AIR TO ESP
COOLER 17
MAJOR INNOVATIVE PROJECT – 1 Benefits Increase in fly ash consumption from 20 to 22 % Increase in Cement Production :
0.706 LTPA
Reduction in power consumption: 0.5 kwh/ton of cement
Cost Benefit Analysis
( Rs/ annum)
Contribution from increased cement volume
565 lacs
Power saving
65 lacs
Total benefit for one year
630 lacs
Project Cost
899 lacs
Pay back Period
17 Months 18
MAJOR INNOVATIVE PROJECT – 2 UPGRADATION OF KILN - 1
Background :
(2008 – 09)
The plant was initially designed for 1500 TPD in 1982 but because
of high operating cost it was non operative. The mantra for sustaining in highly competitive market is to have low cost of production high volume growth as compared to industry growth. Keeping it in mind we revamped kiln-1 and the same has helped us in getting extra revenue because of increased production at low cost of production.
19
MAJOR INNOVATIVE PROJECT – 2 Activities carried out :
Installation of Iteca Seal at kiln -1 O/L.
Up
gradation of kiln -1 main drive.
Relocate
and upgrade Old Crusher.
cooler. Installation
of new coal mill
Conversion
of cement mill to raw mill.
Installation of
new limestone stacker and reclaimer.
Installation of
new six stage PH with LP cyclone.
Replace
pneumatic conveying system. 20
MAJOR INNOVATIVE PROJECT – 2 Achievements : PARAMETER PARAMETER
UNIT
BEFORE
AFTER AFTER
TPD
1500
2000
mmWG
600
400
Pre heater fan specific power
U/T clink clink
16.8
9.00
Cooler fan specific power
U/T clink clink
4
3.6
Specific heat consumption
Kcal/Kg clk clk
950
750
U/T
40
30
Clinker production Pressure drop across pre heater
Specific Power consumption
Cost benefit Analysis Investment
: Rs. 1500Million
Saving
: Rs. 535.14Million per annum
Simple payback period
: 34months 21
MAJOR INNOVATIVE PROJECT – 3
Up-Gradation of Kiln-2 & 3 Main Drives Background :
(2008 – 09)
The plants were initially designed for 2500 TPD. Numbers of in house modification with practically no-capex and small capex were carried out to enhance the capacity to 3400 TPD and subsequently the capacity increased to 4200 TPD with the installation of prallel preheater. Above 4200 TPD, following problems were faced
1. Build-up at kiln inlet 2. Ring inside the kiln 3. kiln Back spillage 4. Once filled kiln was stopped, it used to take 1hr to come on main drive . In order to get rid off of the above-mentioned problems and to enhance capacity to 4500 tpd, it had been decided to upgrade main drive of both the kilns.
22
MAJOR INNOVATIVE PROJECT – 3 Achievements : PARAMETER PARAMETER
UNIT
BEFORE
AFTER AFTER
Clinker production
TPD
4200
4500
Kiln Speed
RPM
4.2
5
Kiln Filin
%
13.8
12.9
Main drive power (rated)
Kw
300
440
Unit/mt clk clk
24
22.5
Specific Power consumption
Cost benefit Analysis Investment
: Rs. 45 Million
Saving
: Rs. 235.6 Million per annum
Simple payback period
: 3 months 23
ENVIRONMENTAL PROJECTS
Reduction in fugitive emission
Installation of Hybrid ESP bag Filter with PTFE bags at Kiln – 1 Raw Mill.
Installation of Clinker cooler ESP at Kiln – 1 .
Reduction in GHG emission and greenery improvement
Plantation of 6650 nos. neem, 17500 etropha & other varieties of trees in township, power plant, mines & both sides of Banas road.
Installation of Biomass handling system in Kiln 2 & 3 pre calicner to “Replacement of fossil fuel by biomass in Pyro-processing”.
Water conservation
Rain water harvesting to recharge bore wells
Installation of colony drinking water treatment plant
Installation of solar water heating system in guest house field hostel
