ORIENT CEMENT LIMITED (CGU) Jalgaon Presenting Team Mr. Alok Bagaria - GM (Operations) Dr. Anil Kumar Trivedi - GM (Sustainability) Mr. Samaresh Dutta – DGM (Electrical & Energy Manager)
ORIENT CEMENT LIMITED (CGU)Jalgaon
Presenting Team Mr. Alok Bagaria - GM (Operations)
Dr. Anil Kumar Trivedi - GM (Sustainability)Mr. Samaresh Dutta – DGM (Electrical & Energy
Manager)
ORIENT CEMENT LIMITED (CGU), JALGAON
29-Aug-18
DEVAPUR UNIT (IP)JALGAON UNIT
(CGU)CHITAPUR UNIT
(IP)
29-Aug-18
3
Devapur Unit
Telangana
Cap: 3 MTPA
Chittapur Unit
Karnataka
Cap: 3 MTPA
Grinding Unit
Jalgaon- Maharastra
Cap: 2 MTPA
Orient Cement Ltd. operating 3 Cement Plants in India:
- Integrated Plant - Devapur, Telangana State- Clinker Grinding Unit - Jalgaon, Maharashtra- Integrated Plant - Chittapur, Karnataka
ORIENT CEMENT LIMITED - OVERALL PLANT PROFILE
Plant is certified with IMS:• ISO 9001:2015• ISO 14001:2015• OHSAS 18001:2007• ISO 50001:2011• TPM-Phase I & II (Excellence and Excellence in
consistent)• NABL Accredited Quality Control Laboratory
• Member of CSI (WBCSD)
Overall Capacity of Orient Cement is 8.0 MTPA.
29-Aug-18LOCATION DETAILS & CLIMATIC CONDITIONS:
At NH No. 6, PO. : Nashirabad
Taluka and Distt: Jalgaon
State :Maharashtra (India)
Total Plant Area 24.758 Ha.
Weather Conditions
Temperature (⁰C) Summer Season Min. 25 Max. 47
Winter Season Min. 09 Max. 36
Average Rain Fall 821 mm
Altitude 211 m above MSL
Coordinates
Direction Latitude Longitude
North 21°01’20.39” N 75°40’56.93” E
South 21°01’09.49” N 75°40’56.97” E
East 21°01’18.77” N 75°40’47.93” E
West 21°01’18.04” N 75°41’32.42” E
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Plant Cap.:0.70 MTPA
2000
Plant Cap.: 0.80 MTPA
2003 Plant Cap.: 1.0 MTPA
2007Plant Cap.: 2.0 MTPA
2009
Line-I Plant
Line - I Improvement By
Introducing PPC Cement
Line - IUp gradation with
Close Ckt. Of Cement Mill
Line - IIcommissioned
CAPACITY ENHANCEMENT OF JALGAON SPLIT GRINDING UNIT
VisionGrow to be a relevant national player, driven by execution excellence and be the ‘employer of choice’ and ‘neighbour of choice’.
Values
• We embrace change and create opportunities, where others see a challenge
• We have a passion for growth• We have the courage to innovate• We believe in spirited teamwork• We believe in corporate governance and accountability
OUR VISION & VALUES
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2016
2003
ISO 9001:2000
2005
ISO 14001:2004
2008
OHSAS18001:2007
2012
TPM PH-I
2011
NABL
2017
CSI
ISO 50001
MILE STONES OF ORIENT CEMENT LTD.
2017
IMS2015
2010
ISO 9001:2008
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7
PROCESS FLOW DIAGRAM
Wagon
Tippler
Cement
Mill- 1
Clinker
Silo
Gypsum
Yard/Shed
Fly
Ash
Silo
Cement
Silo
Cement
Silo
Cement
Mill- 2
Packing
Plant
Pre-Grinder
Separator
Fly Ash Bin
Gypsum Hopper
Clinker Hopper
Cement Dispatch
Coarser
Particles
Final
Product
LEGEND
Material flow common for line 1 & 2
Line -1 material flowLine-2 material flow
Coarser particle return line
Equipments common for line 1 & 2
Line- 2 equipments
Line- 1 equipments
MANUFACTURING PROCESS
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8
29-Aug-18MANUFACTURING PROCESS
Raw Material Availability:
➢Clinker received through Railway Wagons from Mother Plant located at Devapur (Telangana).
➢Gypsum received through Trucks from Various Dye & Chemical industries located in Gujarat State.
➢Fly Ash received through Bulkers from Bhusawal Thermal Power Station, Deepnagar, Bhusawal (MS).
Storage: Clinker, Fly Ash and final product Cement stored in respective Silos and Gypsum stored inCovered Shed.
Manufacturing Process:
➢ Raw Material Feeding - Feeding of material through Weigh Feeder/ SFM as per productionrequirements.
➢Pre grinding: - Feeding material to Roller Press for pre grinding.
➢Finish Grinding - Transfer of material to close Clinker Ball Mill through a discharge chute. From the millmaterial transferred to through air to Separators.
➢Storage of product in Silo & Packing - The final material storage to Cement Silo, which is connected tothe Packing Machine for automatic filling of OPC & PPC cement into the bags.
➢Loading & Transfer to Destination Point- Finished product is loaded into load carriers and taken to therequired destination as per dispatch need.
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9
29-Aug-18ENERGY CONSUMPTION
26
27
28
29
30
31
32
33
2015-16 2016-17 2017-18
29.17
32.87
28.8
Overall Power Consumption
Energy Consumption (kWh/T of Cement)
Reason for variation:
High Sp. power consumption in 2016-17 due to following reasons –1. Frequent Start - stop due to low market demand.2. Higher percentage of OPC Production .3. Lower grindability of clinker due to usage of pet coke in clinker manufacturing on trial
basis.
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10
29-Aug-18
29.38
26.48
25.96
24.3
24.2923.74
23.29
24.1924.36
24.64
23.72
23.28
22
23
24
25
26
27
28
29
30
Apr-17 May-17 Jun-17 Jul-17 Aug-17 Sep-17 Oct-17 Nov-17 Dec-17 Jan-18 Feb-18 Mar-18
Specific Power Consumption (PPC) - kWh/Ton of Cement
ENERGY CONSUMPTION
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11
29-Aug-18
kWh/T of Cement
24.8423.75
10
20
30
SP. Power
2017-18 NBM
ENERGY – NATIONAL BENCH MARKING
Source: CII (2014-15)
* Overall power does not includes Packing Plant, Lighting and Miscellaneous Power
Reference: Energy Benchmarking for Cement Industry, May 2015, Version 2.0 (Published by CII & CMA)
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12
29-Aug-18ROADMAP TO ACHIEVE BENCHMARK:
Sr. No.
Key Action ProposedExpected Savings kWh/T of cement
Target Date
1Fly ash unloading through mechanical system only
0.6 Jan - 2019
2 Compressor air line optimization 0.09 Jan - 2019
3Polycom Separator bag filter discharge material feeding to final product
0.2 Dec - 2018
4Air slides blowers replacement with new high efficiency blower
0.08 Dec-2018
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13
29-Aug-18ENERGY SAVING PROJECTS
Implemented in FY 2015-16
Sr. No. Title of Project
Annual Electrical Saving (kWh)
Annual Electrical Cost Saving (Rs. million)
Investment Made (Rs. million)
Payback (Months)
1Clinker Feeding Belt Running
interlocking with load3 0.12 0 NA
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29-Aug-18ENERGY SAVING PROJECTS
Implemented in FY 2016-17
Sr. No. Title of Project
Annual Electrical
Saving (kWh)
Annual Electrical Cost
Saving (Rs. million)
Investment Made (Rs. million)
Payback (Months)
1 AVR for wagon tippler lighting 2 0.055 0.125 27.2
2Timer circuit for street light & dusk to down circuit for MCC
0.2 0.0055 0.02 44
3conventional light replaced with LED
34 0.934 1.268 16.29
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15
29-Aug-18ENERGY SAVING PROJECTS
Implemented in FY 2017-18
Sr. No. Title of Project
Annual Electrical
Saving (kWh)
Annual Electrical Cost
Saving (Rs. million)
Investment Made (Rs. million)
Payback (Months)
1Line 2 coarse material partially fed to line 1
160 6.13 5.2 4.24
2Fly ash unloading system modification
50 1.24 1.6 15.52
3OPTIMIZATION OF BAG FILTER PURGING
0.074 0.55 0 NA
4
Replacement of overhead
water conventional pump
with high efficiency pump.
5 0.12 0.075 7.27
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16
29-Aug-18ENERGY SAVING PROJECTS
Implemented in FY 2017-18
Sr. No. Title of Project
Annual Electrical
Saving (kWh)
Annual Electrical Cost
Saving (Rs. million)
Investment Made (Rs. million)
Payback (Months)
5Water lines modified by
reducing bends.2 0.11 0.02 2.20
6Hot Water pump replaced
with high efficiency 2.5 0.10 0.03 3.64
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17
Innovative Idea Implementation:
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18
29-Aug-18
Theme: Productivity improvement through diversion CM-2 coarse material to CM-1 Mill
Background: Line 1 commissioned in 2000 and retro fit mill circuit and detailed study has been
done and concluded that CM-1 ball mill having excess capacity to take further material.
Simultaneously studied CM-2 circuit and noticed that Roller Press Separator having excess
capacity.
Partial diversion of CM-2 coarse material to CM-1 Mill
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19
29-Aug-18
Benefits:
Description of Modification:Airl side along with weighing system installed and also feed bucket elevator capacity enhanced.
1. Mill production rate increased by 15 TPH .2. Sp. Power consumption has reduced by 1.5 kwh/MT of Cement.3. Smooth operation.
Investment made : Rs. 52 Lacs
Payback : 4.24 months
Savings:
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20
29-Aug-18
Theme: Pneumatic Fly ash unloading system replaced with partially pneumatic - partially mechanical system .
Fly ash unloading with conventional pneumatic systems to silos at 40 mtrs.
Solution: • Provided intermediate 50 Mt bin with lower height (i.e. 10 mtr)• Due to lower height of bin, blower air is sufficient to convey
material in place of costly Compressed air.• Bin to Silo material conveying by existing bucket elevator.
Implemented in FY 2017-18
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21
29-Aug-18
Fly ash unloading comparison
With Blower 160 kW compressor
Equipment
Blower Compressor 160 Water pump Bag filter fan 30 kwSilo aeration roots blower Air slide blower Bucket ElevatorDC Fan RAL BE Dis Blower
Load kWh kWh105 155
Power Benefits (kWh) 50Investment 1.6 Lac
Cost Savings (Rs in Million/year) 50 kW x 10 hr/d x 330 x 7.5 1.2375ROI (Months) 15.52
Implemented in FY 2017-18
29-Aug-18
Modifications to reduce power consumption in water pump
1. Removing bends 2. Reduction in the length of pipeline
Comparison of power consumption (previous vs present pump)
Results after modification
Modification cost and payback period
Theme: Water lines modified by reducing bends.
Implemented in FY 2017-18
29-Aug-18
MODIFICATIONS TO REDUCE HEAD LOSSES
1. Reduction in number of effective bends-Total no of bends bypassed from earlier pipeline = 6
23
6th Bend
5th Bend
4th Bend
3rd Bend
2nd Bend
1st Bend
Implemented in FY 2017-18
29-Aug-18
2. Reduced length with respect to earlier pipeline = 9m (reduction in length of pipeline reduces frictional loss)
New pipe line(Bypassed)
Old pipe line
Old pipe line
New pipe line(Bypassed)
▪ New pipe length = 21 mtrs
▪ Old pipe line length =30 mtrs
Implemented in FY 2017-18
29-Aug-18
25
COMPARISON OF POWER CONSUMPTION (PREVIOUS VS PRESENT PUMP)
* Both pumps having same discharge = 120 m3 /hr.
DETAILS OF PUMP PREVIOUS PUMP PRESENT PUMP
DESIGNED HEAD (IN meter) 75 55
RATED POWER (IN KW) 37 37
RUNNING KWH 37 23
RUNNING HRS/DAY 12 12
KWH CONSUMPTION/DAY 444 276
Power Savings (kWh) -- 14
Cost incurred Rs. -- 50000
Implemented in FY 2017-18
Payback in 1.6 months
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26
29-Aug-18
1 kVA Solar Power Generation System installed in Sep, 2016 .
UTILISATION OF RENEWABLE ENERGY SOURCES
Units Generated in FY 2016-17 Units Generated in FY 2017-18
739 kWh 1376 kWh
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29-Aug-18GHG INVENTORISATION
Year T CO2/T of Cement)
2015-16 0.0239
2016-17 0.0269
2017-18 0.0236
GHG Emission due to Purchased Power Consumed:
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29-Aug-18GREEN SUPPLY CHAIN
Green Purchase Policy:
Our Policy to Purchase Energy Efficient Equipment -
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29-Aug-18GREEN SUPPLY CHAIN
Procedure to Purchase Energy Efficient Equipment :
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Team work, Employee Involvement & Monitoring
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Unit Head
Head OperHead - Engg
HOD – EM Cell
Team of Electrical, Chemical, Mechanical Engineers
ENERGY MANAGEMENT CELL
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29-Aug-18DAILY ENERGY MONITORING
➢ Capturing of Section wise energy meter reading.
➢ Calculation of Section / Equipment wise Specific energy consumption.
➢ Analysis of SPC.
➢ Find out the root cause of deviation, if any.
➢ Further corrective/ preventive action, if applicable.
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29-Aug-18REVIEW MEETING
Energy review meeting conducted at various level :
1. Plant level : Meeting is conducted on Daily Basis and Chaired by Plant Head
2. COO Level : Review meeting is on Monthly Basis and Chaired by COO
3. MD Level : Overall performance review meeting is on Monthly Basis and Chaired by Managing Director.
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ENERGY CONSERVATION BUDGET 29-Aug-18
Sr. No YearBudget (Rs.
Crore)% of Turnover
1 2017-18 0.52 0.08
2 2018-19 1.48 0.24
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29-Aug-18
External training programs attended
S.No. Topic Man Hrs.
1 12th Green Cementech 2016-CII 16
2 Optimization of Grinding Syatem - NCCBM 16
3 National Conclave on Recent advances in Cement Industry 8
4 Plant Maintenance Summit - 2016 16
5 Energy Management & Conservation in Cement Industry 8
6Best Practices in Energy Efficiency in Cement Sector" under KEP
24
Internal training programs conducted
1 Training Programme on -L T Motor Maintenance 10
2 Grinding Media Optimization 123 Fan efficiency calculation 20
4 Impact of Compressed air utilization in bag filters on SPC 13.5
5 Healthy Maintenance of Gear Boxes 24
6 EnMS ISO - 50001 160
7 Reduction in Auxiliary power 19
TRAINING AND AWARENESS PROGRAMME
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36
Energy efficiency / awareness training program:
29-Aug-18
Inter Plant Knowledge Sharing Sessions .
Awareness:
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37
Projects implemented through Kaizens ( Workers and Supervisor level)
29-Aug-18
➢ Replacement of Gypsum Feeding Belt with Chute
➢ Replacement of HPMVs, Sodium Vapour lights with LED lights
➢ Interlocking of cooling tower fan with temperature.
➢ Compressed Air Pressure Optimization
➢ Interlocking of equipments to avoid Idle equipment running
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29-Aug-18IMS CERTIFICATION
IMS - ISO 9001-2015, 14001-2015, 18001-
2007
EnMS ISO-50001-2011
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29-Aug-18INITIATIVES TO REDUCE GHG EMISSION
41% Area Covered under Green belt Development
Major Species Planted:NeemShishamPlantoformPeepalBargadSatparni,Mango,Amla,Badam,Cheeku,Guava plantsPoplarGulmoharPalm
GREENBELT DEVELOPMENT
29-Aug-18GREENBELT DEVELOPMENT
29-Aug-18GREENBELT DEVELOPMENT
29-Aug-18GREENBELT DEVELOPMENT
29-Aug-18
Photographs:
GREENBELT DEVELOPMENT
29-Aug-18
Thank You