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National Award for Excellence in

Energy Management - 2013
CEMENT SECTOR-
DALMIA CEMENT (B) LTD-ARIYALUR 1

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We are Committed to..

Monitor, Control & Upgrade Technology and Operational Practices

Comply with all applicable legal and other Requirements

Prevent Pollution, Injury & ill- health
Conserve Energy and Natural Resources
Optimize utilization of Resources for Sustainable Development
Create a Work Environment Conducive for Enhanced Employee
Participation and Involvement

Unit Head.
3

We at DCBL believe in Value Creation for All Stakeholders.

Our Core Values :

We have coined the acronym LETS EXCEL!

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Dalmia
Description ICL MCL CCL
Ariyalur

Power Overall Cement 72.49 92.4** 78.15** 77.42**

(Kwh/Ton)

Specific Heat Consumption 718 770* 720* 723*

(Kcals/Kg of Clinker)

#At normal operating condition, DCBL - Ariyalur heat consumption is 700

kcals/kg of clinker. However, the YTD consumption is 718 due to monthly kiln
startups as the market demands.
* Based on information
**Based on 2012 Annual report

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Specific Energy National International

Achieved
Consumption Benchmark ** Benchmark ***

Thermal (Kcal/kg of #
718 740 716
Clinker)

Electrical KWh/T of
69.85 73 70
Cement (Actual)

# Even at 5 stage Preheater

**As per Source-http://www.authorstream.com/Presentation/Perrin-49534 -nccbm1-ENERGY-CONSUMPTION-NORMS-CEMENT-
SECTORUNDERENERGY-CONSERVATION-nccbm[1-as-Entertainment-ppt-powerpoint/
*** As per Source-http://www.chinaeci.com/admin/upload
/20090817021600.pdf

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9
9

Regional Training Centre Colony Park

CII One among all India top 10 Energy

Efficient Cement Units FY 2012-13
10

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Regional Training Centre Colony Park

First Prize at all India level for Power and Fuel Efficiency in
Cement sector from Bureau of Energy Efficiency, Ministry of
Power for FY 11-12
11

Annual Electrical Annual thermal Invest

Title of Energy Saving Savings savings Made Payback
project implemented months
Units Tons of
Lakhs Lakhs Lakhs
Million Fuel
Optimization of Kiln and Coal -
1.0 49 131 -
Cooler 1849
Reduction of Fuel Coal -
Consumption in RVRM with 1299
100 10 <1
Booster Fan inlet Diesel -
Modification 13
In house Modification of
1.5 76 10 <2
RVRM
Inhouse Modification of
CVRM and Installation of 1.1 56 15 <4
VFD for Compressor
12

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Annual Annual Invest

Title of Energy Saving Electrical Savings Thermal savings Made Payback
project implemented Units Tons of months
Lakhs Lakhs Lakhs
Million Fuel
Reduction of Diesel Diesel -
146 6 <1
Consumption in CVRM 249
Optimization of Coal Mill
0.3 13
with Reducing False Air
Reduction of Packing house
Power with Installation of
0.8 40 6 <2
VFD and reducing idle
Running Hours
Total 234 377 47
Total savings (Electrical and thermal ) - 6.1 Cr with 0.47 Cr
13

Pay
Savings Investment
Sl.no Encon Initiatives back
Lakhs Lakhs
months
1 Reduced the excess air in the Preheater exit 67 - -
Coal stacker Belt Converted from Delta mode to
2 1.3 - -
Star mode
2 Water Pumps ideal Running hours reduced 7.2 - -
Avoided running of 2 nos ( 7.5 kw) silo extraction
3 0.2 - -
Bag Filters in Packing House
GRR Cooling Fan stopped through Auto logic after
4 4.5 - -
SPRS started
Modification in Isolation valve of PYRO
5 0.1
Compressor
All the Bag Filter fans converted from timer mode
6 4.4 - -
to DP mode
7 Coal bin Aeration optimized with coal tonnage 3.8 - -
8 Optimization of Reduced Cooler Fans speed 1.3 - -
14

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Pay
Savings Investment
Sl.no Encon Initiatives back
Lakhs Lakhs
months

9 Hammer crusher casing modification 36 20 7

10 Installed VFD for Cement Mill Compressor 11 10 11
11 Optimization of Load Center AC Power 9 2 3
Optimization of Fire hydrant pump
12 9 0.1 <1
(Operated with phone )
13 Compressored air leakages arrested 2.5 1 5
14 Installed VFD for Packing Plant Compressor 6.3 6 11

15 Modification in Dense phase Bag Filter Fan 0.05 0.1 16

16 Reduced Paper Bag Wastage from 0.6 % to 0.2 % 27 3.5 2

15

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Problem
Frequently stoppage on account Rotary air lock high load.

One of our workman identified lumps in wet fly ash

Suggested screen for weigh feeder discharge to avoid lumps.
Action Taken
Accordingly screen arranged
A programming logic was also changed for auto reversal of Rotary air lock
up to 45 sec after reaching 25 Amps to dislodge the jammed piece.
Result:

Saving

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Encon-1: Awards and Appreciation

19

Extent of man-power involved : Cross functional team formed with 6 nos

Pipe line modification was done for connecting 45 KW compressor with

the pyro compressors (165KW) circuit,
Arrested the leakages in the distribution lines
Reduced the operating pressure (maintaining avg 6 bar ) from 7.2 bar

Achieved min saving.

20

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Awards and Appreciation

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22

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Encon-3: Awards and Appreciation

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24

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Encon-4: Awards and Appreciation

25

26

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Encon- 5: Awards and Appreciation

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28

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29

30

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Before After

31

Team identified scope of improvement with modification of both

the booster fans

RVRM booster fan speed increased from 990 RPM to 1064 RPM (107
%) with the help of VFD drive

In house Modification of RVRM booster fan inlet cone portion with the
help of vibcon engineers consultancy

CVRM fan speed increased from 990 RPM to 1100 RPM (110 %) with
the help of VFD drive

In house Modification of CVRM booster fan inlet cone portion with the
help of vibcon engineers consultancy .

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33

34

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First in India to Utilize Coal Fired Raw Mill HAG

for Cement Mill during Kiln stopped condition

35

Utilizing Raw Mill HAG in Cement mill when kiln

stopped condition

Raw Mill HAG located more than 250 m far from Cement Mill
Maintaining < 350 0 C gas temperature before it reaches ducting
is difficult
Installation of additional booster fan and ducting ,costs more.
Controlling the HAG outlet temperature with high CV coal is
difficult

36

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Implemented Innovative idea

Removed RVRM booster fan impeller & Fully closed the chimney
damper
Dummy plate arranged in Raw mill inlet and cooler vent fan outlet
Running the CVRM booster fan
Coal mixed with 50 % Alternate fuel for reducing NCV
using the HAG coffee pot damper for dilution air to maintaining the
temperature < 350 0 C inside the duct

1.6 lit/Mt of PPC during kiln stopped condition

Net saving of Rs 174 lakhs/Annum

37

Increased Utilization of CPP reject water from 300 to 1500 m3

Conceptual change of reject generation from supplier driven to customer

focus and hence reject is generation cycle is synchronized with cement
mill
Communication channel developed between cement mill and CPP
through PLC
Auto starting of reject water logic was provided as soon as the Cement
mill water spray ON
Close monitoring of reject water consumption even by the top
management in the unit

Increased utilization of CPP reject water from 300 to 1500 m 3 / month

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90
800

799 80
780
70 86.17
760 60 72.49

740 50 69.85
40
720 730
30
718
700
20

680 10

0
660 2010-11 2011-12 2012-13
2010-11 2011-12 2012-13

39

40

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Savings Pay
Investment
S.No ENCON effort Lakhs / back
Lakhs
Yr months
Utilizing Raw Mill HAG in Cement Mill
1 174 153 11
when Kiln stopped condition

2 CFD analysis for Raw Mill Cyclones O/L duct 30.2 10 4

Installation of Dilution Air Dampers at

3 30 25 10
Cooler Exit Duct

4 Installation of Liquid Alternate Fuel System 34 42 15

Installation of VFD for Raw Mill Reject Bag
5 2.7 3 14
Filter Fan
Installation of VFD for Coal Hopper Bag
6 2.7 3 13
Filter fan
41

Savings Pay
Investment
S.No ENCON effort Lakhs / back
Lakhs
Yr months
Installation of Additional Hopper in Raw Mill
7 238 171 9
Section
Additional linear Reclaimer for Wet Fly Ash
8 166 700 51
Usage
9 Inlet Static part Modification for RVRM Fan 15 11 9

10 Installation of Solid Alternate Fuel system 325 1821 67

Utilizing all the Cooler Waste Gases to Raw
11 97 380 47
Mill
Installing low Pressure Compressor for Dry
12 5 18 48
Flyash unloading
Total 1089 3327
42

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43

2010-11 2011-12 2012-13

Type Installed Energy Energy Energy

Annual Annual Annual
of Capacity Generated Generated Generated
RES in MW Savings Savings Savings
(Million (Million (Million
(Lakhs) (Lakhs) (Lakhs)
kWh) kWh) kWh)

Wind 16.5 28.3 777.2 28.2 774.6 31.7 870.7

Planning for installation of 5 MW solar Farm in the plant

* Through Dalmia Wind Farm

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Solar Water Heater for Guest House purpose.

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SolarEnergy Lighting System for Two Wheeler

Parking Shed.

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Per unit
Per unit
energy Type of inputs
Name of Energy
Name of consumed % / projects
S. service consumed
associate / after improve provided to
No provided to prior to
vendor implementa ment the vendor/
vendor implementing
tion of associate
Encon
Encon
Increased
R.Bhuminathan
1 Bhuminathan 7 T/Lt 9 T/Lt 28.6 capacity from
transport
6 to 16 tons
1.Converted
DC to VFD
Dalmia 0.85 0.7 2. Reduced
2 M.K.Jain 17.6
laminators Ltd Units / Kg Units / Kg idle running
hrs

48

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Energy Conservation initiations to our associates

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50

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On line Energy management System (EMS) installed

Reporting of Power on continuous basis
Linked with DCS
Software for Compressors, Idle running hours of Major Equipment
Energy reports were taken from Energy management system
Analyzed in daily co-ordination meeting
Action plans are made
Reviewed Periodically.

51

Energy conservation committee formed with cross functional team members

and best energy saving initiatives discussed and implemented.
Best tracking system for speedy implementation
Quick fund allocation by the management based on the pay back period
Best Energy saving initiatives are awarded periodically.

52

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Section wise Online Specific Energy Consumption is Monitored by

CCR operators with the help of DCS and EMS.

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Responsibilities of Energy Manager:

Conducting Monthly Energy Conservation Review Meeting
Monitoring the Section wise daily Power consumption
Analyzing & Brain Storming to Reduce the Power Consumption.
Action Plan & Implementation of Projects
Comparison with cluster and International Bench Marking

56

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Rewards

Achieving Goals

Action Plan &

Implementation

Analyzing & Brain Storming to evolve

Energy improvement projects

Energy Conservation Monthly Review

Meeting

Daily Monitoring

Responsibilities of Designated Energy Manager

CFT Based Energy Team

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Environmental Projects & Projects

linking with Carbon Emission Reduction

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Equivalent of
Type of Quantity of waste Conventional Waste fuel as
S.No Waste Fuel fuel used (Tons or energy used (kWh % of total
used any other Eq Unit) of electricity or Ton energy
of fuel)
High CV fly
1 3934 781.4 0.71
ash (Tons)
Dola char
2 418 220.1 0.2
(Tons)
Char coal
3 3642 1562.8 1.42
(Tons)

4 Total 7994 2564.4 2.33*

* 2.33 % (TSR ) achieved with out any investment for the FY 2012-13 60

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2.5

2
2.33

1.5

0.5 0.77

0
0
2010-11 2011-12 2012-13

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From the above initiatives, Carbon Emission is reduced for the

year 2012-13 is 6734 tons of Co2

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Usage of Lime sludge from ETP/CETP as Alternative Raw material .

Around 6 Lakhs tons of Lime Sludge available in Tiruppur,

Coimbatore, Erode, Karur and Salem area within 150-200
km from Ariyalur plant.
This is an initiative as part of eco-friendly drive to use
waste material as useful raw material.
Accordingly DCBL ALR conserved lime stone 1399 tons
in 2011-12 and 653 tons in 2012-13 with replacing lime
sludge

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80168

76505

55128 Colony Park

2010-11 2011-12 2012-13

Visitor comment Plant in the Garden and not the garden in the plant.
64

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65

Development of Kitchen garden -

Output goes to the employee
canteen

66

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Saplings are donated to school students

Best cared plants get cash award on every World Environment Day
Cash Award used for buying books for School Library
More reading enables students to secure (Incidentally our Brand

67

Regional Training Centre Colony Park

Bagged the First Prize Green Award 2012

instituted by Government of Tamil Nadu

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Specific water consumption Recharge shaft constructed in

M3 / MT of cement Rain water harvesting pond.

0.168

0.131
0.122

2010-11 2011-12 2012-13

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Rain water Harvesting

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Rain water harvesting Pond & Canals inside the plant

Rain water harvesting pond

Capacity - 41,840m3

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Linking to
CARE AIR
Centre

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World Environment Day

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75

Saplings and Tree guard

Donated to Near by
Villages

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We are regularly buying and donating the saplings to near

by villages.
We are having our own nursery for producing and donating
the saplings to near by villages on continuous basis.
77

Cement Sustainability Initiative

(CSI)

WBCSD

CSI -
Charter

CSI in
India

CSI in
DCBL

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CSI & DCBL

79

MD Signing the new Charter at Seoul , Oct 2012

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E-Waste Handling
practices

81

82

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Ariyalur Unit Winner of

Asian Responsible Enterprise Award
for CSR & Green Leadership
(International Award for Asia Pacific Region by Dalmia Ariyalur)

Regional Training Centre Colony Park

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Regional Training Centre Colony Park

Excellence In HR award 2012 Runner up - Manufacturing sector

Hosted by Manufacturing Today, India

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Accreditations, awards and certifications received for the year 2012-13

Awards

Bagged BEST MANUFACTURING UNIT Cycles funded by Best

award In Dalmia Business group for the 3rd manufacturing Unit award prize
consecutive year (Hat trick) for money for going round the plant
Manufacturing, SHE & CSR

85

Achieved In a Record time of 6 months

Planning for 50001

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S. No Description Corrective Action Preventive Action

1 Since the E-Waste (Management & As E-waste management
Handling) Rules, 2011 has been reviewed rules has come into
& made applicable by M/s Dalmia Cement effect from 01.05.2012
- Ariyalur, the Applicable Sections of these only, understanding the
Rules (Rule 6 & Form 2) maybe identified provisions and addressing
in the Organization's Legal Register & the took time.
appropriate "Monitoring and Measuring /
Compliance Requirements" also to be
included.
2 A more robust system like 'token The names of the
surrender/ display system' at the entry for personnel going inside the
tracking the head-count of the people confined space is entered
authorized to work in confined spaces, in work permit only at
may be initiated. present. No display system
is in practice.
A. We have updated the legal
register with E-waste handling
management rules.
B. We have formulated the
procedures for monitoring &
compliance requirements as part of
legal register.
C. Environment department has
created awareness on the
provisions for users and Commercial
department
A system has devised to implement
Token System for head count of
people entering into confined space
and now it has been incorporated
with work permit.

3 The reliability of the controls for the Already Limit switch is Redundancy limit switch has
signaling/ stopping the tilting of the introduced in the system introduced in 2 truck tipplers as a
Tippler may be re-evaluated and for starting and stopping preventive measure
improved. truck tippler. But
redundancy limit switch is
not there as per
design. 87

Thank you
AND THE JOURNEY OF
EXCELLENCE CONTINUES

88

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ICL

89

MCL

90

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CCL

91

92

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93

94

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Reducing the variation in the quality/chemical parameters in

the limestone pile and in kiln feed.
Reducing the excess air in the preheater exit .
Optimization of cooler for maximum heat recuperation (TAD
temp increased from 930 to 970 C).
Increasing the flame momentum in kiln (1800 to 2300 % m / S)
Online Thermal Energy Consumption indication - instantiation.
Running the kiln consistently at 4500TPD level.
Monitoring the Thermal Efficiency- Monthly Heat Balance
Exercise.

95

Periodical Measurement & Corrective action Twice in a

Month False air Entry.
Increased availability of kiln despite of using high sulfur fuels
Cooler tower pressure increased from 590 to 615mmWC
Cooler fans flow switched over to Auto control
Utilizing expert optimizer for optimization
Introduced new programming logics for avoiding stoppages
Maintaining the minimum Blending silo level (15mtr) to
achieve the homogeneity of raw meal

96

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97

20.34

17.92
16.97

2010-11 2011-12 2012-13

98

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PH fan power reduced through reducing the PH exit O2.

Increased availability through better maintenance practices
All the shell cooling fans changed from delta mode to star
Introduced new programming logics for avoiding stoppages
Running the Pyro in expert optimizer mode
Optimized compressor power with reduced pressure and
capacity
Running the Cooler fans in Auto control
Arresting false air entry
99

100

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2.5
0.06

0.06 2.0
0.06
0.06

0.05 1.5 2.0

0.05
1.0
0.05 1.2
0.05 0.05 0.5

0.05
0.0
0.04 2011-12 2012-13
2011-12 2012-13

101

Facing heat availability problem in the raw mill grinding circuit since
beginning.

As the raw material was high in moisture it reduces the mill output. To
enhance the production we are running HAG in raw grinding circuit,
which increases the thermal and electrical energy consumption

Decided to utilize the maximum heat from cooler vent gases to RVRM
when ever the cement mill stopped condition and CVRM OPC running
condition by modifying the RVRM booster fan.

102

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Team identified scope for improvement with modification of the

Booster fan

RVRM booster fan speed increased from 990 RPM to 1064 RPM with
the help of VFD drive resulting in increasing the flow by 8.7 % and 1
MKcal / hr heat availability.
In house Modification of RVRM booster fan inlet cone portion was done
with the help of VIBCON engineers consultancy, resulting further increase
in flow by 8 % and 0.85 MKcal / hr heat availability
Due to increased heat availability HAG Running hrs were reduced and
thus reduction in cost of production.
103

104

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20.00

19.00

18.00

17.00

16.00

15.00
2010-11 2011-12 2012-13

Reduced dam ring height to 80 mm from 130mm

Introduced new programming logics for avoiding stoppages
RA fan running with RABH differential pressure
Increased nozzle ring area blockage up to 36 %
Increased availability through better maintenance
practices
Accumulator pressure reduced to 38 bar so as to reduce
the operating pressure up to 65 bar.

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Increased the dust load at mill outlet ( gms / m3)

Increased SPRS availability
Reduced false air entry
Optimized compressor power with reduced pressure
and capacity
By utilizing maximum heat from cooler

108

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2010-11 2011-12 2012-13

KWH / MT Cement

35.0 29.5

29.0
34.0
34.9 29.5
28.5
33.0
28.0

32.0 27.5
32.2
28.7
27.0
31.0
31.5 27.1
26.5
30.0
26.0

29.0 25.5
2010-11 2011-12 2012-13 2010-11 2011-12 2012-13

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In house modification was done in Dam ring to reduce the

table power consumption of Clinker Grinding.
Nozzle ring was modified to reduce the air volume
requirement and thus the mill fan could be run on SPRS
mode, yielding to the reduction of fan power consumption
Decreased idle running hrs
Increased SPRS availability

Introduced new programming logics ( like RAL reversal ) for

avoiding stoppages
Arranged grill for separating lumps in wet fly ash for
avoiding Mill stoppage
Increased Mill availability through better maintenance
practices
Reduced infiltration air entry in CVRM circuit
Installed VFD for compressor

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113

1.20

1.00
1.16

0.80

0.60 0.74

0.40
0.52

0.20

0.00
2010-11 2011-12 2012-13

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Increased clinker temperature from 90 deg C to 130 deg C

During OPC grinding, diesel consumption was stopped by mill hot
air optimization even when the kiln hot gas is not available
Reduced the mill water spray quantity by modifying the water spray
pattern and location inside the mill.
By optimizing water spray with optimizing damring and nozzle ring
False air reduction in the cement mill circuit.
Booster fan inlet static part modification for increased utilization of
cooler waste gases.
Cooler optimization to get higher grade heat from kiln
Increased Mill availability through best production planning

116

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2010-11 2011-12 2012-13

Introduced new programming logics ( like RAL reversal ) for avoiding

stoppages
Running the coal mill in Expert optimizer mode
Reduced idle running hrs
Reduced false air entry
Optimized compressor power with reduced pressure and capacity

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119

2.5 2.74

1.95
1.5

1.35
1

0.5

0
2010-11 2011-12 2012-13

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Installed VFD for compressor.

Arrested compressed air line leakages
Avoided running of 2 nos ( 7.5 kw) silo extraction bag filters with out
effecting environment
Reduced the infiltration of atmospheric air
Improved productivity
Reduced idle running hrs
Reduced paper bag wastage from 0.6 % to 0.2 % with modification of
all chutes with ceramic liners

61