MADRAS CEMENTS LTD
Alathiyur
Best Practices on Energy
Conservation
17 Oct 2006
Madras Cements Ltd, Alathiyur
Profile
ISO 14001:2004
ISO 9001:2000
IS 18001:2000
A flagship company of RAMCO Group, having four Cement
manufacturing units of Total capacity 6 MTPA.
The plant at Alathiyur, Perambalur District was setup in two
phases.
Total Plant Capacity - 6600 TPD of Clinker.
Manufacturer of Ordinary Portland Cement and Portland
Pozzolana Cement as per Indian Standards and Ordinary
Portland Cement as per British and Srilankan Standards.
Coal based Power Plant 2 X 18 M.W
ISO 9001, ISO 14001 & OHSAS 18001 Certified Company.
State of Art
Technologies
adopted at
Alathiyur
Limestone
Mining
Mining is done with Surface
Miners (6 Nos) imported
from Germany
SM 2100 3 Nos,
SM 2500 1 No.
SM 2200 2 Nos
Advantages
* Avoids Drilling, Blasting,
& Primary crushing
* No noise, No ground
Vibration & No air borne
Dust generation.
Limestone Crushing
Make : M/s.MMD Ltd, UK
MMD 750 Series (Primary)
MMD 625 Series (Secondary)
Capacity : 1000 TPH
Advantages
* Dust and noise free
* 40% less power consumption
than Conventional Jaw Crusher.
Raw meal
preparation
Make : Loesche LM 38.3
Capacity : 235 TPH
Fineness 17% @ 90
Advantages
* 30% less pow cons
than ball mill.
CF silo internal
* Uniform PSD
CF Silo
Clinker Cooling and Storage
The first SF Cooler installed in India and commissioned in Alathiyur Line-II.
This is a SF 3 x 4 module Cooler with fixed inlet. Less
maintenance, Less wear and tear, least moving parts and
better fuel & electrical efficiency.
OPERATIONAL PARAMETERS OF SF-CROSSBAR COOLER
COMPARED
WITH CIS / CFG COOLER.
SF
CIS/CFG
CFG
Grate Area (Sq.m)
71.72
47.52
46.33
Total Cooler Input (Nm3/kg cl)
1.58
1.84
2.1
Clinker Temperature ( C)
100 120
140 150
150-160
Tertiary Air Temperature ( C)
960
900
850
Sp. Power Consumption (kwh/t mat)
(Drive, Fans & Crusher)
4.6
7.2
9.4
Cooler Efficiency (%)
78
70
66
Clinker grinding
& Cement
Storage
Make : Loesche LM 56.2 +2C
Capacity : 250 TPH
Fineness 3200 blaines for PPC
Largest in South Asia
Advantages
* Consistent product quality
* Effective fine grinding and
narrow PSD.
* Less Power consumption.
World Class
Technologies
Incorporated at
Design Stage
World Class Technologies Implemented:
Deployed Surface Miner for entire mining activities.
SM 2500 is first of its kind by size and design. This
totally avoids drilling and blasting. Power savings is
about 0.7 KWH / t of cement. SM output is restricted
to 150 mm resulting in crusher power saving.
MMD Crusher Unique and compact crusher to
handle moisture up to 15 % with output size of
75 mm. Power saving is about 1 KWH / T of cement
than conventional crusher.
Pre-blending system: Covered Stacker & Reclaimer
for limestone / coal. This ensures consistent quality
and moisture free feed during rain also.
Installed Vertical Roller Mills for Raw meal, Coal and
Clinker grinding. Power consumption is 30 % less
compared to ball mill system.
Transportation: Only by Belt conveyors and Bucket
elevators. There is no pneumatic conveying system.
Power saving is 35 % compared to pumping
system.
Blending and Homogenization: CF silo for Raw
meal. Blending efficiency is 7.5 : 1 compared to
industrial average of 4.5 : 1. This ensures consistent
chemistry, quality clinker, productivity and hence
thermal efficiency.
Preheater, Kiln and Cooler:
- Five stage Preheater with low pressure drop Cyclones
and Inline Calciner.
- First time in South Asia installed SF-Crossbar cooler
for high heat recuperation resulting in low heat and
power consumption.
Vertical Roller Mill for Clinker grinding:
- Fuller O.K 33.4 VRM for first time in South Asia.
- Loesche 56.2+2 VRM largest mill in operation.
- Consistent product quality.
- Effective fine grinding and narrow PSD.
- Less power consumption.
Fans are operating with 80 % efficiency. Major
Process fans are connected to SPRS / VVVF panels
and hence power saving is achieved.
Online O2 / Co / Nox analyzer to ensure combustion
efficiency.
Duoflex multi channel burner is used for less
Primary air and hence thermal economy.
OPTO 22 / Fix SCADA instrument system for
efficient Process control.
List of Energy Conservation Projects
implemented during 2003 2006
gy
Investment
Annual thermal
Total
Made
savings
Savings
Tons of
Rs
Coal or Rs
Rs
Million Oil
Million Million Rs Million
Annual Electrical
Savings achieved
Sl No
1
2
4
5
Title of Energy Saving
project implemented
Cement Mill bag filter purging
time increased
By pass duct installed for
Cement mill booster fan from
cooler vent fan
Nozzle ring modification and
grit cone extension at Coal
Mill
Air balancing and
optimization at Coal Mill
Collecting airslide blower one
number stopped at Cement
mill
Classifier grit cone
extension,flap adjustment and
nozzle area modification at
Line - II Cement mill
Armour ring and grit cone
extension at Line - I Cement
Mill
Units
Year of
Implementation Million
03-04
0.015
0.0525
0.0525
03-04
1440
5.4
5.4
0.26
03-04
0.5465
1.913
1.913
0.05
03-04
0.2049
0.717
0.717
03-04
0.0012
0.0042
0.0042
03-04
4.68
16.38
16.38
0.5
03-04
0.594
2.079
2.079
0.15
gy
g
Annual thermal Total Investment
savings
Savings Made
Tons of
Coal or Rs
Rs
Rs
Million Million Rs Million
Million Oil
Annual Electrical
Savings achieved
Title of Energy Saving
Sl No project implemented
15 Changed 100 nos of fittings
from 80 Watts HPMV lamp to
50 Watts MH lamp at Packing
plant
16 Godrej ControlAir for
compressed air system at
Flyash handling
17 Modification of inlet box in
Line -II Prehaeter fan
18
Nozzle ring modification&Grit
cone extension at Coal mill
19 Classifier blades modified from
Flat to Curved at Both raw
mills
20 Raw mill inlet duct
modification at Line -I
21
2 X 18 M.W Coal based power
plant to reduce the energy cost
Units
Year of
Implementation Million
04-05
0.0131
0.045
0.045
0.12
04-05
0.1353 0.4736
0.4736
0.69
04-05
0.18
0.63
0.63
0.07
04-05
0.546
1.913
1.913
0.05
04-05
1.296
4.536
4.536
1.5
04-05
784
2.89
2.89
0.05
04-05
110
110
950
Annual thermal Total Investment
savings
Savings Made
Tons of
Rs
Coal or Rs
Rs
Million Oil
Million Million Rs Million
Annual Electrical
Savings achieved
Units
Year of
Title of Energy Saving
Implementation Million
Sl No project implemented
8 Classifier sealing correction
and deflector ring fixing at Raw
Mill
03-04
0.2116 0.741
9 Armour ring angle modification
and grit cone extension at Raw
mill
03-04
0.6348 2.222
10 Installation of seperate
conveying and dozing system
for alternative fuels
03-04
1.656 5.796
11 Coal Conveying line
Optimization at Kiln-II
04-05
0.0792 0.277
12 Pre heater cyclone modification
at Kiln I
04-05
0.7425 2.599
Provide
software
interlock
to
13
stop the dedusting fan
whenever feeding conveyor
stops
04-05
0.016 0.056
14 Provided dampers in the inlet
of dust collector fans in packer
to control the suction whenever
the packer operates with single
discharge
04-05
0.125 0.439
0.741
0.05
2.222
0.1
5.796
0.2
0.277
0.02
2.599
0.056
0.439
gy
g
Annual thermal Total Investment
Savings Made
savings
Tons of
Rs
Coal or Rs
Rs
Million Oil
Million Million Rs Million
Annual Electrical
Savings achieved
Title of Energy Saving
Sl No project implemented
22 Replacement of high efficiency
I.D.Fan in Line-1
23 Replacement of high efficiency
Vent.Fan in Line-1
24 Introduction of Delta Tube in
Cement Mill - II
25 Installation of Power Boss for
variable load applications such
as conveyors & Elevators to
reduce power
26 Stopping of bag filter fan in
Line II kiln
27 Optimization of extraction
blowers.
Units
Year of
Implementation Million
05-06
0.432
1.512
1.512
1.6
05-06
0.0594 0.2079
0.2079
0.5
05-06
0.0749 0.2622
0.2622
0.04
05-06
0.0168 0.0588
0.0588
0.21
05-06
0.075 0.2625
0.2625
0.014
05-06
0.048 0.1680
0.1680
0.016
Total projects implemented
: 27 Nos.
Total investment for the projects
957.19 Rs in Million
Total savings after implementation :
161.63 Rs in Million
List of Energy Conservation Projects with Nil investments during 2003 06
Annual Electrical
Savings achieved
Sl No
Title of Energy
Saving project
implemented
Cement Mill bag filter
1 purging time increased
Air balancing and
optimization at Coal
2 Mill
Collecting airslide
blower one number
3 stopped at Cement mill
Year of
Implementati Units
Million
on
Rs
Million
Annual thermal
savings
Tons of
Coal or Rs
Oil
Million
Total
Investment
Savings Made
Rs
Million
Rs Million
03-04
0.015
0.0525
0.0525
03-04
0.2049
0.717
0.717
03-04
0.0012
0.0042
0.0042
0.016
0.056
0.056
0.125
0.439
0.439
Provide software
interlock to stop the
dedusting fan whenever
4 feeding conveyor stops 04-05
Provided dampers in
the inlet of dust
collector fans in packer
to control the suction
whenever the packer
5 operates with single
04-05
Total projects implemented
: 5 Nos.
Total investment for the projects
: NIL
Total savings after implementation : Rs.1.268 million
Total energy savings
: 0.362 million kwh.
Sp.Power (kWh / T of Cement)
Reduction in Sp. Power Consumption
from 2001 2006
64.15
62.44
60.19
60.10
59.92
01 - 02
02 - 03
03 - 04
Year
04- 05
05-06
Sp.Heat (Kcal / kg clinker)
Reduction in Sp. Heat Consumption
from 2001 2006
695
690
687
685
685
0.71%
0.71%
0.43%
01 2000
- 02 - 01
02 - 03
03 - 04
Year
04-05
05-06
MAJOR PROJECT NO.1
Optimisation of Raw Mill - II
Description
Mill
Make
Mill size
Drive
: M/s.Loesche, Germany
: LM 38.3
: 1750 Kw
Modifications
1. Classifier blades where changed
to Curved from Flat surface
2. Configuration of static blades were
modified .
Before
Modification
After
Modification
Optimisation of Raw Mill II
Feed
TPH
Before
Modification
235
Flow
m3/hr
315000
302000
Mbar
KW
KW
KW
Kwh / t
Kwh / t of
Material
77 to 83
1135
1325
2460
10.47
71 to 75
1138
1195
2333
9.72
Units
Mill D.P
Mill Power
Fan Power
Total
Savings
Total Savings
After
Modification
240
0.75
= 0.75 Kwh X 24 hours X 240 MT
X 300 Days X Rs.3.5
= Rs.4.54 Million
MAJOR PROJECT NO.2
Optimisation of I.D.Fan
We have upgraded our kiln and were running with
the old fan,within a short period.We found that there
was a potential in the Fan.So we changed a High
efficiency impeller in place of old impeller.
Modifications
1. High efficiency impeller installed: Efficiency
improved from 68% to 76%
2. Inlet cone re-engineered
Result
Power saving around 150 K.W per hour
Before
After
Modification Modification
Fan inlet
Fan inlet
Flow
m3/hr
465000
472000
Temp
Deg c
295
304
Power
KW
1510
1360
Savings
KW/Hr
150
Power Savings = 150 KW / Hour
= 150 KW X 24 Hours X Rs.3.5
Total Savings = Rs.1.51 Million / Annum
MAJOR PROJECT NO.3
In Line II Kiln circuit we have two bag filters (one for dedusting of kiln feed bucket elevator and one for blending
silo air slides & bin venting).From the suggestion scheme
it was found that by suitable modification in the ducting
one bag filter can be eliminated.So,we have modified the
suction line and one bag filter was stopped.
Summary:
Power Savings = 10.36 KW / Hr
Cost saved
= Rs.2.61 Lacs per Annum
Major Project No:4
Installation of By-Pass duct at
Cement Mill Booster Fan
Introduced a
duct
at
by-pass
Cement
mill
Booster fan to regain
Before Modification
the heat energy from
the hot air that was
vented from Cooler.
After Modification
Hot Air Duct After Modification
Summary:
Thermal Savings = 4.0 MT of Coal per day
= 4.0 MT X 360 Days
Coal Saved
= 1440 MT
Total Savings
= Rs.5.40 Million
MAJOR PROJECT NO.5
In Line II blending silo raw meal extraction two roots
blowers were being operated. Our Quality circle team
had suggested that by suitable modification (Aeration
lines rerouting ) we can stop one blower.By suitable
rerouting we have stopped the blower and have saved
power.
Summary:
Power Savings= 6.7 KW/Hr
Cost saved
= Rs. 1.69 Lacs per Annum
Annual Report and Balance sheet
Power Consumption Kwh/Mt of
Cement
Combined data of our four plants
72.6
72.47
72.4
72.2
72
71.86
71.8
71.6
71.51
71.4
71.2
71
2002-03
2003-04
04-05
Year
05-06
Annual Report and Balance sheet
Combined data of our four plants
Fuel Consumption
% of Fuel
consumption
20
15
11.37
11.58
11. 47
10
5
0
2001
- 02
2003-04
04-05
Year Average
Year
05-06
Environmental Improvements
Clean environment is one of the major objectives of the
organization.
The plant is an
ISO 14001 and OHSAS 18001
Company . The emission levels speaks of the eco & enviro-friendly
environment in the plant.
The results of test conducted by the TNPCB is given below:
Stack
TNPCB
Norms
(Mg/N Cu.m)
Actual results
(24.1.2006)
(Mg/N Cu.m)
Equipment
Raw mill
100
Baghouse
Coal mill
100
45
Bag filter
Cooler
100
14
ESP
Cement Mill
100
11
DG
Power Plant
100
49
ESP
AWARDS
Awards Won by MCL, Alathiyur
Best Energy Efficient unit Award bagged at 21st National
Seminar on Cement Industry conducted by Madurai
Productivity Council at Chennai during Aug 1999.
National Level Excellent Energy Efficient unit award (For the
years 1999,2000,2001,2002,2003,2004,2005 and 2006) by the
Confederation of Indian Industry, Chennai
National Level Best Electrical Energy Performance Award
(For the years 1999-2000, 2001-02, 2002-03 and 2004-05) by
NCCBM.
National Energy Conservation Award 2000 (First prize in
Cement Sector) by The Ministry of Power, Government of India.
National Level Best Environment Excellence in Plant operation
Award (For the years 2001-02, 2002-03 and 2003-04) by
NCCBM.
Awards Won by MCL, Alathiyur
National Energy Conservation Award 2003 (Second prize in Cement
Sector) by The Ministry of Power, Government of India.
Greentech Excellence in Environment Silver Award in Cement sector
for the year 2003 04.
National Energy Conservation Award 2004 (Third prize in Cement
Sector) by The Ministry of Power, Government of India.
National Energy Conservation Award 2005 (Second prize in Cement
Sector) by The Ministry of Power, Government of India.
State Safety Award 2002 (First prize) by Inspectorate of Factories
Highest Green Rating of Cement Sector - 2004 by Centre for Science
and Environment, New Delhi.
Recently telecasted by National Doordarsan
Recently telecasted by National Doordarsan
Average Power Consumption 2005-06
Equipment
KWH/T Cement
Crusher
0.92
Raw mill
15.21
Coal mill
2.64
Kiln
Services I
Cement mill
13.70
1.30
22.00
Packing
2.00
Services II
2.15
Total
59.92
Exit Gas
(Include Dust &
Evaporation)
Figures in Kcal / Kg clinker
179
Cooler Vent
92
Heat of
Reaction
Radiation
Losses
35
400
Clinker
27
266
Recirculated
Heat
Heat from Fuel
Sensible Heat
48
685
Specific Heat Consumption for the year 2005 06
2 x 18 MW CPP
