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Second Workshop on Best Practices in Energy Efficiency in Cement Sector

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Date/Time
Date(s) - 07/07/2016 - 08/07/2016
9:30 am - 5:30 pm

Location
My Home Industries

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7th -8th July, 2016, Mellacheruvu, Telangana: The 2nd Workshop on ‘Promoting Exchange of Best Practices in the area of Energy Efficiency in Cement Sector’ was organized on 7th-8th July, 2016 at Mellacheruvu, Telangana. The workshop was hosted by My Home Industries Limited and organized under the Knowledge Exchange Platform (KEP) initiative. KEP is a joint initiative of Bureau of Energy Efficiency (BEE) and Institute for Industrial Productivity (IIP) to promote energy efficiency by facilitating exchange of knowledge, experiences and best practices in industries covered under the Perform Achieve and Trade (PAT) scheme.

The workshop was inaugurated by Shri Ashwani Pahuja, Director General, National Council for Cement and Building Materials.  In his inaugural address, he congratulated BEE and IIP for establishing the Knowledge Exchange Platform, which will assist the industries to share ideas and best practices. He mentioned that India is the second largest producer of the cement in the world and has adopted sustainability initiative. He mentioned the industry may enhance the usage of renewable energy and waste heat recovery in-order to reduce the energy cost. Sector has been in a position to reduce its GHG emissions from a level of 1.12 ton CO2 emissions per ton of cement in late 1990’s to 0.72 recently. Still there is significant potential to reduce GHG emissions by incorporating cleaner technologies. He informed the participants that BIS have released the standards for composite cement, which may bring down the clinker factor to 0.35 in comparison to 0.70 in case of PPC manufacturing, which means only half the quantity of energy intensive clinker would be required in comparison to PPC.   Shri Pahuja hoped that this platform will support the work being undertaken by the industries in the area of energy efficiency and to explore additional channels for the promotion of cleaner technologies.

Welcome address and introduction to the workshop was delivered by Shri K K Chakarvarti, Expert Consultant, Bureau of Energy Efficiency. He provided an update on KEP initiatives and mentioned that in order to ensure that KEP continues to act as a forum for sustain interaction within and across industry sectors, it is important that KEP’s efforts are strengthened by providing continuous input and feedback. He informed that besides initiating sectoral workshop, quarterly newsletter, best practice exchange visits, KEP has also developed an interactive website (www. knowledgeplatform.in). He mentioned that KEP intends to develop this website as a strong tool in promoting not only the KEP activities but also as a one stop solution to all the information needs of the industry. Shri Chakarvarti concluded his welcome address by stating that focous of KEP in its second year of operation is assess the technology gap and promote energy efficient technologies in the PAT Sectors.

Shri Naren Pasupalati, Commercial Diplomacy Officer – Energy, Climate and Growth Unit, British High Commission in his address gave an overview on BHC’s role in supporting and assisting India’s initiatives in the area of energy efficiency. He urged the industry members to proactively participate and support KEP initiative and develop and disseminate best practices in and across different sectors.

Shri V S Narang, Director-Technical, My Home Industries Limited in his special address mentioned that India has only 40 WHR power generation projects in the Cement sector in comparison to 740 WHR power generation projects in China and therefore there is a need to promote Waste Heat Recovery Projects in the country by treating them at par with renewable energy generation projects and granting fiscal incentives, as deemed appropriate by the Government. While concluding his Special address, Shri Narang stated that Cement Sector has over achieved the PAT-1 Cycle targets by about 80% but PAT-2 Cycle will be more challenging. In order to meet the targets, process optimization and WHR should be given more thrust. This will require collaboration for knowledge exchange and a dedicated platform like KEP which can provide the essential medium for sharing of tools, practices and technologies.

Vote of Thanks was presented by Shri MM Patil, Joint President (Works), My Home Industries Limited. He conveyed his thanks to the dignitaries, speakers and delegates for their presence and participation in the workshop and assured the full support of My Home Industries Limited in future activities under KEP initiative.

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Dignitaries at the inaugural session

The inaugural event was followed by three technical sessions and a panel discussion. The first technical session was Chaired by Shri K K Chakarvarti, Expert Consultant, Bureau of Energy Efficiency. The discussion in the session focused on Perform Achieve and Trade scheme and best practice presentations from industry representatives. He presented the overview of Perform Achieve and Trade scheme which covered success stories achieved under PAT 1 Cycle for Cement sector, information on the current status as well as the mandatory requirements to be fulfilled by DCs, key aspects of ESCerts trading scheme and the progress made so far which included status of ESCerts Exchange Regulations, roles and responsibilities of entities involved, methodology to be adopted for second PAT cycle, amendments made in PAT Rules in the area of fuel auto sampler, ESCerts, baseline setting methodology for new and existing DCs, validation of fuel quality and brief on the new plants that are introduced in second cycle of PAT.

Besides PAT, the session also focused on sharing of experience of the industry on implementation of innovative best practices. The industries that shared their experience included My Home Industries Limited, Zuari Cement Limited, The KCP Limited, JSW Cement and technology presentation by Danfoss Industries Private Ltd.  Sharing and discussing their innovative best practices, the presentation by My Home Industries Limited highlighted the energy efficiency gains achieved by installing recirculation duct at VRM to reduce inlet gas temperature, reducing Specific power consumption in Unit-3 Preheater fan by modifying fan inlet box area and installing in-house designed & fabricated dust hood to cover the open wagon in order to reduce clinker dust dispersion at wagon loading which led to an annual monetary savings of Rs. 23 Lakhs, Rs. 17 Lakhs and Rs. 8.5 Lakhs respectively. The presentation by Zuari Cements Limited claimed the energy efficiency initiatives taken in various process streams viz. VRM- 2 (ATOX – 55) Optimization with reject B.E and  replacing entire start up diesel with liquid alternative fuel. The presentation by The KCP Limited highlighted initiative taken to reduce carbon emissions by 270 MT/annum by increasing cooler Stack height up to 6.5 meters which thereby provided natural draft which resulted in energy saving in ID Fan of 32.5 KW. The presentation by JSW Cement explained the energy savings achieved by optimizing pyrofloor cooler, modifications done in cooler horse shoe, upgradations in cooler fans, installation of shock blowers, and inter-compartment leakage arrest. The presentation by Danfoss Industries Private Ltd explained the energy efficiency drives approach to hybridization via energy storage.

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Shri K K Chakarvarti with the panelists of first technical session

The second technical session was focused on sharing of experience of the industry on implementation of energy management systems (EnMS) ISO 50001, was Chaired by Shri Ashwani Pahuja, Director General, National Council for Cement and Building Materials. The presentation by JK White Cement, Ambuja Cements Limited: Maratha Cement Works and Ramco Cements Limited explained the road map followed, challenges faced, appropriate action taken, commitment from top management, internal audit procedures, external audit procedures, their respective energy policy and benefits achieved after implementing EnMS. The presentations explained the benefits of implementing ISO 50001 are better use of existing energy consuming assets, promotes energy management best practices, implementation of new energy efficient technologies, helps organization in  increasing efficiency, reducing costs and improving energy performance, reduces environmental impact and GHG emissions and brings an overall change in employee culture with sensitization towards energy savings and increases voluntary initiatives to reduce the energy consumption.

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Shri Ashwani Pahuja with the panelists of the second technical session

The third technical session (part A) focusing on sharing of experience of the industry on implementation of innovative best practices, was Chaired by Shri VS Narang, Director-Technical, My Home Industries Limited. The presentation by Dalmia Cement (Bharat) Ltd, Ariyalur explained the energy efficiency gains achieved by in-house modification of primary crusher gear arrangement, raw mill output increased from 375 to 450 TPH by modifying silo feed elevator discharge chute and VFD installation, in-house modification in RVRM hot gas inlet duct, reduction of coal and diesel consumption in RVRM by increasing heat availability through dilution damper. The presentation by CII highlighted the energy efficiency benchmarking for cement industry, explaining the improvement opportunities by following different approaches viz. energy benchmarking, innovative projects to reduce SEC, assessing the performance reports in captive power plants and innovative ideas from other sectors. The presentation by Vasavadatta Cement explained the energy efficiency gains by installing roto scale for fly ash feeding, by implementing various condition based monitoring systems viz. vibration monitoring, oil and grease analysis, thermography, thickness measurement and ultrasound technique. The presentation by UltraTech Cement Limited, Hirmi Cement Works detailed the energy efficiency achieved by optimizing the compressor systems, cone gap correction in RM2, raw material size optimized by optimising grinding path in crusher and modifications in separator inner seal plate in coal mill. The presentation by UltraTech Cement Limited, APCW, Tadipatri highlighted the energy efficiency initiatives viz. Installation of low air pressure screw compressors in place of high pressure compressors for fly ash unloading, modifications in Kiln coal firing pipe line, removal of venturi in CM-3 bag house fan inlet duct, replacement of venture with straight duct at cement mill 3 bag house outlet duct and power reduction by production enhancement by installing pneumatic barrier in CM5.

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Shri VS Narang with the speakers of the third technical session (Part A)

The third technical session (Part B) was focused on energy efficient technologies for cement sector, was Chaired by Shri MM Patil, Joint President (Works), My Home Industries Limited. This session was planned in a manner that it brought together the technology providers and industry representatives with a view to promote interactions between the two stakeholder groups that can help in facilitating adoption of cleaner technologies. The session had presentations on technologies available for various processes in cement sector viz. improving energy efficiency in cement plants using computational fluid dynamics (CFD) by Mechwell Industries Limited and automatic tube cleaning system (ATCS) by CQM-RAJ India.

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Shri MM Patil with the panelists of Technical Session 3 (PART B)

Technical sessions was followed by a Panel discussion on technology gap assessment in which the panelist shared their thoughts and views on the need for mapping the present status of cement industry in terms of energy efficiency technology deployment and the need of technological advancement in order to achieve the targets set under the 2nd cycle of PAT. Shri Ashwani Pahuja, Director General, National Council for Cement and Building Materials mentioned the technology advancements required in terms of short, medium and long term basis. He mentioned that although all the developed technologies present anywhere in the world are directly available to the Indian cement industry. There are no barriers or hurdles for export/import of technologies or development of technologies as such, so there is very little technology gap between the technology developed and available in the world v/s what is available in the Indian market, but still keeping in view the energy and technological advancements required there are many processes which can be focused. For short term basis, waste heat recovery (WHR) systems, advanced automation and control systems, artificial intelligence based expert systems; medium term would be technological advancements for the grinding systems, as the current grinding efficiency in cement industries is much below the theoretical efficiency and further improvements can be incorporated and long term being technological advancements in overall process streams in order to reduce greenhouse gas (GHG) emissions.

Shri V S Narang, Director-Technical, My Home Industries Limited mentioned that in order to reduce energy consumption in the cement plants, it’s important to explore the technological solutions to reduce thermal energy consumption in pyro process in clinker production. Also, explore best practices and technological solutions in-order to increase Thermal Substitution Rate (TSR) in Indian cement industries. Shri MM Patil, Joint President, My Home Industries Limited mentioned that cement industry must work as a team in-order to bridge the gap so as to achieve higher energy efficiency gains.

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Panelists in the Panel discussion on Technology Gap Assessment

On behalf of Bureau of Energy Efficiency and Institute for Industrial Productivity, Shri K. K. Chakarvarti thanked the top management of My Home Industries Limited, in particular, Shri Ranjith Rao J, Managing Director, My Home Industries Limited; Shri VS Narang, Director-Technical, My Home Industries Limited; Shri MM Patil, Joint President (Works), My Home Industries Limited and the entire team of  My Home Industries Limited for extending their earnest support to the KEP initiative and pulling through an event of this scale. He also conveyed his sincere thanks to Shri Ashwani Pahuja, Director General, NCCBM for his presence and sharing his experience with the participants at the workshop. He also thanked all the speakers and delegates who participated in the workshop and thanked them for their comments and suggestions and assured that each will be given consideration so that future workshops will be even more of a success.

The workshop had participation from over 110 distinguished speakers, eminent cement industry leaders’, technology providers, energy managers and auditors, and senior Industry professionals amongst many others.

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Participants at the 2nd Cement sector Workshop under Knowledge Exchange Platform initiative

The field visit to My Home Industries Limited was organized on 8th July, 2016, which was attended by 80 officials from cement Industry. Delegates were taken around the MLM Mines- Mellacheruvu Lime Stone60 MW Captive Power PlantAlternate Fuel  Plant (pharma waste)Line 3 Cement Plant: comprising of Kiln ,Preheater ,Packing Plant and Rly siding and  Safety Park – a unique practical learning centre on safety across the cement industry. This industrial visit facilitated interaction with the plant personnel on energy efficiency improvement initiatives, maintenance practices, efficient operation and monitoring practices.

plant visit-feeev

At the conclusion of plant visit, delegates thanked the management of My Home Industries Limited and congratulated the initiative taken by Knowledge Exchange Platform for organizing the Two Days’ workshop and plant visit for the benefit of industry.

2nd WORKSHOP AND FIELD VISITS
BEST PRACTICES IN ENERGY EFFICIENCY IN CEMENT SECTOR
INAUGURAL SESSION (9.30 AM- 10.15 AM)
Lighting of Lamp
Welcome Address, introduction and strategies for the next phase of KEP initiativeShri K. K. Chakarvarti, Expert Consultant, Bureau of Energy Efficiency
Overview on BHC’s role in Energy SectorShri Naren Pasupalati, Commercial Diplomacy Officer - Energy, Climate and Growth Unit , British High Commission
Special AddressShri V S Narang, Director-Technical, My Home Industries Limited
Inaugural AddressShri Ashwani Pahuja, Director General, National Council for Cement and Building Materials
Vote of ThanksShri MM Patil, Joint President ( Works), My Home Industries Limited
TEA BREAK (10.15 AM -10.35 AM)
TECHNICAL SESSION I (10.35 AM – 12.00 PM): PAT and Best Practice Presentation by Industry Representatives
ChairmanShri K. K. Chakarvarti, Expert Consultant, Bureau of Energy Efficiency
Overview of PAT 1 and PAT 2nd Cycle by Bureau of Energy Efficiency Shri K. K. Chakarvarti, Expert Consultant
Best Practices adopted by My Home Industries LimitedShri D. Venu Babu , Senior Manager – Electrical & Energy Manager
Best Practices adopted by Zuari Cement LimitedShri Nareshkumar Macherla, Senior Manager - Process
Best Practices adopted by The KCP LimitedDr. G.V.K. Prasad, Executive President-Operations
Energy Efficient Technology solutions by Danfoss Industries Private LtdShri Sunil Jha, Assistant Manager
Best Practices adopted by JSW CementShri Yatin Kothari, Manager – Production
Shri Santhana Mariappan , Deputy Manager
TECHNICAL SESSION II (12.00 PM – 1.00 PM): Best Practice Presentation by Industry Representatives
ChairmanShri Ashwani Pahuja, Director General, National Council for Cement and Building Materials
Experiences of Implementing ISO 50001 by JK White Cement Shri Virendra Singh Rathore, Manager-Planning
Best Practices adopted by Ambuja Cements Limited, Unit: Maratha Cement WorksShri Sheshmani Shukla, Sr. Manager
Best Practices adopted by Ramco Cements LimitedShri A.V. Satyanarayana, Senior Manager
Shri Chandan Kumar Parasar, Deputy Manager
LUNCH BREAK (1.00PM – 2.00PM)
TECHNICAL SESSION III (2.00 PM – 4.45 PM): Best practice presentation and Energy Efficient Technology Solutions for Cement Sector
ChairmanShri V S Narang , Director-Technical, My Home Industries Limited
PART A- Best Practice Presentation by Industry representatives
Best Practices adopted by Dalmia Cement (Bharat) Ltd, Ariyalur Shri Anand, Engineer – Process
Energy Efficiency Benchmarking for Cement Industry – Opportunities for Improvement by CII – Godrej Green Business CentreShri Vaibhav Girdhar, Counsellor
Condition based maintenance management by Vasavadatta CementShri Kundan Singh T., Sr.Manager-Mechanical
Best Practices adopted by UltraTech Cement Limited, Hirmi Cement WorksShri Vivek Kumar Mishra, Deputy General Manager
Best Practices adopted by UltraTech Cement Limited, APCW, TadipatriShri G Harikishore, Manager – Technical Services
TEA BREAK (3.30 PM -3.50 PM)
PART B: Energy Efficient technologies for Cement sector
ChairmanShri MM Patil , Joint President ( Works), My Home Industries Limited
Improving Energy Efficiency in Cement Plants using Computational Fluid Dynamics (CFD)Shri Akshay Shah, Jr. Engineer - Marketing
Automatic Tube Cleaning System (ATCS) by CQM-RAJ India Shri Aashish Sharma, Dy. General Manager – Sales & Business Development
PANEL DISCUSSION (4.45 PM – 5.15 PM) : Technology Gap Assessment- Mapping the present status of cement industry in terms of EE technology deployment and the need of technological advancement in order to achieve the targets set under the 2nd cycle of PAT.
CONCLUDING REMARKS (5.15 PM - 5.30 PM)
Shri V S Narang , Director-Technical, My Home Industries Limited,
Shri Ashwani Pahuja, Director General, National Council for Cement and Building Materials
Shri MM Patil, Joint President ( Works), My Home Industries Limited,
Shri K. K. Chakarvarti, Expert Consultant, Bureau of Energy Efficiency

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