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There are about 148 large cement plants in the country with an installed capacity of 219.17 MTPA and more than 350 mini-cement plants with an estimated capacity of 11.1 MTPA, making the total installed capacity of 230.27 MTPA up to year 2009/10. Due to the demand in the past and recent growth of economy, the capacity of the industry has increased by 21.41 MTPA.

The cement industry uses coal and electricity as the main sources of fuel. Energy cost accounts for about 40% of the total manufacturing cost in some of the cement plants and coal accounts for 15%–20% of the total production costs.

The specific thermal energy consumption and electrical energy consumption for state of-the-art cement plants are as low as 658 kcal/kg of clinker and 67 kWh/ton of cement respectively. These are comparable with the best cement plants in Japan, where the specific thermal energy consumption and electrical energy consumption are 650 kcal/kg of clinker and 65 kWh/ton cement respectively.

This section contains best practices followed in the industry in achieving efficient energy use.

Resource Name: Best Practices in Energy Efficiency by Mangalam Cement Limited

Abstract: The case presents the activities carried out at mangalam cements to improve energy performance of the manufacturing unit. It covers various activities from retrofits to new technology induction. The sepecific energy consumption performance of the plant for last three years has also been shown in the case study. It covers in details the energy saving recommedations which includes, use of VVFDs for high capacity motors, use of new and efficient vertical roll machine and cross bar cooler, fuel switch and use of green energy in the industry, reduction in CPP auxilliary load by optimization.

Published by: Presented by Mangalam Cement Limited at KEP launch workshop

Resource: Best practice case study- IIP-Mangalam-cement_KEP02-01

Resource Name: Best Practices in Energy Efficiency- Ultratech Cement Limited, Kotputli works

Abstract: This resource presents efforts made by the Ultratech Cement Limited, Kotputli in improving energy performance of the plant. The technology interventions include use of VRM over ball mills, hydraulic cooler with high recuperator efficiency, energy efficient screw compressor, use of Computational Fluid Dynamics CFD in ducts and cyclones to reduce the pressure drop, use of VVFDs for major fan drives, use of intelligent MCC, improvements in lighting, installation of guide plate in side the twin cyclone. The benefits realized are also included in the case study.

Published by: Presented by Ultratech Cement Limited in KEP launch workshop

Resource: Best practice case study-IIP_Ultrarech-Cement-Limited-KEP02-02

Resource Name: Best Practices in Energy Efficiency- J.K White Cement Works 

Abstract: This resource highlights the work of J.K White Cements in energy efficiency improvement in the manufacturing process. The major area sof intervention are; high temperature steam recovery from kiln operation, use of VFD in boiler feed pumps, raw mill-1 circuit modification, pulse optimization in ESP. Some other process and machinery upgrades are also discussed in the resource

Published by: Presented by Sh. Rajeev Sharma, J.K White Cements, in KEP launch workshop

Resource: Best Practice Case Study IIP_JK-Cement_KEP02-03

Resource Name: Best Practices in Energy Efficiency – ACC Limited

Abstract: This case study presents the energy performance of all the cement manufacturing units of ACC in the country and the technology interventions carried out in these plants. It also indicated various factors which affect the overall energy footproint in cement manufacturing. The major technology interventions include waste heat recovery systems, use of AFR, use of CFD in to reduce pressure drop in cyclones ansd ducts, mechanical conveying over pneumatic conveying, use of high efficiency 3rd generation separators, use of advanced automation like Kiln Master etc.

Published by: Presented by Sh. K.N.Rao, ACC, Mumbai, in KEP launch workshop

Resource: Best Practice Case Study_IIP_ACC_KEP02-04