Professional Documents
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EFFICIENCY
It is India's first split location dry process cement plant with Fuller
technology having four-stage suspension pre-heater, in-line flash
calciner, reverse air bag house dust collector, vertical roller mills
besides to be the first to unload imported South African coal at plant
jetty. It transports 100% clinker to grinding units is in bulk by sea
route. The special feature of this plant is 'Just in Time‘ design for raw
mill circuit. As against conventional norms of 20,000 MT silo for raw
meal storage it has 2,000 MT silo.
Overview of NCJW
The grinding units associated with Jafrabad Cement Works are Magdalla Cement
Works having capacity of 0.80 MMTPA and Ratnagiri Cement Works having
capacity of 0.50 MMTPA. All three coast-based split location units have Jetties for
marine transportation. Narmada Cement was the prime supplier of fly ash based
Portland Pozzolana Cement (PPC) to Sardar Sarovar Dam on river Narmada,
which is the World's second largest concrete gravity dam (by volume). We
created a benchmark in Indian cement industry with installation of SF 3 X 6 cross
bar cooler supplied by FLS, in record 41 days.
With the hand holding of DuPont Sustainable Solutions, we are marching towards
"Zero Accident" goal and articulating "Safety" as fundamental core belief with
the theme "Life is precious, We care for it"as advocated by Shri O P
Puranmalka, Business Director. Moving ahead in the safety journey, we achieved
lost time injury frequency rate (LTIFR) 0.00 in the year 2014-15.
ENERGY SAVING PROJECTS
4
1.0 Case Study-Elimination of material settling at separator
inlet duct by providing hump to increase air velocity.
1. Problem Statement: Dust settling in separator inlet duct.
2. Impact of Problem : Higher power consumption of separator fan to
maintain the velocity in duct and maintain the DP in separator.
3. Action taken :
Separator all duct pressure readings were taken.
Dust settle point identified
Velocity measured in the separator inlet duct & found velocity was
lower than desired.
It was decided to provide the hump in the inlet duct to increase the
velocity.
Hump size & location decided in the duct & provided.
Dust accumulation in duct
Calculation for Hump size
Before After
Area Measurement UOM Area Measurement UOM
Sep I/L Duct
1.5 Mtr Radius (Ra) 1.25 Mtr
Radius(Rb)
Duct Area 1.7671 M2 Duct Area 1.23 M2
Before After
Separator
Inlet Duct
8
Hump view in separator
Hump in
separator inlet
duct
9
Power Saving Calculation
BEFORE AFTER
Existing Fan running
Previous fan power in KW 96 84
KW
Run Hrs 24 Run Hrs 24
Power/Day 2304 Power/Day 2016
Power per month 69120 Power per month 60480
Saving
21.23 21.23
m/sec m/sec
41.35
m/sec 30m/sec
21.23
m/sec
21.23
m/sec
12.09 12.09
m/sec m/sec
Result
Kiln Riser DP
Before After
90 84
80
70
60
50
42
40
30
20
10
0
Before After
Result
18
4. Various energy saving projects
Saving
SNo. Title Action Taken
KW/Month
Grinding aid motor running For optimizing Grinding Aid system
with constant speed without VFD installed. Now Motor speed is
1 136.80
considering variation in Cement varied with TPH.
mill Feed.
Pre grinder dust collector
material conveying air slide Interlock provided such that if pre
2 blowers were running grinder stopped two blowers stopped 1367.81
continuously even if pre grinder after 10 min.
is kept stop condition.
1) Sep. Fan control changed from
Separator fan was running on RPM base to KW base.
RPM basis so power is not 2) Trommel screen was taken in
3 monitored, also due to material operation to reduce the nibs 17561.84
settling in duct it was difficult settling in duct
maintain the draft in circuit. 3) One hump is provided to increase
the velocity in duct.
4. Various energy saving projects
Saving
SNo. Title Action Taken
KW/Month
To maintain the mill discharge Blaine mill
4 Reduction in Mill fan RPM 688.03
fan rpm maintaining from 400 to 460.
Mill taking more power with Mill power optimized with maintaining the
5 7495.20
considering TPH. media size & qty.
Close loop system was developed and
Pre grinder running hrs was feed was controlled w.r.t. reject .Through
6 more because fresh feed was put set point to be kept manually by 13200
monitoring manually. monitoring the crusher load.
21
Saving calculation of G-Aid motor after VFD.
Power calculation on Last year performance Power calculation on current year performance
Operating current in Amps 8.8 Operating current in Amp 7.05
Operating KW 4.81 Operating KW 3.85
Running hours 24 Running hours 24.00
Power/day in KWh 115.37 Power/day in KWh 92.43
Power per month in KWh 3461.18 Power per month in KWh 2772.88
Power calculation on Last year performance Power calculation on current year performance
Operating KW 1363.63 Operating KW 1353.22
Running hours 24 Running hours 24
Power/day in KWh 32727.12 Power/day in KWh 32477.28
Power per month in KWh 981813.6 Power per month in KWh 974318.4
Power per month in KWh 58800 Power per month in KWh 45600