Points under EA at Cement plant to cover

The proposal must cover all the major energy consuming areas (both thermal energy
and electrical energy) in the Cement Plant, mines and Captive Power Plant.

a) Overall plant power requirement, power management philosophy (demand

management) and power quality assessment (Power factor, harmonics etc)
b) Comprehensive energy audit shall be done in different sections - as per our
cost centers i.e. Raw Material extraction (consumption at Mines), Raw
Material preparation (Consumption by Crushers), Raw Meal preparation (Raw
Mills consumption upto Kiln feed), Clinker production (Consumption by Kilns,
Coal mills), Cement grinding, auxiliaries (T&D Losses, workshop, colony,
guest house, water supply pumps and other infrastructure) and consumption
by Packing plant.
c) Startup power consumption (hot to hot, hot to cold stop, cold to hot start up)
shall be ascertained by the auditor. This is for the Normalization factors
developed which shall be used during Verification process under PAT
scheme.
d) Benchmarking of the production unit at sub-process level shall be done
against other technologically similar units and design parameters.
e) Projects identified shall be classified according to the implementation and
further shall be categoriesd into short term ( < 2 Years ), Medium term ( 2-5
Years ) & Long term (> 5-10 Years ) shall be determined
f) During audit, production level and product mix to be recorded.
g) Payback calculation to be done by simple pay back and reported irrespective
of the payback period for all the identified Energy reduction initiatives
/opportunities.
h) Technical viability of the projects identified should be checked and verified as
per the plant condition
i) The consultant/ Service provider should synchronize with ACC’s inhouse
optimisation projects already identified by ACC plants and their technical
department.
j) The recommendations should be implementable and should comply with the
PAT requirement.
k) All mainstream process equipment energy efficiencies must be assessed;
major auxiliary equipment must also be studied.
l) All leakages to be identified.
m) All pressure drop reduction opportunities to be assessed.
n) All bag filter fan as well as purging system should be optimized on the basis
of pressure drop

Deliverables expected from the Audit

 a) Energy Balance of the plant with clear categorization of Input, output ,
processing & Losses
b) Road map of energy saving opportunities to synchronize with the PAT cycle.
c) Current T& D Losses and opportunities to reduce the same
d) List of projects that are Techno commercially viable arranged in the order of
Simple payback period.
e) Budgetary proposal for the projects with pricing accuracy of better than 20%.
f) Projects spanning Multiple PAT cycles are to be decided in consultation with
the plant. .
g) Clear roadmap for optimization of heat rate and auxiliary power consumption
for CPP.
h) Suggestion should include best operating practice for achieving optimal
efficiency at part load.

1.0 List of Sections / equipment to be audited

1.1 Electrical and thermal energy efficiency improvements in Kiln and Pre heater

The following aspects to be studied in detail to develop possible schemes for energy
saving:

 A detailed mass and heat balance to be conducted on the kilns system

 Flue gas analysis (O2) & feasibility of reducing false air infiltration in the preheater
system
 Optimization of fans in kiln section
 Identification higher radiation areas using infrared thermo-graphy suggesting
measures for minimizing the same
 Identification of areas in cyclones and down comer ducts where pressure drops
can be further minimized- Actual scope of implementation may be based on the
CFD study.
 Fine tuning of kiln feed and coal conveying systems
 Pressure and temperature profile for the gases shall be studied and
recommended suitably.
 Kiln feed and coal conveying systems shall be analysed for optimizing the phase
density, pressure and velocity
 Optimization of raw meal feeding points in cyclones. Raw meal feeding points in the
pre heater cyclones shall be studied for maximum heat transfer and suggestions
shall be given based on the existing potential.
 Homogenizing sections shall be studied for energy savings
 Analysis of any abnormal parameter value in kiln /pre heater system & suggesting
corrective action
 Bag house pressure drop and performance shall be studied

1.2 Energy efficiency improvements in Coolers

 Detailed Cooler heat balance

 Studying the performance of existing cooler
  Feasibility study of retrofitting existing conventional reciprocating coolers with
latest generation coolers
 In plants already having modern high efficiency coolers, the performance of the
existing cooler shall be studied in comparison with design and suggestions shall
be provided to improve performance (if there is any deviation / further improvement
opportunity)

1.3 Retrofit of Uni-Flow burner with advanced multi channel burner

 Study on existing burner and its performance

 Explore the feasibility of installing advanced burner with alternate fuel feeding
capability
 In plants which are having multi-channel burners, the operating performance of the
existing multi channel burner like momentum, conveying air quantity and primary air
quantity shall be studied and compared with design

1.4 Raw Mill, Coal Mill and Cement Mills

The energy audit team must make a detailed study of all the mills and their accessories.
The study shall cover draught & the flow through the mill and control system. Efforts to
be made to identify possible energy saving proposals to reduce the specific energy
consumption.
The following to be studied for identifying possibilities of energy saving

 Air infiltration across the path and consequent higher loading of fans/blowers
 Optimization of fans based on the design/operating parameters
 Feasibility of reducing false air entry in mill circuits
 Identification of areas in mill circuits (cyclones, ducts and separators) where
pressure drops can be further minimized- Actual scope of implementation may be
based on the CFD study. Optimization of the separator system in ball mills
 Optimization of coal fineness in line with clinker & coal mill production
 Advanced control mechanism of cement mills
 Optimization of flue gas used for drying the raw material
 Optimization of louvre velocity - Existing louvre velocity shall be studied against the
recommended value considering the reject handling system, heat requirement and
the pressure drop across the mill system
 Optimization of mechanical recirculation system- If mechanical recirculation system
is not available, then feasibility of its installation will be studied. In the existing
system, operation in terms of reject rate % will be studied along with existing Louvre
velocity
 Assessment of the liner profiles and opportunities for improvements.
 Optimization of Grinding media through chamber sampling based on the grindability
curve and the existing grinding media; suggestion shall be given to improve the
 grinding by altering the grinding media pattern in consideration with material
characteristics including hardness and target fineness.
 Optimization of material fineness : Material fineness maintained in the raw mill and
coal mill shall be studied in accordance with the target free lime, material burnability,
coal characteristics and mill output.
 Optimization of Particle Size Distribution (PSD) of cement.
 Optimisation of separator system through circuit sampling : Separator performance
shall be evaluated and suggestions shall be given based on the reject rate and its
fineness, separator efficiency and existing condition of the separator.

1.5 Fans and Blowers

A detailed survey of all major fans & blowers in the Crusher, raw mill, pre heater, coal
mill, cement mill sections to be made and to suggest methods of reducing power
consumption.

 All the necessary measurements to calculate the fan efficiency must be made.
 The operating characteristics of motors driving the fans such as loading, power
factor etc. to be measured.
 Based on these measurements and the subsequent analysis, recommendations
about improving the operating efficiency shall be made.
 Deviation in the operating point from the design point/parameters to be observed
and recommended for suitable correction.
 The operating efficiencies of the fans shall be compared with the BEP and
recommendation for improving the energy efficiency/ reducing input power
consumption to be made.
 Study of the efficiency of various variable speed mechanisms operating in the plant.
 The study must cover the following possibilities:

 Fine tuning of fans & blowers

 Installation of right size fans matching with system requirement
 Installation of variable speed drives
 Reducing the system resistance for the flow
 Installation of high efficiency fans
 Optimising operation of bag filter fans
 Reducing the pressure drop at the suction side, system pressure drop
optimization
 Interlocking fan operation with process

1.6 Packing Plant

The possibilities include

  Fine tuning of compressors
 Optimizing air requirement from compressor/ PD blower as per the user point
requirement of pressure and quantity
 Fine tuning of dedusting fans

1.7 Electrical Distribution System

During the detailed energy audit, detailed electrical energy balance shall be carried out.
All the distribution transformers and electrical distribution system to be studied for possible
energy savings. Operating efficiency of transformers to be established.

Performance of the existing reactive power management system in the plant at different
bus levels shall be evaluated. This would essentially include evaluation of the plant power
factor and actual kVAR delivered by existing compensation system.

Suitable recommendations shall be made, wherever feasible, in the following areas:

 Distribution and cable losses

 Reduction in transformer losses
 Optimization of transformer loading
 Sufficiency of capacitors
 Performance evaluation of capacitors
 Sizing of capacitors, location and switching of banks shall be studied.

A detailed analysis of incoming voltage conditions would help in arriving at possible

measures to improve the same at various bus levels. Total harmonic distortion (THD)
percentage upto 50th order shall be measured at main distribution panel. The measured
values shall be compared with the IEEE 519 limits and suitable recommendation shall be
made for mitigating harmonics.

1.8 Motors Survey

The detailed power measurements of all major motors (above 20 HP) to be conducted

 Loading pattern and operation of the connected load

 Percentage of load
 Optimization of transmission ( Pulley/V Belt/ coupling/ Chains etc)
 Operating power factor
 Energy saving opportunities to be suggested, by the application of following
items:

 Auto Star-Delta-Star converters

 Replacing with lower capacity motors
 Replacing with higher efficient motors
  Efficiency level and loss through old motors and developing criteria for
replacement.

Utilities

1.9 Air Compressors and Compressed Air System

Energy audit team shall study the compressors and compressed air system for the
feasibility of energy conservation aspects, such as-

 Specific power consumption for each compressors to be evaluated and shall be

compared with the benchmark
 Inter cooler and after cooler performance shall also be studied.
 Fine tuning of the operation of compressors
 Optimisation of operating pressure of compressed air system
 Estimation of actual FAD based on pump-up method wherever it is feasible
 Exploring the possibility of installing new compressors in place of old
compressors
 Exploring the opportunities for segregating the high pressure & low pressure
users
 System modification to minimize compressor operation and minimize system losses
 Feasibility of installing Variable Frequency Drive (VFD) for screw compressors
 Leakage test to be conducted wherever feasible
 Optimization of use of compressed air in the end use point (in Bag filters, ash
handling, pneumatic conveying etc)
 Possibility for installing supply side & demand side controller, Heat of Compression
(HOC) dryers
 Replacement of inefficient compressors with efficient compressor

1.10 Pumps

All the major pumps (centrifugal pumps) to be studied in detail:

 Flow and head should be optimized for different applications

 Optimize pumps as per the operating conditions
 The operating characteristics of motors driving the pumps such as loading,
efficiency, power factor etc. to be measured.
 Deviation in the operating point from the design point/parameters to be observed
 The operating efficiencies of the pumps shall be compared with the best efficiency
point (BEP)
 Recommendation for improving the energy efficiency/reducing input power
consumption should be made.

Possibility of following energy saving opportunities shall be explored:

 Optimizing the operation of pumps

  Installation of new energy efficient pumps
 Installation of correct size (capacity & head) pumps
 Feasibility of installing suitable speed control mechanism

1.11 Air conditioning systems

All the major air conditioning units shall be studied:

 It is proposed to evaluate efficiency of air conditioning system. The operating
parameters such as temperatures and pressure of refrigerant and power
consumption of compressors would be monitored.
 Performance indicators such as specific power consumption (kW/TR) and CoP
(coefficient of performance) shall be evaluated and compared with designed
values.
 The scope for improvement in overall refrigeration system shall be explored and
suitable recommendations shall be provided for the individual plant.
 Alternative technologies like VAM, Geo cooling shall be explored.

2.0 Power plant

2.1 Steam system

Performance evaluation of boilers and steam system indicating the following:

 Detailed heat balance

 Operating efficiency of boiler (s)
 Details of individual losses and ways to reduce them to be provided as below:

 Dry flue gas loss

 Heat loss due to the presence of CO in flue gas
 Losses due to combustion of hydrogen and moisture, which depends
on H2 in fuel, moisture in fuel, combustion air, excess air quantity and
exit gas temperature.
 Unburnt carbon losses in bottom ash and fly ash
 Sensible heat loss in ash
 Structural heat losses
 Radiation losses
 Blow down losses

 Performance evaluation of air pre heater

 Air infiltration at various flue gas path
 The steam and water leakage to be quantified wherever possible.
 Measures to improve the combustion efficiency to be suggested.
 The suggestions to reduce these losses to be covered in the report.
  The condition of insulation of boilers, turbines and steam pipelines, heaters, etc.,
to be checked
 The radiation losses shall be calculated
 Use of advanced control system for better operation to be suggested

Suitable measures to be recommended to reduce all types of losses and improve the
resource efficiency.

2.2 Turbine system

Performance evaluation of turbine system establishing the following:

 Detailed heat balance of the system to be calculated by recording the parameters

of intermediately stages.
 The stage efficiency
 Heat rate of the turbine to be calculated and to be compared with design data.
 The performance indicators-Terminal temperature difference (TTD), Temperature
rise (TR), Drain cooler approach (DCA), and steam extraction quantity of all feed
water heaters by of the feed water system heat balance, are to be derived
 Low pressure heaters,
 High pressure heaters,
 Gland steam condenser,
 Steam jet air ejector and
 De-aerator

2.3 Condenser and Cooling tower

A detailed analysis of condenser to be conducted resulting in

 Operating performance of the condenser

 Temperature rise and terminal temperature difference
 Comparison with the design data.

Performance of the cooling tower to be measured:

 Suitable measurements to be made to measure the water flow and temperature

differences of supply and return water
 Parameters such range, approach and effectiveness to be calculated.
 Condition of the cooling tower to be observed
Suitable recommendations to be made to improve the performance of the condenser and
cooling towers.

2.4 Fans and Pumps

The draft system (primary air fans, secondary air fans and induced draft fans) of the boiler
to be studied.

 The operating characteristics of motors driving the fans such as loading, power
factor etc. to be measured.
 Based on these measurements and the subsequent analysis, recommendations
about improving the operating efficiency (if any) shall be made.
 Deviation in the operating point from the design point/parameters to be observed
 The operating efficiencies of the fans shall be compared with the BEP and
recommendation for improving the energy efficiency/ reducing input power
consumption's to be made.

The performance analysis of BFP, CEP and CWP shall be carried out.

 Flow and head should be optimized for different applications

 Optimize pumps as per the operating conditions
 The operating characteristics of motors driving the pumps such as loading,
efficiency, power factor etc. to be measured.
 Deviation in the operating point from the design point/parameters to be observed
 The operating efficiencies of the pumps shall be compared with the best efficiency
point (BEP)
 Recommendation for improving the energy efficiency/reducing input power
consumption's would be made.
Possibility of following energy saving opportunities shall be explored:

 Optimizing the operation of pumps

 Installation of new energy efficient pumps
 Installation of correct size (capacity & head) pumps
 Feasibility of installing suitable speed control mechanism
 Installation of variable frequency drives for the pumps

2.5 Coal Handling plant

Study to be carried out at coal handling plant to arrive at-

  The performance analysis of coal crushers and conveyors in terms of output and
power consumption of the driving motor and shall be compared with the designed
figures.
 Optimize the operation of coal crushers and conveyers with respect to plant
requirement
 Suggestion for improvements in the above areas shall be provided in the study.

2.6 Electrical Distribution System

During the detailed energy audit, detailed electrical energy balance shall be carried out.
All the distribution transformers and electrical distribution system to be studied for possible
energy savings. Operating efficiency of transformers to be established.

Performance of the existing reactive power management system in the plant at different
bus levels shall be evaluated. This would essentially include evaluation of the plant power
factor and actual kVAR delivered by existing compensation system.

Suitable recommendations shall be made, wherever feasible, in the following areas:

 Distribution and cable losses

 Reduction in transformer losses
 Optimization of transformer loading
 Sufficiency of capacitors
 Performance evaluation of capacitors
 Sizing of capacitors, location and switching of banks shall be studied.

A detailed analysis of incoming voltage conditions would help in arriving at possible

measures to improve the same at various bus levels. Total harmonic distortion (THD)
percentage upto 50th order shall be measured at main distribution panel. The measured
values shall be compared with the IEEE 519 limits and suitable recommendation shall be
made for mitigating harmonics.

2.7 Motors Survey

The detailed power measurements of all major motors (above 20 HP) to be conducted.

 Loading pattern and operation of the connected load

 Percentage of load
 Optimization of transmission ( Pulley/V Belt/ coupling/ Chains etc)
 Operating power factor
 Energy saving opportunities to be suggested, by the application of following
items:
 Auto Star-Delta-Star converters
  Replacing with lower capacity motors
 Replacing with higher efficient motors
 Efficiency level and loss through old motors and developing
criteria for replacement.

2.8 Air conditioning systems

All the major air conditioning units shall be studied:

 It is proposed to evaluate efficiency of air conditioning system. The operating
parameters such as temperatures and pressure of refrigerant and power
consumption of compressors would be monitored.
 Performance indicators such as specific power consumption (kW/TR) and CoP
(coefficient of performance) shall be evaluated and compared with designed
values.
 The scope for improvement in overall refrigeration system shall be explored and
suitable recommendations shall be provided for the individual plant.
 Alternative technologies like VAM, Geo cooling shall be explored.

2.9 Auxiliaries
The following aspects of Power plant auxiliary operation to be looked into for possible
energy savings:

 Performance improvement of other auxiliaries like , Ash handling plant

 Develop better operating practices for higher efficiency and monitoring
mechanism for efficiency parameters.

3.0 Lighting System

The objective of the lighting audit shall be to check the existing illumination levels (across
entire plant area) and comparing these values with available norms. Study also shall be
carried out to identify suitable energy efficiency lighting system and maximum possible
use of natural light. Suitable recommendations shall be provided to conserve energy by
maintaining illumination levels as per requirement.

The feasibility of following shall be studied in the lighting system:

 Installation of electrical energy savers
 Optimisation of lighting distribution system voltage
 Energy efficient lighting practices
 Modification in lighting system to minimize power consumption
 Use of modern lighting equipment which will result in reduced energy consumption
  Opportunity for using day lighting system at different shop floors, control room shall
be explored

4.0 METHODOLOGY OF DETAILED ENERGY AUDIT

 At the end of the detailed audit for each plant, all findings of the energy audit to be
discussed with each department in charge for their concurrence
 A detailed presentation on the findings to be made to all the executives of the plant
on the last day of site work of energy audit highlighting the readily implementable
recommendations and other details related to identified projects.
 After presentation, the findings to be submitted to the company in the form of a
report along with all measurement details and detailed calculations.

5.0 DETAILED ENERGY AUDIT REPORT

The energy audit report must contain the following:

 Specific energy savings proposals
 Full descriptions and figures,
 Present energy consumption pattern
 Method of implementing the proposals
 Cost benefit analysis
 Energy Management Guidelines to monitor and sustain the savings identified.
 The recommendations to be classified as non-capital proposals (proposals
requiring no investment or insignificant investment) and capital proposals. It should
be noted that for capital proposals, the budgetary cost estimates have an accuracy
of plus or minus 20 percent.
 For projecting cost benefit analysis, simple payback system technique to be used.
Section wise SEC (kWh/T of material) for all sections below to be calculated and to be
compared with the national benchmark data:
 Single stage crusher
 Double stage crusher
 Tertiary crusher (if any )
 Raw mill
 Coal Mill
 Cement Mill
 Thermal SEC (kcal/kg Cli)
 Packing section
6. General Points

The assignment should be completed in three months.

Along with the offer, the consultant should submit

i) Past credentials including Sector wise reference list

ii) List of instrument to be brought to the plant for carrying out audit
iii) Profile of energy auditors to be deployed for ACC assignment. Number of
auditors, number of support staff for each plant audit to be indicated
separately.
iv) In case independent process experts are hired, their technical expertise
shall be informed to ACC.
v) Price which is inclusive of all taxes. ACC shall provide free lodging and
boarding and local conveyance.

7.0 One day training

The proposal must include a one-day training program on various aspects of energy
conservation along with latest actual implemented case studies.