OCL Bengal Cement Works

(A Unit of OCL India Limited)

Dalmia Bharat Group Co.
 Rich Heritage
The Group was established in 1939 and has a rich heritage of 75+ years of serving India
Cement
Dalmia advertisement on 15th August 1947
Re-published on 60th independence day by Times Of India

Sugar

Refractories

Power

Bengal Cement Works 9/2/2017 2

 Pan India Footprint Of Dalmia Cement
Fourth largest cement group in
India with 27 Million Tons of
installed cement capacity 186 MW
of captive power capacity

BCW
1.35
MTPA

Bengal Cement Works

 OBCW AT A GLANCE
➢ OCL Bengal cement Works (here-in-after referred to as OBCW), a Dalmia Bharat Group
Company, is operating a Cement Grinding Unit having Installed capacity of 1.35 MTPA,
now being upgraded to 1.75 MTPA situated at West Midnapur district in West Bengal .
➢ Cement Plant commissioned on 27th March, 2014
➢ A Solar PV Power Plant of 5.5 MW capacity commissioned on 30th March 2016
➢ Certified for Integrated Management System of ISO 9001,14001 & 18001 ( Quality ,
Environment & OHSAS ) .
➢ Presently operating a FLS OK MILL (42.4) for both PSC & PPC in inter-grinding mode .
➢ Predominantly manufacture PSC & PPC and catering to the entire pockets of West Begal
with 100% road despatches.

Kapilas Cement Manufacturing Works 4

 CERTIFICATIONS
Our Focus area IMS CERTIFIED UNIT

ISO 9001: 2008 ISO 14001: 2004 OSHAS 18001: 2007

 EXCELLENT ENERGY EFFICIENT UNIT AWARD IN 2016

 CERTIFICATE OF MERIT FOR ENERGY EXCELLENCE FROM BEE IN 2016
 CERTIFICATE OF TWO STAR RATING IN 2016

9/2/2017
Bengal Cement Works 5
5
 Process Flow Diagram
Clinker
Fly ash
Clinker Silo
Wagon Tippler Silo
Stacker & reclaimer
Gypsum/slag

Truck Tippler Raw material hopper

Coal
Fly ash bulker

Coal hopper

HAG
Coal mill
CVRM
Bag House Cement Silo

Roto Packers Bulker

Truck
Despatch Despatch

Bengal Cement Works 9/2/2017 6

 Benchmark: Where We Are ..Where To Go…
SPECIFIC ENERGY (KWH/T) FOR PSC SPECIFIC ENERGY (KWH/T) FOR PPC
60 51.4 50 44.7
BENCHMARK BENCHMARK
50 43.27 40
38.94 33.44
40 10% 36 10% 30.01 28
30 27
30
20
20 17% 15%
10 10
0 0
2014-15 2015-16 2016-17 2017-18 2014-15 2015-16 2016-17 2017-18

Kcal/Kg for PSC

KCal/Kg for PPC
85.5 50
81.5 78 40
80 40 37
4% 23%
59 28.6 26.5
30
60
20
40 28% 10 28%

0
20
2014-15 2015-16 2016-17 2017-18
2014-15 2015-16 2016-17 2017-18

Bengal Cement Works 9/2/2017 7

9
 30
40
45
50
55
60

35

Bengal Cement Works

2014-15 50.5

throughput enhancement by
capacity utilisation & optimization
-6.9

cvrm optimization
-2.8

power factor improvement

-0.7

cvrm bag house purging in DP

mode
-0.2

160 KW compressor replacement

by 90 Kw
-0.1

optimizing compressed air usage

-0.3

equipment idling minimization

-0.1
SEC(KWH/T)

2015-16 39.5

cvrm optimisation
-1.2

auxiliary power reduction by raw

-0.6

material circuit optimization

cvrm fan efficiency enhancement &

-0.8

false air reduction

coal mill TPH enhancement

-0.3
Roadmap To Achieve Target SEC ( KWH/T)

packing plant power reduction

-0.6

2016-17-18 Q1 36.0
 ENCON Project with

investments

Bengal Cement Works 9/2/2017 9

16
 ENCON Actions : without investment
Annual Annual INR
SN ENCON actions with out investment Year Million KWH saving
Saving (Million)
1 Reduction of compressed air consumption in CVRM Bag house 2014-15 0.104 0.800

2 Reduction in running hour of Slag feeding group Bag filter fans 2014-15 0.050 0.370

3 Reduction of CVRM main drive SPC through Dam ring height adjustment from 192 to 150 mm 2015-16 2.000 15.400

4 Running of CVRM Bag house in DP mode 2015-16 0.144 1.110

5 Reduction of Packing plant SPC by replacing 160 KW compressor by 90 KW 2015-16 0.100 0.780

6 Reducing idle running of Material handling circuit drives through installation of belt starvation switches 2015-16 0.003 0.020

7 Reduction of WTP Cooling Tower fan power consumption through interlock with temperature sensor 2015-16 0.028 0.210

8 Reduction of Compressor power consumption by optimizing loading/unloading set point 2015-16 0.180 1.390

9 PLC interlock modification for process optimization ( Save 15 no of trippings) 2015-16 0.013 0.100

TOTAL 2.620 20.170

Bengal Cement Works 9/2/2017 10

9
 ENCON Actions : without investment Annual Annual
SN ENCON actions with investment Year Million KWH MINR
saving Saving
1 Gear box radial bearing maintenance & CVRM optimization to run on minimum power mode 2016-17 0.46 3.93

2 CVRM ID fan cone gap correction from 33 mm to 12 mm 2016-17 0.052 0.44

3 Felt seal installation at CVRM dynamic separator seal gap 2016-17 0.03 0.26
Nozzle ring area increment by removal of three nozzle blocks ( from 4.87m2 to 5.4 m2 )(
4 2016-17 0.1 0.92
reduction in nozzle ring velocity from 48 m/s to 40 m/s)
5 Dam ring reduction by 6 mm( from 122 mm to 116 mm ) 2016-17 0.03 0.32
Reduction of false air at mill reject chute flap & belt, mill inlet ducts , mill feed chute ,Separator
6 2016-17 0.09 0.76
outlet flage & Bag house chamber doors. ( from 18.4 % to 14 %)
7 Coal mill grinding media regradation & pattern change ( from coarse to fine) 2016-17 0.09 0.79

8 Stop Auxiliary bag filter fan through tapping in main bag filter fan in each packer 2016-17 0.06 0.52
Packer 1 & 2 bucket elevator group starting interlock modified to avoid group idle running during
9 2016-17 0.003 0.026
shift starting
Packer 1 & 2 belt bucket elevator & CVRM reject elevtor motor connection change from delta to
10 2016-17 0.02 0.18
star
TOTAL 0.94 8.15
Bengal Cement Works
 ENCON Project with

investments

Bengal Cement Works 12

9/2/2017 212
 ENCON Actions: with investment
Annual
Annual
Million KWH Investment Payback
SN ENCON actions with investment Year MINR
saving in year of (MINR) period
Saving
installation

1 Power factor improvement by installing 1500KVAR HT capacitor installation 2015-16 0.500 3.860 1.250 3M
Reducing power consumption of HAG fuel firing blower through VFD
2 2015-16 0.030 0.230 0.040 2M
installation
3 Reduction of Packing plant SPC by replacing 90 KW compressor by 45 KW 2016-17 0.195 1.500 0.900 6M
Reducing power consumption of packing plant bag filter Fan by VFD
4 2015-16 0.130 1.000 1.680 1.25 Y
installation
5 Reducing power consumption of CVRM bag filter Fan by VFD installation 2016-17 0.026 0.200 0.050 3M
6 Solar power generation unit 5.5 MW 2016-17 6.000 46.200 277.200 6Y
Installation of plant logistic automation system to improve operational
7 2015-16 0.200 1.550 2.500 1.6 Y
efficiency of packing plant.
Installation of VFD in 641 FN1 & 642FN1 ( 75*2 kw) Silo bin aeration blower
8 2016-17 0.12 0.99 1.35 1.4 Y
611BL2 ,packing plant compressor & 611FN1 Silo 1 bag filter fan.
Installation of VVFD in reject bucket elevator bag filter fan , reject circuit bag 0.8
9 2016-17 0.092 0.79 1Y
filter fan & raw material feeding belts bag filter fan
TOTAL 7.3 56.32 285.77 1.25 Y

Bengal Cement Works 13

9/2/2017 10
 ENCON Actions: For 2017-18
Annual
Annual
thermal
SN ENCON actions with investment Million KWH Status/Remarks
saving (
saving
MKCal/year)
Partial blocking of left most duct of CVRM hot air By uniform temp distribution heat saving is
1 4052 -
inlet around 3KCal/Kg
2 Trimming of CVRM ID fan impeller - 0.58 Approx 80KW/Hr saving is estimated
3 CVRM ID Fan inlet duct area enlargement - 0.4 Approx 55 KW/Hr is estimated
Reduction of system pressure of CVRM circuit by 25
4 - 0.14 Around 25 KW/Hr is achieved
mmwc through several maitenance activity
Reduction from 14% to 11.6% is achieved.
5 False air reduction from 14% to 10% - 0.20 By reducing upto 10% 15kw/hr saving is
estimated
Reduction of plant lighting power consumption by
6 replacing HPSV light with LED base light - 0.13 In progress

7 9 no of VFD installation at various section - 0.12 In progress

TOTAL 4052 1.57

Bengal Cement Works

 ENCON Methodology: ENCON Approach

MANAGE MEASURE PROTECT

Monthly energy Scope

Unit Head
meeting identification

Weekly energy Action plan

Energy cell monitoring by generation&
energy cell execution

Energy cell Daily energy Quantification ,

head with cross monitoring at analysis &
functional team PD record
Bengal Cement Works 9/2/2017 15
11
 ENCON Methodology: Energy Levers
VRM POWER
OPTIMIZATION Effective use of Energy Levers in 2016-17
1. Dam ring
2. False air
3. Feed size control
4. Separator
efficiency Power factor VRM optimization
& efficient silo
Solar power management to
avoid peak hour
Equipment idle running
usage 10%
11% Compressor power
31% minimization
Fan & blower efficient
running
Thermal energy saving
Equipment idle
run minimization
others
1. Stop interlocks
Fans & blowers
2. starvation stop efficient running 5%
3. Shop stoppage 31%
power
12%

Compressor power
minimization

16
Bengal Cement Works 9/2/2017 12
 ENCON Methodology: Power reports
CCR operation screen with Total KWH & KWH/T display for main drives. Daily Energy report with real time data capture
Dalmia Cements - Active Energy Report
2500 kvA 540kW Cement 2500 kVA 4150 kW 2500 kVA 6500kW Cement Solar 400kW Coal 2500kVA Trafo Spare Spare 400kW Belt MRSS MRSS
CCR Main
Column1 Trafo for Mill Separator Trafo Feeder BagHouse Fan Tafo Feeder- Mill Main Drive Power Mill Main Drive Feeder for Trafo Trafo Conveyor Feeder Outgoing Outgoing
Incomer
Wagon Tippler Fan for 561MD2 -1 for CCR 561FN1 2 for CCR for 561MD1 Feeder for L41MD1 Packing Plant Feeder-1 Feeder-2 for 491BC3 Feeder-1 Feeder-2
18-08-2016 00:02 3139752 918607 8161475 25502312 98944160 5979773 56517248 2E+06 1552036 7368597 22 10 174219 99351864 0
18-08-2016 01:02 3139876 918637 8161882 25503988 98950672 5980121 56520604 2E+06 1552268 7368969 22 10 174219 99358432 0
18-08-2016 02:02 3140001 918670 8162287 25505650 98957104 5980504 56523928 2E+06 1552422 7369341 22 10 174219 99364912 0
18-08-2016 03:02 3140126 918703 8162695 25507300 98963344 5980817 56527292 2E+06 1552422 7369711 22 10 174219 99371208 0
18-08-2016 04:02 3140253 918736 8163105 25508956 98969656 5981199 56530656 2E+06 1552422 7370084 22 10 174219 99377576 0
18-08-2016 05:02 3140378 918769 8163514 25510632 98975904 5981554 56533972 2E+06 1552422 7370441 22 10 174219 99383864 0
18-08-2016 06:02 3140472 918802 8163903 25512324 98982016 5981820 56537324 2E+06 1552422 7370780 22 10 174219 99390024 0
18-08-2016 07:02 3140560 918835 8164277 25514018 98987872 5982181 56540648 2E+06 1552422 7371014 22 10 174219 99395928 0
18-08-2016 08:02 3140652 918867 8164649 25515704 98993328 5982517 56543872 2E+06 1552422 7371288 22 10 174219 99401424 0
18-08-2016 09:02 3140816 918899 8165090 25517392 98998520 5982794 56547104 2E+06 1552462 7371545 22 10 174219 99406664 0
18-08-2016 10:02 3140934 918930 8165547 25519004 99002424 5983055 56549888 2E+06 1552693 7371823 22 10 174219 99410592 0
18-08-2016 11:02 3141020 918961 8166006 25520676 99006216 5983394 56553036 2E+06 1552926 7372062 22 10 174219 99414416 0
18-08-2016 12:02 3141158 918992 8166460 25522364 99009136 5983739 56556208 2E+06 1553156 7372329 22 10 174219 99417360 0
18-08-2016 13:02 3141297 919023 8166825 25524048 99012592 5984151 56559360 2E+06 1553384 7372614 22 10 174219 99420848 0
18-08-2016 14:02 3141380 919053 8167190 25525728 99017112 5984543 56562532 2E+06 1553608 7372890 22 10 174219 99425400 0
18-08-2016 15:02 3141464 919084 8167555 25527404 99021352 5984936 56565752 2E+06 1553608 7373204 22 10 174219 99429672 0
18-08-2016 16:02 3141574 919115 8167920 25529074 99025680 5985349 56568952 2E+06 1553608 7373560 22 10 174219 99434032 0
18-08-2016 17:02 3141734 919146 8168284 25530684 99030672 5985712 56572040 2E+06 1553608 7373898 22 10 174219 99439064 0
18-08-2016 18:02 3141840 919149 8168360 25530032 99031208 5985971 56572040 2E+06 1553608 7374225 22 10 174219 99439608 0
18-08-2016 19:02 3141903 919149 8168433 25530032 99031800 5986170 56572040 2E+06 1553608 7374473 22 10 174219 99440200 0
18-08-2016 20:02 3142046 919149 8168513 25530032 99032496 5986281 56572040 2E+06 1553608 7374836 22 10 174219 99440912 0
18-08-2016 21:02 3142186 919149 8168601 25530032 99033232 5986389 56572040 2E+06 1553608 7375220 22 10 174219 99441640 0
18-08-2016 22:02 3142505 919149 8168682 25530032 99034240 5986549 56572040 2E+06 1553608 7375594 22 10 174295 99442664 0
18-08-2016 23:02 3142571 919149 8168761 25530032 99034904 5986698 56572040 2E+06 1553608 7375954 22 10 174295 99443328 0
19-08-2016 00:01 3142676 919149 8168903 25530032 99035616 5986794 56572040 2E+06 1553608 7376318 22 10 174295 99444048 0
Total Consumption 2924 542 7428 27720 91456 7021 54792 18624 1572 7721 0 0 76 92184 0

Bengal Cement Works 9/2/2017 17

13
 ENCON Methodology: Power reports
Date 06-08-2016 Specific Power Date 06-08-2016 Specific Power
FTD MTD FTD MTD
TOTAL UNIT AVAILED AT OBCW FROM WBSEDCL kWh 169806.2 559274.3 TOTAL POWER CONSUMED IN OBCW 182553.0 621674.0
SOLAR POWER CONSUMPTION kWh 14300.0 68379.0 CVRM RUN HRS - PSC hrs 22.5 64.5
TOTAL POWER CONSUMPTION AT BCW kWh 184106.2 627653.3 CVRM RUN HRS - PPC hrs 0.0 5.8
Distribution Loss % 0.8% 0.95% CVRM - RUN Total hrs 22.5 70.3
Raw material handling with stacker(MCC 3)
kWh 1982.0 12412.0 PSC PRODN ton 4947.4 12926.6
CLINKER SILO FEEDING(491BC3) kWh 2573.0 9312.0 PPC PRODN ton 0.0 1184.8
Total Reclaimer and hopper feeding circuit(MCC
kWh 4)2137.0 7130.0 PRODN - TOTAL ton 4947.4 14111.4
CVRM-IV COAL MILL RUN HRS PSC hrs 12.2 36.9
CVRM MAIN DRIVE kWh 107864.0 333048.0 COAL MILL RUN HRS PPC hrs 0.0 0.0
BAG FILTER FAN kWh 40594.0 133354.0
COAL PRODN ton 47.9 157.4
CVRM CLASSIFIER kWh 1251.0 3430.0
Cement Despatch ton 2384.5 15621.4
CVRM Aux. as per FLS(MCC 5 INCLUDES HYDRAULIC,HAG)
kWh 6172.0 22797.0
Total Reclaimer and hopper feeding circuit(MCC
kwh/t 4) 0.4 0.5
CVRM AUX(CEMENT TRANSPORT+CEMENT SILO BUCKET
kWh ELEVATOR)
2376.0 11795.0
Daily power CVRM COMPRESSOR(70% TOTAL UNIT OF COMPRESSOR)
LIGHTING
kWh
kWh
2511.0
3479.0
15100.0
22113.0
Material handling with stacker
Clinker feeding
kwh/t
kwh/t
0.4
0.5
0.9
0.7
CVRM MAIN DRIVE kwh/t 21.8 23.6
report format MILL WATER SUPPLY MCC2
Total Power consumed for CVRM
KWh
kWh
1424.0 6322.0
160768.0 519524.0
BAG FILTER FAN kwh/t 8.2 9.5
CVRM UNITS 167460.0 548378.0 CVRM CLASSIFIER kwh/t 0.3 0.2
Power consumed for PSC KWh 167460.0 503493.0 CVRM Aux. as per FLS kwh/t 1.2 1.6
Power consumed for PPC KWh 0.0 44885.0 CVRM AUX kwh/t 0.5 0.8
COAL MILL CVRM COMPRESSOR kwh/t 0.5 1.1
COAL MILL MAINDRIVE kWh 3085.0 9298.0 WATER SUPPLY and lighting kwh/t 0.2 0.5
PSC COAL GRINDING kWh 3085.0 9298.0 Total Power consumed for CVRM (Grinding kwh/t
Power) 32.5 36.8
PPC COAL GRINDING kWh 0.0 0.0 Total Power consumed for PSC grinding ofkwh/t
CVRM 33.8
COAL MILL AUX Incl FAN (MCC 6) kWh 1245.0 4388.0 Total Power consumed for PPC grinding ofkwh/t
CVRM 0.0
PSC COAL MILL AUXILLARY kWh 1245.0 4388.0 Total Power consumed up to Grinding stage
kwh/t 33.8 38.9
PPC COAL MILL AUXILLARY kWh 0.0 0.0 COAL MILL MAINDRIVE kwh/t 64.4 59.1
Total Power consumed for COAL MILL 4330.0 13686.0 COAL MILL AUX Incl FAN kwh/t 26.0 27.9
Packing plant Total Power consumed for COAL MILL kwh/t 90.4 87.0
Packing Plant kWh 2660.0 14022.0 Packing Plant kwh/t 1.1 0.9
Packing Compressor kWh 2001.0 10014.0 Packing Compressor kwh/t 0.8 0.6
Lighting kWh Total Power consumed for PACKING HOUSE kwh/t 2.0 1.5
Total Power consumed for PACKING HOUSE kWh 4661.0 24036.0 SERVICES Lighting kwh/t 0.2 0.5
SERVICES WORK SHOP kwh/t 2.0 1.5
PROJECT WORK kWh 0.0 0.0 Total Power consumption for SERVICES kwh/t 0.2 0.5
Lighting kWh 1199.0 7139.0 Power for cement grinding kwh/t 35.0 40.2
LIGHTING AND AUXILLARY UNITS and water supply
kWh 1199.0 7139.0 Packing power kwh/t 2.0 1.6
Total Power consumption for SERVICES kWh 1199.0 7139.0 Plant lighting and auxillaries WITH WATER SUPPLY
kwh/t 1.0 2.0
182553.0 621674.0 power on cement kwh/t 37.99 43.8

Bengal Cement Works 9/2/2017 18

14
 Innovative Project executed & presented last year
❖ Innovative Project (without investment):
1. CVRM dam ring height & internal air circulation optimization

2. Minimization of compressor power consumption

3. Power saving by minimization of idle running

❖ Innovative Project (with investment)

1. RFID system installation to increase packing plant through put Power Factor
1.010
2. Power factor improvement by installing 1500KVAR HT capacitor 1.000
0.990
0.980
0.970
3. VFD installation at packing plant bag filter fans & HAG fuel firing blower 0.960
0.950

Bengal Cement Works

 Innovative Project (without investment): 1
❖ Project : Baffle plate installation at Mill inlet duct to distribute uniform heat content to mill through all ducts
❖ Objective: To save thermal energy consumption by effective utilization of supplied heat inside mill

✓ Scope: Due to in apropriate mixing length after

HAG outlet duct & recirculation air duct joint, the
inlet air through three ducts were having
nonuniform heat distribution . The left most duct
was carrying most of the heat content. This
uniformity was leading non uniforming drying of
material & higher specific heat requirement.

133 Deg C ✓Action taken :

To resolve the non-uniform temperature distribution
at CVRM inlet duct ,a modification with baffles plate
fixing ( 300 mm width) before the left most duct &
between the left & middle duct is done on month of
320 Deg C November & it was further remodified to optimize in
126 Deg C
Mar’17.

9/2/2017
Bengal Cement Works 20
 Innovative Project (without investment): 1
❖ Projec: Baffle plate installation at Mill inlet duct to distribute uniform heat content to mill through all ducts
❖ Objective: To save thermal energy consumption by effective utilization of supplied heat inside mill

Heat contribution by VRM inlet ducts ( Kcal) PSC heat cons(Kcal/Kg) vs Slag moisture%
100 14
Before modification After modification
10.94 10.61 11.6 12
10.09.2016 10.11.2016 04.04.2017 25.05.2017 80
10
Temp ( % of Temp % of Temp ( % of Temp % of total
60 79.5 9.1
Deg C) total ( Deg total Deg C) total ( Deg heat 66.8 8
heat C) heat heat C) content to 59.3 6
content content content mill 40 49
to mill to mill to mill 4

315 49.60% 258 43.80% 280.6 34.30% 287 33.90% 20

2
133 26.80% 138 31.50% 190.1 35.80% 190 40.10%
126 23.60% 118 24.70% 135.6 29.90% 140 25.90% 0 0

FY'17 MARCH APRIL MAY

Heat slag moisture %
Benefits :
▪ Energy saved : 1100 T coal
▪ Energy saved : 7 Kcal/Kg cement
▪ Money saved: 5 Million INR
Bengal Cement Works 21
9/2/2017
 Innovative Project : 2
❖ Project : coal mill productivity enhancement through grinding media optimization
❖ Objective : To save power consumption by coal mill runhour reduction
✓ scope : ✓ Action taken :
▪ coal mill ( equipped with 1st generation static ▪ Media pattern optimized to fine pattern
seperator) was initially designed for :
▪ 70 mm media was removed , 60 mm media
Feed size of 80% retention at 8mm & ground
proportion reduced & 20 mm media is included
product of 15 % retention at 90 Micron sieve. . MEDIA PATTERN
▪ Operational scenario was 30.0%
20.8% 20.8% 22%
Feed size of 40 % retention at 8 mm & ground 15.0%
25.0% 14.2%
20.0%
product required of 5% retention at 90 Micron 20.0% 26.4%
22.3%
sieve. 15.0% 12.2%
12.7%
7.1%
▪ The supplier recommended media pattern was 10.0% 6.4%
not efficient as it was too coarse for the feed & 5.0%
obtained TPH of coal mill was only 3.8 -4 TPH 0.0%
leading to SEC of around 0.7 KWH/T of cement. 0.0%
70 60 50 40 30 25 20
Ball size ( mm)
9/2/2017
Bengal Cement Works 22
21
 Innovative Project : 2
Coal mill TPH Coal mill main drive KWH/T Cement
6.0 5.5 1.0

5.0 0.8
4.4 4.4 0.8 0.7 0.7
4.1 4.0 4.0 3.9 4.0 0.65
4.0 3.8 0.6
0.6 0.6 0.5
0.5 0.4
3.0
0.4
2.0
0.2
1.0

- .0 0.0
Apr-16 May-16 Jun-16 Jul-16 Aug-16 Sep-16 Oct-16 Nov-16 Dec-16
April'16 May'16 JUNE'16 JULY'16 AUG'16 SEP'16 OCT'16 Nov'16 Dec'16

Benefits :
▪ Energy saved : 92000 KWH in 2016-17
▪ Energy saved : 0.3 KWH/T
▪ Money saved: 0.79 Million INR

9/2/2017
Bengal Cement Works 23
 Innovative Project ( without investment ): 3
❖ Project : Elimination of Auxiliary bag filter fan through tapping in main bag filter fan in each packer
❖ Objective : To save the power consumption for two dedusting fan with successfull dedusting of the circuit
✓ Scope: Each packer is facilitated with two bag filters of 46000m3/hr & 23000 m3/hr. wheteher as per flow
measurement it was analysed that @ 17 m/s velocity , the circuit dedustiong volume requiremet is only 32000 m3/hr, can
be managed by running a single fan of 75 KW.
✓ Action taken :
▪ An inhouse modified tapping is provided from the small bagfilter to larger one . the dedusting duct at designated
sources kept unaltered.
▪ The dedusting fan ( 37 KW, 23000M3/HR) is stopped. & through the suction of the remaining bigger fan ( 75 KW, 46000
M3/HR) the whole dedusting purposed is successfully resolved.
▪ saving of around 15 Kw/Hr for two packer each i.e 30 KWH .

Benefits :
▪ Energy saved : 60000 KWH in 2016-17
▪ Energy saved : 0.2 KWH/T
▪ Money saved: 0.52 Million INR
Bengal Cement Works 24
9/2/2017
 Innovative Project (without investment): 3
❖ Project : Elimination of Auxiliary bag filter fan through tapping in main bag filter fan in each packer
❖ Objective : To save the power consumption for two dedusting fan with successfull dedusting of the circuit

9/2/2017
Bengal Cement Works 25
 Renewable
energy

Bengal Cement Works 26

9/2/2017 267
 Renewable Energy Usage :
 5.5 MWp solar power plant is commissioned on April’16 to utilize non conventional renewable energy & reduction of
carbon di oxide emission.
11256009
14000000
Inverter

KWH
Solar 15%
Panel Transformer 12000000
Rating: 2500 MVA
Volts: 11KV / 415 10000000
Volts 85%
Nos of Tx.: 2 8000000
Solar Module, Poly 6000000
Photovoltaic Inverter
Crystalline Rating: 310
Watt
Rating: 648 KW/ 406 4000000 1910991
Volts
Nos of module: 17760 2000000
Total Output: 5.5 MWp Rating: 800 Amp HT Breaker 0
Volts: 12KV
Nos of Breaker: 2 Own
Solar Grid
consumption
System
Monitoring SOLAR POWER UTILISATION
20%
15%
15% 11%
10%
5%
0%
FY17 FY18

9/2/2017
Bengal Cement Works 27
 Water
consumption
reduction
Bengal Cement Works 9/2/2017 28
33
 Reduction in process Water consumption :
Water consumption KL/T
0.17
0.18

0.16

0.14

0.12

0.10
0.08

0.08 0.07

0.06
 Zero water spray for PSC
0.04

0.02
 water spray for PPC is only 2 % of total feed.
0.00
2014-15 2015-16 2016-17

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34
 Carbon
foot print

Bengal Cement Works 30

9/2/2017 30
 Carbon Footprint Reduction
❖ Initiatives to reduce carbon footprint :
CO2 emission (T/T of Scope 2: Indirect CO2 emission
▪ Installation of 5.5 MWp solar power plant to utilize renewable energy Cement) TARGET from purchased electricity
0.4
0.067
▪ Reduction of total KWH consumption through various initiatives. 0.4 0.29
0.25 0.220
0.3
0.047
▪ Reduction of thermal energy (Kcal/Kg) by process optimization 0.2 0.041 0.038
0.1
▪ Improving clinker factor by higher addition of slag/fly ash to cement. 0.0

▪ Reduction of internal vehicle fuel consumption by commissioning

wagon tippler & use of battery driven vehicles. 2014-15 2015-16 2016-17 2017-18

▪ Reduction of Fuel oil consumption by improving reliability Scope 1 : Direct CO2 emissions Scope 3: Indirect emissions from
0.047 recieved clinker
0.262
0.026 0.221
Slag % in PSC Fly ash % in PPC 0.025 0.180 0.169
0.020
80 35.5
63.15 63.16 64.06 34.89 34.83 34.86
35
60 50.14 34.5 2014-15 2015-16 2016-17 2017-18 2014-15 2015-16 2016-17 2017-18
34
40 33.21
33.5
33
20
32.5
0 32
2014-15 2015-16 2016-17 2017-18 2014-15 2015-16 2016-17 2017-18

9/2/2017 31
Bengal Cement Works 31
 Going
green
Bengal Cement Works 9/2/2017 32
35
 Greenbelt Development Initiative
PLANTED SAPLINGS ( SURVIVED) PLANNED DEVELOPEMENT OF GREEN BELT
16000 14378
14000 3% valuable trees with
11423 big trunk
12000
10000 8701 flower
8000 31% 38%
6000 fruits
4000 3031
2000 medicinal
0 6%
2014-15 2015-16 2016-17 2017-18(4M) 7% ornamental
15%
❖ Systematic green belt development initiative :
▪ Total 37500 nos of survived saplings till FY 2017-18 . Survival
rate is around 85%.
▪ 25% of total acquired area is developed as a green belt
▪ 126 types of different species is planted through out the plant
area.
▪ Quick growing forest tree plantation initiative along boundary
line having wood value & dust prevention potential.
▪ Landscaping garden development at around 3 acre area for
beautification
 Greenbelt Development Initiative
Green house for seedling development

❖ Systematic green belt development initiative :

▪ Organic farming vegetable cultivation through out 4500 Sq Ft area.
▪ Canteen waste ,other agriculture & garden waste are used to prepare
vermin compost along with cow dung- received from distributed cows to
near by villagers. This eliminates the hazard of chemical fertiliser usage.
Also ground water contamination is prevented.
▪ Development of green house round 300 Sq Mt for seedling development
▪ Plantation of saplings around 2000 nos with medicine value
Bengal Cement Works 9/2/2017 35
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