Professional Documents
Culture Documents
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Salient Features
Plant Location :Itga (V),
Chittapur (Tq) ,
Gulbarga (Dist.)
Karnataka
Commercial Production :Sep 2015
Capacity
Clinker : 2MTPA
Cement : 3MTPA
CPP : 45MW
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Optimization of fuel & Raw mix 0.00 0.00 923.08 83.1 83.1
45 50
45
40 40
2016-17 2017-18 2018-19 2019-20 2016-17 2017-18 2018-19 2019-20
(Q1) (Q1)
*The power consumption includes idle power of the plant & Pollution control equipments.
*During the 2018-19 the plant run factor is 75.3 % against 74.41 & 75.49 75.3% in 2016-17 & 2017-18
Target by 2021-22 : 59 kWh/T of cement
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*The includes number of heat up , Alternative fuel utilization & pet coke fuel.
• Number of startups due to market demand
• Target by 2021-22 : 675 kcal/Kg cli
84.31 70 67.67
85
65
80
60
56.72
75 73.45
55
69.71 50.64
70
50
65 45
60 40
2016-17 2017-18 2018-19 2019-20 2016-17 2017-18 2018-19 2019-20
(Q1) (Q1)
Cement grinding Power : 23.0 kWh/T of OPC & PPC : 19.0kWh/T of PPC
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14
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Electrical
Thermal Total Invest
energy
savings Savings ment Pay
Energy conservation project savings back in
Units in Rs in Rs in months
Tones fuel
lakh Lakh Lakh
Electrical
Thermal Total Invest
energy
savings Savings ment Pay
Energy conservation project savings back in
Units in Rs in Rs in months
Tones fuel
lakh Lakh Lakh
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17
Main
Drive
Water sprinkler
through 4 nozzles
High coating & evaporation due
to high temperature no much
impact on strength
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Main
Drive
20.0
Savings achieved (2018-19)
18.0
Power cost , Rs : 7.5/unit
Mar-19
Nov-18
Jul-18
Sep-18
Feb-19
Jun-18
Jun-19
Oct-18
Dec-18
Jan-19
May-18
May-19
Apr-18
Aug-18
Apr-19
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Result/Solution
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Results achieved 22
-
• Conservation of natural resources. Se
• Cost of carbon black Rs: 0.9 / 1000 Million cal p-
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• Cost of natural resources Rs: 1.3/ 1000 Million cal
• Cost saving per 1000 million cal = Rs:0.4
❖ ROI : 6 months
Project implemented
Roller Press Performance & Efficiency of Mill
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Project implemented
Raw mill Optimization
22
-
Why this project was selected? Se
1. Raw mills are critical to operate the kiln. p-of Raw mills
Sp.Power Consumption
2. Raw mills tripping on vibration . 19
Orient Cement, Chittapur
17.0
3. Raw mill energy consumption is high compared to best 16.0
16.0 15.6 15.4
operation.
12.0
Modifications Done in Raw mills
11.0
1. Raw mill static gap reduced from 28 mm to 20 mm
to increase the grinding efficiency. 10.0
Refractory Consumption 26
❖ Burning Zone life increased due to Dalburn bricks used in zone & consistency in kiln
operation with quality.
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2018-2019 2019-2020(Apr-July)
Installed
Source of
capacity, Energy Annual Energy Annual
Renewable energy
kW purchased, Savings in purchased, Savings in
kW lakhs kW lakhs
Solar/wind - 5200000 150.8 400000 42.4
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Environmental Projects 32
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Kiln , Coal mill , Cement mill bag houses & cooler ESP33
Solid Alternative fuel system Liquid Alt fuel & SNCR System
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✓ Carbon black
✓ Liquid AFR
✓ Solid AFR
✓ Dolachar
✓ Super Poly diesel
• We have made inhouse system for carbon black & solid AFR.
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Alt fuel (TSR %)
20.0
20
15
12.0
10
5.2
5 3.97
0
2018-19 2019-20 2020-21 2021-22
•We are planned to install Solid Alt fuel system for pyro section to increase the TSR.
•Use of recycle materials like plastic chips, RDF etc.
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Carbon footprint 40
700 694
650
630
600
600
550
500
2016-17 2017-18 2018-19 2019-20
❖ Company has projected, CO2 target of 550 kg CO2 /MT of Cement by FY 2021-22.
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Carbon footprint
Environmental Projects 42
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Raw materials storage yard & Conveyor Belts are covered with Sheets covered with sheets
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Acacia, Neem, Tamarind, Honge trees, Eucalyptus, Ashok, Peepal tree, Hercules fermi, Gilmore
tree, Subabul tree, Hatti tree, Concorpus(Dubai Tree) Feltoform, Bamboo, matti, badam,
alstonia, keshiaseema, keshiya-java, mango, kaaljamun, amla, guava, cesalpinnia and others.
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Water Consumption 50
0.08
0.074 0.076
0.07
0.059 0.06
0.06
Clinker
0.04
Cement
Axis KL\
0.03
0.02
0.01
0
2016-17 2017-18 2017-18
Axis Title
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➢ No wastewater is released from Cement Plant, as water is being used in process for cooling
purpose.
➢ A full-fledged sewage treatment plant (STP) of capacity 500 KLD installed for treatment of
sewage water.
➢ The sewage water from colony is treated at sewage treatment plant & used for gardening and
dust suppression.
➢ Waste water generated in Power plant is neutralized in ETP(25m3) & utilized for Gardening and
dust suppression system.
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Environmental Projects
Environment Protection Expenses
Investment
S.NO Description
In Lakhs
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Plantation By Chief Guest Dr.S.R Mise & Unit Head-Shri P.K Singhania
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Completed &
compressor power Middle Engineers ,
3 2017-18 Process
optimization Management Fitter &Welder
engineer
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Best Suggestion
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Unit Head
S.V.P-Works
Energy Auditor/
Manager
Head Mines Head Operations Maintenance head Head Electrical & Quality head
AGM-Mines Sr.GM-process Sr.GM-Mech Instrumentation DGM -QC
Mines section Kiln & Coal mill Crushers & raw Packing & Cement grinding
head & section head & mill section dispatch section incharge &
engineers engineers engineers engineers engineers
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➢ Plant have a team of Energy management activities in the plant called “Energy
Management Cell”
➢ Ideas generation from the all the employees through “Abhinandan Mela” &
tracking the work process based on the priority
➢ The members in the team will continuously monitor the day to day energy
consumption of all major energy consuming equipment's in the plant through
knowledge manager.
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Training Programs
Training programs conducted & participated by Engineers & staff for knowledge & implementation & site
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External training programs -
Internal training programs conducted
attended Se
1 12th Green Cementech 2016,2017,2018 & 2019-CII 1 Training Programme on -L T Motor Maintenance
p-
2 Power Plant Summit 2016,2018-CII 2 Training on -Heat balance in pyro-section
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3 National Conclave on Recent advances in Cement Industry 3 Fan efficiency calculation
4 False air measurement in pyro-section
4 Plant Maintenance Summit - 2016
5 Healthy Maintenance of Gear Boxes
5 Energy Management & Conservation in Cement Industry 6 EnMS ISO - 50001
Best Practices in Energy Efficiency in Cement Sector"
6 7 Operations & Maintenance of ESP
under KEP
8 Induction Motors & Control Products
7 PAT M&V Session during Green Cementech 2015
9 Transformer & its Parts
8 14th NCB International Seminar on Cement & Building
10 Lighting Power Optimization
9 IKN Clinker Cooling Technology 11 Plate Heat Exchanger Care & Trouble Shooting
10 Plant Maintenance Summit - 2016 12 Training on Fundamental of Hydraulics & Maintenance
Certifications-Green Pro
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Certifications-IMS
Awards 68
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KRISC Award 2017 -18 (Under the aegis of Department of Factories & Boilers, Karnataka)
1. Best Safe Performance Plant 2. Best Safety Training & Resources
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75
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