Cost Reduction Action Plan – CHK

Financial Year – 2019 20

1
Cost Reduction action plan – CHK

2
1. Fuel Mix – Pet Coke Utilization

Pet Coke utilization (Target 15 %) – 100 % Pet coke utilization at Main through chemical HM 910
P et C o k e P ercen ta g e

20
18
16
14
12
10
8
6
4
2
0 Jul-19 Aug-19 Sep-19 Oct-19 Nov-19 Dec-19

• Pet Coke consumption at Main – 100 %

• Utilization at PC trial not successful, repeatedly again at L-1 campaign last days with change
in PC meal feeding points for complete combustion of Pet coke. 3
2. Cement Grinding – (Maximum Alumina Media utilization)

Grinding Alumina Media Mills (Target 60 %) – Saving 3.0 KWH per ton cement
- Saving Rs. 52.8 per ton cement
A lu m in a M e d ia M ills % a g e
(@ 17.60 Rs/KWH)

100

90

80

70

60

50

40

30

20

10

0
Jul-19 Aug-19 Sep-19 Oct-19 Nov-19 YTD

Nov-19: CM # 2 C- Hope project completed, CM # 3 C-Hope project expected comp 15.12.19

4
3. Peak Hours

Peak Hours utilization (Target 10 %)

Peak Hours %

10.0

9.0

8.0

7.0

6.0

5.0

4.0

3.0

2.0

1.0

0.0
Jul-19 Aug-19 Sep-19 Oct-19 Nov-19 YTD

• Reduction of 1200 KWH achieved through

- Raw Mill stoppage during day and operation in peak hours
- 02 cement mills operation during day and stoppage in peak hours. 5
3. False Air

Preheater & Raw Mills False Air Percentages

Coal Mill False Air Percentages

6
Specific Power Consumption Reduction – CHK
Financial Year – 2019 20

7
1. Power consumption

P o q w e K W H p e r to n c e m e n t
Target : L1/L2 = 81.87 KWH per ton cement
Power Consumption L1

Nov-19 = 81.6 KWH per ton cement 90

Dec-19 =80.7 KWH per ton cement 85

80
75
70
65
60
55
50
45
40

P o q w e K W H p e r to n c e m e n t
35
30
Jul-19 Aug-19 Sep-19 Oct-19 Nov-19 Dec-19 YTD

Power Consumption L2

90
85
80
75
70
65
60
55
50
45
40
35
30
Jul-19 Aug-19 Sep-19 Oct-19 Nov-19 Dec-19 YTD 8
2. Power reduction at Coal Mill fan

Reduction in pressure drop through removal of venture at Raw Mill fan and coal Mill fan

Completed at Coal Mill # 2

on 05.12.19

- Coal Mill # 1 shall be

completed on 30.12.19

1200 ø 1800ø

• Expected saving Coal Mill 0.28 KWH per ton material

9
3. Power reduction at Raw Mill Fan

Reduction in pressure drop through removal of venture at Raw Mill fan and coal Mill fan

2000 ø

2800ø

• Expected saving Raw Mill 0.20 KWH per ton material

10
4. Auto stop sequence to Optimize power consumption

Auto Stop Coal Mills Auto Stop Cement Mills

• Auto Stop for Raw Mill expected completion date 18.12.19.

• Calculated saving 48,000 KWH per year.

11
 Power Cost Reduction - Plan detail

To reduce Idle Running of Major Equipment by close monitoring & interlocks specially in manual operation.
Expected
Sr # Description Area Saving/ Year Target Completion Remarks
(KWH)
Raw Mill, Coal
Phase I - Auto Stop sequence to Completed at 02 Coal - Completed at Cement Mills (04 No's).
1 Mill and
optimize power consumption 48,000 Mills and 04 Cement Mills - Completed at Coal Mills (02 Nos’s)
Cement Mill
3 Preheater lights optimization Kiln Area 10,950 Completed
- Limestone reclaimer and coal reclaimer
Shop wise KWH monitoring operation at full feed during single line
during single line operation and operation. Completed
4 All Area Completed
operation of all feeding area at - Compressors operation during peak hours
full feed to be optimized for further reduction in
power consumption

Peak hours monitoring - Cement Mill shall remained stopped during

Advantage of 1.2 MW for peak hours and Raw mill shall be operated.
5 All Plant Completed
operation of Raw Mill in peak This shall give an additional benefit of 1.2
hours instead of 02 cement mills MW during Peak hours

12
 Power Cost Reduction - Plan detail

Cement Mill Section

Expected Saving/
Sr # Description Area Year Target Completion Remarks
(KWH)

'Cement Mill # 2 and Cement Mill # 3

8 contribution of 60 % in total year grinding Cement Mill 5,100,000 Completed
to reduce power consumption

'Gypsum Crusher operation 02 shifts per Cement Mill

9 Completed Completed and implemented
day

Completed at Cement Both Alumina Media Mills Routes

Trial to check the route change of
10 Cement Mill 105,120 Mill # 2 and Cement change to achieve desired blain at
cement mill feed on blain and mill KWH
Mill # 3 target feed rates.

Feed water pump VFD installation to

11 reduce power consumption during Power Plant 50 KWH per hour Completed
operation

Coal fired boiler shall be taken both in

operation and maintenance stoppage for
12 both boiler shall also be taken at the
same time to avail maximum operational
efficiency from steam turbine
- Boiler maintenance completed and in
the next kiln operational run, both
Power Plant Completed
boilers shall be stopped at same time
for due maintenance and cleaning

13
Specific Heat Consumption Reduction Plan
Financial Year – 2019 20

14
Heat Consumption Graph

15
 Specific Heat Consumption Reduction - Plan detail

Expected
Saving/ Year
Sr # Description Area Target Completion Remarks
(Kcal/kg
clinker)
Kiln # 2 Clinker Cooler Optimization

1. Installation of large capacity fan at ABC

inlet.
2. G14 fan system bottleneck as it is  • Cooler operation is optimized and under grate
becoming positive at high under grate operation increased from 8.2 Kpa to 9.2 Kpa.
1 Kiln # 2 3.0 Completed on 30.09.19
pressure > 8.2 is being replaced by G 10 • Plant operation stabilized with bottle neck of G14 fan
and G 11 fans. mitigated at Line # 2.
3. G14 fan shall be shifted to G 15 fan to
avoid overloading of cooler 3rd chamber
due to high under grate pressure at 1st 2
chambers.
Reduction in
Coal Line replacement at both lines to The diameter of the duct is replaced as per standard and
2 Kiln # 2 CO formation Completed at both lines
reduce coal dozing system variation instruction of M/s FLS. Completed at Line # 1
by 50 %
‘- Preheater top fresh air dampers sealed and welding
3 False air mitigation Kiln # 2 - Completed done . Completed.
- Sealing of Preheater flaps completed
Trial for using Calcium fluoride in raw
9.0 PKR per - Case is under negotiation phase at Head office for trail
4 meal to lower clinkerization reaction Under negotiation
ton saving test.
temperature
Follow up for Fly ash utilization at Under process expected
5 Cement Mill 3.6
Cement Mills 0.5 % completion 30.12.19

  Total Saving   6.6 Kcal/kg Clinker   

16