Energy Benchmarking For Cement Industry
Disclaimer 2014,Confederation of Indian IndustryAll rights reserved.While every care has been taken in compiling this manual CII- Godrej GBCdoes not accept any claim for compensation, if any entry is wrong, abbreviated,omitted or inserted incorrectly either as to the wording space or position inthe Manual. The Manual is intended to be a store of information that will serveas a ready to use reference for the plant personnel involved in production,operations and energy conservation. The source bank for this manual is basedon questionnaire submitted by the participating cement plants, data from CII’senergy award questionnaire, case studies shared by suppliers in various CII’sconferences and CII’s experience from various detailed and preliminary energyaudits. This manual is an attempt to bring out all the best practices adoptedand best energy levels achieved by the cement Industry. While utmost care hasbeen taken to bring out the best operating data, how ever there might have beensections and plants operating better than the results indicated, that may havemissed our notice.No part of this publication may be reproduced, stored in retrieval system, ortransmitted, in any form or by any means electronic, mechanical, photocopying,recording or otherwise, without the prior written permission from CII- SohrabjiGodrej Green Business Centre, Hyderabad.Published by Confederation of Indian IndustryCII - Sohrabji Godrej Green Business CentreSurvey # 64, Kothaguda Post,R R District, Hyderabad - 500 084, India.Confederation of Indian IndustryCII-Sohrabji Godrej Green Business Centre
MESSAGECII-Sohrabji Godrej Green Business Centre, as part of its ‘World ClassEnergy Efficiency initiative’, has been releasing various publications/manuals/ case study booklets, pocket guides, etc. on a regular basis toequip Indian industry with the latest trends & technologies and in theprocess enable them gain the much needed competitive edge.The strategy adopted by CII is to learn from peers on their new & innovative strategies and after extensive ground work compile the learnings intoa publication, which can be shared with all the stakeholders.As part of this initiative, we have compiled this important publication‘Energy Benchmarking for cement industry’.This publication includes section- wise best specific energy consumption levels achieved by various Indian cement plants and the strategiesadopted thereof in bringing down the consumption levels.We are sure, this manual will provide immense opportunities in unearthing new energy saving opportunities and also enable in exploring newgrowth opportunities.We warmly invite you to please share your feedback to us at encon@cii.in. We look forward to your continued support in further greening Indian Cement sector.(G. Jayaraman)Chairman, Green Cementech 2014, CII- Godrej GBC &Executive President, Birla Corporation Ltd.Energy Benchmarking for Cement Industry
MESSAGEIndian cement industry is playing a very important role in the overall development of the Nation. The Sector is also in the forefront in adoptingthe latest and emerging technologies, which is not only bringing downthe energy consumption levels but is also making good business sense.This, indeed, is a step in the right direction and augurs well for botheconomy and ecology.I am pleased to record that Cement Manufacturers’ Association (CMA)established in 1961, being the apex body of large cement manufacturersin India, has been acting as an effective bridge between Indian CementIndustry and the Government.Over the years, Cement Manufacturers Association (CMA) associationwith CII has grown steadily and has been adding great value to the stakeholders. CMA in partnership with CII has been organising conferenceson varied subjects and bringing out various technical publications/manuals.A major step towards this direction is publishing –‘Energy benchmarking for cement industry’. This Manual includes some of the best performance energy consumption data for various sections of cement plant andbest practices adopted. We are sure, this Manual will enable the cementplants in achieving excellence in energy management and provide strategies for ensuring long-term competitiveness.As we march together, we are sure, our partnership will facilitate in consolidating India as one of the global green leaders in Cement Sector.(N.A. Viswanathan)Secretary GeneralCement Manufacturers’ AssociationEnergy Benchmarking for Cement Industry
TABLE OF CONTENTSChapterNoChapter NamePageNoAcknowledgementExecutive Summary1Introduction31.0Indian Cement Industry - Present scenario31.1Major players in Indian Cement Industry41.2Energy efficiency in Indian Cement Industry41.3Factors favoring energy efficiency in Indian Cement Industry51.4CII- Sohrabji Godrej Green Business Centre Initiatives61Benchmarking in cement industry72.02Objective of benchmarking72.1Approach adopted in benchmarking study7Benchmarking in various sections933.1Single stage crushers93.2Two stage crushers113.3Raw mill- VRM123.4Raw mill - Ball mill/HPRG grinding143.5Coal Mill173.6Comparison of Five stage preheaters183.7Comparison of Six stage preheaters223.8Comparison of Sec and production263.9Comparison of Sec (up to clinkerisation)313.10Cement Mill - Ball Mill (close circuit)363.11Cement Mill - Ball Mill with pregrinder/HPRG393.12Cement Mill-VRM413.13Packing Plant433.14Utilities443.15Captive Power Plant464Extract & Outcome of the study495Energy Indicators in Cement Industry716Best Practices in Cement Industry757Monitoring Parameters for Achieving Energy Efficiency87Energy Benchmarking for Cement Industry
ACKNOWLEDGMENTCII-Sohrabji Godrej Green Business Centre would like to express its sincereand special gratitude to the entire Indian cement industry for their continuoussupport in this initiative, providing the required data for completing this study,which makes this manual more useful to all stake holders.CII-Godrej GBC acknowledges with thanks the co-operation and the supportextended by all the suppliers for sharing their technology advancements and casestudies implemented in the cement industry.We would like to place our vote of thanks for the entire national and internationalcement technical experts and associations for sparing their valuable time inoffering inputs and suggestions in bringing out this manual.The interactions and deliberations with the industry, suppliers and sector expertsand the whole exercise was thoroughly a rewarding experience for CII.Energy Benchmarking for Cement Industry
EXECUTIVE SUMMARYThe Indian cement industry is one of the most efficient in the world andcontinuously adopting the latest technologies for energy conservation. Energyefficiency in the Indian cement industry is already high but still there is a scopefor improvement in this area, providing the continued use of energy efficienttechnologies in new plants and old plants.In an objective to further increase the transfer of knowledge among the industryCII –Godrej GBC has prepared the benchmarking manual for the Indian cementIndustry. The main intention of the benchmarking study is to continue theknowledge sharing and allow all cement industries to compare their performancewith the peers in India and identify their performance aspects. CII –Godrej GBChas prepared a detailed questionnaire involving all sectional parameters startingfrom crusher to packing plant. The questionnaire has been sent to more than 140cement factories to fill-in the data. The majority of plants from all over India haveparticipated in this benchmarking study and different parameters are recorded invarious sections from the data provided by the plants.The Collected data is classified in different sections and each individual sectionis compared with respect to section wise specific energy consumption and otherparameters.The best operating values and the outcomes of the study is as follows¾¾ In raw material grinding vertical roller mil is consuming 13.3 kW/MT rawmaterial compared to ball mill consumption 16.5 kW/MT raw material.¾¾ In Pyro section with five stage preheater the best operating sec up toclinkerisation is 16.28 kW/MT clinker where as in six stage preheaters thevalue is close to 23.7 kW/MT clinker.¾¾ In cement mill section ball mill in closed circuit is operating with 27.16 kW/MT cement where as ball mill with pregrinder is operating at 23.75 kW/MTcement and vrm is operating with 21 kW/MT cement¾¾ In over all electric sec the best plants are standing near 67.2 kW/MT cementand in thermal sec 6 stage preheaters are operating at 690 kcal/kg clinkerwhereas 5 stage preheaters are operating near 709 kcal/kg clinker.The other important outcomes of this study are 300 best practices implementedin national and international cement plants and more than 50 performanceindicators in cement industry, all recorded at one place for the benefit of theindustry. Monitoring techniques with the parameter to be monitored andfrequency of monitoring is also provided in each section to further aid the stakeholders in achieving energy efficiency.Finally the benchmarking reveals the best values at which the industry isoperating each section and the best practices and technologies to be adopted tobecome as leader in energy efficiency.Energy Benchmarking for Cement Industry1
CHAPTER-1INTRODUCTION1.0 Indian Cement Industry Present ScenarioIndia’s cement industry plays a vital role in the growth and development of thenation. The cement industry has been expanding with increasing infrastructureactivities and demand from residential buildings over the past many years. India’scement sector has achieved a 5.6 1.per cent growth in 2012–13. The Indian CementIndustry has 146 integrated cement plants and 55 grinding plants accounting to atotal capacity of 365.52 million tons.The Indian cement sector is expected to witness positive growth in coming years,with demand set to increase at compound annual growth rate (CAGR) of morethan 8 per cent during 2013–14 to 2015–16, according to report titled, ‘IndianCement Industry Outlook 2016’. In addition, cement production in India isexpected to touch 407 million tonnes (MT) by 2020.Actual and Expected Production of Indian cement Industry (million tones)Source: Department of Industrial Policy and Promotion, Working group for 12thFive Year Plan, Aranca Research Notes: E - Estimate, CAGR - Compound AnnualGrowth Rate12Indian Brand Equity Foundation (IBEF) updated report on March .pdfGlobal Cement Directory 2013Energy Benchmarking for Cement Industry3
1.1 Major Players in Indian Cement IndustryAlthough the Indian cement industry has some international cement giantsHolcim and Lafarge, the Indian cement industry is broadly home developed.Ultratech Cement the country’s largest firm in terms of cement capacity, holdsaround 22% of the domestic market, with ACC Limited and Ambuja CementsLimited having 15% and 13% shares respectively. The others Indian key players (inorder of market share) include Jaiprakash Associates (10%), The India CementsLtd (7%), Shree Cements (6%), Century Textiles and Industries (5%), MadrasCements (5%), Lafarge (5%), Birla Cement (4%) and Binani Cement (4%)3.1.2 Energy Efficiency in Indian Cement IndustryThe Indian cement industry is one of the most efficient in the world and iscontinuously adopting the latest technologies for energy conservation. Energyefficiency in the Indian cement industry is already high but still there is a scopefor improvement in this area, provided there is a continued use of energy efficienttechnologies in new plants and old plants. The Indian cement industry shoulddeploy existing state-of-the-art technologies in new cement plants and retrofitexisting plants with energy efficient equipment when commercially viable. Thepresent graph shows the current and future specific energy consumption trendsin the cement industry.Comparison of Global and Indian Electrical SEC4A number of plants installed before the 1990s have been modernized to alimited extent by retrofitting with new technologies. However, they need to aimat bringing specific energy consumption levels closer to the best achieved levelsin the Indian industry by further modernization and adoption of best availableprocesses and technologies.344Global Cement Directory 2013 PRo Publications International Ltd., Epsom,UK, November 2012Technology road map -Low carbon technology for the Indian cementindustryConfederation of Indian IndustryCII-Sohrabji Godrej Green Business Centre
Comparison of Global and Indian Thermal SECSource: Low carbon technology for the Indian cement industry1.3 Factors favoring Energy Efficiency in Indian cement IndustryKnowledge Transfer: Cement Industry is known for its technology sharing andopenness in the industry. This is benefiting the Industry in replicating the bestpractices in their organizations without any hesitations.Technology Upgradation: The Indian cement industry has been growing ata rapid pace during the late 20th and early 21st centuries; about 50% of Indiancement industry’s capacity today is less than ten years old. While building thesenew cement plants, manufacturers have installed the latest, energy efficienttechnologies by design. As a result, recent cement plants achieve high levels ofenergy efficiency performance.Increase in Energy cost: The other important aspect electricity tariffs and fuelprice for industry in India being among the highest in the world, implementingsuch energy efficiency measures at the design stage provides significantadvantage to the cement manufacturers by lowering energy and production costs.Increasing energy costs also prompted owners of older manufacturing facilities toadopt gradually the latest energy efficient technologies and improve their energyperformance.Government Initiatives: Another factor which is enabling energy efficiencymovement in India is The Ministry of Power’s Bureau of Energy Efficiency (BEE)Perform achieve and trade. The key goal of the scheme is to mandate reductionin specific energy consumption for the most energy-intensive industries, andincentivize them to achieve better energy efficiency improvements that aresuperior to their specified specific energy consumption improvement targets. Thestar rating program for the equipment is also bringing revolutionary changes inthe energy consumption levels.Energy Benchmarking for Cement Industry5
Technology Suppliers: The most efficient global technologies have been adoptedin the major Indian cement plants due to the continuous efforts in bringing theinnovation and advancement in the technology. There is good interest shown byinternational suppliers to enter into Indian market to supply the energy efficienttechnologies.Associations: Industry Associations like CII, CMA and key organisations likeNCBM are continuously working for the benefit of cement industry. Theseassociations are closely working with government in promoting the growth ofthe industry.1.4 CII- Sohrabji Godrej Green Business Centre Initiatives for CementIndustryIn the efforts to promote sustainable development of cement sector anddemonstrate that green makes good business sense, CII - Sohrabji Godrej GreenBusiness Centre (CII –Godrej GBC) with the support of all the stakeholders isplaying a catalytic role in promoting World Class Energy Efficiency initiative incement industry.Some of the initiatives from CII-Godrej GBC in Indian cement Industry includethe following:1.Development of world class energy efficient cement plants: CII-Godrej GBChave been working with all the major cement plants in the energy efficiencyand sustainable front and significant benefits have been achieved andreported by these units2.CII-Godrej GBC is also organizing national and international missions tofacilitate the industry to achieve excellence in energy and environment.3.CII –Godrej GBC is organizing an annual international conference GreenCementech to provide the latest information and technology update for thebenefit of cement industry.4.Development of a technology road map to make the Indian cement industrypursue a low carbon growth path by 2050, Three units are identified for thefeasibility of implementation of these technologies and few more expressedtheir interest in participating in this initiative.5.Facilitating cement plants in pursuing the PAT (Perform Achieve and Tradeprogram of BEE) targets in a cost effective manner.6.CII in association with Cement Manufacturers Association (CMA) isworking on an initiative to facilitate development of enabling policies andframework by State and Central Pollution Control Boards, to facilitate use ofurban & industrial waste as Alternate Fuel & Raw Materials (AFR) in Indiancement industry. The main objective of the project is to accelerate AFR usagein Indian Cement industry.6Confederation of Indian IndustryCII-Sohrabji Godrej Green Business Centre
CHAPTER-2BENCHMARKING IN CEMENT INDUSTRY2.0 Objective of Benchmarking:With the openness and knowledge sharing across the plants Indian cementindustry has emerged as a leader in energy efficiency. With an objective tofurther increase the transfer of knowledge among the industry CII–GodrejGBC has prepared the benchmark for the Indian cement Industry. The mainintention of the benchmarking study is to continue the knowledge sharing andallow all cement industries to compare their performance with the peers in India,identifying the aspects of their performance as good, bad and indifferent. Thiswill add momentum in the Indian cement industry to perform more in energyefficient front.Benchmarking comprises the analysis and reporting of key energy performanceIndicators to foster continual energy performance improvements in industrythrough comparison with internal and external norms and standards. Anenergy benchmarking analysis generates two important perspectives; it providesan overview of how well a particular industry sector or sub-sector is doing inmanaging energy performance. Second, it enables company participants toperform a benchmarking exercise to compare the performance of their ownplant(s) with the overall industry indicators.2.1 Approach adopted in benchmarking studyCII –Godrej GBC has prepared a detailed questionnaire involving all sectionalparameters starting from crusher to packing plant. The questionnaire has beensent to more than 140 cement factories to fill-in the data. The majority of plantsfrom all over India have participated in this benchmarking study and differentparameters are recorded in various sections from the data provided by the plants.This study describes work with the Indian cement industry to provide a plantlevel indicator of energy efficiency and equipment efficiency for plants thatproduce a variety of products, including ordinary Portland cement (OPC),Portland pozzolana cement (PPC), Portland slag cement (PSC) and otherspeciality cement products.Benchmarking provides a more detailed comparison of a particular aspects ofoperations i.e., energy efficiency, equipment productivity and environmentalperformance.The following specific indicators are compared in the benchmarking study.¾¾ Specific thermal energy¾¾ Specific electrical energy in each section¾¾ Equipment efficiency¾¾ Equipment productivityEnergy Benchmarking for Cement Industry7
¾¾ Equipment reliability¾¾ Auxiliary power consumption in captive power plantThe cement industries who wish to have an annual or periodic comparison ofkey performance indicators across the range of cement industry will find thisbenchmarking study extremely helpful. The idea of benchmarking study isnot only to identify the opportunities to improve energy efficiency but also tounderstand the underlying factors that impede the implementation of the energyconservation opportunities.To address these challenges, CII-Godrej GBC has started a comprehensivebenchmarking study. This benchmarking exercise will answer all typical questionswhich revolve in the minds of plant team:¾¾ What is my plant’s energy performance?¾¾ How can I compare to others in the domestic industry?¾¾ What are the reasons for the differences?¾¾ What opportunities for improvement are available?¾¾ What are the parameters to be monitored?¾¾ What is the potential economic advantage that might be realized?Finally this report describes the basic concept of benchmarking and the statisticalapproach employed, more recent experience gained in developing performancebased energy indicators for the Indian cement industry.8Confederation of Indian IndustryCII-Sohrabji Godrej Green Business Centre
Energy Benchmarking for Cement g filterFan--0.380.7510-124307.9 50 mm:40.50%Product sizemediumSinglePlant 2softSingleCrusher MD-Materialhardness0.70-No. of stagesPlant 1SpecifickW / MTpower conLimestonesumptionunitParameter3.1 Single stage crushersCHAPTER-3-0.450.841909 150 mmhardSinglePlant 30.10.440.92 164380hardSinglePlant 4-0.531.020.5-1.01245-0.671.204-69005 % on50MMhard 5SingleSinglePlant 6medium/hardPlant 5-0.461.32 41550100%passing 50mmhardSinglePlant 7BENCHMARKING IN VARIOUS SECTIONSSinglePlant 9-0.491.330.5-1.01800 5-10-0.361.442-312960medium/mediumhardSinglePlant 8-0.591.83 118780hardSinglePlant 10
10Confederation of Indian IndustryCII-Sohrabji Godrej Green Business Centre----Total(Crusheralone)Pre ---0.85Plant 10.730.350.3800.47Plant 20.84---1.08Plant 30.92-0.920.050.12Plant 41.02-1.02--Plant 51.20-1.20--Plant 61.32----Plant 71.33-1.33--Plant 81.44-1.44--Plant 91.83-1.830.07-Plant 10
Energy Benchmarking for Cement Industry11------Crusher MDBag filter FanCompressorTotal (Crusher alone)Pre BlendingOverall0.650.20---0.450.65Specific power consumption13%kW / MT LimestoneMaterial moisture95015%TPH%Product sizesofttwoPlant 1Operating output--Material hardnessunitNo. of stagesParameter3.2 Two Stage Crushers0.910.26--0.650.9111 to 130.94----0.600.941716 90mm6.5 % retainedon 75 mmscreen750hardtwoPlant 3mediumtwoPlant 21.230.0341.1960.0370.0470.871.23 2.0475NilsofttwoPlant 41.59----1.201.591295 25mmhardtwoPlant 52.35--0.1500.2001.702.351182nilmediumtwoPlant 6
12Confederation of Indian IndustryCII-Sohrabji Godrej Green Business CentreTPHOperatingoutputKg/ m3Sep loadingSEC%False air inthe mwc32020Plant 1Mill fan flow km3/hrMill modelMill DP%%Product sizeFeed Material moisture-UnitMaterialhardnessParameter3.3 RAW MILL-VRM20-25150-1702050480LM 46.4LM30.3 3340-350750229011 -12hardPlant 3900-9301-3225-23016-17mediumPlant 20.5025900800ATOX42.56001340018softPlant 4680219013.50hardPlant 620507652850395Atox 42.5 LM32.40480233011 -12hardPlant 5480-5301276.520-22mediumPlant 8500 -5502-329218mediumPlant 94000.5-1.028518.5-19.5medium /hardPlant 100.5417120745.90.5515806000.4515-1890-110620 to 6400.3815-1860-70757ATOX AM - R–5045, 4.5Ф(TD: 5mUM 50.4 ATOX-45and 3 Nos RD: 3mRollers-3Rollers)750140321Plant 7
Energy Benchmarking for Cement Industry136.40.913.3Mill fanAuxOverallPlant 16.0UnitMill driveParameter13-143.0-3.56.2-6.53.5-4.0Plant 213.81.676.056.1Plant 315.01.87.75.5Plant 415.91.937.76.3Plant 516.02.57.06.5Plant 616.01.15.69.2Plant 717.11.666.09.5Plant 818.01.717.29.1Plant 921.21.927.311.8Plant 10
14Confederation of Indian IndustryCII-Sohrabji Godrej Green Business Centre%m/secDia x3.00 x 10.00 No ball milllengthFeedMaterialmoistureVelocityinside millMill specCyclonepressuredropmmwcSep fan flow m3/hrTPH120-1.1 – %11-15Plant 2Product sizehardPlant 1-unitMaterialhardnessParameter65-75-4.20 x14.078.6 1.5180-18513.0 – 15.0softPlant 33.4 Raw Mill - Ball Mill/HPRG Grinding1.5112920-22mediumPlant 51.91-5245-25531-3311-15Plant 61.817012.013.4Plant 71.56.88040.0hardPlant 82.5-3.11-5165-17522-2411-15Plant 990-11045000035--125000--350-Sep inletto Cycloneoutlet:300174000TUM 2.4KPP5.0 x 8.75 xR1&2: 3.8 x 9.5 FKCP 4.6x11.259.75 2.40850/173.4x12 & (Closed Cir- 0.3 ( drying50, ID 4.61500-1730(dryingR3: 3.4x7.6cuit)chamber)metres, ODx1500-S-Cchamber)5.06 m-3-524018.0mediumPlant 4
Energy Benchmarking for Cement Industry15----m2/ MTSep loading Kg/ m36.27.5-0.2Mill driveRPMill Sep fanMill ventfanSEC-5.58.5--% sep ventvolume--Circulatingload-Grindingmedia surface area-gmPlant 2Grindingmedia piecewtPlant 1unitParameter1.81.4-12.7-198%20.31450Plant 3--10--5.251.04--Plant 40.61.5-18.5-1.9NA-310Plant 5-0.73.813.5-2633.5-4--Plant 6---17.9-2.5NA20.61325Plant 7-2.8-18.9-4.12.119.3-250212 nt 91.126.27800Plant 8
16Confederation of Indian IndustryCII-Sohrabji Godrej Green Business CentreOverall16.5-Sep fan forRPPlant 13.1unitSept ventfanParameter16.8 - 17.5-Plant 217.9--Plant 318.04-Plant 420.6--Plant 520.9 - 21.2-1.9Plant 623.1--Plant 725.1--Plant 825.5 - 26.3--Plant 9
Energy Benchmarking for Cement Industry17VRMPlant-2VRMPlant-35.93.523.9Mill fanAuxTotal portedCoal 30 %ImportedCoal 100 % Indian Coal Coal 100 %70%VRMPlant-114.5kW/MTTPH%UnitMill DriveSECMill OutputCoal CompositionMill TypeParameter3.5 Coal Mill29.32.911.914.581Petcoke 40%, IndianCoal 30 %,Importedcoal 30 3.125Imported Petcoke 100indian%VRMPlant-537.66.019.212.425Pet cokeVRMPlant-740.97.418.415.114Petcoke 100%VRMPlant-8
18Confederation of Indian IndustryCII-Sohrabji Godrej Green Business CentreUnitPlant 1KILN outTPD4500put ratedKiln outputTPD4670operatingPH typeILC / SLCILCNo of PHSinglestringsCalcinerexit O2 /%1.8 /0.01COPH exitDeg C260tempNm3/kg1.39PH exit flowclinkerPH exitmmwc380pressurePressure atmmwc395PH fan inletFalse air%4across 046003200Plant-44000Plant 34000Plant 23.6 COMPARISON OF Five Stage Preheaters6-560-5401.50338SingleILC44003850Plant 5135905201.433150.9 O2SingleILC43003800Plant 613570-1.783181 O2SingleILC13001200Plant 7SingleILC32503150Plant 997807601.613204-820-7601.653101.99/ 0.84 4.5/NILSingleSLC28002800Plant 8106506401.48-1.51320-3302.1SingleILC26502800Plant 10
Energy Benchmarking for Cement Industry1930RABHmmwcVolumetricTPD/ m3loadingThermalMkcal / hrloading/m2DiaxlengthRABH100mmwcKiln size-602.25.84.04.23.95 x 655.64.35 x 6790-1202.0VFDMV VFDNm3/kgclinkerGRRVFDPlant 2Speedcontrol forPH fanSpeed control for KilnBag housefanKiln Baghouse fanflowKiln Baghouse DPKiln Baghouse inletpressureKiln Baghouse typePlant 1UnitParameter4.97.04.15 x 64RABH50100-1103.35.03.95 x t 35.85.73.95 x 62RABH-6090-1202.5VFDVFDPlant 55.07.03.95 x 61RABH551252.4GRRGRRPlant 62.64.33.2 x 48RABH601203.3VFDGRRPlant 72.24.53.8 x60.75RABH30-35125-1351.8VFDGRRPlant 84.66.53.75 x 57ESP-102282.4DC DriveSPRSPlant 93.15.23.8 x 56ESP-40-552.2DampercontrolGRRPlant 10
20Confederation of Indian IndustryCII-Sohrabji Godrej Green Business CentreCooling airflowClinkertempCooler water sprayLoss in PHgasType ofcoolerPhase density – PCfiringPhase density – KilnfiringParameter1.2kg coal /kg air1.02.0Plant 21.14.2Plant 32.62.7Plant-41.71251.2126Nm3/kgclinkerDeg Cm3/hrkcal / kgclinker1785.51651.7161-1401.71844.51202.2SF CROSSBAR3rdCOOLERCIS/CFGgeneration3rd gen- / WITHGRATE(SF CrossSTATICerationCOOLERBar Cooler/ 3RD4 *5)GENERATION2.4Plant 1kg coal /kg airUnit1826.01731.93rd generation2.33.1Plant 514014.01801.8(3x5)SFCross BarCooler1.25.5Plant 61853.71702.2GrateCooler1.42.5Plant 72.01.4Plant 91.42.9Plant 101765.0120- oss ROCATGrateINGBarWith CISCooler GRATEMFR(10x48) (KHD)57.45 m21.93.3Plant 8
Energy Benchmarking for Cement .65.4-1.391.680.3916.2849.94kcal / kgclinker312516.07299Plant 25.0kcal / kgclinkerkcal / kgclinkerLoss inCooler ventLoss inclinkerLoss incooler watersprayThermalSECSECPH fanRABH fanCooler fansCooler ventfanKiln driveKiln feedAuxClinkerisationUpto clinkerisationPlant 1kcal / 83.04.8715-3985Plant 23.001.692.97-0.208.23.55.072921.03273Plant nt nt 87Plant 859.6328.631.501.006.090.2410.92.95.9737-3067Plant 0-115Plant 10
22Confederation of Indian IndustryCII-Sohrabji Godrej Green Business CentreTPDKiln outputoperatingmmwc%Pressure at PHfan inletFalse air acrossPHSpeed control forPH fanmmwcPH exit pressureSPRS2-505601.67PH exit flowo245PH exit tempC2.0-2.1%Nm3/kgclinkerSingleCalciner exit O2/ COILC50003800Plant 1No of PH stringsILC / SLCTPDKILN outputratedPH 03300Plant 23.7 COMPARISON OF Six Stage 0Plant 3VFD15600480-5501.60270-2801.5-2.5/ 0 to0.02DoubleILC5750-60005500Plant 00Plant nt 5588000Plant7
Energy Benchmarking for Cement Industry23mmwcKiln Bag houseinlet pressurekg coal / kg airkg coal / kg airPhase density –PC firingPhase density –Kiln firingThermal loading Mkcal / hr /m2VolumetricloadingKiln sizeTPD/ m3mmwcKiln Bag houseDPKiln Bag housetypeNm3/kgclinkerunitKiln Bag housefan flowSpeed control forKiln Bag housefanParameter---3.944.33-5.24.15 x 64LRABH-25-1202.1SPRSPlant 27.04.55 x 56LRABH-60 to -70110-120450000455000SPRSPlant 1--4.337.04.55 x 56LRABH-60 to -70120-140450000455000SPRSPlant 31.8-2.22.8-4.04.1-4.35.3-5.64.75 x 74LPulse jet90-11090-1302.1-2.2VFDPlant 42.03.03.5-4.07.0-7.24.75 x75LRABH45100-1202.0-2.5SPRSPlant 52.85.674.25.54.15 x 64LRABH-80120-1502.2VFDPlant 61.52.53.05.05
Energy Benchmarking for Cement Industry 3 CHAPTER-1 INTRODUCTION 1.0 Indian Cement Industry Present Scenario India's cement industry plays a vital role in the growth and development of the nation. The cement industry has been expanding with increasing infrastructure activities and demand from residential buildings over the past many years .
Mar 01, 2008 · MSDS: Lafarge Portland Cement Material Safety Data Sheet Section 1: PRODUCT AND COMPANY INFORMATION Product Name(s): Product Identifiers: Lafarge Portland Cement (cement) Cement, Portland Cement, Hydraulic Cement, Oil Well Cement, Trinity White Cement, Antique White Cement, Portland Cement Type I, lA, IE, II, 1/11, IIA, II
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3.2.3. Cement Industry Clinker Process and Electricity Use 3.2.4 Fuel Use and Total Energy Consumption in the Cement Industry 3.2.5 Cement Industry Pollutant Releases: CO2, NOX and Toxics 3.2.6 Cement Industry Waste Management 3.3 Regulatory Structure for Waste and Emissions Management 3.3.1 Emission Controls 3.3.2 Cement Kiln Dust Management
Bad benchmarking Benchmarking has its limitations. Whilst good benchmarking is about performance and best practice, bad benchmarking can lead to mediocrity. Bad benchmarking is using data to justify average performance, rather than challenging and driving improvements. This
CEMENT GRINDING CONSUMES A MAJOR PART OF THE TOTAL ENERGY USED IN CEMENT MANUFACTURING. Higher cement production rate leads to lower specific energy consumption per ton of cement. SikaGrind products increase production rates and therefore reduce energy consumption. As not all cement plants and systems are the same, the best type and amount of .
Effect of Fineness on Hydration of Cement: 1. When the fineness of cement is more i.e. the size of cement particles is very small; then the all the cement particles gets covered with water film easily. Hence the hydration of cement takes place very quickly with added water. 2. When the fineness of cement is less i.e. the size of cement
10 tips och tricks för att lyckas med ert sap-projekt 20 SAPSANYTT 2/2015 De flesta projektledare känner säkert till Cobb’s paradox. Martin Cobb verkade som CIO för sekretariatet för Treasury Board of Canada 1995 då han ställde frågan
Agile software development with Scrum is first introduced with its elements. Next, we use three development process lenses (communication, coordination, and control) to study how Scrum supports each of development processes, how they are related each other, and how they affect the performance of Scrum. In the following section, we analyze Scrum practices from social factor theories (social .
