Vasavadatta Cement Sedam

Unit Profile :
Vasavadatta Cement is the 2nd green field project of Kesoram Industries, Located in the
district of Gulbarga, 3 Kms., away from Sedam town. The Line-I Cement Plant was conceived
in the year 1983-84 and commercial production was started in the year 1986.and line –II went
in to the strem in 1997 The both Line-I & Line-II plant are supplied by world known plant
supplier M/S KRUPP POLYSIUS, GERMANY and their counterparts M/s KRUPP
INDUSTRIES INDIA LTD. The present capacity of Line-I & Line-II is 2.00 MTPA of cement.
This is based on dry process Pre-Calciner technology and the major equipments of the plant
include single stage Hazemag impact crusher for Limestone crushing, Stacker-Reclaimer for
preblending/homogenisation/transport of crushed limestone, Polysius Vertical Roller Mills for
Raw Meal & Coal grinding, Single Continuous Blending Silo for storing Raw meal, Rotary Kiln
for Clinkerisation, Aumund’s Deep Pan Conveyor for Clinker transport, closed circuit mill for
cement grinding and two electronic packers for despatching Cement.
With 16.2 MW Captive Thermal Power Plant was commissioned in 1997 & 9.5 MWCaptive
power plant commissioned in the year 2005.
The Unit manufactures 43Gr OPC,53Gr OPC & Fly ash based Blended Cement(PPC).
Cement being highly Energy Intensive Industry, Conservation of Energy has been a Constant
Endeavor at Vasavadatta Cement with Continuous monitoring Energy Consumption, Periodic
Energy Audits so Vasavadatta Cement is developing as a World class Cement.
The trend of Specific Energy Consumption in past Three years & Current year trend of
Line –1 & Line –2 (L-1&L-2) are given below :

2003-2004 2004-2005 2005-2006

Description Unit
Annual Cement 2042518 2131050 2075870
Production MT
L-1 L-2 L-1 L-2 L-1 L-2
Sp.Electrical Energy Kwh / Ton of 78.82 76.41 75.94 77.87 80.90
Consumption. Cement 74.72
 Sp.Thermal Energy K.cal / Kg of L-1 L-2 L-1 L-2 L-1 L-2
Consumption. Clinker
715 715 708 709 712 712

Current year trend of Sp.Electrical & Sp.Thermal Energy : ( 2003-04 Up to August )

L-1 L-2
Sp.Electrical Energy :
(Kwh/Ton of Cement.) 76.00 76.00

Sp. Thermal Energy 708 708

(K.Cal / Kg of Clinker)

VASAVADATTA CEMENT

ENERGY POLICY

We are committed to Conserve Energy in Cement

Manufacturing, Power generation process and related
activities by Efficient use to Preserve Environment and
to save Natural Resources.

Objectives:
¾ Awareness & Training to Employees for Encon with
Philosophy “Energy Saved is Energy Produced.
¾ Periodic Energy Audit, Continuous Monitoring, Review of
Targets And Bench marks for Energy consumption.
¾ Identify the Potential areas & Equipments for Energy
Conservation.
¾ Implement Innovative Ideas/Modifications, Improvements & Up
gradation of the Equipments.
¾ Process Optimization & Diagnostic Studies to maintain High
productivity & Capacity Utilization To minimize the Sp.Energy
Consumption.
¾ Utilization of Cheaper And other Renewable Energy sources.
¾ Explore utilization of waste & Hazardous material as alternate
source of Thermal Energy.

ENERGY MANAGEMENT SET UP:

 The Energy management set up involves three groups i.e. Top level, Middle level & Bottom
level.
Top group: indicates the involvement &
Commitment of Top Management. This
includes:President, JP(Engg. ), G.M.( P& QC).
This group provides Encouragement, support,
Top Guidance & Resources.

Middle Group: includes “Energy Manager” and

Middle all Departmental Heads .

Working Group: includes the Persons from

Working (Mech) & Electrical
Operation, Maintenance Elect The main functions are :

To Monitor the Process & Power

Consumption. To identify the Problems &
Saving potentials. To Carry out Process
Diagnostic Studies for Optimisation of the
plant Operation.

The Process Parameters are closely monitored for various systems this includes : Gas flow
measurements, Circuit sampling for Particle size distribution, Heat Balance for Kiln system &
Circuit Velocity & Pressure profiles.
This Exercise on regular basis helps us to identify the Saving Potentials / Problems.
Any abnormalities found are brought to the Notice of G.M. ( P& QC). Points are discussed in
the daily HOD’s meeting & same are rectified on top priority with help of Section In charge.
The Energy Conservation Proposals / Modifications duly authenticated by : Data, Drawings,
Values & Expected savings after implementation are submitted to President for approval.
Once the proposal is approved, the equipments / Instruments are purchased and the same is
being implemented.

Developing the VASAVADATTA CEMENT as a world-class cement unit in association with CII
energy score concept is under development for each area & machine

Vasavadatta cement for making overall improvement in the plant started implementing TPM in
1998-99 & prepared around 900 benchmark parameters for improvements. Out of which , all the
sectional power for each section were also made as bench mark parameter.

Targets are fixed for achievement every six months & overall Goal is fixed for two years.

Monthly presentation for review is held in all departments for achievement on bench mark.

Every six month targets & goals are relieved all HOD & senior officers in presentation held by TPM
secretariat.

Bench mark of major parameters is made an IS/ISO-9001:2000 document.

On regular basis comparison is being done between power consumption of unit-I & unit-II for
improvement.

On regular basis comparison of power of various section of other units are compared & being used
as a goal to improve. In this respect regular conference is being held between three units of
Kesoram Industries & cement units owned by B.K. Birla group of companies, where it is discussed
how to improve power consumption in the plant.

Regular audit by reputed organization like CII, is being conducted to find out the potential of energy
saving areas for improvement.

All the vendors interested in bringing new technology & product of power improvement are
encouraged to give presentation in our plant & if found useful, trials are being taken.
Based on our performance on power M/s CII has selected our plant as a model plant to develop it,
as a World-class unit. Order for first phase of implementation is placed on M/s CII , & same is under
implementation . During course of implementation, every score for each & every section, machine
will be created, based on National /International benchmark for improvement.

EXTENT OF TEAM WORK IN ENCON.

1. Awareness & Training To Middle Management, Supervisors, & Work men By Top Management
For Energy Conservation With Philosophy “Energy Saved Is Energy Produced “
2. Periodic Energy Audits, Continuous Monitoring, Review Of Targets & Bench Marks For Energy
Consumption Done By Top Management.
3. Identification of Potential Areas & Equipments For Energy Conservation.
4. Encouraging Employees for giving Suggestions towards Energy Conservation.
5. Comparing Energy Consumption Of Other Plants Time To Time.
6. Looking For Latest Technologies & Implementation.
7. Continuous Study of Operating Parameters to avoid deviation.
8. Time-To-Time Technology Up gradation.
9. Regular In Plant Training For The Employees.

MONITORING AND REPORTING SYSTEM

Power monitoring being done on Hourly / Weekly / Monthly / Quarterly / Half yearly / & Yearly basis
Joint president JP (Engg.)/Energy manager head energy conservation cell, under whom there is
one technical cell headed by GM ( P& QC ) . Technical cell helps in monitoring process parameters
for various equipment. HOD’s make energy conservation proposal duly authenticated by data & the
same is being submitted to president for approval.

Once the proposal is approved, equipments are being purchased & modifications are implemented.

Frequency of review of energy consumption is Daily / Monthly / Quarterly / Half yearly / & Yearly

ROLE OF ENERGY MANAGER

1. Overseeing the formulation and implementation of an energy policy.

2. Introducing and maintaining cost – effective ways of providing management

information about energy consumption and attendant environmental pollution.

3. Reporting such information appropriately and regularly to the staff accountable for
this consumption and to senior managers.

4. Introducing and Maintaining efficient and environmentally benign policies and

practices for the purchase and combustion of fuels.

5. Raising and maintaining energy awareness throughout your organization.

6. Introducing & Maintaining effective “good house keeping” and plant operating
practices throughout your organization.

7. Identifying your Organization’s training needs for energy – related skills and
understanding.

8. Identifying cost – effective opportunities for increasing energy efficiency whether in

new or existing premises.

9. Formulating an investment program for reducing energy consumption and

environmental pollution.

10. Introducing and Maintaining review procedures for establishing the value for money of
energy management activities, both to top management and other relevant staff.
PROPOSED MODIFICATIONS FOR THE YEAR 2006-2007 FOR ENERGY
CONSERVATION AND BETTER ENVIRONMENT

• VFD fitting for CWP-III of unit-I

• Acoustic enclosure for Unit-I TG.
• 2 Nos. 7.5 KW VVF drives ordered for main firing & pc firing of coal dust conveying
system.
• Installation of SPRS System for unit-1 raw mill fan motor.
• Installation of additional capacitor bank in LC1/2 for improving the power factor
• Instillation of SPRS for ESP fan of line –I
• SQ- controllers for ESP chambers

2000 KW SPRS DRIVE FOR ESP FAN

Background study:

Earlier there was no SPRS for ESP fan. The fan RPM was controlled by the GRR
system & the damper>

Observation made:

There was very high GRR losses & the fan RPM variation was in step wise not as per
the requirement.

Technical & Financial Analysis:

We have installed the 2000KW SPRS to the ESP fan

Impact of Implementation:

As per the requirement the fan RPM is varied ( According to the draft required)
90 KW power saved per hour
90 X 24 = 2160 KW / day
2160 X330 days = 712800 KW

Money Saved

712800 X Rs 2.50 = 1782000 / annam

GCT COMPLETE SHELL REPLACEMENT

Background study:
Heavy false air entry in the system leading to higher power consumption of pre heater fan

Observation made:
Existing shell found rusted at many places due to which there was heavy false air entry.

Technical & Financial Analysis:

Complete GCT shell was replaced with new one along with insulation

Impact of Implementation:
False air entry to the system is reduced
Power consumption of pre heater fan reduced by 30 Kw
20 X 24 X 330 X 2.5 = 396000 / Annam
 INSTALLIATION OF LNV CLASSIFIER FOR COAL MILL – II

Background study:
During the kiln higher feed the coal mill out put was not sufficient to maintain the bins. If at all
mill out put increased by varying the static separator the residue will increase

Observation made:
There was no margin to increase the mill out put by maintaining the coal residue

Technical & Financial Analysis:

LNV Classifier was installed to enhance the mill out put along with keeping the residue under
control

Impact of Implementation:
Mill out put increased by 2 TPH
Fine coal residue was controlled
Kiln out put will not affected for fine coal level low

ENERGY SAVING & OPTIMZIATION OF THE COMPRESSED AIR SUPPLY BY

INSTALLING CONTROL AIR SYSTEM

Background study:
High power consumption of pre heater compressors

Observation made:
Compressors are running individually in De-centralized mode in pre heater –I & II. Hence,
enable to optimize the air consumption & to maintain header pressure at precise value. So
saving of energy was not possible.

Technical & Financial Analysis:

Installed the control air system on the basis of Audit report

Impact of Implementation:
Power consumption reduced as
In pre heater –I compressor house - 10.45 % of Existing power
- 13.51 kwh
In pre heater –I compressor house - 24.06 % of Existing power
- 12.41 kwh

Total saving ( Rs) - 13.51 + 12.41 ) * 24* 330*2.5

- 517320 / Annam

INSTALLED ONE WATER COOLED AIR COMPRESSOR IN CEMENT MILL - II

Background study:
Higher air consumption in cement mill –II because of it the maintiance & spares cost was
increasing

Observation made:
Existing model air ( two ) cooled compressors are meant for intermittent operation only. Due
to increase in air consumption they are running continuously. Hence spares consumption &
maintenance cost increased.

Technical & Financial Analysis:

Installed one water cooled (available) compressor with suitable capacity & stopped the air
cooled compressor and kept as stand by

Impact of Implementation:

Man power cost : Rs 5000 / Annum

Spares cost : Rs 35000 / Annum
 Total saving : Rs 40000 / Annum

REDUCTION OF NOZZLE RING VELOCITY AT RAW MILL-I

Background study:
Very high nozzle ring velocity at the raw mill-I was abstraction to increase the feed rate &
residue of product was on higher side.

Observation made:
Keeping all the nozzle open the mill was running with velocity of 73 – 75 m/sec but to have a
better operation, with good feed rate velocity recommended was 65 – 66 m/sec . so to get the
said velocity there was no margin in nozzle blocks as all the nozzles are in open condition.

Technical & Financial Analysis:

With consulting our OEM’s we have cut the partition plates of each nozzle, by doing this the
nozzle area increased by 0.058 m2

Impact of Implementation:
Mill nozzle velocity decreased by 6.0 m/sec
Mill out put was incressed by 5 TPH

INVESTEMENT : Nil

INTRODUCTION OF SECONDARY CRUSHER

Background study:
The raw mill out put was not getting enough to fulfill the needs of kiln feed due to higher size
of lime stone.

Observation made:
The input size of lime stone for VRM’s is – 80mm , to further optimize the mill capacity
proposed to use – 50 mm size feed which was not possible in the existing crusher.

Technical & Financial Analysis:

It was descided to introduce the secondary crusher along with the main crusher.

Impact of Implementation:
Main crusher out put size increased to - 100 mm, & hence the blow bar life increased by 30 %

Getting almost – 50 mm size material for VRM’s feed

Mill out put increased by 10 TPH.

Total saving in Rs - 38.5 Lac

INVESTEMENT : Nil
ENERGY POLICY

"We are committed to conserve energy in cement

manufacturing, power generation, process and related
activities by efficient use to preserve environment and to
save natural resources"