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Presentation for 18th National

Award For “Excellence in

Energy Management-2017’’

1

Mangalam Cement Limited belongs to B.K.Birla Group

of Companies. Our first Plant was commissioned in the

year 1981, with an installed capacity of 4 lacs tons of

cement per annum.

Present capacity of cement production is 3.25 MTPA.

2

COMPANY PROFILE

3

COMPANY PROFILEUNIT-I UNIT-II UNIT-III CPP WIND MILL

CRUSHER TO

PACKING PLANT

CRUSHER TO

PACKING PLANT

NEW CEMENT

GRINDING UNIT &

PACKING PLANT

2 X17.5

MW

13 Nos WIND MILLS

OF 13.65 MW CAP.

INSTALLED AT

JAISALMER (RAJ.)

FLS, KILN 3000 TPD

WITH SIX STAGE

PREHEATER, INLINE

CALCINER,SF 12X33

CROSS BAR COOLER,

ATOX VCM and ATOX

VRM.

THYSSENKRIPP, KILN

4000 TPD WITH 5

STAGE PREHEATER,

INLINE CALCINER,

REPOL SR 312-IKN

GRATE COOLER,VCM

and VRM

THYSSENKRUPP,

CEMENT MILL 1.25

MTPA

ABL, CEMENT MILL

WITH VRPM AS

PREGRINDER IN

CLOSED CKT, LNV

SEPARATOR,

CAPACITY 0.8 MTPA.

THYSSENPRUPP

ROLLER PRESS,

CEMENT MILL WITH

ROLL PRESS IN

CLOSED CKT.

CAPACITY 1.2 MTPA

THYSSENKRUPP

ROLLER PRESS,

CEMENT MILL WITH

ROLL PRESS IN

CLOSED CKT.

CAPACITY 1.25 MTPA

S.No. Year Description of measures Saving in

TOE FY

01 2015-16 Implementation of auto start/stop software logic

in both compressor.26.43

02 2015-16Implementation of software logic in both bag

filter fan (G581FN1 & G581FN3) for auto stop

of bag filter fan.

19.51

03 2015-16 Logic made in PLC for auto start / stop of

heater.

5.34

04 2015-16 Changed loading pressure setting from 6 bar to

5.5 bar and unloading pressure setting from 7

bar to 6.5 bar of all 4 compressors of MGU

packing plant.

97.56

6


TOE FY

05 2015-16

After optimisation of lighting system 44 Nos

400 watt light fittings were removed from

different towers.

20.73

06 2015-16 Bag house discharge material taken directly to

final air slide via direct chute.

12.57

07

2015-16Bag filter fan inlet damper controlled & tuned

from CCR with fan current to save the power of

fan.

21.94

08

2015-16Electrical consumption reduced by controlling

ESP field current as per dust emission through

stack.

29.52

7


TOE FY

09 2016-17 Sealed false air from 37.0 % to 23.3 % in Coal Mill-I,

resulted in power saving of power Coal Mill Fan.23.54

10 2016-17 Sealed false air from 56% to 42.5 % in Coal Mill-II,

resulted in power saving of Coal Mill Fan. 32.51

12 2016-17Sealed false air from 28.0 % to 14.2 % in VRM-I

Circuit, resulted in power saving of VRM Fan.67.46

13 2016-17 Improved Power Factor in Kiln-II PCC Incomer 6.6 KV

from 0.85 to 0.95 .8.69

8

S.No. Year Description of measures Saving

in TOE

Investment

in lacs

01 2014-15Kiln-II: Duplex Graphite Lemmela Seal

Installation in place of Pneumatic Seal to

reduce false air entry.

450 13.20

02 2014-15 CM-II: Installation of DD Cones in all the

four Sepol Cyclones to reduce pressure

drop and replacement of double flap valves

by RALs to reduce false air ingress.

37 7.11

03 2014-15 Replacement of push feeder by sector

gate in Cement Mill-2. 9.87 5.00

04 2014-15Removal of two belt conveyors from LS

feeding circuit of VRM-1 by providing direct

chute to hopper.

35.62 0.50

9


in TOE

Investment

in lacs

05 2014-15

Installation of de dusting cones (DD

cones ) in LNVT separator of VRPM and

both the cyclones of SEPOL separators in

Cement Mill-1.

58.92

2.20

06 2014-15 Installation of de dusting (DD) cone in

dynamic separator of VRM -1.92.79 1.75

07 2015-16

Made a Dam of height 800 mm in TAD to

restrict Tertiary Air flow rate and to reduce

excess air in secondary firing from 20 % to

10 %.

102.21 5.00

08 2015-16

Removed Silencers from all the cooler

fans to reduce the pressure drop ranging

from 60-150mmWG in all cooler fans of

KILN-1.

141.14 0.05

10


in TOE

Investment

in lacs

09 2015-16 Filler material feeding arrangement by PS

pump in place of dense phase.105.26 1.00

10 2015-16Enlargement of Cooler Exhaust Duct Area

from 4.91 m2 to 9.62 m2 to reduce dust

loading in ESP KILN-2.

12.45 1.20

11 2015-16Enlargement of Preheater Down comer

Duct from 5.72 m2 to 10.00 m2 IN KILN-2.168.41

23.35

12 2015-16 Increase of Calciner Length from 48.0

meter to 64.0 meter IN KILN-2.194.63 66.12

11


in TOE

Investment

in lacs

13 2015-16

Increase in cross section area of Tertiary

Air Duct (TAD) from 1.61 m2 to 3.36 m2

in KILN-2.

1550.27 42.55

14 2015-16

Enlargement of Smoke Chamber Area

from 4.74 m2 to 6.51 m2 in KILN-2. 62.33 4.09

15 2015-16

Increase of Inlet Duct Area of Bottom

Cyclone from 9.92 m2 to 13.03 m2 in

KILN-2

.

37.98 5.00

16 2015-16 Enlargement of Take off Duct Area from

5.58 m2 to 8.20 m2 in KILN-2.

19.21 9.15

12


TOE FY

Investment

in lacs

17 2015-16

Replacement of Kiln Inlet Seal from

Pneumatic Seal to Graphite Seal in

KILN-1.

165.31 5.00

18 2015-16

Replacement of belt conveyor

501BC3 & fixing of DPC of 150TPH

in KILN-1.

77.05 44.60

19 2015-16

Through modification of discharge

chute of 903BC5 lime stone fed in

hopper directly without running of

961BC1 and 961BC2 belts in KILN-

1.

50.73 7.78

20 2015-16Installation of auto delta to star

starter in G501BC6 & BC7

conveyor belts drives.

9.76 0.01

13


TOE FY

Investment

in lacs

21 2016-17

Reducing the preheater exit oxygen

from the level of 7% to 4% for

Kiln-I by restricting excess air flow

through TAD.

301.95 10.00

22 2016-17

Reduced the pressure drop through

modification in the separator fan

inlet duct of Cement Mill-3.

58.5220.00

23 2016-17 Installed VFD for 975BL1 (132kw)

root blower in KILN-1.21.28 8.00

24 2016-17 Installed VFD for 212FN2 (75kw) BF

fan in crusher section.22.04 5.00

25 2016-17 Replacement of chain type elevator

150 TPH by belt bucket elevator of

250 TPH in KILN-1.

85.12 30.00

14

15

85.61

82.55

78.23

80.74

78.27

75.44 74.73

73

78

83

88

2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17

kwh/ton of cement

*

* Unit-I, Plant shutdown for Rehabilitation work

16

869860

803

716 709699

760 765 764

755 748738

798781

773

739731

720

680

720

760

800

840

880

2011-12 2012-13 2013-14 2014-15 2015-16 2016-17

THERMAL SEC (GCV BASED)

KILN-I

COMBINED

KILN-II

National

Benchmark

International

Benchmark

Mangalam

Cement Limited

Specific Energy

Consumption Thermal

(Kcal/kg of clinker) (GCV

BASED )

680 650

KILN-I 699

KLIN-II 738

COMBINED 720

Specific Energy

Consumption Electrical

kWh/T of cement (Actual)

(100% PPC)

68 65

66.55

(ON PPC ONLY)

(YEAR 2016-17)

17

LOW DUE TO CABLE

THEFT PROBLEM

18

6.20%

8.30%

11.50%

10.20%

7.60%

8.90% 8.56%9.32%

4.00%

6.00%

8.00%

10.00%

12.00%

2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17

% OF WIND MILL POWER IN TOTAL POWER CONSUMPTION OF PLANT

Wind Power for Captive Use 2016-17 = 163.6 Lacs Units

So Saving in Mkcal = 53194.54 Mkcal

Saving in TOE = 5319.45 TOE

19

15.35%

26.05%

27.47%

31.11% 30.57% 31.08%

10.00%

15.00%

20.00%

25.00%

30.00%

35.00%

2007-10 2012-13 2013-14 2014-15 2015-16 2016-17

FLY ASH CONSUMPTION IN %

20

RE

DU

CT

ION

CO

2 E

MIS

SIO

N

Kg

/Kg

PP

CC

EM

EN

T

CO

2R

ed

uc

tio

n in

to

n

CO2 REDUCTION DUE TO HIGHER CONSUMPTION OF FLY ASH

IN PPC WITH REFERENCE TO 2011-12

18004

33551

66421

78055

15495

0.56000.5500

0.50640.4973

0.4962

0

10000

20000

30000

40000

50000

60000

70000

80000

90000

0.46

0.48

0.50

0.52

0.54

0.56

0.58

2012-13 2013-14 2014-15 2015-16 2016-17

CO2 Reduction in Tonne CO2 Emission, Kg/Kg Cement

Highest ever PPC Production

Less reduction due to less PPC

Production.

21

16.90%

18.10%

12.50%

10.20% 10.50%9.50% 9.56% 9.33%

6.00%

8.00%

10.00%

12.00%

14.00%

16.00%

18.00%

20.00%

2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17

PETCOKE CONSUMPTION IN % OF CLINKER PRODUCTION

85 % PETCOKE &

15 % INDIAN

COAL USED

57% PETCOKE &

43 % INDIAN

COAL USED

100% INDIAN

COAL USED

100% INDIAN

COAL USED

100% PETCOKE

USED100% PETCOKE

USED

100% PETCOKE

USED96.4% PETCOKE ,

1.4 % INDIAN COAL

& 2.2 % US COAL

USED

22

16.14%

17.01%

10.80%10.22%

13.45%

9.40% 7.95%9.02%

7.00%

9.00%

11.00%

13.00%

15.00%

17.00%

19.00%

2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17

BY USING PETCOKE REDUCTION IN % HGLS CONSUMPTION

23

SR.

NO

MEASURES TAKEN FOR

CO2 REDUCTION

2012-13 2013-14 2014-15 2015-16 2016-17

1. DUE TO REDUCTION IN

SPECIFIC HEAT AND

POWER CONSUMPTION

OF CLINKER W.R.T.

YEAR 2011-12

4123 14798 49101 48202 59003

2. DUE TO HIGHER USE

OF FLY ASH IN PPC

PRODUCTION W.R.T.

YEAR 2011-12

18004 33551 66421 78055 15495

3. DUE TO USE OF GREEN

POWER (WIND MILL

POWER FOR CAPTIVE

USE)

20367 13960 20477 17524 19638

TOTAL 42494 62309 135999 143781 94136

24

SR.N

O

MEASURES TAKEN FOR CO2

REDUCTION 2015-16 2016-17

1. BY NOT USING VEHICLES ON EVERY

MONDAY WHILE COMING TO OFFICE2.477 2.821

2. BY REDUCING SP HEAT RATE IN CPP27155 37677

TOTAL 27157 37680

27

11715 10432

30047

114868926 10063

2831

0

5000

10000

15000

20000

25000

30000

35000

2011 2012 2013 2014 2015 2016 2017(JAN-JULY)

GREEN BET DEVELOPMENT -YEAR WISE

GREEN BELT DEVELOPMENT

(PLANT, COLONY & MINES)

TOTAL PLANTATION 243967 (1991 TO July 2017)

30

MANGALAM CEMENT LIMITED

REVIEW STATUS OF DEPARTMENTAL OBJECTIVES (Frequency - Monthly)

FORMAT NO. : F02-4460

UNIT : DEPT :

REV : No : VER : No : Date :

Obj No. Objective

Baseline Status Desired StatusFinal Target

Date

MONTHWISE STATUS

2015-16 2016-17 APR-16 TO MAR-17 YTD

Prepared By Approved By :

Checked By

ENCON EFFORTS PLANNED FOR THE NEXT THREE YEARS

34

Sr.

No

Description of projects Investment

Rs

Expected saving

1Installation of WHR in KILN I & II of 8.5MW & expected generation (net) is 545lacs units /year.

Rs 63 CRORES

Thermal energy saving17493 TOE

2Upgradation of KILN II by modifyingpreheater from 5 stage to 6 stage andupgradation of cooler

RS 15 CRORES

40 kcal/kg of clinker

3 Modification in UNIT -II CEMENT MILL V-separator material feeding system for increase in output & reduction in specific power consumption

20.16 LACS 8.88 LACS KWH

4 Modification in lime stone feeding system of VRM -I 10 LACS 3.15 LACS KWH

5 Reduction in plant lighting consumption by using of high efficient led lights in place of conventional lights.

23.3 LACS 10.10 LACS KWH

36

National Safety Award (Mines) 2011 – “ON LOWEST

INJURY FREQUENCY RATE” in the category of Highly

Mechanized Opencast Mines was given by the President of India in association with

Minister of Labour & Employment (Government of India) at Vigyan Bhawan- New

Delhi.

37

CFBP (Council of Fair Business Practices) Jamanalal

Bajaj Uchit Vyavahar Puraskar for Fair Business Practices

in Manufacturing Enterprises – SME category for the year

2014 was received from Hon’ble Former President of India

late Dr. A.P.J. Abdul Kalam .

38

Rajasthan Energy Conservation award - 2014

Was given by Honorable Energy Minister of Rajasthan.

39

National Award For “Excellence in Energy Management -

2015’ from CIIThis National award is given in recognition of Excellence in Energy

management in cement sector by CII. Award was given by chairman

Bureau of Energy Efficiency (BEE) Dr.Ajay Mathur on 3rd September

2015 at Hyderabad.

40

Productivity Award 2013 - 2014 from Rajasthan State

Productivity Council.This award is given in recognition of “ Improvement in Productivity

Performance” by Rajasthan State Productivity council . Award was

given by Honorable Minister for Industries Govt. of Rajasthan Shri

Gajendra Singh on 30th September-2015.

41

Energy Conservation Merit award – 2015 from Rajasthan

State Government.This award is given in recognition of Energy Conservation in Cement

Sector by Govt. of Rajasthan. Award was given by Energy Secretary of

Rajasthan state Govt. Shri Sanjay Malhotra on 14th December-2015.

42

National Energy Conservation Merit Award 2015 by

Ministry of Power – Government of India.This award is given in recognition of Energy Conservation for Cement

Sector. Award was given by chairman Bureau of Energy Efficiency

(BEE) Dr.Ajay Mathur on 22nd January 2016.

43

Award for outstanding Performance in Rural

Development by Employer Association of Rajasthan for

the Year 2014-15.This award is given in recognition for outstanding Performance in rural

development work by Employer Association of Rajasthan. Award was

given by Honorable Minister for Higher Education Shri Kalicharan

Sarraf on 25th Feb 2016 at Jaipur.

44

26th MINES ENVIRONMENT & MINERAL CONSERVATION AWARDS 2015-16

(Under the aegis of Indian Bureau of Mines, Ajmer Region)

Ist prize in the field of

“ TOP SOIL MANAGEMENT”.

45

26th MINES ENVIRONMENT & MINERAL CONSERVATION AWARDS 2015-16

(Under the aegis of Indian Bureau of Mines, Ajmer Region)

IInd prize in the field of

“ AFFORESTATION”.

46

Rajasthan Energy Conservation Award – 2016

Ist prize in Large Cement Sector of Rajasthan”.This award is given in recognition of Energy Conservation in Cement

Sector by Govt of Rajasthan. Award was given by Energy Secretary of

Rajasthan state Govt Shri Sanjay Malhotra on 14th December-2016.

47

Four Star Award to Morak Limestone Mines of M/s Mangalam

Cement Ltd. for Sustainable Development by Ministry of Mines

, Govt. of India at National Mineral Conclave -2016 at Raipur

Star Award Sustainable Development by Ministry of Mines ,

Govt. of India at National Mineral Conclave -2016

48

Award for outstanding Performance in Rural Development by

Employer Association of Rajasthan for the Year 2016-2017

This award is given in recognition for outstanding Performance in

rural development work by Employer Association of Rajasthan.

Award was given by Honorable State Finance Minister Shri Arjun

Ram Meghwal .

51

Thank You

All

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