Cement Energy and Environment

CEMENT and ENERGY A QUARTERLY NEWS LETTER Vol. Ill No. 3 July 1999 EDITORIAL BOARD R. Partha Sarathy Dr. C. Rajkumar Dr. S.P. Ghosh P.K. Tikku V.K. Arora S.V. Joshi CONTENTS • Energy optimisation through efficient equipment and modifications in Unit-1 of Mangalam Cement • Cooler energy savings • Energy saving in wet process • Energy efficiency consultancy and projects enterprise • National awards for energy efficiency in Indian cement industry • Utilisation of lime sludge and fly ash for value added products and productivity enhancement of lime kilns • Innovative fuel helps revive Barbados cement plant • Cement from wastes • Forthcoming Events For Private Circulation 3 6 9 10 12 13 13 14 ENERGY OPTIMISATION THROUGH EFFICIENT EQUIPMENT AND MODIFICATIONS IN UNIT-I OF MANGALAM CEMENT D.S. Bindra, )oint President & S.K. Agarwal, Vice President (Tech.) Mangalam Cement Limited Introduction M angalam Cement Limited, a unit of B K Birla Group of Companies, commissioned its Unit I in 1980 with a capacity of 1200 TPD clinker, which is now operating at 1400 TPD clinker. The power consumption trend of per-tonne cement was very high before 1996 as may be seen in Table 1. A massive modernisation programme was undertaken during 1996-97 and 1997-98 as a result of which the power consumption could be brought down from 138.21 units to the present 1031104 units per tonne of cement in December 1998. The year-wise unit power consumption before and after the modernisation is shown in Figure 1. Table 1 Trend of Unit Power Consumption from 1987 to 1998 Year Power Consumption, kWh/tonne of cement 1987-1988 150.22 1988-1989 142.3 1989-1990 136.5 1990-1991 143.6 1991 -1992 142.6 1992-1993 141.2 1993-1994 142.33 1994-1995 138.21 1995-1996 131.93 1996-1997 118.37 1997-1998 117.21 1998-1999 115.38