Cement Energy and Environment

112r------------------------------------. 110 109.28 c 108 ., E ., " 106 ~ 104.91 ~ 104 101.91 102 100 +-----------~-----------+----------~ 94-95 95-96 96-97 97-98 Figure 2 Electrical energy consumption trend in Dry process plants Success Stories Brief success stories of some of the plants which received the Awards for 1996-97 nnd 1997-98 (complete li st of the Awardees published in the January 1999 issue of Cement and £11ergy) arc given in the following paragraphs. Manikgarll Cement Recipient of the Awards for the Best Improvement in Energy Performance and the Best Improvement 111 Electrical Energy Performance for 1996-97, Manikgarh Cement, Gadchandur, is a dry process plant having an installed capacity of 15 LTPA. The plant is equipped with a 4-stage SP with precalciner kiln . Ellerf:y Con.H'J'\'ation Measures Adopted by the Plant Overall • Moti vation and team work • Energy auditing Electrical Energy • Conversion of pneumatic system into mechanical hand Iing s.ystem • Adoption of low-pressure Ist stage preheater cyclone • Arresti ng of raise air inriltration • Conversion of PLC controls system to Distributed Contro~ System • Elimination ol some auxiliarie~ in cement mill circuit Thermal Energy • Adoption of IKN technology in cooler • Installation of segmental type immersion tubes for preheater cyclones • Introduction of high efficiency burner in place of conventional burner The KCP Limited Recipient of the Award for the Second Best Improvement in Energy Performance for 1996-97, the KCP Limited, Macherla, is a dry process plant having an installed capacity of 4 LTPA. The plant is equipped with a 5 stage SP with precalciner ki ln. £11ergy Co11servation Measures Adopted by the Plant Overall • Increased awareness th rough training • Internal modifications in machinery to increase utilisation factor Electrical Energy • Minimising false air ingress • Adoption of power monitoring system • Optimisation of cement mi ll • Maintaining high power factor Thermal Energy • Minimising false air ingress • Optimisati on of raw mix design for improved burnability • Installation of energy erficient high-strength insulating bricks Satua Cement Works Recipien t of the Best Energy Performance Award for both I996-97 and 1997-98, and the Third Best Improvement in Energy Performance 1996-97, Satna Cement Works, Satna is a dry process plant having an installed capacity of 7.50 LTPA. The plant is equipped with a 2250-tpd 5-stage SP with precalciner kiln. II