Cement, Energy and Environment July-Sep 2002

ELECTRICAL ENERGY CONSERVATION MEASURES AT BIRLA CEMENT WORKS AND CHITTOR CEMENT WORKS Dinesh Chanda, V.K. Hamirwasia & J.S. Kalra Birla Cement Works and Chittor Cement Works, Chittorgarh The authors survey the energy conservation measures implemented in the twin plants Birla Cement Works and Chittor Cement Works at Chittorgarh and the incremental energy savings achieved year-to-year from 1997-98 to 2001-02. The inyestments made and the returns accrued/expectedfrom each of these measures are duly indicated. Rangingfrom optimisation ofthe existing systems including technological modifications, to outright replacement, as necessary, themeasures touch practically the entire linefrom the limestone crushing plant to the packing plant...Ed Introduction AtChittor there ar~ two plants, namely, Birla Cement Works (BCW) and Chittor Cement Works (CCW). They have a combined cl inkerisation capacity of 17.50 LTPA comprised of 2x1000 TPD ofBCW and 3300 TPD ofCCW. Since electrical energy is a major cost factor in cement manufacture constituting about 25 per cent ofthe total production cost, both plants have been taking systematic conservation measures from 1997 onwards.The present article survey s these measures not only solved the dust nuisance progressively introduced over the completely but saved power too as period April1997 to March 2002 in shown below: different sections of the two plants Designed power with the original and the savings realised from them, BDC = 1.80 units/ton limestone Measures Taken at Mines Actual with the ws. system At Jai Mines which feed both = 1.40 !Jnits/ton limestone the plants, in the limestone crushing system, two bag -dust collectors (BDC) had been originally installed to control the dust emission but they were not very efficient. To overcome this problem a dedicated atomised water spray (WS) sy"stem was installed during 1997-98. This - 6F.LTCONY E\OK cr;:l CJIHTP,S l... S f LOW Net savings per annum = Rs. 30 lac (for 15 LTPA clinker@ Rs. 3.29 per ton limestone) Figure I represents the flow diagram ofthe 1000 TPH limestone crushing plant in which the original BDC's subsequently replaced by the water spray system are also shown. trtrrE RF-JECT L o PILE ->l TO- Il M\1 ~< \\;.rER SPRAY S\"\TDl A U. O.CtDlSCOI>Tll\U£1>} l.S. PILF Fig. I : Flow diagram ofthe 1000-TPH limestone crushing plant at Jai Mines Measures at Birla Cement Works Following is a yearwise account of the energy conservation measures taken at different sections Ill of the plant and the respective savings from them - both specific power saving and the actual saving in financial terms for a year. 1997-1998 • Kiln section Speed of ESP fans of both kilns was reduced by switching over from direct- \o- '