JK LAKSHMI CEMENT LTD

JAYKAYPURAM, SIROHI. (RAJASTHAN)

10th National Award for Excellence in Energy

Management-2009

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 COMPANY PROFILE

Established in Aug 1982 with 0.5 MTPA capacity

Unit – II commissioned in 1995 with 0.9 MTPA capacity

Unit – III commissioned in 1996 with 1.0 MTPA capacity

Present Cement Production Capacity 4.75 MTPA

An ISO – 9001: 2008, ISO – 14001: 2004, OHSAS – 18001: 2007 certified
company.

BHARAT SHIROMANI AWARD FOR CORPORATE LEADERSHIP
CONFERRED ON Mrs. VINITA SINGHANIA, M.D. OF JKLC Ltd.2006-07

“BUILDING INDUSTRY LEADERSHIP AWARD” 2007-2008.

Cont…
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NCB National Award for “ENVIRONMENT EXCELLENCE IN PLANT
OPERATION” in Indian Cement Industry 2007-2008.

NCB National Award for Energy EFFICIENCY in Indian Cement industry
i.e.” Best Improvement in THERMAL ENERGY” 2007-2008.

CII National Award for excellence in ENERGY MANAGEMENT i.e.
“ENERGY EFFICIENT UNIT” 2007-2008.

CEO with HR Orientation Award” at “Asia Pacific HR Congress” 2008-09.

FIRST AWARD IN CEMENT SECTOR FOR “NATIONAL ENERGY
CONSERVATION AWARD” ORGANISED BY “BUREAU OF ENERGY
EFFICIENCY (BEE)” 2008-09.

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 MAJOR ENERGY SAVING PROJECTS
WITH NO INVESTMENT
(Summary for last Three years)

TOTAL PROJECT IMPLIMENTED : 22

TOTAL ELECTRICAL ENERGY SAVING : 58.74 Million Kwh

TOTAL THERMAL SAVING : 3154 MT of Coal

TOTAL SAVING IN Rs
 ELECTRICAL : Rs 205.26 Million
 THERMAL : Rs 12.61 Million
 TOTAL : Rs 217.87 Million

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 MAJOR ENERGY SAVING PROJECTS
WITH INVESTMENT
(Summary for three years)

TOTAL PROJECT IMPLIMENTED : 22

TOTAL ELECTRICAL ENERGY SAVING : 25.70 Million Kwh

TOTAL THERMAL SAVING : 7650 MT of Coal

TOTAL SAVING IN Rs
 ELECTRICAL : Rs 101.17Million
 THERMAL : Rs 35.4 Million
INCREASED PRODUCTION : Rs 677.85Million
 TOTAL : Rs 814.42Million

TOTAL INVESTMENT : Rs 2236.37Million

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 SPECIFIC ENERGY CONSUMPTION
800
89
768
87
768 750
Kwh/Ton Cement

85

Kcal/Kg Clk.
746
82.91
83
700
81 80.25
79.31
79 650
77

75 600
2006-07 2007-08 2008-09
Year
Kwh/Ton cement Kcal/Kg Clinker

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 COMPARISON WITH GLOBAL AND
NATIONAL BENCHMARKS
(SPECIFIC ENERGY CONSUMPTION)

768 800
91 733
750
Kwh/Ton Clinker

Kcal/Kg Clinker
85 667 80.25 80 700
650
79 650
73 69 600
67 65
550
61 500
55 450
Global National JKLC Target
(2009-2010)
Kwh/Ton Cement
Kcal/Kg Clinker
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 ROAD MAP TO ACHIEVE BENCHMARK

S DESCRIPTION EXPECTED SAVING

NO Electrical Thermal
U/T Kcal/Kg
Cement Clinker
1 To increase production of blended 2.00 -
Cement
2 Installation of pre grinder for cement 5.00 -
mills
3 To increase % of Pozzolonic material in 0.50 -
production of blended cement
4 Retrofitting of major process fans 1.00 -
5 To upgrade cooler of kiln-
kiln-2 & kiln
kiln--3 10
6 Optimisation of compressed air system 0.25
TOTAL 8.75 10
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 SUSTAINABILITY

Monitoring & analysis of specific energy consumption on daily,

weekly and monthly basis and take corrective action as per
requirement
Going for WHR Systems

Display of online specific energy consumption data in DCS

Participation in CMA benchmarking exercise

Interfirm comparison for specific energy consumption

Analysis & implementation of best practices adopted by other plants

Participation in BEE cement sector task force meetings &
discussion with other plant officials for improvement

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 SUSTAINABILITY

Regular energy auditing by in house energy audit team and BEE

accredited energy auditors

Regular training programs (In house as well as by external experts)

Participation in national & international seminars

Suggestion and rewarding scheme for energy conservation

Cross functional teams (CFT’s)

Purchase of energy efficient equipment

Installation of energy saving devices (i.e. SPRS, VFD etc.)

Involvement of quality circles (QC’s) for energy efficiency
improvement

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 ENERGY MANAGEMENT POLICY
JK LAKSHMI CEMENT LTD.
JAYKAYPURAM
Energy Management Policy

The management of M/s JK Lakshmi Cement Ltd stands committed to continual

improvement in Energy Conservation in accordance with Energy Conservation Act
– 2001, by taking the following steps :-

Closely monitor, control and analyze the equipment and process performance for
specific Energy consumption through Energy Management Cell and take
corrective action.

Explore the possibility of the use of cheaper alternative fuel and waste products
with a view to protect Environment and Natural Resources.

Create awareness for energy conservation and disseminate information to the
grass-root level by conducting training and motivational programs.

Conduct Energy Audit through accredited auditor and prepare an annual activity
plan to reduce energy consumption.

(GANPAT SINGH)
Place : Jaykaypuram CHIEF EXECUTIVE (WORKS)
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 JK LAKSHMI CEMENT LTD,JKPURAM
FLYASH CONSUMPTION M.T. / YEAR

568392
553449
600000

500000 399345

400000
237316
300000 146446 160321

200000 75250
60779
47530
22513
100000

0
1999- 2000- 2001- 2002- 2003- 2004- 2005- 2006- 2007- 2008-
00 01 02 03 04 05 06 07 08 09

Year
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 CONSUMPTION OF ALTERNATIVE
FUELS AND SOLID WASTES

850000 799550 820608

669511
Qty in MT

700000
515754
550000 445035
389607
400000

250000
2003-04 2004-05 2005-06 2006-07 2007-08 2008-09

Year

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 MAJOR INNOVATIVE PROJECT – 1
INSTALLATION OF FLY ASH DRIER
(2008 – 09)

Background : -

Domestic demand of PPC has increased during last few years.

 Non availability of Dry Fly, forced us for wet fly ash usage to
cater increased PPC demand.
Specific power consumption of Cement Mill section has increased
because of wet fly ash usage
 Above 20% usage of Wet Fly Ash has resulted in Operational
trouble.
 Hence, the need of wet fly ash drying system has arisen

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 MAJOR INNOVATIVE PROJECT – 1
INSTALLATION OF FLY ASH DRIER

Activities carried out : -

Connection from cooler exhaust duct
Installation of Fly ash Drier system.
Installation of wet Fly ash Unloading system.
 Installation of Dry Fly Ash Conveying system.
Problem Facing in Dry Fly Ash System
 Separation of clinker dust from cooler hot air.

 Transportation of Dry Fly Ash.

 Dedusting problem.
 Separation of Foreign material from wet fly ash.
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 MAJOR INNOVATIVE PROJECT – 1
INSTALLATION OF FLY ASH DRIER
CONCEPT OF FLY ASH DRING
Available Heat at Cooler O/L 8.72 x 106
Kcal/hr
Water Evaporation Rate from available heat 13.47 Ton/hr
Cement Grinding Capacity ( when idea was 500TPH
conceived)
For 100% PPC Production, Wet Fly Ash 100TPH (22%dry
Requirement Fly Ash)
Capacity of FLY ASH DRIER
Moisture content in Fly Ash 20 18 16 14 12 11
(%)
Wet Fly Ash (TPH) 67 75 84 96 112 122
Dry Fly Ash (TPH) 55 62 72 84 100 110
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 MAJOR INNOVATIVE PROJECT – 1
FLY ASH DRIER FLOW SHEET

WFA BELT
CYCLONE

Wet
fly ash
hopper DRIER

DRY FLY
WEIGH FEEDER ASH
HOPPER

DRIER FAN

WASTE HOT AIR

TO ESP

COOLER
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 MAJOR INNOVATIVE PROJECT – 1

Benefits
Increase in fly ash consumption from 20 to 22 %
Increase in Cement Production : 0.706 LTPA
Reduction in power consumption: 0.5 kwh/ton of cement

Cost Benefit Analysis ( Rs/ annum)

Contribution from increased cement volume 565 lacs
Power saving 65 lacs
Total benefit for one year 630 lacs
Project Cost 899 lacs
Pay back Period 17
Months

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 MAJOR INNOVATIVE PROJECT – 2
UPGRADATION OF KILN - 1
(2008 – 09)
Background : -

The plant was initially designed for 1500 TPD in 1982 but because
of high operating cost it was non operative. The mantra for
sustaining in highly competitive market is to have low cost of
production high volume growth as compared to industry growth.
Keeping it in mind we revamped kiln-1 and the same has helped us
in getting extra revenue because of increased production at low cost
of production.

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 MAJOR INNOVATIVE PROJECT – 2

Activities carried out : -

 Installation of Iteca Seal at kiln -1 O/L.
Up gradation of kiln -1 main drive.
Relocate and upgrade Old Crusher.
Replaced conventional grate cooler by high efficient IKN Pendulum
cooler.
Installation of new coal mill
Conversion of cement mill to raw mill.
Installation of new limestone stacker and reclaimer.
Installation of new six stage PH with LP cyclone.
Replace pneumatic conveying system.

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 MAJOR INNOVATIVE PROJECT – 2
Achievements :
PARAMETER UNIT BEFORE AFTER
Clinker production TPD 1500 2000
Pressure drop across pre mmWG 600 400
heater
Pre heater fan specific power U/T clink 16.8 9.00
Pre heater fan motor power Kw 1050 750
Cooler fan specific power U/T clink 4 3.6
Specific heat consumption Kcal/Kg clk 950 750
Specific Power consumption U/T 40 30
Cost benefit Analysis
Investment : Rs. 1500Million
Saving : Rs. 535.14Million per annum
Simple payback period : 34months
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 MAJOR INNOVATIVE PROJECT – 3
Up-Gradation of Kiln-2 & 3 Main Drives
(2008 – 09)
Background : -
 The plants were initially designed for 2500 TPD. Numbers of in house
modification with practically no-capex and small capex were carried
out to enhance the capacity to 3400 TPD and subsequently the capacity
increased to 4200 TPD with the installation of prallel preheater. Above
4200 TPD, following problems were faced

1. Build-up at kiln inlet

2. Ring inside the kiln
3. kiln Back spillage
4. Once filled kiln was stopped, it used to take 1hr to come on main drive .
In order to get rid off of the above-mentioned problems and to enhance
capacity to 4500 tpd, it had been decided to upgrade main drive of both
the kilns.

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 MAJOR INNOVATIVE PROJECT – 3

Achievements :
PARAMETER UNIT BEFORE AFTER
Clinker production TPD 4200 4500
Kiln Speed RPM 4.2 5
Kiln Filing % 13.8 12.9
Main drive power (rated) Kw 300 440
Specific Power consumption Unit/mt clk 24 22.5

Cost benefit Analysis

Investment : Rs. 45 Million
Saving : Rs. 235.6 Million per annum
Simple payback period : 3 months
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 ENVIRONMENTAL PROJECTS

Reduction in fugitive emission

 Installation of Hybrid ESP bag Filter with PTFE bags at Kiln – 1
Raw Mill.
 Installation of Clinker cooler ESP at Kiln – 1 .

Reduction in GHG emission and greenery improvement
 Plantation of 6650 nos. neem, 17500 jetropha & other varieties of
trees in township, power plant, mines & both sides of Banas road.
 Installation of Biomass handling system in Kiln 2 & 3 pre calicner to
“Replacement of fossil fuel by biomass in Pyro-processing”.

Water conservation
 Rain water harvesting to recharge bore wells
 Installation of colony drinking water treatment plant
 Installation of solar water heating system in guest house field hostel
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 MAJOR ENVIRONMENTAL PROJECTS

TRANSFER
TOWER

BIOMASS BELT
CONVEYOR 2
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