SATNA CEMENT WORKS
&
BIRLA VIKAS CEMENT
SATNA
Details of Energy saving measures Adopted from Jan-00 to Mar-03
A. Energy conservation Measures adopted at SCW (April, 00 to March, 01)
1. Project detail :
High efficiency Fan for Primary Air Fan along with inverter drive panel for speed control of the fan :
Write up :
Earlier Primary Air Fan (30 KW) was of old generation less efficient fan which was consuming more power. Hence, it was replaced with a High Efficiency Fan to further saving in power consumption. Further, the speed control of Fan was with damper control resulting in more power consumption, hence same was provided with an invertor drive panel for speed control which helps in reducing power consumption.
Calculation :
a) Earlier power consumption of ESP Fan : 23 Kwh/Hr.
(b) Power consumption of ESP fan after above modification : 10 Kwh/Hr.
(c) Power saving per day achieved = ( 23 – 10) : 13 Kwh/Hr.
(d) Power saving during year 00-01 (7404 Hrs.x 13) : 96252 Kwh/Hr.
Considering Clinker production as 831227 Tons
Savings in terms of KWH/ton of Clkr. : 96252/831227
: 0.11 Kwh/ton Clkr.
Monitoring aspects :
Energy meter readings of P.A.Fan taken.
Investment : Rs. 2.25 Lacs
Date / Month of implementation : 28th July 2000
2. Project details :
Modification of LKS Classifier of VRM with LV_technology Classifier
Write up :
Earlier VRM 36.41 classifier of old technology was modified and up-graded with LV-Technology classifier. The basic idea of LV technology is to improve aerodynamics inside the mill by directing the ground material upto the full length of modified classifier by increasing the velocity from bottom to the top by suitably modifying the cross sectional area from the bottom of the mill to the top of the classifier, thereby reducing the pressure drop and turbulance with in the mill body. This has resulted in increase of Mill output and reduction in specific power consumption.
Savings in pressure drop has resulted in higher production rate and reduction in specific power consumption.
Calculation :
(a) Earlier power consumption : 15.65 Kwh/Ton.
( VRM+ESP Fan & Classifier)
(b) Power consumption after modification : 14.61 Kwh/ton.
(c) Actual Power saving : 1.04Kwh/ton of Raw meal
or it is equivalent to ( 1.56 factor) : 1.62 Kwh/ton Clkr.
Monitoring aspects :
Energy meter readings of VRM+ESP Fan & Classifier taken. See Annexure – 3.
Investment : Rs. 64.48 Lacs
Date / Month of implementation : 1st March 3.
Project details :
Installation of Vortex Finder Vanes on top stage Cyclones for reduction in differential pressure
Write up :
The conventional immersion tube of PH stage-I twin Cyclone was replaced with state of the art technology “Vortex Finder Vanes” designed by M/s PMTZyklontechnic, Austria. Vortex finder vane is the latest technology of Cyclone immersion tube, which reduces the pressure drop across the Cyclone by 30%, thereby saving in the Fan power.
Further, keeping the Fan power consumption at the earlier level, PH fan flowcould be increased after installation of VFV and subsequently increase in about 50 TPD clinker production was achieved.
Calculation :
(a) Earlier power consumption in PH Fan : 1068 Kwh/hr.
(b) Power consumption after VFV installation : 1012 Kwh/hr.
( c) Power saving : 56 Kwh/hr.
(d) Power saving per annum 7404 hrs.x 56 : 414624 Kwh
Actual Clinker production as 831227 Tons
Savings in terms of KWH/ton of Clkr. : 414624/831227
: 0.5 Kwh/ton Clkr.
Monitoring aspects :
Energy meter readings of PH Fan taken. See Annexure – 4.
Investment : Rs. 24.62 Lacs
Date / Month of implementation : 1st March 2001
