MADRAS CEMENTS LTD

Alathiyur

Best Practices on Energy

Conservation
17 Oct 2006

Madras Cements Ltd, Alathiyur

Profile
ISO 14001:2004

ISO 9001:2000

IS 18001:2000

A flagship company of RAMCO Group, having four Cement

manufacturing units of Total capacity 6 MTPA.
The plant at Alathiyur, Perambalur District was setup in two
phases.
Total Plant Capacity - 6600 TPD of Clinker.
Manufacturer of Ordinary Portland Cement and Portland
Pozzolana Cement as per Indian Standards and Ordinary
Portland Cement as per British and Srilankan Standards.
Coal based Power Plant 2 X 18 M.W
ISO 9001, ISO 14001 & OHSAS 18001 Certified Company.

State of Art
Technologies
adopted at
Alathiyur

Limestone
Mining
Mining is done with Surface
Miners (6 Nos) imported
from Germany
SM 2100 3 Nos,
SM 2500 1 No.
SM 2200 2 Nos
Advantages
* Avoids Drilling, Blasting,
& Primary crushing
* No noise, No ground
Vibration & No air borne
Dust generation.

Limestone Crushing
Make : M/s.MMD Ltd, UK
MMD 750 Series (Primary)
MMD 625 Series (Secondary)
Capacity : 1000 TPH
Advantages
* Dust and noise free
* 40% less power consumption
than Conventional Jaw Crusher.

Raw meal
preparation
Make : Loesche LM 38.3
Capacity : 235 TPH
Fineness 17% @ 90
Advantages
* 30% less pow cons
than ball mill.
CF silo internal

* Uniform PSD
CF Silo

Clinker Cooling and Storage

The first SF Cooler installed in India and commissioned in Alathiyur Line-II.

This is a SF 3 x 4 module Cooler with fixed inlet. Less

maintenance, Less wear and tear, least moving parts and
better fuel & electrical efficiency.

OPERATIONAL PARAMETERS OF SF-CROSSBAR COOLER

COMPARED
WITH CIS / CFG COOLER.
SF

CIS/CFG

CFG

Grate Area (Sq.m)

71.72

47.52

46.33

Total Cooler Input (Nm3/kg cl)

1.58

1.84

2.1

Clinker Temperature ( C)

100 120

140 150

150-160

Tertiary Air Temperature ( C)

960

900

850

Sp. Power Consumption (kwh/t mat)

(Drive, Fans & Crusher)

4.6

7.2

9.4

Cooler Efficiency (%)

78

70

66

Clinker grinding
& Cement
Storage
Make : Loesche LM 56.2 +2C
Capacity : 250 TPH
Fineness 3200 blaines for PPC
Largest in South Asia
Advantages
* Consistent product quality
* Effective fine grinding and
narrow PSD.
* Less Power consumption.

World Class
Technologies
Incorporated at
Design Stage

World Class Technologies Implemented:

Deployed Surface Miner for entire mining activities.
SM 2500 is first of its kind by size and design. This
totally avoids drilling and blasting. Power savings is
about 0.7 KWH / t of cement. SM output is restricted
to 150 mm resulting in crusher power saving.
MMD Crusher Unique and compact crusher to
handle moisture up to 15 % with output size of
75 mm. Power saving is about 1 KWH / T of cement
than conventional crusher.
Pre-blending system: Covered Stacker & Reclaimer
for limestone / coal. This ensures consistent quality
and moisture free feed during rain also.

 Installed Vertical Roller Mills for Raw meal, Coal and

Clinker grinding. Power consumption is 30 % less
compared to ball mill system.
Transportation: Only by Belt conveyors and Bucket
elevators. There is no pneumatic conveying system.
Power saving is 35 % compared to pumping
system.
Blending and Homogenization: CF silo for Raw
meal. Blending efficiency is 7.5 : 1 compared to
industrial average of 4.5 : 1. This ensures consistent
chemistry, quality clinker, productivity and hence
thermal efficiency.

 Preheater, Kiln and Cooler:

- Five stage Preheater with low pressure drop Cyclones
and Inline Calciner.
- First time in South Asia installed SF-Crossbar cooler
for high heat recuperation resulting in low heat and
power consumption.
Vertical Roller Mill for Clinker grinding:
- Fuller O.K 33.4 VRM for first time in South Asia.
- Loesche 56.2+2 VRM largest mill in operation.
- Consistent product quality.
- Effective fine grinding and narrow PSD.
- Less power consumption.

 Fans are operating with 80 % efficiency. Major

Process fans are connected to SPRS / VVVF panels
and hence power saving is achieved.
Online O2 / Co / Nox analyzer to ensure combustion
efficiency.
Duoflex multi channel burner is used for less
Primary air and hence thermal economy.
OPTO 22 / Fix SCADA instrument system for
efficient Process control.

List of Energy Conservation Projects

implemented during 2003 2006

gy

Investment
Annual thermal
Total
Made
savings
Savings
Tons of
Rs
Coal or Rs
Rs
Million Oil
Million Million Rs Million

Annual Electrical
Savings achieved

Sl No
1
2

4
5

Title of Energy Saving

project implemented
Cement Mill bag filter purging
time increased
By pass duct installed for
Cement mill booster fan from
cooler vent fan
Nozzle ring modification and
grit cone extension at Coal
Mill
Air balancing and
optimization at Coal Mill
Collecting airslide blower one
number stopped at Cement
mill
Classifier grit cone
extension,flap adjustment and
nozzle area modification at
Line - II Cement mill
Armour ring and grit cone
extension at Line - I Cement
Mill

Units
Year of
Implementation Million
03-04

0.015

0.0525

0.0525

03-04

1440

5.4

5.4

0.26

03-04

0.5465

1.913

1.913

0.05

03-04

0.2049

0.717

0.717

03-04

0.0012

0.0042

0.0042

03-04

4.68

16.38

16.38

0.5

03-04

0.594

2.079

2.079

0.15

gy

g
Annual thermal Total Investment
savings
Savings Made
Tons of
Coal or Rs
Rs
Rs
Million Million Rs Million
Million Oil

Annual Electrical
Savings achieved
Title of Energy Saving
Sl No project implemented
15 Changed 100 nos of fittings
from 80 Watts HPMV lamp to
50 Watts MH lamp at Packing
plant
16 Godrej ControlAir for
compressed air system at
Flyash handling
17 Modification of inlet box in
Line -II Prehaeter fan
18
Nozzle ring modification&Grit
cone extension at Coal mill
19 Classifier blades modified from
Flat to Curved at Both raw
mills
20 Raw mill inlet duct
modification at Line -I
21
2 X 18 M.W Coal based power
plant to reduce the energy cost

Units
Year of
Implementation Million

04-05

0.0131

0.045

0.045

0.12

04-05

0.1353 0.4736

0.4736

0.69

04-05

0.18

0.63

0.63

0.07

04-05

0.546

1.913

1.913

0.05

04-05

1.296

4.536

4.536

1.5

04-05

784

2.89

2.89

0.05

04-05

110

110

950

Annual thermal Total Investment

savings
Savings Made
Tons of
Rs
Coal or Rs
Rs
Million Oil
Million Million Rs Million

Annual Electrical
Savings achieved

Units
Year of
Title of Energy Saving
Implementation Million
Sl No project implemented
8 Classifier sealing correction
and deflector ring fixing at Raw
Mill
03-04
0.2116 0.741
9 Armour ring angle modification
and grit cone extension at Raw
mill
03-04
0.6348 2.222
10 Installation of seperate
conveying and dozing system
for alternative fuels
03-04
1.656 5.796
11 Coal Conveying line
Optimization at Kiln-II
04-05
0.0792 0.277
12 Pre heater cyclone modification
at Kiln I
04-05
0.7425 2.599
Provide
software
interlock
to
13
stop the dedusting fan
whenever feeding conveyor
stops
04-05
0.016 0.056
14 Provided dampers in the inlet
of dust collector fans in packer
to control the suction whenever
the packer operates with single
discharge
04-05
0.125 0.439

0.741

0.05

2.222

0.1

5.796

0.2

0.277

0.02

2.599

0.056

0.439

gy

g
Annual thermal Total Investment
Savings Made
savings
Tons of
Rs
Coal or Rs
Rs
Million Oil
Million Million Rs Million

Annual Electrical
Savings achieved
Title of Energy Saving
Sl No project implemented
22 Replacement of high efficiency
I.D.Fan in Line-1
23 Replacement of high efficiency
Vent.Fan in Line-1
24 Introduction of Delta Tube in
Cement Mill - II
25 Installation of Power Boss for
variable load applications such
as conveyors & Elevators to
reduce power
26 Stopping of bag filter fan in
Line II kiln
27 Optimization of extraction
blowers.

Units
Year of
Implementation Million
05-06

0.432

1.512

1.512

1.6

05-06

0.0594 0.2079

0.2079

0.5

05-06

0.0749 0.2622

0.2622

0.04

05-06

0.0168 0.0588

0.0588

0.21

05-06

0.075 0.2625

0.2625

0.014

05-06

0.048 0.1680

0.1680

0.016

Total projects implemented

: 27 Nos.

Total investment for the projects

957.19 Rs in Million

Total savings after implementation :

161.63 Rs in Million

List of Energy Conservation Projects with Nil investments during 2003 06

Annual Electrical
Savings achieved

Sl No

Title of Energy
Saving project
implemented
Cement Mill bag filter
1 purging time increased
Air balancing and
optimization at Coal
2 Mill
Collecting airslide
blower one number
3 stopped at Cement mill

Year of
Implementati Units
Million
on

Rs
Million

Annual thermal
savings
Tons of
Coal or Rs
Oil
Million

Total
Investment
Savings Made
Rs
Million

Rs Million

03-04

0.015

0.0525

0.0525

03-04

0.2049

0.717

0.717

03-04

0.0012

0.0042

0.0042

0.016

0.056

0.056

0.125

0.439

0.439

Provide software
interlock to stop the
dedusting fan whenever
4 feeding conveyor stops 04-05
Provided dampers in
the inlet of dust
collector fans in packer
to control the suction
whenever the packer
5 operates with single
04-05

Total projects implemented

: 5 Nos.

Total investment for the projects

: NIL

Total savings after implementation : Rs.1.268 million

Total energy savings

: 0.362 million kwh.

Sp.Power (kWh / T of Cement)

Reduction in Sp. Power Consumption

from 2001 2006

64.15
62.44
60.19
60.10
59.92

01 - 02

02 - 03

03 - 04
Year

04- 05

05-06

Sp.Heat (Kcal / kg clinker)

Reduction in Sp. Heat Consumption

from 2001 2006
695
690
687
685

685

0.71%
0.71%
0.43%

01 2000
- 02 - 01
02 - 03

03 - 04
Year

04-05

05-06

MAJOR PROJECT NO.1

Optimisation of Raw Mill - II
Description
Mill
Make
Mill size
Drive

: M/s.Loesche, Germany
: LM 38.3
: 1750 Kw

Modifications
1. Classifier blades where changed
to Curved from Flat surface
2. Configuration of static blades were
modified .

Before
Modification

After
Modification

Optimisation of Raw Mill II

Feed

TPH

Before
Modification
235

Flow

m3/hr

315000

302000

Mbar
KW
KW
KW
Kwh / t
Kwh / t of
Material

77 to 83
1135
1325
2460
10.47

71 to 75
1138
1195
2333
9.72

Units

Mill D.P
Mill Power
Fan Power
Total
Savings

Total Savings

After
Modification
240

0.75

= 0.75 Kwh X 24 hours X 240 MT

X 300 Days X Rs.3.5
= Rs.4.54 Million

MAJOR PROJECT NO.2

Optimisation of I.D.Fan
We have upgraded our kiln and were running with
the old fan,within a short period.We found that there
was a potential in the Fan.So we changed a High
efficiency impeller in place of old impeller.

Modifications
1. High efficiency impeller installed: Efficiency
improved from 68% to 76%
2. Inlet cone re-engineered

Result
Power saving around 150 K.W per hour

Before
After
Modification Modification
Fan inlet

Fan inlet

Flow

m3/hr

465000

472000

Temp

Deg c

295

304

Power

KW

1510

1360

Savings

KW/Hr

150

Power Savings = 150 KW / Hour

= 150 KW X 24 Hours X Rs.3.5

Total Savings = Rs.1.51 Million / Annum

MAJOR PROJECT NO.3

In Line II Kiln circuit we have two bag filters (one for dedusting of kiln feed bucket elevator and one for blending
silo air slides & bin venting).From the suggestion scheme
it was found that by suitable modification in the ducting
one bag filter can be eliminated.So,we have modified the
suction line and one bag filter was stopped.
Summary:
Power Savings = 10.36 KW / Hr
Cost saved

= Rs.2.61 Lacs per Annum

Major Project No:4

Installation of By-Pass duct at
Cement Mill Booster Fan
Introduced a
duct

at

by-pass

Cement

mill

Booster fan to regain

Before Modification

the heat energy from

the hot air that was
vented from Cooler.

After Modification
Hot Air Duct After Modification

Summary:
Thermal Savings = 4.0 MT of Coal per day
= 4.0 MT X 360 Days
Coal Saved

= 1440 MT

Total Savings

= Rs.5.40 Million

MAJOR PROJECT NO.5

In Line II blending silo raw meal extraction two roots
blowers were being operated. Our Quality circle team
had suggested that by suitable modification (Aeration
lines rerouting ) we can stop one blower.By suitable
rerouting we have stopped the blower and have saved
power.
Summary:
Power Savings= 6.7 KW/Hr
Cost saved

= Rs. 1.69 Lacs per Annum

Annual Report and Balance sheet

Power Consumption Kwh/Mt of

Cement

Combined data of our four plants

72.6

72.47

72.4
72.2
72

71.86

71.8
71.6

71.51

71.4
71.2
71

2002-03
2003-04

04-05
Year

05-06

Annual Report and Balance sheet

Combined data of our four plants
Fuel Consumption

% of Fuel
consumption

20
15

11.37

11.58

11. 47

10
5
0

2001
- 02
2003-04

04-05

Year Average
Year

05-06

Environmental Improvements
Clean environment is one of the major objectives of the
organization.

The plant is an

ISO 14001 and OHSAS 18001

Company . The emission levels speaks of the eco & enviro-friendly

environment in the plant.
The results of test conducted by the TNPCB is given below:
Stack

TNPCB
Norms
(Mg/N Cu.m)

Actual results
(24.1.2006)
(Mg/N Cu.m)

Equipment

Raw mill

100

Baghouse

Coal mill

100

45

Bag filter

Cooler

100

14

ESP

Cement Mill

100

11

DG

Power Plant

100

49

ESP

AWARDS

Awards Won by MCL, Alathiyur

Best Energy Efficient unit Award bagged at 21st National
Seminar on Cement Industry conducted by Madurai
Productivity Council at Chennai during Aug 1999.
National Level Excellent Energy Efficient unit award (For the
years 1999,2000,2001,2002,2003,2004,2005 and 2006) by the
Confederation of Indian Industry, Chennai
National Level Best Electrical Energy Performance Award
(For the years 1999-2000, 2001-02, 2002-03 and 2004-05) by
NCCBM.
National Energy Conservation Award 2000 (First prize in
Cement Sector) by The Ministry of Power, Government of India.
National Level Best Environment Excellence in Plant operation
Award (For the years 2001-02, 2002-03 and 2003-04) by
NCCBM.

Awards Won by MCL, Alathiyur

National Energy Conservation Award 2003 (Second prize in Cement

Sector) by The Ministry of Power, Government of India.

Greentech Excellence in Environment Silver Award in Cement sector

for the year 2003 04.

National Energy Conservation Award 2004 (Third prize in Cement

Sector) by The Ministry of Power, Government of India.

National Energy Conservation Award 2005 (Second prize in Cement

Sector) by The Ministry of Power, Government of India.

State Safety Award 2002 (First prize) by Inspectorate of Factories

Highest Green Rating of Cement Sector - 2004 by Centre for Science

and Environment, New Delhi.

Recently telecasted by National Doordarsan

Recently telecasted by National Doordarsan

Average Power Consumption 2005-06

Equipment

KWH/T Cement

Crusher

0.92

Raw mill

15.21

Coal mill

2.64

Kiln
Services I
Cement mill

13.70
1.30
22.00

Packing

2.00

Services II

2.15

Total

59.92

Exit Gas
(Include Dust &
Evaporation)

Figures in Kcal / Kg clinker

179

Cooler Vent

92

Heat of
Reaction

Radiation
Losses

35
400

Clinker

27
266

Recirculated
Heat

Heat from Fuel

Sensible Heat

48

685
Specific Heat Consumption for the year 2005 06

2 x 18 MW CPP