ENERGY SAVING - CEMENT PLANT CASE STUDY
ACC plant at Madukkarai ,Tamilnadu
Installation of High efficiency Fan in E- mill
The previous Fan was for rated for a pressure drop of 1100 mmWG.On measurement it was found that pressure
drop requirement was maximum 850 MMWG. Apart from that the improvement in waste heat utilisation and
leakproof ducts reduced the false entry. Due to this the installed fan with 450 KW motor was running at lower
efficiency. It was decided to retrofit a new high efficiency Fan . The new operating parameters were fixed at 850
MMWG at 800 m3/Hr flow.The retrofitted fan at 83 % efficiency saved 35 KW.The expenditure on this project
was Rs 4 lakh and the savings in the first year was 1.38 lakh unit.
Optimisation of air requirement for Mixer basin aeration
The Raw mill homogenisation is done in amixer basin. For continuous aeration ,the compressed air is utilised.It
was observed that the compressed air pressure was only 0.8 KG/Cm2.The power consumed however was 65
KW. On analysis of different capacity of blowers it was found that at same pressure and for 2500 M3/Hr flow ,the
power consumption is only 45 KW.Thus a savings of 20 KW was possible. The blower was installed for
mixer basin aeration at a cost of Rs 4 lakh. In the forst year itself the savings were about 1.65 lakh units.
Flocculant addition in thickner and filteration
The enrichment of lime takes place in flotation and enriched material goes to thickner for settling.It was observed
that the settling was slow and the water overflow was carrying fines below 350 mesh.We tried with various
flocculants .Addition of a particular flocculant increased the settling and material carryover in the overflow was
reduced to zero.The same principle was applied to filteration for improvement in cake thickness.this resulted in
reduction of vacuum pump operation and at a cost of rs 2 lakh/year about 1 lakh unit was saved.
source: Bureau of Energy Efficiency,India
ACC plant at Madukkarai ,Tamilnadu
Installation of High efficiency Fan in E- mill
The previous Fan was for rated for a pressure drop of 1100 mmWG.On measurement it was found that pressure
drop requirement was maximum 850 MMWG. Apart from that the improvement in waste heat utilisation and
leakproof ducts reduced the false entry. Due to this the installed fan with 450 KW motor was running at lower
efficiency. It was decided to retrofit a new high efficiency Fan . The new operating parameters were fixed at 850
MMWG at 800 m3/Hr flow.The retrofitted fan at 83 % efficiency saved 35 KW.The expenditure on this project
was Rs 4 lakh and the savings in the first year was 1.38 lakh unit.
Optimisation of air requirement for Mixer basin aeration
The Raw mill homogenisation is done in amixer basin. For continuous aeration ,the compressed air is utilised.It
was observed that the compressed air pressure was only 0.8 KG/Cm2.The power consumed however was 65
KW. On analysis of different capacity of blowers it was found that at same pressure and for 2500 M3/Hr flow ,the
power consumption is only 45 KW.Thus a savings of 20 KW was possible. The blower was installed for
mixer basin aeration at a cost of Rs 4 lakh. In the forst year itself the savings were about 1.65 lakh units.
Flocculant addition in thickner and filteration
The enrichment of lime takes place in flotation and enriched material goes to thickner for settling.It was observed
that the settling was slow and the water overflow was carrying fines below 350 mesh.We tried with various
flocculants .Addition of a particular flocculant increased the settling and material carryover in the overflow was
reduced to zero.The same principle was applied to filteration for improvement in cake thickness.this resulted in
reduction of vacuum pump operation and at a cost of rs 2 lakh/year about 1 lakh unit was saved.
source: Bureau of Energy Efficiency,India
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Bakery Industry Cement Industry Fertiliser Industry Steel Industry Textile Industry Aluminium Industry
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