J.K. Lakshmi Cement Limited
J.K. Lakshmi Cement Limited
J.K. Lakshmi Cement Limited
Cement
Unit Profile
JK Lakshmi Cement Ltd (JKLC) is a member of well known JK Organisation which is one of the largest privately owned industry group in India. Today JKLC is one of the leading cement companies in the country. The Company strongly believes that a company can grow only when it includes largest sections of the society in its development. Company offers a work culture where every individual gets an opportunity to grow with the company. M/s JKLC have well defined core values such as caring of people, integrity with intellectual honesty, openness, fairness & trust and commitment to excellence. Company have also business vision to become 12 Million Tones by 2012 (12 x 12) with a business mission to be recognized as an efficient, competitive and premium cement brand. The company is confident that with the optimal use of resources and the latest technology, forthcoming years will take the company to even higher levels of glory and it will live up to the rising expectation of all the stake holders in its future journey.
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Energy Consumption
Description Installed capacity Actual production % utilization Coal consumption Total cost of coal Electricity consumption Total electricity cost Energy consumption in terms of % of mfg. cost (variable cost) Specific electrical energy consumption (excluding crusher) Specific thermal energy consumption Coal consumption Unit LTPA LTPA % Tonnes Rs Lakhs Lakh kWh Rs.Lakhs % KWh/Ton of cement kCal /kg clinker kg/ton of cement 2005-06 24.00 29.41 122.54 247193 8177.37 2363.46 10469.13 61.79 % 2006-07 34.00 31.26 91.94 271769 10871.41 2592.92 11636.52 58.36 % 2007-08 36.50 36.10 98.89 296329 14172.42 2880.75 10545.18 54.56 %
82.09 733 84
82.91 768 84
79.31 746 80
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82.91 82.09
82 81 80 79 78
79.31
2005-2006
2006-2007 YEAR
2007-2008
84
770
768
KCAL/Kg OF CLINKER
746
730 720
2005-2006
2006-2007 YEAR
2007-2008
640 620 600 580 568 560 540 2005-2006 2006-2007 2007-2008 616 602
KCAL/ KG CEMENT
YEAR
61.79
62 58.36 57 54.56
85
45.44%
54.56%
Electrical Energy Consumption Year kWh/ton of Cement (excl. crusher) 83.72 82.09 82.91 79.31 1.95 % 0.97 % 5.27 % % Reduction over 2004-2005
Thermal Energy Consumption kCal/kg of Clinker 746 733 768 746 % Reduction over 2004-2005 1.74 % ( -) 2.95 % 0%
for regular monitoring and control of wastage of energy. The unit involves different cement process experts/consultants/energy audit-agencies to identify & suggest scope of improvement in energy efficiency. Actively participate in cement sector task force meeting, organized by B.E.E. and exchange the views regarding energy consumption norms. The energy management committee chaired by the Chief Executive (Works) meets every Monday at 4.00 PM to review the weekly energy performance, action plan and ENCON activities.
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Energy Conservation Measures ( Planned ) Up-gradation of Old Kiln ( Unit-1 ) for production and energy efficiency improvement Installation of one more cement mill to increase grinding capacity. Installation & commissioning of one cement mill with cement silo and packer machine at split location. Installation of fly ash drier for cement mills Dec 08 Replacement of fossil fuel by biomass in pyroprocessing. Retrofitting of C.A. Fan of Cement Mill 2 with high efficiency Fan Power Generation from Waste Heat Recovery system
There are zero discharge effluents from industry. Only domestic waste water (sewage) is being treated at sewage treatment plant (STP).
Major Environmental Projects taken during the year 2006- 07 & 2007-08
Reduction in fugitive emission Cement flooring of truck parking area (14000 Sq feet) Cemented road inside the plant, colony & road to highway (5.0 Km) Installation of vacuum cleaner in packing plant Purchase of road sweeping machine
Reduction in GHG emission and greenery improvement Development of garden / parks in township (15.0 hectare area) Plantation of 5000 saplings JETRPHA in mines area Plantation of 10000 saplings in plant and township Plantation of 500 NEEM trees both sides of road to main highway
Water Conservation Rain water harvesting to recharge bore wells Check dams construction in mines area for water harvest Creation of three dams for rain water storage in township (45000 m)
Safety
JK Lakshmi Cement Ltd. is an OHSAS 18001:1999, certified cement plant. It continuously focus on improving its Safety & Occupational Health standards and recent procurement of a Fire Tender in January 2008 bears testimony to this fact. Every employee at JK Lakshmi Cement Ltd. realizes the importance of safety for himself, his co-workers as well as the equipment.
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Second Prize
Cement
Unit Profile
With an objective of being an active participant in the dynamics of future of the Nations march towards total industrialization and energy conservation, Prism Cement Ltd has set up a state-of-art, energy efficient cement plant near Satna, in Madhya Pradesh. Most advanced machinery and technology imported from M/s FLSmidth Denmark and state-of-art processes lend it a futurist environment.
Energy Consumption
Prism Cement Limited firmly believes in attaining, retaining and reforming its energy conservation initiatives time to time. Originally installed efficient equipments and system, gives glare to the energy conservation drive. Year-by-year increasing production demand is associated with decreasing the specific energy consumption.
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675 675 670 665 660 655 650 645 640 2004-05 2005-06
year
The above fact is accompanied with better electrical energy conservation also. kWh/MT of clinker and cement witnesses result of energy initiatives.
80 70 60 50 40 kwh/mt
Perhaps, these achievements have opened broad road to move ahead in coming years.
kcal/kg clk
2006-07
2007-08
79.9
56.5
55.3
51
2004-05
2005-06
2006-2007 year
2007-2008
Energy Planning
Energy planning for next 3 years with 2005-06 as base year is as follows. Year 2007 08 2008 09 2009 10 kWh/MT cement 66.2 65 64 kCal/kg clinker 654 650 650
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Pollution control equipments at Prism Cement are designed for emission standard of only 50 mg/nm3 for all the main stacks, which is relatively lesser than standards given by the state pollution control board for other stacks. Prism is committed to maintain this stringent standard.
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Certificate of Merit
Cement
Unit Profile
UltraTech Cement Division (part of Aditya Birla Group) consists of five integrated Cement manufacturing Plants and five grinding Units with a total installed capacity of 17Million Tons per annum (MTPA) located in different parts of the country. AP Cement Works (APCW), located at Tadipatri, Anantapur Dist, A.P. with an Installed Capacity of 2.00 MTPA was commissioned in April'1998 with the latest Cement manufacturing technology from F.L.Smidth & Co, Denmark. The plant has been upgraded to 2.70 MTPA through major debottlenecking exercise in 1999 and 2002 by adopting latest technologies. It is always in the forefront in adopting latest technologies or innovations. APCW manufactures three types of Cement, Ordinary Portland Cement (OPC), Portland Pozzolona Cement (PPC) and Portland Slag Cement (PSC) for its major customer groups like Dealers, Stockists Builders / Contractors,cement based Industries. Its ideal location, as far as market is concerned is its advantage. It is, equidistant from all the three major cities in the south Hyderabad, Bangalore and Chennai and caters to Karnataka, Tamilnadu, Kerala and Goa markets, in addition to Andhra Pradesh. The finished product is sold through the Marketing Department, which has a wide dealer network.
Energy Consumption
S.No. 1 2 3 Particulars Electrical Energy* Thermal Energy Total Manufacturing Cost Total Energy Bill Energy as % of Total Cost of Production Unit kWh /Ton of Cement kCal /kg of Clinker Rs. Lakhs Rs. Lakhs % 2005-06 83.67 686.1 24766.05 7653.47 31 2006-07 87.12 691.0 28868.85 5715.97 20 2007-08 84.36 686.7 30959.86 6567.89 21
4 5
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Annual Savings observed: Rs. 304.00 Lakhs 2. Optimizing kiln operation efficiency, bringing stability in productivity levels and reducing electrical and thermal energy losses.
: :
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3. Guest House was using electrical power to water heating in rooms for hot water supply. Hence introduced Solar heating systems for water heating. Totally 14 nos units are installed.
4. 6th cyclone entry is widened in calciner string of pre heater . Due to this modification load on CS fan has reduced from 2100 to 1800 per hour as the pressure drop has reduced.
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