InternationalResearchJournalofEngineeringandTechnology(IRJET)e-ISSN:2395-0056Volume:02Issue:01|Apr-2015www.irjet.netp-ISSN:2395-0072©2015,IRJET.NET-AllRightsReservedPage248DETAILEDENERGYAUDITANDCONSERVATIONINACEMENTPLANTR.VIRENDRA1,Dr.B.SUDHEERPREMKUMAR2,J.SURESHBABU3,D.RAJANIKANT41DeputyDirectorGeneral,NationalProductivityCouncil,Telangana,India.2Professor&Chairman(BoardofStudies),JNTUCollegeofEngineering,Hyderabad,Telangana,India.3AssistantprofessorinMED,K.S.R.M.CollegeofEngineering(Autonomous),Kadapa,A.P.,India.4Dy.Director,EnergyManagementDivisionNationalProductivityCouncil,Telangana,India---------------------------------------------------------------------***----------------------------------------------------------------------Abstract:ACementplantisanenergyintensiveindustrybothintermsofthermalandelectricalenergyandmorethan40%ofproductioncostisaccountedforbythecostofenergy.Withintensecompetitioninthemarketplaceonprice,energyconservationoffersitselfasalowcostoptiontocutcostsandcreateamarketedge.Everyeffortinbringingdownthethermalaswellaselectricalenergyusewouldimpactdirectlyontheprofitabilityofthecompany.Theenergyauditandconservationprojectwascarriedoutinthecementplanttoassesstheperformanceofitsvarioussub-sectionsandutilitiessuchaspyro-processes,fans,compressorsforCementManufacturing.Thisprojectworkalsostrivestoidentifypotentialavenuesforenergyandcostsavings.Theplantmainlyreliesonits12MWcaptivepowerplant(CPP)tomeetitselectricityrequirements.Thisprojectbringsoutinaholisticandsimplefassion,thebroadframeworkandmethodologyrequiredtobefollowedtoconductanenergyauditandconservationstudyinatypicalcementplant.PROBLEMSTATEMENTEnergyauditandconservationinacementplant,involvespainstakingtaskwithenormousamountofdutyparametersthatneedtobemonitoredmeasuredandanalyzedinasystematicmannertobringtomaximumpossibleenergyconservationoptions.Thisprojecthasattemptedtoaddressthepotentialenergyconservationoptionswhichhasamajorimpactonreductionofenergyconsumptionandenergycostsavingsinacementplantandwithanobjectivetoprovideaframeworkforinstitutinganenergyauditinacementplantalongwithevaluationmethodsandanalysistobringoutmeaningfulandsubstantialenergyconservationoptions,inaeasytoimplementmanner.Thisprojectworkwouldserveasareferenceguidetoanypracticingengineertoconductwitheaseanenergyaudit,inafacilityascomplexascementplant,inaprofessionalmanner.1.INTRODUCTIONTheProgressivemanagementofthiscementplanthasbeencontinuouslyimprovingitstechnologyoverthepastfourdecades,sinceitsestablishment.Itstartedwiththewetprocessinthreeseparatecementplants,andnowthesehavebeenwhollyconvertedtodrycementprocessandmoderntechnology.Themanagementofthiscementplantaccordshighimportancetosocialresponsibilityandenvironmentalvalues.Thisismanifestintheinstallationofthelatestpollutioncontrolequipmentintheplant.Tosupporttheproductionofcement,theplanthasmodernverticalrollergrindingmillsalongwithtubemillsbothforrawmealaswellascoal.Cementgrindingisachievedexclusivelybytubemills/horizontalballmills.ThefinalproductsoftheplantincludePPC,OPC,PSGandotherspecialcements.ThemajormarketsareTamilNadu,Kerala,Karnataka,AndhraPradesh,Pudducherryetc.2.PROCESSDESCRIPTIONTheproductionofcementinvolvestwomajorprocesses,a.ThePyro-process,wherelimestonethemainrawmaterialalongwithotheradditivesintheformoffinegroundpowerisconvertedtoclinkerinmultistagecy...
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