Power Reduction Measure for Po

Sr No. Actionable points

1 Separator rotor Sealing to be done by hard faced liner & minimize the
seal gap up to 5mm
2 Dry fly ash unloading compressor to be redesign from 80kw to 45kw or
below
3 Shift wise Optimization of compressor run hours

4 Rota feeder for flyash addition in all cement mills

5 Number of group reduction in cement mills for start -stop

6 Grizzly bar installation gypsum discharge chute to avoid lumps in cement
mills
7 VRM rotary feeder to be run in auto mode in reverse as well as in forward
direction during jamming
8 Compressor loading & unloading through PLC
9 Different operating compress air pressure to be set for loading &
unloading of cement
10 Flow meter & control valve required for all packers & cement mills at
main receiver tank of compress air
11 Individual compressor ideal run to be monitor from CCR & local run
should be eliminated

Power Reduction Measure for Po

Sr No. Actionable points
1 Portable compressor (5.5KW or less) to be utilize for bulk loading
2 Compressor loading & unloading through PLC
3 Different operating compress air pressure to be set for loading &
unloading
4 Flow meter & control valve required for all packers & cement mills at
main receiver tank of compress air
5 Individual compressor ideal run to be monitor from CCR & local run
should be eliminated
6 LP air to be utilize for silo extraction
7 Shift wise Optimization of compressor run hours
8
Interlocking of fans and compressor with packer to minimize idle running.
9 Bag burst analysis to be done category wise by using Pereto chart & root
cause will be eliminated
11 Tilt switch arrangement to by provide for bag jamming
Power Reduction Measure for Post clinkerization (Cement Mills)
Area Benefits at other units FPR
Cement mill
0.11kwh/cement Som Reddy

Cement mill 35kw/Hrs Som Reddy

Cement mill 0.29KWH/T cement Devesh/ Som Reddy

Cement mill 0.19KWH/t cement Jay Shankar

Cement mill 0.03KWH/T cement Jay Shankar/Rajan

Cement mill 0.04kwh/start -stop Som Reddy

Cement mill 0.04kwh/start -stop due to rotary feeder jamming Som Reddy
Cement mill Devesh/ jay Shankar

Fly ash/Cement mill

Cement mill Som Reddy/Jay Shankar

Cement mill Devesh/ jay Shankar

Power Reduction Measure for Post clinkerization (Packing Plant)

Area Benefits at other units FPR
Packing plant Subba Rao
Packing plant Praveen

Packing plant Praveen

Sp power reduction from 1.35 to 1.22 KWH/T material

Packing plant Praveen

Packing plant Praveen

Packing plant Subba Rao/Praveen
0.29kwh/t cement
Packing plant Subba Rao

Packing plant 0.04KWH/T material Praveen

Packing plant Subba Rao

Packing plant Praveen
Remark

fly ash feeding variation was

eliminated, Fly ash addition
increased

Remark