Dinesh Rathi & Associates (DRA) has started energy audit with Save Energy Program of MEDA for Awarpur Cement Works, UltraTech Cement Plant (formally L&T Cement) in 1990.
The good energy savings in Utilities with better reliability in Compressed Air & Water System of old cement plants, UltraTech & Ambuja Group to implemented the energy efficient design in all the new plants constructed in last 12 years from the beginning.
Originally 2 MTA plant in Awarpur Cement Works was installed with 55 nos. of compressors with connected load 3605 KW (before implementation of Energy Audit suggestions) now new plant constructed by Ambuja at Gadchandur (Maharashtra) has only 10 nos. compressors with connected load of 760 KW (designed by Dinesh Rathi & Associates)
The proposed compressed air system specifically designs for cement plant has been design for separation of high-pressure compressed air, low volume, with low pressure; compressed air in high volume consumption has following advantages:-
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a] Reduction in Compressed Air pressure from 7.5 bar to 5.5 bar
b] Reduction in air consumption by 20% in low pressure application.
c] Efficiency improvement in high-pressure equipment.
d] Zero break down on account of Compressed Air & Water System.
e] Reduced No. of equipments.
f] Increase the life of filter bags.
g] Reduce Inventory, O&M and Manpower cost.
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M/s DRA has conducted & successfully completed various energy audit and energy conservations projects in cement industry as following;-
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| Year |
Organization / Company in which energy audit/ EC project completed |
Energy Saving Expected |
Energy Saving Achieved |
| kWh |
In Rs Lakhs |
kWh |
In Rs Lakhs |
| 2006-07 |
i) Ambuja Cements Ltd., Rajasthan, Pali |
1123200 |
44.93 |
1123200 |
50.54 |
| ii) Ultra Tech Cements, Hirmi Cement Works, Chhattisgarh |
1555200 |
62.21 |
1555200 |
69.98 |
| Total |
2678400 |
107.14 |
2678400.00 |
120.53 |
| 2004-05 |
i) Lafarge India Ltd. Bilaspur |
717901 |
12.70 |
564423 |
8.21 |
| ii) Gujarat Ambuja Cements, Kodinar (Line 3) Water |
273600 |
3.70 |
314640 |
4.26 |
| Total |
991501 |
16.4 |
879063.3 |
12.466 |
| 2003-04 |
i) Ambuja Cement Eastern Ltd., Bhatapara |
1085400 |
19.50 |
1248210 |
22.43 |
| ii) Gujarat Ambuja Cements, Kodinar (Line 3) Compressed Air |
1146816 |
17.15 |
1318838 |
19.72 |
| iii) Prism Cement Ltd. Satna |
1395148 |
41.84 |
1534663 |
46.02 |
| Total |
3627364 |
78.49 |
4101711 |
88.17 |
| 2002-03 |
i) Gujarat Ambuja Cements, Kodinar (Line 1& 2) |
3382848 |
44.87 |
3890275 |
51.60 |
| ii) Ras-Al-Khaimah Cement Co., UAE |
1387584 |
13.00 |
1456963 |
13.65 |
| iii) Ambuja Cement Rajasthan Ltd., Rajasthan |
633600 |
13.50 |
696960 |
14.85 |
| iv) Gujarat Ambuja Cements Ltd., Ropar |
696960 |
13.59 |
766656 |
14.95 |
| Total |
6100992 |
84.96 |
6810854.4 |
95.0495 |
| Overall 14.4 Million kWH /Yr. energy savings achieved in cement industries through energy efficiency & conservation measures |
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