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EnergyEnergy EfficiencyEfficiency BulletinBulletin Case Study Bulletins from CII-Sohrabji Godrej Green Business Centre
EnergyEnergy EfficiencyEfficiency BulletinBulletin
Case Study Bulletins from CII-Sohrabji Godrej Green Business Centre
Bulletin No. 11
Replacement of Old Inefficient VRM and Cooler Vent Fans with
High Efficiency Correct Size Fans
October 2007

Company details

Dalmia Cement (Bharat) Limited is one of the oldest cement plants in India, having commenced operations in 1939, with an installed capacity of 250 Tonnes per day. The plant has continuously upgraded the equipment, systems and technology to such an extent that it is one of the most energy efficient units in the country.

Also, in the year 1991, a Regional Training Centre sponsored by World Bank was established at the unit to cater to all Cement Plants, located in South India. A major capacity expansion project was taken up by the unit enhancing the capacity to 4200 TPD.

Dalmia Cements produces Oil Well Cement, Airstrip Cement, Railway sleeper Cement, and special cements like Coastal Cement, Superoof Cement, Super foundation Cement, Ordinary Portland Cement, Portland Pozzolana Cement.

.

Back ground

Fans are major energy consumers in Cement Industry. Fans in the cement industry usually have to handle large gas volumes, high pressure, high temperatures and high dust loading. The various applications of fans include Raw and Cement mill de dusting, Pre heater exhaust, Cooler exhaust, Forced draft, Pre calciner, Turbo separator and Coal grinding plants. Several parameters like selection of fans having lesser efficiency (due to lower capital costs) & operation of fans at points other than the design operating point, contribute to energy inefficiency.

In centrifugal fans, for the maximum operating efficiency the operating point should be very close to the design point. Any mismatch in terms of operating pressure or capacity with the design parameters, would result in lower operating efficiency and would result in higher power consumption.

The reasons for lower operating efficiency could be over sizing of the fan, ageing and wearing out of impeller. This would result in lower pressure development, lower quantity of air delivery and lower efficiency.

The latest centrifugal fans are available with operating efficiency as high as 80%. Hence there is a good potential to

save energy by replacing the existing fans with correct size high efficiency fans.

Project details

During a study to measure the actual efficiencies of the fan the following parameters were measured.

3

Actual Flow delivered by the fan in m / sec Actual Head developed in mm WC Actual Power consumed in kW

Based on the actual measurements it was estimated that the operating efficiencies of the VRM (Vertical Roller Mill) fan and Cooler vent fan were 44% & 18% respectively. The typical benchmark for efficiencies for these applications is 75%.

Further it was observed that there was a mismatch in the design head of the fan & the actual operating head. This resulted in operating point of the fan shifting to an inefficient zone on its performance curve.

Thus, Plant team traced out that there is a very good potential for energy saving by installing a new correct size fans of high efficiency in place of existing VRM fan and cooler vent fan. New higher efficiency fans were installed in place of old fans.

vent fan. New higher efficiency fans were installed in place of old fans. Typical characteristic curve

Typical characteristic curve of centrifugal fan

fan. New higher efficiency fans were installed in place of old fans. Typical characteristic curve of
Effi. Effi. Investment Power FAN Old New RS saving fan % fan % (in Lakhs)
Effi.
Effi.
Investment
Power
FAN
Old
New
RS
saving
fan %
fan %
(in Lakhs)
kWh/hr
Annual
power
saving Rs
( in Lakhs)
VRM
44
75
15
80
19.6
Fan
Cooler
18
70
15
90
25.2
Vent Fan

Results of the project

of

8 months

.

Issues faced during implementation No major issues were faced during the implementation of the project. The fans were made ready and kept in the assembled condition at site. The fans were hooked up during the annual shut down maintenance.

Rs 4.60

CII

350

The

Comments by the plant team The project was implemented by Dalmia Cements, Dalmiapuram in the year 2005. This project was identified and implemented after measuring actual (operating) parameters and estimating the operating efficiencies of the fans. Fans in the cement industry are major energy consumers. Majority of the fans operate in inefficient zone due to mismatch in design and actual parameters. Substantial saving potential exists across the industry by replacing inefficient fans with high efficiency correct size fans.

Financing of the project The plant invested Rs 3.00 million (USD 0.075 million) for implementation of the project. The investment was taken up fully with internal funds.

By installing new high efficiency fans energy savings to the tune of 80 kW was obtained in VRM fan and 90 kW in cooler

vent fan. This translates to a financial saving of

million (USD 0.115 million). The investment incurred was

Rs 3.00 million (USD 0.075 million), with a pay back period

Benefits of the project

Higher operating Efficiency of Fans

Reduction in power consumption

Efficiency of Fans Reduction in power consumption Cost benefit analysis Annual savings – Rs 4.60 million

Cost benefit analysis

Annual savings – Rs 4.60 million (USD 0.115 million)

Investment

– Rs 3.00 million

(USD 0.075 million)

Payback

– 8 months

million (USD 0.075 million) Payback – 8 months About CII & CII-Godrej GBC is a non-government,

About CII & CII-Godrej GBC

is a non-government, not-for-profit, industry led and

industry managed organisation, playing a proactive role in India's development process. Founded over 112 years ago, it

is India's premier business association, with a direct

membership of over 6500 organisations from the private as well as public sectors, including SMEs and MNCs, and an indirect membership of over 90,000 companies from around

national and regional sectoral associations.

Cll-Godrej GBC is a Centre of Excellence in Energy Efficiency, Green Buildings, Renewable Energy, Water, Environment & Recycling and Climate Change activitiesin India.

About 3 Country Energy Efficiency

The Project "Developing Financial Intermediation Mechanisms for Energy Efficiency Projects in Brazil, China and India" aimed to substantially increase investments in energy efficiency by the domestic financial sectors in Brazil, China and India.

project was a partnership between the World Bank, the

United Nations Environment Programme (UNEP) through the UNEP Risoe Centre on Energy, Climate and Sustainable Development (URC), and institutions in Brazil, China and India. Additional information isavailable at www.3countryee.org

Additional information isavailable at www.3countryee.org This Energy Efficiency Bulletin comprises of a series of
Additional information isavailable at www.3countryee.org This Energy Efficiency Bulletin comprises of a series of

This Energy Efficiency Bulletin comprises of a series of case studies on successful energy efficiency projects implemented by Indian industry. The bulletin is supported under the "3 Country EE" initiative and by USAID.

implemented by Indian industry. The bulletin is supported under the "3 Country EE" initiative and by
implemented by Indian industry. The bulletin is supported under the "3 Country EE" initiative and by

For

further

Mr N.Gopalaswamy Whole Time Director Dalmia Cement (Bharat) Ltd Dalmiapuram, Trichy (Dist) 621 651 Phone : 04329-235123 Extn. 503, 203 Fax : 04329-235111 Email : gswamyn@dalmiacement.com

details

contact

Email : gswamyn@dalmiacement.com details contact Mr K S Venkatagiri / Mr K Sivaram Survey No 64,

Mr K S Venkatagiri / Mr K Sivaram

Survey No 64, Kothaguda, Near Hitech City Hyderabad - 500 032

Tel: 040-23112971 – 73 Fax: 040-23112837

,

Email : k.s.venkatagiri@ciionline.org / k.sivaram@ciionline.org www.greenbusinesscentre.com