An energy monitoring system is, therefore, very useful for benchmarking and subsequent reduction of energy consumption in an existing plant.

Methodology

Process wise and stage wise benchmarking is done by connecting instruments at the consuming points and bringing this data to a PC. This PC will obtain on line data from all the selected locations of the plant. This data is then collated into screens which provide instantaneous situation and reports which provide specific energy consumption details at the pre selected periodicity. It is possible to include output measurements also either by direct measurement or by obtaining such data from process control sy

In the cement manufacturing process the maximum cost is incurred in energy component. In other industries it is the raw material which forms 40 to 60% of manufacturing cost the scenario is quite different in cement production where the raw material is of very low cost. In cement the cost of energy is almost 30% of the total cost of production and is divided between electrical units consumed per ton and kilocalories of coal used. Therefore, for cement to be competitively priced the cost incurred in energy for cement production is the focus area.

In the past decade, cement plants have made concerted efforts in the area of optimizing energy consumption and succeeded in bring down the specific consumption from the level of over 100 electrical units per ton to less than 80 units. For coal the figure is down from 750 kilocalories to less than 600. This has been done by some logical steps and modifications in the production process. Each unit of reduction now requires a lot more effort to achieve as compared to the previous reduction. Therefore, the need of the hour is fine tuning the system by more sophisticated means to achieve cost reduction and devising newer ways of lowering consumption.

One of the universally accepted principles of management is that you cannot control what you cannot measure. Therefore, measurement becomes the first step in any energy management effort. In the case of cement plants whilst the overall consumption per ton of cement produced is known it has little value when it comes to focus required for a particular stage or process which consumes excess energy. Therefore, it is necessary that measurement of each stage or process is known and the overall consumption is broken into stage wise and process wise data.

Another factor which is often neglected is the accuracy of such measurement. Most often these measurements are taken manually resulting in human errors and other inaccuracies with relation to real time. Since the energy reduction possible by improving the efficiency of the existing process is a single digit figure most likely to be below 10 percent (this level of reduction can by itself result in saving of many lakhs of rupees) the accuracy can be achieved only if on line data or automotic measurement is available.

Cement industry is a unique example where the exchange of data within the industry is taking place through various bodies and associations. Stage wise or process energy consumption figures are available and can be extremely valuable for comparison and subsequent investigation in the cause of excesses. Once the benchmarking has been done the accurate measurement will provide the main of focus area for energy reduction effort.

An energy monitoring system is, therefore, very useful for benchmarking and subsequent reduction of energy consumption in an existing plant.

Methodology

Process wise and stage wise benchmarking is done by connecting instruments at the consuming points and bringing this data to a PC. This PC will obtain on line data from all the selected locations of the plant. This data is then collated into screens which provide instantaneous situation and reports which provide specific energy consumption details at the pre selected periodicity. It is possible to include output measurements also either by direct measurement or by obtaining such data from process control sys

ng down the specific consumption from the level of over 100 electrical units per ton to less than 80 units. For coal the figure is down from 750 kilocalories to less than 600. This has been done by some logical steps and modifications in the production process. Each unit of reduction now requires a lot more effort to achieve as compared to the previous reduction. Therefore, the need of the hour is fine tuning the system by more sophisticated means to achieve cost reduction and devising newer ways of lowering consumption.

One of the universally accepted principles of management is that you cannot control what you cannot measure. Therefore, measurement becomes the first step in any energy management effort. In the case of cement plants whilst the overall consumption per ton of cement produced is known it has little value when it comes to focus required for a particular stage or process which consumes excess energy. Therefore, it is necessary that measurement of each stage or process is known and the overall consumption is broken into stage wise and process wise data.

Another factor which is often neglected is the accuracy of such measurement. Most often these measurements are taken manually resulting in human errors and other inaccuracies with relation to real time. Since the energy reduction possible by improving the efficiency of the existing process is a single digit figure most likely to be below 10 percent (this level of reduction can by itself result in saving of many lakhs of rupees) the accuracy can be achieved only if on line data or automotic measurement is available.

Cement industry is a unique example where the exchange of data within the industry is taking place through various bodies and associations. Stage wise or process energy consumption figures are available and can be extremely valuable for comparison and subsequent investigation in the cause of excesses. Once the benchmarking has been done the accurate measurement will provide the main of focus area for energy reduction effort.

An energy monitoring system is, therefore, very useful for benchmarking and subsequent reduction of energy consumption in an existing plant.

Methodology

Process wise and stage wise benchmarking is done by connecting instruments at the consuming points and bringing this data to a PC. This PC will obtain on line data from all the selected locations of the plant. This data is then collated into screens which provide instantaneous situation and reports which provide specific energy consumption details at the pre selected periodicity. It is possible to include output measurements also either by direct measurement or by obtaining such data from process control sy

ep in any energy management effort. In the case of cement plants whilst the overall consumption per ton of cement produced is known it has little value when it comes to focus required for a particular stage or process which consumes excess energy. Therefore, it is necessary that measurement of each stage or process is known and the overall consumption is broken into stage wise and process wise data.

Another factor which is often neglected is the accuracy of such measurement. Most often these measurements are taken manually resulting in human errors and other inaccuracies with relation to real time. Since the energy reduction possible by improving the efficiency of the existing process is a single digit figure most likely to be below 10 percent (this level of reduction can by itself result in saving of many lakhs of rupees) the accuracy can be achieved only if on line data or automotic measurement is available.

Cement industry is a unique example where the exchange of data within the industry is taking place through various bodies and associations. Stage wise or process energy consumption figures are available and can be extremely valuable for comparison and subsequent investigation in the cause of excesses. Once the benchmarking has been done the accurate measurement will provide the main of focus area for energy reduction effort.

An energy monitoring system is, therefore, very useful for benchmarking and subsequent reduction of energy consumption in an existing plant.

Methodology

Process wise and stage wise benchmarking is done by connecting instruments at the consuming points and bringing this data to a PC. This PC will obtain on line data from all the selected locations of the plant. This data is then collated into screens which provide instantaneous situation and reports which provide specific energy consumption details at the pre selected periodicity. It is possible to include output measurements also either by direct measurement or by obtaining such data from process control sy

e existing process is a single digit figure most likely to be below 10 percent (this level of reduction can by itself result in saving of many lakhs of rupees) the accuracy can be achieved only if on line data or automotic measurement is available.

Cement industry is a unique example where the exchange of data within the industry is taking place through various bodies and associations. Stage wise or process energy consumption figures are available and can be extremely valuable for comparison and subsequent investigation in the cause of excesses. Once the benchmarking has been done the accurate measurement will provide the main of focus area for energy reduction effort.

An energy monitoring system is, therefore, very useful for benchmarking and subsequent reduction of energy consumption in an existing plant.

Methodology

Process wise and stage wise benchmarking is done by connecting instruments at the consuming points and bringing this data to a PC. This PC will obtain on line data from all the selected locations of the plant. This data is then collated into screens which provide instantaneous situation and reports which provide specific energy consumption details at the pre selected periodicity. It is possible to include output measurements also either by direct measurement or by obtaining such data from process control sy

An energy monitoring system is, therefore, very useful for benchmarking and subsequent reduction of energy consumption in an existing plant.

Methodology

Process wise and stage wise benchmarking is done by connecting instruments at the consuming points and bringing this data to a PC. This PC will obtain on line data from all the selected locations of the plant. This data is then collated into screens which provide instantaneous situation and reports which provide specific energy consumption details at the pre selected periodicity. It is possible to include output measurements also either by direct measurement or by obtaining such data from process control system.

Advantages of the system

1. The system is dedicated towards energy management and, therefore, the focus is on energy as compared to process control system which is aimed at optimum running of the process.

2. The system enables collection of on line data instead of spot readings once or twice a shift or day which do not provide the required trending and a day long assessment.

3. Being on line the system does not depend on manual or human intervention which can bring in errors.

4. Change in levels of consumption over a period of time can lead to better analysis of efficiency of operation.

Remote Operation

Quite often the plant personnel of technical departments are pre-occupied with repair and maintenance. They may not have time available and in some cases the required expertise may not be available within the plant to effectively deal with information provided by Energy Management System and carry out a detailed analysis necessary to improve or correct the process. In such situations it is possible to connect on line system to a remote location with suitable communication feasible by GSM or other means. If there are experts located at this place which could be the corporate office or energy solution provider, it is possible to study the trend at this location and advise the plant about corrective steps or action to be taken.