Training Course on Energy Conservation in

Japan for Indian Cement Industry (ECIN)

at AOTS Yokohama Kenshu Centre
(16-27 Jan06)

Organised by – New Energy and Industrial Development Organisation

(NEDO)
Implemented by – Association for Overseas Technical Scholarship
(AOTS)
 ECIN Participants
1. Mr. S Ramarao, GA Kodinar
3. Mr. M. Rao, Vasawadatta
5. Mr. Vinay Saxena, Shree
7. Mr. K K Jalori, JK Nimbahera
9. Mr. A Saxena, ACC Madukkarai
11. Mr. Rajabalasubramani, Ramco
13. Mr. V Singh, Ambuja Eastern
15. Mr. Gurunathan, India Cement
17. Ms. K. V. Kalyani, NCB HYD
2. Mr. Dinesh Agrawal, Binani
4. Mr. Manish Singh, OCL
6. Mr. J S Kalra, Birla Chanderia
8. Mr. B K Agrawal, JK Lakshmi
10. Mr. M P Joshi, Maihar
12. Mr. S. C. Bhanot, Orient
14. Mr. K. Prakash, GA Mumbai
16. Mr. O. P. Grover, NCB ND
Yokohama Kenshu Center
 LEARNINGS
 Energy Conservation
 Other learning/observation

 Important information

-------------------------------------------------------------

Timings during trg at Japan:

Breakfast 7 – 8.30 am
Presentations/ Lectures/site visits 9 – 12 noon
Lunch 12 – 1.30 pm
Lecture 1.30 – 5 pm
Dinner 6 – 8.30 pm
Group discussions 9 – 9.30 pm
precisely 5 min break after every hour during presentations/Lectures
 Energy Conservation: Scenario in Japan
1. Japan aggressively started conservation activities after
oil crisis of 1973 & 1979 as Japan imports 90% of
energy used. EC Law was enforced in 1979.
Improvement in plant operation and energy
management with low or zero investment for
curtailment of energy usage have been key.
2. Industries succeeded in EC after oil crisis for following
reasons:
 regulation measures, support & subsidy system by govt
 self-help support by companies for cost reduction
 implementation organisations like ECCJ.
 by TQM and investment for improvement
 extensive use of alternate fuel
 energy efficiency enhancement in order to achieve 3E’s
harmonisation:
Economic growth, Environment protection, Energy security
 E.C. Activities in Japan
1. Designated industries have been identified as:
Type I – 3000 Kl/12 mil kWh – Energy Managers
Type II – 1500 Kl/ 6 mil kWh – Energy Officers
2. Energy Managers must for identified industries. It is a
licensed officer by govt. Separate E.Mgr for electricity
and thermal heat.
3. Even hospitals, shopping malls, small companies and
other utility suppliers have to keep Energy Officer, who
is having certified trg.
4. E. Mgr & E. Officers have to set targets for their factory
and submit yearly plan + periodical report to govt.
Targets are set for industries. When most of industries
reach target, it is revised.
5. ECCJ in Japan conducts exam for E. Mgr/Officer.
6. By law plant management is obliged to respect opinion
of E. Mgr.
 E.C. Activities in Japan
1. Top Runner programme to award most efficient energy
user has done wonders.
Under this programme the consumers who achieves
highest efficiency in its category is recognised publicly &
govt gives further subsidies. Achievement by specific
industry/company is set as target for other members of
same segment.

1. Energy labelling being done on products to show that

target achieved.

2. E-CO ambassadors appointed fr promotion

3. Energy management by intensive follow up and

monitoring is most profitable
 Energy Audits
 EC audits are conducted free of cost as it is subsidised
by METI (Ministry of Economy, Technology & Industry).
Recommendations and proposals fr EC are given after
audit, management discusses techno-commercial
aspects with auditor.

 Proposals are implemented by ESCOs (Energy Services

Companies). However ESCOs don’t give any guarantee
of savings by implementation, even then companies hire
them. Govt organisations also are taking services of
ESCOs.
 Three don’ts of EC
 Don’t use > required

 Don’t leak (water, steam, oil etc)

 Don’t release (holes in ESP, kiln i/l-o/l seal, bad

insulation)

Energy cost of cement production is 17% of total cost,

whereas in India it is 40%. Co-generation, use of waste as
alternate fuel & small process improvements have been
major player in this.
 Public Awareness
 Promotion of SMART life – voluntary change of life style
intended for energy saving, with help of check list
circulated by govt free of cost
 Top runner program
 Energy labeling on products
 Ranking catalogue for Energy Efficient Appliances
 Use of energy star logo on EEA
 E-Co-Navi : energy conservation monitoring system for
residences, displaying energy saving amount for
electricity/ fuel gas/ water. 20% reduction in electric
consumption observed after installation.
 Formation of EC Republic in schools, setting targets &
action plans to achieve it. Upto 14% electric bill saving
observed.
 Publicity through exhibitions, poster & essay completions,
promo posters & video, internet, print & electronic media.
 Methods of EC in Japan

 ERP – energy cost reduction program: base- industrial Engg.

 SAVE – systematic approach to valuable energy: base- value

engg

 MAP: base- quality control.

MAP method is used extensively in current days. It is utilised
to systematically discover potential themes thru SGA.
It has two stages: discovery & implementation. MAP can be
applied for other purposes also, like maintenance, office work
etc.
There is comprehensive 3 days trg program fr MAP.
10 steps of E.C.
MAP
 Cement in Japan
 130 yrs of history, currently 33 plants 58 kilns, 70 mil TPA
cap, with 72 mil TPA production, 4th place in world.
 There were 50 plants with 83 kilns till 1983. In 2005 it is
33 plants with 59 kilns. Plants/kilns shutdown due to
decrease in demand & to improve efficiency.
 Taiheiyo Cement #1 (Onoda + Nihon taken over by
Taiheiyo), Mitsubishi Materials with Ube #2, Sumitomo
with Osaka #3.
 10 yrs ago total cement employee strength 17339 was. As
on 2005 it is 9373. it has been possible thru automation.
 EC Practices in Cement

 Target setting is job of energy manager. Target must be

attainable and sustainable.
 Comparing kiln vs. kiln is a good practice in plants which
have more than one kiln.
 JIS standard used for kiln heat balance.
 Depreciation time is 5 yrs for energy effective equipment.
 Fixed cost 50%, variable cost 50%. Energy constitutes of
about 50% of variable cost.
 760 kcal/kg of clkr is approx figure in thermal energy fr 4
stage SP.
 Grinding media should be monitored regularly. Though
power goes down slowly with reduction of gr media, the
o/p of mill reduces drastically.
Example of
energy
committee
 EC Practices in Cement
 Other than limestone many ingredients are used in raw
meal. Main is waste material. It helps in improving
efficiency and heat balance. Also waste is fired in PC as
secondary fuel.

 Lime content in l/s > 90%, very pure l/s, silica 1% in l/s

 Due to purity of l/s, fly ash being mixed as raw material.

 Final total energy is converted from per ton of cement to

per ton of clinker. This method is better from energy
conservation monitoring point of view
 Use of Alternate Fuel
Termed as New Energy, developments have been done to
use following as fuel for kiln/PC:
 Plastic waste
 Municipal Sewage Waste (MSW)
 Wood Chips
 Coal Tailing
 Household Waste
 Meat & Bones
 Tyres as whole or in chips
 Glass & Ceramic Waste
 Using plastics to fire in kiln at ~1400 deg c. Environmental
issue is taken care by the fact that after 1000 deg c there
remains no toxic fumes out of plastics.
 GHG Emissions Control
Kyoto Protocol (KP) entered in force from 16Feb05.

 If controlled as per KP, CO2 emissions will stabilise in

about 300 yrs. Even if CO2 emissions gets stabilised in say
300 yrs, the effect of GHG emitted till so far and by that
time, will keep raising the sea level due to ice melting.

 Environment acts as sink to consume GHG emissions.

 Per capita CO2 emissions (tons of CO2/person):

India – 1.06 lowest, 4.7% of world share

Japan – 9.35 5th 5.2% of world share
USA – 19.86 1st 24.4% of world share
 GHG Emission Control
KP introduces 3 mechanisms to control GHG emissions:

 CDM – between AnexI & Non Anex countries

 Joint implementation – between AnexI countries

 International Emissions Trading– between AnexI & AnexII

countries
Till so far only 5 projects in world have been issued CER
(Certified Emission Reduction). Out of it India got 2

 Discussions for methodology of CO2 capture & storage

under progress
EC in Pumps & Fans

 Pumps and fans have large potential to improve efficiency

& EC, b’coz normally installed cap > required capacity. It
shifts the operating point more than required, resulting
increase in power. Complete ckt. involves many pipes &
valves. If their resistances are added, the op point further
shifts leading to further increase in power.
 Centrifugal force increases with increase in impeller dia or
rpm. Pipe resistance decides the operating point.
 Pumps impeller can be cut /retrofitted to meet power
requirement. By cutting means max 5%.
 Flow rate at temp/ pressure at outlet or inlet must be
specified clearly while designing
 Use of V-belt and changing pulley dia is an effective
method of EC for low cost.
Practical at SMC to
observe impact of
pressure drop
Automated practical
plant set-up
Dust out of Sumitomo Metals,
Kashima. Only stack with dust
which could be noticed while
visiting 4 plants.
 EC in Compressor

 Only 19% of power is utilised. Compression increases air

temp up to 150 deg c due to energy applied for
compression. 20 to 30% air gets leaked. It makes
compressors high energy consumers.

 Measures for EC :
 arrest leakages,
 turndown pressure by improving eff.,
 use of 2 stage compressors,
 proper/re-designing of distribution ckt
 load based maintenance instead of time based.
Effective Thermal Energy Utilisation
Optimise the AIR RATIO ‘m’
m = A/Ao
A = amount of actual air used for combustion
Ao=theoretical amount of air
m can’t be calculated directly, but with help of formulae:
m = 21%(N2)/ 21(N2)-79 [mod( O2-0.5(CO))]
In ideal situation O2 = 0 hence m=1
 In case of access air O2 = 10% => m = 1.9

 In good condition O2 = 3% => m= 1.2

Reverse calculation for O2:
 if m = 1.05 => O2 = 1%

 if m = 1.3 => O2 = 4.8%

 if m = 1.1 => O2 = 2%

Hence it is very important to optimise ‘m’ for good

combustion.
Flame shape & combustion pattern

observation by changing air ratio ‘m’

 Unburnt Material- Repercussions

 If unburnt material goes in upward cyclones with hot

gases, it results in inverted temp profile in PH as material
burns in upper cyclone. This phenomenon results in
cyclone jamming. Lifting of material in upward cyclone
reduces efficiency, increases pressure drop and sometimes
chlorides keep on circulating which causes chocking.

 Dispersion plates are used to reduce the dynamic force of

material, which increases pressure drop.
 Results of Uzbek Plant Study

 Effect of improved operation - highest

 Effect of facility management – lowest

 Effect of equipment change – middle

Hence it is always advisable to improve

operations
Mitsubishi Yokoze Cement Plant
 Established in 1950. MMC market share 12%. Clkr production
1.004 milT, cement prod 1.138 milT in 2004. Employees 67,
(excludes contractor’s 175). Sp power consumption 95 kWh/t of
clkr.
 Cement blaine 3000, ball mills used.
 Uses industrial, municipal, household waste as raw meal
and to generate alternate fuel.
 Fly ash, plastics, tyre chips, clay waste coming out of
construction work, bottom ash, slag, glass waste,
ceramics, wood chips, meat & bone meal, bathroom-toilet-
household sludge (not industrial sludge) are used.
 Plastic, wood chips, meat & bone: crushed to small pieces,
pulverised and fired in kiln thru multi-channel burner.
Mitsubishi Cement
Plant
 Observations during Plant Visit
 Wood chips are saw dust, which are supplied free from
waste generator.
 Plastics – crushed in roll crusher., then pneumatically
conveyed to burner pipe. All short belt conveyors up-to 75
mtr. are enclosed in pipes. De-chlorination/Cl by-pass
plant installed.
 Tyres are cut in pieces ~ 100 mm by supplier and fed at
PC bottom by BC. These go inside in batches thru twin
pneumatic flap gates. Feed rate is pre calculated.
 Sludge comes in closed tippers, then made slurry and
dried before feeding at kiln i/l.
 Meat & bones are crushed, dried and made in powder
form to feed pneumatically in burner pipe.
 Gas analysis at all stacks and in process done bimonthly.
 No energy cell, but energy committee, which mostly
concentrates upon electricity consumption.
 Taiheiyo Cement, Kumagaya
 Established 1962. Clkr 7730 tpd. Employees 105
(contractor employees 200)
Kiln 5.5x100 mtr. Cement ball mills with pre-grinder.
 This plant was first in world to use municipal waste as
alternate fuel
 UNIQUENESS of plant: ECO Cement
 Incinerator ash generated from burning of urban waste is
used as raw meal ingredient after treatment & added with
min quantity of natural material. It forms ECO cement. Fly
ash filter cake used as clay substitute.
 Tankers of fly ash are cleaned before going out. Totally
enclosed dumping to avoid pollution. Dioxins are decomposed
in kiln at high temp of 1350 0C. 1 ton cement comprises 500
kg incinerator waste.
Taiheiyo Cement, Kumagaya
 Pachinko (gamble machines) used to generate fuel. Screw
reducer used to solidify the crushed material. Size up-to
500x100 mm, fed at kiln i/l. CV 5000.
 Waste plastic size < 10 mm, fed pneumatically only at kiln i/l.
 Complete tyre of medium size vehicle fed thru belt conveyor at
kiln I/l.
 Fly ash made from domestic waste. Incinerator belongs to
municipality. Only transport charges.
 Waste product from Saitama, CV 3200.
 Photographs of industrial waste, municipal waste treatment
plant not allowed. We were not taken to kiln i/l, kiln o/l. Plant
very neat & clean
 Plant more congested than our’s. Because all are old plants with
modifications and installation of equipment for generating
alternate fuel from waste.
Tyres feeding at
Kumagaya
Wood chips/Saw dust to feed
in kiln
Bulk loading
Taiheiyo Cement, Kumagaya
 Situated at HIDAKA city with 54000 population and waste
generation of 15000 t/yr, which is completely used by
cement plant.
 One kiln, Dual Firing-De Noxing type PC with 4 stage
PH. Direct employees 100, sub-contractor 200.
 90% despatch by road in bulk. 1% in paper bags
 Not using WHRB. Cooler exit gas of ~ 250/300 deg c used
for CPP.
 UNIQUENESS – Applied Kiln for municipal waste, since
2002 Nov.
 Water spray done on kiln shell for cooling. They said they
have not faced any problem till so far.
 Tyre pieces of ~ 50 cm are fed at bottom of PC, about at
10 mtr height from kiln i/l
Taiheiyo Saitama Plant
Digester AK at Taiheiyo, Saitama
 Applied Kiln for municipal waste, since 2002 Nov. In this
case incinerator is not used, instead one abandoned rotary
kiln is used as digester to degrade the waste biologically.
 Idea came from joint efforts of Saitama Municipal &
Thaiheiyo, b’coz municipal corp. incinerator had completed
its life and instead of going for incinerator govt wanted
some other means for disposal of waste.
 Digester – 3 days waste retention time.
1st day – mechanical breakdown process of bags, MSW
2nd day – breakdown of waste into finer pieces accelerates
aerobic digestion, chemical reaction/fermentation with
aerobic bacteria, no heating, max temp ~ 60 deg c.
3rd day – organic contents of waste convert into soil-like
cement raw material.
150 t produced in 3 days, continuous process. Production
and performance of cement quality improved after using
MSW. Above material after processing is fed at kiln i/l .
MSW feed process at
Saitama
Digester outlet at
Saitama
Other Learning/
Information
Learning through Observations
 Basic thing in Japan is awareness and dedication of people
for EC. It is the most effective way to reduce production
cost and increase profit. They struggle to reduce
production cost.
 5W + 2H technique for making a project report – what,
why, who, when, where, how, how much cost.
 Osborn checklist method must be followed during brain
storming sessions.
 While measuring dynamic pressure tube should be inside
duct up-to centre for long time whereas for static pressure
tube should be just at edge of duct.
 Practical trg on process measurements and power
calculation w.r.t. pressure drop. All the measuring
instruments and ckt were readymade, calculations
automatic on-line thru pc. We could observe the variance
in power consumption with change in air flow by
speed/damper control and response of pressure drop.
Example to show
impact on
profitability by
production cost
reduction(red) vs
sales
increase(blue)
 Other Learning
 Low air supply/m< 1 leads to soot formation to clog burner.

 We could see the flame shape/ thermal consumption trend

& furnace conditions thru open burner by changing the air
ratio at mini-plant in Sumitomo Metals Lab.
 Use of hybrid engines & Hydrogen cell cars becoming
common. People are conscious about car engine idling to
save fuel.

 Cement imports- ready mix concrete, mostly from South

Korea.

 Cement consumption is decreasing in Japan.

 There is no 6 stage PH.

 Kiln shutdown for brick lining- 2 times a year

Other Learnings
 Kiln operation ratio=running days/320 (capacity to run
kiln). It is low b’coz of low requirement.
 Biggest kiln is 10000 tpd at Ube.
 JCA doesn’t regulate the production rate of plants. It
depends upon individual plants to control their production
rate. In fact top 3 cement companies have 80% market
share and these 3 are the market controllers. There is no
price control by JCA because of Entrust Law. Bulk Cement
price ~ 8600 yen/t in Tokyo area.
 Number of employees doesn’t include maintenance
contractors who work during shutdowns for maintenance.
Complete maintenance is done on contract.
 Production workers mean operation/production dept
people
 Capex for new plant @ 150 $/t of clkr. 10% of budget
spent on automation and 10% to 15% on E&I.
Other Learnings
 Fly ash is being used as raw meal as well as performance
improver
 Role of JCA is to lodge petitions with government on
behalf of cement companies.
 In 2004 ready mix sold was 73% of total production.
Biggest consumer is housing sector. Maximum export to
middle-east.
 52% dispatch by sea, 31% by road tankers, and 1% by
rail.
 Per capita cement consumption:
Highest- Korea 1216
Lowest – India 109
Japan – 454
 Coal tailing – very low calorie coal left after excavation. It
is used in PC firing.
 Experience low production during night.
Other Learnings
 Waste heat recovery boilers are very effective fr short
length kilns.
 No dust from stacks, road, fugitive. Very neat & clean.
 Aggressive participation in community welfare and
awareness by all sector companies.
 New plants are not feasible due to high environmental
cost.
 Everybody wearing same quality uniform, shoes and
helmet. Paper caps given to wear under helmet. No
distinction between levels.
 Operation, Equipment & Management groups for EC
 TPM in culture, no one discuss it.
Other Learnings
 Sound barriers installed at both side of the express-
ways to minimize noise pollution.
 Building construction/repair even in central Tokyo were
going on without any problem. Entire building covered
and cranes installed on top for operation.
 In restaurants menu cards were bearing the calorific
value of items.
 Vegetarian food was very good at YKC.
 Smoke chambers made at all places, even at roads at
interval of ~ 250 mtr.
 optimising the process with small improvements has
highest impact.
Effect of improved operation - highest
Effect of facility management – lowest
Effect of equipment change – middle
Building repair work
in central Tokyo
 Covering of
building during
repair work
Sound barrier at road-side
 Electrical
maintenance
 Other Learnings
 High level of courtesy
 High regard for elderly persons
 High level of awareness w.r.t. Energy Conservation.
 Normally all vehicles equipped with GPS. Long trucks, buses,
trailers equipped with rear view CCTV.
 no tea or water glass/bottles provided in conf rooms. It was to
avoid spillage of liquid on floor carpet

 In lanes or roads where traffic signals are not present, reflectors

are positioned is such a way that person/vehicle at turnings can
be seen by approaching vehicle.

 Insulated conductors used for overhead cables on electric poles.

For Our Life

For Our Earth
For Our Future
Insulated overhead
cables
Cable dressing
 IMPORTANT
INFORMATION
 Important Information
 Stress upon use of waste/recycle material as raw meal to
save lime deposits,
 Fuel made of waste constitutes 30% of total fuel used.
 Tyre pieces of ~ 50 cm are fed at bottom of PC, about at
10 mtr height from kiln inlet.
 Taiheiyo gives consultancy for alternate fuel generation
from waste.
 TCS – Taiheiyo Coating System to prevent sulphur coating
due to use of pet coke
 Fly ash made from domestic waste. Incinerator belongs to
municipality. Only transport charges.
 Pachinko- Screw reducer used to solidify the crushed
material. Size up-to 500x100 mm, fed at kiln i/l. CV 5000.
 No dust from stacks, road, fugitive. Very neat & clean.
 Waste generator is penalised, e.g., disposal of 1 bicycle @
2000 yen.
Distant view of
Mitsubishi plant
 Important Information
 Fly ash, plastics, tyre chips, clay waste coming out of
construction work, bottom ash, slag, glass waste,
ceramics, wood chips, meat & bone meal, bathroom-toilet-
household sludge (not industrial sludge) are used to
generate alternate fuel.
 Multi-channel burners are used to fire the pulverised
alternate fuel in kiln.
 Using plastics to fire in kiln at ~1400 deg c. Environmental
issue is taken care by the fact that after 1000 deg c there
remains no toxic fumes out of plastics.
 De-chlorination & de-odouring plants are installed for use
of MSW.
 In Japan 10% of any budget is spent on automation itself
 regulation measures, support & subsidy system by govt to
promote E.C.
 SMC supplies mini-plants for training
 Thanx
fr patient hearing