ultratech cement limited greenco gold certified unit ... · ultratech cement limited andhra pradesh...

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ULTRATECH CEMENT LIMITED Andhra Pradesh Cement Works, Tadipatri

GreenCo Gold Certified Unit

Welcomes all the delegates for Second Workshop on "Best Practices in Energy Efficiency in Cement Sector" under KEP initiative on 7th-8th July, 2016


Contents

1. Leadership & Strategy

2. Employees Involvement in Capacity Building-ISO

3. Energy Management System-ISO

4. Reduction in specific energy consumption

5. Best Practices and Identified Projects

6.Awards and Accolades


ABG Business – FY15

3 3 3 3 5 5 5 5 51010 12 13

2628 30

31

4049 49 49 51

54 69

91

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10019

91

1992

1993

1994

1995

1996

1997

1998

1999

2000

2001

2002

2003

2004

2005

2006

2007

2008

2009

2010

2011

2012

2013

2014

2015

2016

ABG Cement Capacity Exponential growth

49

Mixed strategy of takeover and expansion given results

mT/annum After Jaypee

acquisition


APCW Cluster

B

A

D

C

A

C

D

B

Arakkonam Cement Works 1.1 million MT -- ISO Certified

1.2 million MT - ISO Certified

Ginigera Cement Works

ONE million MT ISO Certified

Sankarapally Bulk Terminal

Andhra Pradesh Cement Works

Phase 1 Clinker – 2.7 Million Ton Phase 2 Clinker – 3.4 Million Ton Total Cement – 6.4 Million Ton

Total capacity Clinker : 6.1 Million Ton Cement : 9.7 Million Ton


Unit Vision & Mission

To be a Model Cement Plant by 2020 with a clear focus on Safety, Environment, Quality, Cost,

Productivity, Delivery, Employee & Societal Satisfaction.

Vision 2020

• Safety, Health & Environment

• Quality & Customer Orientation

• Operational Excellence

Key Focus Area

• Employee Engagement

• Societal Satisfaction

To deliver superior value to our customers, shareholders, employees and society at large with

Systems & Team based, Safe & Environment friendly work culture through Innovation, Skill up-

gradation, Conservation and Technological up-gradation adhering to Aditya Birla Group Values.

Mission


Milestones & Achievements

First ISO:50001:2011 certified unit among the ABG cement units

Achieved 28206 ESCERTS in PAT cycle-1

Established first of its kind(in India) WHRPP

First Time Classifier Replacement globally in Loesche Cement Mill (53.3+3)as Jt. Improvement Project.

Best Energy performance awards every year

Successfully completed Steam blowing with coal in place of HSD for Boiler#4 (first time in the history of Thyssen krupp Boilers).


Baseline(2007-10) Kcal/Kg Major Cem. Eq. 802

Major Cement Product in baseline PSC

Target(PAT Cycle-I) Kcal/Kg Major Cem. Eq. 768

Achieved(Without normalization) AY 2014-15 Kcal/Kg Major Cem. Eq. 744

Achieved(With normalization) AY 2014-15 Kcal/Kg Major Cem. Eq. 707

Baseline Production(2007-10) MT 4623915

ES Certificates (Final Awarded) Nos 28206

PAT CYCLE-I Summary, APCW

28206 ESCerts for PAT 1 Cycle


Management System Certificate


Energy Policy Implementation

Energy Policy implemented in Dec – 2011

Energy Policy states unit’s commitment towards continual energy performance improvement.

Energy policy is communicated at all levels.

Energy policy is regularly reviewed and last reviewed on 1st March’16.


Executive President Unit Head

FH-Tech

Champion

LSC RM KCC CM Packing WT

Clinker Loading

CPP AC,P&V

Township Utilities

Energy Manager

Energy Management Structure


Energy Cell- Focus Area

Energy Cell Functioning Focus Area

Restoring basic condition of equipment

Effective PM07

Process/energy optimisation

Technological up-gradation

Awareness / Campaign

Knowledge management


Annual Business

Plans

Technical Journals,

Consultants etc. KIP Visit, Best practices

Energy mapping

Plant performance

Report

Audit process

Bench-marking report Loss & Cost

Report

Opportunities for improvement

Identified

Identification of Opportunities

EE Credit 1.1


21 19 20

75 47 70

46 42

167

215

0

50

100

150

200

250

2012-13 2013-14 2014-15 2015-16 2016-17

No. Of Projects Investment (in Lakhs)

Energy Saving Projects and Investments


Team:

Frequency:

Responsible Person:

Gross Root Team

Daily

Operator

Daily Coordination

Team

Daily

Sr. Management

Energy Conservation Cell

Monthly

Energy Manager

Energy Audit

Quarterly

Technical Cell

Mandatory Energy Audits

Once in 3 Years

Energy Manager

Energy performance Review Methodology

ENCON team comprises of 8 BEE certified energy Managers and 3 Energy Auditor, and overall EnMS is

supported by 18 internal auditors


Employees Involvement & Capacity Building


Strategies Adopted for employee involvement

Organization Knowledge

KIP Visits

External trainings

Internal trainings

Participation in Seminars

Team competition

Energy conservation Week

Awareness creating to all Colony residents

Training need identification through Poornata

Rewarding & Recognition

Knowledge sharing & recognition at shop floor


Kaizen & Suggestion summary in APCW FY2013-16

We believe there is always scope for improvements

Monitoring of KPE

Team Competition

Monitoring of KPI

Rewards & Recognition

11

64

84

0

20

40

60

80

100

13-14 14-15 15-16

Energy saving suggestion

16

120

148

0

20

40

60

80

100

120

140

160

13-14 14-15 15-16

Energy saving kaizens


Display of Employees Photos along with his achievement on pathway

Out of 10 commandments for FY2015-16 our 1st foremost commandment is reduction SEC


Intranet portal for Energy Management Information


Energy conservation Week at APCW

Inauguration of energy week by UH Poster Competition

Poster Competition Energy speech competition for families


Energy conservation Week at APCW

Greeting to Dr. K. Ravi Kumar(HOD –Phys. Anatapur Degree Collg)

Energy awareness test for families

UH Speech on Energy conservation


Industry-Institute-Interface

As a part of Industry-Institute-Interface, Mr. D.C. Chandrasekhar, HOD-Instrmn. given speech in the name of topic “Role of Automation Engineer for optimization plant operation” and Mr. Suresh Kadali has given speech about Company orientation at Sri Krishnadevaraya Engineering College, Gooty, Anantapur District on 22-03-2012.

As a part of Industry-Institute-Interface, Mr. D.C. Chandrasekhar, HOD-Instrmn. given speech in the name of topic “Role of Automation Engineer for optimization plant operation” and Mr. Suresh Kadali has given speech about “Company orientation” at GATES Institute of Technology, at Gooty, Anantapur District on 22-03-2012.


Program Name Faculty Faculty Type Program Base No of Days

Advanced Training on Energy Efficiency CII, Bangalore External Functional 2.0

Heat Integration for Energy Conservation by Pinch

Gyanodaya Team External Functional 3.0





Best Practices in Energy Efficiency in Power Generation in Thermal Power Sector

K K Chakravarthi - BEE Consultant

External Functional 1.0

13th Edition of Energy Efficiency Summit 2014 CII, Hyderabad External Functional 1.0

Energy Management and Energy Efficiency Kiran Internal Functional 1.0

Energy Savings in Power Plants Kiran, CII Internal Functional 1.0

Internal Auditor - Energy Management Mr. Durga Prasad Dora Internal Functional 1.0

Training and capacity building programs


First Thermal Power Best Practice Workshop conducted by IIP & BEE on 28 Oct 2015,Reliance Power plant ,Dahanu,mumbai


Knowledge sharing portal on Energy Management


Training Identification & Project assignment


Reduction in SEC


Equipment Efficiency Monitoring Schedule


67 65

94.5

88.6 87.8 86.4 87.3 86.4

77.3

60

65

70

75

80

85

90

95

NBM IBM '10-11 '11-12 '12-13 '13-14 14-15 15-16

International Benchmark @

100% PPC

(kWh / MT of cement)

Reduction in Specific Energy Consumption

8.1% Reduction

AT 100% PPC

Blended Cement Ratio%: 48.0 47.00 45.70 43.00 42.78 42.00

National Benchmark

Utilities power increased by 2KW/MT Due to one plant only running


(KCal / Kg. of Clinker)

Specific Heat Consumption

699.9

697

692

692

702

718

675

680

685

690

695

700

705

710

715

720

'10-11 '11-12 '12-13 '13-14 14-15 15-16

Kcal/KgClnkr

Sp.Heat consumption high due to

usage of 100% pet coke in kiln


802.37

768.23

743

707

500

650

800

950

BLY Target 2014-15(GtG) 2015-16(AN)

After

Normalisation

tentative

actual SEC

APCW- PAT Status SEC: kCal/kg Equivalent Cement


Energy Saving Projects


Energy Saving Projects 2015-16 (With Investment)

S.NO Description of Project Imp. Year

Annual Electrical Savings achieved (KWH in Lakhs)

Annual Savings (INR)

(In Lakhs)

Investment (INR)

(In Lakhs)

1 Installation of low air pressure screw compressors in place of high pressure compressors for fly ash unloading.

2015-16 5.54 24.95 52.58

2 Rawmill3 &Rawmill-4 Suction line Venturi replacement work

2015-16 3.91 17.58 40.00

3 Modification of Kiln coal firing pipe line. 2015-16 6.10 27.44 25.00

4 VFD for Line2 RA fan 2015-16 1.85 8.32 7.77 5 VFD for Line2 BH fan 2015-16 0.79 3.56 7.67

6 Removal of Venturi in CM-3 bag house fan inlet duct. 2015-16 7.76 34.90 6.00

7 Replacement of Venture with straight duct at Cement Mill 3 bag house outlet duct.

2015-16 6.98 31.41 6.00

8 Power reduction by production enhancement by installing pneumatic barrier in CM5.

2015-16 14.68 66.08 6.00

9 Replacement of 108 nos 70W HPSV light fittings with 36W LED light fittings in colony

2015-16 0.17 0.78 5.18

10 Optimisation of Coal mill after removal of Venturi 2015-16 2.81 12.62 5.00


Energy Saving Projects 2015-16 (With Investment)

S.NO Description of Project Imp.Year Annual Electrical Savings achieved (KWH in Lakhs)


(In Lakhs)

Investment (INR)

(In Lakhs)

11 Replacement of 28 nos 150W HPSV light fittings with 72W LED light fittings in

2015-16 0.09 0.40 3.22

12 Replacement of 225nos 36W CFL tube lights with 18W LED lights in CCR & other area

2015-16 0.15 0.67 0.90

13 Installation of chutes in place of air slides in intermediate storage silo.

2015-16 0.56 2.54 0.50

14 Modification in Coal mill Bag house Product Transport for reducing specic power consumption

2015-16 0.20 0.88 0.40

15 Installation DP transmitters on 10 JPFs 2015-16 0.06 0.27 0.30

16 Drive derating in P2U19 from 15 KW to 7.5 KW 2015-16 0.07 0.30 0.22

17 Drive derating in P2U11 from 15 KW to 7.5 KW 2015-16 0.04 0.20 0.22

18 Shifting the Line-2 Kiln HTD scs to main PLC & removed split AC.

2015-16 0.10 0.45 0.10

19 Installation light pipe system at PP 2015-16 0.02 0.09 0.06

20 Auto operation of water cooling tower motor with o/l temp of CM pump house.

2015-16 0.02 0.09 0.02


Energy Saving Projects 2015-16 (Without Investment)



(In Lakhs)

21 Bedash cooler Air Optimisation 2015-16 0.27 1.20

22 ACC-3 fan1 Bundle Gap filling with MS Plate 2015-16 0.16 0.72

23 ON/OFF Switch control of Lighting has been provided for Ph-1 DCS I/O Panel Room Lights

2015-16 0.23 1.02

24 Reduction of Power consumption of ACC FANS at TPP 3& 4 Units by providing VFD

2015-16 7.20 32.40

25 ACC 3 &4 fans Power Optimization with Vacuum based Setpoint 2015-16 1.81 8.16

26 ACC-2 fan5 blades changed with Energy efficient profile blades 2015-16 0.87 3.92

27 Single Boiler Feed Pump Operation 2015-16 0.34 1.55 28 Single Boiler Fans Operation 2015-16 0.10 0.45 29 PH-2 Crusher DE fan with DP logic 2015-16 0.25 1.14

30 Stop 11 KW motor operation by separating power feeders for chillers AHU

2015-16 1.39 6.27

31 Local lighting control switch Provided for Ph-1 TG & ESP cable cellar and WTP MCC room.

2015-16 0.24 1.10

32 Occupancy Sensor Provided at Ph-1 Battery & Battery charger room, WTP DCS Room

2015-16 0.07 0.30




(In Lakhs)

33 ACW pump corrocoating 2015-16 0.07 0.30

34 Bypass Line arrangement for Make up Water 2015-16 0.06 0.28

35 CBD Heat recovery 2015-16 0.14 0.64 36 Boiler-1&2 IGCV removal 2015-16 0.74 3.32

37 L.P.Heater drain line connection to CRT (Hot well Bypass) 2015-16 0.21 0.94

38 Ph-2 DE Systems VFD 2015-16 2.84 12.76 39 Lube Oil Heaters indication in DCS 2015-16 0.01 0.04

40 2- Pumps modification in Final waste water pit 2015-16 0.01 0.05

41 1- ETP pumps modification done in ETP pit replaced submersible pumps instead of negative suction pumps.

2015-16 0.02 0.08

42 VFD arrangemnet for Service &inst air compresor 2015-16 3.36 15.12

43 BC-3A low Capacity motor replacement 2015-16 0.11 0.49

44 Pentane pump VFD arrangement 2015-16 5.69 25.61

45 Lighting control in all Electrical Substations 2015-16 1.83 8.21

46 Lighting control in conveyor galleries 2015-16 0.76 3.43

47 Optimizing CCR AC ,P&V operation 2015-16 0.36 1.62




S.NO Description of Project Imp.Year



(In Lakhs)

48 Lighting control of down the Hill area Road to packing plant 2015-16 0.18 0.82

49 Single start command for Line-2 Crusher & RMs 2015-16 0.20 0.90

50 Occupancy sensor provided at various locations. 2015-16 0.00 0.02

51 Provision of PID for Line-2 RM-3 fans speed Vs KW 2015-16 0.08 0.34

52 Reduction of power consumption in phase – II cement mills , by stopping Booster fan.

2015-16 9.06 40.77

53 Power saving by stopping JPF in line-1 cement mills 2015-16 1.80 8.10

54 Sp. Power reduction by improvement of Kiln TPD by optimizing raw mix.

2015-16 73.62 331.30

55 Optimisation of Phase-2 raw mills to reduce the Sp.Power consumption.

2015-16 11.73 52.79






(In Lakhs)

56 Stopping of 1 No roots blower for Line 2 CF silo aeration system

2015-16 1.27 5.72

57 Burner pipe tip cooling fan replacement with fan 2015-16 0.14 0.65

58 Stopping of air slide blower for feeding of 431 BE-1 2015-16 0.07 0.29

59 Stopping of air slide blower for feeding of 431 BE-2 2015-16 0.07 0.29

60 Granados make pump arrangement for Cooler water injection 2015-16 0.18 0.82

61 Modification of Coal Mill-1 fine coal circuit screw con-veyor K1j06 feed chute(Nov-15).

2015-16 0.02 0.07

62 Avoid the operation of flow conveyor (L61CV3) in Coal mill 2 mill reject conveying system(Dec-15)

2015-16 0.04 0.20





(In Lakhs)

63 Optimization of cycle time of Coal mill 2 rejects con-veyor pneumatic cylinder(Jan-16)

2015-16 0.00 0.02

64 Changing of magnetic separator operational interlock with F1J08(Mar-16)

2015-16 0.00 0.02

65 Replacement of Venture with straight duct at Coal mill 2 bag house outlet duct(Dec-15).

2015-16 0.37 1.69

66 Reduction of energy of water pumps from 135 Kw to 105 Kw for operation of Line-1 preclinceration plant.

2015-16 1.78 8.02

67 Water supply to CCR AC from Line-2 water system instead of Line-1 pump running during Line-1 stoppage.

2015-16 0.89 4.01

68 Optimization of energy of Line-2 cement mill cooling tower With temperature interlock.

2015-16 0.99 4.46






(In Lakhs)

69 Reduction of Idle run hours of Line-2 Girth Gear compressor with replacement from 15 KW to lower size available Kw compressor 11

2015-16 0.14 0.63

70 Operation of WHRP with 37 kW compressors instead of 160 Kw compressors.

2015-16 2.25 10.13

71 Stand by arrangement of air dryer with existing air dryers in Line-2 main Compressor house.

2015-16 0.18 0.80

72 Stopping of air slide blowers for feeding of RM-3 CF Silo Bucket elevator

2015-16 0.76 3.42

73 Stopping of air slide blowers for feeding of RM-4 CF Silo Bucket elevator

2015-16 0.57 2.57


Energy Saving Projects 2015-16 (Thermal)

S.NO Title of Energy Saving project

implemented Year of Implementation

Annual Thermal Savings achieved

(Tons of coal or oil)


(In Lakhs)

Investment (INR)(In Lakhs)

1 Insulation doing for improving the effective heat utilisation

2015-16 1058 5.0784 20.15

2 Kiln heat up with Petro-polymer fuel instead of HSD for cost reduction

2015-16 253 4.048 0

3 False air decrease in preheater 2015-16

4 Cooler MFR modification-5KCal/Kg 2015-16

5 Calciner firing line modification-Line 1 2015-16

6 Radiation losses decrease(refractory) 2015-16


Some Projects and Details


Project -1 HOT AIR DUCT3

43

Annual power saving Annual cost saving Invest. Made CO2 reduction

Million kWh Rs Million Rs Million Million Ton

6.15 / 1,302KL 58.314 130.4 3.44


Increase in WHRPP run hours due to hot air duct

(7,962 hours in 2014-15 - ever highest )

7,482

7,037

5,556 5,807

5,247

4,320

5,984

7962 7,858

7,341

6,298

6,066

5,373

4,499

3,923 4048

6,869

6039

3,800

4,300

4,800

5,300

5,800

6,300

6,800

7,300

7,800

8,300

2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15WHR Run Hours Kiln - 1 run hours Kiln - 2 run hours

Increase due to Hot Air Duct


Line-2 CM-3 Process optimization by installing new LSVS Classifier

Background of the project

Line 2 Cement Mills were running at a lower TPH and higher specific power consumption compare to line-1 Cement mills.

To reduce the specific power consumption in line-2 cement mills, installed high efficiency LSVS classifier in Cement mill-3 in the month of Mar’13.

Description of project

High efficiency LSVS classifier installed in Cement Mill-3 with the help of Loesche Germany in Mar’2013.

Cement mill-3 classifier static vanes modification was carried out in May13.

Classifier rotor cassettes gap modification was carried out in Jun’13.

Achieved desired mill output through above modifications.


Line-2 CM-3 Process optimization by installing new LSVS Classifier

Before

Gap b/w Static Vanes and Rotor is 330mm

After

Gap b/w Static Vanes and Rotor is 230mm

Benefits After above modifications the mill output is increased from 189 TPH to 230 TPH in OPC and the power is reduced from 29.5 Kwh/ton of cement to 26.56 Kwh/ton of cement .


LSKS (old design)

• High Velocity Differences

• Energy Loss

LSVS (new design) * Homogeneous Velocity * Distribution

Classifier modification in Cement Mill-3 with new LSVS Classifier


Sl No Implemented section Status Remarks Savings

1 Line-2 Crusher Completed

Observed savings of 5-6 min idle running of

entire RBC group. 80kwh for each start

2 Line-2 Raw Mill-3 Completed

Observed group to group start delay avoided,

saving of 9 minutes. 590 kwh in each start

3 Line-2 Raw Mill-4 Completed

Observed group to group start delay avoided,

saving of 9 minutes 590 kwh in each start

4 Line-1 Cement Mill-1 Completed

Trails taken Observed group to group start

delay avoided, saving of 10 minutes 350kwh in each start



delay avoided, saving of 10 minutes 350kwh in each start



delay avoided, saving of 10 minutes. 397kwh in each start







9 Line-2 Coal Mill Completed Saving of 6 minutes idle running. 105kwh in each start

Single start/ Stop for all crushers and Mills


Guillotine Damper at WHRS inlet

Benefits:

By introducing damper at WHRS inlet

WHRPP gross output increased by 90kW.

HAD fan power consumption reduced by 40kW due to reduction in false air entry.

Overall, a gain of 130kW achieved i.e. 3,120 kWh per day.


Venturi Modification in Cement mill 3

BEFORE AFTER

Benefits Saving of 0.5KWH/MT of cement due to pressure drop

reduction

Saving of 100KW to 110KW fan power


Power generation increased with dummy at HAD fan2

KAIZEN THEME :Power Generation increase at WHRP by provide dummy at HAD Fan 2

BEFORE KAIZEN (Photo / Sketch)

PROBLEM BEFORE KAIZEN: : ESP fan 1 False air taking from chimney through HAD fan 2

KAIZEN ACTIVITIES : 1. Identified the area for power generation by arrest the false air leak through HAD Fan 2 2. Dummy plate fixed before the HAD fan 2 and arrested the false air entry.

BENEFITS TANGIBLE:

1.) Per day power saving 960 KWh

2.) Per annum expected Power savings will be

3.36 lakh KWh and In terms of cost Rs.11.76/-

@ Rs.3.50 per unit.

KAIZEN SCHEDULE: Start Date : 20.04.2016 Completion Date : 22.04.2016

AFTER KAIZEN (Photo / Sketch)

BENEFITS INTANGIBLE:

1. Avoided the dust removing at HAD fan 2.

Had Gas

WHOH ESP FAN

HAD FAN

CHIMNEY

Had Gas

WHOH ESP FAN

HAD FAN

DUMMY

CHIMNEY


Modification of HSLM from 3 power pack to single power pack

Problem Statement At APCW, vertical roller mills were supplied by M/s. Loesche for clinker grinding. In clinker mill -1, great concern in grinding process was unstable operation of mill with high mill body vibration, which lead to frequent tripping of mill without change in process parameters Observations Hydraulic disturbances were creating problem in high vibration of mill. The clinker mill was supplied with individual hydraulic packs for each roller (3 no’s) instead of

conventional hydraulic pack (one power pack for all 3 rollers).

Improper feed material distribution beneath master rollers.

Improper water spray on the grinding table.


Modifications Done

Modified existing hydro-pneumatic spring system with single hydraulic system.

Optimization of hydraulic pack with different pressure settings.

Incorporation of baffle plate in the feed chute for proper distribution of material flow.

Water nozzle was taken out about 100 mm towards dam ring side.




Single HSLM Cabinet 3 power pack HSLM Cabinet


Benefits Mill operation has become very stable

Mill trippings on vibration are almost eliminated (from 4 to 5 trippings per day)

Mill vibrations are reduced from 10 mm/sec to 7-8 mm/sec.

Mill water injection/spray reduced to 5 m3/hr from 7 m3/Hr.



Benefits Mill is in operating with OPC grinding without the support of Hot Gas generator

during absence of kiln hot gases.(Kiln -2 under shutdown)

Achieved saving of Rs.95 Lacs on furnace oil consumption during kiln shutdowns

Mill is responding to operator actions & auto loop operation of air flow.

Good control of product residue standard deviation.




Trend of 24 Hrs Mill operation after modification

Vibration level


HPSV fittings replacement with LED lights in colony

Before After

HPSV Lamps replacement with LED lights in colony


150W HPSV fittings replaced with 72W LED light fittings Benefits Saving of 18250 units/ Per year and thus saving of Rs.0.9Lakhs per year

Improved look of the colony roads

HPSV Lamps replacement with LED lights in colony


Line-2 pre-heater across down comer duct pressure drop is more i.e. in string-1 is 125mmWG and string-2 is 133mmWG. CFD analysis carried out with the help of TRC to reduce the pressure drop in PH down comer. They suggested that baffle plates are to be installed at top to avoid turbulent flow inside duct. As suggested by TRC 4 no's baffle plates are installed at top. By which pressure drop in string-1 reduced from 125 to 101mmWG & in string-2 from 133 to 120 mmWG.

Baffle Plates

Description

Energy saving achieved : 3.96 Lac kWh/year

Line-2 PH DC pressure drop reduction by installing baffle plates at PH Top


Compressor motor rating : 160kW Compressor Average Unload Hrs/Month : 148 Hrs Compressor Average Unload Hrs/Day: 4.95 Hrs (148hrs/30days) Unload Power : 55kW Power saving potential/day : 272.25 units ( 4.95hrs*55kw) Unit Cost : Rs. 4.23 Cost Saving / Year : Rs. 3.80 Lac (272.25*4.23*330days)

Energy saving achieved : 3.8 Lac kWh/year

Compressor Power Savings After VFD Installation (Actual)


Implementation : ABB make ACS-850, 160kW VFD Installed to the compressor, As this is a pressure make up compressor a PID loop introduced with main header tank pressure, which varies the speed of compressor motor as per air pressure requirement. Average Units consumed by total compressors (5 nos)in line-2, - Before VFD installation : 238 units/Hr Average Units consumed by total compressors (5 nos)in line-2, - After VFD installation : 223 units/Hr Unit saving per hour : 15 units Savings per day : 360 units Cost Saving/month : 0.45 lacs Cost of VFD panel : 8.15 lacs Payback : 17.8 months

Compressor Power Savings After VFD Installation


Line 1 shell cooling fans are controlled by shell temp. Power consumption after auto On/Off is: 528-132 = 396units/day Consider 4Rs./Unit then 396*4= 1584 Rs./day saving Per year saving: 47520*12= Rs. 570240/- saving per year.

Line-1 Kiln shell cooling fans auto control by its shell Temperatures

Description of Project:

Energy saving achieved : 5.70 Lac Rs/year


Raw Mill -3 &4 Process Optimization

Background of the project

Line 2 Raw Mills were running at a TPH of 440-445 @19 % residue on 90µ. Power consumption at those running conditions was 23.5 KWH.

Power optimisation studies were carried out during 8th Nov’13 to 30th Nov’13 to improve mills TPH and to reduce Specific Power Consumption.

To decrease the load on mill main motor, table dam ring height reduced from 120 MM to 100 MM, due to which, load came down from 5200 KW to 5050 KW ,which help us to apply more grinding pressure & mill feed. To enhance effective grinding, the hydraulic working Pressure increased from 70-72 to 74-76 bar. To reduce the mill body vibrations and to maintain constant bed levels in the mill water injection increased from 12.5 to 17 M3/Hr and more. Stand by water pump was utilized for additional water spray. Further, fan flow optimized with different separator speed to increase the SPRS recovery

Description of project


Raw Mill -3 &4 Process Optimization

As a result of all the above improvements the Mill TPH was improved from 440 to more than 495 and the Power Consumption reduced from 23.5 KWH to 20.3 KWH. Specific Energy Saving of 3.2 KWH was achieved which resulted in a cost saving of Rs.2.18 Lacs per day (Considering Both Mill operation and unit cost of Rs 4.80)

This optimisation also resulted in reduction of Mill Wear Out and increase in Mill availability for maintenance.

Before During execution job


Occupancy sensors provide a means to ensure that electrical devices in a room are turned OFF when there is no occupancy in the room. They can generate significant energy efficiencies, especially when a space is occupied intermittently. We installed at 20 locations like rest rooms & office. Annual saving Aprox. Is 17520 units = Rs 78840

Provision of Occupancy Sensor to control the lights and ACs in the Offices when there is no occupancy of people

Occupancy Sensor installation in offices


About Light Pipe

Light Collector with roof metal kerb can capture ambient Sunlight when mounted on Roofs. Inside having acrylic sheet.

Laser cut acrylic (Poly(methyl methacrylate) (PMMA), acrylic or acrylic glass )panels have been used to redirect sunlight into a Light Pipe or tubular skylight and, from there, to spread it into a room

Day light pipe installation in Various areas


Packing Plant RBC, Truck Loading and Bag Godwon Floor Light pipe installation

Benefits after Light pipe installation

Approx. saving per year is Rs.67452/ Light Pipe cost Rs.3*25000/ = 75000/- Pay back period 1year 2 months Approx. Lighting cover from Morning 06.00 AM To Evening 06.30 PM

Total no fittings

Each light wattage

controlled average time hours

saving in KWH /day

saving in KWH/ YEAR

Saving amount RS/Year

55 80 12 52.8 19272 67451.8

Day light pipe installation in Various areas


A SOLAR BOTTLE BULB using empty Fanta bottle and ordinary water for TPP CHP container. Sunlight falling

on the exposed part of bottle gets refracted and spreads smoothly in the room delivering light equivalent to

40 - 60 Watt incandescent bulb.

SOLAR BOTTLE BULB


Trend display of Line-2 Lime stone transport JPF 311BF3 in DP mode

Purging OFF Time: 20 Min

Purging ON Time: 3 Min

DP Low Limit: 70 mmWC

DP High Limit: 90 mmWC

JPF Purging ON time / hour : 8 Min. JPF Purging OFF time / hour : 52 Min.

DP Transmitter at site

DP transmitters for JPF


Energy Efficiency improvement in Equipment


Activities leading to Energy Efficiency

1. Daily Variance Analysis and Action Plan

2. Fan efficiency Measurements

3. Section Performance Reports with Action Plan

4. Heat balance Measurements

5. False air measurements

6.CFD Analysis in Collaboration with Corporate CFD Cell

7.Condition Monitoring Cell

8.External and Internal Periodic Audits

9.Replication of Successful Implementations


Compressor efficiency Monitoring


Benchmarking with World Class Performance


BENCHMARKING

Benchmarking with world class performance

International Benchmarking White Hople Man

Sr. No.

Description UOM Best in World

APCW Value

Star Rating

1 Thermal energy Kcal/kg clinker 663.75 715 ****

2 Electrical energy kWh/MT Cem 70.13 84.4 ****

3 Kiln Power kWh/MT clinker 20.9 26.53 ****

4 Grinding Power kWh/MT Cem 21.3 24.07 ****


32

.4

30

.8

25

.3

24

.2 27

.3

20

25

30

35

'09-10 '10-11 '12-13 '13-14 '14-15Actuals

Phase - 1

45

.4

34

.4

30

.3

28

.3

27

.3

20

30

40

50

60

'09-10 '11-12 '12-13 '13-14 '14-15Actuals

Phase - 2

Power consumption - Cement Mills

(kWh / MT of cement)

Up to Dec’14 Up to Dec’14

Sp.Power high

due to received

Fly Ash low

fineness in PPC

grinding

Reduction in Sp.

Power

consumption

due to CM3 out

put increased by

classifier

modification

176


Best Practices

Sl. No Best Practice

1 USAGE OF 100% PET COKE

2 VERTEX ARRANGEMENT in Separator.

3 ONLINE CLEANING OF KILN BURNER TIP

4 KILN HEAT UP WITH POLYMER OIL/ HFO

5 BURNER PIPE CASTABLE LIFE ENHANCEMENT

6 REDUCTION OF WHRPP AULILIARY POWER CONSUMPTION

7 HAZARDOUS MATERIAL INCINERATION IN KILN

8 REDUCTION IN COOLER WATER CONSUMPTION

9 ENHANCEMENT OF BULL NOSE CASTABLE LIFE

10 REDUCTION OF KILN SHUTDOWN TIME

11 ROCKET BLOWERS ON RAIL

12 COAL MILL MODIFICATION

13 REDUCTION OF WATER CONSUMPTION : RAW MILL

14 COMPACTING OF COAL WITH VIBROMAX

15 TEST BED PROVIDED TO CHECK PHASE-2 COOLER UNDER GRATE HYDRAULIC CYLINDER LEAKAGES BEFORE INSTALLATION

16 IN SUITE – ARRANGEMENT OF JIG FOR CHECKING THE COLLAR FITMENT OF ALL TYPES OF JPF BAGS


Sl. No. Best Practice 17 WATER SATURATION SENSORS ARRANGED FOR MONITORING WATER / MOISTURE CONTENT IN KILN MAIN GEARBOX OIL FLOW

18 ONLINE CLEANING OF KILN GIRTH GEAR GREASE SPRAY NOZZLES

19 USAGE OF ALTERNATIVE FUELS

20 MEASURING VOLUMETRIC EFFICIENCY OF COMPRESSOR

21 INSULATION LIFE ENHANCEMENT WITH CHICKEN MESH (RAW MILLS)

22 CAMERA PROVIDED FOR CONTINUOUS MONITORING OF COOLER UNDER GRATE HYDRAULIC CYLINDER OIL LEAKAGE TO AVOID FIRE

23 COOLER UNDERGRATE HYDRAULIC CYLINDERS MODIFIED FROM DOUBLE PORT TO SINGLE PORT

24 MODIFICATION IN PHASE-2 COOLER HYDRAULIC TANK LEVEL SENSOR

25 INSTALLATION OF PNEUMATIC OPERATED KNIFE GATE BETWEEN MULTOCORE AND MULTICELL

26 LOESCHE RAW MILL LM 69.6 MILL ROLLER SEALING ARRANGEMENT

27 FIXING OF PERMANENT MAGNETS IN LINE -2 KILN FEED AIR SLIDES

28 MODIFIED FK PUMP DRIVE CONNECTION WITH DIRECT COUPLED ARRANGEMENT FROM BELT ARRANGEMENT

29 INSTALLED 2 NO‘S OF ADDITIONAL WATER SPRAY NOZZLES

30 PROVIDED DRAUGHT MEASURING POINTS TO BOTH HOT ESP HOPPERS

31 EXPANSION JOINTS PROVIDED TO PH-2 RAW MILL REJECT DISCHARGE CHUTE

32 LED LIGHTS FOR GYPSUM WEIGH FEEDERS

33 MESH TO AVOID LUMPS ENTRY

34 COMMON HEADER TO AVOID DUST ENTRY IN BLOWERS

35 STRENGTHENED DOZING VALVE CYLINDER BY PROVDING ADDITIONAL MS PLATE TO ALUMINIUM CYLINDER BODY TO AVOID FAILURE OF CYLINDER.

36 OCCUPANCY SENSORS IN WASH ROOMS AND OFFICES

Best Practices


Sl. No. Best Practice

37 HOOTER WITH CHAIN LOAD INDICATION TO ENSURE SAFETY OF RECLAIMER BUCKETS.

38 HUMAN CONTACT WITH RUNNING BELT AVOIDED BY PROVIDING A SCREEN IN RECLAIMER ITSELF.

39 INSTALLATION OF WIRELESS TRANSMITTERS

40 PI SYSTEM INSTALLATION @ ALL SITE OFFICES

41 CCTV FOR MONITORING COOLER OIL LEAKAGES

42 PRESSURE TRANSMITTERS FOR LINE -2 COOLER ESP HOPPERS DRAUGHT MEASUREMENT

43 MASS FLOW METER FOR GRINDING AID

44 ONLINE PILE CHANGEOVER

45 NON CONTACT TYPE POSITION SENSOR FOR LINE 1 COOLER GRATES

46 AUTO OPERATION OF KILN SHELL COOLING FANS

47 LINE-2 COOLER AUTO CPM SET POINT Vs LANE DP

48 INSTALLATION OF ANNUBAR TYPE FLOW METER IN LOESCHE MILLS FOR MEASURING BH FAN FLOW RATE

49 REFRIGERANCT BEING COLLECTED FOR FURTHER USAGE INSTEAD OF LEAVING INTO ATMOSPHERE.

50 SOLAR STREET LIGHT POLES INSTALLATION IN MINES.

51 REMOTE AUTOMATION TECHNOLOGY ADOPTED IN GROUND MOUTED LIGHTING TOWERS.

52 APPLICATION OF EVALOC TO REDUCE WATER EVAPORATION.

Best Practices


Sl. No. Best Practice

53 PERMANENT WATER SPRINLING SYSTEM ON MIN RAMPS.

54 INSTALLATION OF SLOW SPEED HD INTELINOVA FOR CEMENT MILL ROLLER PRESS ROLLER BEARINGS

55 SCHEDULE OPTIMISATION FOR EQUIPMENT LUBE OIL ANALYSIS

56 NDT FOR NEW SPARES AT STORES

57 EFFECTIVE DOCUMENTATION OF CONDITION MONITORING ACTIVITIES IN SAP

58 SOP FOR REWARDS & RECOGNITIONS @ APCW

59 BRAIN STORMING SESSION & IDEA GENERATION

60 SINGLE SHOT OPERATION FOR BOTH HGG I & II (Hot gas generator)

61 FUEL FEED CONTROL AUTOMATION

62 MAINTIAINING PLFWITH PROCESS COORDINATION

63 IMPROVE THE ENERGY & PLANT AVAILABILITY

64 SOX CONTROL WITH RAW MEAL

65 BOILER-4 STEAM BLOWING WITH COAL INSTEAD OF HSD

66 TG’S & 220KV GRID AUTO SYNCHRONISATION AND OPERATION THRU “LOAD MANAGEMENT SYSTEM’’.

67 ONLINE HOT CHANGOVER OF PA,ID&SA FANS VFD SYSTEM,COMMON FOR BOILER 3&4

68 ENERGY SAVING BY STAGE BLINDING OF BOILER FEED PUMPS

69 BFP & CEP VFD OPERATION WITH DP BASED CLOSED LOOP

70 REDUDNDANCY OF M LINKS IN LINE 2 KILN MCC’s

71 INSTALLATION OF ENERGY MONITORING SYSTEM.

Best Practices


Sl No. Best Practice 72 INSTALLATION OF CONVERTERS IN ABB MNSIS 73 EXT/RET MOTOR REPLACEMENT WITH BRAKE MOTOR. 74 INSTALLATION OF CUT INSULATOR FOR OHE LINE 75 MODIFICATION IN CRUSHER HT MOTOR VCB’S 76 TOWNSHIP- BMP’S 77 REPLACEMENT OF HPSV TO LED LIGHTS IN COLONY 78 MCB ARRANGEMENT FOR VD4 BREAKER TO AVOID CONTROL PLUG CONTACT DAMAGE DURING ISSUE OF PTW. 79 AUTOMATIC OPENING OF BIOMETRIC DOOR IN CASE OF FIRE.

80 REPLACEMENT OF HIGH SPEED MOTOR BEARINGS EVERY 2 YEARS BASED ON RUN HOURS.

81 PROVIDED DIRECT EARTHING TO ALL ABB MAKE VFD PANELS TO AVOID FALSE TRIPPING.

82 MEASUREMENT OF LUX LEVELS ACROSS THE PLANT IN EVERY QUARTER TO ENSURE PROPER ILLUMINATION IN PLANT PREMISES.

83 LIGHTING CIRCUIT MODIFICATION IN COMBINATION OF SWITCH AND TIMER IN SUBSTATION BUILDINGS TO SAVE POWER CONSUMPTION.

84 LIGHTING CIRCUIT MODIFICATION IN PRE-HEATER BUILDING TO SAVE POWER CONSUMPTION.

85 INTRODUCTION OF PID LOOP FOR UTILITY COMPRESSOR WITH PRESSURE SWITCH TO VARIABLE SPEED DRIVE FOR ENERGY SAVING.

86 LIGHTING CONTROL THROUGH OCCUPANCY SENSORS IN SITE OFFICES

87 TRANSPORTATION CONTRACTS THROUGH REVERSE AUCTION (FAIR & TRANSPARENT PRACTICE)

88 RAIL / ROAD RATIO IMPROVEMENT – KPCL PORT TO PLANT (LOGISTICS COST REDUCTION)

89 PULL CORD LOCATOR FOR PIPE CONVEYOR

90 IN-HOUSE ASSEMBLY OF HEXADUR SLEEVE

91 DOUBLE STAGE SUCTION FILTERS FOR ALL AIRSLIDE BLOWERS

92 GRANITE LINING FOR TRUCK LOADING

93 DOUBLE STAGE FILTERS FOR BAG CLEANING DEVICE FANS

94 AUDIO ALARM WITH HOOTER FOR GATE MOVEMENT TO AVOID OHE LINE TRACK MOVEMENT.

Best Practices


AWARDS & ACCOLADES


National Award for Excellence in Energy Management in 2012


State Energy Conservation Award for 2012 - 2013


National Award for Excellence in Energy Management in 2015


Low rain fall

Nearby no natural source of water

Since the area is Rocky in nature retention of ground water is very less

More conveying system for material handling

High SO3 in limestone

High power consumption in Line-2 Cooler

High bond index in limestone

Challenges

ultratech cement limited greenco gold certified unit ... · ultratech cement limited andhra pradesh...

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