ultratech cement limited: unit-sewagram cement works

CII-20th National Award for Excellence in

“Energy Management System-2020”

UltraTech Cement Limited: Unit-Sewagram Cement Works

Presenters:1.Sajeesh G.-FH-Technical2.R M Sahu-HOD Technical Services3.Krishna Sharma-SH Technical Services

Contents

2

Implementation of ISO50001/Green Pro/IGBC rating

01 Brief Introduction on company/Unit

02

03

04

05

Energy consumption overview

Sp.Energy consumption- Last 03 Years

National and Global Benchmarking

ENCON-Last 03 Years

06 Innovative projects Implemented

07

08

09

10

Utilization of renewable Energy Sources

GHG Inventorisation and Green Supply chain management

Team Work Employee Involvement and Monitoring

11 Implementation of ISO50001/Green Pro/IGBC rating

Other Innovative technologies and Long Term Vision on EE

Waste utilization and Management.

12

3

1.Business Overview-UltraTech Cement Limited

Sewagram Cement Works

Symbol Plant Nos

Integrated Units 23

Grinding Units 27

White Cement & Putty Units 03

Jetty

Under Commissioning

1.Sewagram Cement Works

4

Units Month & Year of Commissioning Installed Capacity

Clinkerization Line I-Sept’09/Line II-Feb’11 3.60 MTPA

Cement grinding CM1-Mar ’09 /CM2-Dec’10 /CM3- May’12 3.10 MTPA

Packing Plant Packing Plant 1-Mar ’09 /Packing Plant 2- Jul’10 4 Nos. x 180 TPH

Thermal power Plant TPP 1-Sept’09 /TPP 2-Jul’11 TPP1-35 MW, TPP2-22.5MW

Desalination Unit Jul’09 6600 M3/Day

Solar Power Plant Aug’18 5MW

PPC PPCSOPC PPCWR

55.45% 1.77%1.68%41.10%

OUR PRODUCTS

1.Sewagram Cement Works-Journey So Far….

5

• Clay Lease execution & opening of mines• Transfer of Baranda Laterite Mining lease to UTCL• Major use of Lignite coal started using in Kilns for the first time.• Clinker silo of 70,000 MT commissioned.• PPCS grade manufacturing started.

• Initial Jetty manual operation started in a small way.

• Transfer of all EC’s pertaining to Mines in the name of UltraTech

• 12th June UTCL took over from Jaypee.2014-15

2015-16

2018-19

2017-18

2016-17

2019-20

• Started Manufacturing of PPCWR Cement.

• Finally mining lease transferred in the name of UTCL (ML1-659 & ML2- 2832 Hac.

• 5 MW solar plant commissioned.• Baranda Laterite mines expansion project approved from

MOEFCC

2.Energy consumption & Summary of saving Initiatives- last 03 Years

7

Year No of Proposals Investments Savings

2017-18 23 81.82 63.78

2018-19 44 119.07 41.79

2019-2020 14 32.58 27.04

Summary of EnCON-Last 03 Year

Energy Consumption Summary-TOE

16774

182155820182172594

TOE

Electrical energy (TOE)

Thermal Energy (Solid & Liguid Fuel)-TOE

TOTAL-TOE

3.Specific power Consumption

8

63.9660.09

57.11 59.44

20

40

60

80

FY 2016-17 FY 2017-18 FY 2018-19 FY 2019-20

Pre-clinkerisation (kWh/MT Clinker)

32.37

30.87

29.30 28.96

20

25

30

35

FY 2016-17 FY 2017-18 FY 2018-19 FY 2019-20

Cement grinding (kWh/MT Cement)

-Up to clinkerization power increased in last FY as Line-1 Kiln stopped for 69.11 Days and Line -2 Kiln stopped 90.26 days in excess clinkertill Feb ’20 & this lead to increase in Misc./Utility power by 3.0-3.5 units.Production of high C3S clinker also lead to increase in sp.power consumption.Power consumption also increased due to increase in bypass% from 13% to 24% t consume high SO3 and Chloride Limestone.Utilization of high moisture and low CV coal also lead to increase in sp.power consumption.

6.1

9 %

Re

du

ction

3.Specific Power Consumption (kWh/T Cement)

9

1.401.36

1.18

1.00

0.80

0.90

1.00

1.10

1.20

1.30

1.40

1.50

FY 2016-17 FY 2017-18 FY 2018-19 FY 2019-20

Packing Plant

15

.25

% R

ed

uctio

n

86.2880.45

75.51 77.06

20

40

60

80

100

FY 2016-17 FY 2017-18 FY 2018-19 FY 2019-20

Overall Specific power consumption

4.2

1 %

Re

du

ction

3.Section-wise Specific Power Consumption (kWh/T Mat)

10

15.8115.54

14.92

15.75

14.00

14.50

15.00

15.50

16.00

FY17 FY18 FY19 FY20

Raw Mill

29.65 29.13

32.73

25.76

15.00

20.00

25.00

30.00

35.00

FY17 FY18 FY19 FY20

Coal Mill

29.39

27.2625.68

26.44

22.00

24.00

26.00

28.00

30.00

FY17 FY18 FY19 FY20

Kiln 3.41

2.82 2.913.37

0.00

1.00

2.00

3.00

4.00

FY17 FY18 FY19 FY20

Utility Services

-Raw mill sp.power consumption increased due to high rain fall (1038 mm in FY20).-Utilization of high moisture coal also lead to high sp.power.-kiln sp.power consumption increased due to increase in bypass% from 13% to 24-25%.

3.Grade-wise Specific Power Consumption (kWh/T Mat)

11

34.09

32.21

29.59 29.69

26.00

28.00

30.00

32.00

34.00

36.00

FY17 FY18 FY19 FY20

OPC Cement

30.53

29.06

28.1827.35

24.00

26.00

28.00

30.00

32.00

FY17 FY18 FY19 FY20

PPC Cement

38.05

36.85

35.57

34.00

36.00

38.00

40.00

FY18 FY19 FY20

PPCS Cement

-Overall cement grinding power reduced by 6.19 % in last 3 FY.-We started production of weather plus cement Sept’19onwards which also resulted in increase of power consumptionto maintain high quality of cement.

3.Specific Heat Consumption wrt Bypass %

12

706.40

700.67

697.43

690.21

14.36%

13.23%

17.58%

23.45%

0.00%

5.00%

10.00%

15.00%

20.00%

25.00%

680

690

700

710

FY 2016-17 FY 2017-18 FY 2018-19 FY 2019-20

Specific heat consumption (Kcal/Kg clinker)

Sp.Heat cons. (Kcal/Kg.Clk) Chloride Bypass (%)

• Avg. SO3 in mines limestone 1.16% and Avg. chloride 0.18%.

• Avg.SO3 0.78% and Avg. chloride 0.08% in mines limestone used in last three years @bypass of 13-14%.

• To sustain the mine life SO3 and chloride being planned to use limestone having Avg. SO3:1.0% and Avg.Cl:0.16% and bypass increased up to 23-24%.

• 1% Chloride bypass result in heat loss of 2.2 kcal/kg clinker and which is equivalent to loss of 52.8 kcal/kg clinker as well as 2.75-2.90 kWh/T clinker

additional power loss due to this bypass system.

1.0

4 %

Re

du

ction

13

4.Roadmap to achieve National/Global benchmark-Electrical

Energy

01

0203

04

Replacement of High efficiency impellers-Upgradation of Bag house Fans

Kiln outlet seal modification

Fan inlet box modification-(Raw mill, Alkali bag house fan, KS and CS fan ) Removal of louvre dampers from KS and CS and Raw Mill fan inlet

Application of ceramic grinding media in Roll press and Ball Mill

National /Global Benchmark-62 kWh/T cement

Current Level: 75.51kWh/T cement

GCW NJFD SCW

Pre clinkerization Sp.Power

53.90 50.63 59.44

Post Clinkerization 32.23 30.64 30.96

Overall Sp.power 77.33 76.72 77.06

Sp.heat consumption 705.18 759 690.21

Cluster Comparison

14

4.Roadmap to achieve national/Global benchmark-Thermal

Energy

01

0203

04

Installation of Coriolis coal feeding system- 2.5-3 Kcal/kg clinker

Reduction in Alkali bypass, Process optimization and False air reduction in preheater up to 5%.-10-12 kcal/kg clinker

Utilization of Fuel catalyst for heat consumption reduction 5-6 Kcal/kg clinker

Application of heat resistant paint in preheater, Kiln and Cooler- 8-10 kcal/kg clinker

Target-675 kcal/Kg clinker

Current Level: 690 kcal/kg clinker *All data reported are without bypass loss

4.Future Energy Saving Projects

15

Sr. N. ProposalAnnual Elect. Saving

(kWh)Annual Cost Saving

(Rs. Million)Annual Thermal SavingQuantity Rs Million

Total Annual Savings (Rs Million)

Investment Made (Rs Million)

1 Replacement of High efficiency impeller in RABH-1 Fan 255840.00 1.07 - - 1.07 5.00

2 Replacement of High efficiency impeller in RABH-2 Fan 255840 1.07 - - 1.07 5.00

3 Ceramic Grinding media for cement mill 315000 1.32 - - 1.32 3.00

4 Pressure drop reduction in Line-1 Preheater (Cyclone modification) 196200 0.82 - - 0.82 6.00

5 Fan inlet box modification in line-1 Kiln sting and Calciner string fan 489600 2.06 - - 2.06 0.45

6 Fan inlet box modification in line-2 Calciner string fan 331200 1.39 - - 1.39 2.2

7 Installation of coroilis feeding system in line-2 311740 1.31 480 3.85 5.16 34.7

8

Energy Saving by reduction of pressure drop across the Cyclone and ducting in the Line-1 Raw Mill Circuit by application of CFD analysis and Modification.(Cyclone riser modification, baffle plates installation as per CFD OFIs)

1660000 6.30 - - 6.30

9 Line-2 Mill operating Dp to be reduced to 670 mmWg, 264000 1.11 - - 1.11 0.5

10 Raw Mill Fan inlet box modidifcation in both line 377200 1.58 - - 1.58 0.3

11 Alkali Bypass Bag House Fan inlet box modidifcation in both line 192000 0.81 - - 0.81 0.8

12 Alkali Bypass Bag House Fan inlet damper removal in both line 144000 0.60 - - 0.60 0.2

13Inlet box modification to reduce fan power consumption in Cement Mill-2 Bag house fan (Sepax fan).

157500 0.66 - - 0.66 0.8

14Inlet box modification to reduce fan power consumption in Cement Mill-3 Bag house fan.

150000 0.63 - - 0.63 0.8

15 Compressed Air Optimisation & Leakage Reduction with automation 230400 0.97 - - 0.97 3.5

16 Radiation reduction in preheater & TAD with surface coating 0 0.00 1535 12.33 12.33 8.0

17Power reduction in bag filter fans by VFD/Energy efficient motors & Damper removal (15 Fans)

375000 1.58 - - 1.58 2.0

18 Power reduction in utility water pumps by efficiency improvement 480000 2.02 - - 2.02 1.5

Total Savings 6185520.00 25.31 2014.32 16.18 41.48 74.75

5.List of Encon-2017-18

16

Sr. N. ProposalAnnual Elect.

SavingAnnual Cost

Saving

Annual Thermal Saving Total Annual Savings Investment Made

Payback

kWh Rs. Million Quantity Rs. Million Rs. Million Rs. Million Months

1Energy saving by replacement of the GRR control with MV drives In Line 1 Kiln String Fan (Aug'17)

789848 3.16 - - 3.16 7.48 28

2Energy saving by replacement of the GRR control with MV drives In Line 1 Calciner String Fan (Aug'17)

3365427 13.46 - - 13.46 10.33 9

3Energy Saving by Reduction of Air Infiltration across K-String of the line -1 SCW

460000 1.75 - - 1.75 - -

4Energy Saving by reduction of air infiltration across Raw Mill-1 fan and there by reduction of Raw Mill-1 fan power consumption

920000 3.47 - - 3.47 - -

5Energy Saving by increasing the Line-2 Kiln Feed Temperature and thereby reducing the specific heat consumption for Clinker Production. 58 to 70 °C

- - 666.5 MT 4.13 - -

6

Energy Saving by improving the cooler-1 recuperation efficiency through replacing the static grate with modified ABC static grate (Make-FLS) (Nov'17)

- - 1083 MT 6.50 17.9 33

7

Energy Saving by reduction of air infiltration across line-2 Alkali Vent by-pass bag filter and thereby reducing line-2 alkali bypass fan power consumption.

29000 1.1 - - 1.1 - -

8Energy Saving by replacement of the Line-2 Calciner String Fan and also installing new MV Drive in place of GRR in (Nov'17). 1538797 6.16 - - 6.16 16.3 31.78

9Energy Saving by replacement of the Line-2 KS Fan and also installing new MV Drive in place of GRR.(Dec'17)

773315.38 3.09 - - 3.09 9.8 38.02

10 Replacement of conventional lights with energy saving LEDs. 19500 0.078 - - 0.078 - -11 Reduction in Raw Mill Dam ring height by 15mm. 378496 1.51 - - 1.51 - -

12Raw Mill nozzle veloctiy optimization by blocking nozzles behind Roller

504661 2.02 - - 2.02 - -

13 Damper removal in cooler fan 32000 0.128 - - 0.128 - -


17

Sr. N. Proposal Annual Elect. Saving

Annual Cost Saving

Annual Thermal SavingTotal Annual

Savings

Investment Made Payback

14Energy Saving by Reduction of Air Infiltration of the line -2 Coal mill Circuit 130000 0.49 - - 0.49 - -

15 Energy saving in CM2 Ball Mill bag house fan by reduction in air infiltration across the bag house

13000 0.05 - - 0.05 - -

16TA duct area decreased from 3500mm to 2800 mm to increase the gas velocity and reduction in TAD dropping. 276.48 MT 1.714 - -

17Reduction in Idle run Hour of RMHS(Limestone, Additive and Coal Circuit) 1182717 4.731 - - 4.73 - -

18VRM table and Roller liner changed from HighChrome to SinterCast.

563024 2.25- - - - -

19Bag House operation with Differential Pressure (DP) inplace of timer in Roller Press Mill (CM2) and VRM Bag House

22521 0.09- - - - -

20 Alkali dust usage in cement Mill 225210 0.90 - - - - -

21Installation of New generation NOVAFLAME five pilaard burner in Line-2 - -

480.0 MT 2.98 10 40

22 Use AF Carbon black and Coal dust as a ulternative fuel in Kiln - - 431 MT 2.67

23 Line1 Burner Replacement in May'17 (Swirlex to Pillard) - - 766 MT 4.60 10 26

Total No of Projects-23 10947515 63.78 81.82


18

Sr. N. Proposal Annual Elect. Saving Annual Cost Saving Annual Thermal Saving Total Annual Savings Investment Made kWh Rs. Million Quantity Rs. Million Rs. Million Rs. Million

1 Installation of 5 MW Solar power plant 5295000 3.71 - - 3.712 Line-2 ABC cooler installation 74127 0.31 384 3.07 3.38 17.903 Installation of Expert optimizer in Kiln-1 175404 0.74 - - 0.74 2.804 Installation of Expert optimizer in Kiln-2 201353 0.85 - - 0.85 2.805 Reduction in false air In Kiln Section 183600 0.77 - - 0.77 0.03

625-30 mmWg Pressure drop reduction in calciner string cyclone 3 and 4 through roof lifting (Line-2)

74127 0.31 - - 0.31 6.00

7 Installation of MV drive in Line-1 Raw Mill Fan 440134 1.85 - - 1.85 11.84

8Installation of aerofoil nozzle ring for pressure drop reduction

77486 0.33 - - 0.33 3.30

9 Installation of MV drive in Line-2 Raw Mill Fan 458611 1.93 - - 1.93 10.00

10Classiifer skirting and optimization of dam ring height in Raw Mill

38743 0.16 - - 0.16 0.025

11 Reduction in false air In Raw Mill Section 214621 0.90 - - 0.90 0.02512 Installation of Expert optimizer in Raw Mill-1 372995 1.57 - - 1.57 2.4013 Installation of Expert optimizer in Raw Mill-2 330562 1.39 - - 1.39 2.4014 Installation of Expert optimizer in Coal Mill-1 38153 0.16 - - 0.16 2.4015 Installation of Expert optimizer in Coal Mill-2 49849 0.21 - - 0.21 2.4016 Installation of MV drive in Line-1 Coal Mill Fan 70505 0.30 - - 0.30 7.9117 Installation of MV drive in Line-2 coal Mill Fan 93299 0.39 - - 0.39 6.0618 Reduction in false air In Coal Mill Section 40502 0.17 - - 0.17 0.025

19CM-2 RP Feeding of Separator reject fines at the bottom of V-Separator instead of Roller Press Bin

108020 0.45 - - 0.45 0.03

20CM-2 RP Optimization of Grinding media charge with several trials with different loading 295666 1.24 - - 1.24 0.02

21 CM-2 RP Stud Roller Installation in place of CHF roller 1404259 5.90 - - 5.90 2.20

22 Expert optimizer for Mill Operation- CM2 293677 1.23 - - 1.23 2.40


19

Sr. N.Proposal

Annual Elect. Saving

Annual Cost Saving Annual Thermal SavingTotal Annual

Savings Investment Made

kWh Rs. Million Quantity Rs. Million Rs. Million Rs. Million23 Expert optimizer for Mill Operation- CM3 415668 1.75 - - 1.75 2.4024 CM-2 Fan flow optimization with fan speed reduction 75951 0.32 - - 0.32 025 CM-3 Removal of Fan inlet damper to reduce the pressure drop 88329 0.37 - - 0.37 0.1026 Reduction in Dam ring height to reduce the main drive load 325410 1.37 - - 1.37 0.02

27Compressed air to be isolate during mill stoppage by providing the SOV in main line of header.

95490 0.40 - - 0.40 0

28 Compressor to be taken into auto mode and start stop from DCS. 63660 0.27 - - 0.27 029 Raw Mill single start stop 10200 0.04 - - 0.04 030 coal mill single start stop 4800 0.02 - - 0.02 031 CM-2 Single start stop 7520 0.03 - - 0.03 032 CM-3 Single start stop 6640 0.03 - - 0.03 033 VFD Installation in bag filter fan 651FN1 (651BF1)

610 1.9

- - 1.90

9.68

34 VFD Installation in bag filter fan 651FN2 (652BF1) - - 0.0035 VFD Installation in bag filter fan 642FN4 (642BF1) - - 0.0036 VFD Installation in bag filter fan 642FN9 (642BF3) - - 0.0037 VFD Installation in bag filter fan 642FN5 (642BF2) - - 0.0038 VFD Installation in bag filter fan 642FNA (642BF4) - - 0.00

39Lighting timers to be replaced by Astro timers in MLDB

29700 0.12 - - 0.12 0.08

40 70W HPSV light to be replaced by 24W LED in phased Manner. 510 nos 83720 0.35 - - 0.35 0.6

41 CCR lightings to be replaced by 20W against 36W (360Nos) 33920 0.14 - - 0.14 0.2842 VFDs for 3 x 75 kW Pumps 109200 0.46 - - 0.46 0.45

43Township area switching OFF Lights of Non Critical Areas Between Mid Night to morning Hours. Or Alternate street light to be switched OFF

24130 0.10 - - 0.10 0

44 Installation of stud roller in CM-2 Roll press 1474190 6.19 - - 6.19 22.50

Total Savings 13179830 38.72 384 3.07 41.79 119.07


20

Sr. N. ProposalAnnual Elect. Saving

(kWh)Annual Cost Saving

(Rs. Million)Annual Thermal SavingQuantity Rs Million

Total Annual Savings (Rs Million)

Investment Made (Rs Million)

Payback(Months)

1Coal Mill-1 fan Louvre damper removal & inlet box modifiaction

167631.36 0.80 - - 0.80 0.65 9.80

2Coal Mill-2 fan Louvre damper removal & inlet box modifiaction

197147.12 0.94 - - 0.94 0.65 8.33

3Line-1 Cooler fans silencer & inlet damper removal (8 Fans)

167771.52 0.80 - - 0.80 0.06 0.83

4 Idle run hour reduction in RMHS circuits. 376300.00 1.79 - - 1.79 0.07 0.50

5Line-2 Kiln string fan impeller replacement with High efficiency impeller (>82%)

784704.00 3.73 - - 3.73 4.50 14.49

6 CM-2 Speax fan changed with high efficiency fan (>82%) 208440.00 0.99 - - 0.99 2.80 33.94

7 Classifying thin liner installation Cement Mill-2 969246.00 4.60 - - 4.60 7.10 18.51

8Coriolis firing system & VFD blower installation for coal conveying in Line-1

226008.00 1.07 481.86 3.87 4.94 16.00 38.84

9 Optimization of TG frequency from 50 Hz to 49.5 Hz 933240 4.43 - - 4.43 0 0

10Optimization of compressed air consumptionby reducing leakages in all sections

363000 1.72 - - 1.72 0 0

11Power saving through reduction of idle running of bag house (both main bag house as well as Alkali bag house and ESP) RALs.

239250 1.14 - - 1.14 0 0

12 Air slide blower air optimization in Raw mill circuit 77000 0.37 - - 0.37 0 0

13 Installation of low pressure blower for cloth cleaning 21600 0.10 - - 0.10 0.15 17.54

14Colony and plant lightning power consumption optimization through timer and LED lights installation

146000 0.69 - - 0.69 0.6 10.38

Total Savings through EnCons in FY19-20 4877338.00 23.17 481.86 3.87 27.04 32.58

6.Theme-1 Installation of high efficiency impeller in KS Fan

21

Issues :

Low efficiency (71-73%) of Line-2 Kiln string fan.

High pressure drop in Line-2 wrt Line-1 Kiln.

High Specific power consumption due to low efficiency

and High pressure drop.

Approach:

A cross functional task force team formulated with fan consultant.

It was found that the efficiency of the fan was lower-71-73%

Pressure drop was also higher side in comparison of Line-1.

6.Theme-1 Installation of high efficiency impeller in KS Fan

22

Results :

Kiln String Fan efficiency was increased from 71-73% to 80-81% which resulted in power saving of 100 kW.

Energy saving by 0.8 Kwh /MT clinker.

Total annual savings achieved: Rs 38.74 Lacs in current FY. ROI achieved in less than 6 months. Horizontal

replication will be done in Line-1 also.

6.Theme-2 Pressure drop reduction by cyclone roof lifting6.

23

Problem Statement : high pressure drop across 3rd and 4th cyclones in Preheater (106 & 100 mmwg respectively).

Issues :

High pressure drop in 3rd and 4th cyclone ie.106 & 100 mmWg.

High specific power consumption due to high pressure drop.

BEFORE

AFTER

6.Theme-2 Pressure drop reduction by cyclone roof lifting

24

Approach:

A detailed CFD analysis done for reduction of pressure drop.

After CFD analysis it was decided for lifting the cyclone roof by 500 mm which lead to reduce the pressure

drop by 20-25 mmWg.

Results :

By cyclone roof lifting project there was a pressure drop reduction by 20-25 mmwg which resulted in

savings of 45 kWh.

Total annual savings achieved: Rs 24.74

Lacs in current FY.

6.Theme-3 Coal mill fan inlet box enlargement and louvre damper removal

25

Issues :

After installation of MV drive Coal mill fan still having louvre dampers having a pressure drop of 30 and 32

mmwg across the damper in Line-1 and Line-2 respectively.

Also it was found that the fan inlet velocity was also at higher side it was in the range of 19-22 m/sec.

A potential identified for removal of damper and fan inlet velocity reduction by inlet box modification.

Feed

Classifier

Grinding table

Grinding rollers

Hot air

Ground material

+ Outlet gas

Bag House

Raw Coal Feed

Hot gases from PH outlet

Recirculated Gas

Fine Coal BinGround Product + Outlet gas

To Stack

--Gas Flow

Material flow

Coal Mill MILL

Before

After

6.Theme-3 Coal mill fan inlet box enlargement and louvre damper removal

26

Approach:

A cross functional team including wage board staff formulated for power consumption reduction.

It was found that the energy consumption reduced by removal of fan inlet damper and fan inlet boxmodification

Fan inlet velocity was also reduced by fan inlet box enlargement.

Results :

Saving of 54 KW without zero investment and in terms of sp. power consumption it was 1.50 kWh/T mat.

Reduction in fan inlet velocity from 19-22 m/sec to 14-15 m/sec. which also reduce the pressure in coal millcircuit.

Due to reduction in pressure drop coal mill fan efficiency increased from 71-73% to 80-83%.

Total Savings achieved 17.05 Las Rs in current FY.

6.Theme-4 Installation of thin classifying liners

27

Issues :

CM-2 roll press with ball mill now converted in mono chamber mill from double chamber mill.

After conversion to mono chamber the liners are still earlier one having thickness of 90mm which lead to

increase the sp. power consumption.

Higher Sp. power consumption due to high weight liners installation.

Old Liners New Thin classifying Liners Before Modification After Modification

28

Approach:

To reduce the specific power consumption a plant level cross functional team formulated which analyse the

detailed power consumption with productivity data.

After that in consultation with OEM and our TPMC cell it was decided to replace the existing liners (150 mm) with

thin classifying liners.

Replacement of old liners with new thin classifying liners having the thickness of 38-42 mm only.

Results :

Cement Mill power consumption reduced by 0.98 kWh/T cement.

Total annual savings achieved 24.67 Lac Rs in current FY.

6.Theme-4 Installation of thin classifying liners

6.Theme-5 Installation of aerofoil nozzle ring

29

Issues :

Line-1 Raw mill having high specific power consumption and high pressure drop.

Pressure drop in the era of nozzle ring was the major concern.

Higher sp.power consumption due to high weight liners installation.

Old Nozzle Ring New Aero foil Nozzle Ring

30

Approach:

To reduce the pressure drop after cross functional teams detailed analysis and OEM reference, it was decided to

replace the nozzle ring armor ring and separator blanketing to be done.

As the material leaves the table at different velocities depending on the table diameter. This is compensated for

the new nozzle ring by having a different inclination of louvres for different diameter; try to match the horizontal

velocity of the material leaving the table with the air velocity.

LNVT nozzle is designed with different inserts in the different areas of the nozzle ring locations, where the

resistance through the nozzle is different for the air entry, as well as louvres of different inclinations, depending

on table diameter.

Results :

Sp. power consumption reduced by 0.15 kWh/T Mat.

6.Theme-5 Installation of aerofoil nozzle ring

7.Utilization of Renewable Sources

32

Capacity is 5.0 MWp (DC) / 4.0

MWp (AC)

Approximate Land Requirement: 25

Acres

Type of System: Fix-Tilt

Expected Life Of Solar Plant: 22 Years

Details of Solar Plant

Expected Generation- 22287 kWh/Day

First Year Power Generation - 85.0

(Lacs Units)

First Contract year adjusted - 2.5%

degradation

Each subsequent Year degradation -

0.7%

Efficiency- 19.4%

Proposed Power Generation& Efficiency

%Share:4.64MkWh:8.50

%Share:3.97MkWh:8.26

%Share:2.23 MkWh:5.3

FY18-19FY20-21(Target)FY19-20

Utilization of Solar Energy

8.Waste Utilization & Management - AFR

33

Sl.No

Year (2019-20)

Waste DetailsQuantity

(MT)GCV

(kcal/Kg)

Heat value (kcal)

Waste as Percentage of total fuel (%)

1 AFCOALDUST 118.0 2109.1 248876 0.01

2 AFEMBROIDERYWASTE 7.0 5309.1 37164 0.003 AFCARBONBLACK 64.0 3157.7 202090 0.01

4 AFMSWDERIVEDFUEL 10.5 4106.0 43114 0.00Total 199.5 2662.9 531243 0.03

Waste material (AF) used as Fuel

Sl.No Waste MaterialQuantity Used

FY 2017-18 FY 2018-19 FY 2019-20

1 AFCOALDUST 780.0 0.0 118.0

2 AFEMBROIDERYWASTE 0.0 0.0 7.0

3 AFCARBONBLACK 45.0 0.0 64.0

4 AFMSWDERIVEDFUEL 0.0 0.0 10.5

Total 825.0 0.0 199.5

34

8.Waste Utilization & Management

Waste material used as Alternative Raw Material (Additive)

Sl.No Waste MaterialQuantity Used (MT)

FY 2017-18 FY 2018-19 FY 2019-20

1 Fly Ash 246683 285874 259758

2 Fly Ash TPP 9550 13987 6434

3 Chemical Gypsum 4462 3350 8433

4 Red mud 509 - -

5 Pond ash 59043 80801 48608

6 TPP Bed ash 11076 14239 11014

7 Fly ash TPP 32657 24556 28431

Total 363980 422807 362677

9.PAT Cycle-II Status

35

Gate to Gate Sp. Energy Cons. (Kcal/Kg Cement)

1000

1075

1150

1225

1300

1222 1148 10701032 1029 1011

Unit registered as Designated Consumers (DC)under PAT scheme. Base line year FY2014-15.

Target given for 1104 kcal/kg of equivalentcement in GtG Specific Energy Consumption atthe end of PAT cycle (2016-2019)

FY18-19 is assessment year so performanceassessment by BEE and achieved 1029.21 inGtG SEC achieved with 13611 Energy savingEscert's.

9.GHG Inventorisation

36

0.9493

0.92940.9227

0.9170

0.90

0.92

0.94

0.96

FY17 FY18 FY19 FY20

OPC-Conversion Factor

0.6774

0.6550

0.6266 0.6265

0.60

0.64

0.68

0.72

FY17 FY18 FY19 FY 2019-20

PPC Conversion Factor

29.11%

31.87%

33.99% 33.89%

25.00%

30.00%

35.00%

FY17 FY18 FY19 FY20

Fly Ash Consumption in PPC (%)

744 744

680

656

640.00

665.00

690.00

715.00

740.00

FY17 FY18 FY19 FY20

CO2-Emissions-kgCO2/MT Cement

3.5

3%

Re

du

ction

0.6

0 %

Re

du

ction

0.0

2%

Re

du

ction

10.Sustainability Strategy- Our Public Commitments

37

EP 100- Double the energy productivity in 25 yrs.(2010/2035 -107/214)

Reduce CO2 emission intensity by 25% (05/06 -20/21)

Water Positivity – 4 times water positive by 2021 (Current level 2.88)

•WHRS - 15% (9.17)

•Solar - 10% (1.9)

Share of Green Energy 25% by 2021 –(Current level 12.20%)

Thermal Substitution Rate- 10% by 2021( internal)–(Current level 3.7%)

Comprehensive Biodiversity Assessment of all the IU by 2024.

Internal Carbon Price of $10 per ton of CO2 emitted.

Supply Chain

Operations

Product

Customers

People

CSR

Climate Change

Communication & BrandingGovernance & Disclosures

10.Sustainability Strategy- Action Plan

38

Supply Chain

Operations

Product

Customers

People

CSR

Climate Change

Communication & BrandingGovernance & Disclosures

Aspect Target Current state Key actions

Climate Change25% reduction in CO2 intensity by 2021

19.14%- Focus on blended cement- Increase share of alternate fuel (AFR%)

WaterBecome 4 times water positive

2.88

- Implementation of two ongoing large integrated watershed project

- Watershed potential assessment at 4-5 locations- Water demand reduction projects- 2 large integrated Water shed projects Tadipatri &

Rajshree

Waste (Alternate Fuel)

10% 3.7%- Implement AFR handling systems- Secure tie-ups for long term fuel availability- Build strong network

Energy (Renewable Energy + WHR)

25% of total electrical demand

12.20%- Implementation of 118 MW WHR projects- Third party + Group captive solar projects (300+

MW)

Biodiversity

Biodiversity assessment and management plan for all integrated Units

5- Implementation of BMP at Sewagram and Raj shree- BMP under process for 3 more plants- Aditya, Balaji,

Kotputli

10.Green Supply Chain-Cement Bulker %

39

Bag/Bulk

FY17-18 FY18-19 FY19-20

Dispatch Quantity

Avg.Distance

Dispatch Quantity

Avg.Distance

Dispatch Quantity

Avg.Distance

Bag 2085279 440 2260199 439 1987549 444

Bulk 160881 372 233803 341 287981 368

Total 2246160 435 2494002 430 2275530 435

Cement dispatch increased through Bulker :54178 MTFuel Savings :51469.1 Liters 72 Rs/Liter DieselCost Savings :37.06 Lakh Rs.

10.Green Area Development

40

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Tree Plantation

2008-14 2015-16 2016-17 2017-18 2018-19 2019-20

52515

65890

78020

8227583315

85315

To

tal

Tre

es

Pla

nte

d

2

Garden

Development

at SCW

10.Sustainability-Mines Life Enhancement

41

Optimized reserves (ML-1 + ML-2) @ 5.40 MTPA)

Actual FY’19(Apr’18-Mar 19)

SO3 : 0.77 CL : 0.11LSF : 244.61

Actual Quality (April 19 to Mar-20)

SO3 : 0.83Cl : 0.12LSF : 235.34

Actual Quality (Apr 20 to June-20)

SO3 : 0.91Cl : 0.12LSF : 253.80

Remarks

Criteria for calculation of Life of deposit

142.40 Million T

Mine life 26.37 years

225.11 Million T


225.23 Million T


Clinker Production : 4.0 MTPALST required @ 1.35 conversion factor = 5.40 MTPAThe production from Apr’18 to 9th June’20 is 7.4 MTPA.

Mineable Reserve(Million T)

As on 31.05.2020

Average Quality of Overall Limestone Deposit (%)

SO3 CL MgO LSF Life @ 5.40 MTPA

620.77(ML-1 & ML-2)

1.15 0.18 2.04 188.20 114.96

1% Bypass lead to loss of 2.2 kcal/kg clinker but all are compensated to enhance the mines life by utilization of high SO3 and Chloride limestone.

42

01 02 03 04 05 06

SAFETY QUALITY

CONTROLRELIABILITY

PROCESS

IMPROVEMENT

COST

REDUCTION

Main focus onsafety started withsafety pause

Analysis of sectionwise performancewrt budget andbest achieved

Analysis of pre andpost clinkerisationquality norms wrtABG& BIS Standard

Analysis of each andevery stoppage toavoid its reoccurrence.

Processimprovementidentification and itsimplementation.

Cost analysis andreductionmeasures

11.Team Work Employee Involvement & Monitoring

PRODUCTIVITY

& ENERGY

Process ImprovementDaily Co-Ordination MeetingValue Month

Raw Mill-1 21.90 21.64 11.83 23.94 23.81 2.30 22.36 June'18

Coal Mill-1 3.51 3.49 5.33 3.21 2.40 -0.28 2.59 Feb'20

Kiln-1 24.34 24.77 18.83 36.19 26.82 11.42 23.87 Nov'17

Misc. Services-1 3.29 3.78 3.00 2.27 -0.78 1.29 Dec'17

Other Utilities Line-1 (Desalination) 0.91 0.82 1.23 0.72 0.41 0.63 Jan'20

Shutdown Power 0.76 3.52 0.00 0.00 -3.52 - -

Power Up to Clinkerization U-1 54.71 58.02 67.56 56.01 9.54 52.33 May'18

Raw Mill-2 21.61 21.49 17.17 24.35 24.28 2.86 21.85 July'18

Coal Mill-2 3.51 3.50 7.08 2.65 2.67 -0.86 2.89 Feb'20

Kiln-2 25.12 25.29 24.00 26.72 26.15 1.43 25.96 Feb'19

Misc. Services-2 3.29 3.78 3.00 2.27 -0.78 1.67 Jan'18

Other Utilities Line-2 (Desalination) 0.91 0.82 1.23 0.72 0.41 0.63 Jan'20

Shutdown Power 0.83 0.00 0.00 0.00 0.00 - -

Power Up to Clinkerization U-2 55.27 54.88 57.95 56.08 3.06 55.70 May'18

Combined power upto clinkerisation 54.99 56.24 61.37 56.05 5.13 53.96 May'18

Best

Parameters Budget / Clk

March'2020

Run

Hrs

ATD

/ Clk

MTD/

ClkDiff

Budget / clk

FY20

11.Team Work Employee Involvement & Monitoring

43

ROBUST ENERGY

MONITORING &

REVIEW

MECHANISM

Online Energy Management System

Energy Consumption monitoring through CCR Desk

Daily Production Report and Power consumption Report.

Daily monitoring of water consumption.

Resource

Line-1 Combined

TODAY PDN( MT )

Monthly PDN

TODAY SP POWER CLK

Monthly SP POWER CLK

TODAY SP POWER CLK

Monthly SP POWER CLK

RAW MILL 5997 135499 25.99 24.90 25.99 24.90

COAL MILL 548 10153 2.54 2.53 2.54 2.53

KILN 4990 94639 25.94 26.53 25.94 26.53

COMMON POWER (KWH) 12731 266536 2.55 2.82 4.82 5.11

Desal 0.33 0.69 0.66 1.34

OVER All CLINKERISATION POWER

57.34 57.46 60.40 61.38

Over All Cement Power/Cement

83.67 82.29 75.49 80.57

11.People Engagement-No of Kaizen and Savings

44

NO OF KAIZEN NO OF SUGGESTION ANNUAL SAVING KPE

4151

1050

1.80

CR.

5.15

Champions of Champion Team award Best KAIZEN Team awardExternal Training on EE

11.People Engagement

01

02

03

04

Theme: Installation of self inertia lump separation wheel for reduction of unplanned stoppages due to lumps and boulders in raw mill.Increase in reliability reduction in unplanned stoppages and power saving of 0.15 kWh/T Mat and Saving impact:25.56 LPA.

Theme: Removal of silencers and fan inlet damper in Line-1 Cooler after installation of slide gate. Savings:0.07 kWh/MT clinker having cost impact of 4.08 LPA.

Theme: Power optimization by stopping stand by blowers in raw mill product transport group.Savings: 2.37 LPA.

Theme: Removal of coal mill fan inlet damper for reduction in pressure drop by 30-32 mmWgSavings:0.30 kWh/MT Mat

05

06Theme: Increase of the life of lighting power JB through modification in JB nut bolt type in place of screw type JB Impact: Increased lighting JB life and reliability.

Theme: Reduction in bag brustage and dust emission by smoothening of bag discharge chute.Savings: Improvement in reliability and reduction in bag brustage

40

6 N

os.

K

aize

ns/

Sugg

est

ion

12System Accreditations so far…..

46

SCW has got “Certification from International organization for standardization for Integrated Management systems for QualityManagement System (ISO 9001:2015), Environment Management System (ISO 14001:2015) , Energy Management System (ISO50001:2018) and Occupational Health and Safety Management System (ISO 45001:2018),Information management System (ISO270001:2013) from certification agency DNV.

47

12.Implementation of Energy Management System

ISO50001:2018 &Green Products

Energy Policy

Gap Identification

Review Mechanism

National Workshops

&REPRISM

Well defined Energy Policy

Formation of Energy cell-Cross functional Team comprising various levels.

Gap analysis with respect to target and systematic action plan to achieve the target

Monthly review by TOP ManagementNew return base CAPEX approved on top priority-ROI<3 Yrs.

Daily review by Technical Head along with all Departmental Head .

Time to Time participation in different energy saving initiative national as well as group level workshop

REPRISM-Implementation of other unit best practices at respective units

Task force teams formation for different sections.

SCW has got “Certification from International organizationfor standardization for Integrated Management systems forEnergy Management System (ISO 50001:2018) fromcertification agency DNV.

GreenPro and LCA studies helped assessed various initiatives taken by the company for reducing the environmental impact of manufacturing cement at every stage of its lifecycle.

13.Other Innovative Technologies

48

CBA

PI-Online Monitoring System

XRDExpert Optimizer

CBA

14.Long Term vision on EE

49

To be the Most Energy Efficient Cement Unit

OperationalEfficiency

Supply Chain Technological Upgradation

Capacity Utilization

Optimizing Fuel Mix cost by utilizing costeffective coals.Increase Clay usage to minimize other additives in Raw Mix.Explore use of AF including carbon black, spent pot liners etc.Working on design parameters of PH cyclones to reduce the pressure drop across tower.

Jetty mechanized system revamping.Higher efficiency fans.New coal firing systems.Cross country belt conveyor for LS Transport.(OLBC)Increase in Solar Powerutilization.Alternate Fuel feeding system.

Increased Jetty UtilizationClinker export.Cement export.More Clinker dispatch to WCW & MGD,RTN via Jetty.Increase PPC-WR Volume

Most economical supply of fuel which possible through Jetty.Inward & outward material logistics integration.Increased share of loose cement.Sourcing of AFR -MSW/RDF.Enhance pond ash usages.New source of gypsum.

48

50

Awards & Accolades

ANY OTHER

Awards &Accolades

51

Sewagram Cement works received 1st

Rank in Kaizen Award underEnvironment- Large Category in 12th

CII National Competitiveness and ClusterSummit 2019 for Lignite based TPP Fly AshUtilisation

SCW received second prize in CII KaizenAward under 5S & Safety at 12th

National Competitiveness & Cluster Summit2019

52

SCW received Third Championship

Award under Digitization/NewTechnology at 12th CII National

Competitiveness & Cluster Summit2019 at New Delhi

Awards &Accolades

Sewagram Cement Works awarded as“ Gold Medal “ under the category of

NAMC Awards-2019 by Intl’ Research

Institute for Mfg. on 18th Oct’19 atMumbai.

53

Awards & Accolades

Sewagram Cement works Best practices recognized at IMC, Mumbai :

1. A giant step towards Green & Clean clinker production.

2. Utilization of AFBC boiler Flyash as fuel in CFBC Boiler(TPP).

The same Best Practices were also published in their Annual Magazine with a Introduction of SCW Plant.

Sewagram Cement Works received

Second prize in CII-GreenConclave-Pune for Water

consumption reduction kaizen, awardceremony held on 6th Dec’18 at CII-Pune.

54

CII-National Kaizen Award-Energy Consumption Reduction

Sewagram Cement Works received

First prize in CII Kaizen Awardunder Energy optimizationCategory at 11th National

Competitiveness & Cluster Summit2018 which was held on 21st Nov’18 atNew Delhi.

Sewagram Cement Works received Gold rating at3rd CII National 5S excellence awards which

was held at India habitat center, New Delhi.

Other-Awards

55

Sewagram Cement Works won IndustrialSafety Excellence Award- 2018 by Center forSocial Development and Ahmedabad TextileAssociation

SCW (Only Cement Plant) have wonNational Kaizen Award (Top -18) forUtilization of Alkali-Chloride Bypass dustin Cement under Environment Category.

Unit won “Certificate of Merit” inManufacturing Category presented atMumbai on 16th March 2017

56

Thanks!

R. M. Sahu-HOD Technical [email protected] Sharma-SH Technical [email protected]

mailto:[email protected]

mailto:[email protected]

ultratech cement limited: unit-sewagram cement works

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