18th national award for excellence in energy management...

18th National Award for Excellencein Energy Management 2017

UltraTech Cement Limited

Unit: Kotputli Cement Works

S.No. CONTENTS

1 Company profile

2 Cement manufacturing process

3 Energy Management System policy

4 List of ENCon measures taken in last three years

5 Plant performance over the years

6 Unit brief summary for PAT status

7 Details of innovative projects

a. Reduction in cooler fans power

b. Process Fan pressure drop reduction

c. Compressor Specific power reduction

8 Plan Matrix for future Encon projects

9Involvement of employees /Sharing of best practices among associates for ENCon projects implementation

S.No. CONTENTS

10Environmental projects / Projects Linked with Carbon emission reduction

11 Energy Monitoring Methodology

12 Utilization of renewable energy sources/waste material

13 Awards & Accolades

Equipment Make Rated Capacity Benefits

Raw Mill Loesche GMBH 735 TPH Improved

energy

efficiency, Easy

maintenance

Coal Mill Loesche GMBH50 TPH for Pet

Coke

First Vertical

Cement Mill in

UTCL

Loesche GMBH 2 X 215 TPH

Kiln KHD GMBH

10000 TPD on

100% Imp. coal

8000 TPD on

100% Pet coke

Six- Stage Pre-

heater twin stringKHD GMBH -

Enhanced heat

& mass transfer

Pyro floor clinker

cooler with roller

crusherKHD GMBH -

High heat

recuperation

efficiency

Online Cross Belt

Analyzer, XRF (02

nos.), XRD (01 no.)

Thermo

scientific,

Panalytical

-

Efficient Quality

Control System

Company Profile

KCW was

commissioned in

the year 2009 with

clinker production

capacity of 3.3

MTPA (10,000

TPD)

ISO 9001

2011

ISO 14001

2011

OHSAS 18001

2013

2014

ISO17025

20152015ISO

27001

ISO 50001

NA

BL

accr

ed

itat

ion

Ene

rgy

Man

age

me

nt

Info

rmat

ion

Sec

uri

ty

Occ

up

atio

nal

H

eal

th &

Saf

ety

Envi

ron

me

nt

Man

age

me

nt

Qu

alit

y M

gmt.

WCM

2010

WC

M

Init

iate

d

WCM

2013

WC

M B

ron

ze

Aw

ard

WCM

2015

WC

M G

old

Aw

ard

Journey Towards Excellence

http://www.presentermedia.com/index.php?target=closeup&id=11749&categoryid=115&maincat=animsp

Cement Manufacturing Process

Crusher

Cooler

Bag House

HAG

ESP

Packing Plant

Raw Mill Hoppers

Coal Petcoke

Mines Stackers

Cement Silos

Clinker Bulk Loading

Pyro sectionKiln

Pre-heater

Raw Mill

Cement Mill

Bag House

Collective Cyclones

Coal Mill

Kiln Burner

Low NOx

-- Material Flow

-- Gas Flow

PC Firing

Stack1

Stack2

Limestone &

Additives

Clinker Gypsum

Flyash

To stack2

Reject

Energy Management System Policy

LIST OF ENCON MEASURES TAKEN IN LAST THREE

YEARS

SN. Energy Saving theme

Energy Saved/yr Savings(Rs.Lac/yr)

Elect (MWH)

Thermal (Mkcal)

1Removal of venturi from coal mill bag house fan inlet duct

58.2 - 2.6

2Provided flap box in DSC discharge feed pipe.

71 - 0.2

3TAD bend modification for reducing dropping of material

- 6499 67.5

4Auto cleaning system at dispersion plates for proper fluidization of fuel with raw meal

- 3249 33.8

5Installed baffle plates in Raw Mill cyclone outlet discharge

232 - 8.11

6Start of cold meal injection system for eliminating coating formation & reducing cleaning process by water jet

- 6499 67.5

Energy saving initiatives with Zero Investment

SN. Energy Saving theme Energy Saved/yr Savings(Rs.Lac/yr)

Elect (MWH)

Thermal (Mkcal)

7 Raw Mill cyclone dip tube modification 231.9 - 8.11

8Heat of formation reduction by Raw Mix optimization

- 2559 27.83

9

Reduction in Limestone, Additives & Coal transport Idle run hours for power optimization by DCS interlocking w.r.t to load (KW).

850 - 29.78

10Maintaining A/S ratio for enhanced petcokeutilization with stable operation by Raw Mix optimization

- 2973 32.34

11Pressure drop reduction of cooler fans (11 Nos.) by removing louvre dampers

643 - 22.50


SN. Energy Saving theme Energy Saved/yr Savings(Rs.Lac/yr)

Elect (MWH)

Thermal (Mkcal)

12Removal of all Flow regulators(MFR) from chamber-2 ,3,4 & 5 of cooler resulting in chamber pressure reduction

428 4284 60.58

13Optimization of 2 coal firing blowers by line modification &running at low air to material ratio

257 - 9.0

14Cement mills power reduction by optimizing the reject circuit running hrs

82.2 - 2.88

15Reduction in packing plant bag filter fan power by change in drive system

576 - 20.16

16Reduction in idle running of cooling tower fan

12.96 - 0.50

Total 3442.26 26063 393.39



Energy Saved/yr Savings(Rs.

Lacs/yr)

Invest(Rs. in Lacs)

Payback (months)Elect

(MWH)Thermal (Mkcal)

2014-15

1

Preheater fans inlet boxenlargement 511.1 - 64.3 0.5 0.01

2Raw Mill Fans inlet box modification

231.9 - 8.9 0.5 0.06

3

Carbon black feeding system modification to increase Carbon black usage

- 6154 84.0 2.0 0.04

4Modular lining in bottom cyclone feed pipe to eliminate stoppages

420 - 315.9 26.0 0.08

Total FY (2014-15) 1163 6154 473

Energy saving initiatives with Investment



Lacs/yr)

Invest(Rs. in Lacs)



2015-16

5Fuzzy logic installation for Kiln /Cooler

269 584 15.8 47.0 36

6Installation of castableretainer in DSC toenhance refractory life

- 1038 8.90 3.0 4.0

7

Installation of newgeneration Haslecastable for burnerpipe

288 5318 43.7 10 2.0

8

Increased therecuperation efficiencycooler by airflowmodification

- 6225 28.9 1.0 0.42




Lacs/yr)

Invest(Rs. in Lacs)



9

Reduction in pressuredrop by installing baffleplate in all 4 nos. topcyclones of Preheater

1345 - 53.8 1.0 0.22

10

Preheater top cyclone water spray system installation for reducing power

721 - 28.9 94 39

11Installation of Static synchronous compensator (STATCOM)

591 - 23.6 18.7 9

12Replacement of kiln firing root blower with screw compressor

232 - 9.3 5.4 70


SN . Energy Saving theme


Lacs/yr)

Invest(Rs. inLacs)



13Removed venturi from Cement Mill 1 Bag House fan inlet duct

221 - 8.8 5 7

14

Modification in cooler water spray for minimizing water cons. & cooler outlet temp.

- 6225 53.7 0.5 0.11

15Removed venturi from Raw mill fan inlet ducts

311 - 12.44 3 1.28

168 Watt CFL in colony replaced by 5W LED lamps

1.4 - 0.1 0.5 105

Total for FY (2015-16) 3979 19390 288


SN .

Energy Saving theme


Lacs/yr)

Invest(Rs. inLacs)



2016-17

17Pressure drop reduction of cooler fans (11 Nos.) by removing Silencers

279 - 9.70 1.50 2

18Optimization of compressor run hrs by various modifications

236 - 8.20 8.0 12

19PH Fan inlet duct enlargement

300 - 10.50 11.0 13

20Removal of venturi from Cement Mill-2 Fan inlet duct

198 - 6.10 0.50 1


SN .

Energy Saving theme


Lacs/yr)

Invest(Rs. inLacs)



21Raw Mill table liners & rollers replacement

3342 - 117 107 11

22Radiation losses reduction by attending all areas of refractory wear & tear

- 2142 19.10 1.0 1

23Extending the Thermal wall(Null point) by 800mm for retaining heat

- 3213 28.70 1.0 0.4

24Installed PID based VFD at Post clinker compressor house

277 - 9.70 8.50 11

25Installed PID based VFD at Pre Clinker compressor house

149 - 5.20 8.50 20


SN .

Energy Saving theme


Lacs/yr)

Invest(Rs. inLacs)



26Installed Energy Efficient Pump at Pre Clinker Pump House

30.5 - 1.10 11.0 124

27Cement Mill -1 Bag house Fan Inlet Box enlargement

95.13 - 3.30 0.50 2

28Cement Mill -2 Bag house Fan Inlet Box enlargement

94.18 - 3.30 0.50 2

29Reduction in separator power of cement mills by removing slave roller

113 - 4.0 2.80 8

30Energy saving by replacing existing conventional light fittings with LED light

53 - 1.90 21.0 136

Total 5166.81 5355 227.8

Grand total for last 3 years 10309.21 30899 988.84


PLANT PERFORMANCE OVER THE YEARS

GOOD

GOOD

GOOD

60

80

100

2014-15 2015-16 2016-17

80.4

94.8 96.4

Petcoke Consumption (%) on Heat BasisPetcoke Consumption (%) on Heat Basis

27.0

27.5

28.0

28.5

2014-15 2015-16 2016-17

28.38 28.40

27.70

Cement Dispatch (Million MT)Cement Dispatch (Million MT)

670

680

690

FY15 FY16 FY17

678.4 680.4

675.5

Cement Dispatch (Million MT)Specific Heat Consumption

9300

9400

9500

9600

9700

9800

2014-15 2015-16 2016-17

9767

9494

9753

Cement Dispatch (Million MT)Kiln TPD

Unit Performance – Last Three Years

GOOD

GOOD

40

50

60

2014-15 2015-16 2016-17 2017-18(Q1)

54.8357.01 55.33 53.80

Cement Dispatch (Million MT)Sp. Power Upto Clinkerisation (KWH/MT Clk)

Unit Performance

40

50

60

70

80

2014-15 2015-16 2016-17 2017-18(Q1)

71.79 74.43 75.57 72.24

54.90 52.6049.62

53.80

Power PPC %

Cement Dispatch (Million MT)Overall Sp. Power Cons. (KWH/MT cement)

GOOD

40.00

45.00

50.00

2014-15 2015-16 2016-17 2017-18(Q1)

42.7144.68 44.79

42.54

Cement Dispatch (Million MT)Sp. Power Upto Clinkerisation (KWH/MT Cem)

GOOD

40

50

60

70

80

2014-15 2015-16 2016-17 2017-18(Q1)

71.79 74.16 74.01 71.62

55 55 55 55

Power PPC %

Overall Sp. Power Cons. (KWH/MT cement)

GOOD

After Normalization

Unit Energy Performance Comparison: At A GlanceWith benchmark/cluster units performance (Year 2016-17)

Overall sp. Power Consumption (Kwh/MT cement)

Sp. Heat Consumption (Kcal/kg clinker)

658678

689676

687

630

690

750

810

International Benchmark

National Benchmark Rajshree Cement(UTCL)

Kotputli Cement(UTCL)

Vikram Cement(UTCL)

KCW

64.00 65.05

80.4875.53 77.38

40

60

80

100

International Benchmark

National Benchmark Aditya Cement(UTCL)

Kotputli Cement(UTCL)

Vikram Cement(UTCL)

Ref- For International Benchmark BEE presentation during interactive workshop on normalization factor in AhmedabadRef. For National Benchmark Data Best Thermal energy efficiency award by NCCBM for FY2014-15.

GOOD

GOOD

UNIT BRIEF SUMMARY FOR PAT

STATUS

GtG energy consumption status

993

937

711670 641 664

400

600

800

1000

1200

2009-10(Baseline year)

Target SEC forPAT cycle 1

ActualPAT Cycle 1

BaselinePAT Cycle 2

TargetPAT Cycle 2

Status PATCycle 2

Kcal

/kg

PP

C E

qu

iv.

No. of Energy Saving Certificates 37153

Unit is registered as Designated Consumers (DC) under PAT scheme.Target given for 5.6 % reduction in GtG Specific Energy Consumption for PAT

Cycle-1 (FY14-15)Implementation of ENCon projects in the unit reflects 28.40 % reduction in SEC in

PAT cycle-1. Now entitled for 37153 Nos. of Escerts costing about Rs.37.0 Crores

28.40 % reduction

PAT Status

DETAILS OF INNOVATIVE PROJECTS

Project 1 – Reduction in Cooler Fans Power

Objective:-

1. To reduce pressure drop of cooler fans (11 Nos.)

2. To reduce fan and Kiln Sp. Power Consumption

Project Description

➢ All the fans were having Louvre damper at the fan inlet, and they were not in

operation and moreover these fans are having VFD drives

➢ After pressure measurement it was found that there was an average of

10mmWg pressure drop in each fan across the damper.

➢ Moreover it was observed that the due to dust, the pores on inner surface of

silencers got clogged and it became ineffective from long period. So we

removed silencer and reduced pressure drop of about 8mmWg.

Project 1 – Reduction in Cooler Fans Power

Before

After

Results:-

1. Reduction in pressure drop by 14-18

mmWg.

2. Power saving of 0.46 KWH/Mt of clinker

3. Cost Saving of 32.20Lacs/annum

6.0

6.5

7.0

Before After

6.776.31

Cooler fans power

Project 2 - Process fan pressure drop reduction

Objective:-

To reduce power consumption of major process fan by pressure drop reduction by

fan inlet box enlargement.

Project Description:-

Preheater fans (2 Nos.) and cement Mill fans ( 2 Nos.) were having high pressure

drop so there inlet box was enlarged to reduce the pressure drop by 15-20 mmWg.


PH Fan - Before Modification PH Fan - Proposed Modification


Cement Mill Fan

Modification

Results:-

1. 15-20mmWg pressure drop reduction in all the fans.

2. Reduction in sp. Power consumption of preheater fans by 0.14KWH/Mt of

clinker.

3. Reduction in sp. Power consumption of cement mill fans by 0.24 – 0.32

KWH/Mt of cement in different grades

142113911395

13601362

1325

1250

1300

1350

1400

1450

Before After

OPC43 OPC53 PPC

Reduction by 30-35 KW in diff. Grade.

7.1 6.8

9.3 9.17.7 7.4

0

2

4

6

8

10

Before After

OPC43 OPC53 PPC

Reduction by 0.24-0.32 KWh/Mt Cem in diff. Grade.

CM Mill Fan Sp. Power – KWH/MT CM Mill Fan Power – KW


Project 3 - Compressor Specific power consumption

Objective:-To reduce compressor specific power consumption.

Project Description:-Compressor power is required in all sections and contribute majorly towards auxiliarypower consumption. So we have carried out following modifications

(1) Installed PID based VFD in one of the compressor to reduce the unloading power,optimized the run hrs and load setting of compressor.

COMPRESSOR LOAD/ UNLOAD SET POINT

S.NOCompressor

no

Before After

Pressure set point

in bar Controller

setting in

bar

Back

pressure

maintained

before

controller

Pressure set point

in bar Controller

setting in

bar

Back

pressure

maintaine

d before

controllerLOAD UNLOAD LOAD UNLOAD

1 L41CP1 5.4 6.4

6 6.8

6.6 7.6

5.2 5.62 431CP1 7.0 8.0 6.2 7.2

3 461CP1 7.2 8.2 5.5 6.5

4 361CP1 5.6 6.6 6.4 7.4


2. Installation of air flow meter in all area to identify key focus area (

blaster operation) to reduce consumption of compressed air.

3. Check pressure drop and replace before and after air filter of air drier

to reduce pressure drop across air drier.

PRESSURE DROP ACROSS DRIERS

S.NODRIER

TYPEDRIER NO.

PRESSURE IN BAR

Before After

Inlet before

pre filter

Outlet after

post filterDiff

Inlet

before

post

filter

Outlet

after

post

filter

Diff

1 REFRIGRATOR L41DR1 7.4 6.2 1.2 6.8 6.6 0.2

2 REFRIGRATOR 431DR1 6.9 6 0.9 6.2 6.2 0.3

3 REFRIGRATOR 461DR1 6.9 6.5 0.4 6.2 6.2 0.2

4 REFRIGRATOR 361DR1 6.8 6.5 0.3 6.4 6.2 0.2


4. Installed PID based VFD in pre and post Clinkerisation pump house


Results:-

1. Reduction in sp. Power consumption of compressor by 0.17 KWH/Mt of clinker.

2. Cost saving of Rs. 23.20 Lakhs/ year

0.5

1.0

1.5

Before After

1.120.94

10795

10033 10131

9472 9353 9349

8,500

9,000

9,500

10,000

10,500

11,000

Oct-16 Nov-16 Dec-16 Jan-17 Feb-17 Mar-17

Average Compressor power per Day – KWH/Day Sp. Power consumption KWH/T clinker

PLAN MATRIX FOR FUTURE ENCON PROJECTS

S.N. Energy Saving theme

Potential Energy SavingTarget For

CompletionElect (MWH)

Thermal (Mkcal)

1.Raw mill bag house fan power reduction by inlet duct modification

948 - Jul-17

2.

Reduction in kiln coal firing blower power and Nox level reduction through burner modification

158 - Aug-17

3.Reduction in cooler ESP rotary air lock power consumption

7.8 - Sep-17

4.Optimization of compressor power by running bag filter in DP mode

78 - Oct-17

5.Enhancement in burner castable life by using new generation Hasle castable

- 5066 Nov-17

Plan matrix for Future ENCon Projects

S.N. Energy Saving theme

Potential Energy SavingTarget For

CompletionElect (MWH)

Thermal (Mkcal)

6.Installation of modular lining (Hasle) in all feed pipes of cyclones.

- 5066 Aug-17

7.Installation of Hasle imported castable in DSC.

- 2096 Aug-17

8. Coal mill fan inlet duct modification 133 - Dec-17

9.Running Pyroclone burner coal transport blowers through VFD

277 - Dec-17

10.CFD of preheater cyclone to reduce pressure drop

237 - Aug-18

11.Cooler fan power reduction by Installation of baffle / flow guiding plate

429 - Aug-18

12. Installation of WHR system 3900 - Mar-19

Plan matrix for Future ENCon Projects

S.N. Projects

1 Saving of Natural fossil fuels by utilization of Petcoke upto 96%.

2Rain water harvesting system (New 4 nos. Structure covered with a total of 23 nos of structures developed at plant colony, mines and its near by areas till March 16.)

3Utilization of high MgO% limestone by blending it for enhancing Mines life &conserving high grade Limestone.

4 Utilization of hazardous waste like ETP sludge 2016

5Green belt development (Developed 54.77 hectare in plant and 44 hectare in mines as on March 16)

6 100% reutilization of waste water

7 Fugitive dust control (Under progress additive shed of 41.68x30M & 50.35x90M)

8 CO2 & NOx reduction measures

9 Enrichment in TSR by increasing usage of Carbon Black and FMCG waste as an AFR

10 8 Watt CFL replaced by 5W LED lamps in colony

11Reduction in sp. water consumption by proper monitoring & metering in eachSection

Environmental Initiatives


Carbon Management Policy Water Policy

3909252359

6873885697

104713122050

137683

94% 95% 92% 91% 91% 91% 91%0

25000

50000

75000

100000

125000

150000

2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17No's of sapling planted Survival rate

About 42% area is covered under green belt against the requirement of

33%.

Cumulative Survival rate = 91%

GOOD


Ground water recharging through injection well Rain Water Harvesting Ponds

Green Belt DevelopmentSapling Distribution to Villagers


Covered conveyor belts & dust filters at all the material transfer points

Covered storage facility for raw materials, fuel & clinker

Concreted roads & floor area100 kw solar power plant in colony

INVOLVEMENT OF EMPLOYEES/ SHARING OF

BEST PRACTICES

Loss Matrix

Improvement Projects-Operating Teams

Suggestions-Operating Teams

SII Team/Operating team Monthly

meeting

WCM team meetings

Energy mapping & Balancing

Section wise Budgeting

PLC Based Energy Monitoring System

Relative Monitoring of TPP, RSEB, IEX Cost

Daily Power report

Daily production Report/Meeting

Monthly Comparison-Benchmark Units

Monthly MPR Meeting

Energy Audit through CETS

Benchmarking

Monthly P&B Data on Group Units

Monthly Capex Meeting

Approach, Deployment & Review- Improvement Projects /Kaizen/Suggestions

Action by WCM

Shop floor Teams

Kaizens Operating Teams

WCM steering committee meeting

ENERGY MONITORING

METHODOLOGY

Past andpresent

energy use

Analyze Energy Use and Consumption

Identify Area of significant energy use and consumption

Identify opportunity for improving Energy Performance

•Energy Baseline

•Target

•Action Plan to achieve target

Measuring and Monitoring of Result Indicators.

Review

Inputs Saving/ Result Quantification

Energy Planning

• Relevant Variable affecting significant energy use•Performance Indicators

S.No. Category of Findings Total No.

1. OFI 03

2. Observation 03

3. Minor NC 01

4. Major NC 00

Total 07

Periodic external audit takes place, below is the outcome of FY17 Audit

PA2_LOF (1).xlsx

Maintenance Production

Quality

Unit Head

FH(Tech)

Crusher & RMCH Raw Mill

Kiln & Coal Mill

Cement Mill Packing Plant

Energy Monitoring System

Daily Monitoring & Review Formats

S.No. Description Format

1 Daily Power Report

2Daily Section Performance Review Report

3 Daily Compressor Power Report

4 Daily HOF Optimization Report

5 Daily Idle run hrs report

Daily power report 31.03.2017.pdf

Daily section performance review report.pdf

Daily compressor specific power report.pdf

Daily HOF optimization report.pdf

Daily monitoring of idle run hrs.pdf

UTILIZATION OF RENEWABLE ENERGY

SOURCES/WASTE MATERIAL

Utilization of Renewable Energy sources/ Waste Material

➢ Solar Power Generation (kwh)

0

50000

100000

150000

2014-15 2015-16 2016-17

12

09

34

10

81

26

10

01

36

Utilization of waste material➢Use of TPP bed ash in limestone pile with ~0.11 % Limestone replacement

➢Use of Fly ash up to 29.50 % in PPC production

➢Use of waste from Carbon Black Industry and FMCG waste in fuel firing with ~0.70%

TSR

➢ Use of wet Flyash about 6% of total PPC production.

➢ REC purchased 6438 solar certificates under RPO

AWARDS & ACCOLADES

constituted by National Council for Cement and Building Materials

CII Energy Efficient AwardConsecutively 5th year..

Rajasthan Energy Conservation Award

Year : 2012 & 2014

18th national award for excellence in energy management...

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