BEE: Best Practices in Energy

Efficiency in Cement Sector

Ambuja Cements Ltd., Chandrapur

1 2015

Presented by: Sheshmani Shukla 7th July-2016

Index:

2015 2

1. Electrical energy reduction in Cement mills, CM-2 & 5 by Grinding media optimization 2. Improving Clinker quality & increasing fly ash absorption 3. CM-3 Main Bag Filter Fan Pulley diameter increased to reduce the fan speed 4. Best practices of maintenance

Cement Plant:

Power Plant:

1. Boilers Bed Ash draining automisation system implementation. 2. Station Heat Rate Improvement 3. Reduction of Aux. power consumption by various measures.

3

Reduction in specific electrical energy consumption in Cement Mill No. 2 by

1.9 kWh/t cement

110

112

114

116

118

120

122

124

126

128

130

0.00

10.00

20.00

30.00

40.00

50.00

60.00

Aug/15 Sep/15 Oct/15 Nov/15 Dec/15 Jan/16 Feb/16 Mar/16 Apr/16 May/16

SEEC, KWh/t cem

Production Rate TPH

Before After

4

100

105

110

115

120

125

130

135

140

0.00

10.00

20.00

30.00

40.00

50.00

60.00

Aug/15 Sep/15 Oct/15 Nov/15 Dec/15 Jan/16 Feb/16 Mar/16 Apr/16 May/16

SEEC, KWh/t cem

Production Rate TPH

Reduction in specific electrical energy consumption in Cement Mill No. 5 by

2 KWh/t cement

Before After

5

Sr No. Actions taken

1 Media pattern change, increased finer charge media in 2nd chamber, all 50 and 40 mm media removed from 2nd chamber as per sieve analysis result.

2

Regrade 1st and 2nd chamber, all the deformed media in 2nd chamber replaced by new media.

3

Separator worn out static guide vanes and rotor vanes replaced by new one, resulted in increased separator efficiency, since separator bypass reduced from 20% to 5%

4 Sepol inlet duct air guide vanes adjusted.

5

Sepol bag filter exit & Fresh air balancing done to get max. separation efficiency.

6 Regular Inspection of Separator fan & cleaning of inlet box.

7 Regular Inspection of BE lip plate for any recirculation.

6

Change of the raw mix design :

Silica Ratio increased from 2.40 to 2.51

Liquid content reduced from 26.65 to 25.93

High purity corrective material used to maintain raw mix composition

without increasing limestone pile LS target.

The raw mix control QCX-online done on moduli value.

Limestone Saturation factor reduced from 115.1 to 109.0.

Change in Clinker Quality strength. Clinker LSF maintained at same level of 91%.

Clinker SR increased from 2.43 to 2.53.

Clinker AR increased from 1.52 to 1.53.

Improvement in clinker

Year LSF

2013 115.1

2014 113.8

2015 111.9

YTD-June-16 109.0

7

Achieved Higher Fly ash absorption & lower Sp. Elect. Energy cons.

Increase in Fly ash Absorption

% Fly ash

Year 2013 27.70

Year 2014 30.00

Year 2015 31.00

Year 2016 ( YTD June-2016) 31.70

Grinding PPC RESIDUE

Year ON 45 Micron

2013 5.61

2014 5.54

2015 5.43

YTD June-2016 5.47

Cement Fineness

Increase in Cement Fineness from 5.4 to

5.5 % on 45 micron sieve.

8

Cement Mill no. 3, Bag Filter Fan Pulley size increased

from 460 mm to 610 mm for reduction in fan rpm from

1208 rpm to 929 rpm.

Before modification of fan pulley, main bag filter fan

damper operated at 40% and consumed 66 KW, In sp.

power consumed 0.5 kWh/t cem.

After modification of fan pulley, main bag filter fan

damper operating at 70% and consuming 29 KW. In sp.

power consuming 0.2 kWh/t cem.

Achieved energy saving 0.3 KWh/t cem

9

0

1

2

3

4

5

6

7

8

9

10

2011 2012 2013 2014 2015 YTD, June-2016

0.57 1.35

2.26 1.98

4.36

6.81

10

70

80

90

2011 2012 2013 2014 2015 YTD, June-2016

79.57 78.99

76.45 77.34 77.28 75.38

11

Bang !

Daily Walk-by inspection

• Simple visual, audible, smell and touch inspection of the equipment or area

– Reading parameters, such as vibration, voltage, current, fault messages, etc.

– Observing items such as slip ring-carbon brush contact on MV motors

• Blowering, cleaning, greasing, oiling and also finding out the abnormal condition of the equipments.

• Sharing information to the internal and external customer

Burning smell,

Chemical smell

Vibration and

temperature

monitoring

Unusual Sound,

Noise

Oil, water, grease leaks,

cleanliness of the area, loose

bolts, smoke,

....and many more

12

Vibration Monitoring & analysis of major drives

Oil analysis of all Power & Distribution Transformer

IR/PI Value Testing of Electrical Equipments

Protection Relay Testing during annual shutdown .

Overhauling of HT/LT Motors during annual

shutdown as per Conditioning Monitoring Report therefore no any motors failures for last long period.

Thermography of LT switch gears & Thermography point attended.

HT/LT Switchgears Maintenance during annual shutdown.

Pre

ven

tiv

e

Main

ten

an

ce

Service

Replace

Condition

Monitoring

Energy Efficiency Measures

taken at CPP

13 2015

100% Elimination of Hot Bed Material Manual

Draining

14

Bed Ash Cooler modified from continuous top drain type to Batch bottom drain

type.

Dome valve seal failure minimised by introducing new material cut-off valve above

the Dome valve. Now hot material not come in contact continuously to the seal

15

311.52 287.07 293.82 278.29 165.88

12.02

11.53 11.24

11.31 10.57

0

50

100

150

200

250

300

350

9.5

10

10.5

11

11.5

12

12.5

2012 2013 2014 2015 YTD June-2016

Generation (Mio kWh) Aux %

Installation of VVF drives.

Installation of Aero dynamic fan in Cooling tower fans.

Boiler # 3 Fans Up gradation.

Replacement of Electrical heaters with heat exchange heaters in DG set..

Boiler Draft in auto loop.

Zero blackouts.

Installation of LED lights.

Generator Frequency reduce.

16

S H R 2012 2013 2014 2015

YTD, June-2016

•Fully Loading of HP turbines. •Maintaining design vacuum levels across the STGs . •Online Steam leakage arresting. •Good Quality of coal.

Plant Station heat rate

3658 Kcal/kwh

3608 Kcal/kwh

3521 Kcal/Kwh

3388 Kcal/Kwh

3373 Kcal/Kwh

Coal(Tons) 365909 317312 231041 247851 163616

17

Date Generation Kwh Aux Units

Kwh

PLF

%

Avg Load

MW

Aux

%

23.01.2016 9,15,000 80806 63.54 38.12 8.83

29.12.2015 10,07,000 89451 69.93 41.96 8.88

20.12.2015 10,03,000 90876 69.69 41.79 9.06

19.01.2014 10,14,000 92650 70.42 42.25 9.14

15.02.2013 10,38,000 95418 72.08 43.25 9.19

Old

Benchmark

8.88%

New

Benchmark

8.83%

Four Blackouts

Three

Blackouts

Zero

Blackouts

Zero

Blackouts

Zero

Blackouts

Benefits of ISO 50001-2011

Certification

19 2015

20

With ISO 50001-2011 certification (International, best-practice Energy Management standard), our organization achieved many benefits, some are as below:

Target driven Energy efficiency measures: With this standard we have to meet current or future voluntary and/or mandatory energy efficiency targets or GHG emission reduction legislation. It will help to reduce greenhouse-gas (GHG) emissions and carbon footprint

Increased energy savings which will reduce energy costs for producing one ton of cement via a structured approach of managing our energy consumption.

With this system we know better about equipment efficiency. By integrating our existing management systems, we can align our Energy Management System (EnMS) with existing management systems for additional organizational benefits.

21

Increased energy awareness among staff members at all levels.

Structured approach to adopt Right work at First Time methodologies.

Improved corporate image and credibility with all stakeholders and customer.

Enhanced security of energy supply as we have identified our energy risk exposure in areas within the organization and getting remedial measure against it.

Improved operational efficiencies and maintenance practices

22

A significant improvement of the energy performance level from an initial energy baseline.

A systematic approach (plan-do-check and act) that leads to continuous energy efficiency improvement. ISO 50001 enables organizations to:

Develop a policy for more efficient use of energy Fix energy efficiency targets and objectives to meet the policy Use data to better understand and make decisions concerning energy use and

consumption Measure the results of energy efficiency improvements Review the effectiveness of the energy policy

Continually improve energy management

ISO 50001 supports the development of an energy policy and contributes to the structure of an energy plan to achieve targets.

23

ISO 50001 facilitates engagement (commitment and agreement) of management and has a positive contribution towards the energy targets.

An ISO 50001-based EnMS creates awareness and a commitment about energy (i.e. consumption, use, efficiency, renewable sources) within the organization.

ISO 50001 improves the ability of organizations to manage energy risks concerning possible impacts in an efficient and effective way.

ISO 50001 strengthens the competitiveness of organizations and reduces their vulnerability with respect to energy price fluctuation and availability of energy.

ISO 50001 allows the establishment of a benchmarking process.

An ISO 50001-based EnMS allows organizations to gain credible external visibility of energy saving actions.

24

An ISO 50001-based EnMS provides a better understanding between predictable energy demand and supply.

An ISO: 50001-based EnMS reduces energy costs and improves profitability.

In addition, implementing ISO: 50001 yields significant benefits beyond energy and energy cost savings. Early adoption experiences have shown that conformance with the standard results in some non-energy benefits such as greater productivity and lower maintenance needs. In many cases significant energy and energy cost savings were achieved with minimal or no capital investment. This is because ISO:50001 fosters a change in culture that engages and empowers employees to identify and address energy saving opportunities as they materialize. Then, by continuously monitoring and improving energy efficiency, company achieve persistence in energy savings.

25

Thank you very

much