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Unit: Sewagram Cement Works 1
UltraTech Cement Limited
(Unit: Sewagram Cement Works-Power Plant)
Welcomes all On 18th National Award for Excellence in Energy Management 2017
Welcome to All 19th National Award for Excellence in Energy Management 2018
Unit: Sewagram Cement Works 2
We are going to share…
Company Profile
Unit Profile
Plant Configuration and Flow diagram
List of ENCON Projects
Plant Performance over the years
Innovative Projects
Sustainability Initiatives
Methodology of Energy monitoring
Best practices/ Involvement of Employees
CSR initiatives
Awards & Accolades
Way forward
2
Unit: Sewagram Cement Works 3
Selected as Superbrand 2011-12 by the Super brands council along
with Powerbrand awarded by the institute Power Brands India.
Company Profile
Star Brand India
Unit: Sewagram Cement Works 4
One stop shop
for all
construction
needs of
Customer
Unit: Sewagram Cement Works 5
Sewagram Cement Works (Acquired from Jaypee in June-14)
Clinker Capacity :3.6 mtpa(2X5500 TPD) & Cement Capacity – 2.4 mtpa
Captive power plants (CPP) CPP-I 35 MW & CPP-II 22.5 MW capacity.
Mines with reserve of 246.45 MT,
Captive Jetty, a Desalination plant that can filter 2200 Kl of water every day
Unit At Glance
Unit: Sewagram Cement Works 6
Broad Specification of TPP Equipment
Package Make Type Capacity &Feature
Boiler-1 TKIL CFBC 170TPH, Pr.-87 Kg/cm2, Temp.-515 +/-50C
Boiler-2 IJT AFBC 110TPH,Pr.-87 Kg/cm2,
Temp.-515 +/-50C
Turbine-1 Siemens Condensing 35 MW, Pr.-84 Kg/cm2
Temp.-515 +/-30C, Steam Flow -143.5TPH
Turbine-2 Siemens Condensing 22.5 MW, Pr.-84 Kg/cm2
Temp.-515 +/-30C, Steam Flow -93.5TPH
Generator-1 &2 TDPS+Andritze
Hydro
Brushless
Excitation 11KV,43.75 & 28.125 MVA, PF-0.8
Coal &Lime stone
Handling Masyc
Blow bar
crusher
Coal-180TPH & Lime-60TPH, Flip flow screen
for High Moisture coal
DG (03 Nos.) Man B&W 12.5MW +12.5MW +10.8MW
Desal Plant ION Exchange PTP + RO 6700 KLD
Unit: Sewagram Cement Works 7
List Of ENCON Projects
Unit: Sewagram Cement Works 8
Without Investment
Rs. 489.8 Lacs
With Investment
Rs. 1508.6 Lacs (ROI- 1.8 Yrs)
Total Saving
Rs. 1998.4 Lacs
Savings in last Three year through EnCON Projects
Unit: Sewagram Cement Works 9
SN Energy Saving Projects (06 Nos.)
Saving Achieved
Electrical Energy
(Rs. Lacs)
Saving Achieved
Thermal Energy (Rs. Lacs)
1 Boiler -1 ID draft optimized at -15mmWC against -25mmWC 2.3 -
2 Running of one BFP in place of 02 BFP up to 80 % load for
Both Plant (Design is 2*50%) 191.1 -
3 Reduction of LOI from 10.5 to 4.5% 45.2
4 Further optimization of Instrument air pressure from 6.5
kg/sq.cm to 6.0 kg/sq.cm 3.5 -
5 Operation of Boiler at Lower Bed Height i.e. Reduction by
50MMWC. 87.1 -
6 Start Using of Pet Coke as alternate fuel to improve Boiler
Efficiency of Both TPP - 12.9
Sub Total 284.0 58.1
Grand Total 342.1
Energy Savings Projects with No Investment FY’15-16
Unit: Sewagram Cement Works 10
Energy Savings Projects with No Investment FY’16-17
SN Energy Saving Projects (14 Nos.)
Saving Achieved
Electrical Energy
(Rs. Lacs)
Saving Achieved
Thermal Energy
(Rs. Lacs)
1 Boiler-1&2 efficiency increase by optimize excess O2 in flue gas at
3.9 % against 4.5 % - 31
2 DM plant operation running hour optimized at 5 hrs./5 days
against 2 hrs./day 1.4 -
3 For Boiler -1 &2, Lime screw feeder stop due to pre mixing of
lime in Coal conveyor belt 1.6 -
4 For Boiler -1 & 2, 10 Nos. Lime stone belt conveyor stop due to
pre mixing of lime in Coal conveyor belt 1 -
5 TG-1 Deaerator O/L temp. increased upto 155 Deg C from 150 Deg
C - 2
6 Boiler -1 Bed ash cooler optimized running hrs. to reduce PA fans
power consumption 5.5 -
7 TG-1&2 Vacuum controlling through PID controller 11.3 -
Unit: Sewagram Cement Works 11
SN Energy Saving Projects (14 Nos.)
Saving Achieved
Electrical Energy
(Rs. Lacs)
Saving Achieved
Thermal Energy
(Rs. Lacs)
8 Cooling tower fan power consumption optimized by PID
controller of CW outlet temperature to start of CT fan 3.1 -
9 Ash conveying air cons optimized by reducing nos. of hole of
orifice 0.1 -
10 All lights are stopped at CHP area in night shift 2.1 -
11 Flue gas temp. of ESP I/L reduced from 135 to 130 Deg C looking
to the sulphur due point - 4.0
12
Service air compressor running Hrs. optimized at 18 Hrs./day
against 24 Hrs./day by optimized operation of ash conveying
system
8.6 -
13 Optimization of CHP running hours 4.7 -
14 Improvement of Boiler-2 Efficiency by increasing Petcoke
percentage by weight in fuel mix from 7.3 to 40.2% -
43
Sub Total 39.4 80
Grand Total 119.4
Energy Savings Projects with No Investment FY’16-17
Unit: Sewagram Cement Works 12
SN Energy Saving Projects
Saving Achieved
Electrical Energy
(Rs. Lacs)
Saving Achieved
Thermal Energy
(Rs. Lacs)
1 Boile-2 APH line diverted to Boiler-1 to reduction in LOI of fly
ash 6.50 -
2 P & V system stopped by proper ventilation through efficient
exhaust fan in TG building 15.30 -
3 Service air comp. running Hrs. reduced by use of Instrument
air as service by optimizing ash handling operation. 4.60 -
4 Both Boiler ESP Power reduced by adjusting optimized field
voltage as per fuel selection in boiler 1.30 -
5 Coal impactor VFD RPM set point varies with respect to fuel
selection to reduce APC 0.60 -
Grand Total 28.30
Energy Savings Projects with No Investment FY’17-18
Unit: Sewagram Cement Works 13
SN Energy saving Projects (04 Nos.)
Saving Achieved
(Rs. Lacs)
Investment (Rs.
Lacs)
1 Wet steam washing of TG-2 to improve efficiency 34.8 5
2 Overhauling of TG-1 for Heat Rate improvement 599.8 85
3 Installation of VFD in TPP-2 CEP 10 4.3
4 Installation of VFD in TPP-1 CEP & PID controller 19.3 4.3
Grand Total 663.9 98.6
Energy Savings Projects with Investment FY’15-16
Unit: Sewagram Cement Works 14
Energy Savings Projects with Investment FY’16-17
SN Energy saving Projects (08 Nos.) Saving Achieved
(Rs. Lacs)
Investment (Rs.
Lacs)
1 AFBC high LOI ash used in CFBC to increase boiler efficiency 211.7 5
2 TG-1&2 ACC internal Fins cleaning carried out through HP pump
water pressure to reduce ACC fan power cons. 41 2.2
3 APH tube change to improve APH efficiency & reduces PA fans
Auxiliary power 2.6 5
4 Instt Air used as service air 6.2 0.2
5 Replacement of Start-up vent 14.1 4.6
6 VFD in Inst. Comp & PID Logic Operation 12 7.2
7 Use of efficient LED lighting in place of conventional lamps. 1.8 9.3
8 Improvement of Boiler-1 Efficiency by increasing Petcoke
percentage by weight in fuel mix from 11.3 to 46.1% 223 0.5
Grand Total 512.4 34
Unit: Sewagram Cement Works 15
Energy Savings Projects with Investment FY’17-18
SN Energy saving Projects Saving Achieved
(Rs. Lacs)
Investment (Rs.
Lacs)
1 Installation of VFD in Boiler-1 BFP 40.0 32.9
2 Installation of VFD in Boiler-2 BFP 25.1 30.9
3 Installation of VFD in Instrument compressor-01 4.8 7.7
4 Installation of VFD in Service compressor-05 8.1 7.7
5 TPP-1 ACC fan 1&5 Tube bundle replaced 24.9 225.0
6 ACC APC reduce by its Fin Cleaning of TPP-1 16.2 1.8
7 ACC APC reduce by its Fin Cleaning of TPP-2 8.2 1.3
8 Boiler-1 APH tubes (1340 Nos.) replaced 93.3 17.6
9 Boiler -2 ESP outlet expansion bellow replacement 1.5 0.9
10 08 Nos. 150 Watt LED installation in place of 32 Nos. 250 Watt
HPSV lights in TG Building 17.3 1.0
Unit: Sewagram Cement Works 16
Energy Savings Projects with Investment FY’17-18
SN Energy saving Projects Saving Achieved
(Rs. Lacs)
Investment (Rs.
Lacs)
11 08 Nos. 150 Watt LED installation in place of 32 Nos. 250 Watt
HPSV lights in TG Building 17.3 1.0
12 LED Installation work and Circuit separated in TPP areas 3.8 6.6
13 RO Reject line modification work 3.2 6.7
14 Intake Pipe Line modification Work 2.4 4.7
15 PSF PUMP VFD installation. 3.7 4.7
16 Stilling Pump VFD installation. 10.9 4.7
17 Turbocharger Based HP Pump for RO Plant 48.3 184
18 Startup vent valve replacement done for TPP-1 1.7 4.5
19 Startup vent valve maintenance of TPP-2 1.6 4.5
Grand Total 332.3 548.2
Unit: Sewagram Cement Works 17
Plant Performance
Over The Year
Unit: Sewagram Cement Works 18
Sustainable Plant Performance
77.69 73.37 66.28
2015-16 2016-17 2017-18
10.80 10.20 8.92
2015-16 2016-17 2017-18
Aux. Power Cons.(%)
G
O
O
D
3172
3040 3018
2015-16 2016-17 2017-18
Heat Rate (Kcal/Kwh)
G
O
O
D
4.85% Reduction
4.00 3.68 3.79
2015-16 2016-17 2017-18
G
O
O
D
Power Cost (Rs./Kwh)
17.41% Reduction
PLF (%)
Unit: Sewagram Cement Works 19
Comparison with Group Units
8.4% 8.9% 9.0% 9.4% 9.6% 9.6% 9.7% 9.8% 9.8% 10.1% 11.9%
81%
66%
88% 78% 74% 70%
84% 79% 80% 80% 62%
0%
100%
0.00%
20.00%
KCW SCW RDCW RC VC RWCW GCW ACW AC APCW HCW
APC Vs PLF
3004 3018 3075 3102 3113 3127 3128 3129 3137
3320 3387 81%
66% 74% 79% 80% 80% 84%
78% 70%
62%
88%
0%
100%
2700
3500
KCW SCW VC ACW AC APCW GCW RC RWCW HCW RDCW
PHR Vs PLF
Unit: Sewagram Cement Works 20
Comparison with Benchmark & Cluster Units
7.5% 8.9% 9.7%
11.9%
100%
66%
84%
62%
0%
100%
0.00%
20.00%
National Benchmark SCW GCW Sanghi Cement
APC Vs PLF
2980 3018 3128
3147
100%
66% 84% 62%
0%
100%
2700
3500
National Benchmark SCW GCW Sanghi Cement
PHR Vs PLF
Unit: Sewagram Cement Works 21
Innovative Projects in FY’17-18
1.New Turbo
System Installation in Desal
2.Reduction of LOI
% in Boiler
3. Lignite firing in Boiler
4. MV Drive
installation in TPP
BFP
Unit: Sewagram Cement Works 22
1.New Turbo System installation in Desal
Objective
Reduction in specific Power Consumption of Desalination RO Plant . (Reduction from 7.99 Kwh/KL to 4.50 Kwh/KL)
Background of Project
Water production cost is high due to high Sp. Power consumption (7.99Kwh/Kl) in
Desalination RO plant.
Less reliable of existing pump due to pump life was distorted by Sea water operation.
Approach
Unit: Sewagram Cement Works 23
23
Old design energy recovery system Installation of high efficient turbocharger with new design single pump
Efficiency of Energy recovery system is less Low efficient turbocharger
02 Nos. High pressure pumps installed in place of single and operating on DOL mode with high pressure against design Membrane efficiency, Re-handling of reject water
Desal RO Power consumption is very high (50% cost contribution)
Root Cause
Analysis
Pump power consumption is high Power consumption is 430 KW and operating at DOL mode
High RO Power Consumption
High Power consumption at RO
[VALUE] 6.50 4.90 4.50 4.80
SCW ABG Cement IR Veraval Tata Power Adani Power
Sp. Power Consumption (Kwh/KL)- Cluster
Power Consumption – WHY-WHY Analysis
1.New Turbo System installation in Desal
Unit: Sewagram Cement Works 24
UOM A B C D E F G H
CF Inlet HPP_1 HPP-2 HPP Common ERT RO inlet RO Product RO Reject ERT Reject
M3/Hr. 238 119 119 238 238 76 162 162
Kg/Cm2 1.6 38 38 38 61.5 1.5 60 1
KWH 0 225 225 0 0 0 0 0
KWH/KL 5.95
Code UOM A B E F G H
Desc. CF Inlet HPP _1 ERT RO inlet RO ProductRO Reject ERT Reject
Flow M3/Hr. 268 264 264 85.15 178.85 178.85
Pressure Kg/Cm2 2.92 30.88 57.92 0.5 57.22 0.6
Power KWH 0 352 0 0 0 0
Sp.Power KWH/KL 3.87
Before After
1.New Turbo System installation in Desal Performance Parameters
4.50 7.99
Unit: Sewagram Cement Works 25
1.New Turbo System installation in Desal Benefits
Performance parameter Before After Saving
Specific Power consumption
7.99 Kwh/KL 4.39 Kwh/KL 3.60 Kwh/KL
Power Cost for water Gen.
170.39Lac/Annum 109.21Lac/annum 61.18
Lacs/Annum
Reliability
Breakdown frequency of pump/its
Motor was increasing trend
( 2-3 time per month)
Breakdown frequency of pump
and its Motor eliminated
OEE was less OEE increased
Uniqueness Water Lubricated Bearing
Reduction in Power - 44%
Unit: Sewagram Cement Works 26
2. Reduction of LOI % in Boiler
Objective
To reduce power cost ,by increasing Boiler Efficiency through reduction in Boiler ash LOI from 4.5% to 2.0%
Background of the Project
LOI of Boiler was on higher side i.e.4.5%. Lower Boiler efficiency due to Higher LOI % Power cost was increasing due lower Boiler efficiency.
Unit: Sewagram Cement Works 27
Method/Process
Analysis of crushed Coal Size
Material
High Fly Ash LOI
Coal Quality
High Fines in Coal
Man
Skill
Knowledge
Training
Machine
Screen Size of Coal
Gap of crusher
2. Reduction of LOI % in Boiler Causes & Effect Diagram
Coal Crushing
Operation
Improper Air Flow/ Turbulence
Unit: Sewagram Cement Works 28
Key Initiatives Adjust the impactor Gap for proper Fuel fines on fortnightly basis.
Optimized the air flow ratios i.e. Primary air Vs secondary air Vs tertiary air .
Analysis of coal started on shift basis and maintained the coal size within range.
Results Reduction in Fly ash LOI by 1.8%
Increment in Boiler Efficiency by
1.20%
Saving of Rs. 92 Lacs/annum
2.Reduction of LOI % in Boiler Benefits
5.9 6.1 5.4 5.2
5.8 6.2 6.1
5.4 4.8
4.2 4.8
4.3 4.1 4.6
1.9 2.1 1.7 1.5
2.2 1.8 1.5
1 5 10 15 20 25 30
% LOI TREND
Oct-17 Nov-17 Dec-17
Unit: Sewagram Cement Works 29
3. Lignite firing in Boiler
Reduction in Power Generation cost by utilization of available low cost fuel- Lignite
Objective
Problem /Background
Boiler is not design for 100% lignite firing.
Available Imported coal cost Rs/MCV is higher compare to Lignite.
Volatile matters is very high in lignite which increasing high temperature in convection zone of boiler during firing of Lignite .
Lignite have high VM & due to same it get self ignite & create fire risk in fuel handling system
Unit: Sewagram Cement Works 30
Erected one new discharge chute (size 20’’) with manual isolation gate from Lime screen discharge chute which divert lime stone in coal feeding conveyor belt.
Provision for Raw meal extraction from Raw meal silo
Raw Meal feeding system at Boiler Lime bunker.
Looking to VM Boiler furnace draft reduced from -25mmWc to -10 mmWc which resulted saving of Aux. power
Action Initiated
3. Lignite firing in Boiler
Unit: Sewagram Cement Works 31
3. Lignite firing in Boiler
By this modification, Up to 80 % Lignite fired in boiler . For 100% Lignite firing Boiler FGD proposal in under process.
Better reaction between Lime Powder & SOx.
Fire risk minimized near belt conveyors by blending of lime stone with lignite at belt conveyor.
Saving of Aux. Power at ID fan – 33.24 Lacs/annum
Saving of amount 687 Lac/Annum by selection of Lignite fuel.
Results
Unit: Sewagram Cement Works 32
4. MV Drive Installation in BFP
Objective
Background of Project
TPP Power generation is directly depend upon power demand by Cement plant.
TPP PLF varying between 40 to 85 % as per load requirement & due to same DOL- BFP taking high power at low MW Generation & that was increasing the aux. power consumption.
Analysis & Implementation required to reduce APC of BFP at low MW Generation of TPP.
Reduction in Auxiliary power consumption by Installation of MV drive in Boiler Feed Pumps
Unit: Sewagram Cement Works 33
0.00
Aux. Power (13.2 cr.)
10.20%
MOP/AOP
(0.15%)
Boiler Fans (3.5%)
Boiler (6.5%) SA Fan (0.5%)
Turbine (0.15%)
CEP (0.5%)
PA Fan(1.8%)
ACC (2.5%)
BOP (0.70%)
BFP (2.5%)
ESP (0.5%)
ID Fan (2.2%)
Material handling
(0.20%)
ACC Fans (2.0%)
DM Plant (0.10%)
ACW &CT (0.30%)
CHP (0.15%)
LIme Stone
(0.05%)
Compressors(0.40
%)
Causes & Effect Diagram Value Driver mapping
4. MV Drive Installation in BFP - Analysis
Unit: Sewagram Cement Works 34
4. MV Drive Installation in BFP - Analysis
Analysis
To reduce power cost ,it is very important to optimize the BFP power consumption . By cause
& effect analysis following causes has been identified
Plant Running on Low capacity
Losses due to Recirculation
Losses due to Feed control valve throttle at low feed water demand to boiler drum
DOL Operated BFP
Implementation
Team TPP adopted Engineering & technological change in BFPs by installing of MV Drive in BFP with proper PID & Logic implementation as follows-
Feed water discharge pressure set point = Boiler Drum pressure + 7 Kg/Cm2( Head loss+ Bend Loss + Piping/tube friction loss)
Unit: Sewagram Cement Works 35
4. MV Drive installation in TPP BFP
Results
Throttling losses minimised by opening Feed control to maximum
BFP recirculation become zero at low load.
Power Saving Rs. 1173 Mwh/Annum
Saving of Rs. 46.92 Lacs /Annum on fuel Cost
Unit: Sewagram Cement Works 36
Sustainability Initiatives
Unit: Sewagram Cement Works 37
GtG energy consumption status (Cement & Power Plant)
1223 1104 1149 1064 1032
2014-15(Baseline Year)
Target SEC for PAT-2 cycle(04/16 to 03/19)
2015-16 2016-17 2017-18
Gate to Gate Sp. Energy Cons. (Kcal/Kg PPC)
Unit registered as Designated Consumers (DC) under PAT-2 scheme
Target given for 7.57 % reduction in GtG Specific Energy Consumption at the end of PAT-2 cycle
(2016-19)
Implementation of Encon projects in the unit reflects 15.61 % reduction in SEC upto 2017-18
without normalization.
Unit: Sewagram Cement Works 38
GHG Emissions in MT/Yr (Cement & Power Plant)
221480
267746 251163
219191
2014-15 2015-16 2016-17 2017-18
GHG Emission TPP
Unit: Sewagram Cement Works 39
Green Belt development
Green cover of about 144.6 Ha in Plant, Mines and Colony premises
Total tree planted – 49629 Nos. in Plant, Mines & Colony area till date Survival Rate of plants are 79% Extensive Plantation undertaken at Colony, Plant and Mines.
Unit: Sewagram Cement Works 40
Green Belt development
Unit: Sewagram Cement Works 41
Utilization of Renewable Energy/ Alternate fuel/ Wastes
Unit: Sewagram Cement Works 42
5 MW Solar Plant Installation
Details of Solar Plant
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
Proposed Power Gen. & Efficiency
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%
Plant Commissioned on 14th August-18
Unit: Sewagram Cement Works 43
Solar Power Plant
Unit: Sewagram Cement Works 44
Use of Alternate Fuel/Wastes
Used 784 MT of Coal Dust i.e. reject of steel plant as alternate fuel.
Used 45 MT of Carbon black powder as alternate fuel
Used 334 MT Soya husk/Cow dung/Wooden Chips as a alternate fuel
Used PPF for boiler Light up – Usage of Petro Polymer fuel in place HSD.
Used 8196 MT AFBC Fly ash in CFBC as a fuel
Used 8105 M3 N-Pit water in dust suppression (zero water discharge).
Unit: Sewagram Cement Works 45
Energy Cell
Unit: Sewagram Cement Works 46
Energy Policy
We Committed to demonstrate excellence
in reduction in Energy Consumption &
Carbon emission in all our activities of
manufacturing of cement & Clinker on
continual basis so as to make our unit & its
surrounding environment sustainable for
future
Unit: Sewagram Cement Works 47
Methodology adopted for Energy Monitoring
Energy management cell headed by FH-TPP.
Daily monitoring of PLF, Heat rate and Aux. power deviation.
Analysis of equipment performance for deviation.
Identification of energy conservation scope through - Loss Cost Matrix, Brain
Storming and Theme base suggestions/Kaizens scheme under “Energy Saving ”.
Feasibility study of suggestions & submit proposal for sanction.
Preparation of detail action plan.
Monthly review to monitor project progress.
Benefits analysis after project implementation.
Sustainability of the project
Unit: Sewagram Cement Works 48
Energy Monitoring
Energy Monitoring System
Unit: Sewagram Cement Works 49
Implementation of corrective /
Preventive action
Unit: Sewagram Cement Works 50
ISO 9001:2015
ISO 14001:2015
OHSAS 18001:2007
ISO 50001:2011
Under Implementation
System Accreditation in 2016-18…..
Unit: Sewagram Cement Works 51
IMS (ISO:9001,14001 and OHSAS:18001)
SCW has got Certification from International organization for standardization for Integrated Management systems for
Quality Management System (ISO 9001:2015), Environment Management System (ISO 14001:2015) and Occupational
Health & Safety Management Systems (OHASA18001:2007) from certification agency DNV.
Unit: Sewagram Cement Works 52
S.No. Non-conformity Description Corrective Action Taken
1 EMP is not evident to consistently meet compliance to new Stack emission norms of 30 micrograms/Nm3 in Clinker cooler Unit1 and in different stacks Unit Though improvement is observed in Unit stacks after replacement of
Bag filters, Clinker Cooler emission was found to be 29 micrograms/Nm3 in Feb 2018.
All Management programs identified.
2 As per the consent condition AWH-60839 clause 4.4, of limestone mines, ambient noise monitoring to be carried out. Organization shall take necessary authorization for the generation
and disposal of the hazardous waste.
Ambient Noise monitoring started
3 Failure - compliance to above condition is not evident. Evidence various hazardous waste such as Oily cotton waste, oil filters, used
Oil drums etc. are generated, however consent shows authorization for Used oil only.
Hazardous waste - such as Oily cotton waste, oil filters, used Oil drums etc., generation and disposal mechanism made for putting in Kiln.
Implementation of Corrective & Preventive Actions
52
Unit: Sewagram Cement Works 53
Best practices
Team Work
Knowledge Sharing
Unit: Sewagram Cement Works 54
Best Practices
• Examples are as under –
Analysis of area wise Aux. Power consumption on daily basis
Impact analysis in bearing by vibration spectrum analysis technique for lubrication of equipment
Energy efficient Motors & Illumination System
AFBC boiler converted into CFBC boiler without any technological upgradation
100% ash of boiler, utilized for Cement Manufacturing .
All new procurement is on the basis of energy efficiency.
Unit: Sewagram Cement Works 55
Team Work in EnCon
SN EnCon idea * Idea originated
in FY ** Extent of man-power involved
*** Progress of
implementation
1 Installation of MV Drive at Boiler Feed Pump 2017-18 O&M ,E&I & M/s Toshiba Team Completed
2 Closed Loop operation ACW pump operation with discharge pressure
2017-18 O&M and E&I Team Completed
3 New Turbo System installation in Desal 2017-18 O&M ,E&I and M/s Fedco Team Completed
4 Reduction of LOI in Fly Ash from 4.5 to 1.8% 2017-18 O&M Team Completed
5 Solar Power Generation 2017-18
E&I Team and M/s ABRL Team Completed
6 Closed loop operation of Lignite fuel feed in boiler
2017-18 O & M and E&I Team Completed
Unit: Sewagram Cement Works 56
Knowledge Sharing with Group Units / Vendors
Kaizen Souvenir shared to all Group Units. Achieved 15 KPE (Kaizen Per Employee) in Fy’18
Conversion of AFBC Boiler to CFBC horizontally replicated to other Group Units and same has implemented at Balaji and Aditya Cement.
Shared Erosion protection Plate modification to M/s ThyssenKrupp
Bed ash handling of AFBC Boiler through Primary Air fan in place of Compressed air shared with M/s ISGEC
Provision of MCB before signal isolator in VFD shared with M/s ABB
Unit: Sewagram Cement Works 57
Green Supply Management
Two way transportation for Raw meal and fly ash with bulker.
Two way Transportation for Fuel receipt and Clinker Export to Port.
Two way transportation of Clinker and receipt of Pond ash (Wanakbori Unit
& Gandhi Nagar Plant).
Operational of Captive Jetty for Coal.
Unit: Sewagram Cement Works 58
Corporate Social Responsibility
Corporate CSR
CSR Vision
CSR Policy
Focus Area
58
Infrastructure Development
Education
Health care Sustainable Livelihood
Unit: Sewagram Cement Works 59
Glimpses
Shala Praveshotsav and Kanya Kelvani Program
230 School Kit Distribution to surrounding Government 20 school and 55% Girls Involved .
Unit: Sewagram Cement Works 60
Awareness campaign for
Personal hygiene, Family
planning, Immunization
camps.
Awards to best students
nearby Villages.
Corporate Social Responsibility
60
Unit: Sewagram Cement Works 61
“ Women Empowerment ”
Installed of 7 Automatic Sanitary Pads vending Machine and Automatic Electrical
Incinerator in 7 Block in Model Girls Hostel. Total 839 Girls Model Hostel benefited by
activity
Unit: Sewagram Cement Works 62 62
Award & Accolades
Unit: Sewagram Cement Works 63
CII National Kaizen Award-2017 (Env. Category)
SCW (Only Cement Plant) have won National Kaizen Award (Top -18) for Utilization of Alkali-Chloride Bypass dust in
Cement under Environment Category.
The Award was presented by Dr.Baldev Raj (Indian scientist and former director of the Indira Gandhi Centre for Atomic
Research) on 10th CII National Competitiveness and Cluster Summit which was held at India Habitat Centre, New Delhi on 6th December 2017.
Unit: Sewagram Cement Works 64
CII-National Award for Excellent Energy Management
Sewagram Cement Works awarded as Energy Efficient Unit at CII 18th National Award for “Excellence in Energy Management” (Category: Captive Power Plant)
Unit: Sewagram Cement Works 65
Sewagram Cement Works Best practices recognized at IMC, Mumbai on 9th Mar’18 :
1.A giant step towards Green & Clean clinker production.
2.Utilization of ABC boiler Flyash as fuel in CFBC Boiler(TPP).
MQH Best Practices Recognition at IMC Mumbai
The same Best Practices were also published in their Annual Magazine with a Introduction of SCW Plant.
Unit: Sewagram Cement Works 66
Harudi-Kharai Limestone Mines
AWARDED 5 STAR rating mines
Amongst Top 5 best performing mines in INDIA
Kharai-Harudi Limestone Mines
Also AWARDED
5 STAR rating MINES
Receiving award from Hon’ble Union Minister of Mines & Panchayat Raj Shri Narendra Singh Tomar for Harudi
–Kharai Limestone Mine
Receiving award from Shri Haribhai Parthibhai Chaudhary Hon’ble Union Minister of State for
Mines for Kharai –Harudi Limestone Mine
Limestone/Raw Material
Unit: Sewagram Cement Works 67
We have received the official
Invitation letter for 2nd Intl’ Global
Cem Process Conference 2018 as
Keynote speaker For the presentation
on “A giant step towards ‘green and
clean’ production by replacing
conventional fuel for Cement Plant
(petcock and coal) with nearby
available lignite”.
Global Cem Process Conference
Unit: Sewagram Cement Works 68
Way Forward
Unit: Sewagram Cement Works 69
Energy Saving Projects
SN Energy Saving projects Proposed Saving
Per Annum (Rs. Lac) Target date
1 Energy Efficient Boiler Feed Pump Installation 25.5 Jan’19
2 Energy Efficient PA & ID fan Installation in CFBC
Boiler 27.6 Feb’19
3 Energy Efficient FD & ID fan Installation in AFBC Boiler 22.3 Feb’19
4 Optimization of CHP running hours 3.6 Oct’18
5 Installation Heat Exchanger at CBD tank 15.5 Nov’18
6 Installation of Energy Efficient fans in ACC 45.5 Oct’18
7 Installation of Energy efficient Boiler feed pump 14.5 Mar’19
Unit: Sewagram Cement Works 70
Team Sewagram Cement Works
JOURNEY CONTINUES TOWARDS ACHIEVING
HEAT RATE 2950 KCAL/KWH AND AUX. POWER
7.5%.........
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