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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
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
Energy saving initiatives with Zero Investment
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 saving initiatives with Zero Investment
SN. Energy Saving theme
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
SN. Energy Saving theme
Energy Saved/yr Savings(Rs.
Lacs/yr)
Invest(Rs. in Lacs)
Payback (months)Elect
(MWH)Thermal (Mkcal)
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
Energy saving initiatives with Investment
SN. Energy Saving theme
Energy Saved/yr Savings(Rs.
Lacs/yr)
Invest(Rs. in Lacs)
Payback (months)Elect
(MWH)Thermal (Mkcal)
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
Energy saving initiatives with Investment
SN . Energy Saving theme
Energy Saved/yr Savings(Rs.
Lacs/yr)
Invest(Rs. inLacs)
Payback (months)Elect
(MWH)Thermal (Mkcal)
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
Energy saving initiatives with Investment
SN .
Energy Saving theme
Energy Saved/yr Savings(Rs.
Lacs/yr)
Invest(Rs. inLacs)
Payback (months)Elect
(MWH)Thermal (Mkcal)
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
Energy saving initiatives with Investment
SN .
Energy Saving theme
Energy Saved/yr Savings(Rs.
Lacs/yr)
Invest(Rs. inLacs)
Payback (months)Elect
(MWH)Thermal (Mkcal)
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
Energy saving initiatives with Investment
SN .
Energy Saving theme
Energy Saved/yr Savings(Rs.
Lacs/yr)
Invest(Rs. inLacs)
Payback (months)Elect
(MWH)Thermal (Mkcal)
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
Energy saving initiatives with Investment
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.
Project 2 - Process fan pressure drop reduction
PH Fan - Before Modification PH Fan - Proposed Modification
Project 2 - Process fan pressure drop reduction
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 2 - Process fan pressure drop reduction
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
Project 3 - Compressor Specific power consumption
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
Project 3 - Compressor Specific power consumption
4. Installed PID based VFD in pre and post Clinkerisation pump house
Project 3 - Compressor Specific power consumption
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
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
Environmental Initiatives
Ground water recharging through injection well Rain Water Harvesting Ponds
Green Belt DevelopmentSapling Distribution to Villagers
Environmental Initiatives
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
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
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