UltraTech Cement Limited Unit: Vikram Cement Works

“Bureau of Energy Efficiency”“Bureau of Energy Efficiency”Knowledge Exchange Platform

2015

23rd June’15

Vikram Cement WorksVikram Cement Works

ABG ABG -- Largest Cement Producer in India.Largest Cement Producer in India.

1010thth Largest in the World.Largest in the World.

Capacity : 4.0 MTPA Capacity : 4.0 MTPA

Win T P M award : JIPM, Japan in 1992.

First ‘Cement Plant’ in India to :First ‘Cement Plant’ in India to :

Obtained ISO :14001 in 1997.

Obtained ISO : 27001 ISMS certification in 2009

Obtained ISO : 50001 Energy Management System (EMS) in 2013

Use MSW as ‘alternate fuel’ – since July 2007.

Use 100% high sulfur pet coke as fuel in kilns.

Achieved lowest annual kiln shut down period.

Achieved + 350 days of continuously kiln run.

WHY Energy Conservation ?WHY Energy Conservation ?

• Cement Industry is the one of the largest Energy Intrinsic Consumer.

• Energy cost is 50 - 52 % of Cement manufacturing cost

• Own Power Cost increased from Rs. 3.36 to 4.23 per unit in last four years

Need For Energy ConservationNeed For Energy Conservation

• Own Power Cost increased from Rs. 3.36 to 4.23 per unit in last four years

• Higher Energy Consumption as compared to competitors with New

Technology.

• Increasing trend of energy cost due to fossil fuel depletion.

• Energy audit once in two year.

• Specific energy audit for compressors, water pump etc.

• Pyro process audits from OEM’s like, KHD, FLs etc.

• Suggestions.

Energy Conservation Energy Conservation Initiatives Initiatives

• In-house improvements & Kaizens.

• Literature review.

• Participation in Awards & Seminars.

� CII has done “Resource Study” for energy efficiency improvement in Line-2 Kiln.

� Under this study 36 energy improvement was identified and almost 30% short term

projects has completed and Capex projects under implementation in phase manner

Energy Conservation (Energy Conservation (EnCONEnCON) )

ProjectsProjects

Maximum utilization of Alternate Fuel

Project No-1

Reduction of fossil fuel consumption

Description:

� Use of Alternative Fuel (AF) as thermal energy substitute to replace the conventional fossil fuel for pyro-processing.

� Vikram Cement line-3 kiln has alternate fuel feeding system. Till 2009-10, Vikram Cement achieved 0.77% Thermal Substitute Rate (TSR) through AF consumption i.e. Municipal Solid Waste (MSW) and Agro waste.

� Line-1 & 2 kiln there was no any alternate fuel feeding system. Plastics waste used by manual feeding into the calciner through a hopper, waste used by manual feeding into the calciner through a hopper, hence very low TSR%.

� VCW is committed to improve upon TSR and achieve up to 4.0 % TSR.

Goal: Maximum utilization of alternate fuel on consistent basis with high

calorific value alternate fuel and without involve capital expenditure.

Approach:

� Identified the bottlenecks to improve TSR%

o Inconsistent feeding due to frequent problem of concrete hopper jamming of

MSW feeding System

o CO generation in the system

o Identify the new source of alternate fuel

� Carbon dust was identified as high calorific value alternate fuel for line-� Carbon dust was identified as high calorific value alternate fuel for line-1& 2, which is available at vicinity area.

� Feasibility study in existing storage and feeding system.

Alternate Fuel Feeding System for Line-3 Kiln

Action:

� Modification in A-29 screw conveyor discharge

Belt A36 Belt A34

Screw Conveyor A29

Belt A36 Belt A34

Screw Conveyor A29

Slide gate

Before After

Screw Conveyor A29 Slide gate

� At AF discharge chute air blaster & dispersion air provided.

Power consumption save 34kwh by above modification

Action:

Line-1 & 2 Kiln

� Installation of carbon dust unloading system form bulker to storage hopper.

� Installation of compressed air line for bulker unloading.

� Mix grinding with the Petcoke and fired with fine Petcoke in calciner.

Manual feeding system

Plastic Feeding Hopper

KILN

A

F

E

L

E

V

A

T

O

R

KILN

INLET

KILN

RISER DUCT

ALTERNATE

FUEL

BELT

CONVEYOR PLASTIC FEEDING CHUTE

CHUTE PNEUMATIC SHUT OFF GATE FOR SAFETY

PLASTIC FEEDING HOPPER

HOPPER FEEDING COVER

INSTRUMENT SWITCHS FOR SAFETY

Manual feeding system

Tyre dust unloading system

Results:Alternate fuel consumption (MT) year wise in Line-3

Description (L-III) 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15

MSW 3397 3555 4092 5498 4772 3673

SOYA HUSK 638 0 0 0 0 0

SARSO HUSK 558 793 1210 1309 1742.9 4.60

TYRE CHIPS(INDIAN /IMP) 198 559 421 228 161.7 181.35

PLASTIC WASTE 146 400 646 284 211.35 64.57

WOODEN DUST 21 1398 1659 150 1.97 0

GROUND NUT HUSK 1643 2959 3884 180 0 0

PAINT SLUDGE 0 38 305.07 85.02 78.19 43.49

AFSGRI WASTE ( Doda Chura) 0 14.80 46.17 35.22 26.04 3165.98

OPIUM MARC 0 199.20 0.00 0 108.14 0

ISABGHOL HUSK 0 0 1493.00 2475 0 0

DHANIA HUSK 0 0 1550.00 3197 1000.4 0

AFMIXAGROWASTE 0 0 0 7724 11985 9184AFMIXAGROWASTE 0 0 0 7724 11985 9184

MSWRDFFLUFF 0 0 1884.00 3570 1028.6 330.25

DATESEEDS 0 0 5.00 0 0 0

TYRE DUST 0 0 0 991 1493 2674

ETP SLUDGE 0 0 0 2.50 0.86 277

AF Pyrolysisoil 0 0 0 0.00 0.00 11.82

TOTAL QTY (MT) In Line-III 6601 9916 17195 25729 22610 19610

1.8

5 3.6

2 5.9

7 9.2

8

9.3

0

8.7

7

0.7

7

1.5

0 2.7

8 4.5

4

4.1

2

4.0

2

0

2

4

6

8

10

2009-10 2010-11 2011-12 2012-13 2013-14 2014-15

Year wise Alternate fuel TSR%

Kiln-3 Combined

Results:

0.5

0

0.2

3

0.2

5

0.1

4

0.0

4

0.3

1

0.1

9

0.4

2

0.1

0 0.7

4

2.4

5

0.4

5

0.8

2

3.9

5

0.5

3

0.3

7

0.5

5

0.1

1

0.0

6

0.3

0

0.0

1

0.4

5

0.0

0

2.4

2 3.0

9

6.2

3

6.5

7

5.2

5

1.00

2.00

3.00

4.00

5.00

6.00

7.00 Monthly: Alternate fuel TSR%

� Vikram Cement achieved more than 4.0% TSR on consistent basis.

0.2

3

0.2

5

0.1

4

0.0

4

0.3

1

0.1

9

0.1

0

0.3

7

0.1

1

0.0

6

0.3

0

0.0

1

0.0

0

0.00

1.00

Kiln -1 Kiln - 2

Installation of Energy Efficient Screw Compressors

Project No-2

Screw Compressors

Description: Higher power consumption of old and low efficiency

Reciprocating air compressors which is sp. power consumption 14-17kW/100m3/hr. Due to it’s low efficiency, higher power consumption, frequentmaintenance & higher maintenance cost. Replacement of reciprocating typecompressors into the high efficiency compressors.

Goal: To reduction of specific energy consumption of compressors.

Approach: Identification of low efficient compressors.

Compressor No Measured FAD Atual kW SPC /100m3

800.51 612.0 107.00 17.48

800.52 589.0 84.00 14.26

800.53 560.5 82.50 14.72

800.01 270.8 40.00 14.77

800.11 502.9 86.00 17.10

Total 2535.1 399.50

Actual kwh

Action: Replacement of low efficiency 8 nos. compressors with new 2 Nos.

energy efficient Screw compressor of 2500 m3/hr (GA 110) capacity with specific power consumption of 10kW/100m3/hr.

Results:POWER SAVING STATEMENT FOR Line-1 SCREW

COMPRESSOR

POWER SAVING STATEMENT FOR Line-2 SCREW

COMPRESSOR

Old

Compressors

KWH

consumption

from 1.10.13

to 31.12.13

Run

Hours

Avg.

kwhMF

Actual

kwh

Old

Compressors

Kwh

20.05.14 at

10.30 to

24.00hrs

Run

Hours

Avg.

kwhMF

Actual

kwh

COMPRESSOR

NO. 01 1,43,485 1832.2 78.3 1 78.3

COMPRESSOR

NO. 011,037 13.5 76.8 1 76.81

COMPRESSOR

NO.-02 4,97,170 2207.7 225.2 0.33 74.3

COMPRESSOR

NO. 023,280 13.5 243 0.33 80.18

COMPRESSOR

NO. 04 4,34,283 2205.2 196.9 0.4 78.8

COMPRESSOR

NO. 03317 13.5 23.5 3.15 73.97

COMPRESSOR COMPRESSOR COMPRESSOR

NO. 03 2,76,779 1803.9 153.4 0.5 76.7

COMPRESSOR

NO. 04172 13.5 12.7 6.25 79.63

Average Kwh of all

compressors 308.1

Average Kwh of all

compressors 310.59

New Screw

Compressor

KWH

consumption

from 13.02.14

to 18.03.14

Run

Hours

Avg.

kwhMF

Actual

KW

New Screw

Compressor

Kwh

19.06.14 at

00.00

to 24.00hrs

Run

Hours

Avg.

kwhMF

Actual

KW

Screw

compressor 189248.7 789.2 239.8 1 239.8

Screw

compressor 5789 24 241.2 1 241.21

Total Power saved 68.3 Total Power saved 69.4

Net power saving annually:

� Power saving

Line-1 = 68.3 kwh

Line-2 = 69.38 kwh

� Annual power saving = 137.68kwh X 24hrs X 330days = 1090425.6 kWh

� Cost saving 4.19 INR/ kW = 1090425.6 X 4.19 = Rs. 45.68 Lacs.

Results:

� Cost saving 4.19 INR/ kW = 1090425.6 X 4.19 = Rs. 45.68 Lacs.

Payback period:

� Total cost including equipment, civil, mechanical, electrical, instrument is = Rs. 77.5 Lacs.

� Pay back period = Total cost / Net saving yearly.

=Rs. 77.5 Lacs / Rs. 45.88 Lacs

= 1.68 YEAR

Provide Quality & Reliable

power to Kilns by TPP

Project No-3

power to Kilns by TPP

Description:

� Grid is a vast system & likely to have fault.

� Power system frequency & Voltage floating with grid because, TPP

follow the variation in grid voltage/frequency to remain parallel with grid.

� Whenever any Grid disturbance occurs plant severely affected.

Goal:

� Provide quality & reliable power to plant (kiln) without impacting of grid

disturbance (voltage & frequency).

Approach:

� Feasibility study to provide isolated power from TPP to plant.

� Most critical process Kilns load are suitable for TPP one unit capacity.

Previous distribution (before TPP )

GRID

132 KV BUS

Tr-

G G G

Kiln &,

CO/M section

RM, CM

6.6kV BUS VC-3VC-2VC-1

DG Generator

Tr-

1 Tr-

2Tr-

3

Kiln &,

CO/M section

RM, CM Kiln &,

CO/M section

RM, CM

Previous distribution (after TPP)

GRID TPP- 1 TPP- 2

132 KV BUS

Tr-

G G G

6.6kV BUS VC-3VC-2VC-1

DG Generator

Tr-

1Tr

-2Tr-

3

Kiln &,

CO/M sectionRM, CM

Kiln &,

CO/M sectionRM, CM Kiln &,

CO/M section

RM, CM

Action: Install additional transformer

GRID TPP- 1 TPP- 2

Trafo-4

Sync.

Present distribution

132 KV BUS

G G G6.6kV BUS

VC-3VC-2VC-1

DG

Sync.

BkrTr-

1Tr-

2Tr-

3

Kiln &,

CO/M sectionRM,

CM

Kiln &,

CO/M sectionRM, CM Kiln &,

CO/M sectionRM, CM

Results:

� We have taken trial of all thee kiln on TPP-2 (Without grid) at optimized

voltage & frequency from 26.04.2015 to 30.04.2015.

� At the time of voltage dip or any Grid disturbance all kilns remains

unaffected.

� Plant run at optimized frequency & voltage.

� Efficiency of Plant is improved.� Efficiency of Plant is improved.

� Saving expected in kiln power by 0.33 kwh/ton of material and actual

achieved – 0.60 kwh/ton of material

Saving

Previous

calculation & study

Description:

Bag house fan was running at higher speed (800 – 830rpm) and

consuming more power (430-460kw) to maintain required draught at PH fan outlet.

Bag house fan power consumption reduction

Project No-4

PH fan outlet.

Goal:

Reduction in power consumption & optimise the fan speed by reducing

pressure drop and minimise false air ingress in system.

Approach:

• Pressure drop across damper checked and it was found on higher side (50mmWg) in full open condition.

• Fan inlet suction eye gap checked.

• Repair/replacement of bag house inlet duct to reduce false air entry.

Fan inlet damper: Pressure drop reduction across damper

Fan inlet damper vanes repairing.

BeforeBeforeInlet

Damper

AfterAfter

Inlet

Damper

Action: 1st Improvement

Damaged Inlet Damper

Open

Vanes

Vanes

not fully

open

Repaired inlet damper

All open

Vanes

Fan inlet suction eye: Eye gap optimise

Replaced fan inlet suction eye

BeforeBeforeAfterAfter

Suction Suction

EyeEye

Suction

Eye RotorRotor

Action: 2nd Improvement

Suction eye

GapGap 15 mm

New Suction Eye

OverlapOverlap 7, 25

mm

Bag house inlet duct: To reduction of false air

Replacement of Bag house inlet duct

• Replace bag house inlet duct of Dia. 3450 mm and Length 37 Mtr.Before After

Action: 3rd Improvement

Damage Duct New Duct*To reduce corrosion ceramic resistance coating was done

Benefit of Improvement

1) Power consumption- 438 KW

438X24X330=3468960 KW

2) Maintenance on duct-high risk job

3) Cleaning of spillage material-

1) Power consumption- 403 KW

403X24X330=3191760KW

Before After

3) Cleaning of spillage material-extra manpower required

Loss-Saving

Bag house fan motor: Resizing to utilize SPRS

Before After

1. Motor Power :- 1060 KW 1. Motor Power :- 550 KW

� Bag house fan SPRS is designed for 70 to 95% RPM So fan was running at

700 rpm and further control was being done by Inlet Damper.

� So Motor replaced with low RPM( 990 to 743 RPM) and KW (1060 to 550 KW)

now control of RPM below 700 was possible that resulted in power saving

Further 4th Improvement

1. Motor Power :- 1060 KW

2. Fan RPM :- 990

3. Running RPM: 700+

1. Motor Power :- 550 KW

2. Fan RPM :- 743

3. Running RPM: 535 to700

Power consumption- 400 KW

400X24X330=3168000 KW

Total cost- 3168000 X4.75= Rs. 15048000

Power consumption- 340 KW

340X24X330=2692800KW

Total cost- 2692800 X4.75= Rs. 12790800

Description:� Presently low efficiency Chinese pumps are installed for feeding the

water into boilers.� Maintenance expenditure as spare parts cost of these Chinese

Project No-5

Replacement of Boiler Feed Pumps with high efficiency indigenous pumps

� Maintenance expenditure as spare parts cost of these Chinesepumps are very high & no service support is available in India.

Goal:Replacement of low efficiency water pump with high efficiency indigenouspumps to save the energy.

Approach: Two boiler feed pump were identified as low efficiency

pump.

Action: Installation of Indigenous KSB pump

Before After

Chinese Pump Indegnious Pump

Results:

S.No.Load

(TPH)Amps

KSB

Pump

Power

cons. kw

KSB Pump

average

Power

cons. kw

Chinese

Pump power

cons. (kw)

Chinese Pump

average power

cons. (Kw)

Net

saving

in Kw

Net average

saving in Kw

1 102 37.86 615 790 175

2 118 40.2 675 790 115

3 109 41.97 683 790 107

Saving analysis:

643 790 147

3 109 41.97 683 790 107

4 98 39.58 630 790 160

5 94 39.76 632 790 158

6 94.5 40.06 635 790 155

7 89 38.7 630 790 160

Before pump installation After pump installation

Energy consumed = 18960 kwh / day Energy consumed = 15432 kwh / day

Net average saving per day = 3528 kwh

Net average saving per annum = 1287720 kwh

In term of Rupees = 1287720X3.45X = Rs 4442634/ annum

Saving for two nos pump installed = 4442634 X 2 = Rs 8885268 / annum

Thank YouThank You