Best Practices Towards Energy Excellenceqcfihyderabad.com/cementconclave2018/wp-content/uploads/2018/10/ACC... · 1.Replaced FLS duplex burner to KHD pyro jet burner 2. Jet air nozzle

Wadi Cement Works 15th Oct. 2018

Best Practices Towards Energy Excellence

1

ACC Limited, Wadi Cement Works

ACC Wadi Geographic Location

KARNATAKA

STATE

Plant Site

Clinkering : 5.83 MTPA, Cement - 6.03 MTPA Power - 125 MW

Wadi-1

Wadi-2

2


Genesis of the plant...............Wadi Cement Works

1978 1983 1995 2001 2006 2010 2014

1968

1968: Wadi I set up with installed capacity of 0.4 MTPA

Kiln 1 & 2 1978: MFC Installation

1983: Ist 1.0 MTPA Indigenous

Plant in India & 25 MW

CPP installed

1995: CPP expanded to 50 MW

Wadi-2 Commissioning

2.0 MTPA

2006 With in house

modification at Wadi II total capacity of Wadi- 4.2 MTPA

WD 2Expansion

clinkering & CPP(50 MW)

Total capacity 6 million Tons &

125 MW CPP

CommissioningAFR platform

(16 TPH)

India’s Ist 1.0MTA Plant

2018-19

Expansionof AFR platform

(20% TSR)

ACC Wadi 2 - Video edited.wmv


Plant layout_Wadi-2

L&T make impact bar crusher Crusher 1 – 1000 TPHCrusher2 – 1200 TPH

Raw Mill-1 (Atox 50)Capacity – 450 TPHRaw Mill-2 (Pfeiffer 5600 B)Capacity – 560 TPH

Raw Meal Silo1 Nos. CF SiloCapacity – 21000 T

Complex SLC & ILC Combination of

6 stage PH

ILC Height –182 mSLC Height - 120 m

Kiln : Size – 6 m Dia X 96 m Length,BDP – 12500 TPD, Make –FLS, Inclination – 4%, RPM – 5 max. ,Drive – Twin Drive

RM1 RM2

Coal Mill-1 (Atox KM25)

Capacity – 50 TPH

Coal Mill-2 (Loeshe LM43.4 D)

Capacity – 93 TPH

Cr1 Cr2

SLC

ILC

K4

KM1 KM2

CM (Ball Mill)– 2 Nos.Capacity – 220 TPHx 2Make - FLS

VRPM – 2 Nos.Q –230 TPHMake- AMCL

Clinker SiloQ. – 1.15 LT

Cement SiloCap.- 10000t Tx 3

Packer- 4 Nos.Cap. -180 TPHX 4Double discharge


Energy performance improvement over one year

5

Sl. No Description Units 2016-17 2017-18

1 MTOE reduction TOE/Ton 0.0811 0.0761

2 Kiln Thermal SEC kCal/kg cli 718.73 718.37

3 Specific Electrical Energy - clinkering kWh/T of clinker 62.62 59.61

4 Specific Electrical Energy – Grinding kWh/T of cement 37.57 37.09

5 CPP Heat rate kCal/kWh 3375 3359

6 CPP auxiliary consumption % 13.32 12.83

7 Thermal Substitution Rate % 6.32 11.2

8 Clinker factor % 0.72 0.68

9 Blended cement *%) of total cement % 83.54 89.76

10 Renewable Purchase Obligation (Solar+ Non Solar) REC 27017 41517

11 REC Purchased – Solar REC 1542 0

12 REC Purchased – Non Solar REC23744

26000

13 Mitigation of RPO through Solar Power Consumption REC 1700 15517


SEC Performance Clinkering in last 3 - Years

In Year 2016, both SEC & STEC have been increased from previous years due to;

✓ Low PRI of Kiln; 83.79% in Y’16 from 93% in Y’15 after 100% pet coke firing.

✓ Increased AFR consumption from 4.17 % - TSR in Y 2015 to 6.23 % -TSR in Y 2016.

✓ Low PRI of Kiln due to TA Duct failure in Dec 2016 (PRI-50%) and Jan 2017 (PRI-48%)

57.50

58.00

58.50

59.00

59.50

60.00

60.50

61.00

61.50

62.00

62.50

Y'15 Y'16 Y'17 Y'18

60.06

62.19

60.6

59.35

Clinkering SEEC KWh/Tcli. Including 70% NP Power

685.0

690.0

695.0

700.0

705.0

710.0

715.0

720.0

725.0

Y'15 Y'16 Y'17 Y'18

697.6

709.7

722719.6

STEC K Cal/ Kg Clinker

Including 70% Non Process Power


SEC Performance Grinding/Total in last 3 - Years

72.00

74.00

76.00

78.00

80.00

82.00

84.00

Y'15 Y'16 Y'17 Y'18

79.47

82.6

78.86

76.48

Total SEEC KWh/T cem including NP Power

36.2

36.4

36.6

36.8

37

37.2

37.4

37.6

Y'15 Y'16 Y'17 Y'18

36.73

37.47

37.33

37.05

Grinding SEEC KWh/T cem. Including 30% NP power

ACC Limited, Wadi Cement Works 8

Road map to achieve benchmark/global best SEEC

Sr. No.

Title of Project Saving

1 Expansion of Alternative Fuels project TSR increase from

12 to 20%

2 Replacement of Beumer pan conveyor with Aumund 1.7 KWh/T Cem

3 PIT navigation system - Intelligent optimization software for

Cement Kiln 1 KWh/T Cem

10 K Cal/Kg Clic.

4 Replacement of DC drive of Kiln String Fan with MV Drive0.4 KWh/T Cem

5 Replacement of DC drive of old Baghouse Fan with MV Drive0.57 KWh/T Cem

6 Replacement of DC drive of old Cooler ESP Fan with MV Drive0.2 KWh/T cem

7 Replacement of Cross bar cooler with IKN Cooler 1.5 KWh/T Cem

10 K Cal/Kg Clic.

8 Installation of double flap damper below Coal mill #2 BH

discharge0.1 KWh/T cem


Road map to achieve benchmark/global best SEEC

Sr. No.

Title of Project Saving

9 Tapping heat from Cooler & Kiln exhaust gases by installing

waste heat recovery system13.2 MW Potential

10 Replacement of Cement Mill & Raw Mill separator DC drive with

LV drive0.17 KWh/T Cem

11 Replacement of Coal Crusher & Lime stone crusher Apron feeder

DC drive with LV drive 0.11 KWh/T Cem

12 Replacement of calciner string fan impeller with lower sized

impeller in order to improve operating efficiency 0.14 KWh/T Cem

4 Kcal/Kg Cli.

13 Replacement of existing three way separator with V separator0.7 KWh/T Cem

14 Maximization of fly ash absorption from current level of 33.5%

to 35% 0.8 KWh/T cem

Total 7.39 KWh/T Cem

24 K Cal/Kg Clic.


INNOVATIVE PROJECT -1 Page 1 of 4

Plant : WD` Title of the measure :

Reduction in primary air in firing burner

from 9.73 % to 6.7% by modification of jet air nozzle

Category A Known concept with Unique Application

❑ Description of the energy conservation measure:

The Wadi2 Kiln operates with KHD pyrojet burner commissioned in Oct 2017. The jet air nozzles diameter was reduced from 27 mm to 17mm.

There are total 16 holes for jet air. The area is reduced from 9156 mm2 to

3632 mm2

❑ Problem Faced:

✓ Higher Primary Air intake

✓No any significant reduction in NOx emission

✓ Higher Fuel consumption

✓ Poor Nodulisation of clinker

✓ Lower C3S & Higher C2S


Problem Analysis and action taken Page 2 of 4

Problem Action taken

1. Higher PA

consumption & Low Burner momentum

1.Replaced FLS duplex burner to KHD pyro jet burner

2. Jet air nozzle dia. reduction from 27 mm to 22 mm3. Replacement of PA fan with Blower

2. Formation of

coating in raiser duct.

1.Started using high alkali content material in raw meal

corrective to maintain A/S in clinker.2.Installation of Cardox socket in kiln raiser duct to

dislodge the coating.

3.Cyclone / Raiser duct air blaster sequence changed to auto mode.

3. Flushing of

clinker in pan conveyor tunnel

due to fine clinker.

1. Increased alumina ratio for better nodulization.

2. Cooler operation mode changed from random to shuttle.

3. PC discharge chute modification

4. Higher NOx

Emission

1. Reduction in PA Air

2. Jet air nozzle dia. reduction from 27 mm to 22 mm


Picture/ sketch before modification Picture/ sketch after modification

PRODUCTIVITY IMPROVEMENT POTENTIAL Page 3 of 4

22 mm Dia.


TANGIBLE IMPACT OF THE PROJECT Page 4 of 4

Result & Benefit

•The jet air blower operating speed is reduced from 1260 rpm to 860 rpm

•NOx reduction from 905 mg/Nm3 & 1027 mg/Nm3 to 730 mg/Nm3 & 887 mg/Nm3

respectively. (reduction by 175 mg/Nm3 and 140 mg/Nm3)

•The reduction in primary air from 9.6% to 6.7% - Savings of 4.1 Kcal/Kg

Clinker


INNOVATIVE PROJECT -2 Page 1 of 4

Plant : WD Title of the measure : Improvement in RM#2

PRI from 560 to 570 TPH by internal modification

in Raw Mill #2 (Pfeiffer 5600 B)Category B New concept (risks taken/self driven / beyond OEM)

❑ Description of the energy conservation measure:

Problem Faced:❖Mill body vibration high 16 to 18 mm/sec & air Separator was running in the range

of vibration levels 20-22 mm/sec. There was no any oil cooling arrangement for the

hydraulic system. This causes following problems–•Mill buffer seal & Pull rod failure frequently

•Buffer & it’s side liner got damage .•Cracking of mill surrounding Platform

•Damage of hydraulic Cylinder top bush & seal

•Not Able to increase the Feed more then 560 tph

❑ Identification of problem and root Cause Analysis

✓ Continuous studies by OEM Since 2010 but no solution was provided✓To reduce the oil temperature we have installed separate oil cooling arrangement

✓ Carried out brainstorming session & also taken ideas from sister Works i.e. Chanda

Works



Electrical Energy Conservation Case Study Page 2 of 4

Before dam ring increase Material empty After dam ring increase material height



Innovative Project 2 Page 3 of 4

Oil Tank

Pump

Filter 10 µ

Valve Block

Hydraulic

Cylinder 3 Nos

Pump

Oil Tank

Pump

Hydraulic Cylinder

3 Nos

Valve Block

Filter 20 µ

Filter 20 µ

Heat Exchanger

Pump


Electrical Energy Conservation Case Study Page 4 of 4

❑ Execution & Implementation

Dam ring height & feed chute height has been increased & mill body vibration & separator vibration reduced drastically

❑ Result & Benefit

✓ Decreased mill internal recirculation of material resulted in lower mill DP caused

increase in feed by 15-20 TPH.

✓MILL vibration Reduced from 20- 22 mm/sec to <7 to 8 mm/sec

✓Silo feed bucket elevator load increase around 15 to 20 Amps

✓Buffer seal & Liner plate life has been increased

✓Cracking of Mill surrounding platform eliminated

✓Hydraulic Cylinder top bush life increased

✓Reduction in frequent mill breakdown due to seal damage & pump failure

✓Reduction in oil temperature resulting in reduction in seal damage, solenoidmalfunctioning & oil consumption.

Total reduction of around 1 KWh/T mat has been achieved


Energy Saving projects implemented in FY 2017-18

Sr. No.

Title of Project

Annual SavingElectrical(KWh) Thermal (Mio. K

Cal)

Total Annual Saving (Mio. INR)

Investment made (Mio. INR)

1 Improvement in RM#2 PRI from 560 to 570 TPH by1) Arresting false air from 25 % to 13 %2) Modification in Mill feed chute3) Maintaining crusher output size 90% passing 75 mm

561250 2.81 0

2 Interlocking of crusher hopper level sensor with apron feeder RPM to reduce idle running & reliability of lamella plate

99000 0.495 0.05

3 Old stacker travel drive converted from Rdol to VFD 79200 0.396 0.05

4 Replacement of soft starter with VFD in old high grade & shale reclaimer 217661 1.1 0.2

5 Reduction in rake (coal & Gypsum) unloading time from 9.6 hrs to 7 hrs 449000 2.25 0



Sr. No.

Title of Project

Annual Saving

Electrical(KWh)

Thermal (Mio. K Cal)



6 Cooling tower Hot water pumping system modification & replaced 75 KW motor with 45 KW motor. 144000 0.7 0.05

7 Replacement of Conventional lights with LED lights 171915 0.86 2

8 Reduction in clinker cooler Temperature by 1) replacement of cooler fan FA 4 & 5 with motor 2) Replacement of impeller of Cooler fan FA 6 & FA 7 3) Replacement of Cooler 3rd compartment plates

11467.94 (T) 13.76 8.2

9 Reduction of avoidable electrical energy loss in GRR by replacing GRR with SPRS in RM#1 fan (3400 KW & 6.6 KV)

1222000 6.11 7.5



Sr. No.

Title of Project

Annual SavingElectrical(KWh) Thermal (Mio. K

Cal)



10 Improvement in NAI of both VRPM to ensure 100% Cement Mill running with Pre-grounded material by carrying out following jobs 1) Replacement of separator rotor & stator 2) Replacement of impeller of Sepax fan3) installation of chillers unit for gearbox

oil cooling

2245000 11.23 5.6

11 Reduction in primary air in firing burner from 9.9 % to 6.7% by replacing the existing fan with high pressure& low volume blower.

13696 (T) 15.89 20


Utilisation of waste for replacing the conventional energy

Pre-processing: Capacity- 200 M3/Hr

Co-processing: Capacity- 150M3/Hr

❑ Consists of Metso M&J 4000 S

hook shredder, REMA belt

conveyors, Steinert Magnetic

Separator & Eco-star screen.

❑ Suitable for material with bulk

density= 0.1 to 0.6 t/m3

❑ Suitable for material having

moisture range= 0 to 70 %

❑ Facility to handle both HZ & NHz

Waste


Utilisation of waste for replacing the conventional energy


0.02

4.09

6.43

9.69

11.39

10

71

70

15

51

62

23

94

66

16

79

30

2994242340

62530

40521

0

50000

100000

150000

200000

250000

300000

Y'14 Y'15 Y'16 Y'17 Y'18

0.00

2.00

4.00

6.00

8.00

10.00

12.00

TSR (%) TSR (m Kcal) TSR (MT)

Plan to increase TSR % from 12% to 20% by the year 2020 by

adding another Pre-processing line of having investment of Rs. 70 Cores – In progress

AFR Performance


Green Procurement & Green mission Policy

1. Optimization of natural resources

2. Installation waste heat recovery system to produce green energy

3. Sustainable reduction in Plant Energy consumption

4. Reduction in plant water consumption

5. Cement manufacturing with Zero harm to Environment

6. Our slogan “Manufacturing of Green Cement”


Projects implemented in Green mission Policy

1. Dispatch of Bulk Cement to bulk terminal at Mumbai via rail transportation (16% of total dispatch- 359730.8 MT)

2. Major portion of Cement Bag dispatch through rail to reduce GHG emission (53% rail & 47% road)

3. Major portion of Clinker dispatch through rail to reduce GHG emission (82% rail & 18% road)

4. Finalizing the order of electrical equipments based on efficiency & BEE star rating.

5. 100 % own fly ash transportation through pumping. Bulker movement has been eliminated.

6. Zero waste discharge from the boundary of the plant.

7. Major portion of fly ash transportation through rail transportation.


Organization Chart for Energy & Environment Dept.


Involvement of Employees, Team work in ENCON, ….

✓To achieve our objective of manufacturing of Green Cement we have formed various cross functional team to improve the performance by enhancing energy Efficiency & minimum harm to environment✓Identifying the gap in performance and develop Roadmap for bridging the GAP✓Monitoring progress in weekly review meeting along with functional manager chaired by unit head for improving operational excellence


Online monitoring of electrical energy – EMS

Hourly Tracking of section wise SEC through auto generated SMS


2

9

Energy Management System & Energy Policy


PAT Cycle Performance

Baseline SEC Target SEC Assessment year Normalized SEC

0.0922

0.0874

0.0829

GtG

SEC

(to

e/t

on o

f eq.

Cem

)

Nos. of ECerts: (+) 23426 Nos.


Major Investment for Energy Conservation

# Project Description AmountRs. Cr.

Current Status

1 Replacement of SF Bar Cooler fans 0.82 Implemented

2 Bed Ash Coolers for AFBC & CFBC Boilers 6, 7 at CPP 4.1 Implemented

3 New PYROJET Burner 1.5 Implemented

4 CPP – Zero Liquid discharge project 8.25 Implemented

5 Online condenser cleaning system 0.82 Implemented

6 Replacement of GRR with SPRS in RM#1 fan. 0.93 Implemented

7 Up gradation of CM inlet fly ash feeding system 0.70 In progress

8 To increase TSR % from 10% to 20% in Y’2020 by adding another Pre-processing line.

70 In progress

9 Air cooled condenser for TG4 & TG5 50 In progress

10 Replacement of PH ILC string fans with high Efficiency fan 2 In progress

11 Replacement of 3-way separator to standard separator 5 In progress

12 Up gradation of DCS Operating 3 In progress

13 Replacement of Condenser Tubes TG5 1.5 In progress

14 PIT navigation system - Intelligent optimization software for Cement Kiln

2.5 In progress

Total 151.08 cr. (10% of turnover)


National Energy Conservation Day Celebration (Awareness Drive)


National Energy Conservation Day Celebration (Awareness Drive)



Mr. Piyuesh Goyal, Hon’ble Minister of State (Independent Charge) forMines, Power, Coal & New Renewable Energy GOI awarded the trophy toDr. S B Singh, Cluster Head South, ACC Limited

FIMI – Health & Safety Award

35

Wadi Cement works bagged the FIMI – Health & Safety Award Y15-16


19th National Award for Excellence in Energy Management by CII

National Award as “Excellent Energy Efficient Unit” by CII in year 2018


National Award for Excellence in Energy Management by CII

National Award as “Energy Efficient Unit” by CII in year 2017, 2016 & 2015


Awards & Accolades

Green Manufacturing Excellence Gold Award - 2012

National Award for Excellence in Energy Management- 2011

India Manufacturing Excellence Gold Award - 2012

Green Manufacturing Excellence Award- 2014


▪ National Award for outstanding performance in promoting rural and agriculturaldevelopment – by ASSOCHAM

▪ Indira Priyadarshini Vrikshamitra Award - by The Ministry of Environment andForests for "extraordinary work" carried out in the area of afforestation

▪ FICCI Award - for innovative measures for control of pollution, waste management& conservation of mineral resources in mines and plant

▪ Subh Karan Sarawagi Environment Award - by The Federation of Indian MineralIndustries for environment protection measures

▪ Drona Trophy - By Indian Bureau Of Mines for extra ordinary efforts in protectionof Environment and mineral conservation in the large mechanized mines sector

▪ Indo German Greentech Environment Excellence Award

▪ Golden Peacock Environment Management Special Award - for outstandingefforts in Environment Management in the large manufacturing sector

▪ Indira Gandhi Memorial National Award - for excellent performance inprevention of pollution and ecological development

Awards And Accolades


Thank You

40

Documents

Best Practices Towards Energy Excellenceqcfihyderabad.com/cementconclave2018/wp-content/uploads/2018/10/ACC... · 1.Replaced FLS duplex burner to KHD pyro jet burner 2. Jet air nozzle