UltraTech Cement Limited: Unit - Rawan Cement Worksgreenbusinesscentre.com/energyaward2017presentations/Cement/12... · UltraTech Cement Limited: Unit - Rawan Cement Works Team

Integrity Commitment Passion Seamlessness Speed

CII 18th National Award for Excellence in Energy Management 2017

UltraTech Cement Limited: Unit - Rawan Cement Works

Team Members:1. Mr. Ram Prakash Nolkha 2. Mr. Pradeep Agrawal 3. Mr. Deepak Kumar


1. Business and Unit Overview

2. Cement Manufacturing Process & Unit’s Milestones

3. Various Certifications and Energy Management System

4. Reduction in SEC, Innovation and Various Encon Projects

5. GHG Inventorization, Sustainability, Safety & CSR Activities

6. Best Practices (Green Supply Chain), Awards and Accolades

Contents


Hirmi Cement Works

Jafrabad Cement Works

Magdalla Cement Works

Ratnagiri Cement Works

Andhra Pradesh Cement Works

Arrakonam Cement Works

Awarpur Cement

Works

Jharsuguda Cement Works

West Bengal Cement Works

Bathinda Cement Works

Aditya Cement

Vikram Cement

Gujarat Cement Works

Kotputli Cement Works

Hotgi Cement Works

Rajashree Cement Works

Ginigera Cement

Works

Panipat Cement WorksDadri Cement Works

Aligarh Cement Works

RWCW

Integrated Units

Grinding Units

Bulk Terminals

Mangalore Bulk

Terminal

Shankarapally Bulk Terminal

Navi Mumbai Cement Unit

Dankuni Cement Works

Patna Cement Works

Cochin Bulk Terminal

Pune Bulk Terminal Unit

Sewagram Cement Works

Wanakbori Cement

Works

Nagpur Cement Works

Jhajjar Cement Works

Units SymbolNumber of

Units

Integrated Plants 18

Grinding Units 25

Bulk Terminals 7

Business Overview

BSBT- Dodballapur

Reddipalayam Cement Works

Largest Cement Player in India by an Even Larger Margin

14 MILLION TPA

(2004)

93.00MILLION

TPA(2017)

Balaji Cement Works

Sidhi Cement Works

Bela Cement Works

Baga Cement Works

Dalla Cement Works

Bagheri Cement Works

Roorkee Cement WorksSikandarabad Cement Works

Tanda Cement Works


Our Aspiration, Going Forward

Looking Ahead

No. 3 in the World

25% Market Share

Add 30 Million Tonne Capacity

Double our revenues

Triple the EBITDA

One in three homes built in India with UltraTech Cement


UltraTech Rawan Cement Works At a Glance

RWCW Major Equipment Details

Line 1 (1995) Line 2 (2013)

RAW MILL

Loesche VRM 375 TPH

KHD Roller Press 3 × 275 TPH

COAL MILL

Loesche VRM 40 TPH

Pfeiffer VRM 90 TPH

KILN

FLSmidth (SLC + ILC)5600 TPD

KHD (4 Strings ILC)10000 TPD

CEMENT MILL

KHD RP + Ball Mill (PPC – 305 TPH)(OPC – 220 TPH)

Polycom for Slag Grinding

(PSC – 220 TPH)

BrownfieldProject

3.30 MTPA Year 2013

Capacity Enhanced 1.87 MTPA Year 2008

Greenfield Project1.0 MTPA Year 1995

Clinker: 5.17 MTPA Cement: 2.50 MTPATPP Capacity: 55 MWWHRS: 15 MW

Plant Capacity RWCW is the largest unit of UltraTech

Cement Ltd. in Eastern Cluster of India

RWCW


VISION

To be the Leader in Building Materials with focus on our Values & create a Sustainablefuture in the UltraTech Cement of Aditya Birla Group.

MISSION

Leading with latest technologies for delivering the values to our customer's by followingfour focal areas:

1. Sustainability

2. Quality & Bosstomer Satisfaction

3. Employee Engagement & Team Empowerment

4. Cost Effectiveness & Innovation

Unit’s Vision & Mission


Cement Manufacturing Process

Mining CrushingClinkerisation

Clinker

Grinding

PackingDelivery

Truck

Coal Grinding

Delivery

Rack

Delivery

Bulker

Additives

Stacking & Reclaiming

LS Grinding

Post Clinkerization

Pre Clinkerization


Our Final Products

PPC PSC OPC 43 Grade


Unit’s Milestones & Achievements

Rated as one of the best Cement plant in Safety with clear focus on Environment, Zero %Ground Water usage in Plant & Colony, Green Band in External BCE Audit

Highest Conversion factor of 1.72 – Lowest Carbon Footprints/Specific CO2 Emissionsamong all UltraTech plants

Manufacturing of Green Clinker & Successful Plant scale trial of Composite Cement(received license from BIS for manufacturing of Composite cement)

First Unit in UltraTech to achieve output of >12500 TPD Clinker from line-2 Kiln with100% Petcoke, SEC of <50 kWh/MT of Clinker & 695 kCal/kg of Clinker

2nd Lowest Cost of Cement manufacturing in UltraTech for FY 2016-17 and presently weare at no. 1 in Q1 – FY18 among all plants of UTCL

In-house manufacturing of Grinding Aid and lowest power consumption in PPC grindingamong all UltraTech Cement Plants (22.22 kWh/MT in July’2017)


Unit’s Best Practices

❖ Effective Safety Culture deployment in every action

❖ Cross functional SWOT Analysis every year in presence of Top management

❖ Structured Energy Management System for continual improvement

❖ Centralized Total Lubrication Management

❖ Use of Slag as Raw Material in Clinkerisation – Green Clinker

❖ Shutdown Management System

❖ Well organized Inspection System (R1R2/S1S2) & Effective Preventive Maintenance

❖ Organized Hazardous Waste handling system

❖ Man less Operation of LS Stacker and Reclaimer in both lines

❖ Execution of Basic Condition Evaluation

❖ Use of PPF in place of HSD during light up of Kiln and TPP

❖ Effective Cross functional Why-Why Analysis of each breakdowns on fortnightly basis


Certifications

SA 8000 ISO 27001ISO 9001, 14001, OHSAS 18001


Energy Management Policy

❖ Energy Policy implemented in 2009

❖ Energy Policy states unit’s commitment towards continual energy performance improvement

❖ Energy policy is communicated at all levels

❖ Daily Review of Energy & PAT data w.r.t BEST

❖ Dedicated Energy Cell with fortnightly review

❖ Three layer Team Structure for stringent Monitoring

❖ Six Sigma Projects on Energy Conservation

❖ Real time power consumption data monitoring through online Energy Monitoring System

❖ Committed for continual improvement


Energy Management Structure

COO & EP Chairman

FH-TechChampion

LSC RM Kiln CMPacking

Plant

WT Clinker Loading

TPPAC, P&V

Township Utilities

Energy Manager

Energy Cell Functioning Focus Area

Restoring Basic Condition of Equipments

Process/Energy Optimization

Awareness / Campaign /Knowledge Management

Technical Cell

Innovation

Technological Up-gradation


Energy Monitoring, Reporting & Implementation Methodology

Online Energy Monitoring System


Energy Monitoring, Reporting & Implementation Methodology

❖ Energy Management Cell with clear cut responsibilities.

❖ Daily monitoring of Energy Deviation report.

❖ Benchmarking with National/International/Group

Units/Cluster units and action plan for improvement.

❖ Regular study of Equipments on deviation and their

analysis.

❖ Process Evaluation & Identification of Energy Conservation

scope.

❖ Feasibility study of suggestions and designing proposals for

sanctions.

❖ Promoting energy saving idea generation by shop floor

teams and time bound implementation

❖ Organizing Internal and External Energy Audit.

Monitoring & Review Formats

Description Formats

Daily Co-ordination meeting on Power and Performance review

Review of Daily Power Report for any deviation

Energy Cell Meeting Points Compliance review

Energy Audit (Internal & External) Points Compliance


Dedicated Energy Cell

1 LS Crusher

Mr. Lalit Nayak Electrical(SH)

Mr. Amit Shekhar Mech.

Mr. Rishi Verma Instt.

Mr. Devendra Deshmukh Mines Operations

Mr. Manish Paliwal Elect.

2 Raw Mill

Mr. Yogendra Verma Electrical(SH)

Mr. Pushraj Mech.

Mr. Shashikant Tiwary Mech.

Mr. Rishi Verma Instt.

Mr. Sanjay Kateria Process

3 Coal Mill

Mr. Prakash Hardeniya Electrical(SH)

Mr. Karan raj Gupta Mech.

Mr. Animesh Sumen Mech.

Mr. kishor Nalge Instt.

Mr. Sanjeev Choubey Process

4 Kiln

Mr. Byomjit Dixit Electrical(SH)

Mr. R.K. Tiwari Mech

Mr. Pramit Ujjain Mech

Mr. Adityaram Instt.

Mr. Vikas Sahu Process

5Cement

Mill

Mr. Ashok Ojha Electrical(SH)

Mr. Sudhanshu Barik Mech

Mr. Rajesh Jaiswal Instt.

Mr. Manish Mishra Process

6Packing

Plant

Mr. Ashok Ojha Electrical(SH)

Mr. Sanjeev Mishra PP Operation

Mr. Rajkumar Soni Mech

Mr. Rajesh Jaiswal Instt.

7 TPP

Mr. P.S. Rangnath Electrical(SH)

Mr. Neeraj Singh Mech

Mr. Lovkesh Kumar Instt.

Mr. Pawan Pothghan Operation

8 WHR

Mr. Ravi Raw Electrical(SH)

Mr. Dharmendra Manikpuri

Mech

Mr. Abhishek Sen Instt.

Mr. Rajesh Sharma Operation

9 Utility

Mr. Yogendra Verma Electrical(SH)

Mr S P Yadav Utility (SH)

Mr. Shyam Narayan Sahu Mech.

Mr. Krishnakanth Singh Instt.

Mr. Ankush Gwande Electrical

Cross Functional Action Team for Energy ConservationEnergy Cell Meeting

All team presentssectionwise Powerand Performance

Discussion overdeviation (if any)

New Ideas on powersaving

Target date andResponsibilityallocation

Last meeting MOMreview


Employee Involvement & Team Work

Kaizen & Suggestions Schemes

Annual Improvement Projects

Organization Knowledge

KIP Visits

External & Internal Trainings on Energy

Participation in Seminars

Team competition

Energy Conservation Week

Awareness creating to all Colony residents for Energy Conservation

Online Training need identification throughPoornata on Energy Conservation

Reward & Recognition

1000

1500

2000

2500

3000

2014-15 2015-16 2016-17

1821 17572112

NO

S.

Kaizens/Suggestions Implemented

75

95

115

135

155

175

2014-15 2015-16 2016-17

142.2

122.54

162.31

Monetary Savings in Rs. Lacs



Annual SWOT Analysis



Monthly Masscom Meeting

Award – Encon Project

Best Encon Suggestion Award

Good Work Done Award

COO & EP Addressing

Monthly Masscom Meeting


Unit’s Performance



5.00

15.00

25.00

35.00

45.00

2014-15 2015-16 2016-17

34.7938.85

43.04

Clinker Production (LMT)

5.00

10.00

15.00

20.00

25.00

2014-15 2015-16 2016-17

19.49 19.88 19.84

Cement Production (LMT)

GO

OD

GO

OD

Production figures are combined for both Lines



%

26

28

30

32

34

36

2014-15 2015-16 2016-17 NationalBM

30.10

33.68 34.35 35.00

Flyash Addition %

%

20253035404550556065

2014-15 2015-16 2016-17 NationalBM

42.04 45.9849.55

65.00

Slag Addition %

GO

OD

GO

OD

In Q1: FY 2017-18 Flyash Addition is 34.72 % In Q1: FY 2017-18 Slag Addition is 54.07 %


Electrical Energy Performance

National Benchmark Reference: CII Energy Benchmarking Manual 2015, Version 2.0Global Benchmarking: BEE presentation during interactive workshop on normalization factor in Ahmedabad

40

50

60

70

2014-15 2015-16 2016-17 NationalBM (Top 3

Plants)

61.38 61.2056.10

49.17

KW

H/M

T O

F C

LIN

KER

Specific Power Consumption KWh Per MT of Clinker (Both Lines)

In Q1 2017-18: Achieved 55.90 kWh/MT of Clinker

GO

OD

30

40

50

60

70

2014-15 2015-16 2016-17 NationalBM

61.50 60.9254.92

49.17

KW

H/M

T O

F C

LIN

KER

Specific Power Consumption KWh Per MT of Clinker (Line-2)

GO

OD

In August’17: Achieved Output of >12500 TPD with 100% Petcoke with SPC of <50 Units/MT of Clinker


Electrical Energy Performance

58

60

62

64

66

68

70

72

74

2014-15 2015-16 2016-17 NationalBM

GlobalBM

72.5670.79

68.59

65.0464

KW

H/M

T O

F C

EMEN

T

Total Specific Power Consumption KWh Per MT of Cement

In Q1 2017-18: Achieved 65.99 kWh/MT of Cement

GO

OD

10

20

30

2014-15 2015-16 2016-17 NationalBM

22.41 23.37 23.67 23.75

KW

H/M

T O

F C

EMEN

T

PPC Specific Power Consumption KWh Per MT of Cement

In Q1 2017-18: Achieved 22.57 kWh/MT of PPC

* Lowest Power Consumption in PPC Grinding among all UTCL (22.22 kWh/Mt in July’2017)

GO

OD


Thermal Energy Performance

620

640

660

680

700

720

2014-15 2015-16 2016-17 NationalBM

GlobalBM

711715

704

686

658

Specific Heat Consumption(kCal/KG of Clinker)

SHC Values are combined for both Lines

10

30

50

70

90

2014-15 2015-16 2016-17

57.94

75.8384.70

Petcoke Consumption (%)Heat Basis

GO

OD

Lower %age in Line-1

Petcoke Consumption % of both LinesG

OO

D

100 % Petcoke Consumption in Line-2 since 2015-16


PAT Status

0.057

0.058

0.059

0.06

0.061

0.062

0.063

0.064

0.065

Base Line PAT Cycle 2 Target SEC PAT Cycle 2 Actual in FY 2016-17Series1 0.0647 0.0616 0.0598

0.0647

0.0616

0.0598

MTO

E/TO

N O

F EQ

UIV

ALE

NT

CEM

ENT

GTG Energy Consumption GO

OD

Save Energy - Save Money - Save the Planet


There is a thin line between using energy and wasting energy

Innovative Projects


Innovative Project – 1Manufacturing of Green Clinker

Benefits: Electrical Energy saving of 15.78 Lac KWh/Annum

Increase in Clinker production by 2.0 %

CO2 emission reduction 744.20 Lacs kgCO2 per annum

Conservation of natural resources (Limestone) 1.49 times of slag

Converting waste to wealth

Savings of 5.02 Crore INR per annum @ 2% GBFS addition

1000

6000

11000

16000

21000

26000

2015-16 2016-17

9453

24434

GREEN CLINKER (MT)

In Q1 FY18: Total Green Clinker produced is 17796 MT

Actions: Characteristics of GBFS was found very near to Clinker

In house Design and Execution of Fully automatic Raw SlagFeeding system in line-1 and line-2

Dedicated feeding system made for both lines by FOC material

Compatibility of GBFS with Raw Mix established keeping in mindchemical constituents such as MgO, Mn2O3 & Al2O3

Daily target of adding 300 MT Raw Slag in both lines

Phases Normal Clinker Green Clinker

C3S 46.80 46.89

C2S 26.33 26.83

C3A 9.15 9.69

C4AF 10.52 11.07

GO

OD


Slag and AFR Feeding System

Slag Feeding in Line-1 Ramp for Slag

Feeding in Line-1

Slag Feeding BC in Line-1

Slag Feeding Hopper

in Line-2

Slag Feeding BC in

Line-2

Slag Feeding BE in

Line-2


Innovative Project – 2In-house Grinding Aid Manufacturing

Agitator for Mixing Powder Feeder

Transfer Pump Dosing SkidBenefits:❖ Reduction in Grinding Power

Consumption 0.85 KWh/Ton of Cementby production enhancement

❖ Cement Quality enhanced and we are thebest among all competitors in the cluster

❖ Reduction in Cement Manufacturing Cost

Objective:To Develop and manufacture top quality, costeffective In house Grinding Aid by setting upa manufacturing facility at Rawan CementWorks.

The Grinding Aid manufacturing system

successfully commissioned at RWCW.


Innovative Project – 3Modification in Roller Press Material Feeding System

Objective:To modify existing material feeding system of line-2 Roller

Press SKS Separator discharge to Roller press feeding Pre Bin

through chute instead of existing conveying air slide (362AS1

/AS2/ AS3)

Benefits: 6 Nos. Blowers were eliminated from the system

Electrical saving of 2.83 Lac kWh/Annum

Elimination of frequent Airslide jamming

Elimination of 3 Nos. Airslide maintenance

Increased availability of Roller press

Total Saving for 3 nos. Roller Press on account of AirslideMaintenance, Production loss, Blower Power = 270.58lacs/annum


:Case Study:

Specific Power Reduction in Line - 2 Pyro Section by 15.0%

Encon Projects

Energy conservation is the only solution


A PARETO Chart of section wise power consumption was plotted and analyzed.

9.48

5.284.66 4.36

2.55

0.47

0

10

20

30

40

50

60

70

80

90

100

0

1

2

3

4

5

6

7

8

9

10

PreheaterFans

KilnAuxiliaries

CoolerFans

BaghouseFans

Kiln MainDrive

Vent Fan

Power Consumption Cummulative %

The major contributors forhigher Kiln section powerare:1. Preheater fans, 2. Kiln Auxiliaries, 3. Cooler fans4. Baghouse fans.

RWCW Line-2 Pyro Powerconsumption for Q1-FY16was 26.80 kWh/Mt of Clk

Problem Analysis


Tools & Methodology Used

Problem Solving Tools/Methods were adopted for Energy Conservation:

ISHIKAWA Diagram (Fish Bone Analysis)

Cause and Effect Diagram, Pareto Analysis, DMAIC Approach etc.

Brainstorming Sessions

Why-Why Analysis

Monthly Energy Cell Meeting

Adoption of Energy Saving Methods

Replication of Ideas from sister concern units

Energy Audit


Due to Rain water

penetrating into the system

High Moisture

Variation in

Raw Mix

Humidity

Ambient

Temperature

Process Fans Power High

Inadequate

TrainingLack

of Experience

Unnecessary high

speed of fan

Poor

Maintenance

Mother Earth MaterialMan

MethodMoneyMachine

Unstable

Operation

Not performing timely

Cleaning of PH

Cyclones & Inlet

Adjustment

of Power

Variation in

Fuel Mix

Old Design

Over Rated

Overloading of

Equipment

Frequent change in

Power frequency

Higher Preheater

Fan Outlet

Draught

Measuring

Instrument not

correct

Wrong method of

operation

Frequent start-stop

Not following of

fan curve

Consumption of

Unsized AFR

Frequent variation

in output rate

Frequent speed

variation

High Pressure

Drop

Higher Cone Gap

Poor calibration of fuel

& kiln feeding system

High

False Air

High

Excess Air

Poor Process

Optimization

Analyzer readings

not correct

High

Dust loading

Petcoke

residue high

Kiln feed

Residue high

High CO

formation

in system

High Sulphur

Petcoke

Idle

Running

Low Fan

Efficiency

ISHIKAWA Diagram


Encon Project – 1Cooler Fans Inlet Duct Modification

BEFORE

55.00 mmWC

98.00 mmWC

240 mmWC

480 mmWC

∆ P = (240 - 98 = 142 mmWC)

Vertical Casing Horizontal Casing

AFTER❖ Total 14 nos of

Cooler Fans

❖ Cooler fanswere consuming2100 kWh(Beforemodification)

❖ Power SavingPotential wascalculated 505kWh


4.17

3.793.33 3.07 3.50 3.42

2.00

2.50

3.00

3.50

4.00

4.50

FY 2016 Q1 - FY17 Q2 - FY17 Q3- FY17 Q4 - FY17 FY 2017

Cooler Fans Power Consumption (kWh/Mt of Clinker)

After identifying the power losses, Vertical inlet casing of cooler fans had been modified tohorizontal to reduce the excess pressure drop. Further cooler fans flow rate was alsooptimized w.r.t. kiln feed rate and desired WHRS inlet temperature in close association withOEM. After implementing the both tasks,

Achieved the Specific Power reduction of 0.75 kWh/MT of Clinker

Benefits Achieved

Due to Breakdown


Baghouse Fans process optimization work was done to save power. After false airreduction, Preheater fans speed was reduced and therefore we got enough margin toreduce BH fans speed also. Logic was modified after brainstorming & trials to operatethe Baghouse at reduced inlet pressure from -60 mmWG to -30 mmWG which reducedthe BH fans power consumption by approx. 0.84 kWh/MT of Clinker

3.26

2.622.40

2.382.31

2.42

2.002.202.402.602.803.003.203.40


RABH Fans Power Consumption (kWh/Mt of Clinker)

Encon Project – 2Process Optimization of RABH Fans


Encon Project – 3Cooler ESP Stack Height Increase

BEFORE AFTERBenefits Achieved

❖ Static head of Coolervent fan was reduced.

❖ ESP fan powerconsumption reducedfrom 0.52 Units to0.36 kWh/Mt ofClinker.

❖ Power saving of 0.16kWh/Mt of Clinker

Project Execution Cost was Rs. 24.0 Lacs


Encon Project – 4Size Reduction of Kiln Coal Firing Line

BEFORE AFTER

❖ With use of 100%

Petcoke in line-2 it was

calculated that pipe dia

was over sized.

❖ Reduced the line size

from 324 NB to 273 NB

❖ Power saving of 0.10

kWh/Mt of Clinker.

Benefits Achieved


Encon Project – 5Louver Dampers Removal in PH Downcomer

Excess Pressure Drop of 35 mmWG across

Louver Damper

BEFORE AFTER

Benefits Achieved:After executing the task,Specific Power saving of0.311 kWh/Mt of Clinkerwas achieved.

4 nos. Louver Dampers were removed


Encon Project – 6Optimization of Dilution Air Fan

Before After

Benefits Achieved:

Dilution Air Fan wasstopped during normalplant operation afterkeeping the outletdamper 100% open andinlet damper 90%closed.

❖ Total power savingswas achieved 0.16Unit/Mt of Clinker

Logic was made for automatic operation when RABH Inlet

Temperature is high


Encon Project – 7Optimization of Reverse Air Fan

REVERSE AIR FAN

Reverse air fan in RABHsection is having VFD andexcess pressure drop of 20mmWG was measuredacross the dampertherefore it was removedfor power saving.

We had also developed the logic forRA fan operation w.r.t. DP to savepower consumption. At present, RAfan is running at 150 rpm when theDP is <110 mmWG & Whenever theDP is >110 mmWG, RA fan speedincreases to 1450 rpm.

Benefits Achieved:

Fan Inlet Damper

Removed

❖ Fan Running Hrs at 1450 RPM = 11Hrs/day (Power Consumption is 86kWh)

❖ Fan Running Hrs at 150 RPM = 13Hrs/day (Power Consumption is 5kWh)

❖ Power Saving = 0.10 kWh/Mt of Clk


Encon Project – 8Suction Box Modification of Preheater Fans

There was a high velocity at preheater fan inlet suction box 29 to 30 m/sec which was

leading to high resistance (pressure drop of 30 mmWG from common down comer to

fan inlet suction box). We have done in house modification of suction box by enlarging

area by 32%. Same has been done without taking any help from consultant / OEM /Experts.

Initially Suction Box width was 1010

mm, it was increased up to 1335 mm.

By enlarging the area we were able to

reduce the suction box velocity from 29

to 20 m/sec. Project was implemented

successful with power saving of 0.20

kWh/Mt of Clinker.

BEFORE AFTER


Encon Project – 9False Air Reduction in Pyro Section & WHRS

After commissioning of WHRS, False air ingress throughout the system (Pyro clone

outlet to fans inlet) became very high resulting to increase in power consumption of

Preheater fans. Cross function team was prepared for identifying the ingress areas

across the preheater and WHRS on weekly basis as well as action plan were made for

arresting the identified leakages which was well executed on priority basis to reduce

false air in the system.

❖ Feed Pipes Flange Joints❖ Welding Cracks❖ Expansion Joints❖ Cyclone Man Doors ❖ Poking Holes❖ Feed Pipes Flap Gates

❖ WHRS Bypass Dampers❖ WHRS Inlet & Outlet Dampers❖ Downcomer Ducts Expansions❖ Thermocouple Points❖ PC Analyzer Probes❖ Various Locations of WHRS

Concern Areas were identified as:


WHRS Inlet Damper Flap Gates

Thermocouple Flange Joints Cyclone Doors

WHRS

WHRS

WHRS

Leakages Identification Task


35.62

27.24

22.34

15.90

9.88

5

10

15

20

25

30

35

40

FY16 Q1-FY17 Q2-FY17 Q3-FY17 Q4-FY17

RWCW Line-2 Pyro Section False Air %age Trend With WHRS

False Air Trend


7.98

7.30 7.41

6.406.58

6.92

5

6

7

8

9


Preheater Fans Power Consumption (kWh/Mt of Clinker)

After continuous team efforts, we were able to reduced the false air infiltration aggressively inPreheater & WHRS and achieved the target i.e. below 10% (combined for Preheater + WHRS).Achieved Result: PH fans power consumption reduced by 1.06 kWh/MT of Clinker

Benefits Achieved


Encon Project – 10Modification in Opening of Inlet Dampers of PH Fans

BEFORE AFTER

Benefits Achieved:

After execution oftask, total powersaving was achievedin Preheater fanswas 0.18 kWh/Mt ofClinker.


After putting cross functional efforts and doing several improvement tasks for power saving inline-2 Pyro section, we are able to achieve specific power consumption <19.0 in Q3-FY17 andoverall SPC of FY17 was 19.77 kWh/Mt of Clinker (FY17)

(Cost Benefits = 3.30 Units × 3091736 Mt × Rs. 3.80 = 387.70 Lacs/Annum)

23.07

20.9319.88

18.9319.47 19.77

15161718192021222324


Line-2 Pyro Power Consumption (kWh/Mt of Clinker) • Poor market demand in themonth of Jan’17

• Line-2 Cooler breakdown inthe month of March’17

• Use of High Sulphur SaudiPetcoke in Q4

Final Outcome


Total saving = 387.70 Lacs/Annum (Saving in Power) + 422.94 Lacs/Annum (Saving in Thermal)

₹ 810.64 Lacs/Annum for FY 2016-17

Particulars FY 2015-16 FY 2016-17

Specific Heat Consumption 714 kCal/kg of Clinker 698 kCal/kg of Clinker

Total Clinker Produced 26.16 LMT 30.917 LMT

Thermal Saving 16 kCal/kg of Clinker

Monitory Saving ₹ 422.94 Lakhs/Annum

By reducing the Preheater Exit Gas Losses & Increased Cooler Efficiency we were able toreduce line-2 Specific Heat Consumption

Benefits on account of Thermal Energy


Replicability of Encon Projects

❖ Installation of VFD and PID based operation (without fan inlet damper) in allBagfilters (above 15 kW):

❖Modification in Process fans Inlet suction Box:

❖ Cooler chimney height increase:

❖ Dilution Air Fan Optimization:

RC-IV

Dhar Project in Madhya Pradesh

RWCW - II RC-IV (Coal Mill) APCW

RC-IV RWCW - II RC-IIIPlanned at KCW &

RWCW-I

RWCW - II RC - IV

RWCW

Journey Towards Excellence Continues…


Energy Conservation Projects 2014-15

A thing which burns never returns



S.No. Energy Saving TasksAnnual Energy Savings Savings

(Lacs/Annum)Electrical (kWh) Thermal (MTOE)

1PH Fan GRR logic taken in Plant PLC for stopping when driverunning in SPRS mode.

285120 - 10.83

2Raw Meal transport CKT modified to remove air slides and its 06nos blowers.

283140 - 7.22

3 Elimination of Roots blower for K Pump 32400 - 1.70

4 Reversible belt conveyor elimination from line 2 Coal Crusher 323400 - 16.90

5 Provision of Energy savers in lighting load circuit 81468 - 4.30

6 Stage Reduction in feed pump 380160 - 19.90

7Cooler ESP Discharge Modification in Line-2 (Discharge Chute inplace of Screw Conveyor)

58608 - 3.10

8Provision of speed control in place of damper control by installingMVVFD in BFP & SA fan

1550400 - 81.20



Save Today – Survive Tomorrow





1Instrument Air Consumption optimization by Interconnection ofInstrument Compressors of Line # 01 & Line # 02

316800 - 14.20

2Install EE pump of 200 m3/hr and 30 M head at WHRB in place ofexisting ACW pump

257416 - 11.60

3 Removal of Louver damper in Roller Press Separator fans in line-2 495000 - 22.22

4 Removal of Louver damper in Preheater fans in line-2 (4 Nos) 660000 - 29.60

5 LED street lights Installation 8773 - 0.33

6 Optimization of Dilution Air Fan in Line-2 RABH Section 494672 - 18.79

7Stopped the Hotbin Bucket elevator and Transport system byProviding a By Pass Conveyor system

173135 - 6.57

8Energy saving in reducing Idle Running of Line-1 & 2 RAL for Rawmill Transport system with Logic Modification

110774 - 4.20

9 8 Nos Bagfilters of Line-2 Coal transport system had been stopped 190852 - 7.25





10Replacement of W/T-1 water spray pump motor from 18.5 kw to9.3 kw

19800 - 0.75

11One compressor stopped among 4 compressors for line-2 processoperation after arresting the leakages

1188000 - 45.14

12 High mast towers convention lights were replaced by LED 19833 - 0.75

13 Installation of VFD in all ACC fans, BFP, ACW 2958450 - 35.50



Energy conserved is Energy produced



S.No. Energy Saving Tasks

Annual Energy SavingsSavings


1 Manufacturing of Green Clinker in both lines 1578067 - 63.10

2 Single bucket elevator operation for Line 2 Raw Meal feed 576198 - 21.89

3 Line-2 Cooler ESP Stack Height Increased By 10 M 494678 - 18.79

4 Line-2 Preheater Fans Inlet Modification 772934 - 29.37

5 LED lights in Plant 10205 - 0.38

6 Heat resistant Painting in line-2 top cyclones - 0.000211

7 Insulation fixing work in line-2 top cyclones - 0.000256

8Kiln RABH RA Fan (422FN3) damper removed and PID basedoperation w.r.t. RABH DP

309174 - 11.74

9Cooler ESP RAL-16 nos motor intermittent stopping of RAL forpower reduction

63360 - 2.40





(Lacs/Annum)Electrical (kWh)

Thermal (MTOE)

10 Line-1 Coal Mill Fan Inlet Damper Removal 297660 - 11.31

11 Line-1 Raw Mill Fan Inlet Damper Removal 363000 - 13.79

12 Ball Mill Close circuit separator fan inlet damper removal 376200 - 14.30

13 Slag Mill V-Separator fan inlet damper removal 281952 - 10.70

14 Slag Mill main & auxiliary Baghouse fans inlet damper removal 217800 - 8.27

15Removal of clinker silo bag filter damper & installation of DP transmitter toregulate the fan speed with VFD in PID loop.

556512 - 21.14

16Parallel kiln firing pipe line for petcoke of size 250 NB ( size reduced fromexisting 300 NB to 250 NB), to reduce the transport air quantity & in turnpower consumption.

309174 - 11.74

17Crusher main bag filter damper removal & intermittent stoppage of bag filtermaterial transport ckt. i.e. (2 nos screw conveyor)

264000 - 10.03

18 VFD installation at bag filter fan 332 FN1 & 332FNC 145200 - 5.51





19RP-1 V separator modification (increase in guide vanes height toincrease material retention time and to improve air flow).

2627976 - 99.8620 RP-1 feed gate zero position adjustment.

21Raw mill hopper feeding system modification to improve/ balancesegregation.

22Logic modification in RM transport circuit to eliminate idle runningof equipment

1082095 - 41.11

23Logic modification in RM additive hopper feeding circuit toeliminate idle running of equipment

772925 - 29.37

24DP point relocation to optimize PH outlet draft and to reduceRABH fan power

927521 - 35.24

25Increase in crusher output up to 1800 TPH & reduction in idlerrunning of Equipments

927520 - 35.24

26 Stopping of seal air fan after 2 hrs stoppage of line-1 Raw Mill 6878 - 0.26






Thermal (MTOE)

27 Orifice removal from line-2 coal mill fan duct 61835 - 2.34

28 Reduction of Pressure drop in downcomer duct of line-2 6449896 319.26

29 Arresting of air leakages in line-1 coal mill circuit 1238926 61.32

30 Arresting of air leakages in line-1 PH Calciner circuit 918720 45.47

31 Arresting of air leakages in line-1 ILC circuit 1573704 77.89

32 Arresting of air leakages in line-1 kiln string 148896 7.37

33 Arresting of air leakages in line-2 Roller Press Circuit (3 nos.) 10585080 523.96

34 Arresting of air leakages in line-2 coal mill circuit 1386000 68.60

35 Arresting of air leakages in line-2 PH circuit (String 1&2) 5513112 272.89

36 Arresting of air leakages in line-2 PH circuit (String 3&4) 6443712 318.96






Thermal (MTOE)

37 Arresting of air leakages in line-1 Raw Mill Circuit 2198592 - 108.83

38 Installation of EE pump of 450 m3/hr & 35 M head in place of WP 7/8 316008 - 15.64

39 Installation of PID based VFD at one compressor of line-2 245520 - 12.15

40 Slag feeding circuit modification & Extension of 611BC-3 145200 - 5.51

41 Running of stand by Blower 681BL6 stopped 49896 - 1.89

42 Improved the Generator terminal power factor from 0.91 to 0.95 - - 48.19


Ongoing Projects 2017-19

Energy Conservation for the Future Generation


Ongoing Encon Projects


Energy Savings Capex Required (Rs. Lacs)

TargetElectrical (kWh)

Thermal (MTOE)

1 ABC Inlet modification in line-1 Cooler - 0.001067 250.00 Nov’17

260 nos VFD is to be installed in Bagfilters (>15 kW) and PID based operation after inlet damper removal

1980000 - 120.00 Oct’17

3 Installation of dedicated power line between RWCW and HCW - Mar’18

4 2 Nos. VFD installation in line-1 Cooler fans 178200 - 20.00 Nov’17

5 3 Nos. VFD installation in line-1 Coal firing blower 311256 - 32.00 Nov’17

6 Replacement of 2 nos line-1 Cooler fans with high efficient 122400 - 17.00 Nov’17

7 Installation of EE pump of 350 m3/hr & 60 M head in place of WP 14B pump 340243 - 7.00 Nov’17

8 Installation of EE pump of 200 m3/hr & 50 M head in place of WP 15B pump 272842 - 5.00 Nov’17

9 Installation of EE pump of 50 m3/hr & 50 M head in place of WP 12 51181 - 2.00 Nov’17

10Replacement of existing ELGI 821CP1 compressor with EE compressor in line-1

369468 - 20.00 Nov’17

11 Installation of VFD at 821CP4 compressor to save unload power in line-1 129730 - 5.00 Nov’17


Ongoing Encon Projects


Energy Savings Capex Required (Rs. Lacs)

TargetElectrical (kWh)

Thermal (MTOE)

12 Installation of VFD at 341CP3 compressor to save unload power in line-1 429660 - 10.00 Nov’17

13 Line-1 kiln String Top Cyclone Modification - 0.000446 N.A. Aug’17

14 Line-1 Kiln Burner Replacement with low NOx burner - 0.000342 Aug’17

15 Cement Mill ESP to Baghouse Conversion - - Sept’17

16 Line-1 Cooler Chimney Height Extension by 15.0 meter 396000 - 30.00 Nov’17

17Hot Air Recirculation connection to seal air pockets at SKS separator bottom of line-2 Roller Press (3 Nos)

- N.A. Sept’17

18 Replacement of line-1 Kiln String fan with high efficiency 396000 - 50.00 -

19 Replacement of line-1 PC String fan with high efficiency 1425600 - 50.00 -

20 Line-1 SLC Precalciner Modification - - 350.00 Nov’17

21 Line-1 Coal Mill Cyclones are to be removed to reduce excess pressure drop 726000 - 10.00 Nov’17


GHG Inventorization

250300350400450500550

2014-15 2015-16 2016-17 NationalBM

506472 465 450

KG

CO

2/M

T O

F C

EMEN

T

Specific CO2 Emission

500

550

600

650

700

2014-15 2015-16 2016-17

676661 644

KG

CO

2/M

T O

F P

RO

DU

CT

Specific CO2 Emission

Cementitious Product Cement

* Lowest Carbon Footprints/Specific Emissions among all UltraTech plants

GO

OD

GO

OD


Utilization of Renewable Energy

GREEN TOWNSHIP

800 KWp Solar Panels Installed in plant

Working since FY 2011-12

Colony Power requirement mainly catered through Solar power generation

700000

800000

900000

1000000

2014-15 2015-16 2016-17

840476913376

966506

KW

H

Solar Power Generation

GO

OD


Utilization of Waste Material

List of Alternate fuel used at Rawan Cement Works WOODEN CHIPS

FMCG WASTE

MIX AGRO WASTE

PHARMA LIQUID

PHARMA SOLID

SAW DUST

SUGARCANE BAGGASE

PLASTIC WASTE

NON HAZARDOUS WASTES (POULRTY)

CASHEWNUT SHELL

COCONUT SHELL

FOOTWEAR SCRAP

250

300

350

400

450

500

550

2014-15 2015-16 2016-17

291.50

364.57

667.52

MET

RIC

TO

NN

E

AFR Consumption

GO

OD

In Q1 FY 2017-18: Total AFR Consumption = 625 MT


Utilization of Waste Material

Plastic Waste Solid Pharma Waste FMCG Waste

Liquid Pharma WastePlastic Waste Charota


Waste Heat Recovery System

Waste Heat Recovery System of 15 MW (6 nos.Boilers) at Rawan Cement Works is meant to operatecontinuously with any of the Clinkerisation systemrunning. Running of WHRS results in fossil fuelconservation, better environment and low power costdue to reduction in Grid and TPP power mix %

2

22

42

62

82

102

2014-15 2015-16 2016-17

83.26 80.1275.44

16.746.53

2.69

013.07

21.57

Power Mix % - Increase in WHRS Power Share

TPP GRID WHRS

GO

OD


Best Practices in Green Supply Chain

Reuse Rakes

❖ Reverse Logistics in Fly Ash Bulker, Coal Wagons,

Raw Material Trucks (Hywa)

❖ Eye on Wheels – to reduce truck turnaround time

❖Maximise Bulk Cement Dispatches

100150200250

2015-16 2016-17

231259

NO

S.

Reverse Logistics – No. of Rakes

GO

OD


Safety InitiativesWe Care For Safety

Unit’s Safety Best Practices

Gate meeting on every 1st day of month

Full Day Safety Round “One Day Safety Officer”

Mentor-Mentee Engagement of workers for Safety cultureimprovement

Extending safety beyond work place: First- Day, First –hour,Safety- hours & Bicycle helmet for ABPS School students

Safety Observation by all Management cadre employees(two nos. per month)

On the Job Safety awareness by animated cartoon/videosthrough “Safety Rath”

Daily Tool box talk at different location in plant

Theme based Safety Campaign on Monthly basis

Online Permit System

Online reporting system for EHS


Glimpses of Safety Activities

Gate Meeting Theme Based Campaign

Theme Based CampaignGate Meeting

Daily Tool Box Talk

Daily Tool Box Talk



Safety Helmets for Students

Training on wheel

Mentor Mentee

Mentor Mentee Safety Awareness at School

Training By Animated Films



Foot over Bridge & Drop Gate Road Safety Initiative LOTOTO System

Foot over Bridge & Drop Gate LOTOTO System Road Safety Initiative


Environmental Initiatives

Green Belt Development

5000

10000

15000

20000

25000

2014-15 2015-16 2016-17

21126

1514712982

19124

14214

11631

Area: Plant, Colony & Mines

No. of Sapling Planted Survived Plants

Rain Water Harvesting Pond

Entire water requirement for Plant and Colony is being fulfilled by Rain Water Pond

Unit is committed to develop Green Belt in Plant, Colony & Mines with cumulative survival rate of >90%



Line-1 Raw Mill ESP to Baghouse Conversion FY 2016-17

Capex Amount: Rs. 21 Crore

Line-1 Coal Mill ESP to Baghouse Conversion FY 2016-17

Capex Amount: Rs. 6 Crore

Before: 50 mg/Nm3After: <20 mg/Nm3

Before: 50 mg/Nm3After: <20 mg/Nm3



Covered Belt Conveyors Coal & Petcoke Shed

Limestone Pile Shed Green Township with LED Lights


Green Township and Plant


CSR Initiatives

State : ChhattisgarhDistrict : BalodabazarFamilies : 6197 Population : 30598

Adopted 22 Operational Villages

100

150

200

250

300

350

2014-15 2015-16 2016-17

235 226

308

253 253201

Expenditure Under CSRRs. Lacs

Budget Actual

GO

OD


CSR Initiatives

Unit’s Key Focus Area under CSR are: Education, Health, Skill Development, Basic Needs like Road, Electricity, Water etc.

Scholarship Distribution

Medical CampDesk Bench in School

Plantation by MLA Health Centre

Concrete Road


Glimpses of CSR Initiatives

Beauty Training Tailor Training IT Training

Mother School Lab Training Thela Distribution


Glimpses of CSR Initiatives

Pond Cleaning Rangmanch Mass Marriage

Driving TrainingBorewellCommunity Centre


Awards: Journey Towards Excellence

Rajiv Gandhi

CII

En

erg

y A

war

d

Exce

llen

ce in

In

no

vati

on

-C

WC

M

Raj

iv G

and

hi

Nat

ion

al Q

ual

ity

Ch

airm

an W

CM

GO

LD

Aw

ard

Stat

e -

Ene

rgy

Effi

cie

ncy

A

war

d b

y C

RED

A

(Co

nse

cuti

ve S

ince

20

14

)

IMC

Ram

a K

rish

na

Baj

aj

Qu

alit

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DL

Shah

Qu

alit

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war

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(GO

LD)

CSR

Exc

elle

nce

Aw

ard

20

17

2008

2008

2008

2009

2011

2014

2015

2016

2017

CII 18th National Award for Excellence in Energy Management 2017



IMC Rama Krishna Bajaj National Quality Performance Excellence Trophy 2015

in Manufacturing Category

3rd Position in Overall Performance CategoryMines Environment & Mineral Conservation

2016



Energy Efficiency Award 2015 & 2016 in Cement Sector

organised by CREDA, Raipur

QCI - DL Shah Quality Awards 2016GOLD AWARD

organised at New Delhi



CSR India International Conclave - 2017 CSR Excellence Award 2017 - Project of the Year in

Cement Sector & Skill Development

Regional Level presentation in National Level Competition “REPRISM-2017” by Aditya Birla Group

in the category of Energy Conservation


Documents

UltraTech Cement Limited: Unit - Rawan Cement Worksgreenbusinesscentre.com/energyaward2017presentations/Cement/12... · UltraTech Cement Limited: Unit - Rawan Cement Works Team