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UltraTech Cement Limited W E L C O M E

W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

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Page 1: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

UltraTech Cement Limited

W E L C O M E

Page 2: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

Presenters

Mr.Akhilesh Jain

Senior General Manager, TPP Electrical &

Instrument

Mr. A.G.Narasimmalu

Assistant Manager, Technical Services

Mr. Udaykumar Pandya

General Manager,

Process

Page 3: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

Contents

Business and Unit Overview

Cement Manufacturing Process

Unit Mile Stones

Various Certifications

Reduction in SEC

Innovation & Encon Projects

Sustainability

Best Practices

Page 4: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

1 8.5

31 35

52

69

117.5

0

20

40

60

80

100

120

140

1983-85 1998 2004 2008 2011 2016 2019

Cement Installed Capacity Growth in MTPA

UltraTech Journey

Page 5: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

23 Integrated Units (IU)

26 Grinding Units (GU)

7 Bulk Packaging Terminals (Sea Rail)

2 White Cement & Putty Units

5 Jetties

UltraTech Journey

Page 6: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

Plan

Unit Overview

Clinker 2.9/3.0 mTpa (Rated/EC)

(2 Kiln)

Cement 2.6/3.5mTpa (Rated/EC) (2

Cement Mill)

Capacity

Thermal Power Plant 35 MW/ IJT (1Nos) 60 MW /CVL (2Nos)

124.78 MnT (Life 27.72 Years)

Mines Life

Proposed

Solar WHRS

7.5 MW 15.2 MW

Under Execution

Page 7: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

Manufacturing Process & Product range

Page 8: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

Unit’s Miles stones & Achievements

Ever Lowest Clinkerization Power Line -1 57.13 Kwh/ Clinker during the month Mar 2020

Ever Lowest Clinkerization Power both line (Lines 1 + 2) 56.69 Kwh/ Clinker during the month Mar

2020

Ever Lowest Total Raw Mill -1 & 2 power – 17.88 Kwh/ Material during the month Mar 2020

Ever Highest Red Mud Consumption - 10569 MT Previous best was 10374 MT in Feb'20. Saving

around Rs.17 Lakh

Ever highest TSR% - 1.11 in March-20(Month wise)

Beema Bamboo sapling received and Planted

Ever Lowest Variable Clinker Cost Rs. 1675 / Mt. of Clinker during the year 2019-20

Ever Lowest Avg. Naked Variable Cost of Cement Rs. 75.07 / Bag during the year 2019-20

Page 9: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

System Certifications

ISO :9001:2015,ISO 14001:2015 & BS OHSAS 18001:2007

Page 10: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07
Page 11: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

Unit Performance

10.9

22.6

18.4

5.67

0

5

10

15

20

25

2017-18 2018-19 2019-20 Till July2020

Clinker Production (Lac MT)

6.5

15.0 15.4

3.91

0

5

10

15

20

2017-18 2018-19 2019-20 Till July2020

Cement Dispatch (Lac MT)

GO

OD

Less Market

Demand due to

COVID-19

GO

OD

Page 12: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

31.10

33.14

34.15 34.70

30

33

36

2017-18 2018-19 2019-20 Till July2020

Flyash Addition in %

100.0 98.0 100.0 100.0

35

85

2017-18 2018-19 2019-20 Till July2020

Blended Cement %

Unit Performance

Almost reaching maximum allowable % 100 % Blended cement

GO

OD

GO

OD

Page 13: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

67.28 64.77

59.64 63.11

25

35

45

55

65

75

2017-18 2018-19 2019-20 Till July2020

Specific Power consumption Line-1 Kwh/Mt of Clnk.

66.89 64.91 61.86

55.98

25

35

45

55

65

2017-18 2018-19 2019-20 UPTO July2020

Specific Power consumption Line-2 Kwh/Mt of Clnk.

Unit Performance

Less operation

due to COVID

17 % SPC reduction compare to 2017-18 11% SPC reduction compare to 2017-18

Page 14: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

32.44 31.82

31.02 31.35

25

35

2017-18 2018-19 2019-20 Till July2020

Specific power consumption (Grinding + Packing in Kwh/Mt of Cement)

77.38 74.64 70.48 69.29

25

35

45

55

65

75

85

2017-18 2018-19 2019-20 Till July2020

Specific power consumption (Clinker + Grinding + Packing in Kwh/Mt of

Cement)

Unit Performance

4 % reduction compare to 2017-18 10% reduction compare to 2017-18

Page 15: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

3538

3273 3404

3240

2000

3000

4000

2017-18 2018-19 2019-20 Till July2020

TPP Heat Rate Kcal/Kwh

13.00

9.31 9.90 9.80

5

15

2017-18 2018-19 2019-20 Till July2020

TPP APC %

Unit Performance

60 MW plant

commissioned

7 % Reduction compare to 2017-18 23% Reduction compare to 2017-18

60 MW plant

commissioned

Page 16: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

692

694

698

696

680

690

700

2017-18 2018-19 2019-20 Till July 2020

Heat Rate Kcal/Kg (Both line 1 & 2)

Unit Performance

Utilisation of High MGO Lime

stone, Manufacturing only

PPC, Change in quality

requirement of market

Page 17: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

PAT Status TOE / Ton of Product

0.094

0.069 0.074

0.00

2017-18 2018-19 2019-20

Page 18: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

List of Encon Projects Proposed in 2020-21

Title of Project

Annual Electrical

Saving (Million kWh)

(Projected)

Annual Thermal Saving

(Million Kcal) (Projected)

Total Annual Savings

(Projected)

(Rs million) Cement Mill-2 outlet bucket elevator conversion from chain to belt bucket elevator

52.24 7.50

VFD for bag filter fans 324.72 2.49

Installation of secondary limestone crusher 4,120.00 70.70

Installation of LED lights for plant 217.44 1.54

Installation of LED lights for CPP 136.67 1.27

High efficiency screw compressor 875.37 12.00

Construction of 75M^3 water tank provision for Cooling tower blow down water utilization

91.98 1.45

AFR System 15 TPH 2,42,550.00 50.00

Page 19: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

List of Encon Projects implemented in 2017-18

Title of Project Annual

Electrical Saving (kWh)

Annual Thermal Saving

kcal/kg Clk

Total Annual Savings

(Rs million)

Performance improvement of clinker cooler fans 3, 4, 8 and 9 of Unit #1 2,20,888.00 11.04

Performance improvement of cooler vent fan of Unit #1 1,14,048.00 5.70

Performance improvement of raw mill fan 7,80,240.00 39.01

Performance improvement of raw mill bag house fan 8,46,093.60 42.30

Performance improvement of fans 511 FN1, 512 FN1, 532FN2 and 532FN1 2,84,700.00 14.24

Reduction in coal mill air ingress 40,234.00 2.01

Performance improvement of boiler #1 1,560.00 62.40

Performance improvement of boiler #2 700.00 28.00

VFD installation at both boiler PA fans 1,77,408.00 8.87

Performance improvement of 35 MW TG set 2.22

VFD installation with boiler feed pumps 4,90,560.00 22.07

Replacement of 35 MW CEP 1,29,888.00 6.49

Page 20: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

List of Encon Projects implemented in 2018-19

Title of Project Annual Electrical

Saving (kWh)

Annual Thermal Saving

kcal/kg Clk

Total Annual Savings

(Rs million)

Performance improvement of power plant ash handling air compressor 4,11,840.00 19.77

Arrest identified compressed air leakage of power plant 40,392.00 2.02

LED lights installation 54,450.00 2.72

Usage of Boiler bleed off water (IBD& CBD)& solar heater in DG set jacket water heating.

3,46,750.00 19.07

Optimized ACC & WCC operation as per ambient temp.and loading,changed ACC Fan blades & CT Fan ,CT Refurnishment

20,95,100.00

2,500.00 MT 115.23

Plant heat rate improvement(ejector nozzle, maintaining vacuum, turbine operation as per HMBD. Replacing BLR-FCS 6'' Valve

4,000.00 MT 2.81

False air reduction, maintaining O2<4%,Insulation work 28,835.00 1.58

Performance improvement of plant air conditioners 4,84,387.00 24.22

Replacement of 35 MW ACW pump 1,02,960.00 5.15

Performance improvement of power plant instrument air compressor 65,340.00 3.27

Page 21: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

Title of Project Annual Electrical

Saving (kWh)

Annual Thermal Saving

kcal/kg Clk

Total Annual Savings

(Rs million)

Coal Dosing System - Sidhi-1 6,02,640.00 2.71

Coal Dosing System - Sidhi-2 8,43,336.00 3.80

SPRS for line 2 raw mill fan (4150KW ) 43,73,208.00 19.68

SPRS for line 1 raw mill fan (3300 KW) 27,84,528.00 12.53 Outlet Seal Line 1 1.38 2.44 Outlet Seal Line 2 2.39 4.51 Line 2 Inlet Seal 0.89 1.68

Fan / Impellor Upgradation - CM1 Sep. fan Impeller change (retrofit) 3,02,400.00 1.36

BLDC (brush less direct current) ceiling fans 43,738.20 0.20

Overhauling of TPP2 1X60 MW for continued reliable operation 38,53,396.80 17.34

PH fan 2250 kw MVVFD line2 8,43,638.40 3.80

List of Encon Projects implemented in 2019-20

Page 22: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07
Page 23: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

Innovation Project-1 Replacing DG Electric heater by using Boiler CBD waste water

Replacement of DG water heaters (Set Capacity 2 X 10.86 MW) by using waste water

• Unit don’t have the facility of Grid Connection. • DG set are used for power back-up in emergency, for that need to keep ready always. • To start DG Set, water jacket temperature 50°C need to be maintained, for that , 72KW

heaters were in operation having power consumption of 1555 Kwh.

• Boiler blow down water (having temp. 280-310°C) is getting blowdown every shift to maintain the boiler water parameter

• The hot waste blow down water is used in DG set to maintain the water tank temp. • In house modification carried out to utilize the waste blow down water with nominal

expenditure.

Total Units Saving/annum –5.67 Lacs Kwh (Power Rate– Rs.4.92/Kwh) Total Power Saving per annum Rs. 27.89 Lacs. Resulting in energy conservation and reducing our carbon foot-print. This solution is applicable to all those Units which do not have a power grid connection.

Theme

Problem/

Background

Solution/

Execution

Result/

Benefit

Page 24: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

24

DMW

Tank

Engine 1

Engine 2

El. Heater DMW

Tank

Engine

1

Engine

2

Boiler 1 &

2

CBD hot water

El. Heater

eliminated

Before After

Replacing DG Electric heater - using Boiler CBD waste water

Page 25: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

Innovation Project-2 To supply the raw water to cooling tower by gravity

To Reduce the TP1 auxiliary power consumption by utilizing the head of the raw water tank to supply the raw water to cooling tower by gravity.

• Raw water pump of 36.4KW has to run around 10hrs for to supply raw water to clarifier • Additional to that clarifier to cooling tower make up pump -7.5KW has to run 10hrs for cooling

tower make up. • Cumulative of 450KW/day consumed for cooling tower make water

• Since the TDS and water quality is within the acceptable limit. Clarifier had bypassed. • Tapping were made before clarifier to cooling tower make up from raw water line. • Now water is taken to cooling tower by the virtue of gravity.

• Both raw water make up & cooling tower make up pump service minimized. • Operation and Maintenance of pump minimized • Reduction in plant auxiliary power consumption • Annual savings of 455*300days = 136500KW/year • Annual savings in terms of money – INR 677040

Theme

Problem/

Background

Solution/

Execution

Result/

Benefit

Page 26: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

Before After

Page 27: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

Improvement Project-1 Reduction in Power consumption in Process fans

Objective:

Reduction Power consumption in process fans

Problem:

Higher power consumption in Process fans due to oversized design & GRR losses

Action:

Installation of MV Drive (04 Nos) & VFD (30 Nos) in process fans & bag filter fans respectively

Investment:

250 lacs

Benefit: Reduction in Sp. Power consumption 4.55 kWh/t Clk has been achieved.

Page 28: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

Improvement Project-2 Power reduction in process fans

Objective:

Reduction in process fan power consumption

Problem:

High pressure drop across (30 to 35 mmwg) fan inlet louver damper in major 09 No's process fans

Action:

• Installation of slide gate in place of louver damper in in Raw Mill 2 fan

Fan Inlet damper removed in 10 Fans (Coal mill / RABH / Cooler vent / Preheater fans)

Investment:

16 Lacs

Benefit: 1.67 KWh/T Clinker power reduction achieved

Page 29: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

Improvement Project- 3 Cooler fan power reduction

Objective: Optimization of Power Consumption in cooler fans

Problem:

High Cooler fans Sp. Power consumption

Action:

Suction duct modification by area enlargement &

operation in PID mode

Investment:

Nil

Benefit:

0.73 KWh/T Clinker power reduction achieved

Page 30: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

Improvement Project-4 Formation of TAD Ramp at kiln-2 Objective:

Kiln smooth operation

Problem: Having chronic issue of High CO- formation tendency effected in un even combustion resulted Quality of Clinker ( Unburned clinker )

Action: TAD Ramp has been made to increase the oxygen percentage at kiln inlet and around 45% blocked the area.

Investment:

0.75 Lacs

Benefit: 1. Kiln – 2 Productivity increased from 165- to 195 TPH 2. Smooth kiln Operation 3. Free Lime % in clinker was reduced

Page 31: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

Improvement Project- 5 Installation of New LNVT Classifier at Coal Mill-1

Objective:

Enchantment of mill out put

Problem: Residue of pet coke was running 10-11% @R90)

Action:

Installation of New LNVT Classifier at Coal Mill-1

Investment:

80 Lacs

Benefit: 1. Kiln – 2 Productivity increased from 165- to 195

TPH 2. Smooth kiln Operation 3. Free Lime % in clinker was reduced

Page 32: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

Improvement Project- 6 Installation of Energy Efficient Pumps

Objective:

Improvement of equipment efficiency & power reduction..

Problem:

Cooling Tower pumps (4 nos) efficiency was running lower side as 54,58,33 & 36 %.

Action:

Study done of all pumps efficiency. Replaced all conventional pumps by Energy efficient pumps. Investment:

41.5 Lacs

Benefit: Currently residue is running 4-5 % @ R90

Page 33: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

Improvement Project- 7 Cement Mill-1 Sep. Fan Retrofit

Objective:

Improvement of equipment efficiency & power reduction.

Problem: Cement mill 1 separator fan efficiency was running lower side as 67 %.

Action:

Cement mill 1 separator fan retrofit has been done for efficiency improvement.

Investment: 17 Lacs

Benefit: After cement mill -1 separator fan retrofit, 81 % Efficiency has been achieved. 0.19 kWh/t cement power saving has been achieved.

Fan Parameter UNIT Existing Modified

Fan Make Ventioelde Andrewyule

Fan Model HRV 63S-1800 SI.BCB-2430

Gas Flow m3/hr. 271200 281112

Gas Flow m3/sec 75.33 78.10

Fan Static Pressure (Inlet)

mmwg -561 -423

Fan Static Pressure (Outlet)

mmwg 0 -49

Fan Static Pressure (Diff)

mmwg 561 374

Dust Load gm/m3 40 40

Fan Speed RPM 990 860

Fan Shaft Power (with dust)

KW 543 357.55

Fan Static efficiency (with Dust)

% 76.3 80.08

Page 34: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

Improvement Project- 8 SPRS in Raw Mill -1 & 2 Fan

Objective:

Power saving by installation of SPRS in raw mill 1 & 2 fan’s

Problem: Raw mill 1 fan was running on GRR in which power losses in the form of heat through GGR resistances.

Action:

Installed SPRS in both Raw Mill Fans

Investment:

80.66 Lacs (Each Fan)

Benefit: 0.76/0.64 kWh/Mt clk. power saving has been achieved respectively.

Page 35: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

Improvement Project-9 Installation of New Coal Dosing (Pfister Pump) – Both Coal Mill’s

Objective:

Avoid to fluctuation in coal firing & frequent coal flushing .

Problem: Fluctuation in coal firing & frequent coal flushing. Action:

installed new coal dosing System (Pfister Pump).

Investment:

304 Lacs (Each Mill’s)

Benefit:

0.45/0.58 kWh/Mt clk power saving has been achieved. fluctuation in coal firing & frequent coal flushing has stopped.

Page 36: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

Improvement Project-10 Kiln-1 Outlet Seal Replacement

Objective:

Reduce the heat losses in kiln 1.

Problem:

Heat loss through kiln-1 outlet seal was 2.75 kcal/kg clk. Action:

kiln-1 outlet seal has been Replaced. Investment:

65 Lacs

Benefit: 1.38 kcal/kg clk. thermal saving has been achieved.

Page 37: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

Improvement Project-11 Kiln-2 Inlet & Outlet Seal Replacement

Objective:

Reduce the heat losses in kiln 2.

Problem: Heat loss through kiln-2 outlet seal was 2.54 kcal/kg clk & through inlet seal was 0.95 kcal/kg clk. Action: kiln-2 Inlet & Outlet seal has been Replaced. Investment:

60 Lacs (Each Seal)

Benefit: 2.39/0.89 kcal/kg clk. thermal saving has been achieved.

Page 38: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

Improvement Project-12 Replacement of Fly Ash Unloading Compressor

Objective:

Improvement of equipment efficiency & power reduction.

Problem: Fly ash unloading with HP compressor & loading was running 105 kW. Action:

Replaced fly ash unloading compressor with LP compressor, loading is running 75 kW. Investment:

20 Lacs

Benefit: 0.28 kWh/t cement power saving has been achieved

Page 39: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

Utilisation of Renewable Energy Sources

Particulars 2017 - 2018 2018 - 2019 2019 - 2020

RPO Target 8.5% of Annual

Electrical Energy Consumption

9.25% of Annual Electrical Energy

Consumption

12% of Annual Electrical Energy Consumption

RPO Achieved 107.5733 Lakh

Kwh, 8.5% Achieved

179.77 Lakh Kwh ,9.2% Achieved

196.79 Lakh Kwh, 12% Achieved

Renewable Solar Energy Produced (Business) in TJ

16.72 54.65 41.13

Renewable Wind Energy Produced (Business) in TJ

6.37

6.16

5.81

Page 40: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

GHG Inventorization

674.0

642.0

570

590

610

630

650

670

690

710

730

750

2017-18 2018-19 2019-20

Kg CO2 / Ton of Final Product

No such

practice in

acquired

unit

CO2 emission reduction plan

Use of AFR up to 3 % of Coal consumption.

Increase of Fly Ash up to 35 % in PPC .

Proposed Solar Power Plant to increase green

energy consumption.

CO2 Emission Trend

Page 41: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

Green supply chain management

UltraTech voluntarily joined the Cement Sustainability Initiative (CSI), from 2006

Reverse logistics in, Raw material trucks

Eye on wheel (GPS) to reduce TAT (Truck Turn around time )

Maximizing PPC dispatches

Maximizing alternate Raw materials usage

Reducing types of lubrication by effective implementing Lub Management culture

Computer-based order management system with real-time

Customer service level measurement on real-time basis

GPS-based vehicle tracking system for dedicated fleet

Automation at secondary service points like railheads and warehouses

Page 42: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

32 34

36 38

25

30

35

40

Green belt Development /

Coverage %

Water positive No. of times

0.65 1.25

2.80

0.50

2.50

2017-18 2018-19 2019-20

1.37

0.75 0.60

0

1

1

2

2

3

3

2017-18 2018-19 2019-20

Green supply chain Initiatives

Water Withdraw LM3/ LMT Cement

Page 43: W E L C O M E []...VFD installation at both boiler PA fans 1,77,408.00 8.87 Performance improvement of 35 MW TG set 2.22 VFD installation with boiler feed pumps 4,90,560.00 22.07

Beema Bamboo

BEEMA BAMBOO is a superior clone, selected from Bambusa balcooa, a higher Biomass yielding

Bamboo species.

It can grow in the field for more than hundred years with no need for replanting.

BEEMA BAMBOO maintains a fast growth rate, giving the opportunity to constantly yield high and

predictable harvest.

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Team work & Employee involvement

Best Shop Floor Team

Award

Best Energy Team

performance Award

Suggestion & kaizen

Good work award

Near Miss Award

Section Wise

GRT Structure

OPEX Sub

committees

Energy Cell

Team

competitions

Reward and

recognition

Scheme

Meeting with

Seniors

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Unit Head

Energy Manager

FHT Technical Cell

LSC RM KILN COM UTILITIES CM PACKING

Plant TPP

Energy Cell Functioning focus area

Restoring Basic condition of the Equipments

Process / Energy Optimization

Innovation Technology Upgradation

Awareness / Knowledge

management

Unit Energy Cell Structure

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Intellectuals- Energy Managers

Mr.Komal kumar Verma

Energy Manager

EA- 17183

Mr.Akhilesh Jain

Energy Manager

EA - 5730

Mr.Amit Singh

Energy Manager

EM - 6089

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Energy Monitoring and Reporting

Dash board

SAP integration

180 Meters fixed in designated location & Mapped in SAP

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Unit’s Best Practices

1. Safety Behaviour observation Rounds

2. Shop floor meetings

3. QCDIP performance monitoring Culture

4. Ownership culture

5. Daily self maintenance drive

6. Opportunity identification culture

7. Kaizen & suggestion portal

8. Mass communication Meeting

9. Multilevel review

10. Synergy meets

11. Dash boards

12. Sustainability & Energy Cell

13. Best Practice sharing sessions

14. Energy audits Internal / External

15. Projects Review

16. Talent management

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Implementation of ISO 50001

ISO

50001

D

C

A

P Planned to implement ISO 50001 in FY 2021-

22

Preliminary activities : Teams formed ,

Energy Management System commissioning

under progress

Monitor energy performance & PAT Status

,Identify & propose opportunities of

improvement to management are in practice

Monthly energy cell, Technology management

,Systematic improvement Sub committees are

formed to identify the Technology Gap and

upgrading the technology. Kaizen campaigns

regular evaluation of kaizens and rewarding

scheme in practice

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Percentage of investment for Encon projects

251.0

144.8

109.4

0

50

100

150

200

250

300

2017-18 2018-19 2019-20

Investment (in Rs. Million)

0.084

0.023 0.022

0

1

2017-18 2018-19 2019-20

Investment (%) on Total Manufacturing Cost

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Long time vision on Energy Consumption

Journey Phase : 2 Clinkerization Power reduction

49.99 kWh/

MT Clinker

52.14 kWh/ MT

Clinker

Project 1 (Secondary

crusher )

Project 2 (Compressor Replacement)

Project 3

(Raw Mill Fan Retrofit )

Project4

(False Air

Reduction )

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Theme- Installation of Secondary Crusher

Background- Presently crusher O/P size is having sieve analysis of 35% of more than

40 mm size & 20% more than 63 mm.

Proposal- Installation of secondary crusher to reduce the size of Limestone i.e., 84 %

below 40 mm.

Benefit-

a. Improvement in Raw Mill output by 10%

b. Power saving by 1.5 units/Mt of material

Investment & Payback-

• Total investment for modification - 707 Lacs

• ROI: 3.43 Years (Power Saving- 206 Lacs/ Annum)

Project- 1 Secondary Crusher installation (Long Term)

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Theme- Reciprocating compressors replacement with Screw compressor

Background- Presently we are using reciprocating compressor (CFM-682) having

higher power consumption (0.17 KW/CFM).

Proposal- Replacement existing reciprocating compressor with screw compressor

(CFM-1542) for reducing energy consumption (0.14 KW/CFM). Proposed to install 3

nos. Screw compressor in phase 1.

Benefit-

Power Saving by 0.35 units/Mt of clinker.

Investment & Payback-

• Total investment for installation -120 Lacs

• ROI: 2.7 Years (Power Saving- 43.77 Lacs/ Annum)

Project- 2 Screw Compressor Installation (Long Term)

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Project- 3 Raw Mill fan retrofit (Short Term)

Theme- Raw Mill Fan Retrofit

Background- Fan operating efficiency 73% after Installation of SPRS ( Before: <

63%) - Design 80% Margin available : Flow: 14% Pressure: >25%, Speed : >18%

Proposal- Retrofit Fan (with Impeller + Shaft ) utilizing existing Casing, Foundation,

Motor, Drive etc. (with 80% Operating Efficiency)

Benefit-

Power saving by 0.50 units/Mt of clinker

Investment & Payback-

• Total investment for modification – 34.49 Lacs

• ROI: 1.67 Years (Power Saving- approx. 25 Lacs/ Annum)

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Project- 4 False Air Reduction (Short Term)

Kiln

TAD

6

5

4

3

2

1

6

5

4

3

2

1

PC

Mixing Chamber

CS Fan

KS Fan

Hood

Fan O/LO2 = 4.7 %

Fan I/L O2 = 4.6 % Fan I/L O2 = 4.2 %

Fan O/L O2 = 4.3 %

PC O/L O2 = 3.3 %

Kiln I/L O2 = 3.1 %

Calciner feedKiln feed

DiverterCoal firing

Coal firing

VRM

Recirculation Duct

mixing chamber

Baghouse

mill Fan

Transport

Bypass DuctBaghouse Fan

361LD5

361 LD3361LD4

361LD2

Stack

Fresh Air

361CN1 361CN2

Mill I/L O2 = 7.05 %

Mill / Separator O/L O2 = 7.9 %Fan I/L O2 = 8.80 %

Fan O/L O2 = 8.9 %

361LD6

Separator I/L O2 = 7.10 %

Coal Mill

Mill Fan

Recirculation Air Duct

Fan I/LO2 : 9.4 - %

Mill I/LO2 - 8.2 %

Fine Coal

Fan O/LO2: - 9.5 %

Separator /Mill O/L O2- 8.8 %

From PH

Separator I/L O2 - 8.4 %

Baghouse

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Prakash.G. Kalyanshetti

UltraTech Cement Limited

Unit - Sidhi Cement Works

Majhigawan, PO- Bharatpur, Tehsil: Rampur Naikin,

Distt: Sidhi – 486776, MP

Mobile: +91 8499998547 |Extn: 226 | E mail:

[email protected]