Rajashree Cement Works

Transcription

1 Continual Journey for Reduction in Specific Energy Consumption in Cement Manufacturing Process by Rajashree Cement Works (A Unit of UltraTech Cement Limited) at CII - 19 th National Award for Excellence in Energy Management

2 Contents of Presentation Company & Unit Profile Year-wise Specific Energy Consumption and Energy Benchmarking ENCON Projects Utilization of Renewable Energy Green House gasses- Inventorisation Sustainability Initiatives Energy Monitoring & Management Green Supply Chain Initiatives ISO Certifications CSR Initiatives

3 UltraTech Cement The largest Cement Manufacturer in India And a 360 degree construction solutions company Sustainability Proud Member of CSI Water Positive Company On the lines of preserving Bio-diversity Implemented DuPont Safety Standards Energy Conservation Utilizing Pet-coke to the maximum Maximizing the usage of AFR s Utilizing Waste Heat Recovery Utilizing Solar & Wind Power Human Resource Rajashree Cement Works, Malkhed Road, Gulbarga- Karnataka UTCL is Part of Aditya Birla Group, recipient of AON Hewitt s : Best Employer

4 Unit Profile Inception to Present Day st plant set up by Indian Rayon with Production capacity of 1500 TPD, upgraded to 3100 TPD through modifications. Plant Supplier: KHD 1990 Commissioned 2 nd Line with clinker production capacity of 3000 TPD, upgraded to 4150 TPD through modifications. Plant Supplier: KHD L-2 : 4150 TPD Total : 7250 TPD 1995 Commissioned 3 rd Line with clinker production capacity of 3500 TPD, upgraded to 5250 TPD through modifications. Plant Supplier: KHD L-3 : 5250 TPD Total : TPD 2013 Commissioned 4 th Line with Clinker Capacity of TPD. With potential for TPD, Plant Supplier: KHD L-4 : TPD Total : TPD Premium Quality Clinker OPC 53 Products OPC43 and IRST PPC PPC Super L-1 : 3100 TPD Total : 3100 TPD

5 Safety Initiatives

6 Unit Profile Manufacturing Process & Equipment Details Details of Major Equipment Equipment Line-3 Line-4 Crusher Raw Mill Coal Mill Pyro Cement Mill Packer Impact Type Crusher, L&T 1200 TPH Ball Mill with RP, KHD- 350 TPH VRM, Loesche- 30 TPH 6 Stage 2 String- SLC Preheater, Kiln: 4.6 X 60 m, KHD TPD Ball Mill with RP, Krupp Polysius- 350 TPH Rotary Packer Enexco- 180 TPH each 2No.s Impact Type Crusher, L&T 1650 TPH Finished Mode RP- 3 No.s, KHD- 290 TPH VRM, GPAG- 90 TPH 6 Stage 4 String- ILC Preheater, Kiln: 6 X 88 m, KHD TPD Ball Mill with RP, KHD- 250 TPH 2 No.s Rotary Packer Enexco- 120 TPH each 8 No.s

7 Unit Profile State of Art Technology First of its Kind 11 m3 Bucket Pay loader TPD Clinkerisation Facility Robotic QC Laboratory QCX First of its kind 1100 TPH Excavator Dedicated Silo for Various Grades First of its kind 100 MT Dumpers Energy Saving MV Drives for Slip Ring Motors Online- PSA XRF Analyzer

8 Unit Profile Awards & Accolades Energy Efficient Unit by Confederation of Indian Industries at its National Award for Excellence in Energy Management summit 2016 & 2017 IMC Ramakrishna Bajaj National Quality Award for Performance Excellence 2015 ABG World Class Manufacturing Gold Award Winner for 2015 & 2017 Unnatha Suraksha Puraskara Awards 2017 by National Safety Council - Karnataka Golden Peacock Award for HR Excellence -2015

9 Specific Energy Consumption Trends

10 TCE Benchmarking Tool Path for tool download :

11 Road Map to achieve Benchmarks Target : 676 Kcal/ Kg Clk & 65 kwh/t Cement Reduction in Pressure Drop across the circuit Reduction of bends in conveying length of coal pipe-line Reduction in pressure drop across cyclones and ducts Optimizing the Process fans Reduction in Fan I/L Suction Box Velocity Reduction in false air across the circuit Increase in Fan system efficiency Reduction in Thermal Energy Losses Regulating the Preheater & Cooler Vent losses Refractory Changeover & upgradation to superior properties Reduction in radiation losses by aluminizing the surface Optimizing the Raw & Final Grinding Power Blending the limestone as per Bond Index Maintaining Optimum Grinding Media Filling Percentage in Ball Mill Using lighter weight grinding media for grinding in Ball Mill Installation of Energy efficient Conveying, Firing & Aeration Blowers Turbo-blowers for Coal Conveying & Firing Turbo-Blowers in place of smaller Cooler Fans Increase in Share of Blended Cement Maximize the PPC/PPC-S production

12 ENCON Projects S.No. 1 Projects without Investment Line 4 cooler fans suction box modification to reduce specific power during Sept Annual power saving (Million kwh) Annual cost saving (Rs Million) Cooler vent fan PID tuned and Speed reduction of CV fan from 65 to 60% RM3 Grinding Media Optimization for power reduction Raw Mill fan RPM reduction from 94% to 90% hence reduction on power consumption by 40kw VFD for compressor, IFC Installation & Pressure setting optimization 6.2KG/Cm Bag House fan PID tuned to keep PH fan just -ve & Fan speed reduction Speed reduction of Dust collector fan with pulley change, delta to star conversion & high efficiency water pump for CM3 O/H Tank Removal of PH Downcomer Lower dampers & Sep. Fan Damper (RC4) Lighting Transformer Tap reduction & Lighting Circuit Modifications Bypass duct installation in cooler vent & PA Fan discharge Pressure reduction Total

13 ENCON Projects S No. Projects without Investment Annual power saving (Million kwh) Annual cost saving (Rs Million) 1 Installation of VFD for U-3 Kiln Pfister & Kiln/pyro (standby) Pfister feeders (3K58 & 3K60) Raw mill-2 grinding media Optimization to reduce Specific power consumption Operation of Bauxite crusher of Unit-3 in remote mode from control desk by providing ZSS & 4 Temperature RTDs which reduced the idle running of LSSR circuit. 4 Coal mill IV bag house pressure drop reduction by mmwg by modifying the purging arrangement False air reduction in Preheater, Raw Mill and Coal Mill of Unit Automation and Centralization of Crusher & Stacking Operation Cement mill 3 grinding media optimisation and Cake Breaker Installation Total

14 S.No. ENCON Projects Projects with Investment Annual power saving ( Million kwh) Investment Made (Rs, Million) Total Annual cost saving (Rs, Million) 1 Line IV Preheater suction box modification to reduce velocity from 29 to 21 m/sec Hot air recirculation to L4 raw mill SKS bottom to reduce false air across Raw mill circuit & bag house fan power consumption in July Removal of orifice of coal mill bag house fan to reduce power consumption in Line 4 in June Coal mill fan suction box modification to reduce velocity from 24 to 17 m/sec at Line IV Increase in Cooler ESP chimney height by 10.5 Mtr at Line IV to reduce fan power Cement mill IV SKS fan impeller replacement with high volume impeller to increase the mill output Installation of SPRS in Coal Mill 2 Fan Coal Mill-3 ESP to Bag house conversion and cyclone removal MV drive installation in Raw Mill-3 fan Installation of MV drive in U3 Pyro preheater fan Installation of MV drive in U3 kiln Preheater fan Removal of damper at raw mill 3 fan inlet to reduce pressure drop across the damper

15 S.No. ENCON Projects Projects with Investment Annual power saving ( Million kwh) Investment Made (Rs, Million) Total Annual cost saving (Rs, Million) 13 Installation of MV drive in U3 Coal mill fan Installation of fresh air damper at RABH inlet to stop dilution air fan operation Removal of damper at coal mill 3 fan inlet to reduce pressure drop across the damper Removal of damper at unit 3 kiln preheater fan inlet to reduce pressure drop across the damper Extension of unit 3 cooler ESP chimney height extension from 50.3 mtr to 57.5 mtr Removal of cooler fan inlet dampers and mesh size increasing Replacement of Cooler vent fan HT motor with LT motor Reduction in Air loading /Power Consumption of RABH fans Erection of refractory hump has been to block the T A D, for reducing air flow through TAD Kiln 3 Jet air Blower line modification to reduce the turbulence creating due to bends at blower outlet lines Total

16 S No ENCON Projects Projects without Investment Optimizing the Preheater Fan Speed & Reduction in false air across the pyro system leading to YOY reduction of 0.5 kwh/mt Clk. Reduction in Baghouse Fan Speed by optimizing the PID loop leading to SPC YOY reduction from 1.82 kwh/t to 1.54 kwh/t Clk. Optimization of grinding media charge & pattern in Cement Mills leading to main drive SPC YOY reduction from to kwh/t Cement. Annual power saving (Million kwh) Annual cost saving (Rs Million) Reduction in false air across the Circuit & optimizing the operation of Coal Mill leading to SPC YOY reduction from kwh/t Mat. To 34.95kWh/T Mat. Optimization of grinding media charge & pattern in Raw Mill leading to main drive SPC YOY reduction from 4.46 to 4.13 kwh/t Mat. Optimization of roller & feed regulating gate gap settings, reduction in false air of circuit and reducing the idle run of equipment lead to reduction in YOY SPC by 0.20 kwh/t Mat. Reduction in miscellaneous & utility YOY SPC by 0.02 kwh/t Clk by optimizing compressed air pressure settings, reducing leakages, optimizing AHU running Total

17 ENCON Projects S.No Projects with Investment Raw Mill-6 Fan In-house Impeller Tipping resulting in SPC reduction of Fan from 4.39kWh/MT to 4.07kWh/MT material. Blanking of Cage of Cement Mill Separators for speed reduction of separator fans resulting in SPC reduction by 0.70 kwh/mt Cement. Modification of Burner tip for reduction in flame momentum & stopping one jet-air blower attached to burner leading to SPC reduction by 0.34 kwh/t Clk. Increase in Kiln-inlet area by 12m2 for enriching oxygen concentration in kiln inlet resulting in speed reduction of PH fan impacting SPC by 0.1kWh/T Clk. Installation of Vortex Breaker in Preheater Cyclone for pressure drop reduction. Installation of Low NOx burner leading to reduction in power consumption of Primary Air blower Incorporation of Expert Optimiser system for reduction in SPC in 1 Raw Mill by 1.61% and 1 Cement Mill by 2.50%. Annual power saving ( Million kwh) Investment Made (Rs, Million) Total Annual cost saving (Rs, Million) Total

18 Ongoing/Planned ENCON Projects in S.No. Projects 1. Reduction in pressure drop across raw mill circuit for reduction in Fan loading. 2. By-passing GCT from PH fan outlet circuit. 3. Optimizing grinding media charge & pattern in ball mills 4. Reduction in fly ash handling & conveying power during PPC manufacture 5. Incorporation of Expert Optimizer system for process control & upgradation of existing Expert Control system 6. CFD analysis of Cooler ESP Inlet duct & PH Down comer duct for reduction in fan loading. 7. Installation of Vortex Rectifier in PH cyclones 8. Raw mix grindability & burnability optimization. 9. Process Fans efficiency improvement 10. Reduction in radiation losses across pyro-section.

19 Innovative Projects in Line of Energy Conservation Project-1 : Reduction in Pressure Drop of Cyclone by installation of REPDS Innovative Idea Generated :- As per the CFD analysis found most feasible solution of REPDS installation for reduction in pressure drop across the cyclone without disturbing the original cyclone geometry & structure. The REPDS will act as a Vortex-Breaker for the cyclone. Changes done :- Installed 300 mm dia SS-Pipe in the cyclone from roof to cone. Benefits Achieved:- Calculation :- Pressure drop across cyclone : = 12mmwg Reduction in total pressure drop across preheater = 12 mmwg /640mmwg) * 2077kWh = 38.94kWh Total kwh saving /Day = 38.94*24 = kWh/day Total kwh saving/day/tclinker = /10700 = 0.08kWh/Tclinker Total saving = 38.94kWh*24Hr*320Days*2.8Rs/kWh = 9.86 Lacs Rs. / Annum Net Saving including investment : = Rs 5.86 Lacs /Annum for one cyclone

20 Innovative Projects in Line of Energy Conservation Project-2 : In-house Impeller Tipping of Raw Mill-6 Separator Fan Fan original Impeller Dia was 2290mm Before Welding 10mm Thickness MS Plate of 25mm Width on Blade to increase Shroud Disc Dia: X2=2340 mm After Innovative Idea Generated :- Impeller Tipping to increase the impeller diameter will result in operating the fan at lower/ safe speed range with the same volume delivery. Changes done :- Increased the impeller diameter by 50 mm. Benefits Achieved:- With an investment of Rs 32,000 the following benefits were achieved : Fan Speed reduction from 1040 RPM to 1010 RPM, leads to SPC reduction from 4.39kWh/T to 4.07 kwh/t. Raw Meal Production after Modification = MT Units Saved = ( ) X = Monetary Savings = X 3.3 (Avg. Power Cost. Rs 3.3/ KWh) = Rs 8.23 Lacs in 5 months = Rs Lacs/ Annum

21 Innovative Projects in Line of Energy Conservation Project-3 : Maintaining the Specified Cage Wheel Velocity at Reduced Air Flow Rate across the Separator. Before 400 mm in complete circumference After Innovative Idea Generated :- To maintain same cage wheel velocity (4.5 m/s) even on reduction of volume passing through separator by reducing the area of air-entry. Changes done :- Blanked dynamic separator Cage from top by 400 mm in circumference of Cement Mill to reduce the effective height thereby effective area of air-entry. Benefits Achieved:- Able to reduce the Fan Speed by upto 80 RPM in Cement Mill product wise. Difference in Fan SPC attained after blanking the cage is 0.70kWh/MT Cement. Total Cement Ground in Mill after carrying out the blanking = 6.51 Lac MT Savings = 4,50,000 Lac Kwh = Rs Lacs in 7 months =Rs 25 Lacs/ Annum

22 Utilisation of Renewable Energy Solar Power Generation Share, % kw Solar Power Bio-gas for Colony

23 Waste to Energy- WHRS WHRS Power Generation Share, % MW WHRS for Line-4 Kiln

24 Waste to Energy- AFR Quantity of AFR consumed, MT Semi Solid Mixing pit Wood chipper machine: Capacity 6 TPH

25 Green House Gasses- Inventorisation Specific CO 2 Emmission, kg/mt of Cement National Benchmark Action plan for CO2 Emission reduction Sapling Survival rate % Maximize AFR usage Maximize Fly ash usage Energy consumption reduction Consistent operation of WHR Use of non-conventional source of energy like solar, biogas etc. Total No. of plants (Plant area) 4.49 lakhs in 5 years Total area covered under green belt (Plant & Colony) : % Total No. of plants (Mines) 2.99 lakhs Biological study conducted in 2010 No Flora & Fauna is affected by Plant operations No Forest land & Protected areas in the Plant and Mining area

26 Sustainability Initiatives Implementing green building concepts: Installation of transparent sheets. Installation of Sun Light tube. Rain water harvesting mechanism. Use of Fly ash brick. Use of Robo sand. Use of Apex paint. Use of star rated appliances. Replacement of incandescent lamps with LED bulbs. Plantation of native plants. In Mines Building No electrical illumination is required during day time.

27 Water Conservation Water Consumption, Lac m Specific Water Consumption, m3/mt Clinker

28 Environmental Protection Capex Expenditure on Environment Protection in Cost (INR Crores) Conversion of Line 1 Kiln & Pyro ESP in to Bag house 8.91 Conversion of Line 3 Kiln ESP in to Bag house 9.24 Line 4 WTP, Pumps & Pipes 3.13 Line 4 Bag house 2.91 Line 4 Cooler ESP 1.19 Capex Expenditure on Environment Protection in Cost (INR Crores) Conversion of Line 3 Coal mill ESP in to Bag filter 3.82 Conversion of Line 3 Cement mill ESP in to Bag filter 0.88 Line 2 & 3 Cooler ESP T/R Sets 0.54 Road sweeping machine 0.53 Capex Expenditure on Environment Protection in Cost (INR Crores) Carbon Powder Unloading System 0.40 Low NOx burners for Line-3 Kiln 1.50

29 Energy Monitoring & Energy Management System Energy Projects Implementation- Methodology Competent Evaluation Team No. of Certified Energy Managers 7 No. of Certified Energy Auditors 1 No. of Certified Six-Sigma Green Belt Champions 50 No. of Certified Six-Sigma Black Belt Champions 3

30 Energy Monitoring & Energy Management System Dedicated Energy monitoring system is provided in the main substation through which the performance of all the major HT, DC Drives can be monitored continuously. All the major Drives, Incomers, Transformer feeders are connected with the individual MassiBus meters are communicated to Micrologix PLC through RS485 port for EMS scada system. Daily Power Reporting Procedure -RC Meter energy data (Electrical) log at 00:00 hrs. Meter wise report generated and Same report uploads in SAP. Process data like TPH, Running hrs etc. upload in SAP by Process dept. Final power report generated in SAP.

31 Energy Monitoring & Energy Management System

32 PAT Performance Details Average Year Target Year Actual Year Target Year Actual Year Actual Year Actual Year Gate to gate SEC (Kcal/Kg of Cement On OPC Basis) Base Line Year ( ) SEC Target SEC in year SEC Reduction Target Actual SEC achieved Actual SEC Reduced Target SEC in year Kcal/kg OPC 1039 Kcal/kg OPC 52 Kcal/kg OPC 1026 Kcal/kg OPC 65 Kcal/kg OPC 994 Kcal/kg OPC

33 Employee Engagement in Energy Conservation & Improvement Kaizen-1 : Reduction in frequent damages of Blending Silo Top distributor. Problems faced :- Frequent damage of the air slide Cloth of the silo top distributor. Stoppages (freq-3nos) of Raw-mill due the jamming of the distributor. Loss of Rs- 0.20L per stoppages. Total Loss-0.60L in FY Root cause derived: Direct material impact on the air slide fabric causing more wear. Kaizen Idea Generated :- To provide the impact cone below the discharge point, so that direct impact is avoided. Benefits Achieved:- Stoppages avoided. Inventory control Manpower cost control. More productivity obtained Before After

34 Employee Engagement in Energy Conservation & Improvement Kaizen-2 : Providing fluidizing air in Multi-core & Multi-cell of Coriolis Feeder Problems faced :- FC Min. Root cause derived: fault in Coriolis Feeder 1. Insufficient & uneven air flow through Multicell & Multicore which leads leads to failure of Coal improper fluidization leading to Sudden Dosing resulting in stoppage & flushing of fine coal from Bin operational disturbance to Calibration tube. in Kiln. Kaizen Idea Generated :- 1. Providing external aeration to avoid clogging/ air-pocketing of fine coal in the system so as to continuously fluidize the fine coal. Benefits Achieved:- Kiln operational disturbances avoided. Changes done :- Provided Compressed air-purging in tube calibrator with additional ring & blower air in multi-cell & multi-kor for maintaining the fluidization of fine After coal. Before

35 Employee Engagement in Energy Conservation & Improvement Kaizen-3 : Smoke Chamber area enlargement In-house for enriching the oxygen at Kiln inlet Problems faced :- Frequent jamming of Kiln Inlet with operation of high sulfur pet coke. Root cause derived: 1. Due to jamming there is narrowing of inlet section leading to increase in velocity of gasses passing through the area & thus reduces the retention of gasses here, as a result reducing atmosphere is created which aggravates the coating tendency. Kaizen Idea Generated :- To decrease the velocity of gasses at kiln inlet keeping the same flow through kiln so as to increase the retention time of gasses for enhancing the Oxygen Concentration so as to avoid reducing atmosphere. Before Changes done: - Kiln inlet roof area increased 12 m 2 by extending the roof 400mm up. Benefits Achieved:- With an investment of Rs 5,00,000, the following benefits were achieved : Enrichment in oxygen at kiln inlet by 1-1.5% Less coating kiln inlet.decreasing the kiln inlet gas velocity by from 19.50m/s to 11.55m/s. The reduction in velocity gave an opportunity to reduce preheater fan Speed and thus achieved a SPC reduction of 0.10 kwh/t Clk. Roof height increased by 400 mm After

36 Awareness Initiative on Energy & Environment Kaizen Per Employee Kaizen Participation Index

37 Green Supply Chain Initiatives

38 ISO Certifications Information Security Management System ISO-27001:2005 (ISMS) Environmental Management System ISO-14001:2015 (EMS) Occupational Health & Safety Assessment Series ISO-18001:2007 (OHSAS) Social Accountability SA8000:2014 National Accreditation Board for Testing and Calibration Laboratories ISO :2005 (NABL) Energy Management System ISO (EMS)- final audit for certification under progress Quality Management System ISO-9001:2015 (QMS) Systems for continual improvements

39 CSR Initiatives KGBV Residential Education facilities with vocational training for Drop out girls in the age group of years from 6th to 10 th std Merit Scholarship Selecting brilliant Students for providing the Merit Scholarship in 41 Govt. Schools. Tree Plantation Efforts to maintain the ecological balance in villages with planting Farm equipment's distribution Agricultural equipment are provided to small and marginal farmers living below poverty line.

40 Excellence is Nothing But A Passionate Journey driven by Positive Attitude... Thank You