UltraTech Cement Limited

Transcription

1 UltraTech Cement Limited (-Power Plant) Welcome to All 19th National Award for Excellence in Energy Management 2018 Welcomes all On 18th National Award for Excellence in Energy Management

2 We are going to share Company Profile Unit Profile Plant Configuration and Flow diagram List of ENCON Projects Plant Performance over the years Innovative Projects Sustainability Initiatives Methodology of Energy monitoring Best practices/ Involvement of Employees CSR initiatives Awards & Accolades Way forward 2 2

3 Company Profile Star Brand India Selected as Superbrand by the Super brands council along with Powerbrand awarded by the institute Power Brands India. 3

4 One stop shop for all construction needs of Customer 4

5 Unit At Glance Sewagram Cement Works (Acquired from Jaypee in June-14) Clinker Capacity :3.6 mtpa(2x5500 TPD) & Cement Capacity 2.4 mtpa Captive power plants (CPP) CPP-I 35 MW & CPP-II 22.5 MW capacity. Mines with reserve of MT, Captive Jetty, a Desalination plant that can filter 2200 Kl of water every day 5

6 Broad Specification of TPP Equipment Package Make Type Capacity &Feature Boiler-1 TKIL CFBC 170TPH, Pr.-87 Kg/cm2, Temp /-50C Boiler-2 IJT AFBC 110TPH,Pr.-87 Kg/cm2, Temp /-50C Turbine-1 Siemens Condensing 35 MW, Pr.-84 Kg/cm2 Temp /-30C, Steam Flow TPH Turbine-2 Siemens Condensing 22.5 MW, Pr.-84 Kg/cm2 Temp /-30C, Steam Flow -93.5TPH Generator-1 &2 TDPS+Andritze Hydro Brushless Excitation 11KV,43.75 & MVA, PF-0.8 Coal &Lime stone Handling Masyc Blow bar crusher Coal-180TPH & Lime-60TPH, Flip flow screen for High Moisture coal DG (03 Nos.) Man B&W Desal Plant ION Exchange 12.5MW +12.5MW +10.8MW PTP + RO 6700 KLD 6

7 ENCON Projects List Of 7

8 Savings in last Three year through EnCON Projects Without Investment Rs Lacs Total Saving Rs Lacs With Investment Rs Lacs (ROI- 1.8 Yrs) 8

9 Energy Savings Projects with No Investment FY SN Energy Saving Projects (06 Nos.) 1 Boiler -1 ID draft optimized at -15mmWC against -25mmWC 2 Running of one BFP in place of 02 BFP up to 80 % load for Both Plant (Design is 2*50%) 3 Reduction of LOI from 10.5 to 4.5% 4 Further optimization of Instrument air pressure from 6.5 kg/sq.cm to 6.0 kg/sq.cm Saving Achieved Electrical Energy (Rs. Lacs) Saving Achieved Thermal Energy (Rs. Lacs) Operation of Boiler at Lower Bed Height i.e. Reduction by 50MMWC. Start Using of Pet Coke as alternate fuel to improve Boiler 6 Efficiency of Both TPP Sub Total 5 Grand Total

10 Energy Savings Projects with No Investment FY SN Energy Saving Projects (14 Nos.) Saving Achieved Electrical Energy (Rs. Lacs) Saving Achieved Thermal Energy (Rs. Lacs) Boiler-1&2 efficiency increase by optimize excess O2 in flue gas at 3.9 % against 4.5 % 2 DM plant operation running hour optimized at 5 hrs./5 days against 2 hrs./day For Boiler -1 &2, Lime screw feeder stop due to pre mixing of lime in Coal conveyor belt For Boiler -1 & 2, 10 Nos. Lime stone belt conveyor stop due to pre mixing of lime in Coal conveyor belt TG-1 Deaerator O/L temp. increased upto 155 Deg C from 150 Deg C 6 Boiler -1 Bed ash cooler optimized running hrs. to reduce PA fans power consumption TG-1&2 Vacuum controlling through PID controller

11 Energy Savings Projects with No Investment FY SN Energy Saving Projects (14 Nos.) Cooling tower fan power consumption optimized by PID controller of CW outlet temperature to start of CT fan Ash conveying air cons optimized by reducing nos. of hole of orifice All lights are stopped at CHP area in night shift Flue gas temp. of ESP I/L reduced from 135 to 130 Deg C looking to the sulphur due point Service air compressor running Hrs. optimized at 18 Hrs./day 12 against 24 Hrs./day by optimized operation of ash conveying system 13 Optimization of CHP running hours Improvement of Boiler-2 Efficiency by increasing Petcoke 14 percentage by weight in fuel mix from 7.3 to 40.2% Sub Total 11 Saving Achieved Electrical Energy (Rs. Lacs) Saving Achieved Thermal Energy (Rs. Lacs) Grand Total 11

12 Energy Savings Projects with No Investment FY SN Energy Saving Projects Saving Achieved Electrical Energy (Rs. Lacs) Saving Achieved Thermal Energy (Rs. Lacs) 1 Boile-2 APH line diverted to Boiler-1 to reduction in LOI of fly ash P & V system stopped by proper ventilation through efficient exhaust fan in TG building Service air comp. running Hrs. reduced by use of Instrument air as service by optimizing ash handling operation Both Boiler ESP Power reduced by adjusting optimized field voltage as per fuel selection in boiler Coal impactor VFD RPM set point varies with respect to fuel selection to reduce APC Grand Total 12

13 Energy Savings Projects with Investment FY SN Energy saving Projects (04 Nos.) Saving Achieved (Rs. Lacs) Investment (Rs. Lacs) 1 Wet steam washing of TG-2 to improve efficiency Overhauling of TG-1 for Heat Rate improvement Installation of VFD in TPP-2 CEP Installation of VFD in TPP-1 CEP & PID controller Grand Total 13

14 Energy Savings Projects with Investment FY SN Energy saving Projects (08 Nos.) AFBC high LOI ash used in CFBC to increase boiler efficiency TG-1&2 ACC internal Fins cleaning carried out through HP pump water pressure to reduce ACC fan power cons. APH tube change to improve APH efficiency & reduces PA fans Auxiliary power Saving Achieved (Rs. Lacs) Investment (Rs. Lacs) Instt Air used as service air Replacement of Start-up vent VFD in Inst. Comp & PID Logic Operation Use of efficient LED lighting in place of conventional lamps Improvement of Boiler-1 Efficiency by increasing Petcoke percentage by weight in fuel mix from 11.3 to 46.1% Grand Total

15 Energy Savings Projects with Investment FY SN Energy saving Projects Saving Achieved (Rs. Lacs) Investment (Rs. Lacs) 1 Installation of VFD in Boiler-1 BFP Installation of VFD in Boiler-2 BFP Installation of VFD in Instrument compressor Installation of VFD in Service compressor TPP-1 ACC fan 1&5 Tube bundle replaced ACC APC reduce by its Fin Cleaning of TPP ACC APC reduce by its Fin Cleaning of TPP Boiler-1 APH tubes (1340 Nos.) replaced Boiler -2 ESP outlet expansion bellow replacement 08 Nos. 150 Watt LED installation in place of 32 Nos. 250 Watt HPSV lights in TG Building

16 Energy Savings Projects with Investment FY SN Energy saving Projects Saving Achieved (Rs. Lacs) Investment (Rs. Lacs) Nos. 150 Watt LED installation in place of 32 Nos. 250 Watt HPSV lights in TG Building LED Installation work and Circuit separated in TPP areas RO Reject line modification work Intake Pipe Line modification Work PSF PUMP VFD installation Stilling Pump VFD installation Turbocharger Based HP Pump for RO Plant Startup vent valve replacement done for TPP Startup vent valve maintenance of TPP Grand Total 16

17 Over The Year Plant Performance 17

18 Sustainable Plant Performance Aux. Power Cons.(%) PLF (%) Heat Rate (Kcal/Kwh) G O O D G O O D Power Cost (Rs./Kwh) 4.85% Reduction % Reduction G O O D

19 Comparison with Group Units PHR Vs PLF % 66% % 79% 80% 80% 84% % % % 88% % 2700 KCW 20.00% 100% SCW VC 88% 81% 66% 8.4% 8.9% 9.0% ACW AC APCW GCW RC RWCW HCW 84% 79% 80% 80% 9.8% 9.8% 10.1% RDCW APC Vs PLF 78% 9.4% 74% 9.6% 70% 9.6% 9.7% 100% 62% 11.9% 0% 0.00% KCW SCW RDCW RC VC RWCW GCW ACW AC APCW HCW 19

20 Comparison with Benchmark & Cluster Units PHR Vs PLF 100% % 66% % 62% % National Benchmark SCW 100% GCW Sanghi Cement APC Vs PLF 20.00% 100% 84% 66% 7.5% 8.9% 9.7% 62% 11.9% 0.00% 0% National Benchmark SCW GCW Sanghi Cement 20

21 Innovative Projects in FY New Turbo System Installatio n in Desal 4. MV Drive installatio n in TPP BFP 2.Reducti on of LOI % in Boiler 3. Lignite firing in Boiler 21

22 1.New Turbo System installation in Desal Objective Reduction in specific Power Consumption of Desalination RO Plant. (Reduction from 7.99 Kwh/KL to 4.50 Kwh/KL) Background of Project Water production cost is high due to high Sp. Power consumption (7.99Kwh/Kl) in Desalination RO plant. Less reliable of existing pump due to pump life was distorted by Sea water operation. Approach 22

23 1.New Turbo System installation in Desal Power Consumption WHY-WHY Analysis High RO Power Consumption Old design energy recovery system Installation of high efficient turbocharger with new design single pump Root Cause Analysis Efficiency of Energy recovery system is less Low efficient turbocharger 02 Nos. High pressure pumps installed in place of single and operating on DOL mode with high pressure against design Membrane efficiency, Re-handling of reject water High Power consumption at RO Pump power consumption is high Power consumption is 430 KW and operating at DOL mode Desal RO Power consumption is very high (50% cost contribution) Sp. Power Consumption (Kwh/KL)- Cluster [VALUE] SCW ABG Cement IR Veraval 4.50 Tata Power Adani Power 23

24 1.New Turbo System installation in Desal Performance Parameters After Before UOM A B C D E F G H CF Inlet HPP_1 HPP-2 HPP Common ERT RO inlet RO Product RO Reject ERT Reject M3/Hr Kg/Cm KWH KWH/KL 5.95 Code UOM A B E F G H Desc. CF Inlet HPP _1 ERT RO inlet RO ProductRO Reject ERT Reject Flow M3/Hr Pressure Kg/Cm Power KWH Sp.Power KWH/KL

25 1.New Turbo System installation in Desal Benefits Performance parameter Before After Saving Specific Power consumption 7.99 Kwh/KL 4.39 Kwh/KL 3.60 Kwh/KL Power Cost for water Gen Lac/Annum Lac/annum Lacs/Annum Breakdown frequency of pump/its Motor was increasing trend ( 2-3 time per month) Breakdown frequency of pump and its Motor eliminated OEE was less OEE increased Reliability Uniqueness Water Lubricated Bearing Reduction in Power - 44% 25

26 2. Reduction of LOI % in Boiler Objective To reduce power cost,by increasing Boiler Efficiency through reduction in Boiler ash LOI from 4.5% to 2.0% Background of the Project LOI of Boiler was on higher side i.e.4.5%. Lower Boiler efficiency due to Higher LOI % Power cost was increasing due lower Boiler efficiency. 26

27 2. Reduction of LOI % in Boiler Causes & Effect Diagram Material Method/Process Analysis of crushed Coal Size Coal Quality High Fines in Coal Coal Crushing Operation Improper Air Flow/ Turbulence High Fly Ash LOI Skill Screen Size of Coal Knowledge Gap of crusher Training Machine Man 27

28 2.Reduction of LOI % in Boiler Benefits Key Initiatives Adjust the impactor Gap for proper Fuel fines on fortnightly basis. Optimized the air flow ratios i.e. Primary air Vs secondary air Vs tertiary air. Analysis of coal started on shift basis and maintained the coal size within range. Results % LOI TREND Oct-17 Reduction in Fly ash LOI by 1.8% Increment in Boiler Efficiency by 1.20% Nov Dec Saving of Rs. 92 Lacs/annum 20 28

29 3. Lignite firing in Boiler Objective Reduction in Power Generation cost by utilization of available low cost fuel- Lignite Problem /Background Boiler is not design for 100% lignite firing. Available Imported coal cost Rs/MCV is higher compare to Lignite. Volatile matters is very high in lignite which increasing high temperature in convection zone of boiler during firing of Lignite. Lignite have high VM & due to same it get self ignite & create fire risk in fuel handling system 29

30 3. Lignite firing in Boiler Action Initiated Erected one new discharge chute (size 20 ) with manual isolation gate from Lime screen discharge chute which divert lime stone in coal feeding conveyor belt. Provision for Raw meal extraction from Raw meal silo Raw Meal feeding system at Boiler Lime bunker. Looking to VM Boiler furnace draft reduced from -25mmWc to -10 mmwc which resulted saving of Aux. power 30

31 3. Lignite firing in Boiler Results By this modification, Up to 80 % Lignite fired in boiler. For 100% Lignite firing Boiler FGD proposal in under process. Better reaction between Lime Powder & SOx. Fire risk minimized near belt conveyors by blending of lime stone with lignite at belt conveyor. Saving of Aux. Power at ID fan Lacs/annum Saving of amount 687 Lac/Annum by selection of Lignite fuel. 31

32 4. MV Drive Installation in BFP Objective Reduction in Auxiliary power consumption by Installation of MV drive in Boiler Feed Pumps Background of Project TPP Power generation is directly depend upon power demand by Cement plant. TPP PLF varying between 40 to 85 % as per load requirement & due to same DOL- BFP taking high power at low MW Generation & that was increasing the aux. power consumption. Analysis & Implementation required to reduce APC of BFP at low MW Generation of TPP. 32

33 4. MV Drive Installation in BFP - Analysis Value Driver mapping Causes & Effect Diagram PA Fan(1.8%) Boiler Fans (3.5%) SA Fan (0.5%) Boiler (6.5%) BFP (2.5%) ID Fan (2.2%) ESP (0.5%) Turbine (0.15%) MOP/AOP (0.15%) CEP (0.5%) Aux. Power (13.2 cr.) 10.20% ACC (2.5%) ACC Fans (2.0%) DM Plant (0.10%) BOP (0.70%) ACW &CT (0.30%) Compressors(0.40 %) Material handling (0.20%) CHP (0.15%) LIme 0.00 Stone (0.05%) 33

34 4. MV Drive Installation in BFP - Analysis Analysis To reduce power cost,it is very important to optimize the BFP power consumption. By cause & effect analysis following causes has been identified Plant Running on Low capacity Losses due to Recirculation Losses due to Feed control valve throttle at low feed water demand to boiler drum DOL Operated BFP Implementation Team TPP adopted Engineering & technological change in BFPs by installing of MV Drive in BFP with proper PID & Logic implementation as follows Feed water discharge pressure set point = Boiler Drum pressure + 7 Kg/Cm2( Head loss+ Bend Loss + Piping/tube friction loss) 34

35 4. MV Drive installation in TPP BFP Results Throttling losses minimised by opening Feed control to maximum BFP recirculation become zero at low load. Power Saving Rs Mwh/Annum Saving of Rs Lacs /Annum on fuel Cost 35

36 Sustainability Initiatives 36

37 GtG energy consumption status (Cement & Power Plant) Gate to Gate Sp. Energy Cons. (Kcal/Kg PPC) (Baseline Year) Target SEC for PAT-2 cycle (04/16 to 03/19) Unit registered as Designated Consumers (DC) under PAT-2 scheme Target given for 7.57 % reduction in GtG Specific Energy Consumption at the end of PAT-2 cycle ( ) Implementation of Encon projects in the unit reflects % reduction in SEC upto without normalization. 37

38 GHG Emissions in MT/Yr (Cement & Power Plant) GHG Emission TPP

39 Green Belt development Green cover of about Ha in Plant, Mines and Colony premises Total tree planted Nos. in Plant, Mines & Colony area till date Survival Rate of plants are 79% Extensive Plantation undertaken at Colony, Plant and Mines. 39

40 Green Belt development 40

41 Utilization of Renewable Energy/ Alternate fuel/ Wastes 41

42 5 MW Solar Plant Installation Proposed Power Gen. & Efficiency Details of Solar Plant Capacity is 5.0 MWp (DC) / 4.0 MWp (AC) Expected Generation kwh/day Approximate Land Requirement: 25 Acres First Year Power Generation (Lacs Units) Type of System: Fix-Tilt First Contract year adjusted - 2.5% degradation Expected Life Of Solar Plant: 22 Years Each subsequent Year degradation - 0.7% Efficiency- 19.4% Plant Commissioned on 14th August-18 42

43 Solar Power Plant 43

44 Use of Alternate Fuel/Wastes Used 784 MT of Coal Dust i.e. reject of steel plant as alternate fuel. Used 45 MT of Carbon black powder as alternate fuel Used 334 MT Soya husk/cow dung/wooden Chips as a alternate fuel Used PPF for boiler Light up Usage of Petro Polymer fuel in place HSD. Used 8196 MT AFBC Fly ash in CFBC as a fuel Used 8105 M3 N-Pit water in dust suppression (zero water discharge). 44

45 Energy Cell 45

46 Energy Policy We Committed to demonstrate excellence in reduction in Energy Consumption & Carbon emission in all our activities of manufacturing of cement & Clinker on continual basis so as to make our unit & its surrounding environment sustainable for future 46

47 Methodology adopted for Energy Monitoring Energy management cell headed by FH-TPP. Daily monitoring of PLF, Heat rate and Aux. power deviation. Analysis of equipment performance for deviation. Identification of energy conservation scope through - Loss Cost Matrix, Brain Storming and Theme base suggestions/kaizens scheme under Energy Saving. Feasibility study of suggestions & submit proposal for sanction. Preparation of detail action plan. Monthly review to monitor project progress. Benefits analysis after project implementation. Sustainability of the project 47

48 Energy Monitoring Energy Monitoring System 48

49 Implementation of corrective / Preventive action 49

50 System Accreditation in ISO 9001:2015 ISO 14001:2015 OHSAS 18001:2007 ISO 50001:2011 Under Implementation 50

51 IMS (ISO:9001,14001 and OHSAS:18001) SCW has got Certification from International organization for standardization for Integrated Management systems for Quality Management System (ISO 9001:2015), Environment Management System (ISO 14001:2015) and Occupational Health & Safety Management Systems (OHASA18001:2007) from certification agency DNV. 51

52 Implementation of Corrective & Preventive Actions S.No Non-conformity Description Corrective Action Taken EMP is not evident to consistently meet compliance to new Stack All Management emission norms of 30 micrograms/nm3 in Clinker cooler Unit1 and in identified. different stacks Unit Though improvement is observed in Unit stacks after replacement of Bag filters, Clinker Cooler emission was found to be 29 micrograms/nm3 in Feb programs As per the consent condition AWH clause 4.4, of limestone Ambient Noise monitoring started mines, ambient noise monitoring to be carried out. Organization shall take necessary authorization for the generation and disposal of the hazardous waste. Failure - compliance to above condition is not evident. Evidence various hazardous waste such as Oily cotton waste, oil filters, used Oil drums etc. are generated, however consent shows authorization for Used oil only. Hazardous waste - such as Oily cotton waste, oil filters, used Oil drums etc., generation and disposal mechanism made for putting in Kiln

53 Best practices Team Work Knowledge Sharing 53

54 Best Practices Examples are as under Analysis of area wise Aux. Power consumption on daily basis Impact analysis in bearing by vibration spectrum analysis technique for lubrication of equipment Energy efficient Motors & Illumination System AFBC boiler converted into CFBC boiler without any technological upgradation 100% ash of boiler, utilized for Cement Manufacturing. All new procurement is on the basis of energy efficiency. 54

55 Team Work in EnCon SN Idea originated Extent of man-power involved in FY ** *** EnCon idea * Progress of implementation 1 Installation of MV Drive at Boiler Feed Pump O&M,E&I & M/s Toshiba Team Completed 2 Closed Loop operation ACW pump operation with discharge pressure O&M and E&I Team Completed 3 New Turbo System installation in Desal O&M,E&I and M/s Fedco Team Completed 4 Reduction of LOI in Fly Ash from 4.5 to 1.8% O&M Team Completed 5 Solar Power Generation E&I Team and M/s ABRL Team Completed 6 Closed loop operation of Lignite fuel feed in boiler O & M and E&I Team Completed

56 Knowledge Sharing with Group Units / Vendors Kaizen Souvenir shared to all Group Units. Achieved 15 KPE (Kaizen Per Employee) in Fy 18 Conversion of AFBC Boiler to CFBC horizontally replicated to other Group Units and same has implemented at Balaji and Aditya Cement. Shared Erosion protection Plate modification to M/s ThyssenKrupp Bed ash handling of AFBC Boiler through Primary Air fan in place of Compressed air shared with M/s ISGEC Provision of MCB before signal isolator in VFD shared with M/s ABB 56

57 Green Supply Management Two way transportation for Raw meal and fly ash with bulker. Two way Transportation for Fuel receipt and Clinker Export to Port. Two way transportation of Clinker and receipt of Pond ash (Wanakbori Unit & Gandhi Nagar Plant). Operational of Captive Jetty for Coal. 57

58 Corporate Social Responsibility Corporate CSR CSR Vision Infrastructure Development Education Sustainable Livelihood Health care CSR Policy Focus Area 58 58

59 Glimpses Shala Praveshotsav and Kanya Kelvani Program 230 School Kit Distribution to surrounding Government 20 school and 55% Girls Involved. 59

60 Corporate Social Responsibility Awareness campaign for Personal hygiene, Family planning, Immunization camps. Awards to best students nearby Villages

61 Women Empowerment Installed of 7 Automatic Sanitary Pads vending Machine and Automatic Electrical Incinerator in 7 Block in Model Girls Hostel. Total 839 Girls Model Hostel benefited by activity 61

62 Award & Accolades 62 62

63 CII National Kaizen Award-2017 (Env. Category) SCW (Only Cement Plant) have won National Kaizen Award (Top -18) for Utilization of Alkali-Chloride Bypass dust in Cement under Environment Category. The Award was presented by Dr.Baldev Raj (Indian scientist and former director of the Indira Gandhi Centre for Atomic Research) on 10th CII National Competitiveness and Cluster Summit which was held at India Habitat Centre, New Delhi on 6th December

64 CII-National Award for Excellent Energy Management Sewagram Cement Works awarded as Energy Efficient Unit at CII 18th National Award for Excellence in Energy Management (Category: Captive Power Plant) 64

65 MQH Best Practices Recognition at IMC Mumbai Sewagram Cement Works Best practices recognized at IMC, Mumbai on 9th Mar 18 : 1.A giant step towards Green & Clean clinker production. 2.Utilization of ABC boiler Flyash as fuel in CFBC Boiler(TPP). The same Best Practices were also published in their Annual Magazine with a Introduction of SCW Plant. 65

66 Limestone/Raw Material Harudi-Kharai Limestone Mines AWARDED 5 STAR rating mines Amongst Top 5 best performing mines in INDIA Receiving award from Hon ble Union Minister of Mines & Panchayat Raj Shri Narendra Singh Tomar for Harudi Kharai Limestone Mine Kharai-Harudi Limestone Mines Also AWARDED 5 STAR rating MINES Receiving award from Shri Haribhai Parthibhai Chaudhary Hon ble Union Minister of State for Mines for Kharai Harudi Limestone Mine 66

67 Global Cem Process Conference We have received the official Invitation letter for 2nd Intl Global Cem Process Conference 2018 as Keynote speaker For the presentation on A giant step towards green and clean production by replacing conventional fuel for Cement Plant (petcock and coal) with nearby available lignite. 67

68 Way Forward 68

69 Energy Saving Projects SN Energy Saving projects Proposed Saving Per Annum (Rs. Lac) Target date 1 Energy Efficient Boiler Feed Pump Installation 25.5 Jan 19 2 Energy Efficient PA & ID fan Installation in CFBC Boiler 27.6 Feb 19 3 Energy Efficient FD & ID fan Installation in AFBC Boiler 22.3 Feb 19 4 Optimization of CHP running hours 3.6 Oct 18 5 Installation Heat Exchanger at CBD tank 15.5 Nov 18 6 Installation of Energy Efficient fans in ACC 45.5 Oct 18 7 Installation of Energy efficient Boiler feed pump 14.5 Mar 19 69

70 JOURNEY CONTINUES TOWARDS ACHIEVING HEAT RATE 2950 KCAL/KWH AND AUX. POWER 7.5%... Team Sewagram Cement Works 70