National Award for Excellence in Energy Management Plant Name: Thondebhavi

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1 National Award for Excellence in Energy Management 2018 Plant Name: Thondebhavi LafargeHolcim Ltd 2015

2 Company Profile 1 Set up as a Green Field Project in Lush Green Village of Thondebhavi 2 Installed Capacity 2 Million MT (OPC/PPC) 3 Grinding System with VRM (Make : Loesche) Capacity 250 TPH (PPC) Product Portfolio 6% 4 ISO 14001: 2015 and ISO 50001:2011 Certified 42% 5 Lowest SEEC across ACC/ACL 53% OPC PPC C+ 2

3 Plant Process Layout - TCW Fly Ash Bulker Unloading Fly ash storage silo 1X3500 t Gypsum Gantry 15000t Reclaimer (120TPH) Fly ash feeding silo 1X 500 t Gypsum Hopper (300T) Gypsum Cr Building Gypsum Crusher (150TPH) RMH Building Clinker Hopper (500T) Wagon Tippler Clinker silo t Packing Plant Truck Loading & Bulk Loading Cement silos 2x 10000t 1x1000t PPC OPC Mill Bag House & Fan (3300KW fan motor) Mill Building WF Vertical Roller Mill LM (250 TPH PPC) Installed Motor capacity 5400 KW 3

4 1. Specific Electrical Energy Consumption SEEC (kwh/t Cement) Auxiliaries Mill Section YTD July'18 Aspiration

5 1. Specific Electrical Energy Consumption Product wise OPC PPC YTD July' YTD July'18 Mill Section Auxiliaries

6 2. Internal Benchmark SEEC (kwh/t Cem) YTD 2018 SEEC (kwh/t Cem) THONDEBHAVI THONDEBHAVI Plant Plant Plant Plant Plant Plant Plant Plant Plant Plant Plant Plant Plant Plant Plant Plant Plant Plant Plant Plant Plant Plant Plant Plant Plant Plant Plant Plant Plant Plant Plant Plant Lowest Specific Electrical Energy Consumption across ACC/ACL

7 2a Road Map to achieve National Benchmark S N o Projects Energy savings (kwh/t of cement) Timeline 1 Usage of Grinding additive 1.0 Sept 18 YTD July'18 Grinding additive Removal of Venturi at Bag house fan inlet duct to reduce pressure drop 0.3 Dec 18 3 Installation of high efficient screw compressor for Flyash unloading to 0.3 Dec 18 improve unloading rate 4 Re orientation of Armour ring angle from 25 Deg to 15 Deg 0.35 Dec 18 5 Replacement of Mill feed rotary feeder 0.20 Sept 18 Venturi removal High Eff. Screw Compressor Armour angle to 15Deg Mill Rotary feeder replacement Strengthening of Flyash pumping system for improving pumping 120 TPH 0.25 Sept 18 7 Installation of 7.5 KW compressor for instrument air at Big Flyash Silo 0.20 Oct 18 8 Grit cone segment replacement and feed chute repair job 0.20 Dec 18 Total 2.80 Flyash 120 TPH Instrument compressor at FA Silo Grit cone replacement Mission

8 3a. Energy saving projects implemented in FY No Title of Project Annual Electrical Saving (kwh) Annual Electrical Cost Saving (Rs million) Total Annual Savings (Rs million) Investment Made (Rs million) Payback (Months) 1 Optimisation of Flyash pumping circuit VFD for cement Silo Bag filter Fan False air arresting VRM Roller seals Plant lighting section wise through DCS Total

9 3b. Energy saving projects implemented in FY No Title of Project Installation of 7.5 KW compressor for Flyash unloading in place of 132 KW False air arresting across mill and bag house circuit Replacement of Rotary feeder with hard faced liners Provision of reverse interlock to reduce idle running in critical belts Annual Electrical Saving (kwh) Annual Electrical Cost Saving (Rs million) Total Annual Savings (Rs million) Investment Made (Rs million) Payback (Months) Total

10 3c. Energy saving projects implemented in FY No Title of Project Installation of mesh at mill inlet ducts to avoid material accumulation and pressure drop Modified Water Spray Nozzles with compressed air for uniform distribution of water Build up of Support ring Height from 40mm to 65 mm and Width from 35 mm to 55mm. Removal of stump cone and extension of grit cone chute by 400mm to reduce main drive load Annual Electrical Saving (kwh) Annual Electrical Cost Saving (Rs million) Total Annual Savings (Rs million) Investment Made (Rs million) Payback (Months)

11 3c. Energy saving projects implemented in FY No Title of Project Optimisation of counter and Working pressure for smooth operation of mill Optimisation of compressed air by arresting leakages Installation of LED lights in place of HPSV lights Installation of 3rd flyash unloading line to improve flyash unloading rate Improvement in Mill MTBF from 180 hrs to 250 hrs by inhouse designed SMART app. Reduction of average Rake unloading time from 7 hrs to 5 hrs Annual Electrical Saving (kwh) Annual Electrical Cost Saving (Rs million) Total Annual Savings (Rs million) Investment Made (Rs million) Payback (Months) Total

12 Innovative Projects Implemented Removal of stump cone and extension of grit cone chute and maintained 600mm height from table. Build up of Support ring Height from 40mm to 65 mm and Width from 35 mm to 55mm. Modified Water Spray Nozzles with compressed air for uniform distribution of water Optimisation of counter and working pressure for smooth operation of mill Installation of mesh at mill inlet ducts to avoid material accumulation and pressure drop Increase in BA pressure from 40 to 45 bar and reduce PA pressure from 10 to 8 bar Installation of Flyash unloading line No.3 using existing compressor 12

13 4. Implemented Innovations 1. Table Support Ring Build up from 40 X 35 mm to 65 X 55 mm 55 mm 65mm Action taken: Build up of Support ring Height from 40mm to 65 mm and Width from 35 mm to 55mm. Distance between Roller tyre back face and support ring reduced from 30mm to 15mm when rollers rest on buffer Benefits realised: Consistent bed height above 65 mm as against previous level of 50mm, resulted in increase grinding efficiency. Increase in throughput of mill from 280 TPH to 295 TPH in PPC. Savings ~ 0.25 kwh/t Cem 13

14 14 4. Implemented Innovations 2. Removal of Stump cone from table Before Grit Cone Chute After Stump Cone Action taken: Removal of stump cone and extension of grit cone chute by 400 mm. Distance from Table to reject chute reduced from 700mm to 600mm for uniform distribution of material Benefits realised: Reduction in Main drive load Savings - ~ 0.15 kwh/t) Uniform distribution of material across grinding path. Better mill stability

15 4. Implemented Innovations 3. Installation of 60 deg and Armour 25deg Armour Ring : 10 Deg Nozzle ring Angle : 80 Deg Armour Ring : 25 Deg Nozzle ring Angle : 60 Deg Action taken: Reinstallation of Louver ring with the angle of 60 deg and armour ring angle to 25 deg Maintaining louver ring area of 3.97 m2 by blocking 2 louvers behind each roller (Total 12 Nos) Benefits realised: Reduction of mill fan power consumption by ~270 KW Impact ~ 1.0 kwh/t Cem

16 16 4. Implemented Innovations 4. Modification of Table Water Spray Nozzles Before After Water Spray Nozzle with single pipe at height of 100mm from Dam ring Modified Water Spray Nozzles with compressed air for uniform distribution of water Height above Dam ring 50 mm Distance from Inner Dam ring 100 mm Distance from Roller 50 mm Angle towards Roller 35 Deg *Better distribution of water resulted in uniform bed there by reduction in vibrations to the level of 5 mm/s from previous 6 to 7mm/s. *Water requirement reduced from 4.5M3/hr to 3 M3/hr

17 4. Implemented Innovations 5. Installation of mesh in inlet duct to reduce pressure drop by 4 mbar at mill inlet Action taken: To Reduce pressure drop at inlet duct due to material accumulation, mesh of 2 size installed at inlet ducts to avoid accumulation Benefits realised: Reduction of material accumulation at inlet duct, resulting in reduction of mill inlet draft from -50 mm WC to -20 mm WC Reduction of Bag house power consumption by 0.3 kwh/t Cem 17

18 4. Implemented Innovations 6. Installation of Fly-ash Unloading line No 3 in 500 MT Silo Improvement in unloading rate from 50 TPH to 80 TPH. Minimizing pumping and Unloading of Fly-ash from Big Silo, reduction in SEEC Minimizing stoppage of mill on account of Fly-ash silo level. Utilization of Mill operation person dedicatedly for Mill Line No 1 Line No 2 Line No 3 Improvement in unloading rate from 50 TPH to 80 TPH. Minimizing pumping and Unloading of Fly-ash from Big Silo, reduction in SEEC Minimizing stoppage of mill on account of Fly-ash silo level. Utilization of Mill operation person dedicatedly for Mill Before After 18

19 4. Implemented Innovations 7. Optimisation of mill by operating counter pressure from 23 Bar to below 18 Bar Action taken: Operating the mill counter pressure below 18 bar. Reduction of piston accumulator N2 pressure from 10 bar to 8 bar and increased bladder accumulator pressure from 40 bar to 45 bar. Working pressure Min set point fixed at 65 bar. Counter Pressure Min set point fixed at 12 bar. Maintaining Net Grinding pressure at 50 bar Benefits realised: Reduction in mill vibrations from 7 mm/s to 5 mm/s Reduction in mill reject load from 30 to 34 amps from 24 to 27 amps. Reduction in main drive power and Baghouse power 19

20 4. Implemented Innovations Installation of compressor of 7.5 KW for Flyash unloading during Mill Stoppage, Eliminating running of 110 KW compressor Provision of Lighting ON/OFF through DCS in timer mode 20

21 4. Implemented Innovations - SMART App To strengthen the quality of WBI (walk by inspection) and develop full proof system to eliminate the human errors. To improve the health of equipment by immediate reporting and action executed. To minimize time for actual WBI and report generation. 21

22 4. Implemented Innovations SMART App Equip scan WAN QR CODE ON EQUIPMENT INPUT BY WBI INSPECTOR DATABASE SERVER WAN TIMELY EXECUTION SMS ALERT ALERT

23 4. Implemented Innovations - SMART App Entering the Observations with photographs, readings along with Risk level in the app 23

24 4. Implemented Innovations - SMART App Reports will be generated automatically at mentioned time slot and will be sent to concerned team. If high priority alarms persists, notification will be triggered to concerned person as message/mail. 24

25 5. Green Power Sourcing Renewable Energy 7% 5% 24% 42% 45% 93% 71% 22% 20% 36% 35% YTD July' Solar Purchase BESCOM I Ex Solar power in used extensively for cement manufacturing at Thondebhavi To use about 15 MW of solar power to meet over half of annual power requirement - ~23 MU of solar power Switching to solar power will reduce CO2 emissions by 19,000 tonnes every year Eqv. to 22.5 trees every year or a saving of 45 million litres of water 25

26 6. TEAM and Review Mechanism Weekly Performance review along with steering committee chaired by Director Plant TEAM Sourabh Modi Team Leader Mr. H.S Rathore Director Plant ACC Thondebhavi Swaroop G (Process) AK Tripathy (E&I) Saravanan (Mech) Team Members (MS) Vikram, Arvind Karthik Lakshmi Velu, Chandru Naveen, Paramesh, Rajasekhar Patrollers, SFAs Deepak, Anil, Mumtaj, Ganga, Rajesh Murthy Vikram, Guruchaan Business Partners Formation of Cross functional team including contract workmen Continuous monitoring of Specific Electrical Energy Consumption (SEEC) through EMS Hourly reporting of SEEC through Whatsapp Weekly performance review with Director Plant and deriving and implementation of action plan 26

27 6.TEAM and Review Mechanism Identification and Rectification of leakages through Walk by inspections and shared in Whatsapp. Immediate action by shift engineer to rectify. Discussion with operation team to optimise mill further Rewarding the best performers in the shift operation

28 6.TEAM and Review Mechanism Innovation Lab Developed an Innovation Lab set up in Plant Brainstorming and Ideation sessions conducted on regularly Motivational and Positive Environment for Ideation session Implementation of Innovate Ideas and Reward Program in Place

29 7. ISO 50001:2011 Certified, GreenCo Rating Greenco Silver Rating in Dec 2012 Participating for Recertification on

30 8. Awards & Accolades Innovative Project Award National Energy Management Award 2013 Energy Efficient Unit National Energy Management Award 2013 Energy Efficient Unit National Energy Management Award

31 8. Awards & Accolades CII ITC Sustainability Awards National Energy Conservation Award BEE 2012 Golden Peacock National Quality Award Winner

32 8. Awards & Accolades Awards for Lowest Ever Specific Power consumption across ACC Award for Consistent Performing Plant for the period of 3 years in SEEC 32

33 Plantation Plantation in Plant Plantation at Railway Station Plantation at Community School 2000 Nos saplings ( 400 Nos Fruits Saplings) Plantation inside plant and near by communities 33

34 Greenbelt Development BEFORE AFTER BIRD S EYE VIEW

35 Greenbelt Development

36 Greenbelt Development Fruits Trees inside Plant Herbal Garden 36

37 Bio Diversity We facilitated Bio diversity at our Plant premises to encourage Birds by providing Welcome Rest Shelter, Bird feeders and Drinking Water

38 Techport-Cement Industrial India 38