The Ramco Cements Limited, Alathiyur Profile

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2 The Ramco Cements Limited, Alathiyur Profile A flagship company of RAMCO Group, having five Cement manufacturing units, four grinding units and one packing unit with the total capacity of 16.5 MTPA. Alathiyur plant was setup in two phases 1997 & 2001 with Cement capacity of 3.05 Million Tons / Annum and 2 X 3700 TPD Kilns. The manufacturing products are Ordinary Portland Cement, Portland Pozzolana Cement and SRPC as per BIS & SLS standards. 2X MW - Coal based Thermal power plant 2

3 Integrated Management System Certification IS/ISO 9001: 2015 Quality Management System IS/ISO 14001: 2015 Environment Management System IS 18001: 2007 Occupational Health & Safety Management System IS/ISO 50001:2011 Energy Management System 5S Excellence Certified Company 3

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6 Energy Monitoring & Reporting System Energy consumption both electrical & thermal : Daily Energy conservation projects : Weekly Review meeting conducted by : Unit Head 6

7 Energy Management System 7

8 Implementing Strategy Selectio n Formati on Coordin ation Responsi bilities Department - Plant Management, Production,Maintenance Quality Control,Accounting Each department Provide one or more Representatives to the Energy Management team Each Energy management Clusters will be headed by Team leader and the whole is monitoring by Energy Manager Define Objectives, Prepare Energy Planning, Optimal Energy Operation, Detect Weakness Plan and Perform Measures/Projects Prepare Energy Performance & Reporting Establish & perform Energy Controlling Review achievements 8

9 Core Committee Team Energy Cell UNIT HEAD WORKS HEAD HOD MINES HOD P & QC HOD MECH ENERGY MANGER HOD E & I HOD CDS & PP HOD TPP INCHARGE MINES & CRUSHER INCHARGE RAW MILL & COAL MILL INCHARGE PYRO INCHARGE CEM MILL INCHARGE PACKING INCHARGE TPP INCHARGE UTILITIES 9

10 Responsibilities of Steering Committee False air study in all major sections i.e., Kiln, Raw Mill, Coal Mill and Cement Mill on monthly basis. Monitor production performance vis-à-vis SEC. Monitor fan performance and initiative corrective action required, if any, on monthly basis. Identify/Evolve new ENCON projects with and without investment. Encourage employee participation through effective implementation of Suggestion Box Scheme, 5S & Quality Circle. IMS EnMS Management Review Meetings, EMAP will be reviewed. 10

11 Energy Performance Improvement Sl. No Description Units MTOE reduction MTOE Kiln Thermal SEC kcal/kg clinker Specific Electrical Energy - clinkering kwh/t of clinker Specific Electrical Energy Grinding kwh/t of cement CPP Heat rate kcal/kwh CPP auxiliary consumption % Thermal Substitution Rate % Clinker factor % Blended cement *%) of total cement % Specific CO2 emission Kg CO2/ kg cement

12 Energy Conservation Projects Implemented in the years No. of Projects : 6 Projects with NIL investment Total amount invested Cost savings achieved Electrical energy saved Thermal Energy saved : 5 Nos. : Rs. 149 Lacs : Rs. 233 Lacs : 52.5 Lac Kwh : 350 MT of coal Reduction in GHG emissions : 5305 MT of CO 2 12

13 Energy Conservation Project Sl. No. Title of Project Annual Electrical Saving (kwh) Annual Electrical Cost Saving (Rs million) Annual Thermal Saving (Ton/ye ar) Annual Thermal Saving (Rs million) Total Annual Savings (Rs million) Investment Made (Rs million) Payback (Month s) 1 Modification of Line-1 Coal mill main bag filter purging from low pressure to high pressure 792, Retrofitting of Line-1 Cement Mill fan 3,896, Removal of damper in Line-1 RABH fan 216, Installation of Pillard burner in Line-1 Kiln Installation of VRF AC System in Rawmill-2 IO Room 275, Replacement of 70W / 250W SON light fittings by energy efficient 36W / 100W LED 68, fittings 13

14 Gate to Gate Energy Consumption for PAT Cycle-I Kcal/ Kg of Cement 19th National Award for Excellence In Energy Management BEE-PAT Scheme : 8946 Nos. of Energy saving certificates issued Target Achieved 768

15 Gate to Gate Energy Consumption for PAT Cycle-II Kcal/ Kg of Cement Baseline Target

16 Road Map To Achieve Benchmark 16

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18 Innovative Project -1 In our Alathiyur plant we have 2 nos. of Vertical Roller Mill for Clinker grinding. Line-1 mill FLS make OK 33.4 capacity of 160 TPH for PPC and Line-2 mill LOESCHE make LM 56.2 capacity of 260 TPH for PPC. Line-1 Cement mill is consuming about 4kWh/MT higher than Line-2 Cement mill, due to this we are operating Line-1 Cement mill very less. We have identified the difference is in the specific power consumption of fan. 18

19 Innovative Project -1 Fan Power consumption high: We have identified the reasons for low fan efficiency and done stage wise modifications like: Increasing the fan inlet duct dia from 2 m to 2.8 m Modification of fan outlet to chimney duct Modification of bag filter outlet duct by conducting CFD Modification of fan inlet suction box. 19

20 Innovative Project -1 By carrying out above all modifications, the fan inlet turbulence has reduced, but the fan outlet turbulence did not reduce and Reason is due to the recirculation duct tapping immediately after the fan outlet, due to this the fan outlet pressure is varying from -100mmwg to -200mmwg. Action taken to reduce fan power: Replacement of existing low efficiency fan (50% eff.) with high efficiency fan (83% eff). Installation of junction box at the mill fan outlet and rerouting recirculation duct to eliminate turbulence at the fan outlet duct. 20

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22 Modified recirculation duct routing from the junction box 22

23 Innovative Project Savings achieved : 6.6 Kwh/Mt of Cement Productivity Improvement : 15 TPH Cost savings : Rs lacs Investment Cost : Rs. 50 Lacs Simple Pay Back Period : 4 Months

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25 25 Innovative Project -2 Line-1 Coal Mill Main Bag Filter is designed for low pressure high volume purging. During normal operation in Line-1 Coal mill, Bag filter DP is high which causes the frequent disturbances in Mill operation. The disturbances causes reduction in mill output, increase in specific power consumption. Due to this we have even forced to reduce the kiln feed occasionally. We observed that when ever there is mill trip, lot of material is collected from the bag filter to the fine coal bins. We have taken trial with increased purging pressure up to 3.5 bar and increased the on time of purging, but there is no any significant improvement. From the above trials we observed that the bag cleaning (purging) is not adequate.

26 Innovative Project We studied the root cause for inadequate bag cleaning: Line-1 coal mill is designed for Lignite / Coal grinding. During pet coke grinding, the mill output is low and also not able to achieve the desired residue. We have modified the mill internals and classifier to suit pet coke grinding, due to this the mill Dp has increased by mmwg. The bag filter is designed for the inlet draft of -650 mmwg. After the modification of the mill it has increased to -900 to -950 mmwg. Due to increase in the bag filter draft, the low pressure high volume purging is not adequate for cleaning of the bags.

27 Innovative Project We have decided to change the purging from low pressure high volume to high pressure low volume purging. The modification was carried out in-house. We designed and fabricated the purging air headers, purging pipes. We procured the solenoid valves, venturi.

28 Description Before modification Low pressure purging After modification High pressure purging Bag Ø in mm Bag length in mm Bag seating type Snap band Snap band Qty in Nos Venturi Availability No Yes ( Provided ) Purge pipe Ø 80 NB 50 NB Tube sheet to purge pipe height Purge pipe purge hole dia 190 mm 120mm 16mm (Nozzle pipe Ø 36mm) 4.5mm (Nozzle pipe Ø 6.3mm) Operating air pressure 2.5 bar 5.5 bar Compressor air volume 380 CFM 260 CFM Purging Sequence 1,2-3,4-5,6.. 1,33-2,34-3,35. On Time Sec Sec Off Time (Pass Time) 7 Sec 6 Sec 28

29 Innovative Project -2 Before After 29

30 Innovative Project -2 Before After 30

31 Before Bag filter purging modification 31

32 After Bag filter purging modification 32

33 Innovative Project Investment Cost : Rs. 25 Lacs Cost Savings : Rs. 32 Lacs/Year Simple Pay Back Period : 10 Months Electrical energy savings : 5.08 kwh/t matl

34 Best Improvement in Energy performance in Manufacture of Blended Cements from NCCBM 34

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