Salient Futures of Ramasamy Raja Nagar Unit

Transcription

1 P.M.RAMASUBRAMANIAN V.SURESH S.MUTHUKUMAR GM Process & QC AGM - Process Dy.Manager - Mech

2 Salient Futures of Ramasamy Raja Nagar Unit A flagship company of RAMCO Group, having five Cement manufacturing and 4 Grinding units with a capacity of 16.5 MTPA We are the leaders in First to introduce latest technologies like Surface Miner, Vertical roller mill, SF cross bar cooler, Limestone Beneficiation Plant - Optical sorter, Cross Belt Analyser, X-Ray analyser, ESPs etc., Manufacturing 100% Blended Cement Ramco Super Grade Certified as Green Product by CII

3 Integrated Management System Certification IS/ISO 9001: 2008 Quality Management System IS/ISO 14001: 2004 Environment Management System IS 18001: 2007 Occupational Health & Safety Management System IS/ISO 50001: 2011 Energy Management System 5S Workplace Management System 3

4 Kwh / MT Cement Specific Electrical Energy Consumption - Cement

5 Kwh / MT Clinker Specific Electrical Energy Consumption - Clinker

6 Kcal/Kg Clinker Specific Thermal Energy Consumption

7 ENCON Projects with Zero Investment No. of Projects : 23 Savings on Electrical Energy : 39.5 Lakh Kwh Savings on Thermal Energy : 630 MT of Coal Total Cost savings : Rs Lakhs

8 ENCON Projects with Zero Investment Sl.No ENCON Projects Implemented for the year Savings (Rs. in Lakhs) 1 Installation of VFD in Kiln-1 primary firing blower Productivity optimization in Raw mill Productivity optimization in kiln Reduction of idle run hours in fly ash unloading Removal of Damper in Cement mill Bag house fan Replacement of reciprocating compressors in Packing Plant Compressor air usage optimization Removal of Damper in Raw mill-1 Separator fan Removal of Damper in Raw mill-1 Hot gas fan 1.0

9 Sl.No 1 2 ENCON Projects Implemented for the year Reduction of False air and Elimination of Top Cyclone Water spray in Kiln-1 Preheater fan Improvement of excavator productivity and reduction of fuel consumption by reducing the marching time Savings (Rs. in Lakhs) 3 Reduction of False air in Kiln-2 Preheater from 11 % to 8.5 % Removal of Damper in Roller press bag house fan ENCON Projects with Zero Investment Replacement of de-dusting ducts in Kiln Tunnel venting bag filter Elimination of DG operation in SVP-North mines and switch over to electrical supply by upgrading the existing transformer Elimination of unnecessary pipeline in the pump delivery to reduce the line losses

10 Sl.No 1 ENCON Projects with Zero Investment ENCON Projects Implemented for the year Raw mill productivity improvement by increasing raw meal residue on 90mic from 13 to 15% Savings (Rs. in Lakhs) DG power plant auxiliary system idle power consumption reduction by optimization of heaters Elimination of 6.6kV/3.3kV transformer to reduce transmission loss 4 De-dusting bag filter optimization in Mines Air slide blower optimization in Kiln N2 plant optimization to reduce its run hour, by installing Solenoid valve at Tank discharge External clinker unloading bag filter compressor air purging optimization

11 Return on Investment Projects No. of Projects : 18 Total Cost Investment : 310 Lakhs Savings on Electrical Energy : 27.2 Lakh Kwh Savings on Thermal Energy : 720 MT of Coal Total Cost savings : Rs Lakhs

12 ENCON Projects with Investment Sl.No ENCON project implemented for the year Savings (Rs. in Lakhs) Investment made (Rs. in Lakhs) 1 Installation of VFD in Kiln-1 bag house fan Installation of VFD in Kiln-2 ESP fan Elimination of Elevator in raw mill limestone feeding circuit Installation of new dilution damper in Kiln-1 bag house LED lights replaced in place of Sodium vapour & fluorescent lamps

13 ENCON Projects with Investment Sl.No ENCON Project Implemented for the year Savings (Rs. in Lakhs) Investment made (Rs. in Lakhs) 1 Installation of gas analyser in Kiln-2 inlet Compressor stopped in Kiln bag filter by inter linking Installation of VFD in Raw mill-1 Vent fan Installation of VFD in Primary Air fan of Thermal Power Plant Installation of VFD in Kiln-2 Primary air fan Transmission Loss reduced in Mines power line A/C unit system Replaced with Split A/C

14 ENCON Projects with Investment Sl.No ENCON Project Implemented for the year Savings (Rs. in Lakhs) Investment made (Rs. in Lakhs) 1 Installation of VFD for feed water pump Installation of high efficiency Pillard burner in Kiln-2 Interlinking of Kiln-1&2 CCTV compressors after changing the pipe size Factory lighting optimization by replacing LED lights in place of conventional lights Primary air fan outlet duct modification to reduce pressure loss Package AC cooling tower replaced with individual split AC in accounts department

15 GLOBAL NORMS - SHC & SEC INTERNATIONAL BENCHMARK SHC-670 Kcal/Kg Clinker SEC-65 Kwh/T Cement NATIONAL BENCHMARK SHC-709 Kcal/Kg Clinker SEC-66 Kwh/T Cement THE RAMCO CEMENTS LIMITED, RR NAGAR SHC-699 Kcal/Kg Clinker SEC Kwh/T Cement Reference : CII Energy benchmarking for Cement Industry May 2015 Version 2.0

16 ENCON Projects Proposed Sl.No ENCON Projects Planned for the year Installation of SPRS for Kiln-2 preheater fan in place of GRR Replacement of efficient shell cooling fan (8 nos.) in Kiln-1 Installation of VFD for Fly ash unloading bag filter since most of the time one bay only in use Low pressure compressor installation for Kiln bag filter to avoid losses in regulator Installation of VFD for cement mill higher capacity (>450 CFM,75Kw) compressor Installation Dp transmitter for all the unit bag filters their by saving power in compressor Expected Electrical Saving (Kwh/Year) Expected Thermal Saving (MT/Year) 3,37,920-2,23,560-1,65,600-1,24,200-93,600-84,500 -

17 Sl.No 7 ENCON Projects Planned for the year Kiln feed extraction to Pre-heater top air slide blower capacity to be reduced Expected Electrical Saving (Kwh/Year) Expected Thermal Saving (MT/Year) 72,864-8 Installation of VFD for Coal mill-1 Bag Filter fan 66, ENCON Projects Proposed Installation of VFD for Kiln-1 Secondary firing blower as same done for Primary firing Unit bag filter in fine coal bin-2 to be stopped by changing the common venting line Installation of VFD for CM Ball mill-2 Bag Filter fan 49, ,540-43, Installation of VFD for Coal mill-1 Booster fan 39, Fuzzy Logic System for Kiln-1 to reduce fuel consumption by improving kiln steady operation - 686

18 Waste Heat Recovery system installation work under progress Planned to utilise waste heat from Kiln-1&2 Preheater and cooler exit. Total power generation is 4 MW/Hr After commissioning WHR, existing TPP load steam generation will be reduced. Expected coal saving Project Cost Payback Period : 8,400 MT/annum : Rs.24 Cr : 5 years

19 Kcal/Kg Cement BEE PAT Scheme PAT Target

20 Innovative Project - 1 : Modification of Kiln-1 bag house

21 Constraints in present operation Bag house differential pressure maintained mmwg Compressed air pressure maintained 4.0 to 4.5 bar Bags damage and less life due to clustering of bags The bag house inlet temperature is high due to pressurization Not able to increase the preheater fan speed further The compressor is running always in loading condition Above condition resulted increase in bag house fan & compressor power consumption Dust emission mg/nm3

22 Development of New in-house solution Newly designed & In-house fabricated Grid system installed at bag filter bottom portion to hold each bags. Before After

23 Development of New solution Compressed air purging pipes replaced with new design Before After Insertion & U clamp fixing of purge pipe Flange type fixing of purge pipes

24 Development of New solution Height between purging pipe and tube sheet has been reduced Before After 350mm 245mm

25 Performance Improvement & Benefits achieved The Bag filter Dp is reduced by 40 mmwg with reduced compressed air pressure of 3.5 to 4.0 bar Power saving in Bag filter fan & Compressor is 25 Kw/hr Dust emission level reduced from 40 to 8 mg/nm3 Kiln performance has improved by increasing preheater fan flow rate Bags life increased due to reduction in purging air pressure & avoiding clustering of bags

26 Innovative Project - 2 : Auto Sampler for Clinker Sampling

27 Constraints in present operation Manual Spot sampling shows only the instantaneous clinker quality Taking corrective action based on the spot sampling gives wrong result some time In manual sampling, person to person the sampling techniques are changing Man hour utilisation is high due to sampling and sieving Dust emission during sieving

28 Development of In-House Solution In-house made auto sampler has been installed at clinker crusher outlet DPC It collects the average sample for every 10 minutes. Its provide litre weight sample and raw clinker separately This sampler connected with CCR PLC We can adjust the sample collection period and quantity as required

29 Working of Auto Sampler Cooler Outlet Clinker collection tray DPC Guide pulley Drive pulley Clinker Silo

30 Working of Auto Sampler Pneumatic cylinder Vibrating screen 6mm to 12 mm material Sample for Litre weight analysis >12 mm material < 6 mm material To DPC Sample for Elemental analysis Drive system

31 Benefits achieved Clinker sampling is more representative from hourly spot sample to once in 10 minutes average sample collection. Consistency in quality improved due to more representative sampling. Frequency of operating parameters changing has reduced. Specific fuel consumption reduced by 1.6 Kcal/Kg Clinker Coal Saving 248 MT/annum

32 kg CO2e/MT of cement Road Map to Reduce Carbon Foot Print Activities Year Scope 1 Emissions CO 2 e (MT) Scope 2 Emissions CO 2 e (MT) Scope 3 Emissions CO 2 e (MT) kg CO2e/MT of cement Baseline 9,55,158 1,21,410 35, ,67,956 3,78,350 44, ,47,927 2,24,008 50, ,98,303 1,42,932 55, We have reduced 18.0 % Carbon Emissions compared with baseline year. Further to reduce carbon emissions we have planned the following Projects: 1. Installation of stacker & Reclaimer for Limestone and Fuel 2. Installation of VFD for Kiln-1 Secondary firing blower 3. Fuzzy Logic System for Kiln-1 CO 2 Reduction Baseline

33 Encon Efforts Sl.No Source of ENCON IDEA Idea originated Details of members involved Progress of implementation 1 Engineer Kiln-1 Process & Mechanical Team 2 Workmen Workmen Packer Mechanical & Instrumentation team Kiln Mechanical & Instrumentation team Completed Completed Completed 4 Middle Management Kiln-1 Process & Mechanical Team Completed

34 Project - 1 : Prevention of Coal mill inlet jam In Kiln 1 Coal mill, we frequently noticed coal accumulation in the inlet chute. Due to this accumulation the productivity of the mill was poor and there was occasional firing of the accumulated coal. Engineer suggested the idea to modify the inlet feed chute by providing a guide plate to uniformly feed coal to the mill without accumulation. Implementation of that idea resulted in the reduction of coal mill run hours from 15:30 Hours to 15:00 hours a day. Power Saving Cost Saving : Units/annum : Rs Lakhs/annum

35 Project - 2: Cement Bag Weight optimization We are operating two 12-spout packer supplied by M/s. FLSmidth with Ventomatic electronics. Due to frequent additional dosing the productivity of the packer was low. Instrumentation & Mechanical workmen together gave an idea to provide an additional dosing valve so that the slide gate cylinder opening is controlled during fine feed. Implementation of that idea resulted in increased productivity by 5%. Power Saving Cost Saving : 1.2 Lakh units/annum : Rs Lakhs/annum

36 Project - 3: N 2 Gas plant Compressor Optimization N 2 used as a inert gas for purging in coal grinding and firing section bins and bag filters The valve for purging is located nearer to the bag filter thus 40 meter away from the N 2 storage tank N 2 gas generation compressor is running daily while reducing the N 2 storage tank pressure due to leakage Kiln fitter suggested to relocate the valve nearer to N 2 tank outlet for avoid leakage from pipe line. Power Saving Cost Saving : 16,900 units/annum : Rs. 67,600/annum

37 Project - 4: Primary air fan outlet duct modification In Kiln-1, the pressure drop across the Primary air fan outlet to burner is found 90 mmwg High pressure drop within short distance consumed more power and high primary air percentage One of the manager studied and recommended to reduce the duct bend from 90 to 30⁰ Implementation of this idea resulted in saving of power and fuel Power Saving Fuel Saving Cost Saving : 38,400 units/annum : 83 MT of Coal/annum : Rs. 7.3 Lakhs/annum

38 Renewable Energy Replacement of Electrical Energy with Renewable Energy Wind mill (Group) Annual Energy Generated (Lakhs kwh) % Share Annual Energy Generated (Lakhs kwh) % Share Annual Energy Generated (Lakhs kwh) % Share During 1996 wind mill installed with capacity of MW, Present Capacity is 160 MW Replacement of Thermal Energy with Renewable Energy Biogas (Canteen) Equivalent Fuel Saving (Lakhs Kcal) % Share Equivalent Fuel Saving (Lakhs Kcal) % Share Equivalent Fuel Saving (Lakhs Kcal) % Share

39 Utilization of Waste as Fuel Name of the Fuel Quantity (MT) Waste fuel as % of Energy used Quantity (MT) Waste fuel as % of Energy used Quantity (MT) Waste fuel as % of Energy used TPP Coal Ash Saw Dust Wood Chips

40 Implementation Of Energy Front Amongst Associates Sl. No Name Of Associate / Vendor M/s. Vignesh Traders M/s. Ammaiyaper Transports M/s. CIBI Transports Name Of Service Provided To Vendor O&M contract for Fly ash Handling plant Transportation of TPP ash Transportation of Wet ash Per Unit Energy Consumed Prior To Implementing ENCON Lakhs Kwh/Year 700 Ltrs/ year 239 Ltrs/ year Per Unit Energy Consumed After Implementation Of ENCON 9.72 Lakhs Kwh/Year 540 Ltrs/ Year 80 Ltrs/ year % Improvement 25% 23% 67 % Type Of Inputs / Projects Provided To Vendor/ Associate Compressor replaced with Higher efficiency compressor New Concrete road provided via shortest route Material stock kept nearer to the weigh bridge

41 Implementation of Corrective/Preventive Actions Problem Root Cause Corrective Action Preventive Action Cooler Crusher tripping frequently due to overload Fine clinker rushing from cooler Clinker bed thickness reduced Additional air blaster installed in cooler to avoid accumulation Fugitive dust emission in Coal handling area Fine powder flying from belt conveyor discharge chutes Water Spray done in raw coal unloading hopper De-dusting duct connected in discharge chutes

42 Environmental Projects Sl. No 1 2 List of the Major Environmental Projects Surveillance camera is located at all the hopper discharge and transfer points to monitor and avoid any spillage External Clinker Unloading hopper and Packer-2 de-dusting bag filter capacity increased from to m3/hr Investment (Rs. Lakhs) Nos. of de-dusting bag filters installed in the plant Nos. of unit bag filters installed in Coal handling area and coal mill Nos. of de-dusting bag filters installed in Crusher area Kiln-1 main bag filter modified and the dust emission reduced to less than 10 mg/nm3 Gas analyzer is installed at the kiln-2 inlet, to monitor the kiln condition and thereby improve the combustion, and to predict the quality of clinker

43 Environmental Projects Sl. No 8 9 List of the Major Environmental Projects 16 Nos. of Solar lights in place of 16 Nos. of Sodium vapour lights in Colony Re routing of de-dusting ducts in Roller press to avoid the fugitive dust generation Investment (Rs. Lakhs) Change over from box vehicle to bulkers for dry fly ash handling Nos. of LED lights in place of Fluorescence tube light in material store Modification of crusher and its screen discharge chutes to avoid material spillage and dust emission Installation of water spray system at belt discharge in mines to avoid dust emission

44 Future Environmental Projects Sl.No 1 List of the Future Environmental Projects 5 Nos. of additional Dust Collectors for transfer points at plant Investment (Rs. Lakhs) Nos. of Dust Collectors for transfer points at mines crushing plant Stacker & Reclaimer with closed shed for Coal Stacker & Reclaimer with closed shed for Limestone Nos. LED lights in place of Conventional lights 6.0 Total Project Cost: Rs. 399 Lakhs

45 Green Belt Development Sl. No Location Area in Acres Up to 2017 No. of Trees Area in Acres No. of Trees 1 Mines 45 12, ,65,700 2 Factory ,750 3 Colony ,060 4 School ,000 5 Nearby Villages ,060 Grand total 55 18, ,25,570