Installed Capacity (Clinker) Installed Capacity (Cement) Captive Power Plant (CPP)

Transcription

1 Installed Capacity (Clinker) Installed Capacity (Cement) Captive Power Plant (CPP) Product Type - 2 MTPA 3 MTPA 27MW OPC, PPC 1 Building Culture Nurturing Talent

2 Major Process Equipment Specifications Building Culture Nurturing Talent 2 Equipment Supplier Rated Operating Beyond Capacity Crusher MMD 900 TPH 800 TPH -11% Raw mill Pfeiffer 400 TPH 450 TPH 13% Pyro-5Stage Preheater FLsmidth 4500 TPD 6500 TPD 44% Coal Mill Pfeiffer 40TPH-HG, 25-Pet-coke 24 TPH -4% Cement mill Pfeiffer 300TPH 350 TPH 17%

3 1. Specific Energy Consumption in last 3 years National Best Building Culture Nurturing Talent 3

4 1. Specific Energy Consumption in last 3 years Building Culture Nurturing Talent National Best

5 1. Specific Energy Consumption in last 3 years Due to high volume model National Best Building Culture Nurturing Talent 5

6 1. Specific Energy Consumption in last 3 years Building Culture Nurturing Talent 6

7 1. Specific Energy Consumption in last 3 years Building Culture Nurturing Talent 7

8 2. Information on Competitors, National & Global benchmark Building Culture Nurturing Talent 8 Parameters Comparison of specific energy consumption (SEC) ENERGYBENCHMARKING Electrical SEC (kwh / T of Cement ) Thermal SEC (kcal / kg of Clinker) SEC : Dalmia Cement Ariyalur Plant SEC Values for Competitor - 1 : (Ultra Tech) SEC Values for Competitor - 2 : (Ramco) SEC Values for Competitor - 3 : ( Chettinad) National Benchmark for SEC : International Benchmark for SEC : SEC Target for FY Year : Please mention the sources / references for the furnished data (National & International Data) rnational Benchmark) national Benchmark)

9 Road Map To Achieve Benchmark/National/Global Best Building Culture Nurturing Talent 9 Action plan for Reduction of Upto Clinkerization Power from 48.5 to 45.5 kwh/mt S. No Energy Conservation Projects Expected Saving Kwh/ Mt of clinker Target 1 New Impact Crusher (Tertiary) to reduce power consumption 0.10 Jun'19 2 Separate Crusher for Additives to improve the productivity 0.11 Mar'19 3 Up gradation of Raw mill Classifier to increase mill productivity by 3-5% 0.30 Jan'19 4 Up-gradation of Raw Mill Fan to increase the efficiency 0.21 Mar'19 5 Up-gradation of Preheater Fan to increase efficiency from 77 to 83% 0.52 Nov'18 6 Reduction of False Air from 5.6 to <4% 0.09 Mar'19 7 Up-gradation of Top Cyclones to reduce the pressure drop from 130 to <100 mmwg as well as to reduce the power consumption 0.38 Jun'19

10 Road Map To Achieve Benchmark/National/Global Best Action plan for Reduction of Specific Heat Consumption S.No Thermal Energy Conservation Projects Expected Saving Kcal/kg clinker Target 9 Cooler CIS to ABC inlet to increase the Cooler efficiency by 2% 5-6 May'19 10 Cooler 4th compartment bifurcation to increase the Cooler efficiency by 1% 3 Dec'18 11 Extending PC height to increase the calcination 3-5 Jun'19 12 Up-gradation of Cooler to achieve Cooler efficiency 70% 8-10 Jun'19 13 Reduction of False Air from 5.6 to <4% 1 Oct'18 Action plan for Reduction of Grinding Power S.No Energy Conservation Projects Expected Saving KW/Mt of cement Target 14 Up-gradation of Mill Fan to increase from 77 to 82 % 0.26 Mar'19 15 Cement Mill Productivity increase by 3% by modification of Classifier Annular Gap 0.22 Oct'18 16 Cement Mill Productivity increase by 2% by up-gradation of Classifier 0.12 Mar'19 17 Cement Mill Productivity increase by 1% by up-gradation of Booster Fan 0.05 Jun'19 10 Building Culture Nurturing Talent

11 Building Culture Nurturing Talent 11 3a. Energy Saving projects implemented in FY S. No. Title of Project Total Annual Savings (Rs million) Investment Made (Rs million) Payback (Months) 1 Reduction of Crusher Sp. Power Consumption by avoiding Primary crusher tripping RVRM Grit Cone Modification RVRM HAG Root Blower Installation instead of Compressor Air HAG Coal Blower VFD Installation RVRM False Air Reduction from 11.2 to 8.3% Silo Feed Elevator Discharge chute & VFD installation In-House Modification of Raw Mill Hot gas inlet duct Sp. Heat Consumption reduction Compressor Power Reduction Coal Mill Sp. Power Reduction by output increased CVRM Sp. Power Reduction in OPC grinding Total Saving

12 Building Culture Nurturing Talent 12 3a. Energy Saving projects implemented in FY In-House Modification of RVRM Hot Gas Inlet Duct Higher Pressure drop across the Mill inlet duct Team decided to increase the mill inlet duct area to reduce the pressure drop in the circuit. Mill inlet duct area was increased from 6 m 2 to 18 m 2. Pressure drop got reduced by 70 mmwg RVRM Specific Power consumption reduced by 0.3 kwh/mt Cost Saving -26 Lakhs/annum

13 Building Culture Nurturing Talent 13 3a. Energy Saving projects implemented in FY Modification of Silo Feed Elevator discharge chute and VFD installation Silo Feed Elevator current high, due to material recirculation because of vacuum created in top portion around -500mmwg To reduce the material recirculation as well as current Silo feed elevator discharge chute was modified and Vacuum pressure came down from 500 to 90mmwg simultaneously reduced the material recirculation. Silo feed elevator motor changed from DOL to VFD. Benefits: Supported for Mill TPH Improvement from 375 to 450 TPH Specific Power got reduced from 0.2Kwh/Ton Cost Saving 19 Lakhs/annum

14 3b. Energy Saving projects implemented in FY S. No. Title of Project Total Annual Savings (Rs million) Investment Made (Rs million) Payback (Months) 1 Innovative Reverse start sequence for Lime stone Crusher Transport Group Raw Mill Classifier Annular Gap Reduction Raw Mill Fan Cone Up-gradation Raw Mill Cyclone Rotary air lock stopped RVRM False Air Reduction from 8.6 to 7.6% Reclaimer Output increased from 450 to 550 TPH Reduction of Coal Mill False Air Coal Mill Rotary Air Lock reverse logic provided Cooler MFR modification Kiln Riser Duct Modification Reduction of False Air in Preheater from 5.7 to 4.7 % Kiln Coal pumping line changed from 250 to 200 mm Reduction of False Air in Cement Mill from 14 to 11% Total Saving Building Culture Nurturing Talent 14

15 3b. Energy Saving projects implemented in FY Reduction of Idle Running Hours in Crusher Cost Saving 3.6 Lakhs/annum Building Culture Nurturing Talent 15

16 Building Culture Nurturing Talent 16 3b. Energy Saving projects implemented in FY Modification Of Kiln Riser Duct By In-house Design Kiln Riser Duct area was increased from 4.58 to 5.7m2 Kiln riser Duct Velocity reduced from 32 to 26 m/sec Area -4.58M2 Velocity 32m/s Area 5.7 m2 Velocity 26 m/s kiln inlet O2 was increased by 1.0 % Smoke Chamber Increased Clinker production = 100 TPD Smoke Chamber Preheater Fan Speed reduced by 1% KILN KILN Kiln Coating Tendency Reduced

17 3c. Energy Saving projects implemented in FY S. No. Title of Project 1 Reduction of Crusher Sp. power consumption by elimination of primary crusher tapper tooth problem Total Annual Savings (Rs million) Investment Made (Rs million) Payback (Months) Raw mill classifier seal gap reduced from 12 to 6 mm Raw Mill False Air reduced from 7.5 to 6.5% Coal Mill Dam Ring & Nozzle Ring optimization Reduction of Kiln radiation losses by applying the heat resistant paint Cooler Recuperation Efficiency increased from 63 to 64 % CVRM Bag House purging sequence modified CVRM Classifier seal gap reduced from 10 to 6mm CVRM Bag house False air arrested by adjusting Rotary Airlock Gap CVRM Fan cone Gap reduced Installation of Fresh Air Damper at mill inlet duct Packing plant Bag Filter optimized the DP Packing Plant Lighting replaced with LED Total Saving Building Culture Nurturing Talent 17

18 Building Culture Nurturing Talent 18 3c. Energy Saving projects implemented in FY Reduction Of Coal Mill Specific Power Consumption Dam ring was reduced from 180 to 80 mm Nozzle Ring Blockage also reduced from 20% make into 0% Thereby Specific power consumption got reduced by 4 Kwh/Mt of Material Cost Saving 12 Lakhs/ Annum

19 3c. Energy Saving projects implemented in FY Kiln Shell painted with Lithophone + Sodium Silicate to reduce the Radiation Losses Kiln Radiation loss reduced by 1.2 Kcal/ kg clinker Cost Saving 15 Lakhs/Annum Surface Area (m2) Clinker Productio n TPH Shell Temp C Shell Temp K T a oc T a ok Convection (Q c) Kcal/Hr m2 Radiation Q r Kcal/Hr m2 Total Heat Loss Q Kcal/Hr m2 Heat Loss Kcal/ kg clinker Before After Reduction of Radiation Loss( Kcal/ kg clinker) 1.2 Building Culture Nurturing Talent

20 3c. Energy Saving projects implemented in FY Increased OPC Productivity Problem: Mill output <260 TPH Water injection high Higher clinker temperature Our CFT Team taken initiative to install the fresh air Thereby mill output increased by 10 TPH Hence, Sp. Power consumption reduced by 0.2 Kwh/Mt Building Culture Nurturing Talent

21 4. Innovative Project - 1 Cement Mill Bag House Purging Sequence Modified Problem Statement: Silo feed Bucket elevator is bottle neck to increase the Output Material flushing from Bag house to Bucket elevator Frequent tripping of Bag house transport group due to High Bucket elevator load Root Cause: Chamber L1 L2 L3 L4 L5 L6 L7 L8 Existing Sequence B/H Inlet B/H Out Let Chamber R1 R2 R3 R4 R5 R6 R7 R8 Building Culture Nurturing Talent 21

22 4. Innovative Project - 1 CVRM Bag House Purging Sequence Modification Source - QC Circle Innovation BH Purging based on the Elevator Load Replication - Possible Benefits: Elevator current optimized from 150 to 140 Amps. Cement mill output increased from 350 to 375 TPH Sp. Power consumption reduced by 0.5 kw/mt Cost saving of Rs lakhs per annum 22 Building Culture Nurturing Talent

23 Building Culture Nurturing Talent Innovative Project - 2 Cooler Fan -1 Fan speed - 100% Increased Cooler Re-cuperation Efficiency from 63 to 64% Before Cooler Static Part Compartment -1 Cooler Fan -1 Fan speed -105% After Cooler Static Part Compartment -1 Cooler Fan -2 Fan speed - 100% Compartme nt -2 Compartme nt -3 Cooler Fan -3 Fan speed - 100% Cooler Fan -2 Fan speed - 105% Compartme nt -2 Compartme nt -3 Cooler Fan -3 Fan speed - 105% TAD Temperature Deg C Cooler Efficiency 63 % TAD Temperature Deg C Cooler Efficiency 64 %

24 4. Innovative Project - 2 Building Culture Nurturing Talent 24 Increased Cooler Re-cuperation Efficiency by modification of higher size MFR Cooler MFR size increased for increasing the air quantity Cleaning the ADP for uniform distribution of air Benefits: Cooler Recuperation Efficiency increased by 1% Heat Rate reduced by 4 Kcal/ kg clinker TAD Temp increased from 1000 to 1050 Degc Cost Saving 48 Lakhs per annum Source - OEM Innovation - Achieved Beyond limit Replication - Possible

25 4. Innovative Project - 3 Cement Mill Bag House RAL Modification Before Modification After Modification Source - Front line Technician Innovation - Reduce the False air Replication - Possible Reduction in False air entry from 11.5% to 9.85%. Easier access while removing bags through RAL. Cost saving of Rs.5.70 lakhs per annum Our sister concern, Kadapa plant have installed this modification Horizontal deployment It is applicable to all the cement industries. Building Culture Nurturing Talent 25

26 5. Utilization of Renewable Energy Sources Building Culture Nurturing Talent 26 Replacement of Electrical Energy with Renewable Energy Annual Energy Generated in (million kwh) % Share Annual Energy Generated in (million kwh) % Share Annual Energy Generated in (million kwh) % Share Wind Energy Replacement of Thermal Energy with Renewable Energy Equivalent Annual Fuel Savings in (million kcal/year) % Share Equivalent Annual Fuel Savings in (million kcal/year) % Share Equivalent Annual Fuel Savings in (million kcal/year) % Share Solar Thermal Energy Biomass Plant

27 6. Utilization of waste material as fuel Green Fuel Dolachar Charcoal Carbon black Plastic waste/rdf Spent wash DFA-HCV Solid Waste Mix Tyre chips Resin Waste % TSR Alternate Raw Material Tannery Sludge - MT Lime Sludge - MT % 1.63% 4.3% Building Culture Nurturing Talent 27

28 7. GHG Inventorisation Building Culture Nurturing Talent 28 CO2 emission Kg/ MT of Cement (Baseline Year)

29 7. GHG Inventorisation Lowest Carbon footprint globally CO2 emission Kg/ MT of Cement Note : As per the GNR data published by Cement Sustainability Initiatives (CSI) in 2016 in the cement world Building Culture Nurturing Talent 29

30 Building Culture Nurturing Talent Green Supply Chain Cement Bulker % Bag/Bulk Dispatch Quantity FY FY Avg Distance Dispatch Quantity Avg Distance BAG BULK Grand Total Bulker Quantity increased = MT Fuel Savings Cost Saving = Lits * 70 Rs/ Lits of Diesel = 38 Lakhs

31 8.2 Green Supply Chain Back Hauling % Plant Results: Increased Backhaul Quantity = Distributor Pet-coke from Karikal MT Distance from Karikal = 126 Km Fuel Saved = (939*126)/4.5 = Lits of Diesel Cost Saving = 18.4 Lakhs/annum 31 Building Culture Nurturing Talent

32 8.3 Green Supply Chain Round Trip DPM Mines DPM Plant Results: Limestone Quantity increased by round trip -34,000 MT If direct Trip Lits/ Mt If Round Trip 1.25 Lits/ Mt Ariyalur Plant PNR & PTK Mines Fuel Saved 23,460 Lits of Diesel Cost Saving Lakhs/ Annum Building Culture Nurturing Talent 32

33 9. Team work, Employee Involvement & Monitoring Building Culture Nurturing Talent Daily Monitoring and Reporting System On line Energy management System (EMS) Online Specific power consumption is monitored by CCR operators Software for Compressors, Idle running hours of Major Equipment & Raw water Consumption. Energy reports were taken from Energy management system Best Energy saving initiatives are awarded periodically.

34 9. Team work, Employee Involvement & Monitoring 9.2 Daily Review Meeting Chaired by Technical Head M T TPH R/HRS POWER LS Moisture Building Culture Nurturing Talent 34

35 9. Team work, Employee Involvement & Monitoring Building Culture Nurturing Talent Separate budget for Energy Conservation Energy Task Force Team formed with cross functional team members and best energy saving initiatives discussed and implemented. Best tracking system for speedy implementation Quick fund allocation by the management based on the pay back period less than 40 months Best Energy saving initiatives are awarded every Monthly Gate meeting. Visiting Energy Efficient plant & Participating seminars for new technology adoption Conducting energy Audit by CII every year Investment for energy conservation projects for FY Lakhs ENCON Project Suggestion Box

36 Building Culture Nurturing Talent Implementation of ISO 50001/Green Co/IGBC rating Keys to Success By Implementation of ISO Well defined energy policy to become excellent energy efficient plant Gap analysis for the targets and corrective actions for acheiving the targets. Energy task force team consisting of people at different levels. Systematic approach to improve the energy performance Periodical review by top management. Availability of advanced tools like Knowledge Manager, Expert optimizer & online reporting, etc. Inter-departmental cross-functional energy audits. Active participation in national level energy management programs, workshops. Young enthusiastic work force always quick to learn and eager to innovate and implement out-of-the-box ideas. Reduction of GHG Emission & Carbon footprint

37 IMS Certification ISO 9001:2015, 14001:2015, 50001:2011 & OSHAS 18001: Building Culture Nurturing Talent

38 Carbon Pricing leadership Dalmia Cement (Bharat) Ltd is the first cement company to join RE100 (100% Renewable Energy by 2030) Building Culture Nurturing Talent

39 BEE - Energy Awards Building Culture Nurturing Talent National Energy Conservation Award From Ministry Of Power FY 2012 National Energy Conservation award from Ministry of Power FY 2013 National Award in an Two Categories (Energy & Environment) FY 2017

40 CII - Energy Awards 6 Consecutive Years Building Culture Nurturing Talent

41 Conclusion: Our plant is one among the Top 5 Energy efficient plant in India as per CII Bench marking. Thank you 41 Building Culture Nurturing Talent 4141