ORIENT CEMENT LIMITED (CGU) Jalgaon

Transcription

1 ORIENT CEMENT LIMITED (CGU) Jalgaon Presenting Team Mr. Alok Bagaria - GM (Operations) Dr. Anil Kumar Trivedi - GM (Sustainability) Mr. Samaresh Dutta DGM (Electrical & Energy Manager)

2 ORIENT CEMENT LIMITED (CGU), JALGAON

3 DEVAPUR UNIT (IP) JALGAON UNIT (CGU) CHITAPUR UNIT (IP)

4 ORIENT CEMENT LIMITED - OVERALL PLANT PROFILE Orient Cement Ltd. operating 3 Cement Plants in India: - Integrated Plant - Devapur, Telangana State - Clinker Grinding Unit - Jalgaon, Maharashtra - Integrated Plant - Chittapur, Karnataka Overall Capacity of Orient Cement is 8.0 MTPA. Plant is certified with IMS: ISO 9001:2015 ISO 14001:2015 OHSAS 18001:2007 ISO 50001:2011 TPM-Phase I & II (Excellence and Excellence in consistent) NABL Accredited Quality Control Laboratory Member of CSI (WBCSD) Grinding Unit Jalgaon- Maharastra Cap: 2 MTPA 3 Devapur Unit Telangana Cap: 3 MTPA Chittapur Unit Karnataka Cap: 3 MTPA

5 LOCATION DETAILS & CLIMATIC CONDITIONS: Total Plant Area Ha. Weather Conditions Temperature (⁰C) Summer Season Min. 25 Max. 47 Winter Season Min. 09 Max. 36 Average Rain Fall 821 mm Altitude 211 m above MSL Coordinates Direction Latitude Longitude North N E South N E East N E West N E At NH No. 6, PO. : Nashirabad Taluka and Distt: Jalgaon State :Maharashtra (India)

6 2000 Plant Cap.: 0.70 MTPA CAPACITY ENHANCEMENT OF JALGAON SPLIT GRINDING UNIT Vision OUR VISION & VALUES Grow to be a relevant national player, driven by execution excellence and be the employer of choice and neighbour of choice. Values We embrace change and create opportunities, where others see a challenge We have a passion for growth We have the courage to innovate We believe in spirited teamwork We believe in corporate governance and accountability Plant Cap.: Plant Cap.: 1.0 MTPA 0.80 MTPA 2009 Plant Cap.: 2.0 MTPA Line - II commissioned Line-I Plant Line - I Improvement By Introducing PPC Cement Line - I Up gradation with Close Ckt. Of Cement Mill

7 MILE STONES OF ORIENT CEMENT LTD. IMS 2015 CSI ISO ISO 9001:2008 NABL 2011 TPM PH-I OHSAS 18001: ISO 14001: ISO 9001:

8 MANUFACTURING PROCESS PROCESS FLOW DIAGRAM LEGEND Line- 1 equipments Line- 2 equipments Wagon Tippler Clinker Silo Pre-Grinder Coarser Particles Separator Equipments common for line 1 & Coarser 2 particle return line Line -1 material flow Line-2 material flow Material flow common for line 1 & 2 Gypsum Yard/Shed Clinker Hopper Cement Mill- 1 Final Product Cement Silo Packing Plant Gypsum Hopper Fly Ash Silo Cement Mill- 2 Cement Silo Cement Dispatch Fly Ash Bin 7

9 MANUFACTURING PROCESS Raw Material Availability: Clinker received through Railway Wagons from Mother Plant located at Devapur (Telangana). Gypsum received through Trucks from Various Dye & Chemical industries located in Gujarat State. Fly Ash received through Bulkers from Bhusawal Thermal Power Station, Deepnagar, Bhusawal (MS). Storage: Clinker, Fly Ash and final product Cement stored in respective Silos and Gypsum stored in Covered Shed. Manufacturing Process: Raw Material Feeding requirements. - Feeding of material through Weigh Feeder/ SFM as per production Pre grinding: - Feeding material to Roller Press for pre grinding. Finish Grinding - Transfer of material to close Clinker Ball Mill through a discharge chute. From the mill material transferred to through air to Separators. Storage of product in Silo & Packing - The final material storage to Cement Silo, which is connected to the Packing Machine for automatic filling of OPC & PPC cement into the bags. Loading & Transfer to Destination Point- Finished product is loaded into load carriers and taken to the required destination as per dispatch need. 8

10 ENERGY CONSUMPTION Overall Power Consumption Energy Consumption (kwh/t of Cement) Reason for variation: High Sp. power consumption in due to following reasons 1. Frequent Start - stop due to low market demand. 2. Higher percentage of OPC Production. 3. Lower grindability of clinker due to usage of pet coke in clinker manufacturing on trial basis. 9

11 ENERGY CONSUMPTION Specific Power Consumption (PPC) - kwh/ton of Cement Apr-17 May-17 Jun-17 Jul-17 Aug-17 Sep-17 Oct-17 Nov-17 Dec-17 Jan-18 Feb-18 Mar-18 10

12 ENERGY NATIONAL BENCH MARKING kwh/t of Cement SP. Power NBM Source: CII ( ) * Overall power does not includes Packing Plant, Lighting and Miscellaneous Power Reference: Energy Benchmarking for Cement Industry, May 2015, Version 2.0 (Published by CII & CMA) 11

13 ROADMAP TO ACHIEVE BENCHMARK: Sr. No. Key Action Proposed Expected Savings kwh/t of cement Target Date 1 Fly ash unloading through mechanical system only 0.6 Jan Compressor air line optimization 0.09 Jan Polycom Separator bag filter discharge material feeding to final product Air slides blowers replacement with new high efficiency blower 0.2 Dec Dec

14 ENERGY SAVING PROJECTS Implemented in FY Sr. No. Title of Project Annual Electrical Saving (kwh) Annual Electrical Cost Saving (Rs. million) Investment Made (Rs. million) Payback (Months) 1 Clinker Feeding Belt Running interlocking with load NA 13

15 ENERGY SAVING PROJECTS Implemented in FY Sr. No. Title of Project Annual Electrical Saving (kwh) Annual Electrical Cost Saving (Rs. million) Investment Made (Rs. million) Payback (Months) 1 AVR for wagon tippler lighting Timer circuit for street light & dusk to down circuit for MCC conventional light replaced with LED

16 ENERGY SAVING PROJECTS Implemented in FY Sr. No. Title of Project Annual Electrical Saving (kwh) Annual Electrical Cost Saving (Rs. million) Investment Made (Rs. million) Payback (Months) 1 Line 2 coarse material partially fed to line Fly ash unloading system modification OPTIMIZATION OF BAG FILTER PURGING NA 4 Replacement of overhead water conventional pump with high efficiency pump

17 ENERGY SAVING PROJECTS Implemented in FY Sr. No. Title of Project Annual Electrical Saving (kwh) Annual Electrical Cost Saving (Rs. million) Investment Made (Rs. million) Payback (Months) 5 Water lines modified by reducing bends Hot Water pump replaced with high efficiency

18 Innovative Idea Implementation: 17

19 Partial diversion of CM-2 coarse material to CM-1 Mill Theme: Productivity improvement through diversion CM-2 coarse material to CM-1 Mill Background: Line 1 commissioned in 2000 and retro fit mill circuit and detailed study has been done and concluded that CM-1 ball mill having excess capacity to take further material. Simultaneously studied CM-2 circuit and noticed that Roller Press Separator having excess capacity. 18

20 Description of Modification: Airl side along with weighing system installed and also feed bucket elevator capacity enhanced. Benefits: 1. Mill production rate increased by 15 TPH. 2. Sp. Power consumption has reduced by 1.5 kwh/mt of Cement. 3. Smooth operation. Savings: Investment made : Rs. 52 Lacs Payback : 4.24 months 19

21 Implemented in FY Theme: Pneumatic Fly ash unloading system replaced with partially pneumatic - partially mechanical system. Fly ash unloading with conventional pneumatic systems to silos at 40 mtrs. Solution: Provided intermediate 50 Mt bin with lower height (i.e. 10 mtr) Due to lower height of bin, blower air is sufficient to convey material in place of costly Compressed air. Bin to Silo material conveying by existing bucket elevator. 20

22 Implemented in FY Fly ash unloading comparison With Blower 160 kw compressor Blower Compressor 160 Water pump Bag filter fan 30 kw Silo aeration roots blower Equipment Air slide blower Bucket Elevator DC Fan RAL BE Dis Blower Load kwh kwh Power Benefits (kwh) 50 Investment 1.6 Lac Cost Savings (Rs in Million/year) 50 kw x 10 hr/d x 330 x ROI (Months)

23 Implemented in FY Theme: Water lines modified by reducing bends. Modifications to reduce power consumption in water pump 1. Removing bends 2. Reduction in the length of pipeline Comparison of power consumption (previous vs present pump) Results after modification Modification cost and payback period

24 Implemented in FY MODIFICATIONS TO REDUCE HEAD LOSSES 1. Reduction in number of effective bends- Total no of bends bypassed from earlier pipeline = st Bend 2 nd Bend 3 rd Bend 6 th Bend 4 th Bend 5 th Bend

25 Implemented in FY Reduced length with respect to earlier pipeline = 9m (reduction in length of pipeline reduces frictional loss) New pipe line (Bypassed) New pipe line (Bypassed) Old pipe line Old pipe line New pipe length = 21 mtrs Old pipe line length =30 mtrs

26 Implemented in FY COMPARISON OF POWER CONSUMPTION (PREVIOUS VS PRESENT PUMP) DETAILS OF PUMP PREVIOUS PUMP PRESENT PUMP DESIGNED HEAD (IN meter) RATED POWER (IN KW) RUNNING KWH RUNNING HRS/DAY KWH CONSUMPTION/DAY Power Savings (kwh) Cost incurred Rs * Both pumps having same discharge = 120 m 3 /hr. Payback in 1.6 months 25

27 UTILISATION OF RENEWABLE ENERGY SOURCES 1 kva Solar Power Generation System installed in Sep, Units Generated in FY Units Generated in FY kwh 1376 kwh 26

28 GHG INVENTORISATION GHG Emission due to Purchased Power Consumed: Year T CO2/T of Cement)

29 GREEN SUPPLY CHAIN Green Purchase Policy: Our Policy to Purchase Energy Efficient Equipment - 28

30 GREEN SUPPLY CHAIN Procedure to Purchase Energy Efficient Equipment : 29

31 Team work, Employee Involvement & Monitoring 30

32 ENERGY MANAGEMENT CELL Unit Head Head - Engg Head Oper HOD EM Cell Team of Electrical, Chemical, Mechanical Engineers

33 DAILY ENERGY MONITORING Capturing of Section wise energy meter reading. Calculation of Section / Equipment wise Specific energy consumption. Analysis of SPC. Find out the root cause of deviation, if any. Further corrective/ preventive action, if applicable. 32

34 REVIEW MEETING Energy review meeting conducted at various level : 1. Plant level : Meeting is conducted on Daily Basis and Chaired by Plant Head 2. COO Level : Review meeting is on Monthly Basis and Chaired by COO 3. MD Level : Overall performance review meeting is on Monthly Basis and Chaired by Managing Director. 33

35 ENERGY CONSERVATION BUDGET Sr. No Year Budget (Rs. Crore) % of Turnover

36 TRAINING AND AWARENESS PROGRAMME External training programs attended S.No. Topic Man Hrs. 1 12th Green Cementech 2016-CII 16 2 Optimization of Grinding Syatem - NCCBM 16 3 National Conclave on Recent advances in Cement Industry 8 4 Plant Maintenance Summit Energy Management & Conservation in Cement Industry 8 Best Practices in Energy Efficiency in Cement Sector" under 6 KEP Internal training programs conducted 1 Training Programme on -L T Motor Maintenance 10 2 Grinding Media Optimization 12 3 Fan efficiency calculation 20 4 Impact of Compressed air utilization in bag filters on SPC Healthy Maintenance of Gear Boxes 24 6 EnMS ISO Reduction in Auxiliary power

37 Energy efficiency / awareness training program: Inter Plant Knowledge Sharing Sessions. Awareness: 36

38 Projects implemented through Kaizens ( Workers and Supervisor level) Replacement of Gypsum Feeding Belt with Chute Replacement of HPMVs, Sodium Vapour lights with LED lights Interlocking of cooling tower fan with temperature. Compressed Air Pressure Optimization Interlocking of equipments to avoid Idle equipment running 37

39 IMS CERTIFICATION IMS - ISO , , EnMS ISO

40 INITIATIVES TO REDUCE GHG EMISSION GREENBELT DEVELOPMENT 41% Area Covered under Green belt Development Major Species Planted: Neem Shisham Plantoform Peepal Bargad Satparni, Mango, Amla, Badam, Cheeku, Guava plants Poplar Gulmohar Palm 39

41 GREENBELT DEVELOPMENT

42 GREENBELT DEVELOPMENT

43 GREENBELT DEVELOPMENT

44 GREENBELT DEVELOPMENT Photographs:

45 Thank You