Best Practices Towards Energy Excellence

Transcription

1 Best Practices Towards Energy Excellence Wadi Cement Works 15 th Oct

2 ACC Wadi Geographic Location Wadi-1 Plant Site KARNATAKA STATE Wadi-2 Clinkering : 5.83 MTPA, Cement MTPA Power MW 2

3 Genesis of the plant...wadi Cement Works India s Ist 1.0MTA Plant 1968: Wadi I set up with installed capacity of 0.4 MTPA Kiln 1 & : MFC Installation 1983: Ist 1.0 MTPA Indigenous Plant in India & 25 MW CPP installed 1995: CPP expanded to 50 MW 2006 With in house modification at Wadi II total capacity of Wadi- 4.2 MTPA Wadi-2 Commissioning 2.0 MTPA WD 2 Expansion clinkering & CPP (50 MW) Total capacity 6 million Tons & 125 MW CPP Commissioning AFR platform (16 TPH) Expansion of AFR platform (20% TSR)

4 Plant layout_wadi-2 Cr1 Cr2 RM1 RM2 Complex SLC & ILC Combination of 6 stage PH ILC SLC L&T make impact bar crusher Crusher TPH Crusher TPH Raw Mill-1 (Atox 50) Capacity 450 TPH Raw Mill-2 (Pfeiffer 5600 B) Capacity 560 TPH KM1 Raw Meal Silo 1 Nos. CF Silo Capacity T KM2 Packer- 4 Nos. Cap TPHX 4 Double discharge Coal Mill-1 (Atox KM25) Capacity 50 TPH Coal Mill-2 (Loeshe LM43.4 D) Capacity 93 TPH ILC Height 182 m SLC Height m K4 Cement Silo Cap t Tx 3 CM (Ball Mill) 2 Nos. Capacity 220 TPHx 2 Make - FLS VRPM 2 Nos. Q 230 TPH Make- AMCL Clinker Silo Q LT Kiln : Size 6 m Dia X 96 m Length, BDP TPD, Make FLS, Inclination 4%, RPM 5 max., Drive Twin Drive

5 Energy performance improvement over one year Sl. No Description Units MTOE reduction TOE/Ton Kiln Thermal SEC kcal/kg cli 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 % Renewable Purchase Obligation (Solar+ Non Solar) REC REC Purchased Solar REC REC Purchased Non Solar REC Mitigation of RPO through Solar Power Consumption REC

6 SEC Performance Clinkering in last 3 - Years Clinkering SEEC KWh/Tcli. Including 70% NP Power Y'15 Y'16 Y'17 Y'18 STEC K Cal/ Kg Clinker Y'15 Y'16 Y'17 Y'18 In Year 2016, both SEC & STEC have been increased from previous years due to; Low PRI of Kiln; 83.79% in Y 16 from 93% in Y 15 after 100% pet coke firing. Increased AFR consumption from 4.17 % - TSR in Y 2015 to 6.23 % -TSR in Y Low PRI of Kiln due to TA Duct failure in Dec 2016 (PRI- 50%) and Jan 2017 (PRI-48%) Including 70% Non Process Power

7 SEC Performance Grinding/Total in last 3 - Years Grinding SEEC KWh/T cem. Including 30% NP power Y'15 Y'16 Y'17 Y'18 Total SEEC KWh/T cem including NP Power Y'15 Y'16 Y'17 Y'18

8 Road map to achieve benchmark/global best SEEC Sr. No. Title of Project Saving 1 Expansion of Alternative Fuels project TSR increase from 12 to 20% 2 Replacement of Beumer pan conveyor with Aumund 1.7 KWh/T Cem 3 PIT navigation system - Intelligent optimization software for Cement Kiln 4 Replacement of DC drive of Kiln String Fan with MV Drive 5 Replacement of DC drive of old Baghouse Fan with MV Drive 6 Replacement of DC drive of old Cooler ESP Fan with MV Drive 1 KWh/T Cem 10 K Cal/Kg Clic. 0.4 KWh/T Cem 0.57 KWh/T Cem 0.2 KWh/T cem 7 Replacement of Cross bar cooler with IKN Cooler 1.5 KWh/T Cem 10 K Cal/Kg Clic. 8 Installation of double flap damper below Coal mill #2 BH discharge 0.1 KWh/T cem 8

9 Road map to achieve benchmark/global best SEEC Sr. No. Title of Project 9 Tapping heat from Cooler & Kiln exhaust gases by installing waste heat recovery system 10 Replacement of Cement Mill & Raw Mill separator DC drive with LV drive 11 Replacement of Coal Crusher & Lime stone crusher Apron feeder DC drive with LV drive 12 Replacement of calciner string fan impeller with lower sized impeller in order to improve operating efficiency 13 Replacement of existing three way separator with V separator 14 Maximization of fly ash absorption from current level of 33.5% to 35% Saving 13.2 MW Potential 0.17 KWh/T Cem 0.11 KWh/T Cem 0.14 KWh/T Cem 4 Kcal/Kg Cli. 0.7 KWh/T Cem 0.8 KWh/T cem Total 7.39 KWh/T Cem 24 K Cal/Kg Clic. 9

10 INNOVATIVE PROJECT -1 Page 1 of 4 Plant : WD` Title of the measure : Category A Known concept with Unique Application Reduction in primary air in firing burner from 9.73 % to 6.7% by modification of jet air nozzle Description of the energy conservation measure: The Wadi2 Kiln operates with KHD pyrojet burner commissioned in Oct The jet air nozzles diameter was reduced from 27 mm to 17mm. There are total 16 holes for jet air. The area is reduced from 9156 mm2 to 3632 mm2 Problem Faced: Higher Primary Air intake No any significant reduction in NOx emission Higher Fuel consumption Poor Nodulisation of clinker Lower C3S & Higher C2S

11 Problem Analysis and action taken Page 2 of 4 Problem 1. Higher PA consumption & Low Burner momentum 2. Formation of coating in raiser duct. 3. Flushing of clinker in pan conveyor tunnel due to fine clinker. Action taken 1.Replaced FLS duplex burner to KHD pyro jet burner 2. Jet air nozzle dia. reduction from 27 mm to 22 mm 3. Replacement of PA fan with Blower 1.Started using high alkali content material in raw meal corrective to maintain A/S in clinker. 2.Installation of Cardox socket in kiln raiser duct to dislodge the coating. 3.Cyclone / Raiser duct air blaster sequence changed to auto mode. 1. Increased alumina ratio for better nodulization. 2. Cooler operation mode changed from random to shuttle. 3. PC discharge chute modification 4. Higher NOx Emission 1. Reduction in PA Air 2. Jet air nozzle dia. reduction from 27 mm to 22 mm

12 PRODUCTIVITY IMPROVEMENT POTENTIAL Page 3 of 4 Picture/ sketch before modification Picture/ sketch after modification 22 mm Dia.

13 TANGIBLE IMPACT OF THE PROJECT Page 4 of 4 Result & Benefit The jet air blower operating speed is reduced from 1260 rpm to 860 rpm NOx reduction from 905 mg/nm3 & 1027 mg/nm3 to 730 mg/nm3 & 887 mg/nm3 respectively. (reduction by 175 mg/nm3 and 140 mg/nm3) The reduction in primary air from 9.6% to 6.7% - Savings of 4.1 Kcal/Kg Clinker

14 Plant : WD INNOVATIVE PROJECT -2 Page 1 of 4 Category B New concept (risks taken/self driven / beyond OEM) Title of the measure : Improvement in RM#2 PRI from 560 to 570 TPH by internal modification in Raw Mill #2 (Pfeiffer 5600 B) Description of the energy conservation measure: Problem Faced: Mill body vibration high 16 to 18 mm/sec & air Separator was running in the range of vibration levels mm/sec. There was no any oil cooling arrangement for the hydraulic system. This causes following problems Mill buffer seal & Pull rod failure frequently Buffer & it s side liner got damage. Cracking of mill surrounding Platform Damage of hydraulic Cylinder top bush & seal Not Able to increase the Feed more then 560 tph Identification of problem and root Cause Analysis Continuous studies by OEM Since 2010 but no solution was provided To reduce the oil temperature we have installed separate oil cooling arrangement Carried out brainstorming session & also taken ideas from sister Works i.e. Chanda Works

15 Electrical Energy Conservation Case Study Page 2 of 4 Picture/ sketch before modification Picture/ sketch after modification Before dam ring increase Material empty After dam ring increase material height

16 Innovative Project 2 Page 3 of 4 Picture/ sketch before modification Picture/ sketch after modification Filter 20 µ Hydraulic Cylinder 3 Nos Filter 20 µ Hydraulic Cylinder 3 Nos Valve Block Valve Block Pump Pump Heat Exchanger Oil Tank Filter 10 µ Oil Tank Pump

17 Electrical Energy Conservation Case Study Page 4 of 4 Execution & Implementation Dam ring height & feed chute height has been increased & mill body vibration & separator vibration reduced drastically Result & Benefit Decreased mill internal recirculation of material resulted in lower mill DP caused increase in feed by TPH. MILL vibration Reduced from mm/sec to <7 to 8 mm/sec Silo feed bucket elevator load increase around 15 to 20 Amps Buffer seal & Liner plate life has been increased Cracking of Mill surrounding platform eliminated Hydraulic Cylinder top bush life increased Reduction in frequent mill breakdown due to seal damage & pump failure Reduction in oil temperature resulting in reduction in seal damage, solenoid malfunctioning & oil consumption. Total reduction of around 1 KWh/T mat has been achieved

18 Energy Saving projects implemented in FY Sr. No. Title of Project 1 Improvement in RM#2 PRI from 560 to 570 TPH by 1) Arresting false air from 25 % to 13 % 2) Modification in Mill feed chute 3) Maintaining crusher output size 90% passing 75 mm Annual Saving Electrical(KWh) Thermal (Mio. K Cal) Total Annual Saving (Mio. INR) Invest ment made (Mio. INR) Interlocking of crusher hopper level sensor with apron feeder RPM to reduce idle running & reliability of lamella plate Old stacker travel drive converted from Rdol to VFD Replacement of soft starter with VFD in old high grade & shale reclaimer Reduction in rake (coal & Gypsum) unloading time from 9.6 hrs to 7 hrs

19 Energy Saving projects implemented in FY Sr. No. Title of Project Annual Saving Electrical(K Wh) Thermal (Mio. K Cal) Total Annual Saving (Mio. INR) Invest ment made (Mio. INR) 6 Cooling tower Hot water pumping system modification & replaced 75 KW motor with 45 KW motor Replacement of Conventional lights with LED lights Reduction in clinker cooler Temperature by 1) replacement of cooler fan FA 4 & 5 with motor 2) Replacement of impeller of Cooler fan FA 6 & FA 7 3) Replacement of Cooler 3rd compartment plates 9 Reduction of avoidable electrical energy loss in GRR by replacing GRR with SPRS in RM#1 fan (3400 KW & 6.6 KV) (T)

20 Energy Saving projects implemented in FY Sr. No Title of Project Improvement in NAI of both VRPM to ensure 100% Cement Mill running with Pregrounded material by carrying out following jobs 1) Replacement of separator rotor & stator 2) Replacement of impeller of Sepax fan 3) installation of chillers unit for gearbox oil cooling Reduction in primary air in firing burner from 9.9 % to 6.7% by replacing the existing fan with high pressure& low volume blower. Annual Saving Electrical(KWh) Thermal (Mio. K Cal) Total Annual Saving (Mio. INR) Invest ment made (Mio. INR) (T)

21 Utilisation of waste for replacing the conventional energy Consists of Metso M&J 4000 S hook shredder, REMA belt conveyors, Steinert Magnetic Separator & Eco-star screen. Pre-processing: Capacity- 200 M3/Hr Co-processing: Capacity- 150M3/Hr Suitable for material with bulk density= 0.1 to 0.6 t/m3 Suitable for material having moisture range= 0 to 70 % Facility to handle both HZ & NHz Waste

22 Utilisation of waste for replacing the conventional energy

23 AFR Performance TSR (%) TSR (m Kcal) TSR (MT) Y'14 Y'15 Y'16 Y'17 Y' Plan to increase TSR % from 12% to 20% by the year 2020 by adding another Pre-processing line of having investment of Rs. 70 Cores In progress 23

24 Green Procurement & Green mission Policy 1. Optimization of natural resources 2. Installation waste heat recovery system to produce green energy 3. Sustainable reduction in Plant Energy consumption 4. Reduction in plant water consumption 5. Cement manufacturing with Zero harm to Environment 6. Our slogan Manufacturing of Green Cement

25 Projects implemented in Green mission Policy 1. Dispatch of Bulk Cement to bulk terminal at Mumbai via rail transportation (16% of total dispatch MT) 2. Major portion of Cement Bag dispatch through rail to reduce GHG emission (53% rail & 47% road) 3. Major portion of Clinker dispatch through rail to reduce GHG emission (82% rail & 18% road) 4. Finalizing the order of electrical equipments based on efficiency & BEE star rating % own fly ash transportation through pumping. Bulker movement has been eliminated. 6. Zero waste discharge from the boundary of the plant. 7. Major portion of fly ash transportation through rail transportation.

26 Organization Chart for Energy & Environment Dept.

27 Involvement of Employees, Team work in ENCON,. To achieve our objective of manufacturing of Green Cement we have formed various cross functional team to improve the performance by enhancing energy Efficiency & minimum harm to environment Identifying the gap in performance and develop Roadmap for bridging the GAP Monitoring progress in weekly review meeting along with functional manager chaired by unit head for improving operational excellence

28 Online monitoring of electrical energy EMS Hourly Tracking of section wise SEC through auto generated SMS

29 Energy Management System & Energy Policy 2 9

30 GtG SEC (toe/ton of eq. Cem) PAT Cycle Performance Nos. of ECerts: (+) Nos Baseline SEC Target SEC Assessment year Normalized SEC

31 Major Investment for Energy Conservation # Project Description Amount Rs. Cr. Current Status 1 Replacement of SF Bar Cooler fans 0.82 Implemented 2 Bed Ash Coolers for AFBC & CFBC Boilers 6, 7 at CPP 4.1 Implemented 3 New PYROJET Burner 1.5 Implemented 4 CPP Zero Liquid discharge project 8.25 Implemented 5 Online condenser cleaning system 0.82 Implemented 6 Replacement of GRR with SPRS in RM#1 fan Implemented 7 Up gradation of CM inlet fly ash feeding system 0.70 In progress 8 To increase TSR % from 10% to 20% in Y 2020 by adding another Pre-processing line. 70 In progress 9 Air cooled condenser for TG4 & TG5 50 In progress 10 Replacement of PH ILC string fans with high Efficiency fan 2 In progress 11 Replacement of 3-way separator to standard separator 5 In progress 12 Up gradation of DCS Operating 3 In progress 13 Replacement of Condenser Tubes TG5 1.5 In progress 14 PIT navigation system - Intelligent optimization software for Cement Kiln Total 2.5 In progress cr. (10% of turnover)

32 National Energy Conservation Day Celebration (Awareness Drive)

33 National Energy Conservation Day Celebration (Awareness Drive)

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35 FIMI Health & Safety Award Wadi Cement works bagged the FIMI Health & Safety Award Y15-16 Mr. Piyuesh Goyal, Hon ble Minister of State (Independent Charge) for Mines, Power, Coal & New Renewable Energy GOI awarded the trophy to Dr. S B Singh, Cluster Head South, ACC Limited 35

36 19 th National Award for Excellence in Energy Management by CII National Award as Excellent Energy Efficient Unit by CII in year

37 National Award for Excellence in Energy Management by CII National Award as Energy Efficient Unit by CII in year 2017, 2016 & 2015

38 Awards & Accolades India Manufacturing Excellence Gold Award Green Manufacturing Excellence Gold Award National Award for Excellence in Energy Management Green Manufacturing Excellence Award- 2014

39 Awards And Accolades National Award for outstanding performance in promoting rural and agricultural development by ASSOCHAM Indira Priyadarshini Vrikshamitra Award - by The Ministry of Environment and Forests for "extraordinary work" carried out in the area of afforestation FICCI Award - for innovative measures for control of pollution, waste management & conservation of mineral resources in mines and plant Subh Karan Sarawagi Environment Award - by The Federation of Indian Mineral Industries for environment protection measures Drona Trophy - By Indian Bureau Of Mines for extra ordinary efforts in protection of Environment and mineral conservation in the large mechanized mines sector Indo German Greentech Environment Excellence Award Golden Peacock Environment Management Special Award - for outstanding efforts in Environment Management in the large manufacturing sector Indira Gandhi Memorial National Award - for excellent performance in prevention of pollution and ecological development

40 Thank You 40