CII 18th National Award for Excellence in Energy Management 2018 UltraTech Cement Limited: Unit - Rawan Cement Works-Thermal Power Plant

Transcription

1 CII 18th National Award for Excellence in Energy Management 2018 UltraTech Cement Limited: Unit - Rawan Cement Works-Thermal Power Plant Team Members: Welcome to CII 19th National Award for Excellence in Energy Management Mr. M.G.Ganu (Sr.V.P.-TPP) 2.Mr. Shailendra Pandey (GM E&I & Energy Manager) 3.Mr. Ajay Dhama (Manager TPP)

2 Company Profile UltraTech Cement Ltd - Rawan Cement Works UTCL : A part of ABG which is the best employer in India and Asia Pacific region Rawan Cement Works : An Unit of UTCL 55 MW capacity captive power plant ( ) 16 MW capacity WHRS unit Fullest compliance to Environment Norms. Certified with IS 9001, 14001, HSAS 18001, Rawan Cement Works IS 27001, SA8000 standards Adopted World Class Manufacturing Excellence Model

3 Process Flow Diagram

4 Key Performance Indicators - TPP Specific Energy Consumption Trend PLF (%) G D % G D % G D % 18.9 % Auxiliary Power (%) 14.5 Heat Rate (Kcal/Kwh) Power Cost (Rs./Kwh) G D % %

5 Key Performance Indicators - WHRS Specific Energy Consumption Trend PLF (%) % % % % G D Auxiliary Power (%) Generation (Million /Kwh) G D [VALUE] False Air Reduction % G D 9.5 G D % % % 2.0 [VALUE] % 41.4% [VALUE] %

6 Plant Performance & Benchmarking Benchmarking With UTCL Units RWCW TPP KCW SG RC Rawan VC ACW GCW AC APCW 6.0 HC Aux power consumption of the unit % RWCW TPP APCW ACW SG KCW VC AC GCW RC Rawan Gross heat rate (Kcal/kWh) of the unit 2750 HC

7 Details of Energy Saving Projects Energy Savings Projects Summary Financial SN Year Investment/ No Investment No. of Projects No Investment NA 3.63 Investment NA 13.8 No Investment NA 5.58 Investment NA 2.55 No Investment NA 6.55 Investment NA Total Electrical Energy Heat Energy Savings in (MWH) Savings (Ton/Year) Rs. Million Invested Amount in Rs. Million

8 Major Energy Conservation Projects S.No. Energy Saving Tasks Annual Energy Savings Thermal Energy Electrical (kwh) Ton/Year Savings (Rs million /Annum) 1 Reduction in wind box pressure (1040 from 1250 mmwc) in BLR # 1 2 Reduced pressure of SA air to 350 from 550 mmwc in Boiler# Reduced SA air pressure up to 350 from 550 mmwc and installed VVFD for further energy saving in Boiler # Reduced furnace draft to -1 from -5 mmwc in boiler -1 & Red. in circulating CW pump pre. to 2.8 from 3.0 kg/cm2in line Auxiliary cooling water pumps discharge pressure reduced to 1.3 kg/cm2 from 1.8 kg/cm2 in Line-2. Installed VVFD in PA fan of line -1 Boiler. Installed VVFD in BFP of line Installed VVFD in total 06 nos. ACC fans in line The supply of Instrument air maintained from 75 KW compressor instead of 200 KW Wind box pressure reduced to 1040 from 1250 in Boiler Installed VVFD in CT fans of line Total

9 Major Energy Conservation Projects S.No. Energy Saving Tasks 1 Reduced SA air 650 from 800 mmwc in Boiler Auxiliary cooling water pumps discharge pressure reduced to 2 from 3.8 Kg/cm2 in Line-2. APH-1 module replacement in Line -1 SA circuit Line # 02 Boiler Feed water pump differential discharge pressure reduced to 12 Kg/cm2 from 15 Kg/cm2. Replacement of APH SA & PA Module tubes (168 Nos.) in Boiler-2. Installed VVFD in total 04 Nos. ACC fans in Line-2. 7 New Interconnection of line-1 and line-2 conveying Reduction in bed ash cooler fan dis. pressure to 550 from 800 mmwc and installed VVFD Instrument compressors unloading set point changed from to 5.7 kg/cm2 and loading point 5.2 to 5.5 kg/cm2 in Line2. 8 Total Annual Energy Savings Thermal Energy Electrical (kwh) Ton/Year Savings (Rs million /Annum)

10 Major Energy Conservation Projects S.No. Energy Saving Tasks Annual Energy Savings Thermal Energy Electrical (kwh) Ton/Year Savings (Rs million /Annum) 1 Reduced BFP dis. Diff. pressure to from 30 kg/cm2in line ptimization of PA/SA air ratio 60/40 respectively in Boiler Replacement of SA APH-1 module in line 1 Boiler Maintaining ₂ level 3.5 in place of 4.2% in Boiler ptimization of PA/SA air in Boiler Wind box pre. reduced to 1080 in place of 1250 mmwc in Boiler New interconnection line of inst. air between line-1 & line Reduction in wind box pressure to 1080 from 1250 mmwc in Boiler Installed VVFD in SA fan of line -1 Boiler Total

11 Way Forward: Energy Saving Projects SN Year Title of Project Modification of ejector steam supply source from TG extraction in line # Replacement of existing halogen vapour light fitting with LED Installation of control valve at auto recirculation line of boiler feed pump at TPP line # Interconnection of cooling water line Installation of lighting transformer at Both TPP units as well as at CHP Saving of ID fan power through draft reduction verall APC to be reduced by 1% Boiler exit flue gas temperature to e redu ed C through reduction in feed water temperature Turbine specific steam consumption to be reduced 0.11 MT/MWH through HP heater modification. Total Saving Annual Annual Thermal Electrical Saving Saving (Ton/year) (kwh)

12 Innovative Projects & Implementation Analysis: Key Factors Causing High Power Consumption Material Machine Boiler tube Transportation Uneven Storage Sampling Fuel Carpet stock System Leakage ver charging SA / PA fan ACC fan Delivery High GCV Skills High Power Consumption Load variation Combustion efficiency Experience peration ccupational disease Abilities External AMC charges service Heat loss & Air leakage Training Concentration Manpower Work Scheduling quality & planning Idle running CHP Belts Fatigue Behaviour at work Attitude Maintenance peration Fly ash & Bed ash LI ver times Misalignment Spares Quality BFP, ACW ver-running CT fan Cess Services Crusher DCS logic Compressors Statutory dues Drain losses Health Breakdown High Power Consumption Electricity dues Bed material AVR tripping Appliances Frequent start ups Pressure & flow Inadequate Control Parameters Probes & gauges Fuel feed Error & fault Method SPs & logic Causing Factors

13 Innovative Projects & Implementation Energy Saving by ptimization of Air Compressors : Project-1 Initiative taken : 200KW Comp Dryer Line-2 TG and DM Plant peration of 37 kw + 11 kw air compressor in place of 75 kw compressor for instrument air req. for both units. K-Pump System Before : ne 75 kw air compressor was in operation for catering the req. to both TPP as well as WHRS unit. It was operated mostly in loaded condition. IFC Ash Handling System Air Receiver 37 KW Comp Line-1 & Line-2 Boiler After : The same req. is now fulfilled by running kw air compressors. The average loading comes to 47 kw of both compressors Daily energy saving : 24*(74-47) = 648 kwh. Total yearly energy saving : Kwh ( 648 X 321 Days) 75 KW Comp Isolation Valve Air Receiver WHRS Section 11 KW Comp

14 Innovative Projects & Implementation Energy Saving by 132 KV Dedicated pooling power line : Project-2 bjective: Cement manufacturing is an energy intensive process where 65-70% of production cost is energy. ur team emerged with an innovative idea of interconnection of both units through 132 KV line installation. Benefits: Reduction in Black ut System Reliability Improvement Expected Reduction in Auxiliary Power Consumption to 7.95 % & Heat Rate 3144 to 2993 K Cal/ KWH Improvement in PLF 69 to 93 Stopping of 1 Power Plant & Surrendering of one grid connection.

15 REDUCTIN IN PWER CNSUMPTIN F BFP WHRS Project -3 Before 2 BFP was running, which consumed 320 kw power per hour. BEFRE :- Now one BFP of 160 kw and one LP BFP of 18kw was running, which consumed 178 kw power per hour. Now saving-142 kw/hr. AFTER :- Common Discharge header BFP-1 BFP-2 LP BFP Common Discharge header BFP-1 BFP-2 BFP-3 BFP-3 Common suction header From Deareator Power- 160 Kw,Each To All boiler ( only HP line ) To All boiler ( only LP line ) Discharge To All boiler(hp & LP) Common suction header From Deareator Power-178 kw

16 Utilisation / Recycle of Waste Utilization of TPP fly ash & Bed ash : Bed ash as well as fly ash being generated from boilers are conveyed pneumatically to silos. From Silos, fly ash is again transported through dense phased closed pneumatic system up to cement mill silos where it is being consumed 100% for cement manufacturing. Complete bed ash in storage silos is reconditioned through wet unloading system and then loaded in tipper. It is being used completely as a raw material for cement plant. It is added in the raw meal additive hopper for further process at cement plant. Recycle of Waste MT Fly Ash Bed Ash Total

17 PAT Status EVER LWEST Base Line PAT Cycle 2 Target SEC PAT Cycle 2 Actual in FY Actual in FY Datenreihen1 Save Energy - Save Money - Save the Planet GD 0.066

18 GHG Inventorization Cementitious Product KG C2/MT F CEMENT KG C2/MT F PRDUCT GD Specific C 2 Emission GD Specific C 2 Emission 450 National BM Cement * Lowest Carbon Footprints/Specific Emissions among all UltraTech plants

19 Renewable Energy Use Green Township 800 KWp Solar Panels Installed in plant Installed in FY Colony Power requirement mainly catered through Solar power generation GD KWH 10 MW Solar Power Generation in Planning Solar Power Generation 930,407 1,000, , , , , , ,

20 Green Supply Chain Management Projects Implemented : Reverse logistics - Coal rake used to send Clinker to grinding Units. Dedicated 132 KV line between RWCW and HCW. Later, to improver further, the PMS has been hooked up between these two units. Benefits Achieved : Reverse loading of rakes equals to reduction in incoming rakes and resulted in fuel saving. Dedicated 132 KV line along with common PMS has helped significantly to improve reliability of operation and plant performance parameters at both end. Supplier Evaluation : Waste Belt Reuse/ Rebuilding n the basis of sustainability factors- safety, Health & Environment. Joint Improvement projects.

21 Team Work, Emp. Involvement & Monitoring SN EnCon idea Team involved Status 1 Wind box pressure reduced to 1040 from 1250 in Boiler-2. peration Completed 2 Removed the common header damper from line-2 bed ash cooler duct. Mechanical Completed peration Completed peration Completed Mechanical Completed 3 4 Line-1 CEP differential pressure maintained below 5.5 kg instead of 7.5 kg with control valve adjusting and line modification. Line-1 Auxiliary cooling water pumps discharge pressure reduced to 1.8 from 3.2 kg/cm2 through VVFD. 5 APH-1 module replacement in Line -1 SA circuit 6 Installed VVFD in SA fan of line -1 Boiler E&I Completed 7 Installed VVFD in BFP of line -1 Boiler E&I Completed

22 Energy Management System Daily Energy Monitoring Power Generation Planning for HCW & RWCW

23 Energy Management Policy Energy Policy implemented in 2009 Energy Policy states unit s commitment towards continual energy performance improvement Energy policy is communicated at all levels Daily Review of Energy & PAT data w.r.t BEST Dedicated Energy Cell with fortnightly review Three layer Team Structure for stringent Monitoring Regular Improvement Projects on Energy Conservation Real time power consumption data monitoring through online Energy Monitoring System

24 Energy Monitoring, Reporting & Implementation Methodology Monitoring & Review Formats Energy Management Cell with clear cut responsibilities. Daily monitoring of Energy Deviation report.. Benchmarking with National/International/Group Units/Cluster units and action plan for improvement. Regular study of Equipment's on deviation and their analysis. Process Evaluation & Identification of Energy Conservation scope. Feasibility study of suggestions and designing proposals for sanctions. Promoting energy saving idea generation by shop floor teams and time bound implementation rganizing Internal and External Energy Audit. Description Daily Co-ordination meeting on Power and Performance review Review of Daily Power Report for any deviation Energy Cell Meeting Points Compliance review Energy Audit (Internal & External) Points Compliance Formats

25 Rajiv Gandhi CII 18th National Award for Excellence in Energy Management CSR Excellence Award 2017 & REPRISM 2017 DL Shah Quality Award (GLD) IMC Rama Krishna Bajaj Quality Award State - Energy Efficiency Award by CREDA (Consecutive Since 2014) Chairman WCM GLD Award Rajiv Gandhi National Quality Excellence in Innovation CWCM CII Energy Award Awards: Journey Towards Excellence 2017