Welcome to CII 11 th National Award for Excellence in Energy Management Team Members Ashish Panpalia. M.P Singh. G.Suresh Kumar.

Transcription

1 ULTRATECH CEMENT LIMITED (UNIT:-REDDIPALAYAM CEMENT WORKS ) Welcome to CII 11 th National Award for Excellence in Energy Management Team Members Ashish Panpalia. M.P Singh. G.Suresh Kumar. 1 ADITYA BIRLA GROUP - PROFILE GROUP COMPANIES BUSINESSES ABMCL ADITYA BIRLA RETAIL ADITYA BIRLA CHEMICALS ADITYA BIRLA NUVO BCCL BIRLA CARBON BIRLA GLOBAL FINANCE ESSEL MINING & INDUSTRIES GRASIM INDUSTRIES HINDALCO INDUSTRIES IDEA CELLULAR INDAL ALUMINIUM INDUSTRIES INDO GULF FERTILIZERS & CHEMICALS PSI DATA SYSTEMS ULTRATECH CEMENT LIMITED ALUMINIUM CARBON BLACK CEMENT CHEMICALS COPPER FERTILIZER FINANCE GARMENTS INSULATORS INSURANCE IT RETAIL STAPLE FIBRE TELECOM TEXTILE VISCOSE 2

2 ADITYA BIRLA GROUP CEMENT BUSINESS CEMENT BUSINESS AT A GLANCE INTEGRATED UNITS RAC W REC W ACW APC W ADC W VCW KCW RCW GCW HCW NJFD Bhatinda Dadri (G) Noida Gurgaon Panipat Aligarh Jodhpur Shambhupura Kotputli Jawad 49 Million MT capacity 12 Integrated Units. 11 Split Grinding Units. 5 Bulk terminals. 69 Ready-mix concrete plants. Durgapur (G) GRINDING UNITS NRC W ARC W NCMW WBC W JCW BCW DCW PCW ALC W GEC W BIRLA WHITE HOC W 3 B Jaffrabad Magdalla(G) Kovay a Awarpur NaviMumbai B Ratnagiri (G) White cement plant Ready mix Concrete plants Ultratech Cement Plants Ultratech Grinding Units (G) Ultratech Cement Terminals Hotgi(G) Hirmi Raipur Jharsuguda(G) Hyderabad Malkhed Ginigera Tadipatri Bangalore MangaloreB B Chennai Arakonam(G) Reddipalayam RECW 4

3 CEMENT MANUFACTURING PROCESS PLANT SALIENT FEATURES Mines Truck Loading Crusher Dispatch Packer Stacker & Reclaimer Cement Silo Raw Material Hopper Cement Mill Raw Mill Raw Meal Silo Clinker stockpile 4 Stage Preheate r Coal Mill Kiln Cooler Reddipalayam cement works capable of using multiple fuels successfully Leader in waste fuel utilization in India First Cement Plant in the World to get CDM Cross Belt Analyzer - Use of different limestone mix from four to five mines on daily basis - Use of Marl (low grade limestone) up to 10 % - No additives used other than Limestone & Marl for raw meal quality correction No fatal accident since last Eight years Ripper Dozer for environment friendly mining operation Established schools one with CBSE & another with Matriculation (State board) syllabus 5 6

4 PLANT SALIENT FEATURES PLANT SALIENT FEATURES TECHNOLOGICAL FEATURES ECO-FRIENDLY TECHNOLOGICAL FEATURES State of the art technology adopted taking into consideration Quality, Safety & Environment friendly aspects. Most of the Technology features introduced like: Robo lab. Raw Meal Proportioning System. Laboratory Information And Management system. Linkman Plant Optimization Designed to operate with 100% Petcoke. Installed ESP & pulse jet bag filters Building Air conditioning Automation software Designed structures, machines to minimize the noise effect always Operated all equipments through DCS RAW MILL ESP Software. (Distributed Control System) to eliminate Knowledge Manager For Process Studies. PI Soft ware for on-line process information's. ROBO LAB 7 the direct exposure of dust and noise to the employees. Alternate/Hazardous Fuel Feeding 8

5 FINISHED PRODUCTS OPC 43 OPC 53 PPC PLANT PERFORMANCE 9 10

6 TURN OVER (SALES) ( ` in Crores) CLINKER PRODUCTION (Lac MT)

7 TOTAL CEMENT PRODUCTION (Lac MT) TOTAL CEMENT DESPATCH (Lac MT)

8 USAGE OF PET COKE (in place of conventional fuel) USAGE OF FLY ASH IN PPC CEMENT Due to non-availability of Petcoke & Cost economics % on CV Basis % Plant capable of utilizing 100 % Petcoke 15 16

9 % OF PPC CEMENT PRODUCTION SPECIFIC FUEL CONSUMPTION % Kcal / Kg of clinker Planned to reduce 20 kcal/kg of clinker by upgrading Existing Pre-heater from 4 Stage to 5 Stage during Nov

10 INTERNATIONAL BENCHMARKING KWh/ton (Whitehopleman) of Cement(PPC) BENCHMARKING / GLOBAL BEST World Best (Whitehopleman) Indian Best (NCCBM) GS (04-05) GS(05-06) GS(06-07) GS(07-08) GS(08-09) GS(09-10) BETTER 19

11 INTERNATIONAL BENCHMARKING OVER ALL POWER (Whitehopleman) KWh/ton of Cement World Best (Whitehopleman) 66.2 Indian Best (Whitehopleman) 79.3 GS (04-05) 74.1 GS(05-06) GS(06-07) GS(07-08) GS(08-09) GS(09-10) BETTER INNOVATIVE PROJECTS IMPLEMENTED 22

12 INNOVATIVE PROJECT-1 INSTALLATION OF WET FLYASH DRYING SYSTEM Title:- Installation of Wet Flyash drying system (WHR-Waste Heat Recovery) Problem Faced:- for effective Utilization of Cooler exhaust gas. Cooler Exhaust gas was going outside as waste to atmosphere Non availability of dry fly ash in the market. Requirement of dry flyash for the manufacturing of PPC cement is 900 MT/day. Total available dry fly ash is 800 MT/day from MTPS / NLC and 150 MT/day from market Abundant quantity of wet flyash is available at MTPS. Due to high moisture in wet fly ash, only 2% of the total fly ash can be used in the system. Shortfall of dry fly ash can be met by drying of wet fly ash. 23 Rectification Done:- dryer Investment:- Benefits & Savings :- MT/Annum. heat recovery WET FLY ASH DRYING SYSTEM Feasibility study carried out and installed flyash Capacity: 16 TPH ` 7.5 Crores. 1. Total coal savings 6165 Tons/Annum 2. Savings ` 38.3 Lakhs/Annum. (Saving in Procurement of Dry flyash ` 400/MT) 3. Additional availability of dry fly ash 1.00 LAC This has been taken as a CDM project under waste (expected saving of ,000 CER s / Annum). 24

13 WET FLY ASH DRYING SYSTEM % % PPC Production Year WET FLY ASH DRYING SYSTEM FLASH DRIER SCHEMATIC DIAGRAM INCREASE IN PPC PRODUCTION REDUCTION OF SPECIFIC POWER IN PPC PRODUCTION Better Kwh Per Ton Of Material

14 INNOVATIVE PROJECT-2 REDUCTION OF POWER CONSUMPTION IN RAW MILL CIRCUIT Innovative Project:- (A) INNOVATIVE PROJECT-2 REDUCTION OF POWER CONSUMPTION IN RAW MILL CIRCUIT Innovative Project:- (B) Title:- mill fan. Problem Faced:- consumption. Rectification Done:- Investment:- Benefits & Savings :- Installation of SPRS (Slip Power Recovery System) in Raw Obsolescence of SPRS panel & High Power Installed the analogue system with Digital system. ` 55 lakhs. Savings ` 5.73 Lacs/Annum. Title:- Modification of Raw mill inlet duct. Problem Faced:- High pressure drop from Pre-heater Outlet to Raw Mil Inlet Around 160 mmwg and velocity in inlet duct was 26 m/sec. Rectification Done:- Raw mill duct modified for reducing pressure and power. Investment:- `129 Lakhs. Benefits & Savings :- Pressure drop reduced from 160 to 136 mmwg; Velocity reduced from 26 m/sec to 18 m/sec there by reduced raw mill powe by 0.5 units per ton of raw meal RAW MILL DUCT MODIFICATION 27 28

15 INNOVATIVE PROJECT-2 REDUCTION OF POWER CONSUMPTION IN RAW MILL CIRCUIT Innovative Project:- (C) Title:- Modification of GCT duct. Problem Faced:- High power consumption and high pressurization in Preheater fan during Raw mill stoppage. Rectification Done:- GCT outlet duct modified. Investment:- ` 56.5 Lakhs. Benefits & Savings :- GCT inlet duct pressure reduced by 60 mmwc. Raw mill ESP fan power reduced by 0.7 unit per ton of clinker. Preheater fan outlet pressurization avoided during raw mill stoppage. INNOVATIVE PROJECT-2 REDUCTION OF POWER CONSUMPTION IN RAW MILL CIRCUIT Innovative Project:- (D) Title:- Replacement of Raw mill Fan. Problem Faced:- High power consumption Rectification Done:- Low efficiency fan replaced by high efficiency. Investment:- ` 56 Lakhs. Benefits & Savings :- Fan efficiency increased from 76% to 84%. Power saving 0.12 unit/ton of material. GCT DUCT MODIFICATION 29 30

16 Kwh Per Ton Of Material INNOVATIVE PROJECT-2 RESULT REDUCTION IN SPECIFIC POWER CONSUMPTION OF RAW MILL INNOVATIVE PROJECT-3 REDUCTION OF POWER CONSUMPTION IN KILN Innovative Project:- (A) Title:- Replacement of Cooler Fans. Problem Faced:- High power consumption Rectification Done:- 3 nos. of Low efficiency fans replaced by high efficiency. Investment:- ` 32 Lakhs. Benefits & Savings :- Fan efficiency increased & Power Saving unit/ton of clinker. 32

17 INNOVATIVE PROJECT-3 REDUCTION OF POWER CONSUMPTION IN KILN Innovative Project:- (B) Title:- Replacement of Reciprocating compressors (2 nos) Problem Faced:- High power Consumption, high noise level and water consumption. Rectification Done:- Replacement of Reciprocating compressors (2 nos) by Atlas Copco Make Screw compressors Investment:- ` 53 Lakhs. Benefits & Savings :- Power saving of 0.34units/ton of clinker, Noise level reduced from 95 to 88 db, No Water consumption for cooling (previously 29.4 m3 / Hr.) INNOVATIVE PROJECT-3 REDUCTION OF POWER CONSUMPTION IN KILN Innovative Project:- (C) Title:- Modification of Pre-heater twin cyclone Aerovane. Problem Faced:- High fuel Consumption. Rectification Done:- Aerovane height increased by 1.3 M and cyclone inlet reduced by 140 mm Investment:- ` 25 Lakhs. Benefits & Savings :- Reduction in heat consumption by 4 Kcal/kg of clinker increase in cyclone efficiency by 1 % Inlet reduced by 140 mm Aerovane increased by 1.3 M 33 34

18 INNOVATIVE PROJECT-3 INNOVATIVE PROJECT-4 Kwh Per Ton Of Material RESULT REDUCTION IN SPECIFIC POWER CONSUMPTION OF KILN REDUCTION OF POWER CONSUMPTION IN CEMENT MILL Innovative Project:- (A) Title:- Replacement of Reciprocating compressors (3 nos) Problem Faced:- High power Consumption, high noise level and water consumption. Rectification Done:- Replacement of Reciprocating compressors (3 nos) by Atlas Copco Make Screw compressors Investment:- ` 79 Lakhs. Benefits & Savings :- Power saving of 0.3 unit / ton of cement, Noise level reduced from 95 to 88 db, No Water consumption for cooling 36

19 INNOVATIVE PROJECT-4 INNOVATIVE PROJECT-4 REDUCTION OF POWER CONSUMPTION IN CEMENT MILL Innovative Project:- (B) Title:- Mill optimization Problem Faced:- High power Consumption, Low out put. Rectification Done:- RP Roller profile re-building at regular intervals RP gap adjustment Grinding media optimization Investment:- Nil Benefits & Savings :- Output increased from 190 to 215 TPH and reduced power consumption from 25 units to of 23.8 units. Kwh Per Ton Of Material RESULT REDUCTION IN SPECIFIC POWER CONSUMPTION OF CEMENT MILL 53 Grade

20 INNOVATIVE PROJECT-4 RESULT REDUCTION IN SPECIFIC POWER CONSUMPTION OF CEMENT MILL PPC INNOVATIVE PROJECT-5 REDUCTION OF POWER CONSUMPTION IN POWER PLANT Innovative Project:- (A) Title:- Installation of VFD for Power plant Cooling Tower fan. Problem Faced:- High power consumption in cooling fans. Kwh Per Ton Of Material Rectification Done:- Temperature. Investment:- Benefits & Savings :- Installed VFD for cooling tower fan with interlock in ` 0.4 Lakhs. Savings ` 2.84 Lakhs/Annum. 40

21 OVERALL POWER CONSUMPTION Kwh/Ton Of Materia ENVIRONMENTAL PROJECTS / CARBON EMISSION REDUCTION 42

22 ALTERNATE FUEL WASTE FUEL MECHANISED FEEDING SYSTEM:A mechanized waste fuel feeding system installed first time in India to reduce fossil fuel usage in Kiln INNOVATIVE METHOD FOR FEEDING ALTERNATE FUEL IN KILN. WOOD CHIPPING MACHINE WEIGH FEEDER PLASTIC CHIPPING MACHINE TRANSPORT SYSTEM STORAGE FACILITY FEEDING SYSTEM 43 44

23 1. De Oiled Rice bran (DORB) 2. De Oiled cashew nut Shells 3. Saw Dust 4. Bio compost 5. Municipal Waste (RDF) 6. Coir Waste / Dust 7. Corn Waste 8. Ground nut shell 9. Palm seed Shell 10. Match stick waste 11. Wood Strips 12. Shredded Tyres 13. Tyres Powder 14. Refinery Sludge 15. Paint Sludge 16. Tyre Chips % OF WASTE FUEL IN KILN ON CV BASIS in % TNPCB trial Due to nonavailability of Alternate fuels & cost economics QUANTITY OF WASTE FUEL IN KILN SL # Type of Fuel UOM Tyre MT 1,897 2, DORB (De oiled Rice Bran) MT 7,939 17, Cashewnut Shell MT Coconut Shell MT 0 1, Wooden Dust MT Oil Sludge MT Paint Sludge MT 666 1, Groundnut husk MT Charcoal MT MOU made Between M/S. UltraTech cement Limited (UTCL) & Municipal Corporation of TiruchirapallI (TMC) For Disposal of Plastic waste from Municipal Solid Waste (MSW)

24 ALTERNATE FUEL CO 2 EMISSION / TON OF CEMENT RESULT & HIGHLIGHTS The First Cement Company in the World to get CDM Carbon Credit Apr 2005 to Mar 2006, CER 22,290 (Received on 3 rd April 2007) April 2006 to Oct 2007, CER (Received on 6 th Nov 2008) Tonne Better Obtained Negative fuel cost for use of Hazardous waste like Paint sludge Year Reduction in CO 2 emission by 16 %( From to ) 48

25 SPECIFIC POWER CONSUMPTION (PPC) REDUCTION IN SPECIFIC POWER CONSUMPTION Kwh /Ton Of Cement

26 ENERGY SAVING PROJECTS ENERGY SAVING PROJECTS IMPLEMENTED LAST THREE YEARS SL No. Title of Energy Saving project implemented Year of Implementatio n Annual Electrical Saving Units Million ` Million Total Saving s ` Million Investme nt ` Million Replacement of old driers by new version of driers in compressor house Compressor air optimization Raw mill and cement mill optimization Maintaining 120 deg centigrade in cement mill clinker weigh feeder. 5. Optimization of Lime stone reclaimer and belt conveyor running time Reducing operating pressure in fly ash compressor Optimization of coal mill firing bag filters Optimization of silo top bag filter in Raw mill Installation of VFD in 361 FN3 Fan CCR AC AHU(Air handling unit) running timing stopped from PM to 7AM

27 SL No. Ti2tle of Energy Saving project implemented Year of Implementatio n Annual Electrical Saving Units Million ` Million Total Savings ` Million Investm ent 11 Installation of control switch in packing plant Common unloading system for flyash Raw Mill main drive cooling fan interlocking Kiln oil pumps interlocking with temperature Interlocking of sampler in cement mill Optimization of bag filter purging with flyash bag filter fan Reviewing of HP fan running on cement mill silo top Replacement of Kiln ESP RAL S for false air leakage Optimization of Lime stone weigh feeder blaster operation ` Million 20 Fixing of an exhaust fan in crusher venting line Placement of double stage compressor with single stage in packing plant. ENERGY SAVING PROJECTS Optimization of coal mill ESP KV SL No. Title of Energy Saving project implemented Year of Implementation 23 Fitting of 45 Watt CFL bulb in place of 150 W HPSV fitting. 24 Installation of separate switch for coal stacker and reclaimer in MCC room. 25 Interlocking provided for roller press P & V blower with roller press motor. 26 Local control switch provided for L21 BC7 tower lighting. 27 Inter connection line made in between pyro & cement mill air receivers. 28 Two stage compressor (K51)converted into single stage compressor. 29 Seggreagation of lighting in long belt area in packing plant. 30 Power saving through interlock for LS reclaimer PCRD motor during pile change. ENERGY SAVING PROJECTS Annual Saving Units Million Electrical ` Million Total Savings ` Million Investment ` Million Power saving in all cable cellars Commissioning of Screw compressor in pyro section Bunker changed for optimizing coal reclaimer P-20 energy saver installed in TPP

28 SL No. ENERGY SAVING PROJECTS Title of Energy Saving project implemented Year of Implementatio n Annual Electrical Saving Units Million ` Million 35 Optimization of coal mill bag filter fan Otimization flow meter air slide fan 431 FN 1 & Total Saving s ` Million Investm ent ` Million School varanda lights taken in street light control Power saved by keeping cement mill 53 grade blaine 275 instead of Upgradation of clinker weigh feeder Optimization of FK pump bag filter Raw mill fan SPRS upgradation Replacement of high efficient GCT pump Installation of low head GCT pump Installation of high efficiency cooler vent fan Installation of high efficiency Raw mill fan numbers of high efficient cooler fans installed Installation of high efficiency Raw mill ESP Fan Reduction in Power consumption in Raw mill circuit Total four numbers of screw Compressor installed in place of reciprocating compressor SL No. ENERGY SAVING PROJECTS Title of Energy Saving project implemented Year of Implementatio n Annual Electrical Saving Units Million ` Million Total Saving s ` Million Investm ent ` Million 50. Installation of high efficient impeller for packer bag filter Preheater twin cyclone aerovanes modification Aluminium impeller changed by FRP impeller for cooling fans CO2 purging system re-placed with N2 Purging system for fine coal bin and bag filters in fine coal circuit Optimization blower motor Optimization of L91 FN1 Coal mill bag filter Optimization air slide fan 431 FN1 & Optimization of supply water for Cooling tower Optimization of silo top bag filter by speed reduction Replacement of Kiln ESP RAL's for False air leakage Optimization of Lime stone weigh feeder by feed deviation Installation of exhaust fan in crusher venting line Replacement double stage compressor with single stage W(HPSV) high pressure sodium vapors lamp replaced by 45 W CFL(Compact florescent lamp) Optimization of bag filters in packing plant

29 SL No. ENERGY SAVING PROJECTS Title of Energy Saving project implemented Year of Implementatio n Annual Electrical Saving Units Million ` Million Total Saving s ` Million Investm ent ` Million 65. Cooling fan of Kiln shell taken in DCS/MCC FN4(Kiln Cooling shell fan) taken in DCS Belt interlocking done in clay feeding area Belt interlocking done in gypsum feeding area Use of energy efficient bearings Interlocking of packing plant bag filters Replacement of new version SPRS in Raw mill fan Replacement of normal pumps by submersible pumps in Raw mill & Coal mill. Interlocking RP cooling fans Replacement of 150W HPSV by 45W CFL Installation of VFD for Power plant cooling Tower fan Installation of Panel Air conditioner & Exhaust fan in Power Plant Waste gas utilization for drying wet flyash (Waste heat recovery system). 57 PROJECTS IMPLEMENTED FROM Total No of Projects implemented :77 Total Units Saved in Million : Total Saved ` in Million : Total investment ` in Million :

30 TEAM WORK IN ENCON INVOLVEMENT OF EMPLOYEES, TEAM WORK IN ENCON, MONITORING & REPORTING AND IMPLEMENTATION METHODOLOGY EMPLOYEE SUGGESTIONS RELATED TO ENERGY CONSERVATION Name:-P.Jayaprakash Designation:-Engineer Department:-Electrical. TITLE:- PROBLEM FACED:- according timers. RECTIFICATION DONE:- on INVESTMENT:- ` 13,640/. Power optimization of colony street lights. Timing of street lights are required to adjust frequently to day light conditions by manual Manual timer replaced by Astronomical timers based on location (Latitude /Longitude) in place for Street light control. BENEFITS & SAVINGS :- Power savings 30 minutes/day. ` /Annum. PAY BACK PERIOD :- 1 Year

31 TITLE:- PROBLEM FACED:- due to 531BC6 becomes Low. RECTIFICATION DONE:- Plastics) Type INVESTMENT:- Cement Mill Old Cooling Tower Replaced with new FRP (Fiber Reinforced Plastics) type Cooling Tower. Cement mill Cooling Tower Contaminated with dust Conveyor Belt Spillage materials and Efficiency Old cooling Tower replaced by new FRP (Fiber Reinforced Cooling tower. ` 3.0 Lakhs. BENEFITS & SAVINGS :- Reduction of 4 units/day and Savings ` 1.09unit/Annum. PAY BACK PERIOD :- TEAM WORK IN ENCON EMPLOYEE SUGGESTIONS RELATED TO ENERGY CONSERVATION Name:-A.James. Designation:-Fitter. Department:-Mechanical work shop. 2.5 years. 61 TEAM WORK IN ENCON EMPLOYEE SUGGESTIONS RELATED TO ENERGY CONSERVATION TITLE:- Installation of Exhaust fan instead of Split A/Cs in MCC Name:-Kulanginathen room of Designation:-Electrician. Department:-TPP DM (Demineralizing Treatment) pant to reduce power consumption PROBLEM FACED:- High Power Consumption. BEFORE MODIFICATION:- In DM Plant MCC room split A/C (2 Tons) was provided to maintain the room temperature to avoid failure of PLC. Power consumption : 2 Kw X 24 Hrs X30 Days X 12 Months = Kwh/Annum AFTER MODIFICATION:- Provided two exhaust fan to enhance air circulation. Now the PLC room temperature is maintained. Power consumption : 0.4 Kw X 24 Hrs X 30 Days X 12 Months = 3600 Kwh/Annum. INVESTMENT:- ` 4000/. BENEFITS & SAVINGS :- Total units saving Per year and ` 41040/year. 62

32 TEAM WORK IN ENCON EMPLOYEE SUGGESTIONS RELATED TO ENERGY CONSERVATION Name:- C.krishnamurthy Designation:-Asst. Manager. Department:-Electrical Department TITLE: Power Saving through Local control Switch for 311 Conveyor belt in Limestone Crusher. PROBLEM FACED:- RECTIFICATION DONE:- We can switch INVESTMENT :- ` 6500/- BENEFITS & SAVINGS :- PAY BACK PERIOD :- High power consumption. Provided Local Control for that Area lighting. Whenever required ON the lighting. Reduction of 5110units/day and Savings ` / Annum. 4.3 months. 63 TEAM WORK IN ENCON EMPLOYEE SUGGESTIONS RELATED TO ENERGY CONSERVATION Name:-Guru Prasad. Designation:-Asistant Mananager. Department:-TPP. TITLE:- Reduction of Auxiliary Power Consumption of TPP cooling tower Fan 2. PROBLEM FACED:- BEFORE MODIFICATION: - continuous of TPP. AFTER MODIFICATION: - regulated with High power consumption. Cooling Tower Fan of 30 KW, 1500 RPM, normally in operation in DOL mode at Full speed at all loading conditions Installed VFD in Cooling Tower Fan -2, and speed is being respect to the loading of TPP INVESTMENT:- ` 32000/- BENEFITS & SAVINGS: - Net Power savings = Units / Annum. Net Cost savings = ` 5 Lacs / Annum. PAY BACK PERIOD :- 1 months. 64

33 ENERGY POLICY ENERGY MONITORING SYSTEMS We at UltraTech Cement Limited (Reddipalayam Cement Works ) are committed to evolving and sustaining excellence in energy conservation to reduce cost of production & improve environment. We will work continuously to conserve energy and achieve world benchmarks in terms of energy consumption in our process. Fostering a culture of participation and innovation amongst employees for continual improvement in energy conservation. Head Unit 65 Plot ENERGY MANAGER software /26/2008 2:55:25 AM 8.00 hours 7/26/ :55:25 AM RP MOV Online MOTOR DE TEMP monitoring of parameters in DCS. RP MOV MOTOR NDE TEMP Roller Press1 CURRENT Roller Press1 HT LOAD motors power and temperature details Roller Press2 CURRENT Roller Press2 LOAD RP FIXED MOTOR DE TEMP RP FIXED MOTOR NDE TEMP GCS CM RPMOVMOTORDETEMP DEG C GCS CM RPMOVMOTORNDETEMP Speed,load,current and running hours of all critical equipments. DEG C GCS CM RP1CURRENT AMPS Compressors, water pumps and bore wells running hours. GCS CM RP1LOAD KW GCS CM RP2CURRENT AMPS Other important parameters like draft,temperature, feed GCS rate CM RP2LOAD are Individual MCC s wise and section wise power details. Start/stop power for all equipments also monitored and recorded KW GCS CM RPFIXEDMOTORDETEMP DEG C GCS CM RPFIXEDMOTORNDETEMP DEG C 66

34 Plot /24/2009 1:05:55 A M 9/24/2009 2:43: hours A M 9/24/2009 4:26:07 AM COOLER GRA TE 2 LOAD COOLER GRATE 2 SPEED UNDERGRA TE2 SETPOINT GCS COOLER GRA TE2LOA D KW GCS COOLER GRA TE2SPEED RPM GCS COOLER UNDERGRATE2SETPOINT mmwc VARIOUS ENERGY MONITORING SOURCES USED Daily Energy Report deviation analysis. METHODOLOGY ADOPTED FOR ENERGY MONITORING Energy management cell with clear cut responsibilities Knowledge Manager. Daily monitoring of Energy Deviation report. Daily Vibration & Bearing Temperature Deviation. Monitoring Benchmarking National/International/group wise/cluster units. Regular study of equipments on deviation and their analysis. PI system Daily Monitoring of Utilization of Various Fuels. RMP system for raw meal Plot GCS CMRP1LOAD KW GCS CMRP2LOAD KW GCS KN MMLOAD KW GCS KN PHFANLOAD KW GCS KN RMESPFAN LOAD Process evaluation & identification of energy conservation scope. Feasibility study of suggestions and designing proposals for sanctions /21/2008 5:40:00 AM minutes 5/21/2008 5:50:00 AM Roller Press1 LOAD Roller Press2 LOAD KILNMM LOAD PH FANLOAD RPM GCS KMCOALESPFANLOAD KW GCS RMMMLOAD KW GCS KN TPPLOAD KW Taking corrective and preventive measures and ensuring implementation. RMESPFAN LOAD COAL ESPFANLOAD RMMMload TPPLOAD 67 Organizing internal and external Energy Audit survey. 68

35 DAILY: Daily Energy deviation report Energy Task Force Meeting WEEKLY: MONTHLY: Energy Conservation Meeting Capex Jobs/Project Meeting Section wise Fortnightly Review Meeting Weekly Review Power Comparison with group units Breakdown Analysis Report Master Action Plan Meeting METHODOLOGY ADOPTED FOR SUSTAINABILITY Monthly Performance Meeting 69 ISO 9001, 14001,18001& CERTIFICATION 70

36 AWARDS & ACCOLADES AUDIT OBSERVATIONS (April-2010) ISO 9001 (QMS) accreditation Certificate in ISO (EMS) accreditation Certificate in OHSAS (OHSMS) accreditation Certificate in ISO (ISO/IEC) accreditation Certificate in Feb ISO 9001 ISO OHSAS ISO

37 AUDIT OBSERVATIONS (April-2010) AUDIT OBSERVATIONS (April-2010) 73 74

38 AUDIT OBSERVATIONS (April-2010) ENVIRONMENTAL INITIATIVES No of Plants in Thousands

39 ENVIRONMENTAL INITIATIVES ENVIRONMENTAL INITIATIVES Trial run taken for different types of hazardous waste in presence of CPCB and TNPCB. Clinker loading chute and accessories for tippers during loading avoiding the heavy dust generation and spillage. Ripper Dozer is being used for Mines operation which is eco-friendly and total avoidance of drilling and blasting. Alternate Fuel Storage Shed For Systematic Storage Of Different Fuels In Closed Shed Eco-friendly. SOX & NOX Analysers in Cement Pant and thermal power plant. Increase in GCT Height in order to reduce the dust emission in raw mill stack by improving the efficiency of electro static precipitator. High Efficient auto tuning EPIC -2 controllers are installed in all ESP s. Limestone transport vehicles are being covered with Tarpaulin and Emission certificate. Green belt developed inside plant as well as Colony. Noise protecting equipments like Ear plugs/ear muffs, are used by personnel 77 LIME STONE STORAGE YARD CLINKER SILO COAL STORAGE YARD 78

40 ENVIRONMENTAL INITIATIVES ENVIRONMENTAL INITIATIVES Ripper Dozer used for Mining. COVERED CONVEYOR S CONCRETE ROAD IN THE PLANT 79 80

41 ENVIRONMENTAL DAY CELEBRATION on 5 TH JUNE Inauguration Plantation At Plant Prize Distribution Plantation - Employees Plantation - School Children Plantation - Family members at Colony UTILISATION OF RENEWABLE ENERGY 81 82

42 UTILISATION OF RENEWABLE ENERGY Type of RES Installed Capacity in kw Energy Generate d (kwh) Annual Savings (Lacs Rs) Energy Generate d (kwh) Annual Savings (Lacs Rs) Energy Generate d (kwh) Annual Savings (Laces Rs) Wind (5*225) KW Solar 500 W UTILISATION OF WASTE MATERIALS We are the first Cement Plant to register With TEDA (Tamilnadu Development Authority) for 100 KW Solar Energy for colony usages. Expected Savings : 1.5 Lakhs units/annum. Savings : ` 7.5 Lacs/Annum. Investment : ` 2 Crores. Energy 84

43 TPP FLY ASH GENERATION & UTILISATION DG SLUDGE GENERATION & UTILISATION Less generation of flyash in TPP due to use of Lignite MT FLYASH GENERATED IN TPP IS COMPLETELY USED IN PLANT 85 KL DG SLUDGE GENERATED IS USED AS AN ALTERNATE FUEL & FIRIED IN THE CALCINER. 86

44 FIRST RO PLANT REJECT WATER PIT Effective Usage of Reject Water in Process SECOND RO PLANT REJECT WATER PIT Pump for conveying Reject water to the Cement Plant WASTE UTILISATION SECOND RO PLANT REJECT WATER PIT Utilising reject / waste water from power plant with help of return valves to cooler for cooling purpose REPLICATION ARISING OUT OF BEST PRACTICES THROUGH ASSOCIATES 1. Installation of New version of ABB Controller (EPIC-3) for Electro static precipitators. 2. Installation of Delta star converters for belt conveyors. 3. Additional Cooling fan drives taken in DCS for interlocking. 4. Installation of P-20 lighting energy saver in TPP (Thermal power plant). 5. Changing of Aluminum impeller by FRP (Fiber reinforced Plastics) impeller in Kiln shell cooling fans. 6. Retrofitting electronic temperature control devices in old and manual window air conditioners for energy savings. 7. Power factor is maintained greater than Installation of VFDs for the Cooling water circulation pumps to optimise the water flow to the condenser for the TG set. 9. VFD for cooling towers. 10. Optimisation of running of air compressors using Compressed Air Management System. 88

45 UNIT INITIATIVES TOWARDS CEMENT SUSTAINABILITY & REDUCTION IN CO2 EMISSION We are a member of CSI (Cement Sustainability Initiative) reporting. Marl usages in raw mix there by avoiding the use of pure limestone,white clay & black cotton soil. Usages of Natural gypsum (low purity), which reduces the clinker consumption in cement. Increasing the consumption of dry flyash up to 27 % in PPC Production. Use of Ripper dozer for mining operation,there by eliminating drilling & blasting. Engaging DUPONT for improving safety standards in side Plant & Colony. Increased Blended cement production. Use of Various high calorific value waste fuels in pyro processing. Tamilnadu Government has selected our unit for consumption of Plastics in 89 SOCIAL ACTIVITIES PROCESS ADOPTED Identified 15 Villages from 4 Panchayats Focused on Education, Health, Welfare, Infrastructure development, Sustainable livelihood, Building Partner ship with Government, Non-Governmental Organisation, Hospitals etc.. Exploring Government Schemes Preparing planning & Budgeting activities Mobilization of Fund (Contributing with Government s various Social welfare activities in terms of finance & infrastructure facility) Implementing Projects & Activities Support on Disaster Management (Fire, Flood, Medical Emergency etc..) 90

46 SOCIAL ACTIVITIES 9th UltraTech Merit Awards Distribution Eye Camp SOCIAL ACTIVITIES Compound wall at Village school Drinking water at Village Schools Toilets at Village Schools 91 92

47 AWARDS & ACCOLADES AWARDS & ACCOLADES ENERGY Global Cement Awards, Lowest Specific Energy consumption, clinker grinding Lowest Specific Energy Consumption, raw meal grinding National Energy Efficient Unit Award by CII (2004 & 2006,2007 & 2008) National Excellent Energy Efficient Unit Award by CII NCCBM Best Electrical Energy Performance Award NCCBM Second Best Improvement in Thermal Energy Performance Award CII Energy Award 2009 NCCBM Award

48 ENVIRONMEN T AWARDS & ACCOLADES Greentech Environment Excellence Silver Award 2006 & 2009 Global Cement Award Lowest specific CO2 emission Most Innovative Scheme for environmental impact abatement FICCI Environment Sustainability of Business Award AWARDS & ACCOLADES SAFETY State Level Safety Award from Tamil Nadu Government (1999,2000,2005 & 2006) Safety Appreciation Award from NSC TamilNadu Chapter 2003 Greentech Safety Award - Bronze in 2006, Silver in 2007 & Silver in Two First Prizes State Level Safety Award from TamilNadu Government (2005 & 2006) n Global Cement Awards Lowest Injury Incidence Rate First prize ($1000).(2006) Global Cement Golden Peacock Award GPOHSA 2009 & Award FICCI AWARD Greentech Environment Award State Government Safety Award Golden Peacock Award 2009 & 2010 GreenTech Safety Award

49 AWARDS & ACCOLADES WCM(World Class Manufacturing) WCM Chairman s Award for Manufacturing Excellence Bronze Award in 2002 WCM Chairman s Award for Manufacturing Excellence Silver Award in 2004 WCM Chairman s Award for manufacturing Excellence Gold Award in S Excellence Award by CII 2005 Best Kaizen Award in Kaizen Mela Competitions 2008 Commitment unlocks the doors of imagination, allows vision and gives us the right stuff to our dreams into reality. Thank You WCM Silver Chairman s Gold WCM Gold Award 97 98