18 th National Award for Excellence in Energy Management UltraTech Cement Limited Unit: Kotputli Cement Works

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Cynthia Dean
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1 18 th National Award for Excellence in Energy Management 2017 UltraTech Cement Limited Unit: Kotputli Cement Works

2 S.No. 1 Company profile 2 Cement manufacturing process CONTENTS 3 Energy Management System policy 4 List of ENCon measures taken in last three years 5 Plant performance over the years 6 Unit brief summary for PAT status 7 Details of innovative projects a. Reduction in cooler fans power b. Process Fan pressure drop reduction c. Compressor Specific power reduction 8 Plan Matrix for future Encon projects 9 Involvement of employees /Sharing of best practices among associates for ENCon projects implementation

3 S.No. CONTENTS 10 Environmental projects / Projects Linked with Carbon emission reduction 11 Energy Monitoring Methodology 12 Utilization of renewable energy sources/waste material 13 Awards & Accolades

3 MTPA (10,000 TPD) Equipment Make Rated Capacity Benefits Raw Mill Loesche GMBH 735

UTCL Kiln Six- Stage Preheater twin string Pyro floor clinker cooler with roller

) Loesche GMBH KHD GMBH 2 X 215 TPH 10000 TPD on 100% Imp.

4 Company Profile KCW was commissioned in the year 2009 with clinker production capacity of 3.3 MTPA (10,000 TPD) Equipment Make Rated Capacity Benefits Raw Mill Loesche GMBH 735 TPH Improved Coal Mill Loesche GMBH 50 TPH for Pet Coke First Vertical Cement Mill in UTCL Kiln Six- Stage Preheater twin string Pyro floor clinker cooler with roller crusher Online Cross Belt Analyzer, XRF (02 nos.), XRD (01 no.) Loesche GMBH KHD GMBH 2 X 215 TPH TPD on 100% Imp. coal 8000 TPD on 100% Pet coke KHD GMBH - KHD GMBH - Thermo scientific, Panalytical - energy efficiency, Easy maintenance Enhanced heat & mass transfer High heat recuperation efficiency Efficient Quality Control System

accreditation WCM Gold Award WCM 2010 ISO 9001 2011

5 WCM Initiated Quality Mgmt. Environment Management Journey Towards Excellence Occupational Health & Safety WCM Bronze Award Information Security Energy Management NABL accreditation WCM Gold Award WCM 2010 ISO ISO OHSAS WCM 2013 ISO ISO ISO WCM 2015

Cement Manufacturing Process Mines Crusher Stackers Raw Mill

Collective Cyclones Limestone & Additives Reject Raw Mill To

Silos PC Firing Stack2 Clinker Gypsum Low NOx Pyro section --

6 Cement Manufacturing Process Mines Crusher Stackers Raw Mill Hoppers Coal Petcoke Coal Mill Bag House Stack1 Bag House Collective Cyclones Limestone & Additives Reject Raw Mill To stack2 Pre-heater Kiln Burner ESP Cement Mill Flyash Cement Silos PC Firing Stack2 Clinker Gypsum Low NOx Pyro section -- Material Flow -- Gas Flow Kiln Cooler Clinker Bulk Loading HAG Packing Plant

7 Energy Management System Policy

8 LIST OF ENCON MEASURES TAKEN IN LAST THREE YEARS

9 Energy saving initiatives with Zero Investment SN Energy Saving theme Removal of venturi from coal mill bag house fan inlet duct Provided flap box in DSC discharge feed pipe. TAD bend modification for reducing dropping of material Auto cleaning system at dispersion plates for proper fluidization of fuel with raw meal Installed baffle plates in Raw Mill cyclone outlet discharge Start of cold meal injection system for eliminating coating formation & reducing cleaning process by water jet Energy Saved/yr Elect (MWH) Thermal (Mkcal) Savings (Rs. Lac/yr)

10 Energy saving initiatives with Zero Investment SN. Energy Saving theme Energy Saved/yr Savings Elect Thermal (Rs. (MWH) (Mkcal) Lac/yr) 7 Raw Mill cyclone dip tube modification Heat of formation reduction by Raw Mix optimization Reduction in Limestone, Additives & Coal transport Idle run hours for power optimization by DCS interlocking w.r.t to load (KW). Maintaining A/S ratio for enhanced petcoke utilization with stable operation by Raw Mix optimization Pressure drop reduction of cooler fans (11 Nos.) by removing louvre dampers

11 SN. Energy Saving theme Energy Saved/yr Savings Elect Thermal (Rs. (MWH) (Mkcal) Lac/yr) Energy saving initiatives with Zero Investment Removal of all Flow regulators(mfr) from chamber-2,3,4 & 5 of cooler resulting in chamber pressure reduction Optimization of 2 coal firing blowers by line modification &running at low air to material ratio Cement mills power reduction by optimizing the reject circuit running hrs Reduction in packing plant bag filter fan power by change in drive system Reduction in idle running of cooling tower fan Total

12 Energy saving initiatives with Investment SN. 1 Energy Saving theme Energy Saved/yr Elect (MWH) Thermal (Mkcal) Savings (Rs. Lacs/yr) Invest (Rs. in Lacs) Payback (months) Preheater fans inlet box enlargement Raw Mill Fans inlet box modification Carbon black feeding system modification to increase Carbon black usage Modular lining in bottom cyclone feed pipe to eliminate stoppages Total FY ( )

13 Energy saving initiatives with Investment SN Energy Saving theme Fuzzy logic installation for Kiln /Cooler Installation of castable retainer in DSC to enhance refractory life Installation of new generation Hasle castable for burner pipe Increased the recuperation efficiency cooler by airflow modification Energy Saved/yr Elect (MWH) Thermal (Mkcal) Savings (Rs. Lacs/yr) Invest (Rs. in Lacs) Payback (months)

14 Energy saving initiatives with Investment SN Energy Saving theme Reduction in pressure drop by installing baffle plate in all 4 nos. top cyclones of Preheater Preheater top cyclone water spray system installation for reducing power Installation of Static synchronous compensator (STATCOM) Replacement of kiln firing root blower with screw compressor Energy Saved/yr Elect (MWH) Thermal (Mkcal) Savings (Rs. Lacs/yr) Invest (Rs. in Lacs) Payback (months)

15 Energy saving initiatives with Investment SN Energy Saving theme Removed venturi from Cement Mill 1 Bag House fan inlet duct Modification in cooler water spray for minimizing water cons. & cooler outlet temp. Removed venturi from Raw mill fan inlet ducts 8 Watt CFL in colony replaced by 5W LED lamps Energy Saved/yr Elect (MWH) Thermal (Mkcal) Savings (Rs. Lacs/yr) Invest (Rs. in Lacs) Payback (months) Total for FY ( )

16 Energy saving initiatives with Investment SN. Energy Saving theme Energy Saved/yr Elect (MWH) Thermal (Mkcal) Savings (Rs. Lacs/yr) Invest (Rs. in Lacs) Payback (months) Pressure drop reduction of cooler fans (11 Nos.) by removing Silencers Optimization of compressor run hrs by various modifications PH Fan inlet duct enlargement Removal of venturi from Cement Mill-2 Fan inlet duct

17 Energy saving initiatives with Investment SN Energy Saving theme Raw Mill table liners & rollers replacement Radiation losses reduction by attending all areas of refractory wear & tear Extending the Thermal wall(null point) by 800mm for retaining heat Installed PID based VFD at Post clinker compressor house Installed PID based VFD at Pre Clinker compressor house Energy Saved/yr Elect (MWH) Thermal (Mkcal) Savings (Rs. Lacs/yr) Invest (Rs. in Lacs) Payback (months)

18 Energy saving initiatives with Investment SN. Energy Saving theme Energy Saved/yr Elect (MWH) Thermal (Mkcal) Savings (Rs. Lacs/yr) Invest (Rs. in Lacs) Payback (months) 26 Installed Energy Efficient Pump at Pre Clinker Pump House Cement Mill -1 Bag house Fan Inlet Box enlargement Cement Mill -2 Bag house Fan Inlet Box enlargement Reduction in separator power of cement mills by removing slave roller Energy saving by replacing existing conventional light fittings with LED light Total Grand total for last 3 years

19 PLANT PERFORMANCE OVER THE YEARS

Unit Performance Last Three Years Petcoke Consumption

Consumption (Million MT) 100 80 80.4 94.8 96.

5 G O O D 60 2014-15 2015-16 2016-17 670 FY15 FY16 FY17

TPD(Million MT) 28.5 28.0 28.38 28.40 27.

20 Unit Performance Last Three Years Petcoke Consumption (%) on Heat Basis Cement Specific Dispatch Heat Consumption (Million MT) G O O D G O O D FY15 FY16 FY17 Cement Dispatch (Million MT) Cement Dispatch Kiln TPD(Million MT) G O O D G O O D

Unit Performance Sp. Power Cement Upto Clinkerisation Dispatch (Million (KWH/MT MT) Clk) Sp.

00 45.00 42.71 44.68 44.79 42.54 G O O D 40 2014-15 2015-16 2016-17 2017-18 (Q1) 40.

(KWH/MT (Million MT) cement) 71.79 74.43 75.57 54.90 52.60 49.62 72.24 53.

21 Unit Performance Sp. Power Cement Upto Clinkerisation Dispatch (Million (KWH/MT MT) Clk) Sp. Power Cement Upto Clinkerisation Dispatch (Million (KWH/MT MT) Cem) G O O D G O O D (Q1) (Q1) Overall Cement Sp. Power Dispatch Cons. (KWH/MT (Million MT) cement) Power PPC % (Q1) G O O D Overall Sp. Power Cons. (KWH/MT cement) After Normalization Power PPC % (Q1) G O O D

Unit Energy Performance Comparison: At A Glance With benchmark/cluster units performance (Year 2016-17) 810 750 Sp.

22 Ref- For International Benchmark BEE presentation during interactive workshop on normalization factor in Ahmedabad Ref. For National Benchmark Data Best Thermal energy efficiency award by NCCBM for FY Unit Energy Performance Comparison: At A Glance With benchmark/cluster units performance (Year ) Sp. Heat Consumption (Kcal/kg clinker) G O O D International Bench mark National Benchmark KCW Rajshree Cement (UTCL) Kotputli Cement (UTCL) Vikram Cement (UTCL) Overall sp. Power Consumption (Kwh/MT cement) G O O D 40 International Bench mark National Benchmark Aditya Cement (UTCL) Kotputli Cement (UTCL) Vikram Cement (UTCL)

23 UNIT BRIEF SUMMARY FOR PAT STATUS

Kcal/kg PPC Equiv. PAT Status GtG energy consumption status No. of Energy Saving Certificates 37153 1200 1000 993 937 28.

Status PAT Cycle 2 Unit is registered as Designated Consumers (DC) under PAT scheme. Target given for 5.

24 Kcal/kg PPC Equiv. PAT Status GtG energy consumption status No. of Energy Saving Certificates % reduction (Baseline year) Target SEC for PAT cycle 1 Actual PAT Cycle 1 Baseline PAT Cycle 2 Target PAT Cycle 2 Status PAT Cycle 2 Unit is registered as Designated Consumers (DC) under PAT scheme. Target given for 5.6 % reduction in GtG Specific Energy Consumption for PAT Cycle-1 (FY14-15) Implementation of ENCon projects in the unit reflects % reduction in SEC in PAT cycle-1. Now entitled for Nos. of Escerts costing about Rs.37.0 Crores

25 DETAILS OF INNOVATIVE PROJECTS

26 Project 1 Reduction in Cooler Fans Power Objective:- 1. To reduce pressure drop of cooler fans (11 Nos.) 2. To reduce fan and Kiln Sp. Power Consumption Project Description All the fans were having Louvre damper at the fan inlet, and they were not in operation and moreover these fans are having VFD drives After pressure measurement it was found that there was an average of 10mmWg pressure drop in each fan across the damper. Moreover it was observed that the due to dust, the pores on inner surface of silencers got clogged and it became ineffective from long period. So we removed silencer and reduced pressure drop of about 8mmWg.

27 Project 1 Reduction in Cooler Fans Power Results:- 1. Reduction in pressure drop by mmwg. 2. Power saving of 0.46 KWH/Mt of clinker 3. Cost Saving of 32.20Lacs/annum Before Before After Cooler fans power After

28 Objective:- Project 2 - Process fan pressure drop reduction To reduce power consumption of major process fan by pressure drop reduction by fan inlet box enlargement. Project Description:- Preheater fans (2 Nos.) and cement Mill fans ( 2 Nos.) were having high pressure drop so there inlet box was enlarged to reduce the pressure drop by mmwg.

29 Project 2 - Process fan pressure drop reduction PH Fan - Before Modification PH Fan - Proposed Modification

30 Project 2 - Process fan pressure drop reduction Cement Mill Fan Modification

Results:- Project 2 - Process fan pressure drop reduction 1. 15-20mmWg pressure drop reduction in all the fans. 2. Reduction in sp. Power consumption of preheater fans by 0.14KWH/Mt of clinker. 3.

31 Results:- Project 2 - Process fan pressure drop reduction mmWg pressure drop reduction in all the fans. 2. Reduction in sp. Power consumption of preheater fans by 0.14KWH/Mt of clinker. 3. Reduction in sp. Power consumption of cement mill fans by KWH/Mt of cement in different grades CM Mill Fan Power KW Reduction by KW in diff. Grade Before After OPC43 OPC53 PPC CM Mill Fan Sp. Power KWH/MT Reduction by KWh/Mt Cem in diff. Grade Before After OPC43 OPC53 PPC

32 Project 3 - Compressor Specific power consumption Objective:- To reduce compressor specific power consumption. Project Description:- Compressor power is required in all sections and contribute majorly towards auxiliary power consumption. So we have carried out following modifications (1) Installed PID based VFD in one of the compressor to reduce the unloading power, optimized the run hrs and load setting of compressor. S.NO Compressor no Pressure set point in bar COMPRESSOR LOAD/ UNLOAD SET POINT Before Controller setting in bar Back pressure maintained before controller Pressure set point in bar LOAD UNLOAD LOAD UNLOAD 1 L41CP CP CP CP After Controller setting in bar Back pressure maintaine d before controller

33 Project 3 - Compressor Specific power consumption 2. Installation of air flow meter in all area to identify key focus area ( blaster operation) to reduce consumption of compressed air. 3. Check pressure drop and replace before and after air filter of air drier to reduce pressure drop across air drier. S.NO DRIER TYPE DRIER NO. PRESSURE DROP ACROSS DRIERS Inlet before pre filter Before Outlet after post filter PRESSURE IN BAR Diff Inlet before post filter After Outlet after post filter 1 REFRIGRATOR L41DR REFRIGRATOR 431DR REFRIGRATOR 461DR REFRIGRATOR 361DR Diff

34 Project 3 - Compressor Specific power consumption 4. Installed PID based VFD in pre and post Clinkerisation pump house

Results:- Project 3 - Compressor Specific power consumption 1. Reduction in sp. Power consumption of compressor by 0.17 KWH/Mt of clinker. 2. Cost saving of Rs. 23.

35 Results:- Project 3 - Compressor Specific power consumption 1. Reduction in sp. Power consumption of compressor by 0.17 KWH/Mt of clinker. 2. Cost saving of Rs Lakhs/ year 11, ,500 10,000 9,500 9,000 8, Oct-16 Nov-16 Dec-16 Jan-17 Feb-17 Mar Before 0.94 After Average Compressor power per Day KWH/Day Sp. Power consumption KWH/T clinker

36 PLAN MATRIX FOR FUTURE ENCON PROJECTS

37 Plan matrix for Future ENCon Projects S.N Energy Saving theme Raw mill bag house fan power reduction by inlet duct modification Reduction in kiln coal firing blower power and Nox level reduction through burner modification Reduction in cooler ESP rotary air lock power consumption Optimization of compressor power by running bag filter in DP mode Enhancement in burner castable life by using new generation Hasle castable Potential Energy Saving Elect (MWH) Thermal (Mkcal) Target For Completion Jul Aug Sep Oct Nov-17

38 S.N Energy Saving theme Installation of modular lining (Hasle) in all feed pipes of cyclones. Installation of Hasle imported castable in DSC. Potential Energy Saving Elect (MWH) Thermal (Mkcal) Target For Completion Aug Aug Coal mill fan inlet duct modification Dec Plan matrix for Future ENCon Projects Running Pyroclone burner coal transport blowers through VFD CFD of preheater cyclone to reduce pressure drop Cooler fan power reduction by Installation of baffle / flow guiding plate Dec Aug Aug Installation of WHR system Mar-19

39 S.N. Projects 1 Saving of Natural fossil fuels by utilization of Petcoke upto 96%. 2 3 Rain water harvesting system (New 4 nos. Structure covered with a total of 23 nos of structures developed at plant colony, mines and its near by areas till March 16.) Utilization of high MgO% limestone by blending it for enhancing Mines life & conserving high grade Limestone. 4 Utilization of hazardous waste like ETP sludge Green belt development (Developed hectare in plant and 44 hectare in mines as on March 16) 6 100% reutilization of waste water 7 Fugitive dust control (Under progress additive shed of 41.68x30M & 50.35x90M) 8 CO2 & NOx reduction measures 9 Enrichment in TSR by increasing usage of Carbon Black and FMCG waste as an AFR 10 8 Watt CFL replaced by 5W LED lamps in colony 11 Environmental Initiatives Reduction in sp. water consumption by proper monitoring & metering in each Section

40 Environmental Initiatives Carbon Management Policy Water Policy

41 G O O D % 95% 92% 91% 91% 91% 91% No's of sapling planted Survival rate About 42% area is covered under green belt against the requirement of 33%. Cumulative Survival rate = 91%

42 Environmental Initiatives Sapling Distribution to Villagers Green Belt Development Ground water recharging through injection well Rain Water Harvesting Ponds

43 Environmental Initiatives 100 kw solar power plant in colony Concreted roads & floor area Covered storage facility for raw materials, fuel & clinker Covered conveyor belts & dust filters at all the material transfer points

44 INVOLVEMENT OF EMPLOYEES/ SHARING OF BEST PRACTICES

45 Approach, Deployment & Review- Improvement Projects /Kaizen/Suggestions Loss Matrix Improvement Projects- Operating Teams Kaizens Operating Teams Suggestions- Operating Teams SII Team/Operating team Monthly meeting WCM team meetings Energy mapping & Balancing Benchmarking Section wise Budgeting PLC Based Energy Monitoring System Relative Monitoring of TPP, RSEB, IEX Cost Monthly P&B Data on Group Units Action by WCM Shop floor Teams Daily Power report Daily production Report/Meeting Monthly Comparison-Benchmark Units Energy Audit through CETS Monthly MPR Meeting Monthly Capex Meeting WCM steering committee meeting

46 ENERGY MONITORING METHODOLOGY

47 Inputs Energy Planning Saving/ Result Quantification Past and present energy use Analyze Energy Use and Consumption Identify Area of significant energy use and consumption Energy Baseline Target Action Plan to achieve target Measuring and Monitoring of Result Indicators. Relevant Variable affecting significant energy use Performance Indicators Identify opportunity for improving Energy Performance Review

48 Periodic external audit takes place, below is the outcome of FY17 Audit S.No. Category of Findings Total No. 1. OFI Observation Minor NC Major NC 00 Total 07

49 Unit Head FH(Tech) Crusher & RMCH Raw Mill Kiln & Coal Mill Cement Mill Packing Plant Maintenance Production Quality

50 Energy Monitoring System

51 Daily Monitoring & Review Formats S.No. Description Format 1 Daily Power Report 2 Daily Section Performance Review Report 3 Daily Compressor Power Report 4 Daily HOF Optimization Report 5 Daily Idle run hrs report

52 UTILIZATION OF RENEWABLE ENERGY SOURCES/WASTE MATERIAL

53 Utilization of Renewable Energy sources/ Waste Material Solar Power Generation (kwh) REC purchased 6438 solar certificates under RPO Utilization of waste material Use of TPP bed ash in limestone pile with ~0.11 % Limestone replacement Use of Fly ash up to % in PPC production Use of waste from Carbon Black Industry and FMCG waste in fuel firing with ~0.70% TSR Use of wet Flyash about 6% of total PPC production.

54 AWARDS & ACCOLADES

55 constituted by National Council for Cement and Building Materials

56 CII Energy Efficient Award Consecutively 5th year..

57 Rajasthan Energy Conservation Award Year : 2012 & 2014

IMPLEMENTATION OF ISO 50001:2011 & BEST PROJECTS ON ENERGY THE RAMCO CEMENTS LIMITED JAYANTHIPURAM

IMPLEMENTATION OF ISO 50001:2011 & BEST PROJECTS ON ENERGY CONSERVATION @ THE RAMCO CEMENTS LIMITED JAYANTHIPURAM Ramco Group Cement Ready Mix Concrete Cement Fiber Products Cotton and Synthetic Yarn Software