Award For Excellence in. Energy Management-2017

Transcription

1 Presentation for 18 th National Award For Excellence in Energy Management

2 COMPANY PROFILE Mangalam Cement Limited belongs to B.K.Birla Group of Companies. Our first Plant was commissioned in the year 1981, with an installed capacity of 4 lacs tons of cement per annum. Present capacity of cement production is 3.25 MTPA. 2

3 COMPANY PROFILE UNIT-I UNIT-II UNIT-III CPP WIND MILL CRUSHER TO PACKING PLANT FLS, KILN 3000 TPD WITH SIX STAGE PREHEATER, INLINE CALCINER,SF 12X33 CROSS BAR COOLER, ATOX VCM and ATOX VRM. CRUSHER TO PACKING PLANT THYSSENKRIPP, KILN 4000 TPD WITH 5 STAGE PREHEATER, INLINE CALCINER, REPOL SR 312-IKN GRATE COOLER,VCM and VRM NEW CEMENT GRINDING UNIT & PACKING PLANT THYSSENKRUPP, CEMENT MILL 1.25 MTPA 2 X17.5 MW 13 Nos WIND MILLS OF MW CAP. INSTALLED AT JAISALMER (RAJ.) ABL, CEMENT MILL WITH VRPM AS PREGRINDER IN CLOSED CKT, LNV SEPARATOR, CAPACITY 0.8 MTPA. THYSSENPRUPP ROLLER PRESS, CEMENT MILL WITH ROLL PRESS IN CLOSED CKT. CAPACITY 1.2 MTPA THYSSENKRUPP ROLLER PRESS, CEMENT MILL WITH ROLL PRESS IN CLOSED CKT. CAPACITY 1.25 MTPA 3

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6 S.No. Year Description of measures Saving in TOE FY Implementation of auto start/stop software logic in both compressor Implementation of software logic in both bag filter fan (G581FN1 & G581FN3) for auto stop of bag filter fan Logic made in PLC for auto start / stop of heater Changed loading pressure setting from 6 bar to 5.5 bar and unloading pressure setting from 7 bar to 6.5 bar of all 4 compressors of MGU packing plant

7 S.No. Year Description of measures Saving in TOE FY After optimisation of lighting system 44 Nos 400 watt light fittings were removed from different towers Bag house discharge material taken directly to final air slide via direct chute Bag filter fan inlet damper controlled & tuned from CCR with fan current to save the power of fan Electrical consumption reduced by controlling ESP field current as per dust emission through stack

8 S.No. Year Description of measures Saving in TOE FY Sealed false air from 37.0 % to 23.3 % in Coal Mill-I, resulted in power saving of power Coal Mill Fan Sealed false air from 56% to 42.5 % in Coal Mill-II, resulted in power saving of Coal Mill Fan Sealed false air from 28.0 % to 14.2 % in VRM-I Circuit, resulted in power saving of VRM Fan Improved Power Factor in Kiln-II PCC Incomer 6.6 KV from 0.85 to

9 S.No. Year Description of measures Saving in TOE Investment in lacs Kiln-II: Duplex Graphite Lemmela Seal Installation in place of Pneumatic Seal to reduce false air entry CM-II: Installation of DD Cones in all the four Sepol Cyclones to reduce pressure drop and replacement of double flap valves by RALs to reduce false air ingress Replacement of push feeder by sector gate in Cement Mill Removal of two belt conveyors from LS feeding circuit of VRM-1 by providing direct chute to hopper

10 S.No. Year Description of measures Saving in TOE Installation of de dusting cones (DD cones ) in LNVT separator of VRPM and both the cyclones of SEPOL separators in Cement Mill Installation of de dusting (DD) cone in dynamic separator of VRM Made a Dam of height 800 mm in TAD to restrict Tertiary Air flow rate and to reduce excess air in secondary firing from 20 % to 10 %. Removed Silencers from all the cooler fans to reduce the pressure drop ranging from mmWG in all cooler fans of KILN Investment in lacs

11 S.No. Year Description of measures Saving in TOE Investment in lacs Filler material feeding arrangement by PS pump in place of dense phase. Enlargement of Cooler Exhaust Duct Area from 4.91 m2 to 9.62 m2 to reduce dust loading in ESP KILN-2. Enlargement of Preheater Down comer Duct from 5.72 m2 to m2 IN KILN Increase of Calciner Length from 48.0 meter to 64.0 meter IN KILN

12 S.No. Year Description of measures Saving in TOE Investment in lacs Increase in cross section area of Tertiary Air Duct (TAD) from 1.61 m2 to 3.36 m2 in KILN Enlargement of Smoke Chamber Area from 4.74 m2 to 6.51 m2 in KILN Increase of Inlet Duct Area of Bottom Cyclone from 9.92 m2 to m2 in KILN Enlargement of Take off Duct Area from 5.58 m2 to 8.20 m2 in KILN

13 S.No. Year Description of measures Saving in TOE FY Investment in lacs Replacement of Kiln Inlet Seal from Pneumatic Seal to Graphite Seal in KILN-1. Replacement of belt conveyor 501BC3 & fixing of DPC of 150TPH in KILN-1. Through modification of discharge chute of 903BC5 lime stone fed in hopper directly without running of 961BC1 and 961BC2 belts in KILN- 1. Installation of auto delta to star starter in G501BC6 & BC7 conveyor belts drives

14 S.No. Year Description of measures Saving in TOE FY Reducing the preheater exit oxygen from the level of 7% to 4% for Kiln-I by restricting excess air flow through TAD. Reduced the pressure drop through modification in the separator fan inlet duct of Cement Mill Installed VFD for 975BL1 (132kw) root blower in KILN Installed VFD for 212FN2 (75kw) BF fan in crusher section Replacement of chain type elevator 150 TPH by belt bucket elevator of 250 TPH in KILN-1. Investment in lacs

15 kwh/ton of cement * * Unit-I, Plant shutdown for Rehabilitation work 15

16 THERMAL SEC (GCV BASED) 840 KILN-I COMBINED KILN-II

17 National Benchmark International Benchmark Mangalam Cement Limited Specific Energy Consumption Thermal (Kcal/kg of clinker) (GCV BASED ) KILN-I 699 KLIN-II 738 COMBINED 720 Specific Energy Consumption Electrical kwh/t of cement (Actual) (100% PPC) (ON PPC ONLY) (YEAR ) 17

18 12.00% 10.00% 8.00% 6.00% 4.00% % OF WIND MILL POWER IN TOTAL POWER CONSUMPTION OF PLANT 6.20% 8.30% 11.50% 10.20% 7.60% LOW DUE TO CABLE THEFT PROBLEM 8.90% 8.56% 9.32% Wind Power for Captive Use = Lacs Units So Saving in Mkcal = Mkcal Saving in TOE = TOE 18

19 35.00% FLY ASH CONSUMPTION IN % 30.00% 25.00% 26.05% 27.47% 31.11% 30.57% 31.08% 20.00% 15.00% 10.00% 15.35%

20 REDUCTION CO 2 EMISSION Kg/Kg PPC CEMENT CO 2 Reduction in ton CO REDUCTION DUE TO HIGHER CONSUMPTION OF FLY ASH IN PPC WITH REFERENCE TO Highest ever PPC Production Less reduction due to less PPC Production CO2 Reduction in Tonne CO2 Emission, Kg/Kg Cement 20

21 20.00% 18.00% 16.00% 14.00% 12.00% 10.00% 8.00% 6.00% 16.90% 100% INDIAN COAL USED PETCOKE CONSUMPTION IN % OF CLINKER PRODUCTION 18.10% 100% INDIAN COAL USED 12.50% 57% PETCOKE & 43 % INDIAN COAL USED 10.20% 10.50% 9.50% 9.56% 9.33% 100% PETCOKE USED 85 % PETCOKE & 15 % INDIAN COAL USED 100% PETCOKE USED 100% PETCOKE USED 96.4% PETCOKE, 1.4 % INDIAN COAL & 2.2 % US COAL USED

22 19.00% 17.00% BY USING PETCOKE REDUCTION IN % HGLS CONSUMPTION 17.01% 15.00% 13.00% 16.14% 13.45% 11.00% 9.00% 10.80% 10.22% 9.40% 7.95% 9.02% 7.00%

23 SR. NO MEASURES TAKEN FOR CO 2 REDUCTION 1. DUE TO REDUCTION IN SPECIFIC HEAT AND POWER CONSUMPTION OF CLINKER W.R.T. YEAR DUE TO HIGHER USE OF FLY ASH IN PPC PRODUCTION W.R.T. YEAR DUE TO USE OF GREEN POWER (WIND MILL POWER FOR CAPTIVE USE) TOTAL

24 SR.N O MEASURES TAKEN FOR CO 2 REDUCTION BY NOT USING VEHICLES ON EVERY MONDAY WHILE COMING TO OFFICE 2. BY REDUCING SP HEAT RATE IN CPP TOTAL

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27 GREEN BELT DEVELOPMENT (PLANT, COLONY & MINES) (JAN-JULY) GREEN BET DEVELOPMENT -YEAR WISE TOTAL PLANTATION (1991 TO July 2017) 27

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30 MANGALAM CEMENT LIMITED REVIEW STATUS OF DEPARTMENTAL OBJECTIVES (Frequency - Monthly) FORMAT NO. : F UNIT : DEPT : REV : No : VER : No : Date : Obj No. Objective Baseline Status Desired Status Final Target MONTHWISE STATUS Date APR-16 TO MAR-17 YTD Prepared By Approved By : Checked By 30

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34 Sr. No 1 2 ENCON EFFORTS PLANNED FOR THE NEXT THREE YEARS Description of projects Installation of WHR in KILN I & II of 8.5 MW & expected generation (net) is 545 lacs units /year. Upgradation of KILN II by modifying preheater from 5 stage to 6 stage and upgradation of cooler 3 Modification in UNIT -II CEMENT MILL V- separator material feeding system for increase in output & reduction in specific power consumption Investment Rs Rs 63 CRORES RS 15 CRORES Expected saving Thermal energy saving TOE 40 kcal/kg of clinker LACS 8.88 LACS KWH 4 Modification in lime stone feeding system of VRM -I 10 LACS 3.15 LACS KWH 5 Reduction in plant lighting consumption by using of high efficient led lights in place of conventional lights LACS LACS KWH 34

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36 National Safety Award (Mines) 2011 ON LOWEST INJURY FREQUENCY RATE in the category of Highly Mechanized Opencast Mines was given by the President of India in association with Minister of Labour & Employment (Government of India) at Vigyan Bhawan- New Delhi. 36

37 CFBP (Council of Fair Business Practices) Jamanalal Bajaj Uchit Vyavahar Puraskar for Fair Business Practices in Manufacturing Enterprises SME category for the year 2014 was received from Hon ble Former President of India late Dr. A.P.J. Abdul Kalam. 37

38 Rajasthan Energy Conservation award Was given by Honorable Energy Minister of Rajasthan. 38

39 National Award For Excellence in Energy Management from CII This National award is given in recognition of Excellence in Energy management in cement sector by CII. Award was given by chairman Bureau of Energy Efficiency (BEE) Dr.Ajay Mathur on 3rd September 2015 at Hyderabad. 39

40 Productivity Award from Rajasthan State Productivity Council. This award is given in recognition of Improvement in Productivity Performance by Rajasthan State Productivity council. Award was given by Honorable Minister for Industries Govt. of Rajasthan Shri Gajendra Singh on 30th September

41 Energy Conservation Merit award 2015 from Rajasthan State Government. This award is given in recognition of Energy Conservation in Cement Sector by Govt. of Rajasthan. Award was given by Energy Secretary of Rajasthan state Govt. Shri Sanjay Malhotra on 14th December

42 National Energy Conservation Merit Award 2015 by Ministry of Power Government of India. This award is given in recognition of Energy Conservation for Cement Sector. Award was given by chairman Bureau of Energy Efficiency (BEE) Dr.Ajay Mathur on 22nd January

43 Award for outstanding Performance in Rural Development by Employer Association of Rajasthan for the Year This award is given in recognition for outstanding Performance in rural development work by Employer Association of Rajasthan. Award was given by Honorable Minister for Higher Education Shri Kalicharan Sarraf on 25th Feb 2016 at Jaipur. 43

44 26th MINES ENVIRONMENT & MINERAL CONSERVATION AWARDS (Under the aegis of Indian Bureau of Mines, Ajmer Region) I st prize in the field of TOP SOIL MANAGEMENT. 44

45 26th MINES ENVIRONMENT & MINERAL CONSERVATION AWARDS (Under the aegis of Indian Bureau of Mines, Ajmer Region) II nd prize in the field of AFFORESTATION. 45

46 Rajasthan Energy Conservation Award 2016 I st prize in Large Cement Sector of Rajasthan. This award is given in recognition of Energy Conservation in Cement Sector by Govt of Rajasthan. Award was given by Energy Secretary of Rajasthan state Govt Shri Sanjay Malhotra on 14th December

47 Star Award Sustainable Development by Ministry of Mines, Govt. of India at National Mineral Conclave Four Star Award to Morak Limestone Mines of M/s Mangalam Cement Ltd. for Sustainable Development by Ministry of Mines, Govt. of India at National Mineral Conclave at Raipur 47

48 Award for outstanding Performance in Rural Development by Employer Association of Rajasthan for the Year This award is given in recognition for outstanding Performance in rural development work by Employer Association of Rajasthan. Award was given by Honorable State Finance Minister Shri Arjun Ram Meghwal. 48

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51 Thank You All 51