18 th National Award for Excellence in Energy Management 2017

Transcription

1 18 th National Award for Excellence in Energy Management

2 RAJASHREE CEMENT FAMILY Awards & Recognitions from 2012 : Safety & Environment Safety Excellence Gold Award in 2013 FIMI Health & Safety Award Regional Industries (GRISD) Safety Award 2012 & 2013 Greentech Environmental Award-2015 Athyunnatha Suraksha Puraskar, NSC-Karnataka Region Others FIMI Excellence Award for the year Hotgi Cement Works, Solapur Birla Super Bulk Terminal, Doddaballapur Mangalore Cement Unit, Mangalore Pune Bulk Terminal RC and its grinding unit Hotgi constitutes 14% of the company asset with 17% of the UTCL production capacity. We are the front-runners in Lowest Manufacturing Cost/Bag of Packed Cement in UTCL, possible only due to energy and process optimization. Golden Peacock HR Excellence Award-2015 IMC RK Bajaj National Quality Award-2015 Chairman s WCM Operational Excellence Gold Award 2015 CII Excellent Energy Efficient Unit Award for the Captive Power Plant-2016 CII Energy Efficient Unit Award for the Cement Plant

3 Plant Overview st plant set up by Indian Rayon with Production capacity of 1500 TPD, upgraded to 3100 TPD through modifications. Plant Supplier: KHD L-1 : 3100 TPD Total : 3100 TPD 1990 Commissioned 2 nd Line with clinker production capacity of 3000 TPD, upgraded to 4150 TPD through modifications. Plant Supplier: KHD L-2 : 4150 TPD Total : 7250 TPD 1995 Commissioned 3 rd Line with clinker production capacity of 3500 TPD, upgraded to 5250 TPD through modifications. Plant Supplier: KHD L-3 : 5250 TPD Total : TPD 2013 Commissioned 4 th Line with Clinker Capacity of TPD. With potential for TPD, Plant Supplier: KHD L-4 : TPD Total : TPD Second largest single location cement plant in India, with a production capacity of TPD

4 Energy Accounting, Monitoring & Implementation System MONITORING SPECIFIC ENERGY CONSUMPTION PER TON OF 1) PRODUCT A) DAILY (DPR) DAILY PRODUCTION REPORT DAILY POWER REPORT B) MONTHLY (MPR) MONTHLY PERFORMANCE REPORT EXCEPTIONAL REPORT MIS-REPORT C) HALF YEARLY MIS REPORT D) ANNUALLY ANNUAL MIS REPORT ANNUAL BALANCE SHEET 2) REVIEW OF TARGETS A) ANNUAL ANNUAL BUDGET MEETING ANNUAL MAINTENANCE CONFERENCE Continuous improvement Energy Projects Implementation- Methodology Shop floor/brain storming Short term No Invest Low Invest Low Invest High Invest Immediate implementation Monitor savings/benefits Innovation management Project selection Medium term Roadmap for Continuous Improvement Measurement & analysis Energy Audit CAPEX Proposal Implement sanctioned project Long term High Invest Creativity management Kaizen Rewards & Recognition Capturing ideas thru Brain storming Implementation Data collection Problem solving tools In house experts Creating platforms Results & Control plan Sharing knowledge Continual improvement & Creativity through Employee Involvement 4

5 List of ENCON Projects with No Investments S No. Project Title Annual power saving (Million kwh) Annual cost saving (Rs Million) 1 Energy Reduction by process Optimization in Raw mill Increase in Coal mill IV output in pet coke grinding by modifying nozzle ring velocity & water spray 5.2 nozzles Operation of additional cooling fan interlock with temperature/operation in kiln shell Energy reduction in Utilities through optimized operations Energy Reduction by process Optimization in Cement mill S No. Eliminate feed cut due to weigh feeder discharge jam to reduce idle operation of cement mills Installation of atomized pneumatic valve in compressed air line in Line 4 cement mill 1 & Project Title 8 False air reduction of 5.5 % achieved across preheater & WHR with implementation of steel putty to arrest false air ingress points 9 Optimization of Calciner temp. by installing additional thermocouple which has stabilized Calciner temp fluctuation 10 Reduction in sp.thermal consumption by optimizing burner insertion length & its momentum Annual power saving (Million kwh) Annual Thermal saving (Ton/year ) Annual cost saving (Rs Million)

6 List of Encon Projects with No Investments S No. Project Title Annual power saving (Million kwh) Annual cost saving (Rs Million) 1 Line 4 Kiln operation without Clinker silo first time in Cement Industry (from Dec 2014 to Jan 2016) Line 4 cooler fans suction box modification to reduce specific power during Nov 2014 & Sept Cooler vent fan PID tuned and Speed reduction of CV fan from 65 to 60% RM3 Grinding Media Optimization for power reduction Raw Mill fan RPM reduction from 94% to 90% hence reduction on power consumption by 40kw VFD for compressor, IFC Installation & Pressure setting optimization 6.2KG/Cm Replacement of new burner tip for Petcoke firing to increase flame momentum up to 2500 % m/sec Bag House fan PID tuned to keep PH fan just -ve & Fan speed reduction Speed reduction of Dust collector fan with pulley change, delta to star conversion & high efficiency water pump for CM3 O/H Tank Removal of PH Downcomer Lower dampers & Sep. Fan Damper (RC4) Lighting Transformer Tap reduction & Lighting Circuit Modifications Bypass duct installation in cooler vent & PA Fan discharge Pressure reduction Cooler vent fan PID tuned and Speed reduction of CV fan from 65 to 60%

7 List of ENCON Projects with No Investments S No. Project Title Annual power saving (Million kwh) Annual cost saving (Rs Million) 1 Installation of VFD for U-3 Kiln Pfister & Kiln/pyro (standby) Pfister feeders (3K58 & 3K60) Raw mill-2 grinding media Optimization to reduce Specific power consumption Operation of Bauxite crusher of Unit-3 in remote mode from control desk by providing ZSS & 4 Temperature RTDs which reduced the idle running of LSSR circuit Coal mill IV bag house pressure drop reduction by mmwg by modifying the purging arrangement False air reduction in Preheater, Raw Mill and Coal Mill of Unit Automation and Centralization of Crusher & Stacking Operation Cement mill 3 grinding media optimisation and Cake Breaker Installation Reduction of PPC manufacturing cost by optimization of fly ash handling cost Energy saving initiatives in packing plant and fly ash handling in Unit-1,2, Cement mill 3 process optimisation Unit 3 kiln output optimization

8 List of ENCON Projects with Investments S.No. Project Title Annual power saving ( Million kwh) Investment Made (Rs, Million) Total Annual cost saving (Rs, Million) 1 Up gradation of Line-3 Cooler (IKN Pendulum) Line-3 Cement Mill Shell Liner modification Installation of Multi purpose Shredder Machine for Alternate Fuel Upgradation of Unit-3 Bag House fan SPRS System Upgradation of Reciprocating compressors with Rotary screw compressor Total

9 List of ENCON Projects with Investments S.No Project Title Line IV Preheater suction box modification to reduce velocity from 29 to 21 m/sec Hot air recirculation to L4 raw mill SKS bottom to reduce false air across Raw mill circuit & bag house fan power consumption in July 2016 Removal of orifice of coal mill bag house fan to reduce power consumption in Line 4 in June 16 Coal mill fan suction box modification to reduce velocity from 24 to 17 m/sec at Line IV Increase in Cooler ESP chimney height by 10.5 Mtr at Line IV to reduce fan power Cement mill IV SKS fan impeller replacement with high volume impeller to increase the mill output Annual power saving ( Million kwh) Investment Made (Rs, Million) Total Annual cost saving (Rs, Million) Installation of SPRS in Coal Mill 2 Fan Coal Mill-3 ESP to Bag house conversion and cyclone removal MV drive installation in Raw Mill-3 fan Installation of MV drive in U3 Pyro preheater fan Installation of MV drive in U3 kiln Preheater fan Removal of damper at raw mill 3 fan inlet to reduce pressure drop across the damper

10 List of ENCON Projects with Investments S.No. Project Title Annual power saving ( Million kwh) Investment Made (Rs, Million) Total Annual cost saving (Rs, Million) 13 Installation of MV drive in U3 Coal mill fan Installation of fresh air damper at RABH inlet to stop dilution air fan operation Removal of damper at coal mill 3 fan inlet to reduce pressure drop across the damper. Removal of damper at unit 3 kiln preheater fan inlet to reduce pressure drop across the damper. Extension of unit 3 cooler ESP chimney height extension from 50.3 mtr to 57.5 mtr Removal of cooler fan inlet dampers and mesh size increasing Replacement of Cooler vent fan HT motor with LT motor Reduction in Air loading /Power Consumption of RABH fans Erection of refractory hump has been to block the T A D, for reducing air flow through TAD. Kiln 3 Jet air Blower line modification to reduce the turbulence creating due to bends at blower outlet lines Total

11 Summary of Energy Conservation Projects With investment Year Year Projects implemented Projects implemented Annual cost Saving (Rs. Millions) Total With no investment Annual cost Saving (Rs. Millions) Total No.of ENCON Projects Savings, Million INR 11

12 Reduction in Specific Energy Consumption 720 Thermal (KCal/Kg Clinker) 71 Electrical (KWh/MT Clinker) % reduction % reduction % reduction % reduction

13 Cement Scenario Reduction in Total Specific Power (KWH/T Cement) % reduction Share of Blended Cement (%, of Total Production) 18.10% increase % reduction % increase

14 Benchmarking for SEC with best in class cement plants Dream India RCW RCW figure for Best India 650 plant 665 FY 16 Target Kcal/Kg Clk kcal/kgclk kcal/kgclk Kcal/kgclk Dream figure for India 62 KWh/T cement India best plant 66 kwh/t cement RCW FY kwh/t cement RCW Target kwh/t cement 45 KWh/T clinker Kwh/t clinker Data source : CII Benchmark Manual

15 Roadmap to reduce SEC to achieve benchmark ( ) S.No. Description Potential saving Target 1 Removal of Venturi and modification of fan I/L Suction box From Coal Mill Line Kwh/T Clinker Oct 17 2 Burner tip replacement to reduce flame momentum and through stopping one blower of 180 Kw.05 Kwh/T Clinker Sep 17 3 Pressure drop reduction study across Pyro section to identify opportunity for reduction in SEC. 1 Kwh/t Clinker Oct 17 4 Trial of Staged combustion in Line-4 Kiln NOX Reduction Oct 17 5 Optimizing Coal Conveying air NOX Reduction Oct 17 6 Installation of Flaps at KIDs area in IKN Cooler Line-4 for better air distribution 1 Kcal/Kg Clinker Oct 17 7 Line 2 and 3 Burner replacement with multichannel burner 136 Tons/ Year Oct Water circulation system to be in auto and to be operated based on requirement this will avoid unnecessary operation of pumps. In belt circuit, discharge chutes provided with self cleaning spring loaded plates, will give benefit in coating / jamming Units Dec Units Jan Vortex rectifier for reduce the pressure drop across the classifier in Vertical Raw Mill and Vertical Coal Mill Units Oct VFD for raw mill & Cement Mill silo top bag filter, it has to interlocked with draught Units Dec P & V system to be switch off at midnight once crusher operation stopped for night shift Units Sep Installation of material starvation switch to avoid idle operation Units Sep Installation of baffle / flow guiding plate, to guide the flow in case of cooler fan discharge duct having bend Units Oct 17

16 Project 1 : Modification of Preheater Fan Inlet Suction Box in Line-4 Kiln Problem : High power consumption of preheater fan close to motor rated power load at 900 rpm, cconstraint to increase clinker production more than TPD. Root cause derived : There was a high velocity at preheater fan inlet suction box 29 to 30 m/sec which was leading to high resistance (pressure drop 30 mmwg from common downcomer to fan inlet suction box Changes done Increased the width of suction box from 1010 mm to 1350 mm. (Increased the area by 30 %.) Modified the suction expansion joint by using the existing expansion joint only. Benefits Achieved : Achieved dream figure of TPD kiln, without taking fan out of SPRS Kaizen Idea Generated : To reduce pressure drop across duct by reducing velocity from 29 to 21 m/sec. To modify bend before suction box which was leading the turbulence.

17 Project 2 : Hot Gas By-pass Duct from V-Separator to SKS Bottom in Line-4 Raw Mill Circuit. Problem : Reduction in Air Loading/ Power Consumption of RABH Fans In process of RC-IV plant optimization,it was observed that Proposed Savings : S.no. Description Val ues Unit RABH fan motor loading was higher side i.e. Fan was handling 15,70,000 m3/hr instead of 13,90,000 m3/hr (design fig).source of this excess air observed to be Fresh air provided at Raw Mill Dynamic Separator bottom during mill optimization as per suggestion by OEM to provide fresh air to Dynamic Separator to increase separator efficiency for this separator bottom plate was removed. This Fresh Air was cause of higher amount of air handled by RABH Fan. S.n Description Value Unit 1 Area of bottom plate 1.05 M2 2 Area of opening (50 % ) 0.52 M2 3 Velocity 30 m/sec 4 Actual False air volume entry M3/hr 5 Normal False air Nm3/hr volume entry 1 False air volume thro SKS bottom Total False air Volume at both bag house fans inlet (105 & -150 mmwg) 3 False air Volume at Individual bag house fan inlet Nm3/ hr M3/H R M3/H R 4 Kw increase due to additional false air 45 kwh in one bag house fan 5 Kw increase due to additional false air 90 kwh in both bag house fans 6 Potential Reduction in Sp. Power consumption (10000 TPD) Kwh/t clk 7 Savings in money Lacs/a nnum Actual Savings: This modification in Raw mill lead to spectacular saving in RABH fan motor loading, detail are : RABH fan loading of each fan before modification :- 370X2 Kwh RABH fan loading of each fan after modification :- 279X2 Kwh in Mill -1,2&3 Total Saving in terms of KW for each RABH fan :- 90X2 =180 Kwh Saving achieved is equivalent to 0.4 Kw/Ton Clinker Total saving in terms of Rs Lakh/Year

18 Project 3 : Increase in Height of Cooler ESP Stack in Line-4 & Line-3 Problem: Cooler ESP fan power consumption was at higher side 0.5 kwh/t clk, than the India Benchmark 0.20 kwh/t clk Root cause derived : Cooler ESP fan operates at static pressure - 60 to -90 mmwg with WHRS at TPD and in Line-3 Cooler ESP fan operates at static pressure -70 to -80 mmwg. With low draft in chimney -10 mmwg the static head increases 50 to 80 mmwg. This has direct impact on power consumption of fan. Kaizen Idea Generated : To reduce static head of fan by increasing the fan outlet pressure means chimney draft. To increase the stack effect i.e. The gas inside the stack is around deg Celsius. The outside ambient air temperature is around 30 to 35 deg Celsius. Consider this as two air columns connected at the bottom. The high density and heavier cold air will be always pushing the low density and lighter hot gases up. This causes the natural flow of gases up the stack. This pressure difference that pushes the hot gas up the flue gas stack is called stack effect. 60 mtr in Line m in Line mtr. in Line m in Line-3 Changes done: 18 Replication potential if necessary Increased the chimney height from 60 mtr to 70.5 mtr. in Line-4 Increased the chimney height from mtr to 57.5 mtr. In Line-3 Benefits Achieved : In Line-4 Reduction in 40 kwh at same production & WHRS generation level, due to this head developed in case of WHRS isolation the CV fan power consumption is minimal approx.: 50 KWh. In Line-3 Reduction in 42 kwh at same production level, This reduction in power led to substitution of CV fan Motor from HT to LT Motor.

19 Project 4: Insulation on top stage (08 Nos) cyclones Problem : To reduce Specific Heat Consumption by minimizing radiation losses in Preheater Replication potential if necessary Case study of insulation on top stage cyclone has been done. (Idea taken from Shree Cement, Raipur) With application of Newton law of cooling excel simulation with different gas temp has been carried out at present hysil & refractory thickness. Applied Heat Resistant Aluminium Oxide paint on 6 No. of Cyclones in Preheater in Line-4, shell temp. reduction is up to 50 Degree Celsius on painted surface. 150 Degree C 60 Degree C APPLICATION OF HR PAINT ON P6 CYCLONE 100 Degree C Feed Rate : 328 TPH K F factor Const. Clinker Prod Rate 4948 TPD Clinker Prod Rate Kg/hr Ambient Temperature 30 C Pyro Cyclone -6 Surface area Surface Temp Radiation Convection Total Sp. Radiation Point Wt. Avg. DIA (m 2 ) ( o C) (kcal/hr) (kcal/hr) (kcal/hr) (Kcal/Kg Clin) cylindrical portion conical portion cyclone top meal pipe duct from previous stage *Reduction In surface temperature of 15 C After HR paint insulation. Pyro Cyclone -6 Point Surface area Surface Temp Sp. Radiation Radiation Convection Total (m 2 ) ( o C) (Kcal/Kg Clin) Savings In Fuel Consumption kcal/kg clinker Coal NCV kcal/kg coal 7170 Kiln Operating days Days 330 Coal Price Rs/ MT 6052 Total saving in Rs Lacs/Annum

20 Green House Gases - Inventorization Specific CO 2 Emission Kg CO2/ MT of Clinker Kg CO2/ MT of Cement Steps undertaken for Reducing Carbon Footprint MW Waste Heat Recovery System at Line-4. Increase Fly ash percentage in PPC manufacturing. Increase in production share of Blended Cement. Heat rate reduction by 20 kcal/kg clinker in Line 3 Cooler. Biogas plant at colony for gasification by using kitchen waste. Use of hazardous waste / Alternate fuels in kilns. 100 KW Solar panels at Township. Planted around 4.93 lacs trees till 2017.

21 Kcal/Kg of equivalent cement PAT (Gate to Gate Sp. Energy Consumption) Target to reduce GTG 4.8% for PAT-I 1077 Assessment year Target to reduce GTG 5.06 % for PAT-II Baseline year Target SEC For PAT-I Target SEC For PAT-II

22 Solar Gen % WHRS Gen % Utilization of Renewable Energy

23 QTY (MT) Performance Trends-Alternate fuel AFR consm. TSR% AFR FY FY FY FY FY FY FY Hazardous material supply from M/s TVS,TATA motors Started in Line-4 Better coordination in between procurement cell, AFR cell & end user Bouser feeding of Carbon powder FY Major contribution from FMCG materials AFR started in RC-4 also Good amount of Hazards waste receipt FY Major contribution from Pharma Waste ETP Sludge, Paper Wastes etc. being disposed Focus to maximize carbon powder usage

24 M 3 /T Clinker M 3 /T MWH Water Conservation Measures Air Cooled Condensers (ACC) at Line-IV CTPP. Line-3 Kiln ESP converted to Bag House KL/D Water saving. Sewage Treatment Plant (STP) with Activated sludge process. Air Cooled Condensers - TPP Rain Water harvesting Mines Treated waste water utilization for Process, Greenbelt & Water Spray. Zero waste water Discharge from Plant & Colony. Rain water harvesting & collection at Mines pit. New clarifier - STP Waste water utilization Pond Plant Water Consumption CPP Water Consumption Lacs M Colony Water Consumption Year Year Year 24

25 Platform for Learning and Sharing Learning Learning Sessions KIP Visit In House Magazine Safety Talk RCW Intranet Site Technical Library KAP and KM portal GroupWise Team Competition Sharing Knowledge Sharing Sessions In House Magazine Safety Talk Knowledge sharing through s General Comm. meeting, Kaizen Capsule Group wise Team Competition KAP portal Pulse & U-Link Specific learning from Sister and Competitor Units are: Enhanced petcoke usage in Kiln and Petcoke usage in TPP (old) from Dalmia Cement unit Top cyclone insulation from Shree cement Caustic soda addition in kiln for petcoke firing from Ambuja Cement Co-grinding of limestone with petcoke in coal mill from Meghalaya Cement Reject chute from SKS in raw mill in place of air slide from Rawan Cement Works (UltraTech) Cooler fans suction box modification from Meghalaya Cement Heat shield installation in cooler from ACW (UltraTech) 25

26 Excellence is Nothing But A Passionate Journey driven by Positive Attitude... 26