Plant history & Details

Transcription

1 Slide 1

2 Plant history & Details 1985 M/s M/S TEXMACO LTD Capacity 00TPD Cement Plant 1993 Enhanced production capacity from -00 TPD to 1800TPD 1995 Management Change to ZUARI INDUSTRIES LIMITED 1998 Plant capacity has enhanced to 5000 TPD (1.8MTPA- Clinker) :50 Joint venture with Italcementi Group 2006 Become 100 % share holder in ZCL Clinker production cap. increased to 1.8 to 2.0MTPA Clinker 2010 Second Clinker Line(2.3 MTPA) Commissioned 20 Management took over by HEIDELBERG CEMENT 1995: Management 1993: Took over by Enhanced ZCL Production 1985: 00 to 1800TPD TEXMACO LTD : Enhanced Clinker Prod 1.6 to 1.8MTPA 2000: 50:50 Joint venture with Italcementi Group 2006: Italcementi become 100 % share holder in ZCL 2009: Enhanced Clinker Product 1.8 to 2.0 MTPA 2010 : New Clinker Line (2.3 MTPA) Commissioned 20 : Management Took over by HEIDELBERG CEMENT Slide 2

3 ZCL Yerraguntla Plant Installed Capacity (Clinker) mmtpa Installed Capacity (Cement) mmtpa Wind Power Installed Capacity - 6 MW Solar Power Installed Capacity Kw Product Range - OPC, PPC, PSC and MC Slide 3

4 Sl. No. Energy Saving Projects Implemented during last 3 years with No Investments Title of Project Year 1 Reduction of damper loss in line-2 cooler vent fan 2 Optimization of Quarry Water Pumps 3 Optimized use of pet coke with red mud & Increased clinker production 4 Optimization of Raw Mill grinding media 5 Optimization of Cement Mill-3 grinding media 6 Optimization idle running power by logic modification 7 Punch plate removal in Raw mill-3 8 Avoiding Coal crusher running during imported & pet coke unloading 9 Reducing the line-2 water pump speed during kiln 20- shut down 10 Replacement of diesel with pyrolysis oil 20- Electrical Saving (kwh) Electrical Cost Saving (Rs million) Thermal Saving (Ton/year) Thermal Saving (Rs million) Total Savings (Rs million) Invest ment Made (Rs million) Pay back (Mon) Slide 4

5 Sl. No. Energy Saving Projects Implemented during last 3 years with No Investments Title of Project 11 Reduction of surface in 43 grade cement 12 Coal Crusher bypass during fine (imported) coal unloading. 13 Increased OK mill PPC grinding Maximizing unloading fly ash in bin instead of 14 unloading in silo Coal mill CA fan inlet damper removal K String PH fan trimming Arresting leakages in VRM-1 18 Arresting leakages in Line-1 PH and optimised PC fan 19 OK Mill Reject pipe modification 20 Installation of Fly ash feeding to mill discharge arrangement Year Electrical Saving (kwh) Electrical Cost Saving (Rs million) Thermal Saving (Ton/year) Thermal Saving (Rs million) Total Savings (Rs million) Invest ment Made (Rs million) Pay back (Mon) Slide 5

6 Sl. No Energy Saving Projects Implemented during last 3 years with Investments Title of Project Optimization of Raw mill-3 circuit air flow volume after reject BE installation Reduction of Pressure drop across venturi in VRM-1 23 Optimization of coal transport blower in kiln-2 24 Line-2 Pyro section compressors Optimization 25 Line-2 Cement Mill section compressors Optimization 26 Line-1 Pyro section compressors Optimization 27 Optimization of pyro cooling water circuit Optimization of line-1 Cement cooling water circuit Reduction of pressure drop between bag house outlet to Fan inlet in CM-4 30 Street lights Optimization Year Electrica Electrical Cost l Saving Saving (Rs (kwh) million) Thermal Saving (Ton/year) Therma l Saving (Rs million) Total Savings (Rs million) Invest ment Made (Rs million) Pay back (Month s) Slide 6

7 Sl. No. Energy Saving Projects implemented during last 3 years with Investments Title of Project Year 31 Cement Mill-2 bag house fan replaced with high efficiency fan 32 Optimization of Line-2 water pump by Installation 20- of VFD 33 Damper and LRS losses reduced by installation of 20- VFD for CM-2 sepax fan 34 Damper and LRS losses reduced by installation of 20- VFD for CM-3 sepax fan 35 Optimised EEL packer Bag filter by Instaltion of 20- VFD 36 Line-2 PA Fan optimised by Instaltion of VFD Direct feeding of cement to EEL packer-2 vibrating 20- screen bypassing CB-2 circuit 38 OK mill separator Felt seal arrangement Line-1 Calciner coal firing blower speed reduced 20- by 10% 40 CM-2 Grinding media optimisation 20- Electrica l Saving (kwh) Electrical Cost Saving (Rs million) Thermal Saving (Ton/year) Thermal Saving (Rs million) Total Invest ment Savings Made Pay back (Rs (Rs (Months) million) million) Slide 7

8 Sl. No Energy Saving Projects implemented during last 3 years with Investments Title of Project Cooler vent fan HT motor replaced with LT Motor and installed VFD Installation of VFD for Line-1 Post Clinker Water Pupms Replacement of 250w HPSV street lights with 60 W LED lights Coal firing blower optimised with reducing blower speed by changing pully Installation of high efficiency bag house fan in cement mill -2 Installation of high efficiency bag house fan in cement mill -3 Installation of Solenoid Valve system In packing Plant for optimization of compressed air Rawmix optimisation after installation of crosbelt analyser Avoiding pnumatic conveying by Installation of new steel silo for export and slag cement. Replacement of 250w HPSV street lights with 60 W LED lights Year Electrica Electrical Cost l Saving Saving (Rs (kwh) million) Thermal Saving (Ton/year) Thermal Saving (Rs million) Total Invest ment Savings Made (Rs (Rs million) million) Pay back (Month s) Slide 8

9 Energy Saving Projects implemented during last 3 years with Investments Sl. No. Title of Project 51 Installation of VFD for Coal Mill FK Pump Optimisation of CF silo dedusting bag filter fan by Installing VFD Optimisation of post clinker compressor power by installing dedicated small compressor with VFD Replacement of line-1 VCLM CA Fan HT motor with high efficiency motor along with VFD Year Calciner Coal firing points connecting to feed box Coal Mill-2 separator rotor replacement 57 Increased usage of liquid pharma waste by installing storage system Electrica l Saving (kwh) Electrical Cost Saving (Rs million) Thermal Saving (Ton/year) Total Therma l Saving Savings (Rs (Rs million) million) Invest ment Made (Rs million) Pay back (Month s) Slide 9

10 Specific Energy Consumption % Reduced % Reduced Pet coke usage Target Target Target Description Unit Kiln-1 Utilization ( 4 th stage PH ) % Pet coke usage % CK Ratio % Slide 10

11 Global norms/bench mark Data & Competitors Comparison with Global Benchmark Data Specific energy consumption ZCL Achieved National bench mark International bench mark Thermal - Kcal/Kg clinker Electrical-kWh/T of cement Comparison with nearest competitors Specific energy consumption Thermal - Kcal/Kg clinker Electrical-kWh/T of cement ZCL Achieved ICL, Chilamkur Bharathi Cements Ultratech Cement Slide 11

12 Energy conservation projects planned Estimated Sl. No Title of Project Year Electrical Savings (kwh/year) Thermal Savings (Ton/year) 1 Kiln-1 K-String top HP cyclones (1A,1B&1C) modification to LP cyclone Kiln-1 Old Pre heater Fan replacing with high efficiency fan Raw Mill-3 rollers and Mill internals modification Kiln-1 cooler modification ( ABC inlet ) Installation of line-1 fine coal dosing system Reduction of Pressure drop in C - line bag house out let to fan inlet duct Installation of Pyrojet burner for line Kiln-2 cooler modification ( ABC inlet ) Replacement of 70w HPSV area lights with 30 W LED lights Replacement of 250w HPSV street lights with 70 W LED lights Installation of mill scan for cement mill Installation of mill scan for cement mill Installation of WHR system for Line-1 and Line Slide 12

13 Innovative project- 1: Increased usage of Pond Ash Increased usage of Pond Ash from 30% to 33.5% Pond ash is having higher moisture and high foreign materials ( wood, stone) resulted jamming of chutes damaging belt conveyors. Also unable to feed fly ash requirement to the Mill resulted lesser fly ash consumption and frequent stoppages of the mill. ZCL developed vibro feeder as a pilot plant for improving feeding and separating foreign materials Utilizing 100% pond ash for PPC production is first in India and In-house design of vibro feeder for separating foreign materials and improving feeding is known concept but applied differently and also it is beyond the scope of OEM and having high Replication Potential in the sector 2282 Kwh / day, 10.2 Tons of coal /Day Installing vibro feeder Slide Lakhs per Annum 30 Lakhs 1 month

14 Innovative project- 2 : Inhouse Convertion of LRS system to LRC system in Atox-20 coal mill Inhouse convertion of LRS system to LRC system in Atox-20 coal mill ZCl installed Atox 20 coal mill in Mill Main drive is designed with LRS system for running full speed 980 RPM for normal coal grinding. As a sustainable and cost economic initiative ZCL decided to use pet coke for kiln firing. Main drive full speed is not required for Pet coke grinding but present LRS system is not possible to control the speed. So ZCL decided to modify LRS system to LRC system by Installing heat exchanger, installing circulating pump and arranged controlled electrodes movements from CCR resulted Main drive speed reduced from 980 RPM to 760 RPM In-house modification of LRS system to LRC system is known concept but applied uniquely. This project is high Replication Potential for the similar companies 60 Kw 10.8 Lakhs per Annum 1.5 Lakhs 2 month Slide 14

15 Innovative project- 3 : Optimization of VRM-2 ATOX-55 is the first mill in Asia order by Zuari cement ltd with design capacity of 430 TPH. Mill is taking higher power So ZCL decided to take the risk and modified the mill internals 1. Mill Fan trimming by 120 mm 2.Armour ring removed 3. Mill Internal Reject pipes extended 4.Water spray nozzle modified 5. Mill table area blocked by 50 Installed small receiver tanks for critical locations ZCL taken the risk and modified the mill internals. All those modifications are in-house and beyond the scope of OEM and having high Replication Potential in the sector 0.5 Kwh / Ton of mat 77.3 Lakhs per Annum Slide Mill Fan Trimming After removing Armour ring Reject Pipe extension Water Spray

16 Utilization of Renewable energy ( % of Total Energy) Description Replacement of Electrical Energy with Renewable Energy Installed Capacity (kw) (million kwh) % Share 20- (million kwh) % Share 20- (million kwh) % Share Wind Energy Solar Energy Total Replacement of Thermal Energy with Renewable Energy Description Fuel Savings in (million kcal/year) % Share Fuel Savings in 20- (million kcal/year) % Share Fuel Savings in 20- (million kcal/year) % Share Biomass Slide

17 Utilization of Waste as Fuel Name of the Fuel Quantity of waste Fuel used (MT) Heat Value Quantity of Heat Value Quantity of (million waste Fuel (million waste Fuel kcal/year) used (MT) kcal/year) used (MT) Heat Value (million kcal/year) Waste Fuel as % of total energy used Rice husk Ground nut shell Bangal gram Sun flower Sugar cane Coconut RDF Ecalyptus Areca nut waste Mangokarnel Carbon waste Dolachar Shredded tyres Jawar husk Supari Husk Subabul bark Liquid Alternative Fuel Spent carbon Liquid pharma waste Solid pharma waste Solid cake Total Slide

18 GHG Emission Inventorisation Year 2013 (Baseline Year) Scope 1 emissions CO 2 e (MT) Scope 2 emissions CO 2 e (MT) Scope 3 emissions CO 2 e (MT) kg CO 2 e/ MTof cement Mitigation Total Reduction in emission intensity since baseline year study CO 2 e (MT) Baseline Year , , , Target % Specific CO2 emission reduced compared to baseline year Slide 18

19 GreenCo and ISO Cetification GreenCo Gold, ISO 9001:2000 and ISO certified Cement Plant Slide 19

20 % Investment for Energy Conservation Projects on turnover S.No Description Units Investment 1 Total budget MINR CBA MINR 20 3 ATS MINR 50 4 Silo MINR VFD MINR 6 6 Bag filter MINR 5 7 Dip tubes MINR 20 8 PLC upgrade MINR 9 Nox measure MINR 4 10 Pharma waste syst MINR Cooler esp MINR.5 12 Lights LED MINR Total MINR % in total budget % 63 Turnover of the Unit MINR 160 % investment on turnover % 2 Slide 20

21 Monitoring, Reporting & Implementation Methodologies Energy management cell formed with cross function team members. The coordinator for the Energy management cell is Energy Manager. We launched CIP Continues improvement program program as plat form for key performance improvement Ideas generation from the all the employees and tracking the work process based on the priority. The daily review of energy monitoring by each section. Weekly review by plant head. Awards for the best idea & Energy savings implemented SMS alert system for stoppages to control the down time. Power Consumption Report for 21-Aug- On Date MTD YTD K Kw Kw Kw w Pro Kw Kw Kwh Kw Kw Kwh Prod Kw Kwh/ h/ Kw Kw Kwh Kw h/ h/ h/ d Kw h/ h/ / Prod R. Kw h/ h/ / Description in R.Hr h/ T R.Hr T h/ h/ / TPH Kwh h/h T T T in TPH Kwh h/h T T T in Hr TPH Kwh h/h T T T Ton s T ceme s Of T T T r Of OP P Ton r OP PP cem Tons s r Of OP cem s Cli nt ma Cli Cli PPC mat C P s C C ent mat C ent t C Crusher #3 MD Aux VRM MD Fan Aux KILN -2 & Cooler MD ID Fan-1 ID Fan-2 BH Fan C Vent fan C Fans Aux VCLM MD Fan Booster fan Aux OK Mill MD BH Fan Booster fan Aux OK Mill total P.Plant Utilities All sections Total Incomer power Misc Total Slide 21

22 Monitoring, Reporting & Implementation Methodologies Energy Management Committee Plant Head S.V.P-Works Idea generation and Tracking Form Energy Manager Head Mines GM-Mines Head production DGM-process Maintenance head GM- Mech Head Electrical & Instrumentation Quality head G.M -QC Team 1: Team 2: Team 3: Team 4: Team 5: Mines section head & engineers Kiln & Coal mill section head & engineers Crushers & raw mill section engineers Packing & dispatch section engineers Cement grinding incharge & engineers Energy Management Committee includes One Energy Auditor & Two Energy Managers : Mr. Jignesh Kumar Duva DGM (Production) - EA Mr. P. Raghuram DGM (Electrical & Instrumentation) - EM Mr. G.SaiSunil Bharathbabu Dy. Manager (Electrical) - EM Slide 22

23 Team work Efforts made in Encon Projects Description of En- S.No Con Project 1 Avoiding pnumatic conveying by Installation of new steel silo for export and slag cement. Source of En- Con Idea Senior Management Idea Originated Year 20- Extent of man power involved Mr.P.S Murthy D.G.M - Mech, Mr.Krishna Reddy Sr.Manager - Elect Mr.Ravi subrahmanyam Asst.Manager - Inst Mr.Satya Narayana Asst.Manager - Mech Progress of Methodology adopted to implementati overcome the constraints on Implemented 1.New steel silo 2 no's Installed 2. Ensuring Grinding of PSC and Export in steel silos 3.Planning the dispatch accordingly 2 Replacement of VCLM CA fan HT motor with high efficiency motor along with VFD Engineer 20- Mr. P.Raguram D.G.M E&I, Mr.Janardhan Reddy Dy.Man - Mech, Mr.Madhu babu Man - Op Mr.Subba Reddy Sr.Man -Inst Mr.Satyanarayana D.M Elect Implemented 1.HT motor replaced with LT motor 2. VFD installed 3. Reducing fan speed 3 Optimization of CF silo dedusting bag filter fan by Installing VFD Workmen 20- Mr.G.Venkateshwarlu S.M-Op, Mr.Ashok Kumar D.M - Inst Mr.N.Rajesh A.M-Elect Mr. Ravi Varman D.M-Mech Implemented 1.Core team formed for monitoring the bag filter 2.VFD installed 3. Reducing fan speed Slide 23

24 Team work Efforts made in Encon Projects S.No Description of En- Con Project Source of En- Con Idea Idea Originated Year Extent of man power involved Progress of implementatio n Methodology adopted to overcome the constraints 4 Installation of Fly ash feeding to mill discharge arrangement Supervisor 20- Mr.Phani Kiran Manager-Prod, Mr. Murali Sr.Man -Mech, Mr.Subramanyam Sr.Officer -Op, Mr.Ragava employee - Prod Implemented 1.Extended Airslide 2.Arranged chute to feed fly ash in BE 3. Continuous monitoring of quality and power 5 Raw mix optimization after installation of crosbelt analyzer Top Management 20- Mr.K.Suresh G.M-QC, Mr.Nareshkumar A.G.M -Proces,Mr.Madhusudan Sr.Officer - Op, Mr. P.Ramesh AGM -Inst Implemented 1.Installed cross belt analyzer 2.Continuous monitoring of the quality parameters. 6 Installation of VFD for Coal Mill FK Pump Engineer 20- Mr. K.Ravi, Manager-Mech, Mr. Subhash, Engineer- Process, Mr.Sunil- Man- Elec, Mr. Srinivas DM Inst Implemented 1.Core team formed for study FK pump 2.VFD installed 3. Reducing fan speed Slide 24

25 Rcognisation Program for Encon Efforts Ideas Contribution Best Suggestion Slide 25

26 ..aiming to conserve natural resources When we heal the earth, we heal ourselves ~ David Orr Great things are not done by impulse, but by a series of small things brought together Slide 26 26