UltraTech Cement Limited (Unit: Kotputli Cement Works-Power Plant) Welcome to CII 18 th National Award for Excellence in Energy Management 2017

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1 UltraTech Cement Limited (Unit: Kotputli Cement Works-Power Plant) Welcome to CII 18 th National Award for Excellence in Energy Management 2017

2 Content Company Profile Plant Configuration and Flow diagram Energy Management System Policy List of EnCon Projects Plant Performance over the years Innovative Projects Environment Projects / Initiatives Renewable Energy Sources/ Waste utilization Methodology of Energy monitoring Best practices/ Involvement of Employees CSR initiatives Awards & Accolades Way forward

3 Company Profile UltraTech Cement Kotputli Cement Works Kotputli Cement Work An Aditya Birla Group Company. 2X23 MW Captive Power Plant 3.3 MTPA capacity Green field Cement plant. Environment friendly due to less emissions. Certified with ISO 9001, 14001, OHSAS 18001, ISO 27001, ISO & ISO Adopted World Class Manufacturing Excellence Model

4 Process Flow Diagram

5 Energy Management System Policy

6 List Of EnCon Projects

7 Energy Savings Projects Summary SN Financial Year Investment/ No Investment No. of Projects Electrical Energy Savings (MWH) Heat Energy Savings (Ton/Year) Savings in Rs. Million Invested Amount in Rs. Million No Investment Investment No Investment Investment No Investment Investment Total

8 Energy Savings Projects with No Investment ( ) Saving Achieved SN Energy Saving Projects Electrical Energy (MWH) Thermal Energy (Ton/Year) (Rs. Million) 1 Reduction of BFP power by developing discharge pressure biasing Reduction in Boiler PA Fan KW by optimizing the PA Air flow according the boiler load Condensate interconnection to reduce heat loss (From Aug-16 to Mar-17) Reduction in SAC running hours through ESP hopper level by Draft transmitter Utilising lower CFM & KW compressor for Fly ash conveying Usage of 90% Pet coke in fuel mix & Reduction in CHP power by increasing through put

9 SN Energy Savings Projects with No Investment ( ) Energy Saving Projects Electrical Energy (MWH) Saving Achieved Thermal Energy (Ton/Year) (Rs. Million) 7 Reduction in AC & lighting power Reduction in ID fan power consumption due low bed ash cooler running hour Reduction in BLR SA fan KW by optimizing the SA air pressure Reduction in instrument air compressor power by optimizing the air flow in BLR MDC sealing Silo bag filter purging air pressure reduction CEP power cons. reduction by inter connecting condensate line during unequal loads on TG

10 Energy Savings Projects with No Investment ( ) SN Energy Saving Projects Reduction of RO Degasser transfer pump power consumption by utilising old CT sump as storage Reduction of raw water pump running hours by continuous make up of cooling tower ACW pump power reduction by optimizing the CW flow of equipment's according the ambient temp. Use of Raw Mill dust to reduce sensible heat loss due to bed drain & Usage of High GCV fuel in the boiler to achieved higher boiler efficiency. Reduction in import of Grid power ( Rs 2.8 in Power generation cost against Grid Power) Power Sale to other group units ( Rs 1.86 in Power generation cost against Grid Power) Electrical Energy (MWH) Saving Achieved Thermal Energy (Ton/Year) (Rs. Million)

11 Energy Savings Projects with Investment SN Energy Saving Projects Electrical Energy (MWH) Saving Achieved Thermal Energy (Ton/Year) Rs. Million Investment (Rs. Million) Pay back Month Year 1 TG 1 ACC fan 2 VFD installation Replacement of TG 1 MOP with high efficiency pump Bed ash cooler fan outlet duct inter connection Boiler-1 BAC fan VFD installed Cooling tower fan VFD installed Power reduction by Installation of submersible pump in main effluent pit for transfer to mines

12 Energy Savings Projects with Investment SN Energy Saving Projects Electrical Energy (MWH) Saving Achieved Thermal Energy (Ton/Year) Rs. Million Investment (Rs. Million) Pay back Month Year 7 Utilisation of TG-2 1st extraction steam in PRDS for ejector (From Nov-16 to Mar-17) Lighting power optimisation LOI reduction in fly ash by U beam straightening to improve ash circulation rate & by MDC replacement Up keepment of steam turbine-2 to improve heat rate Reduction in power consumption of air conditioners by using Nano technology & installing water cooled condensers

13 Energy Savings Projects with Investment SN Energy Saving Projects Electrical Energy (MWH) Saving Achieved Thermal Energy (Ton/Year) Rs. Million Investment (Rs. Million) Pay back Month Year 12 Installation of separate energy efficient side stream filter pump (Grundfos Make) for cooling tower to reduce power from existing ACW pump Usage of renewable (solar)energy for lighting at HSD area Operation of TG-2 ACC with ALE fins tube bundles & Auto PID operation of all ACC fans with VFD

14 Energy Savings Projects with No Investment ( ) Saving Achieved SN Energy Saving Projects Electrical Energy (MWH) Thermal Energy (Ton/Year) (Rs. Million) 1 Improved heat rate of TG-2 by operating with higher vacuum Intermittently stopped service air compressor to avoid idle running during pet coke usage & DP level in ESP hoppers. Developed a logic (Auto set point calculation) for BFP discharge pressure w.r.t. steam drum pressure. Developed a logic (Auto set point calculation) for CEP discharge pressure w.r.t. deaerator pressure. Reduction of both boiler ESP field power by changing charging ratio with respect to fuel types Adiabatic cooling system for inlet air of ACC Fans in unit

15 Energy Savings Projects with No Investment ( ) SN Energy Saving Projects Through put increased & run hours reduction of CHP by using Belt power feedback display on DCS. Indigenous development of auto import -export logic during power export. Reduced Instrument air pressure set point from 6.5 kg/cm2 to 5.8 kg/cm2 (gradually in two phase). WTP running hours reduction by commissioning & utilising dump steam system.(savings of 06 Months) Electrical Energy (MWH) Saving Achieved Thermal Energy (Ton/Year) (Rs. Million) Reduction in BAC fan air flow from 22 to 19 TPH Reduction in idling hours by implementing remote operation of Fly ash compressors

16 Energy Savings Projects with No Investment ( ) SN Energy Saving Projects Improved Boiler Efficiency by increasing pet coke percentage in fuel mix. Boiler operated at lower bed height. Reduced by 200mmwc,power Optimization of steam venting by taking Raw mill initial drive start feed back through PI system. Electrical Energy (MWH) Saving Achieved Thermal Energy (Ton/Year) (Rs. Million) Operation of TPP at Island mode operation Power generated from TG-2 during ACC bundle replacement with ACC single stream operation. ( Difference Rs 0.93/Kwh of TPP vs Grid Power)

17 Energy Savings Projects with No Investment ( ) Saving Achieved SN Energy Saving Projects Electrical Energy (MWH) Thermal Energy (Ton/Year) (Rs. Million) 6 Improved TG vacuum by arresting leakages in TG exhaust path through Helium check Optimised CHP bag filter purging air through DP transmitter instead of timer mode. 8 Reduced power consumption of bag filter fan by parallel circuit operation of CHP & LSHP Modified CHP Start & Stop logic to reduce idle hour. 10 Reduced Hot well transfer pump running hours of unit-1 by rerouting of LP Heater drain to CRT tank

18 Plant Performance & Benchmarking

Key Performance Indicators 85.00 PLF (%) G O O D 3100 3095 Heat Rate (Kcal/Kwh) Under Performance of ACC of Unit-1 G O O D 75.00 75.02 75.85 75.41 76.57 3049 3036 3041 65.

19 Key Performance Indicators PLF (%) G O O D Heat Rate (Kcal/Kwh) Under Performance of ACC of Unit-1 G O O D % reduction Auxiliary Power (%) % reduction % reduction G O O D Power Cost (Rs./Kwh) G O O D

20 Benchmarking With UTCL Units Heat Rate (Kcal/Kwh) HCW ACW RWCW RC APCW GCW AC SCW KCW VC Auxiliary Power (%) Best Across UTCL units HCW RWCW VC GCW AC ACW SCW RC APCW KCW

21 Benchmarking With UTCL Units Plant Load Factor (%) Less Demand of Load RC GCW APCW HCW SCW ACW KCW AC RWCW VC

22 Innovative & EnCon Projects

Project-1 # Reducing heat loss in Aux. steam for Ejector Reason for Selection: The Aux.

350 C respectively by spraying feed water resulting heat loss in the system.

(22 kg/cm2 & 360 C) in ejector & reduced heat loss in Aux.

23 Project-1 # Reducing heat loss in Aux. steam for Ejector Reason for Selection: The Aux. steam for Ejector was supplied from main steam line by reducing its pressure & temperature from 100 Kg/cm2 & 535 C to 11 kg/cm2 & 350 C respectively by spraying feed water resulting heat loss in the system. Technology Adoption: Installed a pressure reducing station & utilized Turbine 1st extraction steam of lower pressure & temp.(22 kg/cm2 & 360 C) in ejector & reduced heat loss in Aux. steam Before: Main Steam Utilisation in Ejector Cost of Implementation: Rs Million Benefits: Total Savings in Coal : 50 MT/Annum Total Savings in Power:4.8 MWH/Annum Total Savings : Rs Million/Annum Uniqueness: Single PRS being utilized for two TG s After: Extraction Steam Utilisation in Ejector

Project-2 # Reduction in LOI of Fly ash by Ash Recycle Reason for

and diverted it to existing bed material bunker of the boiler.

APH Conveying System ESP Conveying System Before: Without Ash Recycle

24 Project-2 # Reduction in LOI of Fly ash by Ash Recycle Reason for Selection: At 90% Pet-coke in fuel mix LOI in Fly ash was higher resulting lower boiler efficiency. Technology Adoption: Modified the fly ash conveying line of ESP & APH and diverted it to existing bed material bunker of the boiler. Recycled the fly ash again to the boiler and reduced the LOI %. APH Conveying System ESP Conveying System Before: Without Ash Recycle Line Benefits: Reduction in LOI by 0.8 % Total Savings : Rs. 2.5 Million/Annum APH Conveying System ESP Conveying System After: With Ash Recycle Line

Project-3 # Reduced Bed Ash Cooler fan power consumption Reason for

discharge duct of both the boiler with pneumatic operated isolation valves.

BAC duct without Interconnection Cost of Implementation: Rs. 0.

25 Project-3 # Reduced Bed Ash Cooler fan power consumption Reason for Selection: Higher Power consumption of boiler-2 Bed ash cooler fan due to DOL drive. Technology Adoption: Fabricated & Interconnected bed ash cooler fan discharge duct of both the boiler with pneumatic operated isolation valves. Operated both bed ash cooler with single fan with VFD. BAC duct without Interconnection Cost of Implementation: Rs Million Benefits: Total Savings in Power : 69.3 MWH/Annum Total Savings : Rs Million/Annum Uniqueness: Single VFD being utilized for Both boiler BAC. BAC duct with Interconnection

Project-4 # Intermittent stoppage of service air compressor Reason for Selection: Earlier ash conveying system of ESP was operated by hopper level switches in

Stoppage of service air compressor was carried out based on manual checking of hopper levels.

26 Project-4 # Intermittent stoppage of service air compressor Reason for Selection: Earlier ash conveying system of ESP was operated by hopper level switches in timer & probe mode resulting idle running of service air compressor due to malfunctions. Stoppage of service air compressor was carried out based on manual checking of hopper levels. Technology Adoption: Installed DP transmitter in hoppers with online display on DCS for continuous monitoring. Intermittently stopped the compressor with respect to Draft level at hoppers to optimized power consumption. Benefits: Total Savings in Power: 340 MWH/Annum Total Savings : Rs Million/Annum

27 Way Forward # Technology Up gradation of ACC (SRC) Reason for Selection: Air Cooled Condensers are supplied with multi row HDG(Hot Dip Galvanized) Fin material of low heat transfer coefficient, resulting higher heat & power consumption. ACC s under performance de-rating TG loading during peak ambient temperature. Replacement of air cooled condenser was initiated. But the cost of it was higher. Complexity: The Capital for new ALE multi row tube bundle replacement had higher cost (10 Cr) & had higher return in investment (>8 Yrs.). Approach: Brainstorming within team & explored opportunity for low cost & efficient alternative technology within & outside India. Technology Adoption: Approached new technology supplier having ACC- Single Row Condenser (SRC) technology at low cost & high heat transfer efficiency resulting lesser heat & power consumption.

28 Way Forward # Technology Up gradation of ACC (SRC) Benefits: Procured at Capital cost to 4.42 Cr with ROI of 3.95 yrs. Proposed savings : 62 Kcal/Kwh & 8.5 Lacs Kwh / Annum. Proposed Savings: Rs. 7.8 Million/Annum Uniqueness: First time installation being carried out in India.

29 Environmental Projects / Initiatives

Kcal/kg PPC Equiv. PAT Status GtG energy consumption status (Cement & Power Plant) No. of Energy Saving Certificates 37153 1200 1000 993 5.6% reduction target 937 28.

32% 800 711 670 641 600 400 2009-10 (Baseline year) Target SEC for PAT cycle 1 Actual PAT Cycle 1 Baseline PAT Cycle 2 Target PAT Cycle 2 Unit is registered as

30 Kcal/kg PPC Equiv. PAT Status GtG energy consumption status (Cement & Power Plant) No. of Energy Saving Certificates % reduction target % reduction Target for reduction 4.32% (Baseline year) Target SEC for PAT cycle 1 Actual PAT Cycle 1 Baseline PAT Cycle 2 Target 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 Crores

31 GHG Inventorisation Year tco2 Emission Sp. CO2 Emission

32 Environmental Initiatives Green Belt development Saplings Planted in last 09 Years: nos. Green belt area developed : hectare

33 Environmental Initiatives Green Belt in Colony Sapling Distribution to Villagers Ground water recharging through injection well Rain Water Harvesting Ponds

34 Renewable Energy Sources / Waste Utilisation

35 Renewable Energy Utilisation Usage of renewable energy for lighting at TPP HSD Area: Installed Solar Power Generation at HSD area : 1000Watts Solar energy : 0.04 % of total power share Solar Unit Generation (kwh) Solar Unit Generation (kwh) 100 KW Solar Power Plant

Utilisation / Recycle of Waste TPP Bed ash 100 % Bed ash being used in Cement plant. a) While using 100% Petcoke in boiler and generating 18-20 TPD bed ash which was creating problem of reuse.

36 Utilisation / Recycle of Waste TPP Bed ash 100 % Bed ash being used in Cement plant. a) While using 100% Petcoke in boiler and generating TPD bed ash which was creating problem of reuse. Discussed with Cement plant Quality Control Deptt. and after detailed analysis & coordination started using in cement plant. b) Recycle of TPP bed ash & fly ash again in boiler to recover un-burnt carbon during pet coke usage. PPF for boiler Light up Usage of Petro Polymer fuel in place of Diesel for every Boiler light-ups, replacing the convectional fuel

37 Energy Monitoring

38 Methodology adopted for Energy Monitoring Well Established energy management cell headed by FH-TPP. Daily monitoring of Heat rate and Aux. power deviation report. Analysis of equipment performance for deviation. Identification of energy conservation scope. Theme base suggestions/kaizens scheme under Energy Saving. Feasibility study of suggestions & submit proposal for sanction. Preparation of detail action plan. Weekly review to monitor project progress. Benefits analysis after project implementation. Sustainability of the project

39 Efficiency Monitoring & Daily report Energy Efficiency

40 Aux. Power Monitoring

41 Online Energy Monitoring System

42 ISO & Accreditations

Management NABL accreditation WCM Gold Award Note worthy Water efficient unit Excellent Energy Award

43 WCM Initiated Quality Mgmt. Environment Management Occupational Health & Safety WCM Bronze Award Information Security Energy Management NABL accreditation WCM Gold Award Note worthy Water efficient unit Excellent Energy Award Journey Towards Excellence Water Award Energy Award WCM WCM 2010 ISO ISO OHSAS WCM 2013 ISO ISO ISO

44 ISO 50001,9001 &14001 for FY Corrective Action against finding related to ISO 50001, 9001 & for FY S.N o 1 Findings Corrective Actions Standard Status Acceptance criteria may be defined against various variable identified for significant energy use. Acceptance criterion is defined in OCP prepared respective sections. ISO Completed. 2 No findings ISO No findings OHSAS 18001

45 Team Work for EnCon SN EnCon idea Idea originated (Year) Team involved Status 1 Reduction in power by Installation of submersible pump in main effluent pit for transfer to mines O&M and E&I Team Completed 2 3 Optimization of heat loss by utilising TG-2 1st extraction steam in PRDS for ejector Replacement of TG 1 MOP with high efficiency pump 2016 O&M and E&I Team Completed 2016 TPP (O&M) Team Completed 4 Pressure biasing for BFP discharge pressure 2016 O&M and E&I Team Completed 5 Increase the power generation during the summer season by adiabatic cooling system for inlet ambient air in ACC Fans in unit FH-TPP/TPP( O&M) & TPP (E&I) team/ M/s Greensole power Completed

46 Team Work for EnCon SN EnCon idea Idea originated (Year) Team involved Status Reduction of Raw water consumption of by utilization of Boiler blow down water for cooling tower make up Replacement of ACC HDG tube bundles with ALE tube bundles. CEP discharge pressure droop mode operation with reference to Deaerator pressure CHP power optimization by increasing through put according to fuel types 2015 TPP (O&M) Team Completed 2014 O&M, E&I Team and M/s Greensole Power Completed 2014 O&M and E&I Team Completed 2014 O & M and E&I Team Completed 10 Blow down water Heat recovery system 2014 O & M and E&I Team & M/s Forbes Marshall Completed

47 Replication Arising Out of Best Practices SN Name of service provided to vendor Replicating Unit Name of associate / vendor 1 Replacement of ACC HDG tube bundles with ALE tube bundles. Aditya Cement, Rajshree cement & new projects at UTCL M/s Greenesol Power 2 ACC Power Reduction by operating all fans with VFD & Vacuum with auto PID control Aditya Cement, Rajshree cement & new projects at UTCL M/s Greenesol Power 3 Island Mode operation of Thermal power plant Rawan cement, Aditya Cement, Rajshree cement - 4 Utilisation of Boiler blow down water as cooling tower make up. Rajshree cement M/s Chembond & Ion Exchange

48 Best Practices Shared to Vendors SN Name of associate / vendor Name of service provided to vendor Energy cons. before Energy cons. After Gain Type of inputs / projects provided to the vendor/ associate 1 M/s Greenesol Power Hotwell transfer pump running hours optimization by modification of LP Heater drain direct to CST. 79 Mwh/ month 62 Mwh/ month 22% Applicable in all existing units & new projects. 2 M/s Thermax Modification in Ejector motive steam line 10 Kcal/Kwh In all Plants where Thermax has supplied the Boilers 3 M/s Greenesol Power Energy efficient ACC fans 100 KW/Fan 80 KW/Fan 20% Installation of these fans in new projects 4 M/s Greenesol Power Replacement of ACC HDG tube bundles with ALE tube bundles. 232 Mwh/month 112 Mwh/month Installation of ALE bundles in new projects

49 Corporate Social Responsibility STRIVING FOR Societal Change

50 Corporate Social Responsibility Corporate CSR CSR Vision CSR Policy Focus Area Education Social Causes Health Care Infrastructure Development Sustainable Livelihood

51 Corporate Social Responsibility Awareness campaign for Personal hygiene, Family planning, Immunization camps. Infrastructure development for hospitals/ schools nearby. Skill Up gradation Training for Black Marble Stone Sculptures

52 Corporate Social Responsibility Coaching classes & felicitation programs for students. Conducting free eye camps to extend hand of help to communities. Formation of Self Help Groups (SHG)

53 Awards & Accolades

54 Awards & Accolades Kotputli Cement Works TPP team receiving award for Excellent Energy Efficient Unit in year Kotputli Cement Works TPP team receiving certificate for Noteworthy water efficient unit in year 2016.

55 Awards & Accolades Kotputli Cement Works TPP team receiving award for Excellent Energy Efficient Unit in year Kotputli Cement Works TPP team receiving award for Excellent Energy Efficient Unit in year 2014.

56 Awards & Accolades Kotputli Cement Works TPP team receiving award for Energy Efficient Unit in year Kotputli Cement Works team receiving award for Rajasthan Energy Conservation in year 2014.

Commendation Certificate by the Ministry of Power, Government

57 Awards & Accolades Kotputli Cement Works TPP team receiving award for Water Efficient Unit in year Commendation Certificate by the Ministry of Power, Government of India in recognition of efforts made to conserve the energy for year

conserve the energy for year 2011-12. First prize by dept.

58 Awards & Accolades Commendation Certificate by the Ministry of Power, Government of India in recognition of efforts made to conserve the energy for year First prize by dept. of energy, Govt of Rajasthan for sincere efforts towards energy conservation & efficient use.

59 Way Forward

60 Way Forward: Energy Saving Projects Replacement of existing ACC tube bundles with upgraded SRC technology tube bundles with APC savings of 8.5 Lacs Kwh / Annum. Overhauling of TG-1 for Heat Rate improvement. Installation of waste Heat Recovery boiler from Kiln PH & cooler outlet gases. 1) For power generation 2) For heat utilization. Existing ETP Pump replacement with Grundfos make energy efficient pump. Installation of VFD drive in bed ash cooler fan-2. Impeller trimming of Raw water pump for power optimization Installation of Energy efficient 3 phase rectifiers for ESP.

61 Energy Simply Burns or Earns, Choice is Ours! Sincere Thanks.. UltraTech Cement Ltd Kotputli Cement Works Power Plant

UltraTech Cement Limited (Unit: Kotputli Cement Works-Power Plant) Welcome to CII 19th National Award for Excellence in Energy Management 2018

UltraTech Cement Limited (Unit: Kotputli Cement Works-Power Plant) Welcome to CII 19th National Award for Excellence in Energy Management 2018 Participants Pintoo Dodiya (Assistant Manager) R.N.Tripathi