Contents. 11 th National Award for Excellence in Energy Management Chennai 1 st & 2 nd September 2010 ACC Wadi-II Plant

Transcription

1 11 th National Award for Excellence in Energy Management 2010 Welcome to World s Largest Clinker Production Line Chennai 1 st & 2 nd September II Plant Contents Company Details Cement Manufacturing Process Energy Conservation & Consumption per unit of Product Comparison with Global norms/benchmark data Innovative & Environmental Projects Involvement of Employees, Team work in Encon, Monitoring & Reporting formats and implementation methodologies Renewable Energy sources, Utilization of waste for replacing the conventional energy & Water Management Implementation on Energy front amongst associates (Vendors / Suppliers, contractors etc) Certifications 2 1

2 Company Details Company Name Address : Limited., Cement Works -II Plant : Limited, Cement Works WADI (P.O) , Gulbarga District, Karnataka State Phone: Fax : Type of Industry Type of Process : Cement : Dry Process Production Capacity of the plant : Product : Portland Pozzolona Cement Capacity : 33.5 Lakh tons cement per annum Energy Cost as a % of manufacturing cost : % 3 Contents Company Details Cement Manufacturing Process Energy Conservation & Consumption per unit of Product Comparison with Global norms/benchmark data Innovative & Environmental Projects Involvement of Employees, Team work in Encon, Monitoring & Reporting formats and implementation methodologies Renewable Energy sources, Utilization of waste for replacing the conventional energy & Water Management Implementation on Energy front amongst associates (Vendors / Suppliers, contractors etc) Certifications 4 2

3 6.1 Cement Manufacturing Process Mass Flow ( Pre- Post Expansion) Raw Material Extraction Crusher 1000 t/h Conv. belts 1000 t/h Crusher 1200 t/h Conv. belts 1300 t/h Shale storage Cap: 2x9000 t Shale Cap: 2x40000 t Limestone Gypsum Cap: t Fly Ash Cap: 2300 t Stock Coal t Coal Mill 50 t/h Fly Ash Cap: 4000 t Stock Coal t Coal Mill 90 t/h Raw material Iron ore, Bauxite & Laterite Cap:20000 Vertical roller mill 425 t/h Vertical roller mill 560 t/h Clinker silo Cap: T Cement ball mill with Pregrinders 6&7 225 t/h (PPC) Clinker silo For bulk transport Cap: 60000T SF Cross Bar cooler Cap: tpd Rotary kiln Dia 6.0m x96m, =12500 TPD Preheater SLC 5500 TPD CF silo t Preheater ILC 7000 TPD Silo -1 Cap:11000T Silo - 2 Cap:11000T Silo - 3 Cap: 11000T Existing Post Expansion 5 Energy Policy Our Mission is : To be amongst the lowest energy consumers in the cement industry We have to accomplish our mission by: Benchmarking our performance against comparable technology & capacity Promoting & encouraging Energy Saving & conservation of natural resources. Creating awareness among all people concerned within the organization through workshops, seminars, external training and Annual Zonal Energy Award Competition. Carrying out regular internal & external audits to identify areas for improvement. Adopting cleaner and energy efficient technologies in all areas. Reducing specific energy consumption by atleast 2.5% every year 6 3

4 Contents Company Details Cement Manufacturing Process Energy Conservation & Consumption per unit of Product Comparison with Global norms/benchmark data Innovative & Environmental Projects Involvement of Employees, Team work in Encon, Monitoring & Reporting formats and implementation methodologies Renewable Energy sources, Utilization of waste for replacing the conventional energy & Water Management Implementation on Energy front amongst associates (Vendors / Suppliers, contractors etc) Certifications 7 Energy Conservation & Consumption per unit of Product Energy Consumption of II Plant: Specific energy consumption includes the power consumption of all auxiliaries including transformer losses, colony power, plant and colony lighting, plant and colony water pumps, ETP etc.. Process power for year 2009 is Units/T as against Units/T in 2008 From the year 2007 onwards, the thermal Energy consumption is calculated on as fired basis (initially it was on as received basis). 8 4

5 Energy Conservation & Consumption per unit of Product Information Provided as per prescribed Form -A of the annual report 9 Energy Conservation & Consumption per unit of Product Energy Consumption per unit of Product: Information Provided as per prescribed Form -A of the annual report 10 5

6 Contents Company Details Cement Manufacturing Process Energy Conservation & Consumption per unit of Product Comparison with Global norms/benchmark data Innovative & Environmental Projects Involvement of Employees, Team work in Encon, Monitoring & Reporting formats and implementation methodologies Renewable Energy sources, Utilization of waste for replacing the conventional energy & Water Management Implementation on Energy front amongst associates (Vendors / Suppliers, contractors etc) Certifications 11 Comparison with Global norms/benchmark data Comparison of specific energy consumption - Region Given below is the comparison with other Energy Efficient units in India. However Vasavdatta Cements, Sedam is our nearest competitor within the region Source: CII - Manual on Best Practices in Cement Industry 12 6

7 Comparison with Global norms/benchmark data Comparison of specific energy consumption With National and International Benchmarks Source: CII - GBC Green Cementech Conference 2010, Hyderabad 13 Comparison with Global norms/benchmark data Road map to achieve benchmark At Cement Works we are committed to achieve and surpass world class standards in Specific Energy consumption. For this we follow the three pronged strategy as under: Implementing the concept of Energy Efficiency at the proposal and design stage itself Identifying the opportunities through internal and external sources like conducting Energy audits, brain storming sessions and training programmes. Increasing awareness among all the stakeholders and by motivating them 14 7

8 Comparison with Global norms/benchmark data Road map to achieve benchmark Energy Efficiency at it s best in the design stage itself 4 After Hookup, the existing Kiln will be the World s single largest kiln of TPD 4 Tallest pre-heater of 175 mt. height with in line calciner to enhance the thermal energy efficiency of the plant 4 World s largest and highly efficient SF 6X8 cross bar cooler, to further improve the thermal energy efficiency. 4 Tallest bag house chimney of 180 mt. height to reduce the fan power consumption by utilizing the natural draft. 4 Total 6 nos.of MV drives for kiln main drive(1350kw X 2), preheater fans(1350kw X 2),Bag house fan(1750kw), and Coal Mill Fan(2000KW) 4 Total 15 nos.of 12 pulse VVFDs (total 6400KW) for Cooler fans, cooler ESP fan, PA fan etc.. and 7 nos.of 6 pulse VVFDs (total 1150KW) for other applications like separators and belt conveyors etc.. 15 Contents Company Details Cement Manufacturing Process Energy Conservation & Consumption per unit of Product Comparison with Global norms/benchmark data Innovative & Environmental Projects Involvement of Employees, Team work in Encon, Monitoring & Reporting formats and implementation methodologies Renewable Energy sources, Utilization of waste for replacing the conventional energy & Water Management Implementation on Energy front amongst associates (Vendors / Suppliers, contractors etc) Certifications 16 8

9 Innovative & Environmental Projects Innovative Projects: Project 1 - Increasing Flyash absorption in PPC: Synopsis: Increasing the fly ash absorption is a very attractive option for the cement plants, in view of the reduction in co2 emissions on one hand and the reduction in manufacturing cost on the other. But maintaining the quality norms of cement, at increased fly ash absorption levels is a challenging task. Approach & Methodology: 4 After internal discussions, we decided to increase the C3S content of clinker by adjusting required CaO & flux. We have increased C3S from 53% to + 55% by adjusting Flux. 4 Laboratory Trials with different sources of gypsum & additives was conducted to get the desired quality of cement 4 Plant scale trials conducted with different additives & gypsum to establish the quality of cement 4 Optimizing the residue levels in the cement & maintaining on the consistent basis. 17 Innovative & Environmental Projects Results & cost benefit analysis: Year avg. FA increased from to 30.34% Maximum monthly average Fly ash achieved: 34.2% Maximum day average Fly ash achieved : 34.8% At 30.34% overall savings in cash cost : Rs 74 / MT Savings accrued for the YR 2009 : Rs Lakhs Impact on energy consumption: Reduction in Total Energy Kwh/Ton of Cement Reduction due to increase in clinker factor =2.35 Kwh/ton of Cement Increase in Grinding Energy = 1.12 Kwh/Ton of Cement Overall Reduction in Total Energy Kwh/Ton of Cement = 1.23Kwh/Ton of Cement 18 9

10 Innovative & Environmental Projects 19 Innovative & Environmental Projects Innovative Projects: Project 2 - Commissioning of Electric shovel at Mines: Synopsis: Shovels and Dumpers are the major energy consuming equipment in the Mines. They consume huge quantity of Diesel oil and in turn release Co2 and other noxious gases into the atmosphere. Electric shovel offers the benefits of reliability in operation with lower carbon footprint compared to their diesel powered counter parts. Results & cost benefit analysis: 1400 TPH Electric Shovel was commissioned in the month of June Investment = 14 Crores Specific Power consumption of Electric Shovel = 0.25Kwh/Ton of material 20 10

11 Innovative & Environmental Projects Operating cost of Electric Shovel = Rs.2.20/- per Ton of material Operating cost of EX 1200 Diesel Shovel = Rs.6.60/- per Ton of material Annual operating cost saving = Rs Crores 21 Innovative & Environmental Projects Environmental Projects: Project Linked with Carbon Emission Reduction initiative 4 Cement industry has the unique opportunity of reducing CO2 through product modification i.e. with the Production of Blended Cement. -II Plant produces PPC only and thus contributes to significant reduction of CO2. The validation of the project under CDM is under progress. 4 Monthly Co2 emissions are quantified at the Plant level and the same is sent to our Central Energy & Environment Conservation Cell. From there, the entire group Co2 emissions are reported to Holcim, which are in turn published to World Business Council for Sustainable Development (WBCSD)

12 Innovative & Environmental Projects Summary of Co2 Emission: 23 Innovative & Environmental Projects Environmental Projects: List of Energy Conservation Projects implemented during , 08, &

13 Innovative & Environmental Projects Energy Conservation Projects implemented during Innovative & Environmental Projects Energy Conservation Projects implemented during

14 Innovative & Environmental Projects Energy Conservation Projects implemented during Innovative & Environmental Projects Energy Conservation Projects implemented during

15 Innovative & Environmental Projects Energy Conservation Projects Porposed for Innovative & Environmental Projects Energy Conservation Projects Porposed for

16 Innovative & Environmental Projects Environmental Initiatives proposed for Contents Company Details Cement Manufacturing Process Energy Conservation & Consumption per unit of Product Comparison with Global norms/benchmark data Innovative & Environmental Projects Involvement of Employees, Team work in Encon, Monitoring & Reporting formats and implementation methodologies Renewable Energy sources, Utilization of waste for replacing the conventional energy & Water Management Implementation on Energy front amongst associates (Vendors / Suppliers, contractors etc) Certifications 32 16

17 Involvement of Employees, Team work in Encon, Monitoring & Reporting formats and implementation methodologies M/S. Ltd., Cement Works is committed for conservation of energy. The Energy Management is the critical focus of the top management. The result is evident from the remarkable improvement in terms of specific power consumption. It has reduced from 78 kwh/ton of cement in 2004 to kwh/ton of cement for the period At the Corporate level we have an Environment and Energy Conservation Cell, directly representing to the Managing Director. They review the energy consumption parameters of all our units regularly. 33 Involvement of Employees, Team work in Encon, Monitoring & Reporting formats and implementation methodologies At the plant level we have the Energy Apex committee and Energy First committees for various departments. There are total seven Energy first committees that belong to various departments and consist of the frontline workforce in each department. They are formed with the clear mandate of 4 Better management of available power 4 Pinpoint the wastages 4 Identify energy efficient measures 4 Increase awareness among all 34 17

18 Involvement of Employees, Team work in Encon, Monitoring & Reporting formats and implementation methodologies The Energy Apex committee works under the leadership of Director (Plant), and Head Operations with all department heads as members. This committee meets once in a fortnight to review the plant energy consumption during that period, status of various on going energy conservation measures and the suggestions received from Energy first committees. Energy Manager acts as a coordinator between these two, and looks after formulation of proposals and their implementation. The energy consumption parameters are reviewed in daily production meetings, and the reasons for variance if any, and the actions to be taken are discussed 35 Involvement of Employees, Team work in Encon, Monitoring & Reporting formats and implementation methodologies Organization Structure for Energy Conservation activities at -II: 36 18

19 Involvement of Employees, Team work in Encon, Monitoring & Reporting formats and implementation methodologies Energy Conservation Projects of -II which involve Employees & Team work with different implementation methodologies: 37 Involvement of Employees, Team work in Encon, Monitoring & Reporting formats and implementation methodologies 38 19

20 Involvement of Employees, Team work in Encon, Monitoring & Reporting formats and implementation methodologies 39 Involvement of Employees, Team work in Encon, Monitoring & Reporting formats and implementation methodologies 40 20

21 Brown paper exercises for energy conservation 41 Brown paper exercises for energy conservation 42 21

22 Involvement of Employees, Team work in Encon, Monitoring & Reporting formats and implementation methodologies % breakup of time currently spent (average basis) of senior executives in various functions are as follows: a) Technology Implementation - 15 % b) Manufacturing excellence - 15 % c) Materials Management - 20 % d) Marketing Coordination activities - 15 % e) Analyzing Competitors Profile - 10 % f) Quality Management - 10 % i) Energy Conversation Measures - 15 % Total - 100% 43 Involvement of Employees, Team work in Encon, Monitoring & Reporting formats and implementation methodologies Monitoring & Reporting: Frequency of review of energy consumption and energy conservation projects are Daily / Weekly / Monthly. The energy consumptions in the plant is monitored daily and reviewed at regular intervals. At the beginning of every financial year targets are fixed for both electrical and thermal energy consumptions. The same parameters are closely monitored by the Energy Manager and concerned Section In charge as follows: 4 Monitoring of specific power consumption for major units 4 Monitoring of energy MCC wise 44 22

23 Involvement of Employees, Team work in Encon, Monitoring & Reporting formats and implementation methodologies Monitoring & Reporting: The daily Power Consumption parameters are reviewed in the daily production meetings, and the performance is reviewed in the fortnightly Energy First and Apex committee meetings. The energy consumption parameters are also closely monitored by the corporate office. The Environment and Energy Conservation Cell (EECC) in the Technical Support Services (TSS) office at Thane reviews the energy consumption parameters of all our units regularly. They also set the targets to be met and provide support in attaining them 45 Involvement of Employees, Team work in Encon, Monitoring & Reporting formats and implementation methodologies Monitoring & Reporting Formats: Format of Daily Specific Power Report: 46 23

24 Involvement of Employees, Team work in Encon, Monitoring & Reporting formats and implementation methodologies Monitoring & Reporting: Format of Fortnightly & Monthly General Management Report: 47 Contents Company Details Cement Manufacturing Process Energy Conservation & Consumption per unit of Product Comparison with Global norms/benchmark data Innovative & Environmental Projects Involvement of Employees, Team work in Encon, Monitoring & Reporting formats and implementation methodologies Renewable Energy sources, Utilization of waste for replacing the conventional energy & Water Management Implementation on Energy front amongst associates (Vendors / Suppliers, contractors etc) Certifications 48 24

25 Renewable Energy sources, Utilization of waste for replacing the conventional energy & Water Management Renewable Energy Sources: The percent share of renewable energy capacity to total captive power capacity of is 6% at present, and the target is to increase this share to 15% by has two wind forms located at Rajasthan and Tamil Nadu, which have generated 40 million units of wind power is during As a part of the CSR activity Cement Works has donated 37 nos.of TATA Solar lamps, worth Rs.5 Lakhs to the neighboring villages, during Renewable Energy sources, Utilization of waste for replacing the conventional energy & Water Management Utilization of Waste as Fuel: As a part of expansion, AFR feeding system is being installed at our plant, which will be in operation from October 2010.This system is designed by FL Smidth, with a capacity of 2 to 20TPH, based on the type of material. This will enable us to replace approximately 55 % of the fuel fired in ILC by RDF (Refuse Derived Fuel). At present AFR usage is being carried out at our I plant. AFR testing lab is also commissioned during the Year 2009 which will cater to the needs of both I and II plants

26 Renewable Energy sources, Utilization of waste for replacing the conventional energy & Water Management Commissioning of AFR testing laboratory in 2009 : 51 Renewable Energy sources, Utilization of waste for replacing the conventional energy & Water Management Water Management: Rain Water Harvesting and Water Management Conservation of Rain water (Water storage in mining area equivalent to 185 days consumption) 24 Lakh cu.m water in mines sump Construction of Barrage at Kagina River Reverse Osmosis Plant Reduction in water consumption Zero water discharge from plant 52 26

27 Renewable Energy sources, Utilization of waste for replacing the conventional energy & Water Management Afforestation and Green belts : 4 Clad with thick band of luxuriant plantations, Mines poses the most modern and one of the biggest Limestone mines of Asia in terms of production. The mines has done systematic plantation on dumps when dump had attained their full heights The slopes are well laid with green grassy lawn to protect the soil erosion 4 The long tree plantation along the mining lease boundary and on edges of ultimate pit limits garlands the mines and motivates for environment propagation at mines 4 Overall 2.05lakh trees have been planted in the plant and neighboring areas. Approximately 10 Ha of green belt has already been developed on the dumps. The trees like Neem, Eucalyptus, Gulmohar, Subabool, Sisso, and Cassacimia have been commonly planted 53 Renewable Energy sources, Utilization of waste for replacing the conventional energy & Water Management Afforestation and Green belts at Mines : 54 27

28 Contents Company Details Cement Manufacturing Process Energy Conservation & Consumption per unit of Product Comparison with Global norms/benchmark data Innovative & Environmental Projects Involvement of Employees, Team work in Encon, Monitoring & Reporting formats and implementation methodologies Renewable Energy sources, Utilization of waste for replacing the conventional energy & Water Management Implementation on Energy front amongst associates (Vendors / Suppliers, contractors etc) Certifications 55 Implementation on Energy front amongst associates (Vendors / Suppliers, contractors etc) Material Transportation (Inbound & Outbound) by Rail: The rail movement of goods is more environment friendly compared to road. At rail transport in large rake loaded quantities is preferred and bulk cement distribution is promoted. dispatches 51% of its cement by rail, compared to the industry average of 37%. At Cement Works, 85% of the cement dispatches are carried out by rail. Apart from this rail transport system for fly ash handling is near completion. At present the fly ash is transported from Raichur Thermal Power station through bulkers by road. After completion of this system, the movement of fly ash by road will be reduced to 50%

29 Implementation on Energy front amongst associates (Vendors / Suppliers, contractors etc) Vendors Policy : As a policy, all our vendors are requested to include only energy efficient motor for their equipment (fans, compressors etc). Environmentally-friendly GREEN BUILDINGS: In a short span of time, has accomplished four instances of environmentally-friendly GREEN BUILDINGS. 4 Our corporate head quarters Cement House, which is a 70 year old corporate building in Mumbai, has received the Gold shield from IGBC in LEED New construction & Major renovation category. 4 A 45 year old residential apartment in Thane (La residency) is redesigned and converted as a state of the art residential facility. This building incorporates the unique and energy efficient Geo-thermal air conditioning system. This is a pre-constructed platinum rated LEED project. 57 Implementation on Energy front amongst associates (Vendors / Suppliers, contractors etc) Environmentally-friendly GREEN BUILDINGS: 4 Greens Village, residential colony at the new plant near Bellary, is under execution. This project promotes solar energy, rain water harvesting and natural air cooling. A climate responsive strategy for the colony has been designed based on climate analysis, factoring sun path, wind Details and water cycles. 4 New CCR building of Chanda cement works, is also planned as an energy efficient green building

30 Contents Company Details Cement Manufacturing Process Energy Conservation & Consumption per unit of Product Comparison with Global norms/benchmark data Innovative & Environmental Projects Involvement of Employees, Team work in Encon, Monitoring & Reporting formats and implementation methodologies Renewable Energy sources, Utilization of waste for replacing the conventional energy & Water Management Implementation on Energy front amongst associates (Vendors / Suppliers, contractors etc) Certifications 59 Certifications ISO 9001:2000 ISO 18001:

31 Certifications IMC RAMKRISHNA BAJAJ NATIONAL QUALITY AWARD 2007 ISO 14001: Certifications National Award for Excellence in National Energy Water Management 2009 Management Award

32 Certifications Institution of Engineers (India) Safety innovation Award 2009 FIMI Abheraj Baldota Environment Award