CII National Award for Excellence in Energy Management Ambuja Cement Ltd., Nalagarh

Transcription

1 CII National Award for Excellence in Energy Management Ambuja Cement Ltd., Vision: To be the most sustainable and competitive company in our industry

2 Presentation Contents/Take Aways Company Profile Plant Profile & Major Process Equipment Energy Saving Projects with no investment Status of Last three years Energy Conservation Projects Electrical Energy Optimization Three years Roadmap for Energy conservation projects Specific Energy Consumption figures & Comparison with Competitors Innovative projects Project Implementation methodologies. Implementation of ISO GHG Initiatives

3 Company Profile Ambuja Cements Ltd, a part of the global conglomerate LafargeHolcim. Total cement capacity of million tonnes.(05 IPs and 08 GUs). Cement Products: OPC, PPC & Ambuja Plus Roof Special. Certified five times water positive and is India's only water positive cement company. Also plastic positive, by burning as much as over 50,000 tonnes of plastic waste in its kilns, equivalent to 1.54 times of total plastic used. Company generates 6.5% of its energy from renewable resources. CSR arm ACF(Ambuja Cement Foundation) with presence in 21 locations spread across 11 states.

4 Plant Profile A Grinding Unit situated in, Himachal Pradesh (India) at an altitude of 334 mtr.commissioned in March Plant rated capacity is 1.50 Million Ton per annum. VRM : Make Loesche -LM56.3+3C; Capacity 250TPH. Classifier; Make Loesche LSKS 102 CS r. Bag House: Make Redycam; Designed Flow M3 /hr; Dust Loading 348 gm/m3; Packer: Make EEL; Two Nos; 16 Spouts double discharge 240 TPH each. Plant connected load :15MW; Contract Demand: 9MVA First cement plant in India certified as ISO

5 Health & Safety Performance Performance Parameter YTD Lag Indicators : Fatality LTIFR LTI * 01* * 02 0 MTI First Aid Lead Indicators : Near miss Hazard s / 363 SOT s LTIFR : LTI Frequency Rate (per million man hrs) LTI : Lost Time Injury MTI : Medical Treatment Injury * Indicates offsite incident

6 Awards & Certifications CII Green Tech Award for Water Positive CII CSR Award FICCI Award for Health & Safety Best Plant Performance Award-ACL Cement Budget Champion Award-ACL -OHSAS 18001:2007 ; QMS (ISO 9001:2008), -EMS (ISO 14001:2004); EnMS (ISO 50001:2011) Most Clean Unit Award-ACL

7 Cost -effective Energy Saving Projects- NIL Investment Sr. No. Initiative Name 1 Optimize operating pressure(grinding roller pressure) in VRM* 2 Controlling of plant Lights and package AC operation from PLC 3 Change in process operation of BH Fan after HAG firing to avoid idle running. 4 Stopped recirculation of fly ash to silo through process modification 5 Max operation of VRM in high level control (fuzzy logic) 6 Optimized distribution transformer loading to avoid no load losses. Spare 03 transformers Power Saving KW Annual Saving INR Lakh *CII recommendations

8 Cost -effective Energy Saving Projects- NIL Investment Sr. No. Initiative Name 7 Optimized capacity of lightly loaded motors converting them from delta to star.* Power Saving KW Annual Saving INR Lakh Stopped idle running of GRR cooling blowers Change in process operation of product group only after VRM grinding mode. 10 Modification in clinker silo extraction chute logic to get homogenous temperature material reduced vibration breakdown by 50% Avoid Idle running of gypsum crusher vent bag filter fan.* Total 93 *CII recommendations

9 Last three years Major Energy Conservation Projects Sr. No. Initiative Name 1 Arresting of false air in VRM grinding section closed loop system from 25 % to 15%. 2 Installed 3000KW SPRS (Slip Power Recovery System) for VRM Fan* 3 Pressure setting regulation along with VFD installation in compressor and making common header line for all. 4 Optimized two PD blower for aeration in fly ash silo and cement silo system* 5 Reject group running optimization by installing a small hopper & level sensor in it. 6 Installation of Honeycomb air washer system in place of pressurized water spray nozzle system Power Saving KW Annual Saving INR Lakh Investment INR Lakh *CII recommendations

10 Last three years Major Energy Conservation Projects Sr. No. Initiative Name Power Saving KW Annual Saving INR Lakh Investment INR Lakh 7 Increasing of feed chute by 75mm to take the feed at the center of table. 8 Installed correct head high efficiency pump for process water pump.* 9 VFD installation for clinker unloading hopper vent to avoid damper losses* 10 Use of FRP blade for cooling tower and motor cooling fan. 11 LED light installation of different wattage in plant* Total *CII recommendations

11 Roadmap for Energy conservation_ Sr. No. Initiative Name 1 Optimize Bag House & Other bag filter purging cycle from 12 cycle/minute to exiting 9 cycle/ minute 2 To stop fly ash tippler unloading bag filter while bulker unloading in process 3 Simultaneous unloading of fly ash from two bulkers at a time 4 Optimization of Mill Parameters to increase the TPH 5 Installation of Waste Air Wind Mill 9 KW Power Saving KW Annual Saving INR Lakh Investment INR Lakh Status Done Done Done (In progress) Sep 17 (Material Received)

12 Roadmap for Energy conservation_ Sr. No. Initiative Name 6 LED light installation of different wattage in plant 7 Elimination of venturi from bag house fan duct to eliminate pressure drop. 8 VFD installation for clinker unloading hopper vent to avoid damper losses* 9 Installation of Light Pipes in Packing plant 10 Direct feeding of clinker from tippler to Hopper building Power Saving KW Annual Saving INR Lakh Investment INR Lakh Status Feb 18 (PO Issued) To conduct Energy Audit from CII 2017 Total *CII recommendations

13 Reduction in Specific Energy(Power) Consumption figures KWH/T Asp.'17 Total PPC Roof Special KWH/T

14 VRM Section Performance VRM Section KWH/T OEM

15 Reduction in Specific Energy(Thermal) Consumption figures Millon'Kcal Asp

16 Reduction in CO2 Emission Ton of CO Asp

17 Energy Reduction Contributing Factor - Improvement in Plant MTBF MTBF (Rolling Hrs) Asp.'17

18 Plant Utilization 1.2 Producton (Million' MT) Bugt'17

19 SEC Benchmarking with peers(gu ACL & ACC power comparison) ACL KWH/T ACC, Kolar ACL, Dadri ACC, Bellari ACC,Sindri

20 Innovative Project-1 Benefit = INR 54 Lakh /annum; Investment: INR 0.3 Lakh Initiative: Coverage of VRM Nozzle Ring to Achieve Higher Gas Velocities. Modification: Louver area reduced from 4.27m2 to 3.95m2 by blocking louvers ring Louver area covered Parameters UOM Before After Velocity m/sec Dust Load g/m Gas Flow m3/kg Air Flow m3/hr TPH t/h Fan Power KWH Saving: 300KWH mm

21 Modification Snapshot Aspects of closing nozzle Rings: Uniform material distribution on the rotor circumference Regulation airspeed in Uniform air distribution all around the table Nozzle-Ring Guide Vanes Modification: Iron rod placed to reduce open area of nozzle ring area

22 Innovative Project-2 Benefit = INR 36 Lakh /annum; Investment: INR 0.1 Lakh Initiative: Reduction in dynamic seal gap of VRM separator Modification: Reduction in dynamic seal gap from 15mm to ZERO mm by using Felt. First ever modification done in VRM separator in the history of cement industry. Impact: R45 decreased from 11% to 5%.(Best PSD in ACL & ACC accredited by CSG ) 2.5% Increase of fly ash consumption from 29% to 31.5%. Reduction in Mill Department Power Consumption by 0.8KWH/Ton (around 200KWH) or saving of around INR 36 Lakh per year

23 Modification Snapshot Before Modification: Seal Gap in Separator Gap 15 MM After Modification: Felt inserted

24 Round Robin Test Results- Best R45 Test 01 Test 02 Test 03 ACL, Ropar ACL, Darlaghat ACL, Bathinda ACL, ACC Limited, Gagal Grasim Industries, Lehra Mohabbat Shree Cement Limited, Beawar JP Cement Limited, Bagheri Solan HP Achievements: Innovation well appreciated by OEM and taken the design of modification to replicate this design in their future separators. Design replicated at 05 other plants of ACL & ACC and achieved similar results

25 Innovative Project-3 Initiative: Reduction of fuel consumption for preheating VRM (grinding) operation Operational Requirement of HAG: VRM Grinding is started only >90 degree C as general practice. Temperature drop of degree C in closed circuit due to false air entrance >25%. To avoid dehydration of final cement product. To avoid condensation of cement in transport circuit and silo. To avoid boulder formation and deterioration of final cement material. Initiatives taken to optimize HAG Operation: OEM & Techport recommendation to operate VRM grinding above dew point. Blocked all false air sources and reduced it to design level of 15%.(CII 13.2%) Online temperature monitoring of final cement discharge to silo. Auto controlling of water spray with above temperature. Modified clinker silo extraction chute logic to get homogenous temperature material during plant operation Utilized required heat from grinding energy and Clinker temperature. Benefit = INR 1.5 Crore /annum; Investment: INR 10 Lakh

26 Initiatives Impact & Saving HSD/HFO Consumtion (K Litres) 450 INR 1.3 Crores Asp.'17-18 Added benefits achieved : Power saving of 2500KWH in one running or INR 22.5 Lakh per annum as idle running of Mill Fan, Classifier, transport group and HAG stopped. Reduction in the boulder formation in cement silo at reduced temp degree C. Minimum handling of hazardous material like HSD/FO in plant Increased production as idle heating time of 2hrs stopped. 0

27 Innovative Project-4(Planned) Benefit = INR 2 Lakh/annum; Investment: INR 8 Lakh Initiative: Waste Air Recovery System which covert waste air velocity and flow to convert it into electrical energy Modification: Installation of 8.6KW Waste Air Recovery System at our packing bag filter vent and utilize it for packing plant lighting. GA Drawing of System: Bag Filter Alternator Waste Air Wind Mill System BF Fan

28 Technical Data Sheet & Saving Potential Velocity Technical Data Sheet 19 m / Sec Velocity Pressure (Static Pr.) 35 mm of W. G. Duct area 0.79 sq.m Outlet flow in M3 / hrs Fan Actual Consumption in Kw. 34 / 23 Capacity Of Alternator 9 KW, 1500 rpm, 440 V, 3ph, specially designed alternator. Power available(potential Saving) in outlet flow: Outlet flow in per min X Velocity Pr. KW = X Effi. Of bag filter fan = 8.6KW Yearly Saving Potential : 8.6X 12X365= KWH or INR 1.8 Lakh Investment = INR 8Lakh

29 Project Implementation methodologies-energy Management Division Alok Sharma (Certified Energy Manager DGM-E&I) Raj Garg (SI-Operation Exp-20yrs) Deepak Dhiman (CEM-Electrical Exp-10yrs) Ravinder Gill (SI-Automation Exp-10yrs) Manish Tandon (SI-Mechanical Exp - 9yrs) Perform daily power analysis Conduct internal audits Evaluate new ideas, Implement new initiatives Ensure compliance of energy audits points Manohar Lal (SI- Electrical Exp-9 years) Aasheesh Kumar (Planner-Mech. Exp-9 years) Durga Verma (Head-Env. Exp-20 yrs)

30 Project Implementation methodologies-energy Circles Energy Circle -1 Energy Circle -2 Energy Circle -3 Energy Circle -4 VRM Mill Section Raw Material Handling Section Utilities & Lighting Section Packing Section 04 Members (02 MS; 02 WB) 04 Members (02 MS; 02 WB) 03 Members (01 MS; 02 WB) 03 Members (01 MS; 02 WB) Daily Energy Observation Tour(EOT) to observe any abnormality Ensure timely compliance of points identified Analyze idle running of equipment operation

31 Project Implementation methodologies-people Power Initiative The systematic 4-month wave process Baseline & Aspiration Setting Boot camp & Wave Planning Data Collection & analyses Idea Generation Practices Identification Evaluation & Approval Implementa tion & tracking Dream Run 1 Week 1 Week 2 to 3 Weeks 3 to 4 Weeks 2 to 4 Weeks 6 to 8 Weeks 4 to 8 Weeks Baseline Data Collection Aspiration Setting Workshop BH & Unit Head approval for the aspirations Technical Modules training at Bootcamp Wave team finalization Wave planning Trend Analyses Benchmarking with other plants Finalization of equipment and sub-equipment targets Idea generation sessions with wave teams, operators, junior engineers & wageboard Identification of SOP/SMPs critical for achieving wave targets Binder evaluation Identifying deep-dive areas for study Idea prioritization on the basis of potential and ease of implementation Signoffs on prioritized ideas in Idea evaluation template Weekly War Room Reviews & MIS tracking Idea implementation templates and signoffs. Tracking progress on ideas Trainings for the SOPs/SMPs identified Branding and communication s Adherence to practices Tracking and review of progress

32 Main Reporting Format- Sample Sr.No. YTD 17 JAN 17 FEB 17 Mar 17 Apr 17 SECTION / EQUIPMENT OWNER Target KWH/T KWH/T KWH/T KWH/T KWH/T A CEMENT GRINDING MAIN DRIVE M.Sharma CLASSIFIER M.Sharma BAG HOUSE FAN M.Sharma AUXILIARIES M.Sharma B PRE PROCESS GYPSUM HANDLING R Garg FLYASH HANDLING Vijay Verma CLINKER HANDLING Raj Kumar CLINKER SILO FEEDING R Garg C UTILITY PLANT COMPRESSOR Harjeet FACTORY LIGHTING Manohar WATER PUMPS Pritam STP1 (Plant) Durga Verma D STP2 (Guest house) Durga Verma Total Grinding Consumption

33 Reporting Format-Section-I Sample

34 Reporting Format-Section-II Sample

35 Implementation of ISO & Investment on Encon Projects CII Energy Saving Proposal Compliance No. of proposal Proposal Executed (Nos) Annual Savings Achieved (Rs Lakh) Cost Incurred in (Rs Lakh) Planned proposal ( Nos) Potential Saving (Rs Lakh) Investm ent Require d (Rs Lakh )

36 GHG Initiative _ Plantation Data Trees Planted Till'17 (Nos) Avg. Tree planted per year(nos) 0 Shrubs Till'17 (Nos) Avg. shrubs planted per year( Nos)

37 GHG Initiative _ Plant Area: 29Hectare ; Green Area : 34 % Views: Central Area

38 GHG Initiative _ Plant Area: 29Hectare ; Green Area : 34 % Views: Truck Yard

39 Thanks!!!