CII Energy Excellence Award UltraTech Cement, GICW, Ginigera

Transcription

1 CII Energy Excellence Award 2017 UltraTech Cement, GICW, Ginigera The Team: Mr. Mahendra P Singh Asst. General Manager Mr. Hanumanthappa. C - Dy. Manager - E&I Mr. Pradeepkumar C K - Manager - Process

2 UltraTech Cement, GICW, Ginigera Plant capacity(cement) MTPA (Commisioned on Sept-2008) Products - OPC, PPC,PSC and GGBS Market - North Karnataka & Goa 2

3 Clinker From APCW Process View, GICW, Ginigera 4000 Tons/rake Clinker Wagon tippler 20 boxes/hr Cement Mill LM blains Clinker Silo Tons capacity Clinker hopper-1000 Tons Slag hopper-1000 Tons Gypsum Hopper: 350 Tons Gypsum Fly ash Slag Cement packer 6-Spouts, 4-nos of 90 TPH Cement Silo 3-compartments 5000 x 3 =15000 Tons Coal Truck loading 6-nos Wagon loading 8-nos Bulk cement loading

4 UltraTech Cement, GICW, Ginigera 4

5 Energy Conservation Projects Completed Sl. No. Title of Project Annual Electrical Saving (kwh) 1 Timer interlock for tripping on idle running for Cement Mill Auxiliary equipment Provided interlock for cement mill stack monitoring system purging air blower to avoid idle running Installed 55 kw compressor with VFD drive in place of 90 kw compressor Installed Air dryer for new 55kw compressor Replaced Conventional Lamps with LED Lamps Installing VFD drive for Packer No-1 & 3 De-dusting fan Improving Fly ash blain at source by modification in the circuit Installing LED lights instead of HPSV for various location Mechanical system for Fly ash Unloading

6 Energy Conservation Projects completed Sl. No. Title of Project Annual Electrical Saving (kwh) 10 Replacing fluorescent lamps with 18 W LED lamps at various locations Single Button start command for Cement Mill (Start up time reduced from 15min. To 8.0min.) Installation of VFD for cement mill reject circuit bag filter fan(22kw) in place of DOL starter Single Blower for Fly ash feeding air slides instead of two blowers To avoid idle running of compressors by providing control valves for cement mill and packing plant and operating from CCR Packer discharge conveying line was connected with 1.1 KW motor for diverter which was consuming power, hence it is decided to install power less diverter and save power

7 Energy Conservation Projects completed Sl. No. Title of Project Annual Electrical Saving (kwh) 16 Raw coal feeding conveyor belts were having delayed start for each belt, hence analyze the start time and reduced idle run hours about 7 minutes on every start stacker conveyor belts were having delayed start for each belt, hence analyze the start time and reduced idle run hours about 3 minutes on every start. Packer floor all lights were working continuously irrespective of working of Packers, modified lighting circuit to switch on lighting for individual packers and control given at CCR. Packing plant P&V system operational control made in auto mode and interlocked with packing plant operation, since packing plant operates only two shifts avoided idle running. 90 KW water cooled compressor was working for running 2 packers, which was consuming more power, hence modified the air line to work 55 KW compressor for running 2 packers Total in Lacs kwh

8 Energy Conservation Projects

9 Action plan for reducing power consumption Sl. No. Title of Project Estimated Annual Electrical Savings (kwh/year) 1 Elimination of 2 Nos. Mill feed conveyor belts by Circuit Modification Modification of Reject circuit by including intermediate Bin Replacement of Venture in Mill Fan circuit Mill Fan Inlet Box Modification Replacing Old AC s with new Energy efficient ACs Changing lighting circuit in packing plant Replacing Conventional Lamps with LED Lamps Total in kwh

10 Future plan for purchasing renewable energy 10 Planned to purchase solar power to fulfill total power requirement about 90% from renewable energy Source Expected units/annum Expected price ABG renewable power project 100 Lacs 5.00 Rs./kwh 10

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12 OPC Grinding Specific power (U/T) 27 Target Reduction 3.9%

13 PPC Grinding Specific power (U/T) Reduction 11.10%

14 Reduction 15.35%

15 50.0% Consumption of dry fly ash Target = 33 % 40.0% 30.0% 20.0% 10.0% 26.4% 29.7% 30.8% % Year Comments % pond ash with high moisture Commissioned dry fly ash system in Apr

16 Comparison of specific power consumption with other grinding units on monthly basis Bench Marking

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18 1. Zero Fuel for Cement Grinding Year Comments % HFO utilization Commissioned coal HAG during Jun % coal HAG Eliminated hot gasses for OPC &PPC in July-15 Sustained Zero fuel for Cement Grinding 18

19 Benefits 1. Zero Coal Consumption during Cement Grinding. 2. Reduced Coal Handling Quantity. 3. Reduced Coal mill run hours. 4. Reduction in process water consumption. 5. Increase in HAG refractory life. 6. Conservation of natural resources Coal : 4800 MT/Year Water : 21 Lakh M 3 /Year 19

20 2. Optimizing Lighting Power Replacing Sodium Vapor Lamps by LED Lamps Switching OFF Excess fittings based on Lux levels By Utilizing natural light during Day Time Variance Saved >400 kwh/day (27%) Reduction

21 3. Mill Fan Venture replacing by Annubar Flow meter Back Ground of the Project :Venture Meter was used for Mill Fan flow measurement which was leading to a pressure drop of 15-20mmWG across the duct.project expected to complete by August 17 Pressure Drop -555mmWG = Total Pressure rise X Power Consumption -570mmWG Pressure Drop = -570 (-555) = -15 Pressure Rise = -30- (-570) = mmWG Power Consumed = 1520 KW = 15/540 *1520 = 42.2 KW 21

22 3. Mill Fan Venture replacing by Annubar Flow meter Modification work in Progress Before After 22

23 4. Installation of VFD`s for fans & pumps By this principle reduced the RPM Of fans & Pumps after analyzing the requirements and process by using VFD Drives. Carried out 6 small projects under this Category and Saved kwh/annum 23

24 5. Compressed air optimization Problem definition: Utility power was on higher side due to the un controlled compressor operation and leakages in the circuit and compressor dedicated for packing & Cement mill separately. Entire Compressors were operated from locally, and there are no isolation valves to separate the Air lines to Wagon Tippler, coal mill etc. whenever it is not in operation. We have four 90KW Compressors, one 55KW air cooled compressor and one 132KW air cooled compressor as follows 24

25 5. Compressed air optimization Installation against requirement: Compressor Available Compressed air (M3/hr) 1 (90KW) (90KW) (90KW) (90KW) 1026 (Dedicated for Fly ash Unloading) 5 (55KW) (132KW) 1443 (Dedicated for Fly ash Conveying) Total 6006 Required as per design for the operation of entire Plant(M3/hr) 5578 As per the study regarding availability and requirement we have made an operation matrix for the compressors other than dedicated ones. 25

26 5. Compressed air optimization Action Plan Sl. No. Activity Description FPR Target Date Status 1 Operation of all compressors to be made from CCR CH Completed Compressor Operation to be synchronized for both packing & Mill operation instead of dedicated operation. Survey for identifying the leakages as well miss usages of compressed air in the entire circuit of plant operation. Pneumatic Isolation valves to be provided at Wagon Tippler & Coal Mill circuit. These valves can be operated from CCR as per the requirement. After studying the compressed air requirement for each section,operation matrix of compressor to be provided to CCR Operator. CKP Completed JSR Completed ADK Completed CKP Completed 6 Mechanical system for Fly ash unloading through existing Bucket Elevator to be done MM Completed 7 Operation of Bag Filters in DP Mode PVM/JSR Completed 26

27 5. Compressed air optimization Operation matrix and logic MIMIC Conditio n-1 Conditi on-2 Conditi on-3 Conditio n-4 Conditi on-5 Conditi on-6 Conditio Conditio n-7 n-8 Packer-1 a a a a a a a Packer-2 a a a a a Packer-3 a a Packer-4 a a Cement Mill a a a a Wagon Tippler a a Coal Mill Compress or-1 Compress or-2 Compress or-3 Compress COMPRESSOR OPERATION a 1&2 or 1&3 or 2&3 or-5 a a a a a a a a 27

28 5. Compressed air optimization - Results Particulars Before After Cement mill & packing plant operation Wagon loading operation with 4-packers Truck loading with 2-packers Specific power consumption for compressed air 4 x 90kW 2 x 90 kw 2 x 90 kw 1 x 90 kw 1 x 90 kw 1 x 55 kw

29 6. Renewable Power Purchase (Wind power) Made long term Agreement with M/s Sembcorp Green Infra from April 2016 and started availing power from September Wind Power Utilization (Till July'17) Total power Wind power % age utilisation 29

30 ENCON Organization Chart GUH Vice President Technical Head Energy co-ordinator Cement Mill Packing plant Raw material Handling and Wagon Tippler 30

31 Energy Management Committee S no Name Designation 1 T.K.M.Reddy UH 2 Mahendra P Singh TH 3 Hanumanthappa.c SH (E&I) Co-ordinator 4 Pradeepkumar.CK SH (Process) 5 Srinivasarao J SH (Mech) 6 PSN. Murthy SH (Comercial) 7 Dada Khalandar Mechanical (FLE) 8 Krishnaprasad B IT 9 Balasreenivasareddy Electrical (FLE) 10 Ravindrareddy.V Instrument (FLE) 11 Ravi Firangi HRD Agenda: 1) Review of previous meeting points 2) Review of action plan 3) Generation of new ideas 4) Any specific issues 5) Conclusion with action plan 12 Thatchinamurthy N SH - QC 13 Prasad Danial Stores 14 Nageshwara Rao Security

32 Online Energy Monitoring-Section wise

33 Section wise Energy Monitoring on daily basis

34 Energy Monitoring in SAP

35 Energy Management System (EnMS)-Policy

36 Rewards & Recognitions Received Energy Efficient unit award from CII

37 Environment Practices Development of pond for rain water harvesting & Greenery Hectares 13.1 Green belt is to be covered 33.0% ie Hector 15.7 Total Area Gree bel to be covered Coverd till today

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