THE KCP LIMITED, UNIT-II

Transcription

1 Second Prize Cement (Clinker & Grinding Unit) THE KCP LIMITED, UNIT-II Krishna Distt. (Andhra Pradesh) Unit Profile The KCP Limited, one of the country's oldest cement producers, has a strong presence in the south India market. KCP strategically chose this Greenfield plant located at Ramakrishnapuram, Muktyala Village, Jaggayyapet Mandal in Krishna District of Andhra Pradesh because of it's close to large limestone reserves and providing easy access to the key markets of Andhra Pradesh, Tamil Nadu, Karnataka and Orissa. KHD Humboldt, Germany designed an energy-efficient plant that could deliver an annual capacity of 1.32 million tonnes of Clinker and 1.52 million tonnes of Cement. MAJOR EQUIPMENT INSTALLED Hazemag Limestone Crusher: Capacity 850 TPH Takraf Stacker & Reclaimer: Capacity 850 TPH MPS 4500B Gebr Pfeiffer, Germany Raw Mill: Capacity 350 TPH CF blending silo 20m diameter x 45m high: Capacity: MT MPS 2800BK Gebr Pfeiffer, Germany Coal Mill: Capacity 40 TPH KHD Humboldt, Germany ILC 6 Stage Pre-Heater with Pre-Calciner 3-support rotary kiln 4.20 m diameter x 64 m long 39

2 Specific Power Consumption Specific Thermal Energy Consumption: ENERGY CONSERVATION MEASURES TAKEN ) Replacement of Coal crusher RP Feeder with Belt conveyor. 2) Reduction of Pyro & Cement Mill Water Pump capacity (By Installation of Cooling Tower & Softner) from 75 kw to 22 kw. 3) Coal Crusher By Pass 4) Cement Mill Production Enhancement 5) Modification of Cooler Static Grate inlet by Horse Shoe shape Refractory (To control the clinker flow in centre and for better Heat Recuperation, which in turn increased both tertiary and secondary air temperatures) 6) Reduction of capacity of Water Pump for filling of Kiln and Cement mill over head tanks for Process Requirement from 75 kw to 22 kw 40

3 7) Packer-2 Bag Filter Vent line Modification. Before 2 nos. bag filter fans of 55 kw and 37 kw operated. After Inter connected both bag filter and operating only 55 kw fan during packer operation. 8) Reduction of Cement Mill Silo extraction Blower from 22 kw to 15 kw 9) Arrangement of Flaps in Place of RAL in Cement Mill Auxiliary Bag Filters. 10) Kiln Feed Bin Aeration Pipe Line Modification (Motor capacity reduced from 55 kw to 37 kw) 11) Optimizing Kiln and cooler by constructing wall at cooler null point. 12) Decreasing the capacity of Compressor in Packing Plant from 75 kw to 37 kw. 13) Optimization of grinding media. 14) Reducing Idle running of Equipments 15) Reducing number of Start/Stop during filling of Raw Material 16) Optimization of Compressed Air 17) Minimizing False Air & Compressed Air Leakages 18) Power Factor Optimization 19) Installation of VFD s for Auxiliary Bag Filters. 20) Plant lighting Optimization. A) MODIFICATION OF CALCINER BURNER KCP INNOVATIVE PROJECTS Coal Pre-mixture of fuel and meal Faster ignition Avoid peak temp inside the calciner Harmonized temp across the calciner Lower NOx & CO No burner Cooling Air Specific heat reduced by 4 Kcal/Kg Clinker Increased the clinker output by 100 TPD PH Fan power reduced by 0.50 KWh/T 41

4 B) ARRANGEMENT OF SPIRAL IN PRE-HEATER EXIT KCP INNOVATIVE PROJECTS Arrangement of Spiral Reduced the dust Loss < 3.50% Reduced Specific Heat Consumption by 5-6 Kcal/Kg Clinker C) EXTENTION OF COOLER STACK HEIGHT KCP INNOVATIVE PROJECTS Extension of Cooler Stack height Increased from 45 Mts to 65 Mts. Fan Speed reduced by 200 RPM Reduced Power by 32.5 KWh Low Fan Maintenance cost Reduced CO2 by 270 MT/ Annum 42

5 D) COOLING TOWER FOR LUBRICATION UNIT AND BEARINGS COOLING KCP INNOVATIVE PROJECTS Cooling Tower for Lubrication Unit & Bearings Cooling Efficiency of the heat exchangers has increased Temperatures of the Lubricant oils has come down by 5-7 Deg C Scaling has come down drastically Maintenance cost has come down by 20% Power saving is achieved by 1,700 KW per day due to reduction in water pumps run hours 43

6 Energy Policy 44

7 Second Prize Cement (Clinker & Grinding Unit) DIAMOND CEMENTS PROP. HEIDELBERG CEMENT INDIA LIMITED Damoh (Madhya Pradesh) Unit Profile The Unit is named as Heidelberg Cement India Ltd (HCIL), situated at Damoh in Madhya Pradesh. Previously HCIL had two production line of Kiln: Line-1 & Line-2 with combined capacity of 1.5 MT clinker production. Line-1 was established in the year 1983 and Line-2 in the year HCIL has further enhanced its production capacity at Narsingarh, Damoh from 1.5 MT to 3.1 MT by initiating commercial production of newly installed 5000 TPD state of art technology kiln (Line-3) in year February, Damoh unit exclusively a clinker producing plant which uses Indian coal and pet coke as source of thermal energy for process and grid power is source energy to cater to the power requirement of the clinker plant. Energy Consumption HCIL is committed to optimize the specific heat and power consumption by implementation of modern technology and practices for reducing its usage of Energy. 45

8 The specific energy consumption figures for FY & are shown below. Description Specific Power Consumption (kwh/mt Clinker) Specific Heat Consumption (kcal/kg Clinker) Specific Power Consumption Trend Specific Heat Consumption Trend Energy Conservation Measures Taken Below mentioned are the major initiatives which had been taken to achieve reduction in energy consumption in all activities: 1. Installation and optimization of new production line of kiln of 5000 TPD capacity having 5 stage, double string pre-heater state of art FLS Technology 2. Installation of water spray in pre-heater Twin Cyclone (Line-2) 3. Dust Settling Chamber Modification in Line-II 4. Speed reduction of calciner Firing Blower in Line-II in Narsingarh 5. Installation of LED light at plant street lights 6. Utilization of Sun light at workshop 46

9 Environment and Safety HCIL is concerned for clean & green environment and committed to eco-friendly processing of Clinker manufacturing. HCIL has a well-established integrated Health and Safety Policy to ensure the optimum safety of the employees, public, plant and equipment, which are embedded in the core organizational values. The Unit is complying with ISO 9001:2008, ISO 14001: 2004 and OHSAS 18001: 2007 by integrated management system. ENERGY POLICY 47

10 Certificate of Merit Cement (Clinker & Grinding Unit) JAYPEE SIDHI CEMENT PLANT Sidhi (Madhya Pradesh) Unit Profile Jaypee group is the 3rd largest cement producer in the country. The groups cement facilities are located in almost all parts of India; however the first cement plant of group was installed in Satna cluster (M.P.) which has one of the highest cement production growth rates in India. Jaypee Sidhi Cement Plant is one of the modern and energy efficient plant of the group situated in Sidhi district of Madhya Pradesh, India. Presently, it has two clinkerization units and its total annual capacity of clinker production is 3.0 MTPA. The first unit was supplied by L&T (SLC KILN 4200 TPD) and was successfully commissioned in January The Second unit was supplied by FLSMIDTH (ILC KILN 4500 TPD) and was also successfully commissioned in January

11 Energy Consumption The specific power consumption figures for FY & shown below. are KPI FY FY Clinker Production Sp. Power Cons./MT Clinker Cement Production Sp. Power Cons./ MT Cement grinding Sp. Power Cons./ MT Cement Energy Conservation Measures Taken Below mentioned are the major initiatives which had been taken to achieve reduction in energy consumption in all activities: 1. Modified Kiln String V down pipe i.e. connected directly to the smoke chamber riser duct towards Kiln side avoiding 3 bends which improved Kiln throughput, quality of clinker and reduction in power consumption. 2. Modified logic and Installed soft starter for reverse air fan, resulting in energy saving 3. Replaced coal firing blowers from AMCL to Kay International and also reduced speed of blower as per requirement. The initial motor kw was 200 kw whereas present motor is 132 kw. 4. Cement mill transportation group interlocking changed to 20 Min instead of 30 Min. 5. Raw mill & coal mill feed belt magnetic separator was interlocked with the running of belt resulting in power savings. 49

12 6. Stacker belt take-up was modified for smooth operation & maintenance by removing 5 no. pulleys also resulting in improved power consumption AS4 air-slide inclination was increased from 6.5 to 9 degree to avoid jamming resulting in reduced power consumption by stopping extra air-slide blower. 8. Interlocking of bag filters with their respective groups. 9. De-energisation of 2 nos. distribution transformers nos. L.T. motors connections were changed from DELTA To STAR. 11. Installation of 4500 kvar capacitor bank in switch yard for improving power factor. Energy Policy 50

13 Certificate of Merit Cement (Grinding Unit) ACC LIMITED, THONDEBHAVI CEMENT WORKS Chikkaballapur (Karnataka) Unit Profile Thondebhavi Cement Works was set up as a Green Field Project in about 120 acres of land, in the lush green village of Thondebhavi in Karnataka. This cement grinding plant was commissioned in the month of December 2009; it is the most modern plant with state of art technology with a capacity of 1.66 million tons of Pozzolona Portland Cement. Major raw material for the production of Pozzolona Portland Cement (PPC) is clinker which is supplied from the ACC s modern plant in Karnataka situated at Wadi in the Gulbarga District. For the production of clinker Wadi cement works is burning alternate fuels like Paint sludge, ETP sludge, waste chemicals etc. By using these fuels ACC is saving natural fossil fuels like coal & there by reducing CO 2 emissions. This clinker is transported by rail, thus saving on logistics and associated CO 2 emissions. 51

14 Energy Consumption With the implementation of various energy conservation measures as ongoing practice, there is decline of specific energy consumption since the commissioning of the plant, the specific energy consumption figures are shown below which depicts reduction in energy consumption due to plant s sustained efforts to conserve with the implementation of various energy conservation measures and ideas to increase efficiency of equipments. Description FY FY Specific Electrical Energy Consumption (kwh/t Cem) Specific Thermal energy consumption (Million kcal /Year) Specific Electrical Energy Consumption - kwh/t Cement Major Energy Conservation Measures taken in Thondebhavi cement works has committed to protect environment by conserving natural resources; some of the energy conservation activities undertaken by the team are as given below: 1. Installation of VVVFD for Bag house fan in place of GRR Achieved savings of 1.2 million kwh 2. Installation of VVVFD for Compressor Achieved savings of 1.0 million kwh. 3. Installation of VVVFD for Bag filter fans (3 Nos.) Achieved Savings of 0.1 million kwh 4. Up gradation of Clinker Weigh Feeder from 220 TPH to 300 TPH for improving TPH in OPC Achieved Savings of 1.5 million kwh 5. Elimination of Hot Air Generator operation Achieved savings of million kcal/year & 1.3 million kwh 6. Compressor air optimization study by External Energy auditor Achieved savings of 0.3 million kwh 52

15 7. Optimizing the clinker rake unloading time - Achieved savings of 0.08 Million kwh 8. Modification of bag filter vent line to reduce pressure drop - Achieved savings of 0.05 million kwh Major Environmental Measures taken in FY Energy Policy ISO

16 Certificate of Merit Cement (Grinding Unit) THE RAMCO CEMENTS LIMITED CEMENT GRINDING UNIT Valapady (Tamil Nadu) Unit Profile Salem Grinding, unit of The Ramco Cements Limited, is set up at Singhipuram village of Valapadi Taluk. Cement grinding capacity of the unit is 1.6 MTPA. The grinding unit has the following salient features: High-efficiency separator to deliver proper size-distribution of cement. Computerized Central Control Room (CCR) to ensure quality assurance. Rotary Packers with high-accuracy for packing of cement. Specific Energy Consumption Details 54

17 Energy conservation projects implemented in year Upgraded capacity of plant from 80 TPH to 230 TPH by installing a pre-grinder. This reduced the specific energy consumption of the total plant. Installed SPRS for Separator fan drive (HT) which is circulate the Recirculation material in the cement mill product circuit. Replaced 50 nos. of existing 70 W MH well glass fittings with 42 W LED Well Glass fittings. Replaced 15 nos. of existing 250 W MH street light fittings with 90 W LED Street Light fittings. Converted some motors connection from delta to star connection in packing plant. Now the packing specific energy reduced from 1.86 to 1.67 kwh per ton of cement. Quality, Environment & Safety Policy 55