BEE: Best Practices in Energy Efficiency in Cement Sector Ambuja Cements Ltd., Chandrapur. Presented by: Sheshmani Shukla 7 th July-2016

Transcription

1 BEE: Best Practices in Energy Efficiency in Cement Sector Ambuja Cements Ltd., Chandrapur Presented by: Sheshmani Shukla 7 th July

2 Index: Cement Plant: 1. Electrical energy reduction in Cement mills, CM-2 & 5 by Grinding media optimization 2. Improving Clinker quality & increasing fly ash absorption 3. CM-3 Main Bag Filter Fan Pulley diameter increased to reduce the fan speed 4. Best practices of maintenance Power Plant: 1. Boilers Bed Ash draining automisation system implementation. 2. Station Heat Rate Improvement 3. Reduction of Aux. power consumption by various measures

3 Reduction in specific electrical energy consumption in Cement Mill No. 2 by 1.9 kwh/t cement Before After Aug/15 Sep/15 Oct/15 Nov/15 Dec/15 Jan/16 Feb/16 Mar/16 Apr/16 May/ SEEC, KWh/t cem Production Rate TPH 3

4 Reduction in specific electrical energy consumption in Cement Mill No. 5 by 2 KWh/t cement Before After SEEC, KWh/t cem Production Rate TPH 0.00 Aug/15 Sep/15 Oct/15 Nov/15 Dec/15 Jan/16 Feb/16 Mar/16 Apr/16 May/

5 Sr No. 1 2 Actions taken Media pattern change, increased finer charge media in 2nd chamber, all 50 and 40 mm media removed from 2nd chamber as per sieve analysis result. Regrade 1 st and 2 nd chamber, all the deformed media in 2 nd chamber replaced by new media. Separator worn out static guide vanes and rotor vanes replaced by new one, resulted in 3 increased separator efficiency, since separator bypass reduced from 20% to 5% 4 Sepol inlet duct air guide vanes adjusted. Sepol bag filter exit & Fresh air balancing done to get max. 5 separation efficiency. 6 Regular Inspection of Separator fan & cleaning of inlet box. 7 Regular Inspection of BE lip plate for any recirculation. 5

6 Change of the raw mix design : Silica Ratio increased from 2.40 to 2.51 Liquid content reduced from to High purity corrective material used to maintain raw mix composition without increasing limestone pile LS target. The raw mix control QCX-online done on moduli value. Limestone Saturation factor reduced from to Change in Clinker Quality strength. Clinker LSF maintained at same level of 91%. Clinker SR increased from 2.43 to Clinker AR increased from 1.52 to Improvement in clinker Ye ar LSF YTD-June

7 Achieved Higher Fly ash absorption & lower Sp. Elect. Energy cons. Increase in Fly ash Absorption % Fly ash Year Year Year Year 2016 ( YTD June-2016) Cement Fineness Increase in Cement Fineness from 5.4 to 5.5 % on 45 micron sieve. Grinding PPC RESIDUE Year ON 45 Micron YTD June

8 Cement Mill no. 3, Bag Filter Fan Pulley size increased from 460 mm to 610 mm for reduction in fan rpm from 1208 rpm to 929 rpm. Before modification of fan pulley, main bag filter fan damper operated at 40% and consumed 66 KW, In sp. power consumed 0.5 kwh/t cem. After modification of fan pulley, main bag filter fan damper operating at 70% and consuming 29 KW. In sp. power consuming 0.2 kwh/t cem. Achieved energy saving 0.3 KWh/t cem 8

9 YTD, June

10 YTD, June

11 Daily Walk-by inspection Simple visual, audible, smell and touch inspection of the equipment or area Reading parameters, such as vibration, voltage, current, fault messages, etc. Observing items such as slip ring-carbon brush contact on MV motors Blowering, cleaning, greasing, oiling and also finding out the abnormal condition of the equipments. Sharing information to the internal and external customer Burning smell, Chemical smell Bang! Unusual Sound, Noise Vibration and temperature monitoring Oil, water, grease leaks, cleanliness of the area, loose bolts, smoke,...and many more 11

12 Preventive Maintenance Condition Monitoring Replace Service Vibration Monitoring & analysis of major drives Oil analysis of all Power & Distribution Transformer IR/PI Value Testing of Electrical Equipments Protection Relay Testing during annual shutdown. Overhauling of HT/LT Motors during annual shutdown as per Conditioning Monitoring Report therefore no any motors failures for last long period. Thermography of LT switch gears & Thermography point attended. HT/LT Switchgears Maintenance during annual shutdown. 12

13 Energy Efficiency Measures taken at CPP

14 Draining 100% Elimination of Hot Bed Material Manual Bed Ash Cooler modified from continuous top drain type to Batch bottom drain type. Dome valve seal failure minimised by introducing new material cut-off valve above the Dome valve. Now hot material not come in contact continuously to the seal 14

15 Installation of VVF drives. Installation of Aero dynamic fan in Cooling tower fans. Boiler # 3 Fans Up gradation YTD June Generation (Mio kwh) Aux % Replacement of Electrical heaters with heat exchange heaters in DG set.. Boiler Draft in auto loop. Zero blackouts. Installation of LED lights. Generator Frequency reduce. 50 0

16 S H R Plant Station heat rate Kcal/kwh 3608 Kcal/kwh 3521 Kcal/Kwh YTD, June Kcal/Kwh 3373 Kcal/Kwh Fully Loading of HP turbines. Maintaining design vacuum levels across the STGs. Online Steam leakage arresting. Good Quality of coal. Coal(Tons)

17 Old Benchmark 8.88% New Benchmark 8.83% Date Generation Kwh Aux Units Kwh PLF % Avg Load MW ,15, ,07, ,03, ,14, ,38, Aux % 17

18 Four Blackouts Three Blackouts Zero Blackouts Zero Blackouts Zero Blackouts

19 Benefits of ISO Certification

20 With ISO certification (International, best-practice Energy Management standard), our organization achieved many benefits, some are as below: Target driven Energy efficiency measures: With this standard we have to meet current or future voluntary and/or mandatory energy efficiency targets or GHG emission reduction legislation. It will help to reduce greenhouse-gas (GHG) emissions and carbon footprint Increased energy savings which will reduce energy costs for producing one ton of cement via a structured approach of managing our energy consumption. With this system we know better about equipment efficiency. By integrating our existing management systems, we can align our Energy Management System (EnMS) with existing management systems for additional organizational benefits. 20

21 Increased energy awareness among staff members at all levels. Structured approach to adopt Right work at First Time methodologies. Improved corporate image and credibility with all stakeholders and customer. Enhanced security of energy supply as we have identified our energy risk exposure in areas within the organization and getting remedial measure against it. Improved operational efficiencies and maintenance practices 21

22 A significant improvement of the energy performance level from an initial energy baseline. A systematic approach (plan-do-check and act) that leads to continuous energy efficiency improvement. ISO enables organizations to: Develop a policy for more efficient use of energy Fix energy efficiency targets and objectives to meet the policy Use data to better understand and make decisions concerning energy use and consumption Measure the results of energy efficiency improvements Review the effectiveness of the energy policy Continually improve energy management ISO supports the development of an energy policy and contributes to the structure of an energy plan to achieve targets. 22

23 ISO facilitates engagement (commitment and agreement) of management and has a positive contribution towards the energy targets. An ISO based EnMS creates awareness and a commitment about energy (i.e. consumption, use, efficiency, renewable sources) within the organization. ISO improves the ability of organizations to manage energy risks concerning possible impacts in an efficient and effective way. ISO strengthens the competitiveness of organizations and reduces their vulnerability with respect to energy price fluctuation and availability of energy. ISO allows the establishment of a benchmarking process. An ISO based EnMS allows organizations to gain credible external visibility of energy saving actions. 23

24 An ISO based EnMS provides a better understanding between predictable energy demand and supply. An ISO: based EnMS reduces energy costs and improves profitability. In addition, implementing ISO: yields significant benefits beyond energy and energy cost savings. Early adoption experiences have shown that conformance with the standard results in some non-energy benefits such as greater productivity and lower maintenance needs. In many cases significant energy and energy cost savings were achieved with minimal or no capital investment. This is because ISO:50001 fosters a change in culture that engages and empowers employees to identify and address energy saving opportunities as they materialize. Then, by continuously monitoring and improving energy efficiency, company achieve persistence in energy savings. 24

25 Thank you very much 25