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
UltraTech Cement, GICW, Ginigera Plant capacity(cement) - 1.3 MTPA (Commisioned on Sept-2008) Products - OPC, PPC,PSC and GGBS Market - North Karnataka & Goa 2
Clinker From APCW Process View, GICW, Ginigera 4000 Tons/rake Clinker Wagon tippler 20 boxes/hr Cement Mill LM 53.3.3 175 TPH @ 350 blains Clinker Silo 35000 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
UltraTech Cement, GICW, Ginigera 4
Energy Conservation Projects Completed 2014-16 Sl. No. Title of Project Annual Electrical Saving (kwh) 1 Timer interlock for tripping on idle running for Cement Mill Auxiliary equipment 8541 2 Provided interlock for cement mill stack monitoring system purging air blower to avoid idle running 1000 3 Installed 55 kw compressor with VFD drive in place of 90 kw compressor 262800 4 Installed Air dryer for new 55kw compressor 63360 5 Replaced Conventional Lamps with LED Lamps. 73563 6 Installing VFD drive for Packer No-1 & 3 De-dusting fan 128480 7 Improving Fly ash blain at source by modification in the circuit 114000 8 Installing LED lights instead of HPSV for various location 18188 9 Mechanical system for Fly ash Unloading 24400 5
Energy Conservation Projects completed 2014-16 Sl. No. Title of Project Annual Electrical Saving (kwh) 10 Replacing fluorescent lamps with 18 W LED lamps at various locations 19523 11 Single Button start command for Cement Mill (Start up time reduced from 15min. To 8.0min.) 47460 12 Installation of VFD for cement mill reject circuit bag filter fan(22kw) in place of DOL starter. 23142 13 Single Blower for Fly ash feeding air slides instead of two blowers 9375 14 To avoid idle running of compressors by providing control valves for cement mill and packing plant and operating from CCR 300000 15 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 11680 6
Energy Conservation Projects completed 2014-16 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. 949 17 18 19 20 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 440 18396 20075 292000 Total in Lacs kwh 14.37 7
Energy Conservation Projects 2017-18 8
Action plan for reducing power consumption 2017-18 Sl. No. Title of Project Estimated Annual Electrical Savings (kwh/year) 1 Elimination of 2 Nos. Mill feed conveyor belts by Circuit Modification 90000 2 Modification of Reject circuit by including intermediate Bin 90000 3 Replacement of Venture in Mill Fan circuit 126000 4 Mill Fan Inlet Box Modification 180000 5 Replacing Old AC s with new Energy efficient ACs 43800 6 Changing lighting circuit in packing plant 5000 7 Replacing Conventional Lamps with LED Lamps 10775 Total in kwh 545575
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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OPC Grinding Specific power (U/T) 27 Target - 25.00 26 26.06 Reduction 3.9% 25 25.27 25.07 25.05 24 2013-14 2014-15 2015-16 2016-17 12
PPC Grinding Specific power (U/T) 30 28.78 28.82 28 26 25.96 Reduction 11.10% 25.62 24 22 20 2013-14 2014-15 2015-16 2016-17 13
35.84 37.32 39.05 42.34 42.1 Reduction 15.35% 2012-13 2013-14 2014-15 2015-16 2016-17 1414
50.0% Consumption of dry fly ash Target = 33 % 40.0% 30.0% 20.0% 10.0% 26.4% 29.7% 30.8% 15 0.0% 2014-15 2015-16 2016-17 Year Comments 2014-15 100% pond ash with high moisture. 2015-16 Commissioned dry fly ash system in Apr-2015. 15
Comparison of specific power consumption with other grinding units on monthly basis Bench Marking
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1. Zero Fuel for Cement Grinding Year Comments 2012-13 100% HFO utilization 2013-14 Commissioned coal HAG during Jun-13 2014-15 100% coal HAG 2015-16 2016-17 Eliminated hot gasses for OPC &PPC in July-15 Sustained Zero fuel for Cement Grinding 18
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
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 50000 40000 30000 20000 46101 Variance 33525 Saved >400 kwh/day 10000 0-10000 -20000 (27%) 2014-15 2017-18 Reduction -12576 20
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) = -540-30mmWG Power Consumed = 1520 KW = 15/540 *1520 = 42.2 KW 21
3. Mill Fan Venture replacing by Annubar Flow meter Modification work in Progress Before After 22
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 204000 kwh/annum 23
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
5. Compressed air optimization Installation against requirement: Compressor Available Compressed air (M3/hr) 1 (90KW) 1026 2 (90KW) 1026 3 (90KW) 1026 4 (90KW) 1026 (Dedicated for Fly ash Unloading) 5 (55KW) 459 6 (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
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 30.04.2016 Completed 2 3 4 5 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 30.04.2016 Completed JSR 30.04.2016 Completed ADK 15.05.2016 Completed CKP 15.05.2016 Completed 6 Mechanical system for Fly ash unloading through existing Bucket Elevator to be done MM 15.04.2016 Completed 7 Operation of Bag Filters in DP Mode PVM/JSR 30.06.2016 Completed 26
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
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 2.27 1.64 28
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 2016 250 236.57 Wind Power Utilization 200 150 100 80.46 50 43 39.6 18 49.2 0 2016-17 2017-18(Till July'17) Total power Wind power % age utilisation 29
ENCON Organization Chart GUH Vice President Technical Head Energy co-ordinator Cement Mill Packing plant Raw material Handling and Wagon Tippler 30
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
Online Energy Monitoring-Section wise
Section wise Energy Monitoring on daily basis
Energy Monitoring in SAP
Energy Management System (EnMS)-Policy
Rewards & Recognitions Received Energy Efficient unit award from CII - 2015 36
Environment Practices Development of pond for rain water harvesting & Greenery 45.0 40.0 35.0 30.0 25.0 20.0 15.0 10.0 5.0 0.0 39.8 Hectares 13.1 Green belt is to be covered 33.0% ie. 13.1 Hector 15.7 Total Area Gree bel to be covered Coverd till today