Experience of Energy Management System and · PDF fileExperience of Energy Management System...
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Experience of Energy Management System
and Monitoring in Hatien-1 Cement Company
(Vicem Hatien)
Presented by Hoang Kim Cuong
Deputy General Director
Hatien-1 Cement JSC.
www.efficiency-from-germany.info
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Experience of Energy Management
System and Monitoring in Hatien-1 Cement Company
(Vicem Hatien)
23.3.2015 Ho chi Minh City
Presented by Hoang Kim Cuong
Deputy General Director
Hatien-1 Cement JSC.
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General
Kinds of used energy
Energy cost
Management
Implementation
Long-term plan
Conclusion
Outline
Energy Effect
Kinds of used energy
Energy cost
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• Since 1964
• 2 plants, 4 cement grinding terminals
• Employees: 2.870
• Production capacity:
– Clinker: 4,5 million tpy
– Cement: 7 million tpy
• Standards ISO 9001: 2008; ISO 14001:
2004; OHSAS 18001: 2007
General
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BINHPHUOC CEMENT PLANT
CAMRANH GRINDING
TERMINAL
PHUHUU GRINDING
TERMINAL
THUDUC GRINDING
TERMINALLONGAN GRINDING
TERMINAL
KIENLUONG CEMENT PLANT
SITE MAP
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Kinds of energy using
Electricity
32%
Coal
55%
DO, 1%
Oil from
cashew
nut shell,
6%
HFO, 3% Other, 2%
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Energy Cost
Energy typeConsumption
rateTarget better cost
Electrical energy for
producing clinker
64 … 85
kWh/T65 60 … 65 kWh/T
Anthracite Coal760 … 900
kCal/kg clinker760 720 kCal/kg
Electrical Energy for
producing cement
34 … 45
kWh/T cement
33 (VRM)
40 (BM)
33 (VRM)
40 (BM)
Product Energy cost / ex-work cost
Clinker 60% … 70%
Cement 5% … 10%
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0
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50 55 60 65 70 75 80 85 90
Power consumption
Min 57.8 max 76.7 Avg 69.0 Median 69.0
0
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60
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100
110
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82
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87
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92
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Heat Consumption
Min 606 max 975 Avg 774 Median 767
Histogram of energy consumption of Binhphuoc Cement Plant for
clinker production - 2014
FrequencyFrequency
kWh/T clinkerkCal/kg clinker
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vnd us
cent
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35
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45
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Power consumption for Cement Grinding &
Despatch
Min 17.0 max 65.6 Avg 33.7 Median 32.5
Loesche’s Vertical Roller Mill
Binhphuoc Cement Plant
Histogram 2014
frequency
kWh/T cement 0
1
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200
400
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1 000
1 200
1 400
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Power price (average), at 110 kV for production
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Management
Awareness of energy saving to
all employees
Upgrading technology
Optimizing operation
Modern technology during
project time
Looking other fuels as
alternative fuels for combustion,
Reducing fossil fuels
Making products with low
energy consumption
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Solutions
• Establish energy management system in each
plant
• Monitoring energy consumption of production
lines by daily report, studying abnormal things to
solve
Entry
Result
Report
Chart
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Solutions
• Executing energy audit by independent service
following government regulation, training for
internal energy audit
• Establishing energy management team in each
plant.
• Starting ISO 50001 from 2015
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Implementation
• Making category of loads according to the energy
unit
• Installing power meters for recording
• Connect to the control system for online
monitoring in each plant
“If you can’t measure it,
you can’t manage it”
Measurement
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Optimizing and improving the operation
Keep equipment operating at designed capacity or more,
not running at no-load or low load, avoid to start / stop
many time.
Increase the productivity of the ball mill by optimization
of the ball quantity.
Select the materials with good and correct quality.
Produce Portland Cement Blended (PCB-40 PCB-50) to
reduce clinker.
Mixing the components of raw materials in a correct
proportion to reduce heat energy (coal) for combustion.
Implementation
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Control operation
Assure that equipment operating properly,
avoid operation in rush hour for some
equipment.
Shut down the bag filter if production line
stops. Establish the bag filter operates in
automatic according to pressure difference
Assure that power factor above 0,9 in order to
reducing the inactive power
Optimize the compressed air system by
centralizing the control system and monitoring
losses
Implementation
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Study experience among internal departments, with other
cement plants frequently in order to find the optimized parameter.
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Optimize the operation parameter
Implementation
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Enhancement of innovation
Encourage everyone give ideas for
upgrading equipment.
Improving the cooling water of
air compressor at cement grinding
and packing area, change the
electrical motor from 37 kW to 5,5
kW for a pump.
Redesign the chute, not use chain
conveyor under the chute (7,5kw),
lengthen the rubber conveyor
instead.
Implementation
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Installing the variable frequency converter for conveyor
2E1BC1. The power reduces from 120 kW to 66 kW. Saving
energy and keep the thickness of material layer to be stable for
PGNAA, ensure the analysis exactly
Enhancement of innovation
Implementation
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Increase the maintenance skill
Training to the maintenance team in order to
decreasing the maintenance time.
Apply preventive maintenance, solve all the repeated
problem thoroughly
Implementation
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Lighting and air conditioner
Lighting: reduce the number of lights reasonably, assembly the
automatic equipment for turning on / off the lighting.
Office: open window for sun light, turn off the equipment in the
room when no anyone in the room.
Air conditioners: set at 25oC .. 26oC for people and for
equipment room.
Step by step to change lighting with energy saving lamps
Implementation
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Implementation
Solution for cost saving
Alternative fuels that are using in Ha Tien 1:
Using a part of Indonesia anthracite coal
(high/medium volatile substance, cheaper price)
for producing clinker.
Oil from cashew nut husk to replace HFO for
combustion in the kiln at Kienluong Cement
plant
Using FO-R (recycle product from wasted
rubber) to replace DO at Binhphuoc cement plant
Using cashew nut husk (after extracting oil) as
an alternative fuel in Binhphuoc cement plant
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Implementation
Solution for cost saving
Using rice husk to replace HFO
at Phuhuu grinding Terminal.
Use wasted heat from kiln to heat
the coal mill instead of HFO at
Kienluong cement plant
These do not save energy but
reduce energy cost and contribute
to reduce CO2 emissions.
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Implementation Typical unit price of some fuels - 2015unit: vnđ/kCal, including logistic cost, no VAT
HFO DO FO-R Cashew oil
Rice husk
Coal 3c
Indo. Coal
Cashew nut
shell
1.3 1.6 1.4 1.1 0.57 0.44 0.38 0.3
1.9 2.3 1.8 1.3 0.4
HCM City
Binhphuoc
Binhphuoc
Kienluong
HCMCPhuhuu
Binhphuoc
Binhphuoc
Binhphuoc
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Long-term plans
Continue to study “Variable frequency converter”
to regulate the flow of the fans instead of dampers.
Optimize the production process, Looking for the
optimization software for operation of the rotary
kiln.
Upgrade technology: replace planet cooling
system with clinker grate cooler. Improving the
preheater of old kiln, use high efficiency burner
for old clinker production line at Kienluong plant.
Study of mineral additives to use for combustion
in the kiln to reducing the heat consumption.
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Study to burn other wastes.
Implement the project of
waste heat recovery system
to generate electricity for
new kiln at Kienluong plant
and Binhphuoc plant. This
will save about 15%
electrical energy for each
plant.
Long-term plans
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Conclusion
Cost saving is different from energy saving,
but both of these are directed to use energy
efficiently
Use energy saving and efficiency will be increasing the
competitiveness of enterprises. It also contributes to reducing
CO2 emissions, towards the goal of sustainable development of
enterprises.
Hatien-1 always thinks about energy saving
and efficiency, gradually optimizing and
improving energy efficiency
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