Comparative Analysis of Orient Cement With Other in Nasik District
ORIENT CEMENT LIMITED Chittapur - Karnataka€¦ · ORIENT CEMENT LIMITED - PLANT PROFILE Plant is...
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ORIENT CEMENT LIMITED Chittapur - Karnataka Team Member: Santosh Sharma Sr. General Manager - Operations
Transcript of ORIENT CEMENT LIMITED Chittapur - Karnataka€¦ · ORIENT CEMENT LIMITED - PLANT PROFILE Plant is...
ORIENT CEMENT LIMITED Chittapur - Karnataka
Team Member:Santosh SharmaSr. General Manager -Operations
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Orient Cement is operating 3 Cement Plants in India:
- Integrated Plant - Devapur, Telangana - Cement Grinding Unit - Jalgaon, Maharashtra- Integrated Plant - Chittapur, Karnataka
Overall Capacity of Orient Cement is 8.0 MTPA.
ORIENT CEMENT LIMITED - PLANT PROFILE
Plant is certified with IMS:
• ISO 9001:2015• ISO 14001:2015• OHSAS 18001:2007• EnMS 50001 :2018
• Member of CSI (WBCSD)
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Salient Features
Plant Location : Itga (V), Chittapur (Tq) ,Gulbarga (Dist.) Karnataka.
Commercial Production : Sep 2015
Clinker : 2MTPA
Cement : 3MTPA
CPP : 45MW
Plant & Colony : 266 Ha
Mines : 519 Ha
Green Belt : 231776 Saplings(Till 31st March 2020)
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4Cement Manufacturing Process
Products :• Ordinary Portland Cement -43Grade• Ordinary Portland Cement -53 Grade• Pozzolana Portland cement - (35% fly ash)• Strongcrete Cement - (18% fly ash)
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7%
15%
78%
Electrical energy (lac kWh)
Grid power
IEX power
Captive powerplant
• Electrical Energy consumption – kWh FY 2019-2020
• Thermal energy consumption Kcal FY 2019-2020
14%
82%
2% 2%Thermal energy million (Kcal)
Indian Coal
Pet coke
AFR(liquid)
AFR ( solid)
Energy Consumption Overview
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Overall energy consumption – TOE
117151.39
132676.46
137119.70
105000.000
110000.000
115000.000
120000.000
125000.000
130000.000
135000.000
140000.000
2017-18 2018-19 2019-20
ton
ne
of
oil
equ
ival
ent
*Inclusion of electrical and thermal energy in terms of Overall energy consumption.
Increase % 14
7
15.86
14.35
13.01
12.00
13.00
14.00
15.00
16.00
17.00
2017-18 2018-19 2019-20
Reduction % – 18
Specific power consumptionkWh/T of Raw Meal
Spp
ow
er in
kW
h/t
on
41.16
35.59 35.94
30.00
32.00
34.00
36.00
38.00
40.00
42.00
2017-18 2018-19 2019-20
Reduction % – 12.7
Specific power consumptionkWh/T of Coal
Sp. Energy Consumption in last 3 years (FY 2017-20)Sp
po
wer
in k
Wh
/to
n
8
8
Specific power consumptionkWh/T of cement
55.28
50.08
46.22
45
47
49
51
53
55
57
2017-18 2018-19 2019-20
Reduction % – 16.38
Specific power consumptionkWh/T of Clinker
76.53
65.8
60.87
40
45
50
55
60
65
70
75
80
2017-18 2018-19 2019-20
Reduction % – 20.42
*The power consumption includes idle power of the plant & Pollution control equipments.
Sp. Energy Consumption in last 3 years (FY 2017-20)
9
724
704
683
660
670
680
690
700
710
720
730
2017-18 2018-19 2019-20
Specific Heat Consumption (2017-2020)
Specific heat consumption, kcal/Kg cli
*This include number of heat up , Alternative fuel utilization & pet coke fuel.* Number of startups as per market demand
Reduction % – 5.66
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Specific power consumptionkWh/T of PPC
84.3
73.45
68.28
60
65
70
75
80
85
90
2017-18 2018-19 2019-20
Reduction % – 19
Specific power consumptionkWh/T of OPC
67.67
56.72
51.32
40
45
50
55
60
65
70
2017-18 2018-19 2019-20
Reduction % – 24.16
Sp. Energy Consumption in last 3 years (FY 2017-20)
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Specific energy consumption OCL Achieved National benchmark
Thermal - Kcal/Kg clinker 683 676
Electrical-kWh/T of cement 60.87 63.91
Comparison with Global Benchmark Data
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Road map to achieve National Bench Marking
Heat resistant paint
Utilization of AFR
Specific heat consumption
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Energy Conservation Projects planned 2020-21
Energy conservation
project
Electricalenergy savings
(In kWh)
Thermal savings
(Million kCal)
Investments(Rs in Million)
Savings
Heat resistance paint on kiln
and kiln hood area
-3.7 0.5 Under progress
Installation of VFD for Bag filters 460000
-0.55 Under progress
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Year No of Proposals Investments(in Millions)
Savings(in Millions)
2017-18 12 - 54.74
2018-19 12 - 106.8
2019-2020 07 9.2 34.90
Energy Saving projects implemented FY 2017-2020
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Energy conservation projectAnnual
electrical savings
Annual Thermal savings tones
Total annual savings
Pay back in months
In lac kWh In Tones In Millions
Optimization of PA fan with VFD installation
0.86 200 1.74 Immediate
Reduce the damper loss in Raw mill fan
2.4 - 1.65 Immediate
Optimize the air volume in Cement mill
33 - 23.1 Immediate
Optimize the air volume in raw mill-2 7.5 - 5.04 Immediate
Optimization of cooling water pumps 1.7 - 1.21 Immediate
Compressor air leakages in Post clinker
5.4 - 3.78 Immediate
Energy saving projects implemented FY 2017-18
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Energy conservation projectAnnual electrical
savings
Annual Thermal savings tones
Total annual savings
Pay back in months
In lac kWh In tons In millions
Optimize Cement mill with grinding aid spray modification
6.6 0 4.62Immediate
Optimization of cooler operation 3.5 375 4.09 Immediate
Reduce the damper loss in Cement mill fan
2.31 0 1.62Immediate
Optimize the air volume in raw mill-1 7.5 0 5.04Immediate
Optimization of coal mill booster fan 2.27 0 1.59Immediate
Idle running optimization 1.8 0 1.26Immediate
Cont….
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17Energy Conservation Projects implemented FY 2018-19
Energy conservation project
Electrical energy savings
Thermal savings
Total Savings
InvestmentPay back in
months
In lac kWh Ton/yrRs in
Million Rs in Million
Optimization of fuel & Raw mix - 923.08 8.3 - Immediate
Optimization of Bag filters in Packing
11.2 - 8.4 -Immediate
Optimization of Raw mill circuit bag filters
2.37 - 1.8 -Immediate
Optimization of Bag filter in fly ash silo
0.68 - 0.5 -Immediate
Optimization of fly ash compressor
3.6- 2.7 -
Immediate
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Cont…..
Energy conservation project
Electrical energy savings
Thermal savings
Total Savings
InvestmentPay back
in months
in lac kWh Ton/yrRs in
Million Rs in
Million
Optimization of OK mill (Cement mill) fan flow
2.7 - 2.3 -Immediate
Modification of OK mill (Cement mill) grinding aid nozzle spray
36 - 27 -Immediate
Optimization of cooler vent fan flow with kiln hood pressure PID
6 - 4.5 -Immediate
Optimization of Preheater fan flow with Outlet pressure PID
18 615.38 19 -Immediate
Optimization of Raw mill (roller press) fan flow
30 - 22.5 -Immediate
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Cont….
Energy conservation project
Electrical energy savings
Thermal savings
Total Savings
InvestmentPay back in
months
In lac kWh Ton/yrRs in
Million Rs in Million
Optimization of Raw mill (roller press) gap
10 - 7.5 -Immediate
Optimization of crusher secondary motor load
3 - 2.3 -Immediate
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20Energy Conservation Projects implemented FY 2019-20
Energy conservation project
Electrical energy savings
Thermal savings
Total Savings
InvestmentPay back
in months
In lackWh Ton/yrRs in
Million Rs in Million
Heat resistance paint on pre - heater and cyclone area
- 1337 10 4.2 5.04
Optimize lighting voltage in line 0.1 - 0.7 -Immediate
Reduction in the generating pressure of Post clinker section compressors
from 7.2 bar to 6 bar3 - 1.8 -
Immediate
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Energy conservation project
Electrical energy savings
Thermal savings
Total Savings
Investment Pay back in
monthsIn kWh Ton/year
Rs inMillion
Rs in Million
Optimization of packing plant operation
10 7 1 1.71
Compressor air leakages in Pre clinker
3 21 2.4 1 5
Optimization of Raw mills fan 4 2.4 1 5
Optimization of coal firing blowers
12 500 10.6 2 2.6
Cont….
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Innovative Projects implemented FY 2017-2020
Installed SNCR system for reduction of NOx Emission 2017-18
S.No UOM Achieveddown comer
AchievedMain stack
Base NOx mg/Nm3
10%O2
654 789
Nox after NH3
injection
mg/Nm3
10%O2
425 552
NOx
reduction %Percentage 34 42
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Installed Liquid AFR handling system for handling Hazardous waste FY 2018-2019
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Heat resistance paint on pre heater cyclone - 2019-20
Before painting average temperature was about – 1400
After painting average temperature is about – 900
Before After
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Technology(electrical)
Type of Energy Onsite/Offsite Installed Capacity (MW)
Generation 2019-2020(million kWh)
% of overall electrical energy
Windturbines
Wind energy Offsite 0 12.7 8.8
Photovoltaic
Solar Offsite 0 4.4 3.05
Hydroelectric power
Small Hydro Plant
Offsite 0 3.9 2.7
Technology(thermal) Type of Energy
Installed Capacity (million kCal)
Usage (million kCal)
% of overall thermal energy
Combustion Alternativefuel
- 44.15
Utilisation of Renewable Energy sources
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RPO Obligation
Year RPO Target RPO Achieved
2017-18 9094 No. of certificates 9094 No. of certificates
2018-19 15291 No. of certificates 15291 No. of certificates-
2019-2020 19907 No. of certificates 19907 No. of certificates
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Waste as alternative raw material
Year Name of Alternative
raw material
Name of material
gets replaced
Quantity used
(MT/ Year)
2017-18 Red mud laterite 10440
2018-19 Red mud laterite 13110
2019-20 Red mud laterite 49090
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Description of waste utilization system/Waste management system for the year 2018-19
Sl No Waste Details Quantity
(MT/year)
GCV
(kCal/kg)
Heat value
(million
kcal/year)
Waste as percentage
of total fuel
1 Dolachar 4279 2615 11190 0.89
2 Carbon black 3796 5852 22214 1.77
3 Pharma waste 2192 2551 5592 0.44
4 Liquid AFR 1652 2150 3552 0.28
*Year: 2018-2019 – Thermal Value : 1249155 million kCal /year
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Description of waste utilization system/Waste management system for the year 2019-20
Sl No Waste Details Quantity
(MT/year)
GCV
(kCal/kg)
Heat value
(million
kcal/year)
Waste as percentage
of total fuel
1 Agro waste 917 3342 3065 0.23
2 Dolachar 1502 2298 3452 0.26
3 Carbon black 3879 5596 21707 1.67
4 Pharma waste 2287 2528 5782 0.44
5 Liquid AFR 3818 2656 10141 0.78
*Year: 2019-2020 – Thermal Value: 1295586 million kCal /year
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Information on GHG Inventorisation and public disclosure
Direct co2 emissions UOM Values
Total CO2 from raw materials
[t CO2/yr] 10,22,173
Total CO2 from fossil-based kiln fuels
[t CO2/yr] 1,24,252
Total CO2 from non-kiln fuels
[t CO2/yr] 62,778
Total direct CO2: all sources
[t CO2/yr] 12,09,203
Scopes for reduction of CO2
Maximum usage of AFR. Reduction of clinker to cement ratio. Installation of Waste heat recovery system. Optimization of specific power and heat consumption.
GHG Inventorisation
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GHG Inventorisation Target for CO2 emission reduction and action plan :
• Application of heat resistance paint on kiln and preheater results in reduction of thermal energy. Thus, reduction of CO2 emissions.
YearSuspended
Particulate Matter (SPM)
Oxides of Nitrogen (NOx)
Oxides of Sulphur (SOx)
2017-18 58.21 1208.06 115.469
2018-19 53.45 1003.245 82.85
2019-20 55.91 318.07 66.17
Absolute Emissions
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0.89
0.65
0.52
0.4
0.5
0.6
0.7
0.8
0.9
1
2017-18 2018-19 2019-20
Reduction % – 41.5
Carbon footprint
Carbon footprint ton of CO2/ MT of Cement
*Direct equivalent CO2 emission for MT of cement .
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Future aspects for Green Supply Chain Management :
Green Supply Chain Management
Usage of Hazardous waste. Usage of Rain harvesting water rather outsource. Usage of agro based waste. Ideas towards reduction of Carbon emissions. Adoption of automation technologies. Safety standards and reliability
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Plant has equipped with Knowledge management system (KMS)supplied by ABB.
The KMS has all the energy consumption data.
Each section has individual equipment specific energy report.
Data used for study of energy performance.
Report will send to concern section in charges & UH.
Teamwork, Employee Involvement & Monitoring
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Review meeting chaired by :
Daily production and power report meeting is reviewed by Unit head .
Breakdown analysis .
Planning of operation and maintenance.
Environment and safety points are reviewed .
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Projects implemented through Kaizens ( Workers and Supervisor level)
Coal reclaimer to be operated in auto mode from CCR is suggested by Reclaimer operator (Supervisor).
Gypsum reclaimer to be operated in auto mode from CCR is suggested by Reclaimer operator (Supervisor).
In- house refractory works such as kiln tip casting , burner pipe and cyclone cone castable by imparting skills to casual workmen (supervisor).
In- house scaffolding works by imparting skills to casual workmen level.
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Energy efficiency / awareness training program
Plant operation and optimization .
NCBM –AFR training program.
Clinker production and optimization – NCBM.
Optimization of clinker cooling air via MFR in CB cooler ( In-house).
Power savings through bag filters (in-house).
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Implementation of ISO
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Long Term Vision on EE
Installation of Waste Heat Recovery system.
Compressor power optimization.
Utility optimization.
Installation of VFD in bag filter system.
Maximum utilization of various alternative fuel and raw materials.
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Major achievements FY 2019-2020
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Major achievements FY 2019-2020
