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Transcript of UltraTech Energy
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UltraTechCementLimited
A.P. Cement Works - Tadipatri
Fourth One-day Cement Sector
Task Force Program onEnergy Conservation
Venue : JACARANDA, India HabitatCentre, New Delhi
( 17th October06)
Team Members
Ali Asgher
D.S.Chandra Sekhar
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Contents
Energy Management at APCW
Energy Conservation Projects (02-06)
Energy Consumption Trends
Benchmarking Recognition
Innovative Project of 2005-06
Future plans
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A.P. Cement Works
ISO 9001 2000 (QMS)
ISO 14001 2004 (EMS)OHSAS18001 1999)
UltraTech Cement Limited
(Aditya Birla Group)
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RAW MEAL
LIME STONE
LS CRUSHER
RAW MILL
ADDITIVES
MINES
Manufacturing Process
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PRE HEATER
BAGS
CLINKER
ARCW
KILN COAL MILL
CLINKER
OPC,PPC,PSC
CEMENT MILL PACKING PLANT
COAL
Market
Tamilnadu, KeralaKarnataka, GOA
Maharashtra, AP
Manufacturing Process
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Development of Policy
Shop floor awareness classes
at each dept.
Preparation of Draft Energy
Policy by each dept.
Review of these Policies
Finalization of Energy Policyby HODs & Management
Owning of this policy by all atAPCW
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Energy Management Policy
We shall be committed to
Explore & maximize the use of latest & efficient technology to
reduce energy consumption.
Reduce the consumption of coal, electricity & fuel oil through
process optimization in order to reduce the Green House Gas
emissions.
Utilize wastes such as fly ash & slag to conserve raw materials& use of alternate fuels to conserve fossil fuels.
Involve all the employees by motivating and training them on
energy efficient practices throughout the plant and to improve
productivity, cost effectiveness and work environment.Spread awareness among all employees and their families for
conserving energy.
C. S. Reddy
Unit Head
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Energy Monitoring System
Energy
Meter
RS 485 RS 232
Converter
RS 485 RS 232
PC
View Power Report
http://10.235.2.191/emshttp://10.235.2.191/ems -
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Energy Consumption Review
Plant & Asset Care Team Continuous
Area Effectiveness Team Daily
Energy Pil lar Team Weekly
Plant Steering Board Fortnightly
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Project Selection
Deployment of Plant Thrust Area
Idea Generation for Projects
Screening of Projects
Priorit ization of Projectson the basis of RPN
Execution of Project byInvolvement of EPT,dept. , PACT
N i l E C i D
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National Energy Conservation DayCelebration Competitions
Most Energy Efficient AET Award
Energy Efficient AET Award
Slogan
Elocution
Drama
Poster
Awareness test
Suggestion Week
Technical Paper
I l t f P lI l t f P l
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Involvement of PeopleInvolvement of People
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Energy Conservation Projects
2002-06
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Optimisation of Cooler ESP Fan
O ti i ti f C l ESP F
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ESP fan speed (rated) 475 rpm
SPRS minimum speed 335 rpm
Damper inlet pressure -38 mmwc
Damper outlet pressure -48 mmwc
Power drawn by motor 190 KWh
SPRS Recovery 50 KWh
Net power drawn 140 KWh
Optimisation of Cooler ESP Fan-Before Modification
Optimisation of Cooler ESP Fan
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Optimisation of Cooler ESP Fan
After Modification
Input T/F Slim Inverter Output T/F
HT Breaker HT VFD forCooler ESP Fan
Fan HT Motor
Optimisation of Cooler ESP Fan
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Power drawn by motor 100 KW
(After commissioning of HTVFD, able to operate cooler
ESP fan up to 50% speed)
Damper opening 100 %
Net saving per annum 3.12 Lac KWh
((40 Units/hour))
Annual savings achieved Rs.12 Lacs
(40 kW x 24 hrs x 330 days x Rs 3.91/unit)
Investment Rs.35 Lacs
Optimisation of Cooler ESP Fan
After Modification contd..
Raw Mill Separator Efficiency
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Raw Mill Separator Efficiency
Improvement
Raw Mill Separator Efficiency
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The air volume inside the mill and
above roller 220 cum/sec
Air velocity before modification 8 mtr/secReducing the area across the separator
by fixing the Tiscral plate 8 mm thick
Covered area 32 %
After modification air velocity 12 mtr/sec
Reduction in specific powerconsumption 0.2 units/t. matl
Annual Savings Rs.31 Lacs(2x85 KW x 14 hrs x 330 days x Rs 3.91/unit)
Investment Rs.12 Lacs
Raw Mill Separator Efficiency
Improvement
Improvement in Cement mill
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Improvement in Cement mill
Sepax Fan
Improvement in Cement Mill
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Improvement in Cement Mill
Sepax Fan
Before Modification :
Though the Damper was full open, unable to maintain
required air volume.
After Modification :
Installed HTVFD(525KW)Operation of damper eliminated
In order to maintain required air volume, fan speed was
maintained at higher side. (100-102%)
Resulted in increased output by 3.0 ton / hour
Annual Savings achieved Rs.24 Lakhs
(80 KW x 22 hrs x 350 Days x Rs 3.91/unit)Investment Rs.35Lakhs
Variable Frequency Drives
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Particulars Saving in KWh Investment
(Lac units /a) (Rs. Lacs)
Reverse air fan(220KW) 6.34 9.0of RABH
Cooler fan -7 & 8 (220KW) 5.5 18.4
Peter silo JPF Fan (110KW) 1.9 5.2
Raw mill feed RBC (R1J04 & R2J04) 1.6 2.2
Cement Mill ESP Fan (Z1P50 & Z2P50) 1.3 3.8
Kiln shell cooling fans (11,18.5,30KW) 0.87 4.5
Variable Frequency Drives
(2003-2004)
Variable Frequency Drives
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Particulars Saving in KWh Investment(Lac units /a) (Rs. Lacs)
Dossimate filter fan ZIP15 & Z2P25 (30KW) 0.5 1.2
Raw mill main motors blower (22KW) 0.4 1.0
CF silo JPF (22KW) 0.1 0.9
Roller press dedusting fans 0.3 1.2
Z1P20 & Z2P20 (30KW)Packing plant compressor (90KW) 0.3 2.0
CF silo aeration blower (18.5KW) 0.2 0.8
JPFs in raw mill reject circuit(18.5KW) 0.2 1.6
Variable Frequency Drives
(2004-2005)
Variable Frequency Drives
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Particulars Saving in KWh Investment(Lac units /a) (Rs. Lacs)
F1J03 Coal RBC (160KW ) 0.4 4.0
Cement transport dedusting JPF 0.3 2.2
(Z3P65,Z3P70 -30KW)
VFD for cement silos extraction 3.02 5.4
screw conveyors (18.5KW)
VFD for Packer RVF 0.5 1.8
RM reject RBC (18.5KW) 0.3 1.4
U1U06 Clinker RBC(160KW) 0.2 4.5
Variable Frequency Drives
(2005-2006)
Pressure Drop Reduction
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Particulars Saving in kWh Investment(Lac units /a) (Rs. Lacs)
Modification in CS 3rd & 5th Cyclone
Riser Duct Roof 3.15 10.6
Installation of dedusting clone inKiln string 2nd Cyclone 1.95 6.5
Increasing the kiln down comer duct
dia from 2.5 mtr to 2.8 mtr 1.16 52
Pressure Drop Reduction
D
o
w
n
Co
m
er
Fan Optimization
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Particulars Saving in KWh Investment(Lac units /a) (Rs. Lacs)
Modification of Raw Mill Fan 1 & 2
Inlet Suction Box 4.6 11.0
Trimming of raw mill 1& 2 Fan
Impeller by 70 mm 7.5 0.3
Widening of speed range of CS fan
SPRS from 78% to 75% 2.6 0.1
Introducing energy saving mode
of operation for cooler fans 1.0 0.1
Fan Optimization
Compressed Air System
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Particulars Saving in KWh Investment(Lac units /a) (Rs. Lacs)
Installation of optimiser
for compressor operation 0.8 3.8
Merging of poking air with main
compressor air grid to reduceunloading hours 2.3 0.7
Installation of new compressor for LSCrusher 0.1 0.5
Provision of 2 bar compressed
air line in place of 5 bar compressed
air line for packing plant aeration 1.5 0.3
Compressed Air System
Optimisation
Idle Running Reduction
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Particulars Saving in KWh Investment(Lac units /a) (Rs. Lacs)
Reduction in packer idle running 0.5 0.1
Reduction in bulk cement loading idle
running 0.1 0.0
LDO ring main pump stopping during
HFO operation 0.15 0.0
Introducing time bound interlocks 2.0 0.0
Optimisation of group start/ stopof cement mills, coal, & Raw mills 0.2 0.0
Idle Running Reduction
PLC interlock
Voltage Optimisation
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Particulars Saving in KWh Investment(Lac units /a) (Rs. Lacs)
Voltage optimisation 2.15 0.0
Reduction in tap position of
transformers at cement mill 1.2 0.0
Reduction in Voltage drop for
CM MCC-5.2 0.1 0.2
Switching off one distribution
transformer at raw mill 0.4 0.0
Voltage Optimisation
Voltage Optimisation
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Particulars Saving in kWh Investment(Lac units /a) (Rs. Lacs)
Voltage drop reduction in RM
MCC 3.4 & MCC 3.3 0.1 0.2
Voltage reduction in PP& RM Transformer 0.3 0.0
Voltage drop reductionfor CCR building MCC 0.1 0.2
g p
Electrical Heating
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Particulars Saving in KWh Investment(Lac units /a) (Rs. Lacs)
Provision of Heater in RM gearunit avoid the idle running 1.1 0.3
Switching off electric heat tracingsystem for HFO separator 0.1 0.0
Removal of Rawmill hydraulic
unit heating element 0.1 0.0
g
Upgradation of Drives
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Particulars Saving in kWh Investment(Lac units /a) (Rs. Lacs)
Water pump from 30 kW to 45 kW
to avoid the running of 75 kWpump when only Kiln & one
CM is operating 0.4 0.2
Coal belt conveyor motor
from 160kW to 200kW resulted in
reduction of slag unloadingHours 0.4 0.3
pg
Equipment elimination
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Particulars Saving in KWh Investment(Lac units /a) (Rs. Lacs)
Bypass chute for bulk clinker loading
reversible belt conveyor [U1U22] 0.1 0.2
Provision of coal crusher bypass
chute for slag unloading to avoidrunning of coal crusher 0.25 0.1
Modification in the ducting forstopping of 2nos 30kw JPF Fans
at Packing Plant 0.7 0.1
Bag Diverter (2.2 kW) elimination by
providing Spiral Chute 0.1 0.1
Equipment elimination
Blowers Jet Pulse Filter Fans
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Particulars Saving in KWh Investment(Lac units /a) (Rs. Lacs)
Cement silo top [6Nos] 2.5 0.3
Cement mill section 1.1 0.2
LS Crusher 0.3 0.1
Cement Transfer JPF ( 4 Nos) 1.7 0.2
Blowers [5Nos] 1.8 0.4
Pulley Modifications
Lighting Optimisation
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Particulars Saving in KWh Investment(Lac units /a) (Rs. Lacs)
Installation of energy saving tube
Lights 500 Nos. in plant 0.6 3.9
Provision of energy saver for lighting
in LS crusher& MRSS section 0.1 2.0Replacement of 400W SV lamp with
MH lamp in colony & CM area 0.1 0.3
Providing transparent fiber sheets
for day light 0.15 0.3
Provision of AVR for factory & township 2.2 18
lighting
Lighting Optimisation
Lighting Optimisation
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Particulars Saving in KWh Investment(Lac units /a) (Rs. Lacs)
Lighting optimization at Gypsum,
Flyash & Slag yard 0.1 0.2
Providing ON/OFF switch for lighting
at WLM, TLM area 0.12 0.1
Replacement of 40w fitting with 11w
fitting in colony 0.1 0.1
Lighting optimization in the plant 1.9 0.2
Master switch control (70% of lighting) 0.4 0.1
Provision of LDR & control of lighting 0.1 0.1
thru PLC at raw mill area
Lighting Optimisation
Others
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Particulars Saving in KWh Investment(Lac units /a) (Rs. Lacs)
Sewage treated water line 0.12 0.3
size increasing
Derating of Motors 1.0 0.4
Changing of Delta to star connection
for RBC's P2U05,12,19,20 2.0 0.2
Fan less cooling tower at
Packing plant 0.4 0.6
Jet cooling tower for DG 1.4 5.5
Others
Others
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Particulars Saving in KWh Investment(Lac units /a) (Rs. Lacs)
Reduction in raw meal reject elevatorheight by 5 mtr 0.5 2.0
Installation of swing cooler at cooler 1.9 3.0
Conversion of V-Belt to Flat Belt 0.1 0.2
Reduction in rpm of HFO unloading
pump 0.1 0.2
Arresting of air infiltration KS & CS fan
casing 1.7 0.1
Others
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Particulars Saving in KWh Investment(Lac units /a) (Rs. Lacs)
Modification of Nozzle Ring atRaw Mill 2 3.7 0.4
Reduction in dam ring height from200mm to 190mm for optimum
loading of the Raw mill 1 & 2
main motor 9.5 0.2
Fan less cooling tower at
main pump house 1.7 7.2
Others
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Particulars Saving in KWh Investment(Lac units /a) (Rs. Lacs)
Optimization of Cooling Water
System in Packing Plant AirCompressor 0.5 0.6
Modification in water distributionline for avoiding 30 kW pumps 1.9 0.2
Reduction in fan inlet pressure dropin cooler fan 5&10 0.7 0.1
Air cooled condensers for CPP 1.2 6.4
(to reduce water consumption)
Projects under pipeline (2005-06)
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Particulars Saving in KWh Investment(Lac units /a) (Rs. Lacs)
Projects under pipeline (2005 06)
Commissioning of Waste heatrecovery system from cooler exhaust
250
Installation of HT Capacitor bank
(4.86 MVAR) to improve the PF
from 0.94 to 0.99
Energy audit proposals in waterPumps, & roots blowers.
Discard poor performing ACs by
replacing with new & other auditProposals of AHU, ACs
1.8
11
2.5 9
3000
14
16
Energy Conservation projects
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6
10
1518
31
41
22
17
26
5
15
25
35
45
98 99 '00 '01 '02 '03 '04 '05 '06NoofEnconProjects
Year
(2000-2006)
Electrical Energy Consumption
Mi t Cli k P d ti
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60.6
53.46
50.6 50.5
54.2
50
55
60
2001-02 2002-03 2003-04 2004-05 2005-06Units
/TonofClinker
Year
Mines to Clinker Production
Electrical Energy Consumption
P ki Pl t
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1.42
1.32
1.19
1.01
0.981
1.1
1.2
1.3
1.4
1.5
2001-02 2002-03 2003-04 2004-05 2005-06Units
/Tonof
Cement
Year
Packing Plant
Electrical Energy Consumption
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87.41
76.6
74.46
76.4
83.6
74
79
84
89
2001-02 2002-03 2003-04 2004-05 2005-06Units
/Tonof
Cement
Year
Electrical Energy Consumption
Thermal Energy Consumption
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689
687
684.9
684.3
686.1
683
685
687
689
2001-02 2002-03 2003-04 2004-05 2005-06
kCa
l/Kgof
Clinker
Year
Energy Conservation in Lac units
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29.4 29.8
36.2
45.8
57.6
68.273.4
20
30
40
50
60
70
80
99-00 '00-01 '01-02 '02-03 '03-04 '04-05 '05-06
La
cunits(kWh)
Year
Energy Conservation in Lac units
Benchmarking
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kWh/t Cement
kWh/t Cement
65 160
91.71 114.71
74.24 156.85
102.14
74.24
Andhra Pradesh Cement Works
2002 Performance
2003 Performance
V Whitehopleman Report
APCW power Consumption Rating 5 Star
Benchmarking
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kWh/t Clinker
10 80
26.05 38.02
12.17 66.73
31.88
28.18 40.82
18.16 59.01
32.66
26.52 38.67
22.90 43.71
30.46
22.90
Peer
Group
All
Kilns
Selected
Kilns
Whitehopleman Report
Kiln Power Consumption is Lowest in Selected Kiln
Benchmarking
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kJ/kg
2250 10000
3382 5396
2757 8331
3761
3185 3684
2757 4597
3402
3052 3287
2864 3483
3239
2864.00
Peer
Group
All
Kilns
Selected
Kilns
Whitehopleman Report
Thermal Consumption is Lowest in Selected Kiln
Major Environmental Projects
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Concreting and black toping of roads.
Mines pit water utilization for plant operation
Conservation of High grade Lime stone by adding
shale.
Conservation of raw water by connecting moresewage lines to sewage treatment plant.
Construction of check dams to improve ground water
levels. Green belt development in and around the plant with
black cotton soil generated from mine lease.
Online stack monitoring system for all process
chimney with PLC interlocks.
Recognition
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g
Winner in Process Category July05
in Ist National Energy Convention Organised by
Andhra Pradesh Productivity Council
Exemplary Work in Energy Conservation Jan03
in Medium Project Category organised by
Petroleum Conservation & Research Association
Energy Efficient Unit Dec02, 04 & Aug06
in National Award for Excellence in Energy
Management organized by CII
Recognition
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Water Efficient Unit National Award for Water
Management(05-06) organized by CII
Excellence in Energy Efficiency Oct05
National Award for Excellence(04-05) in Energy
Management organized by CII
Best Thermal Energy Performance Nov05
First in for best Thermal energy (04-05)organized
by NCCBM, New Delhi
Best Innovative project for WHRU Aug06
National Award for Excellence in Energy
Management organized by CII
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INNOVATION PROJECT -2005-06
Innovation Project of 2005-2006
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Waste heat Recovery system : 4.8 MW
Unique Project : First in India
(using n-pentane)
Second Cement Plant in the World
Technology :- Organic Rankine Cycle
(ORMAT , Israel)
Waste Heat source :- Clinker Cooler exhaust
gases
Waste Heat Recovery System((.best out of waste.best out of waste)
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(( )
Advantage :- Conservation of conventional
Energy Sources. Utilisation
of waste heatGross Out put : 4000 kW
Net out put : 3400 kWThermo oil
Pump load : 65 kW
Net out putSystem : 3335 kW
Annual PowerGeneration : 251 Lac. kWh
Waste Heat Recovery System
Process flow diagram
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Process flow diagram
Waste Heat Recovery System
Contd..
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Co d
WHOH : Waste Heat oil heater
(Tube type oil heat exchanger,
with thermic fluid as heat carrierfluid )
NO WHRU
WHRU
Waste Heat Recovery System
Benefits Contd..
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Meets 9.4 % of the electrical power requirement
(Total - 36 MW)
Zero water consumption as the condensers and
pump seals are air-cooled.
No extra Manpower is required as existing Main
Plant operation staff can do the operation.
Reducing CO2 emission from the combustionassociated with the generation of power by 20851
Ton / annum and attracts CDM benefits .
Waste Heat Recovery System
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Thermic Fluid
n-pentane
203degc
20 bar
320degc
120degc
270 degc
147degc,
2.2bar
Waste Heat Recovery System
System components
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System components
Waste Heat Recovery System(Commissioning stage..)
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Waste Heat Recovery System(Commissioning stage..)
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Waste Heat Recovery System(Commissioning stage..)
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Future Actions
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Non-conventional Energy sources
Wind Power plant 14.4 MW
Solar Power Plant 20.0 MW
Alternate Fuels for Kiln firing
- Project under pipeline
Vapour Absorption Machine 200 TR
Energy Audits
Optimising equipments utilisation
Continuous basis
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ALTERNATE FUELS
Alternate Fuels for Kiln firing
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Non-conventional Energy sourcesWind Power
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Wind Power plant 14.4 MW
Wind tower capacity 800 KW
No of units 18 no.s
Location Nearer to Plant
premises
Advantage 1.Conservation of
Conventional energysources.
2. Directly connecting to
our circuit without anywheeling adjustments.
Non-conventional Energy sourcesSolar Power
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Solar Power plant 20.0 MW
No of units 2no.s (2 X 10.0 MW)
Location With in the plant
premises
Advantage Conservation of
Conventional energy
sources.
Challenge New Technology
First time in Asia
Vapour Absorption MachineFuture Plans contd..
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Capacity 200 TR
Refrigerant Water
Absorbent Lithium bromide
Advantages Phasing out of CFC basedrefrigerants ,Eco-friendlyand Energy saving
Source a) From Baghouse chimneygases
b) From Clinker coolerexhaust gases
Conclusion
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Commitment of Top Management
Involvement of all People
Alignment of Vision , Mission , Objective & Goal
Strategic Planning and Implementation
Campaign for the Energy Conservation
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Journey of Excellence in
Energy Conservation
continues