Ultratech Kotputli Cement
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Transcript of Ultratech Kotputli Cement
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UltraTech
UltraTech CementUnit: Kotputli Cement Works
Welcome To CII
13th National Award for Excellence
in Energy Management 2012
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Unit profile
Cement manufacturing process
Energy Management System policy
Unit performance over the years
Energy monitoring methodology.
ENCON measures taken
Zero investment projects
Small/Medium investment projects
Large investment projects
List of ENCON measures taken in last three years
Environment/CSR initiatives
Awards & accolades
Way forward
Contents
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3.3 MTPA capacity green field cementplant.
An ISO 9001 & 14001 Certified company
Equipped with Energy efficient
equipments.
New generation Pyro Floor clinker
cooler.
Energy efficient variable speed drives &
MV drives for speed control of motors.2 x 23 MW Captive power plant
registered for CDM project.
Efficient grinding mills with VRM
technology.
Kotputli
Cement
Works
Unit Profile
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Cement Manufacturing Process
LS Query Crusher Raw material storage Additive Materials
Feed bins
Cooler ESP
Coal
Coal Mill
Raw Mill
Cement DispatchPacker
Cement Mill
Baghouse
Kiln
Baghouse
CoolerCem additive
Preheater
Bulk dispatch
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Energy Management System Policy
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UNIT PERFORMANCE OVER THE YEARS
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747
714
697
680
700
720
740
760
2009-10 2010-11 2011-12
Sp. Heat cons. (Kcal/kg clinker)
4.4 %
reduction2.4 %reduction
109.05
92.85
79.85
40
60
80
100
120
2009-10 2010-11 2011-12
Overall Sp. Power cons. (Kwh/MT cem)
14.9 %
reduction14.0 %
reduction
1.21
2.29 2.40
0
1
2
3
4
2009-10 2010-11 2011-12
Clinker Production (Million MT)
1.05
1.55
2.15
0
1
2
3
4
2009-10 2010-11 2011-12
Cement dispatch (Million MT)
GO
O
D
GO
O
D
G
O
O
D
G
O
O
D
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Unit Energy Performance Comparison: At A Glance
With benchmark/cluster units performances (Year 2011-12)
682681
779
742 739
699 697
650
700
750
800
850
InternationalBenchmark
NationalBenchmark
J K Cement ACC Cement AmbujaCement
Aditya Cement KotputliCement Works
70 68
8984 85 82
80
40
60
80
100
120
International
Benchmark
National
Benchmark
J K Cement ACC Cement Ambuja
Cement
Aditya Cement Kotputli
Cement Works
Overall sp. Power Consumption (Kwh/MT cement)
Sp. Heat Consumption (Kcal/kg clinker)
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ENERGY MONITORING METHODOLOGY
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Methodology for Energy Monitoring
Established energy management cell.
Daily monitoring of energy deviation report.
Analysis of equipment for deviation.
Identification of energy conservation scope.
Inviting suggestions under Energy Saving Scheme.
Feasibility study of suggestion & submit proposal for sanction.
Preparation of detail action plan.
Weekly review to monitor scheme progress.
Analysis for benefits after scheme implementation.
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Energy Monitoring System
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Issues :
Frequent Cooler jamming/ stalling
phenomena.
Need to operate cooler fans at higher
load to avoid cooler lane stalling.
High Specific heat consumption due to
unstable cooler operation.
Hydraulic cooler lane DP optimization with lane CPM
Theme -1
COOLER
Tertiary Air
Cooling Air
Sec.Air
Hot Clinker
Clinker
to Silo
Ex. air
Dust
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Approach:
Correlation identified between cooler lane DP & cooler lane CPM (Cycle
Per Minute).
A PID was made for & further fine tuned as per operation parameters.
Results :
Specific heat consumption reduced by 3 Kcal/Kg Clinker.
Kiln specific power reduced by 0.8 Kwh/MT clinker.
High cooler recuperation efficiency.
Cooler sp. air consumption reduced by 0.2 Nm3/Kg clinker.
Kiln availability increased.
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Issues :
In routine operation raw mill outlet temperature maintained around 80-82 0C.
Kiln feed temp after raw meal silo, measured as 72-73 0C.
A potential identified to increase kiln feed sensible heat by increasing kiln feed
temperature
Kiln Sp. heat optimization by increasing sensible heat of Raw Meal
Bag House
Inlet
feed
Hot gases from
PH outlet
Recirculated
Gas
Final
Product to
Raw Meal
Silo
Ground
Product +
Outlet gas
To
Stack
--
Gas Flow
Material flow
RAW
MILL
Theme -2
Feed
Classifier
Grinding
table
Grindingrollers
Hot air
Ground
material +
Outlet gas
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Approach:
Mill outlet temperature raised by increasing hot gases (from preheater) &
optimizing recirculation/fresh air to mill subsequently.
Water spray inside the mill optimized to stabilize mill operation.
Results:
Kiln feed temperature raised by 8 0C.
Kiln feed sensible heat increased by ~3 kcal/kg of clinker.
Hot gases volumetric flow reduced from preheater to Bag house.
Bag house fan sp. power reduced by 0.1 Kwh/MT clinker.
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Issues :
Each Packer is equipped with de-dusting bag
filter.
Inlet dampers of bag filter fan set at 40%
opening during normal Operation of packers.
Fan Operation with damper control reduces
its efficiency & results in wastage of power.
Energy savings in packing plant dedusting fans operation
Theme -3
Approach:
Interconnection of fan Inlet ducts of 2 fans.
This results in operation of two bag filters with single fan.
Results :
Energy saved by 0.3 Kwh/MT cement.
Saving of O & M cost in 4 fans & motors.
Bag filter fan (37
KW)
Bag filter fan (37
KW)
New interconnection line
provided
Bag filter fan
Bag filter fan
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Issues :
During Kiln shut down, Operation of HAG (Hot air
Generator) is required for Cement Mills (VRM)
operation.
HAG consumes 500 litres of HSD per Hr of operation.
Diesel saving in cement mills during kiln shutdown
Theme -4
Approach:Dam ring height increased to 390 mm to increase the
material bed height.
Water spray nozzle modified to reduce water consumption.
Results :
Diesel consumption reduced to 250 lit/hr.
Saving of diesel consumption resulted into savings for Rs.176 Lac/ annum .
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Small/Medium Investment Projects
ENCON MEASURES TAKEN
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Approach:Installed VFD for fan motor to regulate DA fan speed.
Logic for controlling DA fan speed through RMBH inlet temperature.
Interlock to stop DA fan when raw mill is in operation.
Results :
RMBH fan flow reduced due to DA fan flow optimization.
Energy saving by 0.3 Kwh /MT clinker.
Th 2
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Issues :
Operation of 02 blowers required to maintain optimum coal conveying air
velocity.
Energy saving by LOW-NOX firing line modification
Theme -2
Approach:
To reduce conveying line diameter from 391 mm to 275 mm.
Coal firing Blower(200 KW)
Coal firing Blower
(160 KW)
Coriolis feeder
LOW NOX firing (Preheater)
391 mm dia
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Results :
Elimination of one 200 KW blower operation. single 160 KW blower is
sufficient to deliver conveying air at set norms.
200 KW rated blower kept as hot standby spare blower.
Electrical energy saving by 0.35 Kwh/MT clinker.
Coal firing Blower
(200 KW)
Coal firing Blower(160 KW)
Coriolis feeder
LOW NOX firing (Preheater)
275 mm dia
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ENCON MEASURES TAKEN
Major Investment Projects
Th 1
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Issues :
Poor cooler recuperation efficiency as ~ 65 %.
High specific heat consumption as 705 Kcal/kg clinker.
High kiln specific power consumption as 29 Kwh/MT clinker.
High cooler specific air consumption as 2.0 Nm3/Kg clinker.
Cooler static grate modification
Theme -1
Approach: Static grate area extension by 7.2 m2 with horse shoe design.
Installed one additional fan for static grate.
Enhanced pressure capacity of all fans in cooler.
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Results :
Kiln sp. power consumption reduced
from 29 to 27.5 Kwh/MT clinker.
Sp. heat consumption reduced from
705 Kcal /Kg to 695 Kcal/kg clinker.
Cooler recuperation efficiency
increased from 65 to 72%.
Sp. air consumption lowered from
2.0 Nm3
/Kg to 1.75 Nm3
/kg clinker.
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List for projects executed in last three years
ENCON MEASURES TAKEN
Energy saving initiatives taken
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S.No.
Energy Saving theme Energy Saved Savings(In lac
Rs.)Electrical
(MWH)
Thermal
(Mkcal)
1 Hydraulic cooler lane DP optimization
with cooler lane CPM
2534 9504 228.7
2 VFD installation & logic modification for
dilution air Fan
1521 4879 126.5
3 Energy saving by LOW-NOX firing linemodification
1109 - 44.9
4 Fine controlling for raw mill fan speed by
up gradation of GRR
929 - 37.6
5 Energy saving by modification in gypsum
feeding to reduce stoppages on account
of wet/ sticky material
622 - 25.2
6 Energy conservation in packers dedustingfan operation
528 - 23.5
Energy saving initiatives taken
Energy saving initiatives taken
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S.No.
Energy Saving theme Energy Saved Savings(In lac
Rs.)Electrical
(MWH)
Thermal
(Mkcal)
7 Optimization of compressor power
through installation of air receivers
446 - 19.9
8 To reduce diesel consumption in cement
mill HAG during kiln shutdown
- 1233 16.4
9 Sp. power reduction in LS reclaimer byscrapper chain modification
201 - 9.0
10 Elimination of 7 air slide blowers in cement
transport circuit through line modification.
206 - 8.3
11 To reduce power consumption by packing
plant optimization.
203 - 8.2
12 Energy saving by providing auto timer in
office building centralized air conditioning
173 - 7.0
Energy saving initiatives taken
Energy saving initiatives taken
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S.No.
Energy Saving theme Energy Saved Savings(In lac
Rs.)Electrical
(MWH)
Thermal
(Mkcal)
13 Reduction in transformer losses by
inter shifting of MCC power source
138 - 5.6
14 Fuel sp. heat optimization by increasing
kiln feed sensible heat
119 9 5.4
15 To optimize air consumption in coalhandling & lime stone circuit
99 - 4.0
16 To reduce idle running of coal
transport belt conveyors.
77 - 3.4
17 To reduce head losses by modification
in water pipe line lay out.
72 - 2.9
18 To reduce firing blower power by kiln
coal conveying line modification.
71 - 2.9
Energy saving initiatives taken
Energy saving initiatives taken
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S.No.
Energy Saving theme Energy Saved Savings(In lac
Rs.)Electrical
(MWH)
Thermal
(Mkcal)
19 To reduce power consumption by fly ash
root blower modification
59 - 2.6
20 Power saving by elimination of one belt
conveyor in coal transport
49 - 2.2
21 Installation of energy efficient fans incooling towers
44 - 1.8
22 Elimination of one pump by
interconnection of both CBD tanks
- 119 1.6
23 Energy saving by controlling CCR MCC
Room lights.
21 - 0.9
24 Installation of timer in water pumps 20 - 0.8
Energy saving initiatives taken
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ENVIRONMENTAL INITIATIVES
Environmental Initiatives
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Environmental Initiatives
Asias largest clear span coal shed
Covered conveyor belts & dust filters at all the
material transfer pointsCovered storage facility for raw materials, fuel & clinker
Concreted roads & floor area100 kw solar power plant in colony
Environmental Initiatives
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Ground water recharging through injection well
3416 4026
15564 16086
13267
0
5000
10000
15000
20000
2007-08 2008-09 2009-10 2010-11 2011-12
Rich plantation area as 110.4 Hectare
Rain Water Harvesting Ponds
794 759720
0
250
500
750
1000
2009-10 2010-11 2011-12
Sp. CO2 emission (Kg CO2/MT cement)
Environmental Initiatives
Environmental Initiatives
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Environmental Initiatives
Water Spray on Mines Haul Road to Control fugitive dust
Sapling Distribution to VillagersGreen Belt in Colony
Plantation across plant Boundary
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Corporate Social Responsibility..
STRIVING FOR
Societal Change
Corporate Social Responsibility
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Corporate Social Responsibility
Education
SustainableLivelihood
Social Causes
InfrastructureDevelopment
Health Care
Corporate CSR
CSR Vision
CSR Policy
Focus Area
Corporate Social Responsibility
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Emphasis on girls education
Felicitation program for students
Formation of Self Help Groups (SHG)
Awareness campaign for Personal hygiene,
Family planning, Immunization camps
Infrastructure development for hospitals/ schools
nearby.
Association with NABARD for livelihood project
Corporate Social Responsibility
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Awards & Accolades
Commendation Certificate for Energy Conservation
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Commendation Certificate by the Ministry
of Power, Government of India in
recognition of efforts made to conserve
the energy in year 2011.
gy
Awards & Accolades
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Felicitation by District
administration for contribution in
the Rescue operations
Felicitation by Mines Environment &
Mines Conservation -MEMC (Ajmer
region) in Noise & Vibration Control
(Mines)
Mines- MEMC week Ajmer Region
Third Prize in Afforestion & Plantation
Third Prize in Welfare Amenities
Protective Equipment & VT
Awards & Accolades
Way Forward
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Way Forward
Installation of VFD for crusher bag house fan.
Installation of SPRS for raw mill fans.
Optimization of clinker grinding power.
Installation of 6 x 100 kw solar power plants.
Usage of alternative fuels in kiln.
Accreditation to ISO 50001- Energy Management System.
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UltraTech
UltraTech Cement
Kotputli Cement Works