CII Energy Excellence Award 2017 UltraTech Cement, GICW, Ginigeragreenbusinesscentre.com/energyaward2017presentation… · · 2017-09-07CII –Energy Excellence Award 2017 UltraTech
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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
2
▪ Plant capacity(Cement) - 1.3 MTPA
▪ Products - OPC, PPC,PSC and GGBS
▪ Market - North Karnataka & Goa
UltraTech Cement, GICW, Ginigera
(Commisioned on Sept-2008)
Process View , GICW, Ginigera
Clinker Silo
35000 Tons
capacity
Wagon tippler
20 boxes/hr4000 Tons/rake
Cement Mill
LM 53.3.3
175 TPH @ 350 blains
Cement Silo
3-compartments
5000 x 3 =15000
Tons
Bulk cement
loading
Cement packer
6-Spouts, 4-nos of 90
TPH
Truck
loading
6-nos
Wagon
loading
8-nos
Gypsum
Fly ash
Slag
Clinker
Coal
Clinker From APCW
Clinker hopper-1000 Tons
Slag hopper-1000 TonsGypsum Hopper: 350
Tons
4
UltraTech Cement, GICW, Ginigera
5
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
2Provided interlock for cement mill stack monitoring system purging air blower to avoid idle
running1000
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
6
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
14To avoid idle running of compressors by providing control valves for cement mill and packing plant and
operating from CCR300000
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 power11680
7
Energy Conservation Projects completed 2014-16
16Raw 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
17stacker 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.440
18
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.
18396
19
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.
20075
2090 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 packers292000
Total in Lacs kwh 14.37
Sl.
No.Title of Project
Annual
Electrical
Saving
(kWh)
8
Energy Conservation Projects 2017-18
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
2Modification 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
10
10
Planned to purchase solar power to fulfill total power
requirement about 90% from renewable energy
Future plan for purchasing renewable energy
SourceABG renewable
power project
Expected
units/annum100 Lacs
Expected price 5.00 Rs./kwh
11
OPC Grinding Specific power (U/T)
12
26.06
25.27
25.07 25.05
24
25
26
27
2013 - 14 2014 - 15 2015 - 16 2016 - 17
Target - 25.00
Reduction – 3.9%
PPC Grinding Specific power (U/T)
13
28.78 28.82
25.9625.62
20
22
24
26
28
30
2013 - 14 2014 - 15 2015 - 16 2016 - 17
Reduction – 11.10%
141414
42
.34
42
.1
39
.05
37
.32
35
.84
2012-13 2013-14 2014-15 2015-16 2016-17
Reduction – 15.35%
15
15
26.4%29.7% 30.8%
0.0%
10.0%
20.0%
30.0%
40.0%
50.0%
2014-15 2015-16 2016-17
Consumption of dry fly ash Target = 33 %
Year Comments
2014-15 100% pond ash with high moisture.
2015-16 Commissioned dry fly ash system in Apr-2015.
Comparison of specific power consumption with other grinding units on monthly basis – Bench Marking
171717
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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
2015-162016-17
Eliminated hot gasses for OPC &PPC in July-15Sustained Zero fuel for Cement Grinding
19
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 M3/Year
20
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
46101
33525
-12576-20000
-10000
0
10000
20000
30000
40000
50000
2014-15 2017-18 Reduction
Variance
Saved >400 kwh/day
(27%)
21
3. Mill Fan Venture replacing by Annubar Flow meter
-570mmWG
-555mmWG
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
-30mmWG
= Pressure Drop
Total Pressure rise
X Power Consumption
Pressure Drop = -570 – (-555) = -15
Pressure Rise = -30- (-570) = -540
= 15/540 *1520
Power Consumed = 1520 KW
= 42.2 KW
22
AfterBefore
3. Mill Fan Venture replacing by Annubar Flow meter
Modification work in Progress
23
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
24
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
25
5. Compressed air optimization
CompressorAvailable Compressed air
(M3/hr)
Required as per design for the operation of entire Plant(M3/hr)
1 (90KW) 1026
5578
2 (90KW) 10263 (90KW) 10264 (90KW) 1026 (Dedicated for Fly ash Unloading)
5 (55KW) 4596 (132KW) 1443 (Dedicated for Fly ash Conveying)
Total 6006
As per the study regarding availability and requirement we have made an
operation matrix for the compressors other than dedicated ones.
Installation against requirement:
26
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
2Compressor Operation to be synchronized for both
packing & Mill operation instead of dedicated operation.CKP 30.04.2016 Completed
3Survey for identifying the leakages as well miss usages of
compressed air in the entire circuit of plant operation.JSR 30.04.2016 Completed
4Pneumatic Isolation valves to be provided at Wagon Tippler & Coal Mill circuit. These valves can be operated from CCR
as per the requirement.ADK 15.05.2016 Completed
5After studying the compressed air requirement for each
section ,operation matrix of compressor to be provided to CCR Operator.
CKP 15.05.2016 Completed
6Mechanical system for Fly ash unloading through existing
Bucket Elevator to be doneMM 15.04.2016 Completed
7 Operation of Bag Filters in DP Mode PVM/JSR 30.06.2016 Completed
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5. Compressed air optimization
Condition-1
Condition-2
Condition-3
Condition-4
Condition-5
Condition-6
Condition-7
Condition-8
Packer-1 a a a a a a aPacker-2 a a a a aPacker-3 a aPacker-4 a aCement
Mill a a a aWagon Tippler a a
Coal Mill
COMPRESSOR OPERATIONCompress
or-1
1&2 or 1&3 or
2&3
a a a aCompress
or-2 aCompress
or-3 aCompress
or-5 a a a
Operation matrix and logic MIMIC
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5. Compressed air optimization - Results
Particulars Before After
Cement mill &
packing plant operation
4 x 90kW 2 x 90 kW
Wagon loading
operation with
4-packers
2 x 90 kW 1 x 90 kW
Truck loading
with 2-packers1 x 90 kW 1 x 55 kW
Specific power
consumption
for compressed
air
2.27 1.64
29
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
236.57
80.46
43 39.618
49.2
0
50
100
150
200
250
2016-17 2017-18(Till July'17)
Wind Power Utilization
Total power Wind power % age utilisation
30
GUH Vice President
Cement Mill Packing plantRaw material Handling
and Wagon Tippler
Energy
co-ordinatorTechnical Head
ENCON – Organization Chart
Energy Management Committee
S no Name Designation 1 T.K.M.Reddy UH
2 Mahendra P Singh TH3 Hanumanthappa.c SH (E&I) Co-ordinator4 Pradeepkumar.CK SH (Process)5 Srinivasarao J SH (Mech)6 PSN. Murthy SH (Comercial)7 Dada Khalandar Mechanical (FLE)8 Krishnaprasad B IT9 Balasreenivasareddy Electrical (FLE)
10 Ravindrareddy.V Instrument (FLE)11 Ravi Firangi HRD
12 Thatchinamurthy N SH - QC13 Prasad Danial Stores14 Nageshwara Rao Security
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
Online Energy Monitoring-Section wise
Section wise Energy Monitoring on daily basis
Energy Monitoring in SAP
Energy Management System (EnMS)-Policy
36
Rewards & Recognitions
Received Energy Efficient unit award from CII - 2015
Environment Practices
Development of pond for rain water harvesting & Greenery
39.8
13.115.7
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
40.0
45.0
Total Area Gree bel to be covered Coverd till today
Hectares
Green belt is to
be covered 33.0% ie. 13.1
Hector
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