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



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After Modification

Input T/F Slim Inverter Output T/F

HT Breaker HT VFD forCooler ESP Fan

Fan HT Motor



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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


After Modification contd..

Raw Mill Separator Efficiency


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Improvement



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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


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


(2003-2004)



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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


(2004-2005)



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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


(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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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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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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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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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




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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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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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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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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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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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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




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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


Others


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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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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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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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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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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


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



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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


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


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



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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


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


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 .



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Thermic Fluid

n-pentane

203degc

20 bar

320degc

120degc

270 degc

147degc,

2.2bar


System components


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System components

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

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