Ultratech Kotputli Cement

8/13/2019 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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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


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




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S.No.


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




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S.No.


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




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S.No.


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



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ENVIRONMENTAL INITIATIVES

Environmental Initiatives


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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



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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)




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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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Education

SustainableLivelihood

Social Causes

InfrastructureDevelopment

Health Care

Corporate CSR

CSR Vision

CSR Policy

Focus Area



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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



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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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Kotputli Cement Works

Ultratech Kotputli Cement

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