UltraTech UltraTech Cement Limited Cement Limited (Unit: (Unit: Kotputli Kotputli Cement Works Cement Works- Power Plant) Power Plant) Welcome to CII 13 th National Award for Excellence in Energy Management 2012 1 We are going to share We are going to share… Company Profile Unit Profile Plant Configuration and Flow diagram Energy Management System Policy Methodology of Energy monitoring Plant Performance over the years List of ENCON Projects/Major ENCON Projects Environment Projects/Renewable Energy Sources CSR initiatives Best Practices Innovative Projects Awards & Accolades Way forward 2
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(Unit: Kotputli Cement Works -Power Plant)U… · Type : IR-CFBC Make : M/s Thermax Rating : 2X102TPH Pressure : 98.5 Ata Temp. : 540+/-5 Deg C Turbine Type : Impulse-reaction Make
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reducing inst air pressure (7.2 BAR TO 6.0 BAR)3.20 NIL
4Optimization of Aux. Power Consumption of
ESP of Boiler-1 & 2.1.40 NIL
5Energy saving by interconnection of
both CBD tank.1.60 0.2
Energy Savings Projects (2011Energy Savings Projects (2011--12)12)
15
Sl.
No.Energy saving Projects
Saving Achieved
(Rs. Lacs)
Investment
(Rs. Lacs)
6To optimize air consumption of coal
Handling & Lime stone Circuit 4.00 NIL
7
Reduction in auxiliary power consumption by
replacing new ACC tube bundle rear to front
side.
55.40 30
8Reduction in Heat rate consumption by replacing
new ACC tube bundle rear to front side.190.0 40
9Reduction of power consumption by installing
VFD in CEP - 1&211.50 6
10Reduction of power consumption Aux. Cooling
Water Pump # 1&3 by installing of VFD.1.40 6
Total Saving 590.21 82.4
Energy Savings Projects (2011Energy Savings Projects (2011--12)12)
Major ENCON ProjectsMajor ENCON Projects
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ThemeTheme--1 # 1 # Operation of BFP through PIDOperation of BFP through PID
Opportunity:
� Operating BFP at constant RPM through
VFD
Approach:
� PID logic made and set point given to VFD
from discharge pressure
Results:
� Saving of 50 KWH/Pump achieved
� Saving of Rs. 30.8 Lacs/Annum
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ThemeTheme--2 #2 # Installation of VFD in CEP &PID controlInstallation of VFD in CEP &PID control
Opportunity:
� Both Units CEP’s (110KW rating) were running
on DOL mode
Approach:
�Installed the VFD in one pump for energy
conservation.
�PID logic made and set point given to VFD from
discharge pressure.
Results:
� Saving of 30 KWH/Pump achieved
� Saving of Rs. 18.0 Lacs/Annum
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BEFORE (Photo / Sketch)
AFTER (Photo / Sketch)
DearatorDearator--11 DearatorDearator--22
BFPBFP--11 BFPBFP--22 BFPBFP--33
BFPBFP--11 BFPBFP--22 BFPBFP--33
CEPCEP--11 CEPCEP--22
CONDENSATE
EXTRACTION LINE
DearatorDearator--11 DearatorDearator--22
INTERCONNECTION OF CONDENSATE LINE
CEPCEP--11 CEPCEP--22
Opportunity:
� Due to individual deaerator for the
Boilers, Heat Rate was getting increased
by cross Operation of TG & Boiler.
Approach:
� Both Units Condensate lines
Interconnected
Results:
� Heat rate decreased by 20Kcal/kwh
� Saving of Rs. 8.8 Lacs/Annum
ThemeTheme--3 # 3 # Improvement in Heat Rate by Improvement in Heat Rate by
interconnection of CEP discharge linesinterconnection of CEP discharge lines
Environmental ProjectsEnvironmental Projects
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ThemeTheme--1 # 1 # CDM ProjectCDM Project
� Boilers registered in UNFCCC (United Nations Framework
Convention on Climate Change) for Carbon Credit.
� First time in Globe, CFBC Boilers selected for CDM benefit.
� Total Credit of CO2 will be 21509 Ton/Year
� M/s UTCL will get benefit of Rs. 1.50 Crores/year for next 15
Years.
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This type of Boiler, first in the Globe to earn Carbon This type of Boiler, first in the Globe to earn Carbon
Credits by using CFBC Technology Credits by using CFBC Technology
Kotputli cement Works
BEFORE (Photo / Sketch)
AFTER (Photo / Sketch)
Baffle Pot
OMF
OMF
Main Oil Tank
Exhaust
ExhaustOpportunity:
� From Turbine Vapor Extraction fan,
oil
particle was going to atmosphere
with fumes.
Approach:
�Installed Baffle pot in discharge line.
�Connected Baffle pot drain directly
to MOT.
Result:
�Saving of Turbine oil of 1.6 Liters/day
�Saving of Rs 0.76 Lacs/Annum
ThemeTheme--2 # 2 # Saving of Turbine OilSaving of Turbine Oil
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Valve
Valve
Main Oil Tank
Green Belt development / Green Belt development / Rain water harvestingRain water harvesting
3416 4026
15564 1608613267
0
5000
10000
15000
20000
2007-08 2008-09 2009-10 2010-11 2011-12
Rich plantation area as 110.4 Hectare
Renewable Energy Sources/Waste Renewable Energy Sources/Waste
UtilisationUtilisation
26
Solar Power PlantSolar Power Plant
Utilization of Renewable
Energy through installation
of 100 KW Solar Power Plant
27
Utilization / Recycle of WasteUtilization / Recycle of Waste
1. Use of effluent Water (Boiler blow down,
CT blow down & DM plant backwash
water)– for Greenbelt and Dust
suppression. Water recycled & saved
70000 M3 in last 03 Years.
3. Power Plant total Fly Ash is used by Cement Plant.
4. Power Plant Bed Ash is used by Cement Plant as a Chemical Gypsum.
2. Cooling Water –Using Side stream
sand filter to reduce blow down
28
Corporate Social Responsibility…..Corporate Social ResponsibilityCorporate Social Responsibility……....
STRIVING FORSTRIVING FOR…………
Societal Change ……29
Corporate Social ResponsibilityCorporate Social Responsibility
Corporate CSR Corporate CSR
CSR Vision CSR Vision
CSR Policy CSR Policy
Focus AreaFocus Area
30
Education� Emphasis on girls education.
� Felicitation Program for students.
� Formation of 06 Self Help Groups.
� Awareness Campaign for personal hygiene, Family
Planning, Immunization - SHGs Meeting.
� Infrastructure development for Hospitals/Schools
nearby.
� Discussion with NABARD for livelihood project
Corporate Social ResponsibilityCorporate Social Responsibility
Best PracticesBest Practices
32
Examples are as under –
� IR-CFBC Boilers selected in place of AFBC to achieve better Thermal
Efficiency.
� Intelligent MCC for better monitoring.
� First time Boiler Feed Pumps & Fans taken on VFD
� Screw type Air Compressors with VFD.
� Energy efficient motors & Illumination System
� 12-Pulse VFD, in view of harmonic reduction
Best Practices since inception of the projectsBest Practices since inception of the projects
33
Innovative ProjectsInnovative Projects
34
ThemeTheme--1 # 1 # Centralized Communication for Intelligent MCCCentralized Communication for Intelligent MCC
35
Opportunity:
Installed ACC was not performing as per design due to heat transfer problem from Tubes to fins.
OEM Recommendation:
To erect newly ALE tube bundles at last stage of existing ACC.
Our Experience:
At our other group units , new bundles were erected at last stage of ACC.
Brainstorming and Decision:
A brainstorming session was conducted with TPP team, looking the Aluminiummetal heat transfer characteristics, the decision was taken to erect new ALE bundles at front and existing old bundles at last stage of ACC as it gives advantage during summer as well as in winter season.
It was discussed with M/s Greenesol and they also agreed with the above advantages.
ThemeTheme--2 # 2 # Extension and Modification of ACC Extension and Modification of ACC
36
Results Achieved (Winter Season):
� After E&C (Unit-2), we have operated both the turbines at same vacuum with all six fans at running condition, we found load on TG 2 - 23 MW and TG 1 - 18 MW i.e. benefit of 5 MW load.
� Again we have operated both the Turbines at same load and vacuum i.e. 21 MW and -0.78 Kg/cm2 by stopping the ACC fans and got benefit of 2400 KW/Day/ACC (Margin of two fan/ACC).
Results Achieved (Summer Season):
� After E&C (Unit-1&2), we found load increment on single TG 6-6.5 MW after operation of all modules at design ambient temperature i.e. 42 Deg C, thus total load increment with both the TG’s found 12-13 MW.
� If we were erected new ALE Bundles at rear side as per recommendation of OEM, then we will benefited only 7-8 MW with both the TG’s.
Thus we got benefit of 5-6 MW with both the units by installation of new ALE Bundles at front side.
Extension and Modification of ACC Extension and Modification of ACC
37
Benefits:
� Benefit due to increased load – Rs. 1.44 Cr./annum
(2*2500Kwh*Rs 1.0 (Cost difference)*24hrs*120 days - Summer)
� Benefit due to reduction in APC – Rs. 0.46 Cr./annum
(2*200Kwh*Rs 4.0 (Gen.cost)*24hrs*120 days - Winter)
TOTAL BENEFIT – Rs. 1.90 CRORES/ANNUM
�And also we are able to run the Cement Plant at Full Capacity.
�Resulting benefit due to Cement production – Rs. 34.86 Cr./annum
Extension and Modification of ACC
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Theme-3 # Synchronization of 21 Nos Breakers
Opportunity:
� No. of Synchronization Breakers are
more & chances of Mis-operation.
Approach:
� Auto synchronization scheme
prepared through redundant PLC
operation and implemented.
Result:
� System can be synchronized from
single location i.e. CCR.
� Plant reliability increased due to auto
Load shedding
� No Black out since last two years
even after 400 islanding.
� Plant sustained at the time of
Northern Grid failure on dated 30 &
31.07.12
Theme-4 # Online Energy Monitoring System
Approach:
� Online Energy monitoring system
implemented.
� All auxiliary transformers connected
with system.
Opportunity:
� No online Energy monitoring
system for Aux. equipment.
Result Achieved:
� Identification of inefficient equipment
( i.e. ACW Pumps, BFP & CEP).
� Optimisation of Auxiliary Power
Consumption ( i.e. APC reduced from
17% to 13.5%).
� Report is being generated on daily basis
for study & analysis of Power.
Efficiency Monitoring & Daily report
TPP Daily Report
Today MTD YTD
Parameters Units Unit-1 Unit-2 Total Unit-1 Unit-2 Total Unit-1 Unit-2 Total