the ramco cements limited, alathiyur profile
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The Ramco Cements Limited, Alathiyur Profile
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A flagship company of RAMCO Group, having five Cement manufacturing units, four grinding units and one packing unit with the total capacity of 16.5 MTPA.
Alathiyur plant was setup in two phases 1997 & 2001 with Cement capacity of 3.05 Million Tons / Annum and 2 X 3700 TPD Kilns.
The manufacturing products are Ordinary Portland Cement, Portland Pozzolana Cement and SRPC as per BIS & SLS standards.
2X18 + 6 MW - Coal based Thermal power plant
Integrated Management System Certification
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IS/ISO 9001: 2015
IS/ISO 14001: 2015
IS 18001: 2007
Quality Management System
Environment Management System
Occupational Health & Safety Management System
IS/ISO 50001:2011 Energy Management System
5S Excellence Certified Company
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Energy Monitoring & Reporting System
Energy consumption both electrical & thermal : Daily
Energy conservation projects : Weekly
Review meeting conducted by : Unit Head
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Energy Management System
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Selection
• Department - Plant Management, Production ,Maintenance Quality Control ,Accounting
Formation
• Each department Provide one or more Representatives to the Energy Management team
Coordination
• Each Energy management Clusters will be headed by Team leader and the whole is monitoring by Energy Manager
Responsibilities
• Define Objectives, Prepare Energy Planning, Optimal Energy Operation, Detect Weakness Plan and Perform Measures/Projects Prepare Energy Performance & Reporting Establish & perform Energy Controlling Review achievements
Implementing Strategy
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WORKS HEAD
HOD
MINES
HOD
P & QC
HOD
MECH
ENERGY MANGER
HOD
E & I
HOD
CDS & PP
HOD
TPP
UNIT HEAD
Core Committee Team – Energy Cell
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INCHARGEMINES & CRUSHER
INCHARGE
TPP
INCHARGE
PACKING
INCHARGE
CEM MILL
INCHARGE PYRO
INCHARGE RAW MILL & COAL MILL
INCHARGE
UTILITIES
Responsibilities of Steering Committee
False air study in all major sections i.e., Kiln, Raw Mill, Coal Mill and Cement
Mill on monthly basis.
Monitor production performance vis-à-vis SEC.
Monitor fan performance and initiative corrective action required, if any, on monthly basis.
Identify/Evolve new ENCON projects with and without investment.
Encourage employee participation through effective implementation of
Suggestion Box Scheme, 5S & Quality Circle.
IMS – EnMS Management Review Meetings, EMAP will be reviewed.
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Sl. No Description Units 2016-17 2017-18
1 MTOE reduction MTOE 175239 170800
2 Kiln Thermal SEC kCal/kg clinker 699 697
3 Specific Electrical Energy - clinkering kWh/T of clinker 52.76 52.58
4 Specific Electrical Energy – Grinding kWh/T of cement 26.16 25.02
5 CPP Heat rate kCal/kWh 3421 3496
6 CPP auxiliary consumption % 10.49 10.43
7 Thermal Substitution Rate % 2.2 5.95
8 Clinker factor % 0.77 0.78
9 Blended cement *%) of total cement % 94 92
10 Specific CO2 emission Kg CO2/ kg cement 702.42 700.35
Energy Performance Improvement
Energy Conservation Projects Implemented in the years
2017-18
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No. of Projects : 6
Projects with NIL investment : 5 Nos.
Total amount invested : Rs. 149 Lacs
Cost savings achieved : Rs. 233 Lacs
Electrical energy saved : 52.5 Lac Kwh
Thermal Energy saved : 350 MT of coal
Reduction in GHG emissions : 5305 MT of CO2
Energy Conservation Project 2017-18
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Sl. No. Title of Project
Annual Electrical
Saving (kWh)
Annual Electrical
Cost Saving (Rs
million)
Annual Thermal Saving (Ton/ye
ar)
Annual Thermal Saving
(Rs million)
Total Annual Savings
(Rs million)
Investment Made (Rs million)
Payback (Month
s)
1Modification of Line-1 Coal mill main bag filter purging from low pressure to high pressure
792,000 3.17 0 0 3.17 2.5 10
2 Retrofitting of Line-1 Cement Mill fan 3,896,640 15.59 0 0 15.59 5 4
3 Removal of damper in Line-1 RABH fan 216,000 0.86 0 0 0.86 0 0
4 Installation of Pillard burner in Line-1 Kiln 0 350 2.3 2.31 5.2 27
5Installation of VRF AC System in Rawmill-2 IO Room
275,800 1.1 0 0 1.1 1 11
6Replacement of 70W / 250W SON light fittings by energy efficient 36W / 100W LED fittings
68,240 0.27 0 0 0.27 1.2 53
750
760
770
780
790
800
Target Achieved
796
768
Gate to Gate Energy Consumption for PAT Cycle-I
19th National Award for Excellence In Energy Management -2018 14
BEE-PAT Scheme : 8946 Nos. of Energy saving certificates issuedK
cal/
Kg
of
Cem
en
t
650
670
690
710
730
750
Baseline Target 2017-18
756
718
697
Gate to Gate Energy Consumption for PAT Cycle-II
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Kcal/
Kg
of
Cem
en
t
Road Map To Achieve Benchmark
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Innovative Project -1
In our Alathiyur plant we have 2 nos. of Vertical Roller Mill for Clinker grinding.
Line-1 mill FLS make OK 33.4 capacity of 160 TPH for PPC and Line-2 mill LOESCHE make LM 56.2 capacity of 260 TPH for PPC.
Line-1 Cement mill is consuming about 4kWh/MT higher than Line-2 Cement mill, due to this we are operating Line-1 Cement mill very less.
We have identified the difference is in the specific power consumption of fan.
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Innovative Project -1
Fan Power consumption high: We have identified the reasons for low fan efficiency and done stage wise modifications like:
Increasing the fan inlet duct dia from 2 m to 2.8 m
Modification of fan outlet to chimney duct
Modification of bag filter outlet duct by conducting CFD
Modification of fan inlet suction box.
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Innovative Project -1
By carrying out above all modifications, the fan inlet turbulence has reduced,
but the fan outlet turbulence did not reduce and Reason is due to the recirculation duct tapping immediately after the fan outlet, due to this the fan
outlet pressure is varying from -100mmwg to -200mmwg.
Action taken to reduce fan power:
Replacement of existing low efficiency fan (50% eff.) with high efficiency fan
(83% eff).
Installation of junction box at the mill fan outlet and rerouting recirculation duct
to eliminate turbulence at the fan outlet duct.
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Modified recirculation duct routing from the junction box
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Savings achieved : 6.6 Kwh/Mt of Cement
Productivity Improvement : 15 TPH
Cost savings : Rs. 155.9 lacs
Investment Cost : Rs. 50 Lacs
Simple Pay Back Period : 4 Months
Innovative Project -1
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Line-1 Coal Mill Main Bag Filter is designed for low pressure high volume purging.
During normal operation in Line-1 Coal mill, Bag filter DP is high which causes the frequent disturbances in Mill operation.
The disturbances causes reduction in mill output, increase in specific power consumption. Due to this we have even forced to reduce the kiln feed occasionally.
We observed that when ever there is mill trip, lot of material is collected from the bag filter to the fine coal bins.
We have taken trial with increased purging pressure up to 3.5 bar and increased the on time of purging, but there is no any significant improvement.
From the above trials we observed that the bag cleaning (purging) is not adequate.
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Innovative Project -2
We studied the root cause for inadequate bag cleaning:
Line-1 coal mill is designed for Lignite / Coal grinding.
During pet coke grinding, the mill output is low and also not able to achieve the desired residue.
We have modified the mill internals and classifier to suit pet coke grinding, due to this the mill Dp has increased by 250 – 300 mmwg.
The bag filter is designed for the inlet draft of -650 mmwg. After the modification of the mill it has increased to -900 to -950 mmwg.
Due to increase in the bag filter draft, the low pressure high volume purging is not adequate for cleaning of the bags.
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Innovative Project -2
We have decided to change the purging from low pressure high volume to high pressure low volume purging.
The modification was carried out in-house.
We designed and fabricated the purging air headers, purging pipes. We procured the solenoid valves, venturi.
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Innovative Project -2
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DescriptionBefore modification After modification
Low pressure purging High pressure purging
Bag Ø in mm 127 127
Bag length in mm 5040 5040
Bag seating type Snap band Snap band
Qty in Nos 1024 1024
Venturi Availability No Yes ( Provided )
Purge pipe Ø 80 NB 50 NB
Tube sheet to purge pipe height
190 mm 120mm
Purge pipe purge hole dia16mm (Nozzle pipe Ø
36mm)4.5mm (Nozzle pipe Ø 6.3mm)
Operating air pressure 2.5 bar 5.5 bar
Compressor air volume 380 CFM 260 CFM
Purging Sequence 1,2 - 3,4 - 5,6 …….. 1,33 - 2,34 - 3,35 …….
On Time 0.120 Sec 0.175 Sec
Off Time (Pass Time) 7 Sec 6 Sec
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Before After
Innovative Project -2
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Before After
Innovative Project -2
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Before Bag filter purging modification
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After Bag filter purging modification
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Innovative Project -2
Investment Cost : Rs. 25 Lacs
Cost Savings : Rs. 32 Lacs/Year
Simple Pay Back Period : 10 Months
Electrical energy savings : 5.08 kWh/T matl
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Best
Improvement
in Energy
performance
in
Manufacture
of Blended
Cements –
2016-17 from
NCCBM
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