ultratech cement limited aditya birla group - … award... · waste fuel – mechanised feeding...
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ULTRATECH CEMENT LIMITED(UNIT:-REDDIPALAYAM CEMENT
WORKS )
1
Welcome to CII “11th National Award for Excellence in
Energy Management- 2010”
Team MembersAshish Panpalia.M.P Singh.G.Suresh Kumar .
ADITYA BIRLA GROUP - PROFILE
ALUMINIUM
CARBON BLACK
CEMENTCHEMICALS
COPPER
FERTILIZER
FINANCE
GARMENTS
INSULATORS
INSURANCE
IT
RETAIL
STAPLE FIBRE
TELECOM
TEXTILE
VISCOSE
ABMCL
ADITYA BIRLA RETAIL
ADITYA BIRLA CHEMICALS
ADITYA BIRLA NUVO
BCCL
BIRLA CARBON
BIRLA GLOBAL FINANCE
ESSEL MINING & INDUSTRIES
GRASIM INDUSTRIES
HINDALCO INDUSTRIES
IDEA CELLULAR
INDAL ALUMINIUM INDUSTRIES
INDO GULF FERTILIZERS & CHEMICALS
PSI DATA SYSTEMS
ULTRATECH CEMENT LIMITED
GROUP COMPANIES BUSINESSES
2
CEMENT BUSINESSADITYA BIRLA GROUP
3
RACW
RECW
ACW APCW
ADCW
VCW KCWRCW
GCWHCW NJFD
NRCW
ARCW
NCMW WBCW JCW BCW DCW
PCWALCW
GECW
HOCW
BIRLA WHITE
INTEGRATED UNITS
GRINDING UNITS
White cement plant
Ultratech Grinding Units (G)Ultratech Cement Terminals
Ultratech Cement Plants
B
Shambhupura
Jawad
Raipur
Malkhed
Jodhpur
Reddipalayam
Hyderabad
Gurgaon
Bangalore
Bhatinda (G)
Hotgi(G)
B
Noida
Chennai
Kovaya
Jaffrabad Magdalla(G)Hirmi
Jharsuguda(G)
Durgapur(G)
Tadipatri
Arakonam(G)
Ratnagiri(G)
BNaviMumbai
BMangalore
CEMENT BUSINESS AT A GLANCE
•49 Million MT capacity•12 Integrated Units .•11 Split Grinding Units.•5 Bulk terminals.•69 Ready-mix concrete plants.
Ready mix Concrete plants
RECW
4
Kotputli
Ginigera
AligarhPanipat
Dadri
Awarpur
CEMENT MANUFACTURING PROCESS
Stacker & Reclaimer
Raw Material Hopper
Raw Mill
Raw Meal Silo
4 Stage Preheate
r
Kiln
Cooler
Clinker stockpile
Cement Mill
Cement Silo
Packer
Dispatch
5
Crusher
Coal Mill
Mines
Truck Loading
PLANT – SALIENT FEATURES
•Reddipalayam cement works capable of using multiple fuels successfully•Leader in waste fuel utilization in India •First Cement Plant in the World to get CDM •Cross Belt Analyzer - Use of different limestone mix from four to five mines on daily basis- Use of Marl (low grade limestone) up to 10 %- No additives used other than Limestone & Marl for raw meal quality correction
•No fatal accident since last Eight years•Ripper Dozer for environment friendly mining operation•Established schools one with CBSE & another with Matriculation (State board) syllabus
6
TECHNOLOGICAL FEATURES
• Robo lab. • Raw Meal Proportioning System. • Laboratory Information And Management system.
• Linkman – Plant Optimization Software.
• Knowledge Manager For Process Studies.
• PI Soft ware for on-line process information's.
State of the art technology adopted taking into consideration Quality, Safety & Environment friendly aspects. Most of the Technology features introduced like:
ROBO LAB7
PLANT – SALIENT FEATURES
• Designed to operate with 100% Petcoke.• Installed ESP & pulse jet bag filters• Building Air conditioning Automation
software • Designed structures, machines to
minimize the noise effect always • Operated all equipments through DCS
(Distributed Control System) to eliminate the direct exposure of dust and noise to the employees.
• Alternate/Hazardous Fuel Feeding
ECO-FRIENDLY TECHNOLOGICAL FEATURES
8
PLANT – SALIENT FEATURES
RAW MILL ESP
FINISHED PRODUCTS
OPC 43 OPC 53 PPC
9
PLANT PERFORMANCE
10
550.25 609.27 621.34
100
500
900
2007-08 2008-09 2009-10
TURN OVER (SALES) ( ` in Crores)
11
10.1 10.32 10.4
56789
1011
2007-08 2008-09 2009-10
CLINKER PRODUCTION (Lac MT)
12
13.51 13.61 13.63
89
1011121314
2007-08 2008-09 2009-10
TOTAL CEMENT PRODUCTION (Lac MT)
13
13.7213.5913.48
89
101112131415
2007-08 2008-09 2009-10
TOTAL CEMENT DESPATCH (Lac MT)
14
79.6
58.246.92
0102030405060708090
2007-08 2008-09 2009-10
% o
n C
V B
asis
USAGE OF PET COKE (in place of conventional fuel)
15
Plant capable of utilizing 100 % Petcoke
Due to non-availability of Petcoke & Cost economics
26.55 26.93 26.94
20
22
24
26
28
2007-08 2008-09 2009-10
%
USAGE OF FLY ASH IN PPC CEMENT
16
73.98 74.2 77.19
405060708090
2007-08 2008-09 2009-10
%
% OF PPC CEMENT PRODUCTION
17
776778
784
770
775
780
785
2007-08 2008-09 2009-10 Kcal
/ Kg
of c
linke
r
SPECIFIC FUEL CONSUMPTION
18
Planned to reduce 20 kcal/kg of clinker by upgrading
Existing Pre-heater from 4 Stage to 5 Stage during Nov-
2011
BENCHMARKING / GLOBAL BEST
19
68.1
62.0
72.2
68.3 67.9 67.4
63.6 63.1
6062646668707274
Wor
ld B
est
(Whi
teho
plem
an)
Indi
an B
est
(NC
CB
M)
GS
(04-
05)
GS(
05-0
6)
GS(
06-0
7)
GS(
07-0
8)
GS(
08-0
9)
GS(
09-1
0)
KWh/ton of Cement(PPC)
BE
TT
ER
INTERNATIONAL BENCHMARKING (Whitehopleman)
78.7
66.2
79.3
74.171.2 70.9
67.1 66.6
6062646668707274767880
Wor
ld B
est
(Whi
teho
plem
an)
Indi
an B
est
(Whi
teho
plem
an)
GS
(04-
05)
GS
(05-
06)
GS
(06-
07)
GS
(07-
08)
GS
(08-
09)
GS
(09-
10)
OVER ALL POWER KWh/ton of Cement
BE
TT
ER
INTERNATIONAL BENCHMARKING (Whitehopleman)
INNOVATIVE PROJECTS
IMPLEMENTED
22
INNOVATIVE PROJECT-1
23
Problem Faced:-• Cooler Exhaust gas was going outside as waste to
atmosphere • Non availability of dry fly ash in the market.• Requirement of dry flyash for the manufacturing of PPC cement
is 900 MT/day.• Total available dry fly ash is 800 MT/day from MTPS / NLC
and 150 MT/day from market• Abundant quantity of wet flyash is available at MTPS . • Due to high moisture in wet fly ash, only 2% of the total fly ash
can be used in the system.• Shortfall of dry fly ash can be met by drying of wet fly ash.
INSTALLATION OF WET FLYASH DRYING SYSTEM
Title:- Installation of Wet Flyash drying system (WHR-Waste Heat Recovery)
for effective Utilization of Cooler exhaust gas.
WET FLY ASH DRYING SYSTEM
24
Rectification Done:-Feasibility study carried out and installed flyash
dryer Capacity: 16 TPH
Investment:- ` 7.5 Crores.
Benefits & Savings :- 1. Total coal savings 6165 Tons/Annum 2. Savings ` 38.3 Lakhs/Annum .
(Saving in Procurement of Dry flyash ` 400/MT)3. Additional availability of dry fly ash 1.00 LAC
MT/Annum.This has been taken as a CDM project under waste
heat recovery (expected saving of 8000 - 10,000 CER’s / Annum).
WET FLY ASH DRYING SYSTEM
25
SCHEMATIC DIAGRAM
% PPC Production
48.42
72.21 77.273.98 74.15
4554637281
2005-06 2006-07 2007-08 2008-09 2009-10
Year
%
INCREASE IN PPC PRODUCTION
25.1723.75 23.26
20222426
2007-08 2008-09 2009-10 Kw
h Pe
r Ton
Of
Mat
eria
l
REDUCTION OF SPECIFIC POWER IN PPC PRODUCTION Better
WET FLY ASH DRYING SYSTEM
26
FLASH DRIER
27
INNOVATIVE PROJECT-2
Innovative Project:- (A)
Title:- Installation of SPRS (Slip Power Recovery System) in Raw mill fan.
Problem Faced:- Obsolescence of SPRS panel & High Power consumption.Rectification Done:- Installed the analogue system with Digital system.Investment:- ` 55 lakhs.Benefits & Savings :- Savings ` 5.73 Lacs/Annum.
REDUCTION OF POWER CONSUMPTION IN RAW MILL CIRCUIT
28
INNOVATIVE PROJECT-2
Innovative Project:- (B)
Title:- Modification of Raw mill inlet duct.Problem Faced:- High pressure drop from Pre-heater Outlet to Raw Mill Inlet Around 160 mmwg” and velocity in inlet duct was 26 m/sec. Rectification Done:- Raw mill duct modified for reducing pressure and power.Investment:- `129 Lakhs.Benefits & Savings :- Pressure drop reduced from 160 to 136 mmwg; Velocity reduced from 26 m/sec to 18 m/sec there by reduced raw mill power by 0.5 units per ton of raw meal
REDUCTION OF POWER CONSUMPTION IN RAW MILL CIRCUIT
RAW MILL DUCT MODIFICATION
29
INNOVATIVE PROJECT-2
Innovative Project:- (C)Title:- Modification of GCT duct.Problem Faced:- High power consumption and high pressurization in Preheater fan during Raw mill stoppage. Rectification Done:- GCT outlet duct modified.Investment:- ` 56.5 Lakhs.Benefits & Savings :- GCT inlet duct pressure reduced by 60 mmwc. Raw mill ESP fan power reduced by 0.7 unit per ton of clinker. Preheater fan outlet pressurization avoided during raw mill stoppage.
REDUCTION OF POWER CONSUMPTION IN RAW MILL CIRCUIT
GCT DUCT MODIFICATION
30
INNOVATIVE PROJECT-2
Innovative Project:- (D)Title:- Replacement of Raw mill Fan.Problem Faced:- High power consumption Rectification Done:- Low efficiency fan replaced by high efficiency.Investment:- ` 56 Lakhs.Benefits & Savings :- Fan efficiency increased from 76% to 84%.
Power saving 0.12 unit/ton of material.
REDUCTION OF POWER CONSUMPTION IN RAW MILL CIRCUIT
INNOVATIVE PROJECT-2
RESULT– REDUCTION IN SPECIFIC POWER CONSUMPTION OF RAW MILL
11.712.4513.09
10
12
14
2007-08 2008-09 2009-10Kwh
Per T
on O
f Ma
teria
l
32
INNOVATIVE PROJECT-3
Innovative Project:- (A)Title:- Replacement of Cooler Fans.Problem Faced:- High power consumption Rectification Done:- 3 nos. of Low efficiency fans replaced by high efficiency.Investment:- ` 32 Lakhs.Benefits & Savings :- Fan efficiency increased & Power Saving 0.216 unit/ton of
clinker.
REDUCTION OF POWER CONSUMPTION IN KILN
33
INNOVATIVE PROJECT-3
Innovative Project:- (B)Title:- Replacement of Reciprocating compressors (2 nos) Problem Faced:- High power Consumption, high noise level and water consumption.Rectification Done:- Replacement of Reciprocating compressors (2 nos) by Atlas Copco Make Screw compressors Investment:- ` 53 Lakhs.Benefits & Savings :- Power saving of 0.34units/ton of clinker , Noise level reduced from
95 to 88 db, No Water consumption for cooling (previously 29.4 m3
/ Hr.)
REDUCTION OF POWER CONSUMPTION IN KILN
34
INNOVATIVE PROJECT-3
Innovative Project:- (C)Title:- Modification of Pre-heater twin cyclone Aerovane.Problem Faced:- High fuel Consumption.Rectification Done:- Aerovane height increased by 1.3 M and
cyclone inlet reduced by 140 mmInvestment:- ` 25 Lakhs.Benefits & Savings :- Reduction in heat consumption by 4 Kcal/kg of clinker increase in cyclone efficiency by 1 %
REDUCTION OF POWER CONSUMPTION IN KILN
Inlet reduced by 140 mm Aerovane increased by 1.3 M
INNOVATIVE PROJECT-3
RESULT– REDUCTION IN SPECIFIC POWER CONSUMPTION OF KILN
30.929.9
29.03
20222426283032
2007-08 2008-09 2009-10
Kw
h Pe
r Ton
Of M
ater
ial
36
INNOVATIVE PROJECT-4
REDUCTION OF POWER CONSUMPTION IN CEMENT MILLInnovative Project:- (A)Title:- Replacement of Reciprocating compressors (3 nos) Problem Faced:- High power Consumption, high noise level and water consumption.Rectification Done:- Replacement of Reciprocating compressors (3 nos) by Atlas Copco Make Screw compressors Investment:- ` 79 Lakhs.Benefits & Savings :- Power saving of 0.3 unit / ton of cement, Noise level reduced from
95 to 88 db, No Water consumption for cooling
37
INNOVATIVE PROJECT-4
REDUCTION OF POWER CONSUMPTION IN CEMENT MILLInnovative Project:- (B)Title:- Mill optimizationProblem Faced:- High power Consumption, Low out put.Rectification Done:- RP Roller profile re-building at regular intervals
RP gap adjustmentGrinding media optimization
Investment:- NilBenefits & Savings :- Output increased from 190 to 215 TPH and
reduced power consumption from 25 units to of 23.8 units.
INNOVATIVE PROJECT-4
RESULT– REDUCTION IN SPECIFIC POWER CONSUMPTION OF CEMENT MILL – 53 Grade
25.1923.7 23.5
20
22
24
26
2007-08 2008-09 2009-10
Kwh
Per T
on O
f Mat
eria
l
INNOVATIVE PROJECT-4
RESULT– REDUCTION IN SPECIFIC POWER CONSUMPTION OF CEMENT MILL – PPC
25.17
23.7523.26
20
22
24
26
2007-08 2008-09 2009-10 Kwh
Per T
on O
f Mat
eria
l
40
REDUCTION OF POWER CONSUMPTION IN POWER PLANTInnovative Project:- (A)Title:- Installation of VFD for Power plant Cooling Tower fan.
Problem Faced:- High power consumption in cooling fans.
Rectification Done:- Installed VFD for cooling tower fan with interlock in Temperature.Investment:- ` 0.4 Lakhs.
Benefits & Savings :- Savings ` 2.84 Lakhs/Annum.
INNOVATIVE PROJECT-5
OVERALL POWER CONSUMPTION
79.30 67.1 66.56
30
40
50
60
70
80
2007-08 2008-09 2009-10
Kw
h/To
n O
f Mat
eria
l ENVIRONMENTAL PROJECTS / CARBON EMISSION REDUCTION
42
WASTE FUEL – MECHANISED FEEDING SYSTEM:A mechanized waste fuel feeding system installed first time in India to reduce fossil fuel usage in Kiln
43
ALTERNATE FUEL
STORAGE FACILITY FEEDING SYSTEM
TRANSPORT SYSTEM
WEIGH FEEDER
44
INNOVATIVE METHOD FOR FEEDING ALTERNATE FUEL IN KILN .
WOOD CHIPPINGMACHINE
PLASTIC CHIPPING MACHINE
1. De – Oiled Rice bran (DORB) 2. De – Oiled cashew nut Shells3. Saw Dust 4. Bio – compost 5. Municipal Waste (RDF) 6. Coir Waste / Dust 7. Corn Waste 8. Ground nut shell 9. Palm seed Shell 10. Match stick waste11. Wood Strips12. Shredded Tyres13. Tyres Powder14. Refinery Sludge15. Paint Sludge16. Tyre Chips
9.57
5.3
10.89 11.26
7.93
13579
1113
2005-06 2006-07 2007-08 2008-09 2009-10
in %
% OF WASTE FUEL IN KILN ON CV BASIS
45
TNPCB trial
Due to non-availability of
Alternate fuels & cost economics.
46
SL# Type of Fuel UOM 2006-07 2007-08 2008-09 2009-10
1 Tyre MT 1,897 2,526 2391
2 DORB (De oiled Rice Bran) MT 7,939 17,392 10136 3097
3 Cashewnut Shell MT 0 264 5159 5235
4 Coconut Shell MT 0 1,580 911 0
5 Wooden Dust MT 0 0 1993 370
6 Oil Sludge MT 226 0 44 0
7 Paint Sludge MT 666 1,461 2010
8 Groundnut husk MT 0 0 14 0
9 Charcoal MT 0 0 0 64
QUANTITY OF WASTE FUEL IN KILN
3117
2547
MOU made Between M/S. UltraTech cement Limited (UTCL) & Municipal Corporation ofTiruchirapallI (TMC) For“Disposal of Plastic waste from Municipal Solid Waste
(MSW)
•The First Cement Company in the World to get CDM Carbon
Credit
Apr 2005 to Mar 2006, CER 22,290 (Received on 3rd April 2007)
April 2006 to Oct 2007, CER 28055 (Received on 6th Nov 2008)
Obtained Negative fuel cost for use of Hazardous waste like Paint sludge.
RESULT & HIGHLIGHTS
47
ALTERNATE FUEL
0.74 0.72 0.62
0.10.20.30.40.50.60.70.8
2006-07 2007-08 2008-09
Tonn
e
CO2 EMISSION / TON OF CEMENT
48
Better
Reduction in CO2 emission by 16 %( From 2006-07 to 2008-09)
Year
REDUCTION IN SPECIFIC POWER
CONSUMPTION
49
63.1463.5667.36
40
50
60
70
2007-08 2008-09 2009-10
Kwh
/Ton
Of C
emen
t
SPECIFIC POWER CONSUMPTION (PPC)
50
ENERGY SAVING PROJECTS
IMPLEMENTED LAST THREE YEARS
51 52
SL No.
Title of Energy Saving project implemented Year of Implementation
Annual Electrical Saving
Total Savings
Investment
Units Million
` Million
` Million
` Million
1.
Replacement of old driers by new version of driers in compressor house.
2007 0.0170.05491
0.05491
0.002
2.
Compressor air optimization. 2007 0.272 0.8774 0.8774 0.001
3.
Raw mill and cement mill optimization. 2007 0.003 0.00960.0096
0
4. Maintaining 120 deg centigrade in cement mill clinker weigh feeder .
2007 1.25 4.037 4.037 0
5. Optimization of Lime stone reclaimer and belt conveyor running time
2007 0.008 0.02580.0258
0
6. Reducing operating pressure in fly ash compressor. 2007 0.017 0.0540.054
0
7. Optimization of coal mill firing bag filters. 2007 0.008 0.025840.02584
0
8. Optimization of silo top bag filter in Raw mill. 2007 0.008 0.02584 0.02584 0
9.
Installation of VFD in 361 FN3 Fan . 2207 0.008 0.0258 0.0258 0.04
10
CCR AC AHU(Air handling unit) running timing stopped from 7PM to 7AM.
2007 0.008 0.02584 0.02584 0
ENERGY SAVING PROJECTS
53
SL No.
Ti2tle of Energy Saving project implemented Year of Implementation
Annual Electrical Saving
Total Savings
Investment
Units Million
` Million
` Million
` Million
11 Installation of control switch in packing plant 2007 0.007 0.02261 0.02261 0.06
12 Common unloading system for flyash 2007 0.024 0.07752 0.07752 0
13 Raw Mill main drive cooling fan interlocking. 2007 0.048 0.15504 0.15504 0
14 Kiln oil pumps interlocking with temperature. 2007 0.024 0.07752 0.07752 0
15 Interlocking of sampler in cement mill. 2007 0.001 0.00323 0.00323 0
16 Optimization of bag filter purging with flyash bag filter fan 2007 0.003 0.0969 0.0969 0
17 Reviewing of HP fan running on cement mill silo top. 2007 0.013 0.04199 0.04199 0
18 Replacement of Kiln ESP RAL’S for false air leakage 2007 0.007 0.02261 0.02261 0.02
19 Optimization of Lime stone weigh feeder blaster operation . 2007 0.002 0.00646 0.00646 0
20 Fixing of an exhaust fan in crusher venting line 2007 0.004 0.01292 0.01292 0.001
21 Placement of double stage compressor with single stage in packing plant.
2007 0.03 0.969 0.969 0
22 Optimization of coal mill ESP KV. 2007 0.204 0.65892 0.65892 0
ENERGY SAVING PROJECTS
54
SL No.
Title of Energy Saving project implemented Year of Implementation
Annual Electrical Saving
Total Savings
Investment
Units Million
` Million
` Million
` Million
23 Fitting of 45 Watt CFL bulb in place of 150 W HPSV fitting.
2007 0.008 0.02584 0.02584 0
24 Installation of separate switch for coal stacker and reclaimer in MCC room.
2007 0.000700 0.001737 0.001737 0.0005
25 Interlocking provided for roller press P & V blower with roller press motor.
2007 0.004176 0.010440 0.010440 0.001
26 Local control switch provided for L21 BC7 tower lighting.
2007 0.002942 0.009504 0.009504 0.001
27 Inter connection line made in between pyro & cement mill air receivers.
2007 0.204 0.0561 0.0561 0.312300
28 Two stage compressor (K51)converted into single stage compressor.
2007 0.153 0.42 0.42 0.15
29 Seggreagation of lighting in long belt area in packing plant.
2007 0.009075 0.027225 0.027225 0.005
30 Power saving through interlock for LS reclaimer PCRD motor during pile change.
2007 0.004140 0.010267 0.010267 0.002
31 Power saving in all cable cellars. 2007 0.015715 0.050760 0.050760 0
32 Commissioning of Screw compressor in pyro section. 2007 0.59 1.916 1.916 5.375
33 Bunker changed for optimizing coal reclaimer. 2008 0.02 0.0942 0.0942 0
3P-20 energy saver installed in TPP. 2008 0.02 0.0942 0.0942 0.25
ENERGY SAVING PROJECTS
55
SL No.
Title of Energy Saving project implemented Year of Implementation
Annual Electrical Saving
Total Savings
Investment
Units Million
` Million
` Million
` Million
35 Optimization of coal mill bag filter fan. 2008 0.018 0.08478 0.08478 0
36. Otimization flow meter air slide fan 431 FN 1 & 2. 2008 0.03 0.1413 0.1413 0
37. School varanda lights taken in street light control. 20080.005
0.02355
0.02355 0.015
38. Power saved by keeping cement mill 53 grade blaine 275 instead of 290.
2008 1.1 5.181 5.181 039. Upgradation of clinker weigh feeder. 2008 0.038 0.17898 0.17898 0.01540. Optimization of FK pump bag filter. 2008 0.03 0.1413 0.1413 0
41. Raw mill fan SPRS upgradation. 2008 0.5 2.355 2.355 6.542. Replacement of high efficient GCT pump 2008 0.5 2.355 2.355 0.543. Installation of low head GCT pump. 2008 0.3 1.413 1.431 0.344. Installation of high efficiency cooler vent fan. 2008 0.861 4.05531 4.05531 4
45. Installation of high efficiency Raw mill fan 2008 1.5027.074
7.074 5.746. 3 numbers of high efficient cooler fans installed. 2008 0.7 3.297 3.297 4.247. Installation of high efficiency Raw mill ESP Fan. 2008 3.2
15.072
15.072 5
48. Reduction in Power consumption in Raw mill circuit. 2008 1.4 6.594 6.594 12.975
49. Total four numbers of screw Compressor installed in place of reciprocating compressor
2008 2.4 11.304 11.304 4.8
ENERGY SAVING PROJECTS
56
ENERGY SAVING PROJECTSSL No.
Title of Energy Saving project implemented Year of Implementation
Annual Electrical Saving
Total Savings
Investment
Units Million
` Million
` Million
` Million
50. Installation of high efficient impeller for packer bag filter. 20080.57
2.6847 2.6847 051. Preheater twin cyclone aerovanes modification. 2008 1.040 4.8984 4.8984 2.5
52. Aluminium impeller changed by FRP impeller for cooling fans. 2008 0.090 0.4293 0.4293 0.040
53. CO2 purging system re-placed with N2 Purging system for fine coal bin and bag filters in fine coal circuit
2008 11.67 5.5 5.5 6.9
54. Optimization blower motor. 2008 0.0161 0.076 0.076 055. Optimization of L91 FN1 Coal mill bag filter. 2008 0.18 0.085 0.085 056. Optimization air slide fan 431 FN1 & 2. 2008 0.382 0.810 0.810 057. Optimization of supply water for Cooling tower. 2008
0.163
0.077 0.077 058. Optimization of silo top bag filter by speed reduction. 2008 0.006 0.02826 0.02826 059. Replacement of Kiln ESP RAL's for False air leakage 2008 0.007 0.03297 0.03297 0
60. Optimization of Lime stone weigh feeder by feed deviation. 2008 0.002 0.0942 0.0942 061 Installation of exhaust fan in crusher venting line. 2008 0.004 0.01884 0.01884 0.0362. Replacement double stage compressor with single stage. 2008 0.03 0.1413 0.1413 0.0363. 150W(HPSV) high pressure sodium vapors lamp replaced by 45 W
CFL(Compact florescent lamp)2008 0.008 0.03768 0.03768 0.8
64. Optimization of bag filters in packing plant 2008 0.09 0.4293 0.4293 0.1
57
ENERGY SAVING PROJECTSSL No.
Title of Energy Saving project implemented Year of Implementation
Annual Electrical Saving
Total Savings
Investment
Units Million
` Million
` Million
` Million
65. Cooling fan of Kiln shell taken in DCS/MCC. 20080.002
0.0942 0.0942 0.01566. 461 FN4(Kiln Cooling shell fan) taken in DCS. 2008 0.003
0.01413
0.01413 0.010
67. Belt interlocking done in clay feeding area. 20090.016
0.0552 0.0552 0.0025
68. Belt interlocking done in gypsum feeding area. 2009 0.015 0.05205 0.05205
0.0025
69. Use of energy efficient bearings. 2009 0.0016 0.005552 0.005552
0.016
70. Interlocking of packing plant bag filters. 2009 0.0816 0.283152 0.283152
0.03
71. Replacement of new version SPRS in Raw mill fan. 20090.261
0.90567 0.90567 5.5 72. Replacement of normal pumps by submersible pumps in Raw mill &
Coal mill.2009 0.04 0.1388 0.1388 0.04
73. Interlocking RP cooling fans. 2009 0.013 0.04511 0.04511 0.001574. Replacement of 150W HPSV by 45W CFL 2009
0.026
0.09022 0.09022 0.01575. Installation of VFD for Power plant cooling Tower fan . 2009 0.0820 0.28454 0.28454 0.0476. Installation of Panel Air conditioner & Exhaust fan in Power Plant 2009 0.048 0.16656 0.16656 0.01677. Waste gas utilization for drying wet flyash (Waste heat recovery
system).2009 0.05045 0.175 0.175 7
58
PROJECTS IMPLEMENTED
FROM 2007-2010Total No of Projects implemented :77
Total Units Saved in Million : 30.47
Total Saved ` in Million : 112.8
Total investment ` in Million : 73.23
59
INVOLVEMENT OF EMPLOYEES, TEAM WORK IN ENCON,
MONITORING & REPORTING AND IMPLEMENTATION METHODOLOGY
60
Name:-P.Jayaprakash Designation:-Engineer Department:-Electrical.
TEAM WORK IN ENCON
EMPLOYEE SUGGESTIONS RELATED TO ENERGY CONSERVATION
TITLE:- Power optimization of colony street lights.
PROBLEM FACED:- Timing of street lights are required to adjust frequently according to day light conditions by manual timers.
RECTIFICATION DONE:- Manual timer replaced by Astronomical timers based on location on (Latitude /Longitude) in place for Street light control.
INVESTMENT:- ` 13,640/.
BENEFITS & SAVINGS :- Power savings 30 minutes/day.` 12893.62/Annum.
PAY BACK PERIOD :- 1 Year.
61
TITLE:- Cement Mill Old Cooling Tower Replaced with new FRP (Fiber Reinforced Plastics) type Cooling Tower.
PROBLEM FACED:- Cement mill Cooling Tower Contaminated with dust due to 531BC6
Conveyor Belt Spillage materials and Efficiency becomes Low.
RECTIFICATION DONE:- Old cooling Tower replaced by new FRP (Fiber Reinforced Plastics) Type
Cooling tower.
INVESTMENT:- ` 3.0 Lakhs.
BENEFITS & SAVINGS :- Reduction of 4 units/day and Savings ` 1.09unit/Annum.
PAY BACK PERIOD :- 2.5 years.
TEAM WORK IN ENCON
EMPLOYEE SUGGESTIONS RELATED TO ENERGY CONSERVATION
Name:-A.James . Designation:-Fitter. Department:-Mechanical work shop.
62
Name:-Kulanginathen Designation:-Electrician. Department:-TPP
TEAM WORK IN ENCON
EMPLOYEE SUGGESTIONS RELATED TO ENERGY CONSERVATIONTITLE:- Installation of Exhaust fan instead of Split A/Cs in MCC
room of DM (Demineralizing Treatment) pant to reduce power
consumption PROBLEM FACED:- High Power Consumption.
BEFORE MODIFICATION:- In DM Plant MCC room split A/C (2 Tons) was provided to
maintain the room temperature to avoid failure of PLC.Power consumption : 2 Kw X 24 Hrs X30 Days X 12 Months
= 17280 Kwh/Annum AFTER MODIFICATION:- Provided two exhaust fan to enhance air circulation. Now the
PLC room temperature is maintained.Power consumption : 0.4 Kw X 24 Hrs X 30 Days X 12
Months= 3600 Kwh/Annum.
INVESTMENT:- ` 4000/.
BENEFITS & SAVINGS :- Total units saving 13860 Per year and ` 41040/year.
63
Name:- C.krishnamurthy Designation:-Asst. Manager. Department:-Electrical Department
TEAM WORK IN ENCON
EMPLOYEE SUGGESTIONS RELATED TO ENERGY CONSERVATION
TITLE: Power Saving through Local control Switch for 311 Conveyor belt in Limestone
Crusher.
PROBLEM FACED:- High power consumption.
RECTIFICATION DONE:- Provided Local Control for that Area lighting. Whenever requiredWe can switch
ON the lighting .
INVESTMENT :- ` 6500/-
BENEFITS & SAVINGS :- Reduction of 5110units/day and Savings ` 17731.7 / Annum.
PAY BACK PERIOD :- 4.3 months.
64
Name:-Guru Prasad . Designation:-Asistant Mananager . Department:-TPP.
TEAM WORK IN ENCON
EMPLOYEE SUGGESTIONS RELATED TO ENERGY CONSERVATION
TITLE:- Reduction of Auxiliary Power Consumption of TPP cooling tower Fan 2.
PROBLEM FACED:- High power consumption.BEFORE MODIFICATION: - Cooling Tower Fan of 30 KW , 1500 RPM , normally in continuous
operation in DOL mode at Full speed at all loading conditions of TPP.
AFTER MODIFICATION: - Installed VFD in Cooling Tower Fan -2, and speed is being regulated with
respect to the loading of TPP
INVESTMENT:- ` 32000/-BENEFITS & SAVINGS: - Net Power savings = 143865 Units / Annum .
Net Cost savings = ` 5 Lacs / Annum .PAY BACK PERIOD :- 1 months.
65
We at UltraTech Cement Limited (Reddipalayam Cement Works ) are committed to evolving and sustaining excellence in energy conservation to reduce cost of production & improve environment.
We will work continuously to conserve energy and achieve world benchmarks in terms of energy consumption in our process.
Fostering a culture of participation and innovation amongst employees for continual improvement in energy conservation.
Unit Head
ENERGY POLICY
RP MOV MOTOR DE TEMPRP MOV MOTOR NDE TEMPRoller Press1 CURRENTRoller Press1 LOADRoller Press2 CURRENTRoller Press2 LOADRP FIXED MOTOR DE TEMPRP FIXED MOTOR NDE TEMP
GCS CM RPMOVMOTORDETEMP
DEG CGCS CM RPMOVMOTORNDETEMP
DEG CGCS CM RP1CURRENT
AMPSGCS CM RP1LOAD
KWGCS CM RP2CURRENT
AMPSGCS CM RP2LOAD
KWGCS CM RPFIXEDMOTORDETEMP
DEG CGCS CM RPFIXEDMOTORNDETEMP
DEG C
Plot-0
7/26/2008 2:55:25 AM 7/26/2008 10:55:25 AM8.00 hours
61.2
61.4
61.6
61.8
62
61
62.2
44.5
48
30
80
100
800
50
120
400
1300
47
48.4
40
43
42.656
48.273
838.53
82.374
404.36
48.302
47.922
62.125
66
ENERGY MONITORING SYSTEMS
Ø ENERGY MANAGER software
ü Individual MCC’s wise and section wise power details.
ü Speed,load,current and running hours of all critical equipments.
ü Compressors, water pumps and bore wells running hours.
ü Start/stop power for all equipments
ü Other important parameters like draft,temperature, feed rate are
also monitored and recorded.
Ø Online monitoring of parameters in DCS.
Ø HT motors power and temperature details
• Daily Energy Report deviation analysis.
• Knowledge Manager.
• Daily Vibration & Bearing Temperature Deviation.
Monitoring
• PI system.
• Daily Monitoring of Utilization of Various Fuels.
• RMP system for raw meal
67
VARIOUS ENERGY MONITORING SOURCES USED
Roller Press1 LOADRoller Press2 LOADKILN MM LOADPH FAN LOADRM ESP FAN LOADCOAL ESP FAN LOADRM MM loadTPP LOAD
GCS CM RP1LOAD
KWGCS CM RP2LOAD
KWGCS KN MMLOAD
KWGCS KN PHFANLOAD
KWGCS KN RMESPFAN LOAD
RPMGCS KM COALESPFANLOAD
KWGCS RM MMLOAD
KWGCS KN TPPLOAD
KW
Plot-0
5/21/2008 5:40:00 AM 5/21/2008 5:50:00 AM10.00 minutes
0
500
1000
1500
-500
2000
-500
2000
0
350
-500
2000
0
500
-50
300
-500
2000
-1000
9000
-483.51
2000.0
-0.2766
0.49301
-7.8736
1.3343
1973.2
-0.30538
COOLER GRA TE 2 LOAD COOLER GRATE 2 SPEED UNDERGRA TE2 SETPOINT
GCS COOLER GRA TE2LOA D
KW
GCS COOLER GRA TE2SPEED
RPM
GCS COOLER UNDERGRATE2SETPOINT
mmWC
Plot- 0
9/24 /2009 1 :05 :55 A M 9 /24 /2009 4:26:07 AM3.34 hours
0
20
40
60
80
-20
100
-20 0
1000
0
100
0.0000
-124.12
-5.0070
0.1 1236861.38
79.931
9/24/2009 2:43:05.022 A M
68
METHODOLOGY ADOPTED FOR ENERGY MONITORING
ü Energy management cell with clear cut responsibilities
ü Daily monitoring of Energy Deviation report.
ü Benchmarking National/International/group wise/Cluster units.
ü Regular study of equipments on deviation and their analysis.
ü Process evaluation & identification of energy conservation scope.
ü Feasibility study of suggestions and designing proposals for
sanctions.
ü Taking corrective and preventive measures and ensuring
implementation.
ü Organizing internal and external Energy Audit survey.
• DAILY: ü Daily Energy deviation reportü Energy Task Force Meeting
WEEKLY:
ü Energy Conservation Meeting
ü Capex Jobs/Project Meeting
ü Section wise Fortnightly Review Meeting
ü Weekly Review
• MONTHLY:
ü Power Comparison with group units
ü Breakdown Analysis Report
ü Master Action Plan Meeting
ü Monthly Performance Meeting69
METHODOLOGY ADOPTED FOR SUSTAINABILITY
ISO 9001, 14001,18001& 27001
CERTIFICATION
70
AWARDS & ACCOLADES
71
•ISO 9001 (QMS) accreditation Certificate in 2001.•ISO 14001 (EMS) accreditation Certificate in 2001.•OHSAS 18001 (OHSMS) accreditation Certificate in 2003.•ISO 27001 (ISO/IEC) accreditation Certificate in Feb.2010.
ISO 9001 ISO 14001 OHSAS 18001 ISO 27001
AUDIT OBSERVATIONS (April-2010)
72
AUDIT OBSERVATIONS (April-2010)
73
AUDIT OBSERVATIONS (April-2010)
74
AUDIT OBSERVATIONS (April-2010)
7576
ENVIRONMENTAL INITIATIVES
27 3039
4960
69
1020304050607080
2004-05 2005-06 2006-07 2007-08 2008-09 2009-10
No
of P
lant
s in
Tho
usan
ds
77
Ø Trial run taken for different types of hazardous waste in presence of CPCB and TNPCB . Ø Clinker loading chute and accessories for tippers during loading avoiding the heavy dust generation and spillage.Ø Ripper Dozer is being used for Mines operation which is eco-friendly and total avoidance of drilling and blasting.
Ø Alternate Fuel Storage Shed For Systematic Storage Of Different Fuels In Closed Shed Eco-friendly.
Ø SOX & NOX Analysers in Cement Pant and thermal power plant.
ØIncrease in GCT Height in order to reduce the dust emission in raw mill stack by improving the efficiency of electro static precipitator.
Ø High Efficient auto tuning EPIC -2 controllers are installed in all ESP’s.
Ø Limestone transport vehicles are being covered with Tarpaulin and Emission certificate.
Ø Green belt developed inside plant as well as Colony .
Ø Noise protecting equipments like Ear plugs/Ear muffs, are used by personnel
ENVIRONMENTAL INITIATIVES
78
CLINKER SILO
COAL STORAGE YARD
LIME STONE STORAGE YARD
ENVIRONMENTAL INITIATIVES
79
COVERED CONVEYORS
ENVIRONMENTAL INITIATIVES
CONCRETE ROAD IN THE PLANT
80
ü Ripper Dozer used for Mining.
ENVIRONMENTAL INITIATIVES
81
ENVIRONMENTAL DAY CELEBRATION on 5TH
JUNE Inauguration Plantation – At Plant Prize Distribution
Plantation - Employees Plantation - School ChildrenPlantation - Family
members at Colony
82
UTILISATION OF RENEWABLE
ENERGY
Type of RES
InstalledCapacityin kW
2007-08 2008-09 2009-10
Energy Generate
d (kWh)
Annual Savings (Lacs
Rs)
Energy Generate
d (kWh)
Annual Savings (Lacs
Rs)
EnergyGenerate
d (kWh)
AnnualSavings(Laces
Rs)Wind (5*225) KW 2306750 69.2 1738109 76.6 2054163 71.2
Solar 500 W1650 0.30 10400 4.89 10400 3.66
UTILISATION OF RENEWABLE ENERGY
We are the first Cement Plant to register With TEDA (Tamilnadu Energy Development Authority) for 100 KW Solar Energy for colony usages.Expected Savings : 1.5 Lakhs units/Annum .Savings : ` 7.5 Lacs/Annum.Investment : ` 2 Crores .
84
UTILISATION OF WASTE MATERIALS
7550.6
8999.88666.6
5192.3
3620.1
3000.04000.05000.06000.07000.08000.09000.0
10000.0
2005-06 2006-07 2007-08 2008-09 2009-10
MT
TPP FLY ASH GENERATION & UTILISATION
85FLYASH GENERATED IN TPP IS COMPLETELY USED IN
PLANT
Less generation of flyash in TPP due to use of Lignite
27.5447.34
44.2659.23
25.0035.0045.0055.0065.00
2006-07 2007-08 2008-09 2009-10
KL
DG SLUDGE GENERATION & UTILISATION
86
DG SLUDGE GENERATED IS USED AS AN ALTERNATE FUEL & FIRIED IN THE CALCINER.
WASTE UTILISATION
SECOND RO PLANT REJECT WATER PIT
FIRST RO PLANT REJECT WATER PIT
SECOND RO PLANT REJECT WATER PIT
Pump for conveying Reject water to the
Cement Plant
Utilising reject / waste water from power plant with help of return valves to cooler for cooling purpose
Effective Usage of Reject Water in Process
88
REPLICATION ARISING OUT OF BEST PRACTICES THROUGH ASSOCIATES
1. Installation of New version of ABB Controller (EPIC-3) for Electro static precipitators.
2. Installation of Delta star converters for belt conveyors.3. Additional Cooling fan drives taken in DCS for interlocking.4. Installation of P-20 lighting energy saver in TPP (Thermal
power plant).5. Changing of Aluminum impeller by FRP (Fiber reinforced
Plastics) impeller in Kiln shell cooling fans.6. Retrofitting electronic temperature control devices in old and
manual window air conditioners for energy savings.7. Power factor is maintained greater than 0.98.8. Installation of VFDs for the Cooling water circulation pumps to
optimise the water flow to the condenser for the TG set .9. VFD for cooling towers.10. Optimisation of running of air compressors using Compressed
Air Management System.
UNIT INITIATIVES TOWARDS CEMENT SUSTAINABILITY & REDUCTION IN CO2
EMISSION
89
• We are a member of CSI (Cement Sustainability Initiative) reporting.• Marl usages in raw mix there by avoiding the use of pure limestone ,white clay
& black cotton soil.• Usages of Natural gypsum (low purity) , which reduces the clinker
consumption in cement.• Increasing the consumption of dry flyash up to 27 % in PPC Production.• Use of Ripper dozer for mining operation ,there by eliminating drilling &
blasting.• Engaging DUPONT for improving safety standards in side Plant & Colony.• Increased Blended cement production.• Use of Various high calorific value waste fuels in pyro processing.• Tamilnadu Government has selected our unit for consumption of Plasticsin
SOCIAL ACTIVITIES
• Identified 15 Villages from 4 Panchayats
•Focused on Education, Health, Welfare, Infrastructure development, Sustainable livelihood,
•Building Partner ship with Government, Non-Governmental Organisation, Hospitals etc..
•Exploring Government Schemes
•Preparing planning & Budgeting activities
•Mobilization of Fund (Contributing with Government’s various Social welfare activities in terms of finance & infrastructure facility)
• Implementing Projects & Activities
•Support on Disaster Management (Fire, Flood, Medical Emergency etc..)
PROCESS ADOPTED
90
SOCIAL ACTIVITIES9th UltraTech Merit Awards Distribution
91
SOCIAL ACTIVITIESEye Camp
92
Toilets at Village Schools
Compound wall at Village school
Drinking water at Village Schools
AWARDS & ACCOLADES
93
•Global Cement Awards, Lowest Specific Energy consumption, clinker grinding –2006. •Lowest Specific Energy Consumption, raw meal grinding - 2006.•National Energy Efficient Unit Award by CII (2004 & 2006,2007 & 2008)•National Excellent Energy Efficient Unit Award by CII - 2009•NCCBM Best Electrical Energy Performance Award 2008-09
•NCCBM Second Best Improvement in Thermal Energy Performance Award 2008-09
AWARDS & ACCOLADES
94
ENERGY
CII Energy Award 2009 NCCBM Award 2009
AWARDS & ACCOLADES
95
ENVIRONMENT•Greentech Environment Excellence Silver Award 2006 & 2009
•Global Cement Award Lowest specific CO2 emission - 2006•Most Innovative Scheme for environmental impact abatement - 2006.•FICCI Environment Sustainability of Business Award 2006 – 2007 .
FICCI AWARD Greentech Environment Award 2009
AWARDS & ACCOLADES
96
SAFETY•State Level Safety Award from Tamil Nadu Government (1999,2000,2005 & 2006)
•Safety Appreciation Award from NSC TamilNadu Chapter 2003•Greentech Safety Award - Bronze in 2006 , Silver in 2007 & Silver in 2010.•Two First Prizes State Level Safety Award from TamilNadu Government
(2005 & 2006) n•Global Cement Awards Lowest Injury Incidence Rate – First prize ($1000).(2006)
•Golden Peacock Award GPOHSA 2009 & 2010 .
State Government
Safety AwardGolden Peacock Award 2009 &
2010GreenTech Safety Award 2010.
Global Cement
Award
AWARDS & ACCOLADES
97
•WCM Chairman’s Award for Manufacturing Excellence – Bronze Award in 2002
•WCM Chairman’s Award for Manufacturing Excellence – Silver Award in 2004
•WCM Chairman’s Award for manufacturing Excellence – Gold Award in 2009.•5’S Excellence Award by CII – 2005
•Best Kaizen Award in Kaizen Mela Competitions – 2008
WCM(World Class Manufacturing)
Chairman’s Gold WCM Silver WCM Gold Award
98
ThankYou
“Commitment unlocks the doors of imagination, allows vision and gives us the ‘right stuff’ to our dreams into reality”.
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