Best Practices in Energy Efficiency

Chanda Cement Works Chandrapur Maharashtra

2

ACC’s brief profile

• Tikaria

• Kymore

• Damodhar • Chaibasa

• Jamul

• Sindri

• Bargarh • Chanda

• Gagal

• Madukkarai

• Wadi

• Lakheri • Tikaria

• Kymore

• Damodhar • Chaibasa

• Jamul

• Sindri

• Bargarh • Chanda

• Gagal

• Madukkarai

• Wadi

• Lakheri

3

ACC Chanda

Ultratech Manikgarh

ACL Maratha

Maharashtra

Chandrapur District

Murali

Plant Location

Location : Ghugus Taluka - 27 KM from Chandrapur and 165

KM from Nagpur in Central Railways

Plant is certified with ISO-9001:2008,ISO-14001:2004 & ISO-

50001:2011

4

Chanda Cement Works…Bird’s Eye View

Chanda cement works – 7000 TPD, single line clinkering and 3.4 million

Ton cement capacity

5

Chronology of Up-gradation

Commissioned in 1970,Chanda is the first cement plant to be set up in the

state of Maharashtra

Lime stone Reserves-

Sindola Mines : 17 km from plant ( Aerial : 8 Km)

Govari Mines : 25 km from plant (Aerial-14 Km)

Limestone bond index : 8-10 Kwh/Sh.T (Govari) and 12 Kwh/Sh.T

Sindola)

Clinker bond index : 17.4 Kwh/T on dry closed circuit basis

2 Kilns with 4 stage

Preheater

Installed Mitsubishi Fluidized Calciner (MFC) in

preheaters

VRPM for cement Mill-

1&2

New 6 stage pre heater

with SLC & 15 MW CPP

New Clinkering line with cement

mill no.3 & 25 MW CTPP

1970 1980 1995 2000-02 2010

6

Moment of Pride for Chanda…

Chanda is adjudged Best Plant in

Holcim India for two consecutive

years (2013 & 2014) based on

Operational Performance Indices

Chanda’s Thermal Energy

consumption is lowest in Holcim

globally & in India

Chanda is 2nd Best Plant in

Electrical Energy in Holcim (South

Asia)

First LEED

PLATINUM Rated CCR in India

Base line Gate to Gate Specific Energy consumption - 898 Kcal/Kg

Target for PAT cycle-I- Kcal/kg (5.12%)

Estimated SEC during the Assessment Year 2014-15: kCal/kg (14.58%

reduction from baseline)

7

Implementation of ISO-9001 has helped to remain vigilant to avoid any

lapses on quality parameters and commit ourselves to supply quality

products to customer on time

ISO-14001 with its focused approach on environmental protection has led

to taking proactive steps in combating pollution with long term vision of

sustainable development, which in turn has fuelled initiatives for finding

ways for optimum energy consumption

Implementation of Energy Management System ISO-50001:2011 has made

a coherent contribution among various wings of energy saving activities:

Consistency in running of cement plant has improved Plant Load

Factor of Power Plant

Increased PRI (5.5% improvement) and MTBF (increase from 47 to

280 hrs) has led to lower energy consumption per ton of cement

production

Created renewed and focused awareness on energy conservation and

has led to many initiatives in energy savings.

Role of Management Systems in Improving Energy Efficiency

8

8.5%

8.8%

3.1%

5.1%

40

45

50

55

60

65

70

75

80

EE-Clinkeringimprovement

Chanda’s Journey…in Energy Efficiency

8.2%7.2%

2.2%6.2%

0

20

40

60

80

100

EE-Total improvement

4.75%

7.9%

-1.75%

5.9%

27

28

29

30

31

32

33

34

35

36

37

EE-Grinding improvement

4.1%

1.8%

Overall 6%

2850

2900

2950

3000

3050

3100

TE improvement

Operating Kiln with higher burner momentum (12-14 N/MW) results in-

Use of low cost and high ash Indian coal Better clinker phases-increased C3S content Short burning zone and better refractory life Use of less excess air and ultimately Lower thermal energy consumption

Increasing clinker bed height pressure from 900 to

980 mmwg in cooler inlet by process optimization results in-

Increased heat recuperation and cooler efficiency Less excess air for burning process Fast cooling of clinker and better clinker phases Less wear of equipment and better reliability

Increased secondary air temp (>1100 deg C) and

tertiary air temp (>950 deg C) resulting in better calcination

Uniform coal mix (Coal pile formation done in auto mode) resulting in better thermal efficiency

False air reduction in the circuit False air ingress in the system reduced to ~6-9%

Improved uniformity of Raw Meal by auto mode of spider discharge operation for CF silo filling Stable kiln operation and better control

Operational Best Practices & Performance Improvement-Thermal Energy

4.1%

1.8%

Overall 6%

2850

2900

2950

3000

3050

3100

TE improvement

41%

500

700

900

1100

2014 YTD-2015

Crusher TPH improvement

14%

1.9

2

2.1

2.2

2.3

2.4

2.5

2.6

2014 YTD-2015

EE RMtP improvement

Operational Best Practices-Crusher

Significant improvement in crusher throughput by few operational changes-

Change in operational strategy (two shifts operation in place of earlier three shifts and maintenance in day shift)

Better fleet management-increase in number and

capacity of trucks, provision for truck maintenance in near by area

Improvement in road condition from Mines to crusher (6 KM long)

Better co-ordination among mines and crusher operation team has led to reduced frequency of hopper empty out

LSF reduced from 121 to 116 improving mines life by at least five years without compromising on quality

Power consumption reduced by 14 %

Operating Limestone Pile with full capacity @ 30000 tons

Reduction in false air from 9%

to 6% Putting additional magnetic

separator at Reclaimer discharge belt reduced reject diversion and helped in improved mill throughput

Extension of feed pipe for better

bed profile and material re-circulation

Reduced empty height from

1.72 mts to 1.09 mts Reduction in dust circulation in

the system resulting in lower mill DP which helps in increasing mill feed rate

Operational Best Practices-Raw Mill VRM

Optimization in dam ring height from 40 mm to 20 mm

Stable bed, resulting in reducing the Mill

vibration from 0.8-1.1 mm/s to 0.6-0.8 mm/s

Removal of orifice plate (used for mill

operation by CCR operator) from fan duct resulting in less pressure drop in the circuit

Ensuring usage of crushed Laterite ore

(high Iron %) to avoid reject diversion by metal detector in Raw Mill

3.4%

16.4

16.6

16.8

17

17.2

17.4

2014 YTD-2015

EE Raw Mill improvement

Performance Improvement in Raw Mill Power

7.3%

520

540

560

580

600

2014 YTD-2015

RM TPH improvement

Achieved 572 TPH in YTD May-15 in spite of

lower grinding pressure

Coal Mill Bag house false air reduction from 26% to 12 %

Coal tippler feed screen size optimization

(300X300 mm opening in place of original 300X100 MM)

Installation of screen below coal mill weigh feeder

Reduced false air in PH system- from 12 % to

6-9 %

Reduced Clinker temperature by better nodulization

Higher Tertiary air (>9500 C) and Secondary

air temperature (>11000 C) on consistent basis

Optimized specific cooling air in cooler~1.6 Nm3/kg clinker (>2.0 Nm3/kg clinker as per standard norm)

Increase in fuel transport load- kiln coal firing

from 3.07 kg/M3 air to 4.4 kg/M3 air

5.5%

7000

7200

7400

7600

7800

2014 YTD-2015

Kiln TPD improvement

Operational Best Practices-Kiln and Coal Mill

3.8%

24

24.5

25

25.5

26

26.5

2014 YTD-2015

Electrical Energy-Kiln improvement

6.4%

20

25

30

35

2014 YTD-2015

EE CM-3improvement

10.3%

230

250

270

290

2014 YTD-2015

CM-3 TPH improvement

Operational Best Practices in CM & Performance Improvement in Grinding Power

Reduced 1st chamber length by 0.9 m for better efficiency in CM-2

Optimization of nozzle velocity inside the mill

Optimization of bag house purging sequence for

uniform feeding to silo feed elevator, creating margin for feed increase in mill

False air reduction in the circuit from 15% to 12%

Increased cement mill output by 10% in YTD May-15

Clinker factor improvement by improving fly ash usage and reduction in OPC % contributed to some extent in over all power improvement

VFDs are used in all fans, belt conveyors, pan conveyors etc

VFDs are used in compressors and water pumps

MV drive is used with VFD system in all major process fans such as pre heater fans, bag house fan, coal mill fan and cement mill separator fans

Installation of VFDs in CPP pumps and major fans are under

implementation

MOC of Kiln shell cooling fans and cooling tower fans are replaced with FRP blades

All conventional lights are being replaced with LED lighting system inside

the plant and colony

Lighting energy saver panels are installed across the plant

Introduction of HT AFC in raw mill circuit for better power factor management

CPP generation frequency is set at 49.7 Hz

Other Best Practices

ACC Limited

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Communication

Capability

building

Knowledge & data

management

Core Services

Boot Camp

COE Centre Of Excellenc

e

Plant Visit Deep Dive & data analysis Find out Encon scope Prepare Road Map Achieve Asp. target

Energy Module Energy Hand book Case study Best Practices HEAT map

Training Model Plant Sharing B.P Benchmarking Dream run Award & Recognition

Newsletter Community meet Conf call WAR room performance dialogue

Model Plant tour Experiential learning Live measurement & calc Sharing best practices Soft Skill training

Chanda - 1st Regional Model Plant-EE

2

Best Practices SnapshotsDescription

Well defined training calendar & attainment of training for

concerned

employees

G

Training calendar for EE definedfor all concerned employees

All concerned employees has100% training attainment forenergy efficiency courses

Weekly updation of plant level dash board

E

Weekly updation of plant leveldash board

Review of EE performance inoperation head review

Monitoring of high tension motors & low tension feeders

F

Illustration

Dash board,

Dashboard

Dashboard & visual display

McKinsey & Company 18

Working D

raft -Last Modified 13/09/2011 17:38:54

Printed

|

Step 2: Piston rod assembly – Work station 1 (w/s 1) (1/2)

Step 2a Select piston rod from the jumbiki (A) as per

the order specifications

▪ The rods are to the right of the code

marked on the Jumbiki. For example, if the

work order calls for V4, locate V4 on the

Jumbiki and pick the piston rod to the right

of the label

1 secA

Step 2b Place in the appropriate sized fixture groove

▪ The “square side” indentation is positioned

in the groove (A)

▪ Slide the clamp to hold the rod steady (B)

▪ The threaded side of the rod is on the

top (C)

A 1.4

secB

C

Step 2c Select appropriate piston head

▪ For Φ 25mm, select LK1; place head with

projecting fastener on top (A)

▪ For Φ 40mm, select LK2; place head with

flat face on top (B); insert washer and

screw on the fastener nut (C)

1.9

secA B

C

STAGE 3 SOP

Description

Time

taken

(sec)Illustration

All high tension drives & lowtension feeders have energymeters attached for central onlinemonitoring

Power factor

maintenanceH

Daily measurement, analysis,problem-solving and taking ofnecessary action of power factormaintenance issues

Dash board,

1

Best Practices SnapshotsDescription

Energy audit in every three years by CII

C

External energy audit conductedby top tier / class A / wellrecognized agency

Audit by external agency in everythree years

Benchmarking of electrical key result areas

D

Annual benchmarking of electricalkey result areas to regional/globalbest performing plants, problem-solving sessions and tracking ofimplementation of new ideas

Section level energy circles with well defined key EE result areas

A

Section level energy circles existsand has well defined EE keyresult areas

Semi annual internal audit by qualified PPE certified professionals

B

Qualified internal auditors withEnergy Audit Certification

Semi annual electrical energyaudit & tracking of ideas

Illustration

Dash board, visual display

Visual display

Dashboard

Dashboard

11

Best Practices SnapshotsDescription

B-Level AuditE

Conducting the B-Level auditannually. Problem solving on theperformance parameter of themill.

Co-ordination of production schedules with CPP

F

CPP co-ordination with thecement mill to minimize energywastage

Illustration

Dashboard

Dashboard, commentary

Institutionalizing the EE Improvement Programme

Thank You

For further information, please contact:

Mr. Tapendu Datta, Head - Energy Conservation & Renewable Energy

& Projects, ACC Limited, tapendu.datta@acclimited.com