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Integrity Commitment Passion Seamlessness Speed

ULTRATECH CEMENT LIMITED

Andhra Pradesh Cement Works, Tadipatri

Energy Excellence

We Preserve We ConserveWe Prevent

Confederation of Indian Industry GreenCo Certified Company


Unit Vision & Mission

Vision 2020

To be a Model Cement Plant by 2020 with a clear focus on Safety, Environment,

Quality, Cost, Productivity, Delivery, Employee & Societal Satisfaction.

Mission 2020To deliver superior value to our customers, shareholders, employees and society at

large with Systems & Team based, Safe & Environment friendly work culture through

Innovation, Skill up-gradation, Conservation and Technological up-gradation

adhering to Aditya Birla Group Values.


Key Focus Areas

Focus Areas

• Safety, Health & Environment • Quality & Customer Orientation

• Employee Engagement • Societal Satisfaction • Operational Excellence

Energy Excellence


Milestones & Achievements

First ISO:50001:2011 certified unit among

the ABG cement units

Achieved 28,206 ESCERTS in PAT

cycle-1

Established first of its kind(in

India) WHRPP

First Time Classifier Replacement in the world, in Loesche

Cement Mill(53.3+3) as Joint Improvement

Project

Successfully completed Steam blowing with coal

in place of HSD for Boiler#4 (first time in the history of Thyssen Krupp

Boilers)

Best Energy performance awards every

year


Energy Policy and its Implementation

Energy Policy implemented in Dec – 2011. It provide the

framework for setting and

reviewing energy objectives

Energy Policy states unit’s commitment

towards continual energy

performance improvement.

Energy policy is documented and communicated at

all levels.

Energy policy is regularly reviewed

and updated as necessary. Last

reviewed on 16th

December 2017


Energy Roadmap

Energy CellFunctioningFocus Area

Restoring basic condition of equipment Effective PM07

Process/energy optimisation

Technological up-gradation

Awareness / Campaign

Knowledge management

Focus Area-

❑ Crusher - Granulometry❑ Raw Mill - RM Fan and Table

Power, Separator performance❑ Coal Mill - Fan & Table,

Separator performance❑ Kiln - KS, CS & CV Fan, False air❑ Cement Mill - MD Power,

Separator & Fan performance

❑ Compressor - Volumetric efficiency,Leakage

❑ TPP &WHRS – Heat Rate, Aux. Power

Cons. & OEE.


Energy Conservation organization in plant

Executive President Unit Head

FH-TechChampion

LSC RM KCC CM Packing WT Clinker

LoadingCPP

AC,P&V

Township Utilities

Energy Manager Energy Cell

LSCPower

Taskforce

KCCPower

Taskforce

UtilitiesPower

Taskforce

CMPower Taskforce

Packing PlantPower Taskforce

WTPower Taskforce

CPPPower

Taskforce

RMPower

Taskforce


ISO:50001:2011 Certification


Energy Performance Improvement over 2016-17 to 2017-18

Sl. No Description Units 2016-17 2017-18 Remarks

1 MTOE Reduction MTOE 7262 8536

2 Kiln Thermal SEC kCal/kg cli 726.1 717.9

3 Specific Electrical Energy - clinkering kWh/T of clinker 66.73 65.61

4 Specific Electrical Energy – Grinding kWh/T of cement 28.33 29.5

Introduced PPCS -17% lower Fly ash as an alternative to OPC and reduce in Co2 emission

5 CPP Heat rate kCal/kWh 3118 3149

6 CPP auxiliary consumption % 10.01 10.00

7 Thermal Substitution Rate % 1.2 4.43

8 Clinker factor % 82.25 81.1

9 Blended cement *%) of total cement % 40.2 45.22

10 Renewable Energy (RPO)

11 REC Purchased – Solar REC 804 10087

12 REC Purchased – Non Solar REC 15639 20175

13 Specific CO2 emission Kg CO2/ kg cement 697.39 681.7


Energy Projects implemented in 2017-18

Sr. No. Project DescriptionSpecific energy reduced

,KWH/MT material

Financial savings ,Rs. Lakhs/annu

m

PAT benefit (MTOE

reduction)

Environment benefits like fossil fuel saved

(MT Coal Saved/annum)

CO2 reduction in MT(considering 92.8Kg CO2/GJ) as per WBCSD-

CSI

1Down comer duct pressure drop reduction by fans(PH-2 ) suction box modification

0.75 103.4 736.8 1424 2859

2Removal of RM - 3& 4 fan inlet dampers to reduce power consumption.

0.37 76.5 545.4 1054 2116

3Partition wall shift in line 2 cooler from 13mts to 19mts from start and reducing velocity at the cooler takeoff by increase in duct area

6 Kcal/kg clinker 191.0 1834 2352 7117

4CM5 Bag house ventury duct replacement with straight duct to reduce pressure drop

1.05 46.1 328.8 635 1276

5Line 2 Mill 3 Raw Mill Fans suction box Modification

0.41 65.5 600.5 1161 2330


Energy Projects implemented in 2017-18

Sr. No. Project DescriptionSpecific energy

reduced ,KWH/MT material

Financial savings ,Rs. Lakhs/annu

m

PAT benefit (MTOE

reduction)

Environment benefits like fossil fuel saved

(MT Coal Saved/annum)

CO2 reduction in MT(considering 92.8Kg CO2/GJ) as per WBCSD-

CSI

6

Modifications Kiln 2:1. Fan Inlet box modification ( Preheater fans and Bag-house fans)2. Preheater 3rd Stage Cyclone height increase 3.Down comer duct modification-Area increase4.Baffle plates in 4th stage riser pipe.

0.88 137.8 866.2 1674 3361

7Process optimization of cement mills alongwith thin classifyig liner modification and grinding media piece weight optimization.

2.00 545.8 1055 2118

8Optimisation of Phase-2 raw mills to reduce the Sp.Power consumption- dam ring reduction and process optimisation

0.22 45.7 326.1 630 1265

9 KIln1 and 2 low nox burner installation 3 Kcal/kg clinker 117.0 917 1176 3558

10Petcock residue decrease to 2% from 3 .5% thereby reducing power in kiln through combustion optimization.

0.32 48.5 311.2 602 1208


12

• Fan Inlet box modification ( Preheater fans and Bag-house fans)

• Down comer duct modification-Area increase

• Preheater 2nd Stage Cyclone height increase

• Preheater 3rd Stage Cyclone height increase

• Baffle Plates in 4th Stage riser pipe

Modifications For Power Saving in Pyro-Processing


Preheater Modifications

1.Preheater Fan Inlet box modification from 1150X3525mm to 1550X3525mm

1150 1150

1550


RABH Modifications

2.RABH fan Suction box modification(200mm to 350mm in bottom and 735mm to 1100mm at the top-damper level)

735


Velocity profile

Outlet = 30.9 m/s

Inlet = 19.1 m/s

EXT

Velocity at fan inlet boxreduced by 7 m/s !!

Outlet = 30.1 m/s

Inlet = 19.1 m/s

EMF

Outlet = 23.6 m/s

Inlet = 19.1 m/s

MFI


Pressure profile

Outlet = 0.2 Pa

Inlet = 284.1 Pa

EXT

Outlet = 0.2 Pa

Inlet = 110.4 Pa

MFI

Reduction in pressuredrop = 17 -22 mmwg !!



3. Roof & riser extension by 1000 mm in stage-2 cyclone

1000 mm


4. Roof & riser extension by 500 mm in stage-3 cyclone


500mm


Velocity profile

Modification done Before Modification After Modification



5.Baffle plates in 4th stage riser pipe-650mm width 400mm from cyclone roof in riser on 4 sides 90 deg. Each.


Model



Velocity profile


Trajectory Profile





6. Down comer duct modification-Area increase


Savings after modifications

Total savings in PH fans UOM Before After

Pressure Reduction mmWg 828 736

RPM Reduction rpm 828 786

Net Saving achieved kWh 3503 3164

PH fan String 1 UOM Before After

Kiln feed TPH 638 638

Pressure at fan I/L mmwg 830 738

Fan speed rpm 830 784

Fan Kwh kWh 1770 1588

PH fan String 2 UOM Before After

Kiln feed TPH 638 638

Pressure at fan I/L mmwg 826 735

Fan speed Rpm 827 788

Fan Kwh kWh 1733 1576

Savings of 0.84KWH/MT Clinker


8800

9150

9500

9800

29.3 28.9

27.23

25.37

8200

8400

8600

8800

9000

9200

9400

9600

9800

10000

15

20

25

30

35

Base data With Raw MixOptimization

With Petcoke residueoptimization

With modifications andProcess Optimization

TPD

KW

H/M

T

Action

Kiln TPD Sp.Power

Kiln Specific Power Consumption reduction Action wise


26

Key Challenges during Implementation

• Fitting the best model as per available Civil structure.

• Optimization with modified parameters to achieve the desired results.

• Executing the Job safely in space constraint.


Key Learnings

• Identifying potential in the system is the Key.

• Input measurements are the Key for the Model.

• Ensuring the best alternatives amongst the available models in coordination with all the stakeholders gives effective results.

• Optimization with modified parameters is also very important.

• Accurate Input measurements would give effective results.


Innovative Ideas in pipeline

❑ Up gradation of Line-2 Cooler with high efficient cooler to reduce the Specific Heat consumption from 716 Kal/Kg clinker to 690 Kal/Kg clinker.

❑ Expert Optimiser for kiln and mill operation.

❑ Thermal oil heater for WHRS output optimisation.

❑ All Bag filter operation in DP mode.

❑ Pressure Drop reduction in Line-2 Preheater Down-Comer.

❑ Line-1 Raw Mill-1,2 Fan impellers replacement with high efficient impellers.

❑ Line-1 Preheater Fan impellers replacement with high efficient impellers.

❑ Line-1 Down-Comer Pressure Drop Reduction.

❑ ACC Bundle replacement

❑ PH-1 feed water interconnection after HP Heater

❑ PH-1 Boiler-2 Tube replacement


Innovative ideas implemented in 2017-18

1

Modification in Preheater for Pressure drop reduction based on CFD analysis-in house : 1.Baffle plates in 4thth stage riser pipe. 2. Stage 2 Cyclone entry modification 3.Roof & riser modification in stage-3 cyclone 4.Down comer duct modification

2Fan Engineering related modifications without effecting efficiency for Preheater fan Fan -2 No.s,Raw Mills fans-4 no.s,Bag housefans-2 no.s and Cement Mill fans-2 no.s

3Partition wall shift in line 2 cooler from 13mts to 19mts from start and reducing velocity at the cooler takeoff by increase in duct area

4 Venturi removal in Mills for reducing Pressure drop and operating fans in auto mode with KW

5 Low pressure compressed air areas identified like flyash unloading etc and connected to low air pressure compressors.

6 Optimizing bag filters in Differential pressure mode thereby reducing compressed air connsumption.

7Idle running of equipment's reduced using timer and other parameters of automation and other features like single command forstarting mills etc.


Renewable Energy Projects under implementation

❑ Offsite solar and wind project

Particulars CapacityGeneration

(1 MW)(In lacs kwh p.a.)

Total Generation (in lacs kwh)

Solar Generation 16 16.20 259

Wind Generation 11 30.00 330

Total 27 46.20 589

The setup of solar power plant of 25 MW DC and Wind Power plant of 16 MW under Long term Open Access on captive basis is under implementation.


Awards and Accolades

AP State Energy Conservation Award – 1st Prize for the year 2011-12” instituted by Non-conventional Energy Development Corporation of Andhra Pradesh in appreciation of its effortsin Energy Conservation

Energy Efficient Unit” by Confederation of Indian Industry in appreciation of its efforts in EnergyConservation - 2012

“AP State Energy Conservation Award –2nd Prize for the year 2012-13” instituted by New &Renewable Energy Development Corporation of Andhra Pradesh in appreciation of its efforts inEnergy Conservation

“Energy Efficient Unit” by Confederation of Indian Industry in appreciation of its efforts inEnergy Conservation – 2015

APCW has received Confederation of Indian Industry GreenCo Gold Award - 2017

APCW's CPP has bagged the “ Excellent Energy Efficient” unit award at the CII Energy Efficiency Summit held at Hyderabad by Confederation of Indian Industry(CII) - 2017


AWARDS & ACCOLADES

State Energy Conservation Award for 2011 - 2012

National Award for Excellence in Energy Management in 2012

State Energy Conservation Award for 2012 - 2013

National Award for Excellence in Energy Management in 2015

CII GreenCo Award – Summit 2016


Thank You

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