ltd. … · rmx plants : 72 cement plants : 6 aggregate plants : 2. date | 5 mejia cement plant...

3Date |

Acquisition of Tata Steel’s Cement Business.

Acquisition of Raymond Ltd’s Cement division

Launch of ConcretoCement

Mejia plant commissionedSonadihCement plant Line 2 addedAcquisition of L&T’s RMX business

Cement business expansion in North

East GU, Clinker de-bottlenecking,

Further expansion projectsLafarge India Limited becomes part of NirmaLimited following divestment from LafargeHolcim

Lafarge India Limited is rebranded

NuvocoVistas Corp. Ltd. (continues to sell products under the Lafarge Brand names

2006-11

2016

20022001

1999

2013-14

2017

RMX Plants : 72

Cement Plants : 6

Aggregate Plants : 2

5Date |

Mejia Cement PlantCement Grinding1.65 MT

OUR HISTORY❖ Mejia cement plant is the

first green field project of our earlier company (Lafarge India Ltd.), it is a grinding unit with present capacity of 1.65 Million Tons per annum.

AREA

❖ 62.26 acres

MANPOWER STRENGTH❖ Permanent Employee Approx 56 Nos❖ Contract manpower Approx 436 Nos

RAW MATERIAL❖ Clinker – Received by rail from

Sonadih cement Plant and Arasmeta Cement Plant

❖ Chemical gypsum – Received by rail from various sources.

❖ Fly-ash – Through Pipeline from DVC

PRODUCTS❖ Duraguard❖ Duraguard MF❖ Infracem

MODE DISPATCH ❖ 45 % despatch by rail

❖ 55% by road.

• Inking of Agreement with DVC

• Start of Project

• Commissioning of Project

• First Cement Dispatch by Road

• First Cement Dispatch by Rail

• Consent to enhance from 1.0MTPA to 1.5 MTPA obtained from WBPCB

• Consent to enhance from 1.5MTPA to 1.65 MTPA obtained from WBPCB

• Awarded with National FICCI CSR Special Jury Award (on Women Empowerment)

• Awarded with Golden Peacock for Health and Safety

• Certified with ISO 14001 : 2015

• Awarded with CII SHE Excellence Award

• Awarded with CII Energy Efficient plant

• MOU with DVC

• Consent to establish for

1.0 MTPA obtained from WBPCB

2001

2006

2009

2012

2015

2016

2017

2018

Temperature

Pressure

Air/Gas flow

Sample

kW

kW

kW

kW

kW

rpm

clinker Gypsum

Fly ash

Reject SFM

Separator

Mill vent fan

Recirculation duct

Separator fan

Mill vent BH

Separator BHFresh air damper

Cement Silo

Stack

Cement mill9.23 Tph

122.1 Tph

62.0 Tph

95 Deg C

Equipment Capacity Make

Ball Mill 150 TPH KHD

Mill Motor 2*2550 KW C.G.

Packer 3*180 TPH Enexco

Clinker Storage 22000 Ton KHD

Cement Storage 12000 Ton KHD

Gypsum Storage 2*4000 Ton KHD

Wagon Tippler 20 Tips Per Hr Elecon

FY 15-16 FY 16-17 FY 17-18

29.86

29.21

28.04

OVERALL PLANT SPC Plant Section FY 15-16

FY 16-17

FY 17-18

Grinding SEC 28.18 27.58 26.59

Fly Ash BulkerHandling

1.64 1.47 1.46

Packing SEC 1.67 1.62 1.19

Overall Mejia Plant SEC

29.86 29.21 28.04

6.01% over FY 15-16

FY 15-16FY 16-17

FY 17-18

28.18

27.59

26.85

Overall PPC Grinding SEC Section FY 15-16

FY 16-17

FY 17-18

Mill Main Drive

22.79 22.20 21.81

Separator & Bag house Fan

1.28 1.42 1.50

Mill Auxiliary 2.66 2.48 2.41

Mill Utility 1.44 1.48 1.11

Overall PPC Grinding SEC

28.18 27.59 26.85

4.71% over FY 15-16

FY 15-16 FY 16-17FY 17-18

1.681.62

1.19

Overall Packing & Shipping SEC

PLANT SECTION

FY 15-16

FY 16-17

FY 17-18

Packing Plant MCC

0.908 0.897 0.585

Packing Plant Utility

0.768 0.725 0.603

Overall Packing SEC

1.676 1.622 1.188

29.16% over FY 15-16

PLANT Plant-1 Plant-2 Plant-5 Plant-6 Plant-7 DCW-Durgapur

UTCL-Durgapur

Ambuja-Sakrail

NVCL-Mejia

Ball Mill Closed Circuit

Rated Capacity

TPH 133 200 - - 200 150 130 90 150

Operating Capacity

TPH 143/186

225 195 205 200 155 192 105 204.5

Overall Plant

SEC/MT

27.8 28.7 30.4 30.8 31.9 38 29.5 36.5 28.04

27.81 28.74 30.4 30.78 31.9238

29.536.5

28.04

❖ Second Best at National level as per CII Benchmark

2.b. National Benchmark (Cement Grinding SEC)

27.16 27.59 29.13 29.37 30.536.05

27.14

35

26.85

❖ Best at National level as per CII benchmark


UTCL-Durgapur

Ambuja-Sakrail

NVCL-Mejia

Overall Grinding

SEC/MT 27.2 27.6 29.1 29.4 30.5 36.1 27.1 35 26.85

2.b. National Benchmark (Packing & Shipping SEC)

0.65

1.15 1.27 1.41 1.42

1.952.35

1.51.19

❖ Top 3 at National level as per CII Benchmark


UTCL-Durgapur

Ambuja-Sakrail

NVCL-Mejia

Overall Packing

SEC/MT 0.65 1.15 1.27 1.41 1.42 1.95 2.35 1.5 1.19

❖ Bench marking done with other plant in Group & National Level.❖ Conducted Energy Audit through CII and got good action points for implementation❖ Prioritized and formulated plant overall SEC target with Management Steering

Committee.❖ Objective set to optimize SEC , Stretched SEC target included in KPI of all concerned

and taken as plant’s one of the primary objective.❖ Energy committee formulated and members are empowered to take decision on any

operational points related to power optimization.❖ Dynamic monthly SEC target set and monthly SEC tracking done by Management

Steering Committee in cost meeting.❖ Priority discussion on shop wise power consumption in Daily Operational meeting.❖ Formulated special task force team for identification and rectification of

compressed air leakages.❖ Specific inspection done as per power mastery guideline.e.g:

✓ Major fan efficiency, separator efficiency, mill volume loading,✓ compressor performance test, Particle size analysis by different samplings

etc.❖ Compressor run hour management supervised by shift in charge, tracking of

compressor loading / unloading hour.❖ Energy Management training conducted at Group Level for key personnel.

Sl Action Plan Energy Saving

kWH/Yr

Savinsgin mINR

Investment mINR

SEC reduction

1. Installation of VFD in Aux. Bag filter Fan to avoid pressure loss across the damper

235,205 1.29 0.35 0.151

2. DP Mode operation of Vent bag house & optimizing compressed air consumption

120,000 0.66 0.15 0.077

3. Addition of low rating Process Pump for Shutdown duration

10,920 0.06 Zeroinvestment

0.007

4. Modification & de-rating of auxiliary circuit motors


0.033

5. Optimization of Process water pump power by rerouting of water pipeline

23,760 0.13 0.30 0.015

6. Blade angle optimization & motor de-rating of Cooling tower fan


0.007

Total no. of Projects : 32

Project with Zero Investment : 21

Project with Investment : 11

Total Energy savings : 44,43,675 kWh

Total Cost Savings : 25.12 mINR

Sl Action PlanEnergy Saving

kWH/YrSavinsg in

mINRInvestment

mINRSEC

reduction

1.Modification of Wagon Tippler lighting system with DCS control

8,856 0.05Zero

Investment0.006

2. Adding Flyash at Cement Mill outlet 545,892 3.00Zero

Investment0.399

3.Optimization and review of raw material transport circuit idle running during clinker and gypsum unloading

109,178 0.57Zero

Investment0.079

4.Optimization of Packing Plant Compressoroperation as per Packer operation to reduce Packing power

24,000 0.11Zero

Investment0.017

5.

Optimizing of Compressor load to minimize the loading hours by tuning the load/unload settings as per actual requirement

64,000 0.29Zero

Investment0.046

6. Installation of Process Optimizer LUCIE 436,714 2.28 0.15 0.319


kWH/YrSavings in mINR

Investmentin mINR

SEC reduction

7.Modification of de-dusting line for Clinker Extraction conveyors with installation of shut-off gates & selective operation

35,640 0.16Zero

Investment0.026

8.2nd chamber media gradation done withHigh Chrome Grinding Media

237,180 1.18 9.6 0.173

9.

Dose optimization Mill performance enhancer (Grinding Aid) resulting to higher Fly-ash addition & improvement in SPC

650,000 3.30Zero

Investment0.476

10.Optimization of Bag Filter purging ON/OFF time in Finished grinding & Packing

12,300 0.50Zero

Investment0.009

11.Optimizing of excess illumination in specific high mast tower area by switching of alternate fittings

8,856 0.4Zero

Investment0.006


kWH/Yr

Savings in mINR

Investment in mINR

SEC reduction

1.Optimization of Plant High Mast Tower lighting and achieved energy saving

77,186 0.41Zero

Investment0.052

2.Replacement of conventional office lightings with LED lights

59,206 0.33 0.38 0.040

3.Replacement of WT Main Bag Filter FanImpeller with High efficiency impeller

34,970 0.18 0.35 0.023

4.Modification in Air Slide Blower pipeline to stop Air Slide Fan 416FA25A

23,680 0.13Zero

Investment0.016

5.Retrofitting of wagon tippler twins Fan to increase the efficiency

14,210 0.08 0.10 0.009

6.Optimizing FA Silo top Bag Filter Fan VFDwith Auto control loop

13,530 0.07Zero

Investment0.009


kWH/Yr

Savings in mINR

Investment in mINR

SEC reduction

7.Installation of Frequency Drive for Wagon Tippler Bag Filter Fans

42,900 0.23 0.08 0.029

8.

Connection of Air Slide 543AS02 with Cement Bin Aeration Blower 543AB01,02resulted stopping543FA02 Air Slide Fan

7,316 0.39Zero

Investment0.005

9.Modification of MF Feeding Air Slide toMF Elevator by Connecting Air Slide Fan 512FA13 resulted stopping of 543FA01 fan

6,458 0.03Zero

Investment0.004

10.

Connection of VAC Elevator feeding blower 543FA04MT10 with Silo Extraction AS Blower resulted in stoppage of 512FA15A

14,481 0.08Zero

Investment0.009


kWH/Yr

Savings in mINR

Investment in mINR

SEC reductio

n

1.Optimization of cooling tower fan operation with temperature control

1,670 0.01Zero

Investment0.001

2.Optimizing the pressure setting of Compressors in plant to reduce compressor running in load

42,000 0.22Zero

Investment0.028

3Replacement of existing process water pump with High Efficiency Pump for Cooling water circulation

95,040 0.50Zero

Investment0.064

4.Replacement & Upgradation of obsoletepackage Air Conditioning system withSplit Air Conditioner and occupancy sensors.

223,072 1.18 1.2 0.150

5.Replacement of conventional Plant lightings,Street Lights and High Mast Area light fittings with LED lights

486,910 2.58 2.4 0.328


kWH/Yr

Savinsgin mINR

InvestmentmINR

SEC reduction

6.Improve Distribution Transformers Loading by using one transformer at a time

12,176 0.06Zero

Investment0.008

7. De-rating of Air slide Fan motors 15,725 0.63Zero

Investment0.010

8Installation of Automatic star-delta converter for under loaded motors

380,160 2.01Zero

Investment0.256

9.De-rating of Motors in Packing Plant Loading Belt conveyor circuits

97,152 0.53 1.50 0.065

10.Installation of Frequency Drive for Packing Plant Bag Filter Fans

475,200 2.61 1.30 0.320

PROJECT – 1

Title :❖ Reduction in Cement Grinding SEC by Automatic Delta Star Motor Controller

Implementation :❖ As some Screw conveyors are running below 40% load but need high torque at starting.

we develop a Current base Functional Block at Distributed Control System to forChange over from Delta to Star as per running load.

❖ Fixed Current Transformer & current transducer in the circuit to measure line current and communicate with DCS.

❖ Making panel with 2 nos contactor for star and delta and brought all the six terminals of the motor to panel and arranged proper way for star-delta operation and Logic developed as per requirement .

❖ Step-1- Motor always stars with Delta mode to reach the starting torque after a certain time limit it will start observing line current for star – delta operation.

❖ Step-2-If Current Transformer( Sensing the line current) is below 50% of full load current then motor will run with star mode (energy saving mode) otherwise it will run with delta mode.

❖ Step-3-If it was running with Star mode after sensing line current and suddenly line current increased more than 40% of F.L current for any process deviation it will convert to delta mode even if any fault in current transformer, motor will operate in delta mode as per logic. (Default value set more than 50% of full load current).

Implementation :

Block developed in DCS (ABB library), ease to implement as & when requirement

Advantages :

❖ Innovative development of DELTA-STAR-DELTA Mono Block in ABB DCS System (STAR-DELAT Block does not exist in ABB DCS Library)

❖ Energy Saving (Reduction in KW and KWH).

❖ Improvement in power factor.

❖ Reduction in line current so it will minimize copper loss and reduces motor temperature and it leads to increase motor life.

Cost benefits in our case:

❖ Saving for in-house development of the energy saver unit (2 nos) : 1.5 Lakhs

❖ Total expected Energy Saving : 23,996 Kwh/Year(Considering Mill running for 330 days)

❖ Total expected cost saving : 1.35 Lakhs/Year(Considering Power Cost – 5.60 Rs./Unit)

PROJECT – 2Title :❖ Energy saving by replacement of existing obsolete package AC system with individual

Split AC units & optimizing the operations.

Implementation :❖ There are conditions that all the cabins & halls are not occupied continuously & all at a

time during the General shift duty hours. Also as per our study the average occupancy of the rooms is for maximum 5 hrs a day & 24 days a month.

❖ But it is required to keep the package AC units continuously on for Servers Room, DCS Room, CCR Room & Lab Room continuously on 24x7 basis to maintain the equipment & system reliability.

❖ Thus there is huge Power consumption due to running of packages for cooling of few areas & even the other areas remain unoccupied.

Benefits :

❖ Individual AC units could be switched off when not required & when there is no occupancy in the rooms or cabins.

❖ AC temperature could be controlled individually as per comfort level.

❖ Gives Energy savings with low Energy consumption. Savings of 217,226 units/year.

❖ New generation AC units are less in maintenance & much more reliable.

PROJECT – 3Title :❖ Temperature Control Start-Stop of Cooling Tower Fan.

Implementation :

❖ It was observed that process water cooling tower Fan (11 kW motor) runs continuously 24x7 even through the process water temperature is very less & does not require further cooling.

❖ Avoided un-wanted running of cooling tower fan, by introducing a temperature control interlock to stop the fan with target temperature Set point.

❖ Thus saved the running power of cooling tower fan during entire 4 months of Winter season when ambient temperature is very low

Cooling Tower fan operation with temp control

Temperature Controller Water Cooling Tower

Temp ControllerRTD

Cooling Tower Fan:❖ It was observed that process water cooling tower Fan (11 kW motor) runs

continuously 24x7 even through the process water temperature is very less & does not require further cooling.

❖ Avoided un-wanted running of cooling tower fan, by introducing a temperature control interlock to stop the fan with target temperature Set point.

❖ Thus saved the running power of cooling tower fan during entire 4 months of Winter season when ambient temperature is very low.

Benefits:❖ Total Energy Saving = 34,830 kWh❖ Total Cost Saving @ 5.60 Rs/Unit = 1.50 Lacs/Yr

❖ In NUVOCO, management is committed to utilise renewable energy source, at first phase, Chittorgarh Unit , Rajasthan, 0.5MW Solar plant is under commissioning stage.

❖ In Mejia, Plant Roof-top 20 KW Solar stations installation project has been proposed for office lighting.

Solar Panels at Chittorgarh Unit

YEAR SCOPE 1 EMISSIONS

SCOPE 2EMISSIONS

TOTAL REDUCTION

(KG)

2014-15 234521000 191513 234712513

2015-16 236880000 2075198 238955198

2016-17 252530000 732030 253262030

2017-18 263817000 1217254 265034254

SCOPE 1 Reduction in Emission due to less consumption of clinker (higher CK ratio)

SCOPE 2 Reduction in Emission due to Savings in kwh

FY 2014-15

FY 2015-16

FY 2016-17

FY 2017-18

FY 2014-15 FY 2015-16

FY 2016-17 FY 2017-18

❖ Total plant area: 25.19 Ha.❖ Green belt developed inside plant: 6.83 Ha.❖ Green belt developed at social forestry

in community : 9.09 Ha.❖ No of sapling planted inside plant : 3550 nos❖ No of sapling planted in community : 11000 nos

Green Belt At Mejia

Plantation Near Workshop

Water Harvesting Pond Plantation Programme at Mejia

❖ Nuvoco Vistas Corp. Ltd is committed for Green Supply Chain Management initiative.

❖ Mejia has already initiated the process to adopt Green purchasing practices in the plant to get benefits like… ✓ To conservation of energy, water and other natural resources.

✓ To lowering of costs incurred towards waste management. ✓ To compliance with the environmental regulations. ✓ To improve brand image & reputation among customers as the organization is focusing

towards greener product.✓ To improve employee health due to lesser environmental impact.

❖ Further to development of green purchase/procurement Novoco is aiming at…✓ Reducing the usage of hazardous (toxic) products / chemicals in their manufacturing facilities &

phasing out toxic chemicals use in a phase manner.✓ The major purchasing like - capital goods, raw materials, maintenance consumables (electrical,

mechanical, oils), building materials, & other consumables will be initiated with green procurement guidelines.

❖ As a initiative towards Green Supply Chain Management implementation at Mejia Cement Plant, is reflecting through its following actions..

✓Mejia is Certified as ISO 14001 : 2015 compliance cement manufacturing unit in 2018.

✓ Environmental Objective and Targets shows the commitment to achieve the Green Supply Chain Management.

Monthly Energy committee MetingEnergy awareness Programme among Shop floor People

Productivity Capex Approved in Last two Finacial Year :

❖ Capex Budget Approved for FY – 2017-18 = 16.5 mINR

❖ Capex Budget Approved for FY – 2018-19 = 10.5 mINR

150.00

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4700.00

Mill kWh VS TPH

Mill Motor KW TPH

Hourly Tracking Through EMS systemSystematic Monthly tracking

Thank You

8/29/2018 43

ltd. … · rmx plants : 72 cement plants : 6 aggregate plants : 2. date | 5 mejia cement plant...

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