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ISO 9001ISO 14001 &
IS 18001
Presentation on Energy Best Practices
The Ramco Cements Limited
Ramasamy Raja Nagar Unit
National conclave on Recent advances in Cement Industry , 15th October, 2018
at HICC, Hyderabad
About The Ramco cements limited , RR Nagar
1. Our unit has Cement production capacity of 2.0 MTPA and the manufacturing
product is 100 % Portland Pozzolana Cement as per BIS
2. We have 25 MW Coal based Thermal power plant
3. We are included in PAT Cycle III and our base line is 0.0847 TOE/T of
Product
4. Integrated management system
1. Quality Management System - IS/ISO 9001: 2015
2. Environment Management System - IS/ISO 14001: 2015
3. Occupational Health & Safety Management System - IS 18001: 2007
5. Five S’ Workplace Management System
6. Energy Management System IS/ISO 50001:2011
7. Man Power Utilization (Permanent & Contract): 5.59 Tonne of
Product/Manpower
Page 1
Page 2
Energy ConservationOrganization Structure
Sr. Vice President
MFG
AVP
WORKS
GM (P & QC)
GM (MINES) DGM (PROJECTS)
ENERGY MANAGER
AGM (MECH)
SDGM (E&I)
DGM (ACCOUNTS)
INCHARGE
MINES
INCHARGE
RAW GRINDING
INCHARGE
PYRO
INCHARGE
CEMENT
GRINDING
INCHARGE
PACKING PLANT
INCHARGE
POWER PLANT
Page 4
ISO 50001:2011 Certificate
Energy Conservation Activities
❖ Daily analysis of specific energy consumption and compare the
same with targets and taking corrective action immediately if any
deviation is observed
❖ Conducting energy audit and preparing proposal for energy saving
❖ Study and implementation of energy saving proposals from
suggestion scheme
❖ Involving energy team personnel in equipment procurement
activities to procure high efficient equipments
❖ Conducting energy conservation meeting to compile and discuss
energy conservation points with management
ISO 50001:2011
❖ Energy Policy formulated
❖ Energy Conservation Teams are formed for each boundary
❖ Specific Energy Usage identified for each boundary
❖ Energy management action plan formulated
❖ EnMS internal auditor training completed
Energy Performance
S No Description Units 2016-17 2017-18
1 MTOE reduction MTOE 107 206
2Kiln Specific Thermal Energy
ConsumptionKcal/Kg Clinker 705 699
3Specific Electrical Energy –
ClinkerisationkWh/T of Clinker 54.9 54.45
4 Specific Electrical Energy – Grinding kWh/T of cement 32.5 32.6
5 Specific Electrical Energy – Cement kWh/T of cement 72.20 71.50
6 CPP Heat rate kCal/kWh
7 CPP Auxiliary Consumption % 10.12 10.02
8 Thermal Substitution Rate % 3.11 6.67
9 Clinker Factor % 0.706 0.710
10Blended Cement (%) of Total
Cement%
100% Inter
Ground PPC
100% Inter
Ground PPC
11 REC Purchased – Solar REC - -
12 REC Purchased – Non Solar REC - -
13 Specific CO2 Emission Kg CO2/ kg cement 0.752 0.730
Top Energy Projects Implemented in 2017-18
S.No ENCON Best Practices ImplementedSavings in
Lakhs
1 Installation of VFD for Boiler feed water pump at TPP 38.8
2 Installation of high efficiency Pillard burner in Kiln-2 23.2
3 Interlinking of Kiln-1&2 CCTV compressors after changing the pipe size 9.1
4Factory lighting optimization by replacing LED lights in place of conventional lights
8.4
5 Eliminating Unwanted Running of Fly ash Unloading Bag filter fan 6.40
6DG power plant auxiliary system idle power consumption reduction by optimization of heaters
6.2
7 Elimination of 6.6kV/3.3kV transformer to reduce transmission loss 2.6
8Package AC cooling tower replaced with individual split AC in accounts department
1.5
Innovative Ideas Implemented in 2017-18
Kiln-1 Bag House Modification
Kiln-1 Bag House
Constraints in present operation
❖ Bag house differential pressure maintained 150-170 mmWG
❖ Compressed air pressure maintained 4.0 to 4.5 bar
❖ Bags damage and less life due to clustering of bags
❖ The bag house inlet temperature is high due to pressurization
❖ Not able to increase the preheater fan speed further
❖ The compressor is running always in loading condition
❖ Above condition resulted increase in bag house fan & compressor
power consumption
❖ Dust emission 40 - 50 mg/nm3
Development of In-House Solution:
❖ Newly designed & In-house fabricated Grid system installed at bag
filter bottom portion to hold each bags.
Kiln-1 Bag House
Before After
❖ Compressed air purging pipes replaced with new design
Insertion & U clamp fixing of purge pipe
Before After
Flange type fixing of purge pipes
Kiln-1 Bag House
❖ Height between purging pipe and tube sheet has been reduced
Before
350mm245mm
After
Kiln-1 Bag House
Performance Improvement & Benefits achieved:
❖ The Bag filter DP is reduced by 40 mmWG with reduced
compressed air pressure of 3.5 to 4.0 bar
❖ Power saving in Bag filter fan & Compressor is 25 Kw/hr
❖ Dust emission level reduced from 40 to 8 mg/nm3
❖ Kiln performance has improved by increasing preheater fan
flow rate
❖ Bags life increased due to reduction in purging air pressure &
avoiding clustering of bags
Page 14
Kiln-1 Bag House
Innovative Ideas Implemented in 2017-18
Auto Sampler Fabrication for Clinker Sampling
Constraints in Present Operation:
❖ Manual Spot sampling shows only the instantaneous clinker
quality
❖ Taking corrective action based on the spot sampling gives
wrong result some time
❖ In manual sampling, person to person the sampling techniques
are changing
❖ Man hour utilisation is high due to sampling and sieving
❖ Dust emission during sieving
Page 16
Clinker Auto Sampler
Development of In House Solution:
❖ In-house made auto sampler has been installed at clinker
crusher outlet DPC
❖ It collects the average sample for every 10 minutes.
❖ Its provide litre weight sample and raw clinker separately
❖ This sampler connected with CCR PLC
❖ We can adjust the sample collection period and quantity as
required
Page 17
Clinker Auto Sampler
Page 18
Working of Auto SamplerWorking of Auto Sampler
Guide
pulley
Clinker Collection
Tray
DPC
Drive pulley
Clinker
Silo
Cooler Outlet
Page 19
Working of Auto SamplerWorking of Auto Sampler
Vibrating screen
6mm to
12 mm
material
>12 mm
material
< 6 mm
material
Drive system
Pneumatic
cylinder
Sample for
Litre weight
analysis
Sample for
Elemental
analysis
To DPC
Benefits Achieved:
❖ Clinker sampling is more representative from hourly spot
sample to once in 10 minutes average sample collection.
❖ Consistency in quality improved due to more representative
sampling.
❖ Frequency of operating parameters changing has reduced.
❖ Specific fuel consumption reduced by 1.6 Kcal/Kg Clinker
❖ Coal Saving 248 MT/annum
Page 20
Clinker Auto Sampler
Innovative Ideas Implemented in 2017-18
Overhead Transmission Line Power Transformer Shifting From Receiving
End to Sending End
OH Transmission Line Power Transformer
Constraints in present operation:
❖ The crushing plant is located 23 Kms from the factory at our
Pandalgudi Mines, which crushes the limestone upto -25mm size.
❖ The average power requirement for operation of this plant is 1.5
MVA.
❖ This Power requirement is met through 11 KV Overhead
Transmission line from Factory to Mines.
❖ During Raining condition and Thunderstorm, Insulators in the
overhead line failed frequently and broken. Hence line tripped due
to earth fault frequently.
❖ During heavy fault condition, Thermal power plant generator
breaker has tripped causing complete block out of Cement plant.
Page 23
6.3 MVA POWER TRANSFORMER SHIFTED
FROM MINES TO FACTORY
Page 24
6.3 MVA POWER TRANSFORMER SHIFTED
FROM MINES TO FACTORY
Numerical Feeder Protection
Relay at Transformer Secondary (For Tripping
During Fault in Power Line)
OH Transmission Line Power Transformer
Solution & Benefits Achieved:
❖ To overcome this issue, we have planned to shift the Power
transformer used at receiving end side (Mines side) for voltage
step up purpose to sending end side (Cement Plant side).
❖ Also we have installed high accuracy Numerical protection relays
at the secondary side of Power transformer for tripping during
earth fault.
Benefits:
❖ By Installing the Power transformer Thermal Power Plant tripping
due to fault in overhead line is completely eliminated.
❖ Transmission loss reduced by 0.5% which is around 7 Lacs/
Annum.
Page 26
Energy conservation Projects/Renewable Energy projects under implementation
Sl.NoENCON Projects Planned for the year
2018-19
Expected Electrical Saving
(Kwh/Year)
Expected ThermalSaving
(MT/Year)
1Installation of SPRS for Kiln-2 preheater fan in place of GRR
3,37,920 -
2Replacement of efficient shell cooling fan (8 nos.) in Kiln-1
2,23,560 -
3Low pressure compressor installation for Kiln bag filter to avoid losses in regulator
1,24,200 -
4Installation of VFD for cement mill higher capacity (>450 CFM,75 KW) compressor
93,600 -
5Installation Dp transmitter for all the unit bag filters their by saving power in compressor
84,500 -
Page 27
Sl.NoENCON Projects Planned for the year
2018-19
Expected Electrical
Saving (Kwh/Year)
Expected ThermalSaving
(MT/Year)
6Kiln feed extraction to Pre-heater top air slide blower capacity to be reduced
72,864 -
7 Installation of VFD for Coal mill-1 Bag Filter fan 66,240 -
8Installation of VFD for Kiln-1 Secondary firing blower as same done for Primary firing
49,680 550
9Unit bag filter in fine coal bin-2 to be stopped by changing the common venting line
45,540 -
10 Installation of VFD for CM Ball mill-2 Bag Filter fan 43,200 -
11 Installation of VFD for Coal mill-1 Booster fan 39,745 -
12Fuzzy Logic System for Kiln-1 to reduce fuel consumption by improving kiln steady operation
- 686
Energy conservation Projects/Renewable Energy projects under implementation
Energy Conservation Day Celebration
Page 29