ultratech cement limited aditya birla group - … award... · waste fuel – mechanised feeding...

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


• 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


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).


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


26

FLASH DRIER

27


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:- (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


RAW MILL DUCT MODIFICATION

29


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.


GCT DUCT MODIFICATION

30


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.



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:- (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:- (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.)


34


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 %


Inlet reduced by 140 mm Aerovane increased by 1.3 M


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


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


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.


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


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.


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


53

SL No.

Ti2tle of Energy Saving project implemented Year of Implementation


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


54

SL No.



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


55

SL No.



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


56

ENERGY SAVING PROJECTSSL No.



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.



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


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


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


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


73


74


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


78

CLINKER SILO

COAL STORAGE YARD

LIME STONE STORAGE YARD


79

COVERED CONVEYORS


CONCRETE ROAD IN THE PLANT

80

ü Ripper Dozer used for Mining.


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”.

ultratech cement limited aditya birla group - … award... · waste fuel – mechanised feeding...

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