UltraTech Cement Limited

A. P. Cement Works - Tadipatri

Fourth One-day Cement Sector Task Force Program on Energy Conservation

Venue : JACARANDA, India Habitat Centre, New Delhi ( 17th October06)

Team Members Ali Asgher D.S.Chandra Sekhar

Contents
Energy Management at APCW Energy Conservation Projects (02-06) Energy Consumption Trends Benchmarking Recognition Innovative Project of 2005-06 Future plans

UltraTech Cement Limited (Aditya Birla Group)

A.P. Cement Works ISO 9001 2000 (QMS) ISO 14001 2004 (EMS) OHSAS18001 1999)

Manufacturing Process

LIME STONE

LS CRUSHER

MINES

RAW MEAL ADDITIVES RAW MILL

Manufacturing Process

COAL

PRE HEATER CLINKER

KILN CLINKER

COAL MILL ARCW

OPC,PPC,PSC Market Tamilnadu, Kerala Karnataka, GOA Maharashtra, AP

BAGS

CEMENT MILL

PACKING PLANT

Development of Policy
Shop floor awareness classes at each dept.

Preparation of Draft Energy Policy by each dept.

Review of these Policies

Finalization of Energy Policy by HODs & Management

Owning of this policy by all at APCW

Energy Management Policy

We shall be committed to Explore & maximize the use of latest & efficient technology to reduce energy consumption. Reduce the consumption of coal, electricity & fuel oil through process optimization in order to reduce the Green House Gas emissions. Utilize wastes such as fly ash & slag to conserve raw materials & use of alternate fuels to conserve fossil fuels. Involve all the employees by motivating and training them on energy efficient practices throughout the plant and to improve productivity, cost effectiveness and work environment. Spread awareness among all employees and their families for conserving energy. C. S. Reddy Unit Head

Energy Monitoring System

Energy Meter
RS 485 RS 232 Converter

PC RS 232

RS 485

View Power Report

Energy Consumption Review

Plant & Asset Care Team Area Effectiveness Team Energy Pillar Team Plant Steering Board

Continuous Daily Weekly Fortnightly

Project Selection
Deployment of Plant Thrust Area

Idea Generation for Projects

Screening of Projects

Prioritization of Projects on the basis of RPN

Execution of Project by Involvement of EPT,dept. , PACT

National Energy Conservation Day

Celebration Competitions
Most Energy Efficient AET Award Energy Efficient AET Award Slogan Elocution Drama Poster Awareness test Suggestion Week Technical Paper

Involvement of People

Energy Conservation Projects 2002-06

Optimisation of Cooler ESP Fan

Optimisation of Cooler ESP FanBefore Modification

ESP fan speed (rated) SPRS minimum speed Damper inlet pressure Damper outlet pressure Power drawn by motor SPRS Recovery Net power drawn 475 rpm 335 rpm -38 mmwc -48 mmwc 190 KWh 50 KWh 140 KWh

Optimisation of Cooler ESP Fan

After Modification
Input T/F Slim Inverter Output T/F

HT Breaker

HT VFD for Cooler ESP Fan

Fan HT Motor

Optimisation of Cooler ESP Fan After Modification contd..

Power drawn by motor 100 KW

(After commissioning of HTVFD, able to operate cooler ESP fan up to 50% speed) Damper opening Net saving per annum ((40 Units/hour)) 100 % 3.12 Lac KWh

Annual savings achieved Rs.12 Lacs (40 kW x 24 hrs x 330 days x Rs 3.91/unit) Investment Rs.35 Lacs

Raw Mill Separator Efficiency Improvement

Raw Mill Separator Efficiency Improvement

The air volume inside the mill and above roller Air velocity before modification
Reducing the area across the separator by fixing the Tiscral plate 8 mm thick Covered area

220 cum/sec 8 mtr/sec

32 % 12 mtr/sec 0.2 units/t. matl

After modification air velocity Reduction in specific power consumption

Annual Savings Rs.31 Lacs (2x85 KW x 14 hrs x 330 days x Rs 3.91/unit) Investment Rs.12 Lacs

Improvement in Cement mill Sepax Fan

Improvement in Cement Mill Sepax Fan

Before Modification : Though the Damper was full open, unable to maintain required air volume. After Modification : Installed HTVFD(525KW) Operation of damper eliminated In order to maintain required air volume, fan speed was maintained at higher side. (100-102%) Resulted in increased output by 3.0 ton / hour Annual Savings achieved Rs.24 Lakhs (80 KW x 22 hrs x 350 Days x Rs 3.91/unit) Investment Rs.35Lakhs

Variable Frequency Drives (2003-2004)

Particulars Reverse air fan(220KW) of RABH Cooler fan -7 & 8 (220KW) Peter silo JPF Fan (110KW) Raw mill feed RBC (R1J04 & R2J04)
Saving in KWh Investment

(Lac units /a) (Rs. Lacs) 6.34 9.0

5.5 1.9 1.6

18.4 5.2 2.2 3.8 4.5

Cement Mill ESP Fan (Z1P50 & Z2P50) 1.3 Kiln shell cooling fans (11,18.5,30KW) 0.87

Variable Frequency Drives (2004-2005)

Particulars
Saving in KWh Investment (Lac units /a) (Rs. Lacs)

Dossimate filter fan ZIP15 & Z2P25 (30KW) 0.5 1.2 Raw mill main motors blower (22KW) CF silo JPF (22KW) Roller press dedusting fans Z1P20 & Z2P20 (30KW) Packing plant compressor (90KW) CF silo aeration blower (18.5KW) JPFs in raw mill reject circuit(18.5KW) 0.4 1.0 0.1 0.3 0.3 0.2 0.2 0.9 1.2 2.0 0.8 1.6

Variable Frequency Drives (2005-2006)

Particulars F1J03 Coal RBC (160KW ) Cement transport dedusting JPF (Z3P65,Z3P70 -30KW) VFD for cement silos extraction screw conveyors (18.5KW) VFD for Packer RVF RM reject RBC (18.5KW) U1U06 Clinker RBC(160KW)
Saving in KWh Investment (Lac units /a) (Rs. Lacs)

0.4 0.3

4.0 2.2

3.02

5.4

0.5 0.3 0.2

1.8 1.4 4.5

Pressure Drop Reduction

Particulars
Saving in kWh Investment (Lac units /a) (Rs. Lacs)

Modification in CS 3rd & 5th Cyclone Riser Duct Roof

3.15

10.6

Installation of dedusting clone in Kiln string 2nd Cyclone

1.95

6.5

D o w n C o m er

Increasing the kiln down comer duct dia from 2.5 mtr to 2.8 mtr

1.16

52

Fan Optimization
Particulars
Saving in KWh Investment (Lac units /a) (Rs. Lacs)

Modification of Raw Mill Fan 1 & 2 Inlet Suction Box Trimming of raw mill 1& 2 Fan Impeller by 70 mm Widening of speed range of CS fan SPRS from 78% to 75% Introducing energy saving mode of operation for cooler fans

4.6

11.0

7.5

0.3

2.6

0.1

1.0

0.1

Compressed Air System Optimisation

Particulars Installation of optimiser for compressor operation Merging of poking air with main compressor air grid to reduce unloading hours Installation of new compressor for LS Crusher Provision of 2 bar compressed air line in place of 5 bar compressed air line for packing plant aeration
Saving in KWh Investment (Lac units /a) (Rs. Lacs)

0.8

3.8

2.3

0.7

0.1

0.5

1.5

0.3

Idle Running Reduction PLC interlock

Particulars Reduction in packer idle running Reduction in bulk cement loading idle running LDO ring main pump stopping during HFO operation Introducing time bound interlocks Optimisation of group start/ stop of cement mills, coal, & Raw mills
Saving in KWh Investment (Lac units /a) (Rs. Lacs)

0.5

0.1

0.1

0.0

0.15 0.0 2.0 0.0

0.2

0.0

Voltage Optimisation
Particulars Voltage optimisation Reduction in tap position of transformers at cement mill Reduction in Voltage drop for CM MCC-5.2 Switching off one distribution transformer at raw mill
Saving in KWh Investment (Lac units /a) (Rs. Lacs)

2.15 0.0

1.2

0.0

0.1

0.2

0.4

0.0

Voltage Optimisation
Particulars Voltage drop reduction in RM MCC 3.4 & MCC 3.3 Voltage reduction in PP & RM Transformer Voltage drop reduction for CCR building MCC
Saving in kWh Investment (Lac units /a) (Rs. Lacs)

0.1

0.2

0.3

0.0

0.1

0.2

Electrical Heating
Particulars Provision of Heater in RM gear unit avoid the idle running Switching off electric heat tracing system for HFO separator Removal of Rawmill hydraulic unit heating element
Saving in KWh Investment (Lac units /a) (Rs. Lacs)

1.1

0.3

0.1

0.0

0.1

0.0

Upgradation of Drives
Particulars
Saving in kWh Investment (Lac units /a) (Rs. Lacs)

Water pump from 30 kW to 45 kW to avoid the running of 75 kW pump when only Kiln & one CM is operating Coal belt conveyor motor from 160kW to 200kW resulted in reduction of slag unloading Hours

0.4

0.2

0.4

0.3

Equipment elimination
Particulars
Saving in KWh Investment (Lac units /a) (Rs. Lacs)

Bypass chute for bulk clinker loading reversible belt conveyor [U1U22] Provision of coal crusher bypass chute for slag unloading to avoid running of coal crusher Modification in the ducting for stopping of 2nos 30kw JPF Fans at Packing Plant Bag Diverter (2.2 kW) elimination by providing Spiral Chute

0.1

0.2

0.25 0.1

0.7

0.1

0.1

0.1

Blowers Jet Pulse Filter Fans Pulley Modifications

Particulars Cement silo top [6Nos] Cement mill section LS Crusher Cement Transfer JPF ( 4 Nos) Blowers [5Nos]
Saving in KWh Investment (Lac units /a) (Rs. Lacs)

2.5 1.1 0.3 1.7 1.8

0.3 0.2 0.1 0.2 0.4

Lighting Optimisation
Particulars Installation of energy saving tube Lights 500 Nos. in plant Provision of energy saver for lighting in LS crusher& MRSS section Replacement of 400W SV lamp with MH lamp in colony & CM area Providing transparent fiber sheets for day light Provision of AVR for factory & township lighting
Saving in KWh Investment (Lac units /a) (Rs. Lacs)

0.6 0.1 0.1

3.9 2.0 0.3

0.15 0.3 2.2 18

Lighting Optimisation
Particulars Lighting optimization at Gypsum, Flyash & Slag yard Providing ON/OFF switch for lighting at WLM, TLM area Replacement of 40w fitting with 11w fitting in colony Lighting optimization in the plant Master switch control (70% of lighting) Provision of LDR & control of lighting thru PLC at raw mill area
Saving in KWh Investment (Lac units /a) (Rs. Lacs)

0.1 0.12 0.1 1.9 0.4 0.1

0.2 0.1 0.1 0.2 0.1 0.1

Others
Particulars Sewage treated water line size increasing Derating of Motors
Saving in KWh Investment (Lac units /a) (Rs. Lacs)

0.12

0.3

1.0

0.4

Changing of Delta to star connection for RBC's P2U05,12,19,20 2.0 Fan less cooling tower at Packing plant Jet cooling tower for DG

0.2

0.4 1.4

0.6 5.5

Others
Particulars
Saving in KWh Investment (Lac units /a) (Rs. Lacs)

Reduction in raw meal reject elevator height by 5 mtr Installation of swing cooler at cooler Conversion of V-Belt to Flat Belt Reduction in rpm of HFO unloading pump Arresting of air infiltration KS & CS fan casing

0.5 1.9 0.1

2.0 3.0 0.2

0.1

0.2

1.7

0.1

Others
Particulars Modification of Nozzle Ring at Raw Mill 2 Reduction in dam ring height from 200mm to 190mm for optimum loading of the Raw mill 1 & 2 main motor Fan less cooling tower at main pump house
Saving in KWh Investment (Lac units /a) (Rs. Lacs)

3.7

0.4

9.5

0.2

1.7

7.2

Others
Particulars Optimization of Cooling Water System in Packing Plant Air Compressor Modification in water distribution line for avoiding 30 kW pumps Reduction in fan inlet pressure drop in cooler fan 5&10 Air cooled condensers for CPP (to reduce water consumption)
Saving in KWh Investment (Lac units /a) (Rs. Lacs)

0.5

0.6

1.9

0.2

0.7 1.2

0.1 6.4

Projects under pipeline (2005-06)

Particulars
Saving in KWh Investment (Lac units /a) (Rs. Lacs)

Commissioning of Waste heat recovery system from cooler exhaust Installation of HT Capacitor bank (4.86 MVAR) to improve the PF from 0.94 to 0.99 Energy audit proposals in water Pumps, & roots blowers. Discard poor performing ACs by replacing with new & other audit Proposals of AHU, ACs

250 3000

1.8

14

11

16

2.5

Energy Conservation projects (2000-2006)

No of Encon Projects

45 35 25 15 15 6 5 98 99 '00 '01 '02 10 31

41

22 18 17

26

'03

'04

'05

'06

Year

Electrical Energy Consumption Mines to Clinker Production

Units / Ton of Clinker

60.6 60

55

53.46 50.6 50.5

54.2

50 2001-02 2002-03 2003-04 2004-05 2005-06

Year

Electrical Energy Consumption Packing Plant

1.5 1.42 1.4 1.3 1.19 1.2 1.1 1.01 1 0.98 2001-02 2002-03 2003-04 2004-05 2005-06 1.32

Units / Ton of Cement

Year

Electrical Energy Consumption

Units / Ton of Cement

89

87.41

84

83.6

79

76.6 74.46

76.4

74 2001-02 2002-03 2003-04 2004-05 2005-06

Year

Thermal Energy Consumption

689

kCal / Kg of Clinker

689 687 687 684.9 684.3 685 686.1

683 2001-02 2002-03 2003-04 2004-05 2005-06

Year

Energy Conservation in Lac units

80

Lac units(kWh)

70 60 50 40 30 20 29.4 29.8 36.2 45.8 57.6

68.2

73.4

99-00 '00-01 '01-02 '02-03 '03-04 '04-05 '05-06

Year

Benchmarking

kWh/t Cement

2003 Performance 91.71 74.24

102.14 114.71 156.85

2002 Performance

Andhra Pradesh Cement Works

65

74.24
kWh/t Cement

160

Whitehopleman Report APCW power Consumption Rating 5 Star

Benchmarking

30.46 26.52 38.67 43.71

Selected Kilns

22.90

32.66 28.18 40.82 59.01

Peer Group

18.16

31.88 26.05 38.02 66.73

All 12.17 Kilns

10

22.90 kWh/t Clinker

80

Whitehopleman Report Kiln Power Consumption is Lowest in Selected Kiln

Benchmarking

Selected Kilns

3239 3052 3287 3483

2864

3402 3185 3684 4597

Peer 2757 Group

3761 3382

5396 8331

All Kilns

2757

2250 2864.00 kJ/kg

10000

Whitehopleman Report Thermal Consumption is Lowest in Selected Kiln

Major Environmental Projects

Concreting and black toping of roads. Mines pit water utilization for plant operation Conservation of High grade Lime stone by adding shale. Conservation of raw water by connecting more sewage lines to sewage treatment plant. Construction of check dams to improve ground water levels. Green belt development in and around the plant with black cotton soil generated from mine lease. Online stack monitoring system for all process chimney with PLC interlocks.

Recognition
Winner in Process Category July05

in Ist National Energy Convention Organised by Andhra Pradesh Productivity Council Exemplary Work in Energy Conservation Jan03

in Medium Project Category organised by Petroleum Conservation & Research Association Energy Efficient Unit Dec02, 04 & Aug06 in National Award for Excellence in Energy Management organized by CII

Recognition
Water Efficient Unit National Award for Water Management(05-06) organized by CII Excellence in Energy Efficiency Oct05 National Award for Excellence(04-05) in Energy Management organized by CII Thermal Energy Performance Nov05 First in for best Thermal energy (04-05)organized by NCCBM, New Delhi Best Innovative project for WHRU Aug06 National Award for Excellence in Energy Management organized by CII
Best

INNOVATION PROJECT -2005-06

Innovation Project of 2005-2006

Waste heat Recovery system : 4.8 MW

Unique Project

: First in India (using n-pentane) Second Cement Plant in the World Technology :- Organic Rankine Cycle (ORMAT , Israel) :- Clinker Cooler exhaust gases

Waste Heat source

Waste Heat Recovery System

(.best out of waste)
Advantage :Conservation of conventional Energy Sources. Utilisation of waste heat 4000 kW 3400 kW 65 kW 3335 kW

Gross Out put : Net out put Thermo oil Pump load Net out put System : : :

Annual Power Generation :

251 Lac. kWh

Waste Heat Recovery System

Process flow diagram

Waste Heat Recovery System

Contd..
NO WHRU

WHRU

WHOH : Waste Heat oil heater (Tube type oil heat exchanger, with thermic fluid as heat carrier fluid )

Waste Heat Recovery System

Benefits

Contd..

Meets 9.4 % of the electrical power requirement (Total - 36 MW) Zero water consumption as the condensers and pump seals are air-cooled. No extra Manpower is required as existing Main Plant operation staff can do the operation. Reducing CO2 emission from the combustion associated with the generation of power by 20851 Ton / annum and attracts CDM benefits .

Waste Heat Recovery System

320degc 203degc 270 degc 20 bar Thermic Fluid

147degc, 2.2bar

120degc

n-pentane

Waste Heat Recovery System

System components

Waste Heat Recovery System (Commissioning stage..)

Waste Heat Recovery System (Commissioning stage..)

Waste Heat Recovery System (Commissioning stage..)

Future Actions
Non-conventional Energy sources Wind Power plant Solar Power Plant 14.4 20.0 MW MW

Alternate Fuels for Kiln firing - Project under pipeline Vapour Absorption Machine Energy Audits Optimising equipments utilisation Continuous basis 200 TR

ALTERNATE FUELS

Alternate Fuels for Kiln firing

Non-conventional Energy sources Wind Power

Wind Power plant Wind tower capacity No of units Location 14.4 800 18 MW KW no.s

Nearer to Plant premises 1.Conservation of Conventional energy sources. 2. Directly connecting to our circuit without any wheeling adjustments.

Advantage

Non-conventional Energy sources Solar Power

Solar Power plant No of units Location 20.0 MW

2no.s (2 X 10.0 MW) With in the plant premises Conservation of Conventional energy sources. New Technology First time in Asia

Advantage

Challenge

Vapour Absorption Machine Future Plans contd..

Capacity Refrigerant Absorbent Advantages 200 TR Water Lithium bromide Phasing out of CFC based refrigerants ,Eco-friendly and Energy saving a) From Baghouse chimney gases b) From Clinker cooler exhaust gases

Source

Conclusion

Commitment of Top Management Involvement of all People Alignment of Vision , Mission , Objective & Goal Strategic Planning and Implementation Campaign for the Energy Conservation

Journey of Excellence in Energy Conservation continues