ULTRATECH CEMENT LIMITED

REDDIPALAYAM CEMENT WORKS WELCOMES

Welcome to CII
“12th National Award for Excellence in
Energy Management- 2011”
 REDDIPALAYAM CEMENT WORKS (RDCW)

UNIT VISION
TO BE RECOGNIZED AS THE “MOST INNOVATIVE COMPANY” IN MEETING THE
CUSTOMER REQUIREMENTS,USE OF RENEWABLE ENERGY & CONSERVING
RESOURCES BY THE YEAR 2015.

UNIT MISSION
• ADOPTING CREATIVITY & INNOVATIVE APPROACH IN CONTINUAL
IMPROVEMENT OF QUALITY, PRODUCTIVITY, SYSTEMS AND PROCESSES.

• ADOPTING STATE OF THE ART TECHNOLOGIES FOR CONSERVING THE

RESOURCES AND USE OF RENEWABLE ENERGY.

• CREATING VIBRANT WORK ENVIRONMENT TO ATTRACT,MOTIVATE & RETAIN

EMPLOYEES TO ACHIEVE THE ORGANIZATIONAL OBJECTIVES.

• BUILDING LONG LASTING CORDIAL RELATIONSHIP WITH SOCIETY AND THE

STAKE HOLDERS BY PRACTICING SAFE ENVIRONMENTAL STANDARDS.

• ADOPTING SAFETY FIRST APPROACH IN ALL OUR ACTIVITIES . 2

 ENERGY POLICY

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
S.Natarajan

3
REDDIPALAYAM CEMENT WORKS – A PIONEER

 State of the art Cement Technology

from FULLER

 Commissioned in 2000
 Capable of using multiple fuel
successfully.

 First Plant in the world to get CDM

RDCW Distance to:
for use of waste fuel.
Chennai – 240 km
Trichy – 75 km  No fatal accident since nine years.

 Pioneered in waste heat recovery

from cooler to dry wet fly ash.
 PLANT – SALIENT FEATURES

Cover storage for raw Robo lab for total

Cross Belt Analyzer Ripper dozer for mining
material and fuel quality control

Energy efficient ball mill Energy efficient Roller Captive Power plant
Electronic Packer
for cement grinding Press for cement grinding

5
 PLANT PERFORMANCE
POWER UP TO CLINKERISATION
60
59.80 59.73 69 SPECIFIC POWER
Monsoon impact 67.93 CONSUMPTION PPC
( 1219 mm) 68 67.36
59

KWH / Ton of Cement

67
KWH / Ton of Clinker

58 57.71
66
57.28
65
57
56.21 64 63.56
63.14 63.02
56
63

55 62
06-07 07-08 08-09 09-10 10-11 06-07 07-08 08-09 09-10 10-11

72.00
71.09
70.81 OVERALL SPECIFIC POWER
71.00
CONSUMPTION (OPC + PPC)
Better
KWH / Ton of Cement

70.00

69.00

68.00
67.02
67.00 66.35 66.18
66.00

65.00 6
06-07 07-08 08-09 09-10 10-11
 INNOVATIVE PROJECTS
IMPLEMENTED 2008-2011

7
 INNOVATIVE PROJECT – RAW MILL

Re engineering of Raw mill circuit

Problem Faced:
High pressure drop from Pre-heater Outlet to Raw Mill inlet Around
160 mmwg and also the velocity in inlet duct was 26 m/sec.

Rectification Done:
Raw mill duct modified for reducing pressure and power.

Benefits & Savings :

Pressure drop reduction from 160 to 136 mmwg and raw mill power RAW MILL DUCT
reduced 0.5 units per ton of raw meal MODIFICATION

Re engineering of GCT circuit

Problem Faced:
High power consumption and high pressurization in Preheater fan
during Raw mill stoppage.

Rectification Done: GCT outlet duct modified.

Benefits & Savings :

GCT inlet duct pressure reduced by 60 mmwc. GCT DUCT
Raw mill ESP fan power reduced by 0.7 unit per ton of clinker. MODIFICATION
Preheater fan outlet pressurization avoided during raw mill
stoppage. 8
 INNOVATIVE PROJECT – RAW MILL

Replacement of Raw mill Fan

Problem Faced: High power consumption

Rectification Done: Low efficiency fan replaced by high efficiency

Benefits & Savings : Fan efficiency increased from 76% to 84%.

Power saving 0.12 unit/ton of material.

13.33
REDUCTION IN SPECIFIC POWER
13.20 13.09
CONSUMPTION OF RAW MILL
KWH / Ton of Material

Monsoon

12.80
impact Better
12.65

12.45

12.40 12.27

12.00
06-07 07-08 08-09 09-10 10-11

9
 INNOVATIVE PROJECT – KILN
COOLER VENT FAN REPLACEMENT

Problem Faced: High clinker temperature & Reduced heat recuperation

Rectification done:
• Backward curved impeller replaced by high efficiency aerofoil blade
impeller.
• Fan Capacity enhanced from 3.8 lac m3/Hr to 4.29 lac m3/Hr
• Reduced fan RPM from 720 to 630.

Benefit:
• Reduction in clinker output temp by 20 deg c
• Savings 0.3 kWh/Ton of clinker

Replacement of Cooler Fans

Problem Faced: High power consumption

Rectification Done:
3 nos. of Low efficiency fans replaced by high efficiency

Benefits & Savings :

Fan efficiency increased & Power Saving 0.22 unit/ton of clinker
10
 INNOVATIVE PROJECT – KILN
Replacement of Reciprocating compressors
Problem Faced:
High power Consumption, noise level and water consumption

Rectification Done:
Replacement of Reciprocating compressors (2 nos) by Atlas Copco
Make Screw compressors

Benefits & Savings :

Power saving of 0.34 kWh/ton of clinker , Noise level reduced from 95
to 88 db, No Water consumption for cooling (previously 29.4 m3 / Hr)

31.00
30.99 30.9 REDUCTION IN SPECIFIC POWER
CONSUMPTION OF KILN
Better
30.05
KWH / Ton of Material

29.91 29.9
30.00

29.00

28.00
06-07 07-08 08-09 09-10 10-11 11
 INNOVATIVE PROJECT – CEMENT MILL
CEMENT MILL BAG FILTER FAN REPLACEMENT
Problem Faced: High power consumption

Rectification done: High efficiency fan installed with VFD

Benefit:
• Fan Capacity enhanced from 60,000 Nm3 to 80,000 Nm3
• Annual Power saving would we achieved 0.15 Kwh/Ton of cement

26.81
27.00

REDUCTION IN SPECIFIC POWER

26.00 CONSUMPTION OF CEMENT MILL - PPC
KWH / Ton of Material

25.17

25.00
Better

24.00 23.75
23.35 23.26

23.00
06-07 07-08 08-09 09-10 10-11 12
 INNOVATIVE PROJECT

Reduction of HFO consumption in crusher

Problem Faced: High HFO Consumption average 250 liters/day

Rectification Done: Air blaster nozzle modification and operation

control taken in to control room.

Benefits & Savings : Fuel Consumption reduced from 250 to 60

liters/day

Modification of Pre-heater twin cyclone Aerovane

Problem Faced: High specific heat Consumption.

Rectification Done:
Aerovane height increased by 1.3 M and cyclone inlet reduced by
140 mm.

Benefits & Savings :

Reduction in heat consumption by 4 Kcal/kg of clinker increase in
cyclone efficiency by 1 % Inlet reduced by 140 Aerovane increased
mm by 1.3 M
13
 INNOVATIVE PROJECT – TPP
Lignite drying system
Problem Faced:-
Heat loss in boiler due to high moisture content in lignite

Hot air line to bunker

top. Temp.100 deg.C

PA fan discharge

Action taken:
• The air line with nozzle arrangement of bunker modified and preheated hot air
taken by PA fan to reduce moisture level around 7%.
Benefits:
• Reduction in Plant heat rate is estimated 35 Kcal/Kwh
• The Specific fuel consumption reduced from 1.34 to 1.17 (kg/kwh) 14
 Energy saving projects with out investment
Electrical Investment
Title of the Projects Implemented Savings (Rs. Milion)
achieved (kWh)
Bunker changed for optimizing coal re claimer 2.28 Nil
Optimization of coal mill bag filter fan 2.05 Nil
Optimization flow meter air slide fan 431 FN 1 & 2 3.42 Nil
Power saved by keeping cement mill 53 grade Blaine 125.00 Nil
275 instead of 290
Optimization blower motor 1.84 Nil
Optimization of L91 FN1 Coal mill bag filter 20.54 Nil
Optimization air slide fan 431 FN1 & 2 43.61 Nil
Optimization of supply water for Cooling tower 18.61 Nil
Optimization of silo top bag filter by speed reduction 0.68 Nil
Replacement of Kiln ESP RAL's for False air leakage 0.80 Nil
Optimization of FK pump bag filter 3.42 Nil
Optimization of Lime stone weigh feeder by feed 0.23 Nil
deviation.
 Energy saving projects with investment
Energy saving projects 2008-09
Electrical Savings Investment
Title of the Projects Implemented achieved (kWh) (Rs. Milion)
P-20 energy saver installed in TPP 2.28 0.25
School verandah lights taken in street light control 0.57 0.015
Up gradation of clinker weigh feeder 4.34 0.015
Raw mill fan SPRS up gradation 57.08 6.5

Installation of low head GCT pump 34.25 0.3

Installation of exhaust fan in crusher venting line 0.46 0.03
Installation of high efficiency cooler vent fan impeller 98.28 4
Installation of high efficiency Raw mill fan 171.46 5.7
3 numbers of high efficient cooler fans installed 79.91 4.2
Installation of high efficiency Raw mill ESP Fan 36.29 5
Optimization of Power consumption in Raw mill circuit 159.81 12.98
Total four numbers of screw Compressor installed in place of 273.97 4.8
reciprocating compressor
Replacement double stage compressor with single stage 3.42 0.03
Pre heater twin cyclone aero vanes modification 118.72 2.5
 Energy saving projects with investment
Energy saving projects 2008-09
Electrical Savings Investment
Title of the Projects Implemented achieved (kWh) (Rs. Milion)
Aluminum impeller changed by FRP impeller for cooling fans 10.27 0.040
CO2 purging system re-placed with N2 Purging system for 1332.19 6.9
fine coal bin and bag filters in fine coal circuit
Optimization of bag filters in packing plant 10.27 0.1
Cooling fan of Kiln shell taken in DCS/MCC 0.23 0.015

461 FN4(Kiln Cooling shell fan) taken in DCS 0.34 0.010

150W(HPSV) high pressure sodium vapors lamp replaced by 0.91 0.8
45 W CFL (Compact florescent lamp)
 Energy saving projects with investment
Energy saving projects 2009-10
Electrical Savings Investment
Title of the Projects Implemented achieved (kWh) (Rs. Milion)
Belt interlocking done in clay feeding area 1.83 0.0025
Belt interlocking done in gypsum feeding area 1.71 0.0025
Use of energy efficient bearings 0.18 0.016
Interlocking of packing plant bag filters 9.32 0.03

Replacement of new version SPRS in Raw mill fan 29.79 5.5

Replacement of normal pumps by submersible pumps in Raw 4.56 0.04
mill & Coal mill
Installation of VFD for Power plant cooling Tower fan 9.36 0.04
Installation of Panel Air conditioner & Exhaust fan in Power 5.48 0.016
Plant
Interlocking RP cooling fans 1.48 0.0015
Replacement of 150W HPSV by 45W CFL 2.96 0.015
Waste gas utilization for drying wet flyash (Waste heat 5.76 70
recovery system)
 Energy saving projects with investment
Energy saving projects 2010-11

Electrical Savings Investment

Title of the Projects Implemented achieved (kWh) (Rs. Milion)

Bobcat IR Machine for removing brick debris from kiln 41.05 2.2

Modification of Control Panel for 650 KW Coal mill ESP Fan 24.66 1.3

Installation of Screw Compressor in place of Reciprocating air 5.85 0.9

compressor
Cooler Vent Fan Replacement 34.82 36.92

729 FN1 Fan replacement 5.71 54.285

 Energy saving projects with investment
Energy saving projects 2011-12
Electrical Savings Investment
Title of the Projects Implemented achieved (kWh) (Rs. Milion)
VFD For Bag filter fan 431 FN4 1.82 0.5
Installation of Solar lighting (100KW) at colony 46.57 20
VFD For Bag filter fan 391 FN4 1.83 0.5
VFD For Bag filter fan 591 FN4 1.83 0.6

VFD For Bag filter fan 531 FN4 3.88 0.7

VFD for ID Fan Motors 11.98 0.463
VFD for Condensate extraction Pump 5.48 0.193
Pre-Heater fan SPRS installation 58.22 6
Stage reduction of boiler feed pump 16.78 0.212
Up gradation of Silo Feed Bucket elevators to increase 2272.83 58.5
cement mill output by 5 TPH
Improvement of Power Factor for EB (Electricity Board) 15.98 1.5
supply
Pressurization and Ventilation system for Pyro process 69.86 2.7
compressor house
 PROJECTS IMPLEMENTED
FROM 2008-2011
Total No of Projects implemented (Nos) : 55
Electrical Savings achieved (million units) : 50.54
Total investment (Rs in Million) : 225.45

21
 FUTURE PROJECTS
IMPROVE THE ROCKER ARM SEALING FOR LM35.4
EXISTING SYSTEM:
The original traditional sealing is having a gap and false air is as high as 22%-24 % due to wear of moving
parts.

PRPOSED SYSTEM:
The new improved design of sealing arrangement offered by Loesche.
INVESTMENT :Rs 65.85 Lacs
BENEFITS:
False air reduction by 4 - 5%.
Power Saving in raw mill fan of 0.92 Kwh/Ton of material.
Reduction in Maintenance time/cost.

REPLACEMENT OF CFG COOLER WITH CROSS BAR

EXISTING SYSTEM:
Existing grate cooler CIS/CFG (1st grate) /RFT (2nd & 3rd) Grate Area: 72 m2
Present heat consumption is 786 Kcal/Kg of clinker at 3125 TPD.

PROPOSED SYSTEM:
Proposed grate area : 77 m2 (IKN) & 81 m2 by FLS. FLS SF cooler with HRB

BENEFITS:
Cooler specific Power reduction by 2 KWH/T of Clinker
Specific heat consumption reduced by 20 Kcal/kg of clinker
22
INNOVATIVE ENVIRONMENT
PROJECTS IMPLEMENTED

23
 ALTERNATE FUEL SYSTEM

WASTE FUEL – MECHANISED FEEDING SYSTEM: A mechanized waste fuel feeding

system installed first time in India to reduce fossil fuel usage in Kiln

STORAGE FACILITY WEIGH FEEDER TRANSPORT SYSTEM 24

 ALTERNATE FUELS

DORB Municipal Waste Palm seed Shell Tyres Powder

Cashew nut Shells Coir Waste / Dust Match stick waste Refinery Sludge
Saw Dust Corn Waste Wood Strips Paint Sludge
Bio – compost Ground nut shell Shredded Tyres Tyre Chips
INNOVATIVE METHOD FOR FEEDING
ALTERNATE FUEL IN KILN ALTERNATE FUEL CONSUMPTION
ON CV BASIS
12.00 10.89 10.92
Low Availability
10.00
7.93 8.11
WOOD CHIPPING MACHINE 8.00

6.00 5.30
%

4.00

2.00

PLASTIC CHIPPING MACHINE 0.00

06-07 07-08 08-09 09-10 10-11 25
 CDM BENEFIT
30000
25060
23431
21004

CER in Nos
20000
14439

9792
10000

0
06-07 07-08 08-09 09-10 10-11

RECOGNITION

The First Cement Company in the

World to earn Carbon Credits by
using alternate fuels and earned 52
million selling credits to Europe
already part of the Aditya Birla
Group

26
 WASTE HEAT RECOVERY SYSTEM
WET FLY ASH DRYING SYSTEM

• Wet fly ash drying system installed to recover the cooler waste heat to dry the
wet fly ash.
• The heat available in the hot gas from the clinker cooler ESP during the clinker
production will be utilized to dry wet fly ash having moisture level of around 30%.
• The benefit is GHG emission reduction of 19344 T CO2/year by substituting
fossil fuel.

BENEFIT

•Reduction in CO2 Emission of 1800 TPA.

•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)
•Dry Fly ash generated through the system 15,956 TPA on Dry Fly ash
procurement.
 WASTE HEAT RECOVERY SYSTEM
FLOW DIGARAM
Bag House

Lump
Breaker

Cyclone
Wet
Fly Ash
Hopper
Flash To Fan & Chimney
Drier

HOT GASES FOM

COOLER
Weigh Dry
Feeder Fly Ash
Hopper
Screw
Feeder

To
Pneumatic
FLASH DRIER Conveying System
 CO2 emission reduction

6
5.34
5.19

5
4.47
Lac MT

3
08-09 09-10 10-11
 UTILISATION OF RENEWABLE ENERGY
Type of Installed 2008-09 2009-10 2010-11
RES Capacity
Energy Annual Energy Annual Energy Annual
in kW Generated Savings Generated Savings Generated Savings
(kWh) (Lacs Rs) (kWh) (Lacs Rs) (kWh) (Laces Rs)
Solar 500 W 10400 0.048 10400 0.036 10400 0.044

Wind (5*250) 1738109 7.66 2054163 7.12 2054163 8.74

KW
 ENVIRONMENTAL INITIATIVES

LIME STONE STORAGE YARD COVERED CONVEYORS CLINKER SILO COAL STORAGE YARD

RIPPER DOZER USED FOR MINING CONCRETE ROAD IN THE PLANT

31
 GREEN BELT DEVELOPMENT

• 33% of plant area covered with tree plantations

• Plants Survival rate - 96%
• Planted 61,642 Nos. of various trees So far developed - 59 Acres
 INVOLVEMENT OF EMPLOYEES,
TEAM WORK IN ENCON,
MONITORING & REPORTING AND
IMPLEMENTATION METHODOLOGY

33
 ENERGY CONSERVATION DAY CELEBRATIONS on 14th Dec 2010

ENERGY CONSERVATION AWARENESS - Drawing Competitions for school children's

 TEAM WORK IN ENCON
EMPLOYEE SUGGESTIONS/KAIZENS FOR CONSERVING ENERGY
& NATURAL REOURCES
Suggestion scheme is launched in RDCW which gives opportunity to employees for
direct participation in energy conservation & productivity improvement initiatives.

311
320.00
275
280.00
Nos of sugesstions/kaizens

240.00
implemented

200.00

160.00
127
120.00 94
80.00
80.00
06-07 07-08 08-09 09-10 10-11
Suggestion Award

35
 ENERGY MONITORING SYSTEMS

 ENERGY MANAGER software

 Individual MCC’s wise and section wise power details.

 Speed, load, current and running hours of all critical equipments.

 Compressors, water pumps and bore wells running hours.

 Start/stop power for all equipments

 Other important parameters like draft, temperature, feed rate are also
monitored and recorded.

 Online monitoring of parameters in DCS.

 HT motors power and temperature details

36
 VARIOUS ENERGY MONITORING SOURCES USED

 Daily Energy Report deviation analysis.

 Knowledge Manager.
 Daily Vibration & Bearing Temperature Deviation. Monitoring
 PI system available in all PC and everyone can monitor all parameters.
 Online Heat balance Software.
 Daily Monitoring of Utilization of Various Fuels.
Plot-0 0.11236
861.38
100 1000 100 79.931 GCS COOLER GRATE2LOAD
-5.0070
KW
GCS COOLER GRATE2SPEED
80 -124.12
RPM
GCS COOLER UNDERGRATE2SETPOINT
0.0000
mmWC
60

40

20

-20 -200 0
9/24/2009 1:05:55 AM 9/24/20093.34 hours AM
2:43:05.022 9/24/2009 4:26:07 AM
COOLER GRATE 2 LOAD COOLER GRATE 2 SPEED UNDERGRATE2 SETPOINT

37
 METHODOLOGY ADOPTED FOR ENERGY
MONITORING

 Energy management cell with clear cut responsibilities

 Daily monitoring of Energy Deviation report.

 Benchmarking National/International/group wise/Cluster units.

 Regular study of equipments on deviation and their analysis.

 Process evaluation & identification of energy conservation scope.

 Feasibility study of suggestions and designing proposals for sanctions.

 Taking corrective and preventive measures and ensuring

implementation.

 Organizing internal and external Energy Audit survey.

38
 METHODOLOGY ADOPTED FOR SUSTAINABILITY

DAILY:
 Daily Energy deviation report
 Energy Task Force Meeting
WEEKLY:
 Energy Conservation Meeting
 Capex Jobs/Project Meeting
 Section wise Fortnightly Review Meeting
 Weekly Review
MONTHLY:
 Power Comparison with group units
 Breakdown Analysis Report
 Master Action Plan Meeting
 Monthly Performance Meeting 39
UTILISATION OF WASTE
MATERIALS

40
 SLUDGE OIL FIRING SYSTEM
Trials with
Refinery
sludge
350 295

300
250
200

MT
150 91
73
100 44
28 30
50
0
05-06 06-07 07-08 08-09 09-10 10-11

DG SLUDGE GENERATED IS USED AS AN ALTERNATE FUEL &

FIRIED IN THE CALCINER.
 WASTE UTILISATION
Effective Usage of Reject Water in Process
FIRST RO PLANT SECOND RO PLANT
REJECT WATER PIT REJECT WATER PIT

SECOND RO PLANT REJECT

WATER PIT

Pump for conveying Reject Utilizing reject / waste water from power plant with
water to the Cement Plant help of return valves to cooler for cooling purpose
 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. Shell 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 & Condensate extraction pump
10. Optimisation of running of air compressors using Compressed Air
Management System.
11. Boiler feed water pump stage reduction.
43
ISO 9001, 14001,18001 & 27001 CERTIFICATION
AUDIT OBSERVATIONS (April-2011)
 Life stand still after Sun set - A total
of 1.6 billion people have no access
to electricity, 80% of them in India

Let us Conserve electricity to light up millions of homes.