AP Cement Works

Captive Power plant

A Unit of UltraTech Cement

Welcome to all

Integrity - commitment- Passion -Seamlessness -Speed 1

 APCW Cluster
A A - APCW – I.P. B
Phase 1 Clinker – 2.7 Million B- ARCW – G.U.
Ton 1.1 Million Ton
Phase 2 Clinker – 3.4 Million Cement
Ton
Total Cement – 6.4 Million
Ton C C- GICW – G.U.
1.2 Million Ton
Total Cement
Clinker : 6.1 Million D
Ton D - SBT – B.T.
Cement : 9.7 Million A
D 1.0 Million Ton
C Cement
Ton
B

2
4x25 MW TPP 1x4 MW WHRPP 2x11.7 MW WHRPP
First ISO:50001:2011 certified unit

Achieved 28206 ESCERTS in PAT cycle-1

Established first of its kind(in India) WHRPP

GreenCo Gold Award Unit

Day lights installation for all machinery buildings

Successfully completed Steam blowing with coal in place of HSD for

Boiler#4 (first time in the history of Thyssen Krupp Boilers).
 Energy Policy implemented in Dec –
2011

 Energy Policy states unit’s

commitment towards continual
energy performance improvement.

 Energy policy is communicated at all

levels.

 Energy policy is regularly reviewed

and last reviewed on 1st March’16.
Integrity - commitment- Passion -Seamlessness -Speed 6
To Reduce TPP Power Cost to the cement
plant by means :
To reduce the auxiliary consumption
To reduce the Plant heat rate .
 FH –CPP
SH-Energy
DH-Operation DH-Mechanical DH-E&I

SH Operation SH Mech SH-Electrical

Responsibility Chart:-
SH-Instrument

Hods/
SH Engineer Engineer Project
Step Project Initiation FH
(Opern) (E) (Electrical) leader
(TPP)
1 Data collection I R I A I
Equipment wise power consumption data
2 R R R A/C I
analysis
3 Identifying Power saving potential area R R R A C
4 Conduct Brain storming session R R R A C
5 Project Execution -PROCESS R I I A I
6 Project Execution -E&I I R I A I
7 Project Execution -MECH I I R A I
8 Post Evaluation R R R A C
9 Sharing of Outcome R R R A I
 Total TPP
Aux.

Common
Unit-1 Aux. Unit-2 Aux. Unit-3 Aux. Unit-4 Aux
Loads
Boiler Boiler Boiler Boiler
Fans CHP
Fans fans Fans

BFP BFP BFP BFP AHP

ESP AC &
ESP ESP ESP
PNV

TG Aux TG Aux TG Aux TG Aux Compr

ACC ACC ACC ACC

Fans WTP
Fans Fans Fans

ACC CEP ACC CEP ACC CEP ACC CEP Lighting

 Total Plant Heat rate
Tree

Coal Handling Steam turbine

Boiler losses ACC loss WTP Losses
plant losses loss

Handling loss Gland sealing Vacuum Higher blow

Dry FG loss
loss losses down

Higher
Wind loss Moisture in Stem Sub cooling
Makeup
fuel dumping loss loss
water

ESP H2 in fuel Friction loss

TG Aux Moisture in
Heaters TTD
Air

UBC in ash Heaters DCA

Radiation loss leakages

Monitoring System

Integrity - commitment- Passion -Seamlessness -Speed 11

Boiler&ST Heat Rate
G MCC Aux. Power Distribution section Wise
5% Losses Wagon
CEP&HTP Steam
AC Lighting 3% Loading
2% Dumping, 75,
2% 2% 0%
2%
Cooling ESP
Water 2% Vacuum
3% deviation, 0, 0%
Chillers
2% Boiler Inlet
Fans Parameters , 4,
CHP 32% Heat rate for 0%
2% Heater
Power Other, 325, effectiveness,
WTP Generation, 10% 17, 1%
Under load
0% 2918, 90%
operation, 183,
6%
ACC
7% Boiler
feed
Compress pump Dry fluegas
or 28% losses, 45, 1%
3%
Ash
Handling
5%
Ambient Temp: Avg 35.13/Max.41.00/Min28.71 22-03-2017Previous best 145.73 MW Aux 8.85% 29-03-2017 Aux 10.09%148.21 MWh
Bench
UOM mark Unit-1 Unit-2 Unit-3 Unit-4 Unit-1 Unit-2 Unit-3 Unit-4 Remarks
Generation MWH 0 506 575 572 0 385 538 546
Plant heat Rate Kcal/Kwh 0 3070 3004 2992 0 3170 3023 3015
Primary Air (PA) Fan Kw/MW 10.2 0.0 25.8 15.4 15.6 0.0 30.4 16.7 16.2
Boiler Oxygen Levels % 5.9 6.1 4.7 9.74 5.46 5.33
Secondary Air (SA) Fan Kw/MW 6.07 0.0 1.5 2.4 2.4 0.0 4.5 2.3 2.3
Induced draft (ID) Fan Kw/MW 10.5 0.0 8.0 6.2 6.2 0.0 12.7 6.0 6.1
Condensate Extraction Pump (CEP) Kw/MW 1.59 0.00 2.82 2.0 2.2 0.00 3.93 2.1 2.1
ACC fans & STG Kw/MW 3.05 0.0 31.8 10.8 8.3 0.0 32.3 11.4 11.5
Boiler Feed Pump (BFP) Kw/MW 22.6 28.4 27.5 35.6 28.0
Inst Compressors Kw/MW 2.4 2.9
Total 12 Rawmeal bowser
Service Compressors Kw/MW 4.26 4.3 3.8 unloaded
Water Treatment Plant (WTP ) Kw/MW 0.74 0.4 0.32m3/kwh 0.3 0.67m3/kwh
Coal Handling Plant (CHP) Kw/MW 0.61 1.6 1.3
CHP Performance KW/MT 2.85 --- --- 3.82 --- --- 3.84
Auxiliary Cooling Water Pump
(ACWP) Kw/MW 1.56 1.9 2.4
ESP MWH 0.832 0.558 0.547 0.865 0.702 0.552
Boiler MCC MWH 0.0 0.403 0.198 0.0 0.542 0.163
Emergency MCC MWH 0.5 0.2 0.386 0.014 0.3 0.2 0.386 0.014
Chiller &AC MW 2.632 2.636 2.720 2.767
Lighting Load & WTP Lab MWH 1.591 1.024 1.565 1.058
Wagon loading& coal Feeding MW 0.333 0.208
Transformer losses MW 5.877 5.440
Dump losses MT 44.000 19.0 14.0 35.000 13.0 15.0
Heat Rate losses Kcal/Kwh
Steam Dumping Losses Kcal/Kwh #DIV/0! 66.957 16.4 10.2 #DIV/0! 70.000 18.6 21.2
Inlet Parameters Deviation Kcal/Kwh 0.000 0.0 0.0 0.0 0.000 12.4 7.6 4.4
Heaters inefficient due to low flow Kcal/Kwh 0.000 0.0 9.9 6.4 0.000 0.0 7.0 4.0
Dry flue gas Losses due to Excess
Air Kcal/Kwh 0.000 0.0 47.8 42.3 0.000 61.5 14.3 19.6
Import from Grid MWh 7.417 12.000
Export to grid(IEX+Injection loss) MWh 18.133 13.000 IEX-0 MWH
Shutdown/Start-up power MWh 0.50

Remarks
 86.7 4th GCW 1st
VC
Plant load factor %

Aux. Consumption %
86.3 RDCW 11.47 RWCW
83.6 KCW
11.37 GCW
78 10.6
75.8
SCW 10.12 ACW
RCW 9.69 RCW
72.4 9.57
RWCW SCW
70.2 9.37
AC RDCW
56.9 9.25
50.8 VC 9.08 KCW
HCW APCW
0 5 10 15
0 20 40 60 80 100
RDCW
3305 334
Heat Rate Kcal/Kwh

VC 4th
AC
3172 325 ACW
APCW
3159 Generation 286
KCW
3127 ACW 281
3109 7th RCW 248 RCW
3103 RWCW 237 RWCW
3103 195 SCW
AC 112
3055 SCW 64 VC
3036 KCW HCW
0 100 200 300 400
2900 3000 3100 3200 3300 3400
 CFBC TPP Power share
with
APC % Net apc
ACC
12 10.95
10 13.31%
A
7.737.828.15 7.69
u 8 6.966.92
x
6
.
4
% 86.69%
2

0
15 18 25 25 27 30 250
Plant Capacity MW
 Action plan to Reduce Auxiliary power from present 9.3% to 7.6%
Expected Per day
S.NO Area Actions FPR Saving Target date
(KWH)
1 TPP Improve PLF by Power wheeling / selling to IEX VPG 1350 Continue
1. Reduce PA fan flow from 20 to 17.5 Kg/s.
2. Optimization of Oxygen in Boilers.
2 Boiler-PA Fan SKR 1250 30.12.17
3. False air entry to be arrested in APH.
4. Reduction of Bed Height from 1010 to 950 mm
1. Avoid parallel unloading of Raw meal Bowzers.
2. Stop Ash handling operation while Unloading of Raw meal
bowzers.
Target-7.2% APC in
3. Ensure Ash handling system operation in probe mode only and
optimize ash handling cyclic time.
Dalmia Cement CPP
4. Avoid Air Cleaning with compressed air.
5. Shut off Air valves of Phase-1 equipments while running only
3 Compressor
Phase-2 TPP is in operation.
,Karnataka SKR 1230 20.03.18
6. Run only VFD operated compressors.
7. Installation of low pressure Air Compressor for raw meal
unloading
8. Air audit to be conducted for CHP,AHP & boiler area

1. Single BFP operation whenever load is less than 16 MW to

operate Two Boilers.
4 Boiler- BFP SKR 960 15.12.17
2. During normal operation, BFPs to be operate in DP from 10 to
8 Kg/Cem2 while low load operation.
Installation of split AC's in office area & stopping 2 Units of
5 Air-Conditioning VPG 950 15.12.17
package AC.

Integrity - commitment- Passion -Seamlessness -Speed 16

 Reduce ACC fan speed from 30 to 20 % in winter or alternatively
6 ACC HH 600 15.12.17
reduce blade angle to reduce air flow.

7 TPP Substation Optimization of Transformer losses VPG 600 30.12.17

8 Boiler-ID Fan Reduce draft progressively from -30 to -20 Kg/cm2. SKR 320 30.12.17

1. Reduce ACW Pump discharge pressure from 3.5 to 2.8

9 Cooling Tower Kg/cem2. SKR/VPG 250 15.12.17
2. CT fan operation interlocked with temperature

Operate SA Fan in close loop with Bed temp and its logic
10 Boiler-SA Fan SKR/VPG 180 30.12.17
preperation in DCS

1. Minimizing Coal handling plant Idle running hours

11 CHP SKR 110 15.12.17
2. Stop Bag filters operation while Petcoke feeding.

1. Installation of solar day lights in WTP, TG building , Project &

Mechanical Workshop.
12 Lighting VPG 100
2. Installation of LED lights

30.01.17
Re-calibration of fuel feeder bed height from 30 TPH to 12 TPH
13 Boiler-Fuel Feeder VPG/VM 60 30.11.17
and logic preperation in DCS

14 WTP Operate WTP once in a Two days. SKR 44 15.12.17

Total Expected saving 8004

Integrity - commitment- Passion -Seamlessness -Speed 17

 Title of Project Annual Annual
Electrical Saving Thermal Saving
(kWh) In Mcal
1 Installation 4 nos of VFDs in ACC-3&4 1360000

2 PH-1 boilers after Heaters feed water inert 1420800

connection
3 Operation of HRPP 37 Kw compressor instead of 225060
160Kw
4 LED lights installation inPh-2 TG building& all areas 8689

5 Day lights installation in TPP 6307.2

6 Reduction of CEP discharge pressure from 8400

9.5 to 8 kg/cm2. and operate cascade operation
with Deaerator pressure
7 Arresting of False air entry in ESP-4 28749
8 Optimization of oxygen levels in Boilers 1626800
18
Intgrity - commitment- Passion -Seamlessness -Speed
 Title of Project Annual Annual
Electrical Saving Thermal Saving
(kWh) In Mcal
1 Auxiliary cooling water pump Corrocating to improve 87600
efficiency
2 Pentane pump VFD arrangement 569000
3 Lighting power optimisation done by providing 53674
occupancy sensor, local lighting switches
4 Chiller operation optimisation by providing 139392
single duct
5 Gravity line provided to makeup water instead of 86400
pumping
6 Boiler Blow down water heat recovery 615.543
7 Boiler fans IGV(Inlet Guide vane ) removal to 243936
Minimise suction pressure.
8 L.P.Heater drain line connection to CRT (Hot 15260
well Bypass)
9 VFD provided for Coal handling Dust extraction System 283532
19
Intgrity - commitment- Passion -Seamlessness -Speed
 Title of Project Annual Annual
Electrical Saving Thermal
(kWh) Saving In Mcal
1 To reduce power consumption of cooling water system.( 360000 -
Cooling towers interconnection )
2 Reduce power consumption of Compressors 520000
(Interconnection of Compressors)
3 To save fuel( HSD) by Doing Boiler-4 commissioning with - 1380000
coal
4 AC,p&vControl room AC One Unit stopped 131400
(Current temp setting is 24 deg,Incresed to 26 deg)

5 ACC fans power optimisation by locking maximum speed 596000

limit
6 ACC-2 bundle shifting/modification job,ACC-2, 1st row 618000
bundles are of HDG MOC and 4th Row bundles are of
Aluminium Extruded
7 Energy saving by stage blinding of Boiler feed pumps 713000

20
Intgrity - commitment- Passion -Seamlessness -Speed
Sn Savings in
o Project Status Kwh Savings in Thermal

1 Install Auto Star delta star convertor for identified under loaded belt conveyor motors Not feasible, It should be considered factor of safety. NA

2 Replace 150 W HPMV Lamps with 48 W LED lamps in TG hall Completed 1787

Phase manner changes with LED lights,200 no s

3 Install Energy efficient florescent lamps for boilers completed approx. 800 pending 22654

4 Reduce the pressure drop across the damper in L91BF1,L51BF2,L11BF1 Completed, All dampers removed 36500

5 Optimisation of instrument air Completed ,Auto drain valve timing adjusted 73000
Total-13
Completed-10
Completed, Reduces the compressor set point as equal
6 Optimisation of service air Not feasible -3 ,isnos
with IFC set point about 3.8 Kg/cm2 at end point 54750

Completed,ACW discharge pressure reduced from 4.2

7 Optimisation of cooling circuit Kg/cm2 to 3.2 Kg/cm2. 456250

Completed,VFD provided and Closed loop developed as

8 Optimisation of RO pump per process requirement. 18250

completed, Closed loop logic developed for avoid

9 Optimisation of Condensate extraction pump pressure drop across the control valve. 201600

Not feasible, While operating steam dumping at 100%

10 Install New efficient pump for CEP in all units additional flow required . NA

Closed loop logic developed with Steam drum pressure.

At pressure minimum DP across the BFP header to Drum
11 Reduce the pressure drop across the FRS in PH-2 BFP's maintained 8 Kg/cm2. 317550

12 Reduction in radiation losses in Boiler Completed ,Identified areas insulation completed 507480 Kcal

13 Installation of expert Optimisation system for CPP Not feasible. NA

Integrity - commitment- Passion -Seamlessness -Speed 21

 Scope 1 Total Reduction in Remarks
emissions CO e MT emission
CO e (MT) intensity since
baseline year
study

2013 - 14 401350 Base line year

2014-15 458620 4556

2015-16 611443 3541

2016-17 432895 9450

Integrity - commitment- Passion -Seamlessness -Speed 22

Sno Title
1 Installed fast bus transfer system to uninterrupted boiler operation While
tripping of turbine .
2 All VFD drives running with Closed loop operation Like Boiler feed pump,CEP
etc.
3 Provided 11 KV VFD with MV drive for Boiler feed pump
4 ESP Charging ratio 1:7 to 1:1 with maintained Environmental norms.
5 Interconnection of Instrument and Service air line
6 Boiler blow down heat recovery with heat Exchanger
7 Ejector Steam tapping from Extraction line in stead of Mainstream line
8 PPF usage instead of HSD for boiler start-up

Integrity - commitment- Passion -Seamlessness -Speed 23

• Installed 12 no's of light pipe for buildings and
Workshops .

Integrity - commitment- Passion -Seamlessness -Speed 24

Used 15.5 Mt of carbon black powder as
alternate fuel.

Integrity - commitment- Passion -Seamlessness -Speed 25

Two way transportation for Rawmeal and fly ash
handling with bulker.
Two way Transportation for Petcoke receipt and
Cement dispatch.

Integrity - commitment- Passion -Seamlessness -Speed 26

 Last 3 years
16.00

90 3400
14.00
13.71

88
88
87 3200
12.00 11.60 3167
11.03 3118
10.01 10.27 3034 3030
86 85.53003 3000
10.00

PHR Kcal/Kwh
APC %

84 2800
8.00

6.00
82
81 2600
81

4.00 80 2400

2.00 78 2200

0.00 76 2000
2013-14 2014-15 2015-16 2016-17 2017-18 2013-14 2014-15 2015-16 2016-17 2017-18
• Planted 200 No's Trees in CPP for Last year 16-
17 in the view of Vanam –Manam.

Integrity - commitment- Passion -Seamlessness -Speed 28

Integrity - commitment- Passion -Seamlessness -Speed 29