Welcome To CII 13th National Award for Excellence in Energy Management 2012

UltraTech

UltraTech Cement Unit: Kotputli Cement Works

Contents
Unit profile Cement manufacturing process Energy Management System policy Unit performance over the years Energy monitoring methodology. ENCON measures taken Zero investment projects Small/Medium investment projects Large investment projects List of ENCON measures taken in last three years Environment/CSR initiatives Awards & accolades Way forward

Unit Profile
Kotputli Cement Works

3.3 MTPA capacity green field cement plant. An ISO 9001 & 14001 Certified company Equipped with Energy efficient equipments. New generation Pyro Floor clinker cooler. Energy efficient variable speed drives & MV drives for speed control of motors. 2 x 23 MW Captive power plant registered for CDM project. Efficient grinding mills with VRM technology.

Cement Manufacturing Process

Feed bins

LS Query Cooler ESP

Crusher

Raw material storage Preheater

Additive Materials
Baghouse

Coal

Coal Mill

Raw Mill Kiln

Cooler

Cem additive

Baghouse

Bulk dispatch

Packer

Cement Dispatch

Cement Mill

Energy Management System Policy

UNIT PERFORMANCE OVER THE YEARS

Clinker Production (Million MT) 4 3 2.29 2 1.21 1 0 2009-10 2010-11 2011-12 1 0 2.40
G O O D

Cement dispatch (Million MT) 4 3 2.15 2 1.05 1.55

G O O D

2009-10

2010-11

2011-12

Sp. Heat cons. (Kcal/kg clinker) 760 740 720 700 680
2009-10 2010-11 2011-12

Overall Sp. Power cons. (Kwh/MT cem)

G O O D

747
4.4 % reduction 2.4 % reduction

120 100 80 60 40

109.05

14.9 % reduction

92.85

14.0 % reduction

G O O D

714

79.85

697

2009-10

2010-11

2011-12

Unit Energy Performance Comparison: At A Glance

With benchmark/cluster units performances (Year 2011-12)
850

Sp. Heat Consumption (Kcal/kg clinker)

800 750 700 650 International Benchmark National Benchmark J K Cement ACC Cement Ambuja Cement Aditya Cement Kotputli Cement Works 682 681 779 742 739 699 697

Overall sp. Power Consumption (Kwh/MT cement)

120 100 80 60 40 International Benchmark National Benchmark J K Cement ACC Cement Ambuja Cement Aditya Cement Kotputli Cement Works 70 68 89

84

85

82

80

ENERGY MONITORING METHODOLOGY

Methodology for Energy Monitoring

Established energy management cell. Daily monitoring of energy deviation report. Analysis of equipment for deviation. Identification of energy conservation scope. Inviting suggestions under Energy Saving Scheme. Feasibility study of suggestion & submit proposal for sanction. Preparation of detail action plan. Weekly review to monitor scheme progress. Analysis for benefits after scheme implementation.

Energy Monitoring System

ENCON MEASURES TAKEN

Zero Investment Projects

Theme -1
Hydraulic cooler lane DP optimization with lane CPM
Issues : Frequent Cooler jamming/ stalling phenomena. Need to operate cooler fans at higher load to avoid cooler lane stalling. High Specific heat consumption due to
Sec.Air Tertiary Air Ex. air

unstable cooler operation.

Hot Clinker

Dust

COOLER
Clinker to Silo

Cooling Air

Approach: Correlation identified between cooler lane DP & cooler lane CPM (Cycle Per Minute). A PID was made for & further fine tuned as per operation parameters. Results : Specific heat consumption reduced by 3 Kcal/Kg Clinker. Kiln specific power reduced by 0.8 Kwh/MT clinker. High cooler recuperation efficiency. Cooler sp. air consumption reduced by 0.2 Nm3/Kg clinker. Kiln availability increased.

Theme -2
Kiln Sp. heat optimization by increasing sensible heat of Raw Meal
Ground material + Outlet gas Classifier Feed
Bag House

To Stack

Grinding rollers

Inlet feed RAW MILL

Hot air Grinding table

Ground Product + Outlet gas

Final Product to Raw Meal Silo Recirculated Gas Hot gases from PH outlet

Issues :

Material flow -Gas Flow

In routine operation raw mill outlet temperature maintained around 80-82 0C. Kiln feed temp after raw meal silo, measured as 72-73 0C. A potential identified to increase kiln feed sensible heat by increasing kiln feed temperature

Approach: Mill outlet temperature raised by increasing hot gases (from preheater) & optimizing recirculation/fresh air to mill subsequently. Water spray inside the mill optimized to stabilize mill operation.

Results: Kiln feed temperature raised by 8 0C. Kiln feed sensible heat increased by ~3 kcal/kg of clinker. Hot gases volumetric flow reduced from preheater to Bag house. Bag house fan sp. power reduced by 0.1 Kwh/MT clinker.

Theme -3
Energy savings in packing plant dedusting fans operation
Issues : Each Packer is equipped with de-dusting bag filter. Inlet dampers of bag filter fan set at 40% opening during normal Operation of packers. Fan Operation with damper control reduces its efficiency & results in wastage of power. Approach: Interconnection of fan Inlet ducts of 2 fans. This results in operation of two bag filters with single fan. Results : Energy saved by 0.3 Kwh/MT cement. Saving of O & M cost in 4 fans & motors.
Bag filter fan Bag filter fan (37 KW) New interconnection line provided Bag filter fan Bag filter fan (37 KW)

Theme -4
Diesel saving in cement mills during kiln shutdown
Issues : During Kiln shut down, Operation of HAG (Hot air Generator) is required for Cement Mills (VRM) operation. HAG consumes 500 litres of HSD per Hr of operation. Approach: Dam ring height increased to 390 mm to increase the material bed height. Water spray nozzle modified to reduce water consumption. Results : Diesel consumption reduced to 250 lit/hr. Saving of diesel consumption resulted into savings for Rs.176 Lac/ annum .

ENCON MEASURES TAKEN

Small/Medium Investment Projects

Theme -1
VFD installation & logic modification for dilution air fan
PH hot gases

Raw Mill

Bag House

Coal Mill

Issues :

DA Fan

Dilution air mixed with process hot gases to raw mill bag house (RMBH) to control bag house inlet temp. Thus to handle additional gas flow, RMBH fan rpm had to increase, resulting into130 KW more fan load. Dilution Air (DA) fan operation for round the clock at rated RPM. Damper regulated operation of DA fan.

Approach: Installed VFD for fan motor to regulate DA fan speed. Logic for controlling DA fan speed through RMBH inlet temperature. Interlock to stop DA fan when raw mill is in operation.

Results : RMBH fan flow reduced due to DA fan flow optimization. Energy saving by 0.3 Kwh /MT clinker.

Theme -2
Energy saving by LOW-NOX firing line modification
Coriolis feeder

Coal firing Blower (200 KW) 391 mm dia

Coal firing Blower (160 KW)

LOW NOX firing (Preheater)

Issues : Operation of 02 blowers required to maintain optimum coal conveying air velocity. Approach: To reduce conveying line diameter from 391 mm to 275 mm.

Results :
Coriolis feeder

Coal firing Blower (200 KW) 275 mm dia

Coal firing Blower (160 KW)

LOW NOX firing (Preheater)

Elimination of one 200 KW blower operation. single 160 KW blower is sufficient to deliver conveying air at set norms. 200 KW rated blower kept as hot standby spare blower. Electrical energy saving by 0.35 Kwh/MT clinker.

ENCON MEASURES TAKEN

Major Investment Projects

Theme -1
Cooler static grate modification
Issues : Poor cooler recuperation efficiency as ~ 65 %. High specific heat consumption as 705 Kcal/kg clinker. High kiln specific power consumption as 29 Kwh/MT clinker. High cooler specific air consumption as 2.0 Nm3/Kg clinker. Approach: Static grate area extension by 7.2 m2 with horse shoe design. Installed one additional fan for static grate. Enhanced pressure capacity of all fans in cooler.

Results : Kiln sp. power consumption reduced from 29 to 27.5 Kwh/MT clinker. Sp. heat consumption reduced from 705 Kcal /Kg to 695 Kcal/kg clinker. Cooler recuperation efficiency increased from 65 to 72%. Sp. air consumption lowered from 2.0 Nm3/Kg to 1.75 Nm3/kg clinker.

ENCON MEASURES TAKEN

List for projects executed in last three years

Energy saving initiatives taken

S. Energy Saving theme No. 1 2 3 4 5 Hydraulic cooler lane DP optimization with cooler lane CPM VFD installation & logic modification for dilution air Fan Energy saving by LOW-NOX firing line modification Fine controlling for raw mill fan speed by up gradation of GRR Energy saving by modification in gypsum feeding to reduce stoppages on account of wet/ sticky material Energy Saved Electrical Thermal (MWH) (Mkcal) 2534 1521 1109 929 622 9504 4879 Savings (In lac Rs.) 228.7 126.5 44.9 37.6 25.2

Energy conservation in packers dedusting 528 fan operation

23.5

Energy saving initiatives taken

S. Energy Saving theme No. 7 8 9 10 11 12 Optimization of compressor power through installation of air receivers To reduce diesel consumption in cement mill HAG during kiln shutdown Sp. power reduction in LS reclaimer by scrapper chain modification Savings Electrical Thermal (In lac (MWH) (Mkcal) Rs.) 446 201 1233 19.9 16.4 9.0 8.3 8.2 7.0 Energy Saved

Elimination of 7 air slide blowers in cement 206 transport circuit through line modification. To reduce power consumption by packing plant optimization. Energy saving by providing auto timer in office building centralized air conditioning 203 173

Energy saving initiatives taken

S. Energy Saving theme No. 13 14 15 16 17 18 Reduction in transformer losses by inter shifting of MCC power source Energy Saved Electrical (MWH) 138 Thermal (Mkcal) 9 Savings (In lac Rs.) 5.6 5.4 4.0 3.4 2.9 2.9

Fuel sp. heat optimization by increasing 119 kiln feed sensible heat To optimize air consumption in coal handling & lime stone circuit To reduce idle running of coal transport belt conveyors. To reduce head losses by modification in water pipe line lay out. To reduce firing blower power by kiln coal conveying line modification. 99 77 72 71

Energy saving initiatives taken

S. Energy Saving theme No. 19 20 21 22 23 24 To reduce power consumption by fly ash root blower modification Power saving by elimination of one belt conveyor in coal transport Installation of energy efficient fans in cooling towers Elimination of one pump by interconnection of both CBD tanks Energy saving by controlling CCR MCC Room lights. Installation of timer in water pumps Energy Saved Electrical (MWH) 59 49 44 21 20 Thermal (Mkcal) 119 Savings (In lac Rs.) 2.6 2.2 1.8 1.6 0.9 0.8

Energy saving initiatives taken

S. Energy Saving theme No. 25 Reduction in fuel consumption for HEMM by dust filter assembly modification To reduce clinker DPC idle running by providing clinker hopper level interlock To reduce idle running of gypsum transport group VFD installation in VRM water spray pumps Energy Saved Electrical Thermal (MWH) (Mkcal) 45 Savings (In lac Rs.) 0.6

26 27 28 29

12 8 8

15789

0.5 0.3 0.3 0.2 592

Energy saving by optimizing auxiliary run 5 time in grinding mills 9274

G. Total

ENVIRONMENTAL INITIATIVES

Environmental Initiatives

100 kw solar power plant in colony

Concreted roads & floor area

Asias largest clear span coal shed

Covered storage facility for raw materials, fuel & clinker

Covered conveyor belts & dust filters at all the material transfer points

Environmental Initiatives

20000 15000 10000 5000 0

15564 3416 2007-08 4026 2008-09 2009-10

16086 13267

2010-11

2011-12
Ground water recharging through injection well

Rich plantation area as 110.4 Hectare Sp. CO2 emission (Kg CO2/MT cement)
1000

794
750 500 250 0

759

720

2009-10

2010-11

2011-12

Rain Water Harvesting Ponds

Environmental Initiatives

Green Belt in Colony

Sapling Distribution to Villagers

Water Spray on Mines Haul Road to Control fugitive dust

Plantation across plant Boundary

Corporate Social Responsibility..

STRIVING FOR

Societal Change

Corporate Social Responsibility

Corporate CSR CSR Vision CSR Policy
Education

Focus Area
Social Causes Health Care

Infrastructure Development

Sustainable Livelihood

Corporate Social Responsibility

Emphasis on girls education Felicitation program for students Formation of Self Help Groups (SHG) Awareness campaign for Personal hygiene, Family planning, Immunization camps Infrastructure development for hospitals/ schools nearby. Association with NABARD for livelihood project

Awards & Accolades

Commendation Certificate for Energy Conservation

Commendation Certificate by the Ministry of Power, Government of India in recognition of efforts made to conserve the energy in year 2011.

Awards & Accolades

Felicitation by District administration for contribution in the Rescue operations

Felicitation by Mines Environment & Mines Conservation -MEMC (Ajmer region) in Noise & Vibration Control (Mines)
Mines- MEMC week Ajmer Region Third Prize in Afforestion & Plantation Third Prize in Welfare Amenities Protective Equipment & VT

Way Forward
Installation of VFD for crusher bag house fan. Installation of SPRS for raw mill fans. Optimization of clinker grinding power. Installation of 6 x 100 kw solar power plants. Usage of alternative fuels in kiln. Accreditation to ISO 50001- Energy Management System.

UltraTech Cement Kotputli Cement Works

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