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Experience of Energy Management System

and Monitoring in Hatien-1 Cement Company

(Vicem Hatien)

Presented by Hoang Kim Cuong

Deputy General Director

Hatien-1 Cement JSC.

www.efficiency-from-germany.info

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Experience of Energy Management

System and Monitoring in Hatien-1 Cement Company

(Vicem Hatien)

23.3.2015 Ho chi Minh City

Presented by Hoang Kim Cuong

Deputy General Director

Hatien-1 Cement JSC.

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General

Kinds of used energy

Energy cost

Management

Implementation

Long-term plan

Conclusion

Outline

Energy Effect

Kinds of used energy

Energy cost

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• Since 1964

• 2 plants, 4 cement grinding terminals

• Employees: 2.870

• Production capacity:

– Clinker: 4,5 million tpy

– Cement: 7 million tpy

• Standards ISO 9001: 2008; ISO 14001:

2004; OHSAS 18001: 2007

General

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BINHPHUOC CEMENT PLANT

CAMRANH GRINDING

TERMINAL

PHUHUU GRINDING

TERMINAL

THUDUC GRINDING

TERMINALLONGAN GRINDING

TERMINAL

KIENLUONG CEMENT PLANT

SITE MAP

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Kinds of energy using

Electricity

32%

Coal

55%

DO, 1%

Oil from

cashew

nut shell,

6%

HFO, 3% Other, 2%

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Energy Cost

Energy typeConsumption

rateTarget better cost

Electrical energy for

producing clinker

64 … 85

kWh/T65 60 … 65 kWh/T

Anthracite Coal760 … 900

kCal/kg clinker760 720 kCal/kg

Electrical Energy for

producing cement

34 … 45

kWh/T cement

33 (VRM)

40 (BM)

33 (VRM)

40 (BM)

Product Energy cost / ex-work cost

Clinker 60% … 70%

Cement 5% … 10%

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0

5

10

15

20

25

30

35

40

45

50

55

50 55 60 65 70 75 80 85 90

Power consumption

Min 57.8 max 76.7 Avg 69.0 Median 69.0

0

10

20

30

40

50

60

70

80

90

100

110

60

0

62

5

65

0

67

5

70

0

72

5

75

0

77

5

80

0

82

5

85

0

87

5

90

0

92

5

95

0

Heat Consumption

Min 606 max 975 Avg 774 Median 767

Histogram of energy consumption of Binhphuoc Cement Plant for

clinker production - 2014

FrequencyFrequency

kWh/T clinkerkCal/kg clinker

10

vnd us

cent

0

5

10

15

20

25

30

35

40

45

50

55

20

25

30

35

40

45

50

55

Power consumption for Cement Grinding &

Despatch

Min 17.0 max 65.6 Avg 33.7 Median 32.5

Loesche’s Vertical Roller Mill

Binhphuoc Cement Plant

Histogram 2014

frequency

kWh/T cement 0

1

2

3

4

5

6

7

0

200

400

600

800

1 000

1 200

1 400

1 600

Power price (average), at 110 kV for production

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Management

Awareness of energy saving to

all employees

Upgrading technology

Optimizing operation

Modern technology during

project time

Looking other fuels as

alternative fuels for combustion,

Reducing fossil fuels

Making products with low

energy consumption

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Solutions

• Establish energy management system in each

plant

• Monitoring energy consumption of production

lines by daily report, studying abnormal things to

solve

Entry

Result

Report

Chart

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Solutions

• Executing energy audit by independent service

following government regulation, training for

internal energy audit

• Establishing energy management team in each

plant.

• Starting ISO 50001 from 2015

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Implementation

• Making category of loads according to the energy

unit

• Installing power meters for recording

• Connect to the control system for online

monitoring in each plant

“If you can’t measure it,

you can’t manage it”

Measurement

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Optimizing and improving the operation

Keep equipment operating at designed capacity or more,

not running at no-load or low load, avoid to start / stop

many time.

Increase the productivity of the ball mill by optimization

of the ball quantity.

Select the materials with good and correct quality.

Produce Portland Cement Blended (PCB-40 PCB-50) to

reduce clinker.

Mixing the components of raw materials in a correct

proportion to reduce heat energy (coal) for combustion.

Implementation

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Control operation

Assure that equipment operating properly,

avoid operation in rush hour for some

equipment.

Shut down the bag filter if production line

stops. Establish the bag filter operates in

automatic according to pressure difference

Assure that power factor above 0,9 in order to

reducing the inactive power

Optimize the compressed air system by

centralizing the control system and monitoring

losses

Implementation

Study experience among internal departments, with other

cement plants frequently in order to find the optimized parameter.

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Optimize the operation parameter

Implementation

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Enhancement of innovation

Encourage everyone give ideas for

upgrading equipment.

Improving the cooling water of

air compressor at cement grinding

and packing area, change the

electrical motor from 37 kW to 5,5

kW for a pump.

Redesign the chute, not use chain

conveyor under the chute (7,5kw),

lengthen the rubber conveyor

instead.

Implementation

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Installing the variable frequency converter for conveyor

2E1BC1. The power reduces from 120 kW to 66 kW. Saving

energy and keep the thickness of material layer to be stable for

PGNAA, ensure the analysis exactly

Enhancement of innovation

Implementation

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Increase the maintenance skill

Training to the maintenance team in order to

decreasing the maintenance time.

Apply preventive maintenance, solve all the repeated

problem thoroughly

Implementation

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Lighting and air conditioner

Lighting: reduce the number of lights reasonably, assembly the

automatic equipment for turning on / off the lighting.

Office: open window for sun light, turn off the equipment in the

room when no anyone in the room.

Air conditioners: set at 25oC .. 26oC for people and for

equipment room.

Step by step to change lighting with energy saving lamps

Implementation

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Implementation

Solution for cost saving

Alternative fuels that are using in Ha Tien 1:

Using a part of Indonesia anthracite coal

(high/medium volatile substance, cheaper price)

for producing clinker.

Oil from cashew nut husk to replace HFO for

combustion in the kiln at Kienluong Cement

plant

Using FO-R (recycle product from wasted

rubber) to replace DO at Binhphuoc cement plant

Using cashew nut husk (after extracting oil) as

an alternative fuel in Binhphuoc cement plant

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Implementation

Solution for cost saving

Using rice husk to replace HFO

at Phuhuu grinding Terminal.

Use wasted heat from kiln to heat

the coal mill instead of HFO at

Kienluong cement plant

These do not save energy but

reduce energy cost and contribute

to reduce CO2 emissions.

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Implementation Typical unit price of some fuels - 2015unit: vnđ/kCal, including logistic cost, no VAT

HFO DO FO-R Cashew oil

Rice husk

Coal 3c

Indo. Coal

Cashew nut

shell

1.3 1.6 1.4 1.1 0.57 0.44 0.38 0.3

1.9 2.3 1.8 1.3 0.4

HCM City

Binhphuoc

Binhphuoc

Kienluong

HCMCPhuhuu

Binhphuoc

Binhphuoc

Binhphuoc

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Long-term plans

Continue to study “Variable frequency converter”

to regulate the flow of the fans instead of dampers.

Optimize the production process, Looking for the

optimization software for operation of the rotary

kiln.

Upgrade technology: replace planet cooling

system with clinker grate cooler. Improving the

preheater of old kiln, use high efficiency burner

for old clinker production line at Kienluong plant.

Study of mineral additives to use for combustion

in the kiln to reducing the heat consumption.

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Study to burn other wastes.

Implement the project of

waste heat recovery system

to generate electricity for

new kiln at Kienluong plant

and Binhphuoc plant. This

will save about 15%

electrical energy for each

plant.

Long-term plans

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Conclusion

Cost saving is different from energy saving,

but both of these are directed to use energy

efficiently

Use energy saving and efficiency will be increasing the

competitiveness of enterprises. It also contributes to reducing

CO2 emissions, towards the goal of sustainable development of

enterprises.

Hatien-1 always thinks about energy saving

and efficiency, gradually optimizing and

improving energy efficiency

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