National Award for Excellence in Energy Management … Award... · by CII Sohrabji Godrej Green...

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ACC Lakheri Cement Works Strength Performance Passion 1st - 2nd Sept.’ 2010

National Award for Excellence in

Energy Management – 2010

by CII Sohrabji Godrej Green Business Centre

ACC Lakheri Cement Works

Lakheri, Bundi, Rajasthan

2ACC Lakheri Cement Works 1st - 2nd Sept‘2010Strength Performance Passion

Lakheri Cement Works

India

Rajasthan

DT. BUNDI

PIN 323603

KOTA 78 km

Tel:

07438 261642

Altitude 224.6 mt

Avg Rain 800 mm

Min Temp 2.0 d c

Max temp 48.5 d c

RH 30~70 %

Population 40000 #

About Lakheri

2


100 Year old Heritage Cement Plant of India

Lakheri with Old lime kilns in 1905

Journey on the tough Path

A fusion-1905 with 2007

Safety officer

of the day


§ Name of plant : Lakheri Cement Works

§ Year of establishment : 1917

§ I up-gradation, 1997 : Wet to Dry process 0.48 MTPA

§ II up-gradation, 2007 : addn’ 1 PH with calciner string

§ Present capacity : 1.5 MTPA

§ Process : Dry

§ No of Kilns : One (1)

§ Types of cement produced : PPC & OPC

§ Captive Power Plant (CPP) : 25 MW

Major suppliers of plant & machinery: Alstom, Pfeiffer, Siemens, ABB, SKF, FLSmidth, BHEL, ELGI, Elecon, MICO, GE, etc.

Company Profile

3


0

200000

400000

600000

800000

1000000

1200000

1400000

1600000

1995-96

1998-99

2002-03

2005 2007 2008 2009 2010 2011 2012 2013

Clinker Total Cement PPC

Before 1997

After Ist up gradation

After In plant

Kaizens

After IInd modificatio

n

PlanAfter Shikhar

Company Profile


Process Flow

Clinkerproduction

Raw materialpreparation

Raw mealpreparation

Cementgrinding

Shipping station Shipping

station

Raw materialextraction

4


v Energy, Environment, OH&S, Shikhar and Quality Policyv Engagement of all level workforce-From shop floor to top

managementv Management by numbers- target v/s actual v/s aspirationsv Daily Performance board discussion at work site by shop floorv Use of problem solving tools-RCA, Ideation, SBS ....etcv Weekly Dash board to review and setting new targetsv Monitoring of Online power consumption daily v Analysis of the deviations Specific equipment wisev SOP, SLA, Nukkads and Training v Formed an Energy Cell at corporate level ( Act as facilitator)

and plant level with Energy Manager as coordinator and participation of various HODs for implementation of identified projects

Management Tools


Management commitment 100%

Team selection in such a way to ensure cooperation between members across departments and across all hierarchy levels

5


Engagement of all – Management and workers


Training for all – MS and NMS

Training

6


Chief manager, CPP

Chief manager, production

RM – HeadRM – HeadIf fly ash silo is full, location of fly ash unloading to be jointly assessed

QA headChief manager , Production

QA headSite lab shift chemistTest results passed on to QA head

Chief manager, CPP; Chief manager, Production, Head –Operations

Head process – Cement mill

Head –quality control

Site lab shift chemistUnloading of fly ash

LOI < 3%; Ratio 1:1

LOI > 4, <5 Ratio 2:1

LOI > 5, -nil

Site lab shift chemist

Chief manager, CPP

Shift incharge CPP

CPP lab chemist (day) / Shift Incharge CPP (A shift) + Site lab shift chemist

Joint testing of LOI and generate test results in 1.5 hours

Site lab shift chemist

Chief manager, CPP

HOD – CPP operations

CPP lab chemist (day) / Shift Incharge CPP (A shift) + Site lab shift chemist

Joint sampling by 2 people from 1 bulker per shift at bulker unloading location in CPP to be sent for testing

InformedConsultedAccountableResponsibleDecision/Information

If fly ash from CPP is unutilized and PPC runs in old mill, 2 bulkers to be used per day in old cement mills to make use of 250 tons of CPP fly ash per day

* Subject to final product quality

Standard operating procedure for use of CPP fly ash in CM


v Brainstorming for energy conservation.

v Small group and kaizen teams are formed comprising of workmen and middle management staff which work towards focused improvements for enhancing the productivity and energy conservation.

v Implementation of energy consumption projects identified throughideation and kaizen teams.

v Internal and external training Programme for all.

v Energy awareness Programme like painting, quiz, slogan, Nukkad conducted at nearby school and plant level.

v Employees are awarded for best innovative projects at plant level, R.O level and H.O level

v Best Kaizen and suggestion from SHIKHAR suggestion box scheme are awarded every month.

v Conducted Internal & external Energy Audits

Energy Conservation Activities

7


Management Commitment “Tomorrow Matters”

Energy Policy

Lakheri Cement Works, a unit of ACC Limited is committed to formulate and implement “Total Energy Management System” and in the process, continuously strive to improve the energy performance in all its activities through -

• Reduction in energy consumption by continuously improving the manufacturing process, without impairing productivity• Minimising the waste and utilise the same for value addition• Adopting energy efficient technologies and optimise utilization of fuels and other resources• Creating awareness among employees through various fora, upgrade their skills to conserve energy and natural resources, to achieve the above goals

-sd-Director Plant

Date: 18.08.2007 Lakheri Cement Works


Chairperson - Director Plant

Head Plant Operation

CORE

COMM

I

T

T

EE

Chairperson-HPO

Chief Mgr

E&I

OP

E

R

A

T

I

ON

A

L

T

E

AM

Chief Mgr

E&I

Chief Mgr Production

Head

Engg.

Head

Mining

Chief Mgr

Finance

Energy

Manager

Energy

Manager

Chief Mgr

Production

Head

Mining

Head

Engineering

HOD

Mines

HOD

Cement Mill

HOD

Kiln

HOD

W/S

HOD

CR

HOD

VRM

HOD

E&I

HOD

Packing

Energy Conservation Cell

8


Energy Monitoring System


Daily Format Monthly Format

Energy Reporting Format

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Energy Variance - Daily /weekly Review


Mass Brain storming session on ENCON

Daily Performance board meeting at site

Engagement of All Level Employee

RCA

High power

consumption in kiln &

coal Mill

MachineMan

MethodMaterial

Idle running

Burner pipe for pet coke grinding

BH RAL frequently start / stop

Size of input

Variation in input quality

Kiln Output

Down comer

duct water spray

Awareness against

operatorsHot seat changeover

VRM stoppages affect to

RA fan/dilutio

n fan Leakages in circuit

RA fan in direct mode

Lack awareness of shift

performance

Clinker extraction belt &

DBC

10


Ideation session


Mass Brain storming session on ENCON

Nukkad by plant Employee on ENCON

Painting competition at school on ENCON

Participation on ENCON programme

Energy Quiz Competition at Colony

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98.45

93.8191.19

84.287

75

80

85

90

95

100

2007 2008 2009 2010 (Jan- Jul)

Target2010

Specific Electrical Energy (Unit/ Ton Cement)

Specific Energy Consumption

726723

721

710 710

700

705

710

715

720

725

730

2007 2008 2009 2010 (Jan- Jul)

Target2010

Specific Thermal Energy ( Kcal/ Kg Clinker)

Specific Electrical Energy

Specific Thermal Energy


18.92 17.2515.36

0.004.008.00

12.0016.0020.00

kWh/ ton Mat.

RML

2008 2009 2010 (Jan-Jul)

39.6037.57

34.99

30.00

32.00

34.00

36.00

38.00

40.00

kWh/ ton Mat.

Cement

2008 2009 2010 (Jan-Jul)

1.80 1.781.45

0.000.501.001.502.00

kWh/ ton Mat.

RMP

2008 2009 2010 (Jan-Jul)

Section Wise Specific Energy Reduction

68.08 65.8761.97

55.0058.0061.0064.0067.0070.00

kWh/ ton Clinker.

Clinkerisation

2008 2009 2010 (Jan-Jul)

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Source: CII-GBC Green Cementech Conference 2010, Hyderabad

National & International Benchmark

63 65

84.2

0

20

40

60

80

100

kWh/ ton Cement

National Bench Mark

InternationalBench Mark

LakheriCement

Comparison of Specific

Electrical Energy

Comparison of Specific Thermal

Energy

663 663710

500

550

600

650

700

kcal/kg Clinker

National BenchMark

InternationalBench Mark

LakheriCement


0.35Installation of Capacitor Banks to improve the Power factor and hence operating efficiency of TG

5.0Installation of Pregrinder in cement mill -06

7.3TOTAL

0.40Medium Voltage Drives (HT VFD) for Coal Mill Vent Fan - 650 KW

1.48

Retrofit impeller of high efficiency (78-80% at operating parameters) in VRM -1 Fan for Power saving

1.25Medium Voltage Drives (HT VFD) for Calciner Fan - 1200 KW

Unit/ ton cmt

Description

Road map to achieve bench mark…..

Electrical Energy

13


10TOTAL

2Kiln inlet seal modification-Utilisation of waste heat from Preheater exhaust8

Modification of remaining Cyclone for improvement of collection efficiency and thermal efficiency

Unit/ kg clkDescription

Road map to achieve bench mark…..

Thermal energy


§ Energy Conservation Projects (Last 3 years summary)qNo investmentNo of project implemented : 44Total Electrical Energy Saving : 4.86 Million kWh

q Medium InvestmentNo of project implemented : 19

Total Electrical Energy Saving : 5.18 Million kWh or Total Thermal energy Saving : 1575 Million kcal

= 270 tons CoalNet CO2 reduction : 8248 Ts

Excellence in Energy Management

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0.11.4Increased availability of VRM -2 by providing chute with manual knife gate to clear accumulation in inlet duct

NIL0.6Optimization of coal vibrating screen for coal feeding to CPP

0.050.4Optimization of Lime stone crusher Feeding system

NIL0.84Effective utilization of coal circuit compressor for CM 6 operation and stopping one compressor of CM 6

0.21.2Replacement of Old & inefficient Cement Mill Crane motors

Investment(Rs.

Million)

Annual Saving

(Rs. Million)

Title of the Projects Implemented

Energy Conservation Projects in year 2007


0.060.55Installation of VFD for Raw coal push feeder for feed control

Nominal0.40Automation for Plant Lightning of crusher, kiln, coal handling, VRM and Cement Mill depts.

0.040.3Modification in impeller of high suction water pump, resulting improved life and reduction in power consumption

0.081.41Modification in central feed pipe of VRM, resulting increased availability

0.060.25Replacing 400 conventional lamps by CFL lamps

Investment(Rs. Million)

Annual Saving

(Rs. Million)



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2.9510.68TOTAL

0.150.53Optimization of cement feeding circuit by stopping the Bucket elevator of Packer 1&3 when ever direct extraction from new silo

NIL0.171Reduction in Idle running of Auxiliaries circuit of pyro-process section with interlocking

0.10.43Installation of flap damper at New VRM Mill rejects system to avoid ingress of false air

0.11.42Modifications in GRR of New VRM fan to regulate the speed

Investment(Rs.

Million)

Annual Saving

(Rs. Million)

Title of the Projects ImplementedEnergy Conservation Projects in year 2007


NIL0.576Energy Saving by stopping one compressor 332CP02

NIL0.2Auto start/stop of Pre heater tank water pump

NIL1.58Speed control of New Pre-heater Fan by modifications in GRR Panel as per process requirement

0.81.56VVVF drive in Cement Mill vent fan

0.61.152E-Mill Bag house fan impeller is replaced with suitable design impeller


Annual Saving

(Rs. Million)



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1.579.0TOTAL

NIL0.6Removal of New VRM fan Inlet orifice to reduce pressure drop

NIL1.2Reduction power consumption by switching off the RABH hoppers Heaters of both the strings.

NIL0.56Dilution Air Fan operation, optimization in compound mode (New VRM running)

NIL0.16Optimization of ESP side cooling blower motor

0.1681.08CFL for colony residence lighting


Annual Saving

(Rs. Million)




3.06.0

Modification in new P.H. lower(C-7) cyclone inlet ,top cyclone(C-1) inlet & dip tube height and Cooler IKN Horse shoe modification)

0.70.95Installation of VFD drive for cooler fan no3, fan no -04

1.442.03Install Multi step capacity controller on selected compressors to optimize operating pressure

1.050.84Installation of VFD for DC Fan in VRM, Packer 4, Primary Crusher

0.7880.19Replacement of low efficiency pumps with a single high efficiency pump


Annual Saving

(Rs. Million)Title of the Projects Implemented


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NIL0.56Dilution Air Fan operation, optimization in compound mode (New VRM running)

NIL0.63Rectify unloading system to reduce unload power for 160 kW screw compressor no.332 CP O4

NIL0.32Reduce operating pressure range for compressors (N0.332CP04,332CP03,442 CP 01)

NIL0.25Operate 132 kW compressor and stop 160 kW compressor top reduce operating load/unload power


Annual Saving

(Rs. Million)




0.61.58Installation of GRR in E-mill Fan

NIL0.14Idle running of dust separation group to be avoided by interlocking with wobbler group

NIL8.56

Mill out put and Sp power optimization through (1) Process optimization (increasing grinding press) (2) size of mill feed L/S (3) Usage of Marvel slurry 4) Mill fan inlet damper removal

0.1350.40CFL for colony residence lighting (1500 nos)

Investment(Rs.

Million)

Annual Saving

(Rs. Million)



18


nominal0.81

Power saving by using 556CP01/CP02 air to old cement mill by providing separate CM-06 GGLS compressor and stopping one old cement mill compressor.

7.8227.75TOTAL

nominal2.59Cement mill power reduction through output Optimization by additive dosing

NIL0.92PID control of cooler fan operation

nominal0.22

Area increased by Removing inlet silencer of cooler fan ( High pressure drop in cooler fan3,5 & 8)* Saving=0.25unit/mmWg*3


Annual Saving

(Rs. Million)Title of the Projects Implemented



Project Title: Utilization of Marble industry waste-Marble slurry as Alternate Raw Material

§ Threats:- Huge generation of Marble slurry by Marble industry and accumulation in near by area – Concern to Environment.- Lakheri Plant own lime stone is Silica rich.- Fast depletion natural deposit of lime stone.

§ Opportunities : - Being fine powder not required crushing and grinding process - Huge availability of marble slurry in nearby area.- Low silica contents of Marble slurry supports LK raw-mix - MgO in MS facilitates burning - reducing fluxing agents.- Higher fineness increase the reactivity of Raw mix

Innovative Project - 1

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Contd….Innovative Project -1

§ Challenges Faced: - Due to higher moisture content & its extreme fineness.- Transportation and handling is a big task.§ Advantages: - Conserve natural lime stone deposits 6-8%.- Productivity of Raw mill increased by 11 %.- Due to fine powder bypassed two process of energy consumption crushing and grinding.- Power Saving in Raw mill by 9.5 %.

§ Energy Savings: - Specific energy reduces 1.82 kWh/ ton material.- Total Energy Saved in 2009 = 2.17 Million kWh.- Annual Saving = Rs 8.7 Million


Project Title: Utilization of Fertilizer Industry waste – Lime sludge as Alternate Raw Material

§ Threats:- Huge generation of Lime Sludge by Fertilizer industry and–

Concern to Environment.§ Opportunities :

- Being fine powder not required crushing and grinding process - Huge availability in nearby area-78 km away.- Low silica contents and other chemical parameters supports

LK raw-mix - Higher fineness and minor constituents acts as mineralizer


20


Contd……Innovative Project -2

§ Challenges Faced: - Higher moisture and slushy nature. - Excessive fineness and foreign material.- Transportation and handling is a big task.§ Advantages: - Conserve natural lime stone deposits 1.5-2.5%.- By pass of two process of energy consumption -

crushing and grinding.

§ Energy Savings: - Specific energy reduction and conservation of natural lime stone resources.


§ Project Title : Reduction in power consumption and CO2 by using self developed grinding additives which enhanced Cement mill output and improving particle size, increase fly ash absorption.

§Threats:-Higher power consumption. -Hard Clinker property .-Higher residue of cement on 45 micron.

§ Opportunities:- Qualified & competent Engineers.- R&D facilities at plant site and research station at Thane.- Availability of latest testing facility.


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Contd…….Innovative Projects - 3§ Methodology:- After R&D and with the support of Research Station

Thane LK developed additives which facilitates grinding process and enhancing fineness.

- Developed in plant automated chemical dosing system.

§ Advantages:- Reduce residue at 45 micron by 2-3 %.- Enhancing the productivity by 8.0 %- Reduce power consumption by 5.4 %- Improve fly ash absorption by 1% in overall PPC

production.


§ Savings:- Year avg. FA increased from 25.70 to 26.74 % i.e. increase of

fly ash around ~ 1.04 % in overall PPC production.- Maximum Monthly average achieved = 28.4 %.- Annual saving @ 26.74% = Rs 1.05 Crore

• Energy Saving:- Specific power reduction = 1.25 unit /ton cement.- Yearly production = 12.95 lac ton- Annual Cost saving = 12.95*1.25*4.1= Rs 67.68 Lac- Total Saving =Rs ( 1.05+67.86)=Rs 1.72 Crore

• Other Benefit :- Conservation of Natural Resources.- Reduction in CO2 emission

Contd…….Innovative Projects - 3

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Project Title : Improvement of preheater cyclone collection efficiency.

§ Threats:- Higher Kiln and Calciner Preheater exit temperature.- Higher specific thermal energy consumption.- Lower preheater cyclone velocity (9.0 -11.0 m/sec)- Lower cyclones collection efficiency.

§ Opportunities:- Competent team to study heat and mass balance.- Availability of design study support tools.- Potential to reduce thermal energy.

Innovative Projects - 4


8

ACC Limited

Cyclone Modification

Reduction in cross section

area

5.13 m2

4.08 m2

Reduction in cross section

area

Increase in DT height

0.5 m

4.3 m2

3.32 m2

1.7 m

K6

K1

Contd……Innovative Projects - 4

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§ Methodology:

- Studied the system heat & mass balance.- Did design modification to increase inlet gas velocity.

§ Advantages:

- Inlet gas velocity has increased to 15-18 m/sec.- Increased 10-12 % production efficiency.- Reduce Preheater outlet (both string ) temperature by 15-20

Deg C- Saving of Rs 0.7 Crore per annum

Contd…….Innovative Projects - 4


Project Title: Utilization of Petroleum industry waste-Pet Coke as Alternate Fuel

§ Threats:- Higher ash contents of Indian Coal - Lakheri Plant own lime stone is Lime deficit.- Fast depletion natural deposit of lime stone and Fossil fuel.- Non availability of preblending system- Higher sulphur contents of Pet coke

§ Opportunities : - Low ash contents of pet coke- Huge availability and low rate.- Use of high silica lime stone of own mines increasing mine life.


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Contd……Innovative Project -5

§ Challenges Faced: - Frequent jamming problems at various places - Low Kiln burner flame momentum.- Transportation, handling and separate grinding § Advantages: - Conserve natural lime stone 6%- fossil fuel deposits by 25%- Consistency in clinker quality STD < 1.5

§ Energy Savings: - Specific energy reduces 0.42 kWh/ ton clinker.


Project Title: 100% Utilization of Own CPP Waste- Fly Ash§ Threats:

- Higher LOI of Fly ash- Disposal and Environmental issues- Scarcity of fly ash from thermal power station

§ Opportunities : - Availability of zero cost Fly ash- CO2 reduction by eliminating distant transportation

§ Challenges Faced: - Blending with thermal Fly ash, maintaining quality.

Advantages: -zero environment harm and reduction in CO2

Energy Savings: - HSD cons. reduction by 175 Kl / annum - CO2 Reduction by 469 Ts / annum


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Thermal Efficiency improvement

Pet coke utilization in Kiln

Continuous Corporate Level Recognition for Innovative Projects


Utilization of biomass ,agro waste, tyre chips in kiln

Green field development in lime stone mines area by Plantation of 50,000 Zatropha saplings

Installation of 7.5 MW wind turbine for power generation

Opacity meters for continuous dust monitoring

Continuous weather monitoring system

Environment monitoring Van for plant and surrounding

Continuous ambient air motoring system

Establishment of Environment Lab

Sealing of Clinker silo open area

Major Environmental Projects

Environmental Projects

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Installation of Bag Filter in Long belt no.1 tail end for dust extraction.Installation of Bag Filter in Long belt no.2 tail end for dust extraction

Mechanized cleaning of factory roads from Road sweeper

Using waste of other industries as a resources (Marble slurry asraw material)

Covered storage and dust suppression for materialsElectro Static Precipitator (ESP) for cooler and CPP

Bag filters for fugitive and stack emission control Kiln Reverse Air Bag House (RABH).

Major Environmental Projects



RABH

ESP

Air Cooling Tower

Sewage Water Treatment


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Continuous Meteorological monitoring system


Jatropha Plantation 7.5 MW Wind power


Marble Slurry Bio mass

Shredded TiresAFR feeding

Alternative Raw materials

• Marble Slurry

• Lime Sludge

• Coagulation Sludge

Alternative Fuels

• Biomass - Mustard Husk, Saw Dust, Rice Husk, tree pruning etc.

• Shredded Tires

• Industrial Solid Waste

• Expired Products

• ETP Sludge

Expired Products Jatropha Plantation

Utilization Of Waste

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8.019571266.88Total AFR_0.080.3MSW0.161927.9White Coal

0.111341.15ETP bio solid sludge

0.3854671.26Nivea Waste products0.075921Animal Waste

3.08368207.27Scrap tyre cutting3.45412721Mustard Husk0.7488174Saw dust

0.01723Soya bean Waste

Waste fuel as % of total energy

Equivalent of Conventional energy

used (kWh of electricity or Ton / kL of fuel)

Quantity of waste fuel used

(Tons or any other Eq Unit)

Type of Waste Fuel used

Utilization Of Waste as AF


Wind PowerInstalled Capacity = 7.5 MW

Total Generation

2008 = 37.8 Lac Unit

2009 = 140.4 Lac Unit

CO2 reduction = 22800 tons

Biomass(Mustard Husk, Saw Dust, rice Husk,

tree pruning etc)

Total Biomass Used

2008 = 400 Tons

2009 = 900 Tons

CO2 reduction = 988 tons

Green Energy

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§ Greentech Safety Award –2010 ( silver category) in Cement Sector

§ Rajasthan Energy conservation Award 2009.

§ Golden Peacock Environment Management Award – 2009.

§ Greentech Environment Excellence Award - 2009

§ Global Cement Award -2006

Awards and Accolades

Rajasthan ENCON Award from Hon Power minister Raj.

Greentech Safety Award-2010

GPEMA Award-2009


ISO 9001:2008 and ISO 14001 AuditContinual improvement of the effectiveness of QMS & EMS –Implementation corrective and preventive actions

No Non-conformities (Major/Minor) for ISO -

9001:2008 during external audit.

No major Non conformities of ISO-14001:2004

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Release of ACC Sustainable Development Reports 2007 & 2009


Global Recognition of ACC Lakheri as Best Improver in Holcim group Companies

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Thank You

Q & A

National Award for Excellence in Energy Management … Award... · by CII Sohrabji Godrej Green...

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Transcript of National Award for Excellence in Energy Management … Award... · by CII Sohrabji Godrej Green...