Trusted Technology Solid Strength Cement_61_Kesoram...Trusted Technology - Solid Strength PAT...
Transcript of Trusted Technology Solid Strength Cement_61_Kesoram...Trusted Technology - Solid Strength PAT...
Trusted Technology – Solid Strength
Trusted Technology - Solid Strength
PRODUCTS
MINE SITE
GULBARGA
☺❖
❖
PLANT SITE
Mining Crushing Stacking & Reclaiming
Clinkerisation
ClinkerGrinding
Packing
Delivery Truck
Coal Grinding
Delivery Rack
Delivery Bulk
Raw MealGrinding
Stacking & Reclaiming
Trusted Technology - Solid Strength
Total Sp. Power Consumption Overall (All Grades) (Kwh/Ton of Cement )
10-11 11-12 12-13 13-14
Kw
h/T
on
of
Ce
me
nt
14-15 15-16 16 - 17
High producti
on in pet coke
Sp. Power Consumption up to Clinkerisation (Kwh/Ton of Clinker )
14-15 15-16 16 - 17
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Sp. Power Consumption on cement grinding (Kwh/Ton of Cement )
Kw
h/T
on
of
Ce
me
nt
14-15 15-16 16 - 17
Sp. Power Consumption on cement Packing (Kwh/Ton of Cement )
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SP. POWER CONSUMPTION ON PPC GRADE (Kwh/Ton of Cement )
Kw
h/T
on
of
Ce
me
nt
Year
Even after Use of pet coke
&Premium cement Trials with 18% FA
Clinker Factor for OPC cement
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Specific Thermal Energy Consumption
K.C
al/K
g C
lk
Low Sp. Heat value even
after regular pet coke use
Bench Mark Comparison with other Industry:
S.No Energy UnitNational
bestInternational best
VC Value
1Thermal
energyKcal / kg clinker 682
667 (Japan)
(values for 16-17)
706.94
(Avg of all four
units)
2Electrical
energy
KWH /MT
Cement (Actual)
(100 % PPC)
65.67 65 (Japan) 56.98
Trusted Technology - Solid Strength
PAT Requirement• New Target of 4.53 % reduction from 949 to 906 K.Cal /Kg Equivalent major Cement
Product given to us
• M/s. Zenith Energy Ltd. has carried out M&V audit, VC has Earned 50741 E-Certs in cycle 1
Base Line value
2010-11 2011-12 2012-13 2013-14 2014-15 2015-16
Heat Value KCal / Kg of Equ of cement
1098.82 1102.30 1097.56 1076.05 996.606 910.00 734.00
Green House Gases Sl.No
YearScope 1 emissions
KgCO2/MT of cement
Scope 2 emissionsKgCO2/MT of
cement
Scope 3 emissionsKgCO2/MT of
cement
Total KgCO2/MT of
cement
1 2014-15 441 238 0 679
2 2015-16 458 260 0 718
3 2016-17 457 247 0 704
4 2017-18 440 240 0 680
Green House Gases
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Utilization of Waste as fuel (Alternate Fuel Utilization)
AFR Consumed MT
2015-16 2016-17 2017-18
Consumed, MT
Coal Saved
Consumed, MT
Coal Saved
Consumed, MT
Coal Saved
Benzo Feron 249 121 261 169 27 10
Tire Chips 7430 10484 21 24.7 Nil Nil
Carbon Black 9865 10139 18429 19010 14336 15292
PU Waste 94 102 Nil Nil Nil Nil
Rubber Chips 129 159 Nil Nil Nil Nil
Plastic Waste 4618 3225 5688 2193 7384 772
Municipal Waste Nil Nil 77 22 29 22
Total 22386 24230 24475 21416 21776 16097
Trusted Technology
- Solid Strength
10
Best Practices implemented in Green Supply chain:
Laterite
• Procurement of Laterite from nearest source, resulting in reduction of CO2
emission from vehicles.
• Procurement ratio is 54% from nearest source i.e., Thatepally (90 kms) and 46%
from the range of 110kms (Vikarabad Area)
Gypsum
• Utilization of Gypsum (By-product from fertilizer companies) in Cement Industry.
• Road movement has been reduced and initiated Rail movement.
Fly Ash
• Utilization of Fly Ash (By-product from Power plants) in Cement Industry.
• Transportation of fly ash by Rail through closed wagons.
Rail - 98% Road – 2%
Rail - 57% Road – 43%
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- Solid Strength
11
Bauxite
• Procurement of Bauxite from Kolhapur area which is nearest source to our
plant.
Coal
• 100% receipt of coal by Rail.
Pet Coke
• Utilization of Pet Coke (By-product from Petrochemical companies) in
Cement Industry.
Rail – 46% Road - 54%
Rail – 100% Road - 0%
Trusted Technology - Solid Strength
Projects With Very Less In House Investments
S.No
Project Description Investment RsLac
Saving(Rs.Lac )
1 Optimization of running hours of 91 No's Air Dryers of IR compressors by introducing Interlock with Compressor.
0 58.50
2 Silencer Removed And Inlet Cone Fabricated For Suitable Condition For Cooler Fans Inlet Duct(Line -3)
0 10.20
4 Optimizing Lighting system in Mines area tower lighting . 0 7.50
5 Avoiding Idle running of Compressors At Different Locations (Pre Heater / Raw Mill / Cement Mill)
0 4.79
6 optimization the HR recirculation fan in Cement Mill 0 6.00
7 Replacement of conventional light fittings with LED light fittings at various locations
5 15.62
Trusted Technology - Solid Strength
Projects With Very Less In House Investments S.
NoProject Description Year Investment
Rs lacSaving
( Rs.Lac )
7 Avoided the running of 1L12BC (Gypsum belt) 17-18 0 1.532
8 Reduce the false air in Polycom 4 circuit & optimise Operation of HR Bag house.
16-17 0 15.25
9 Removed 1N11BF fan from the circuit 17-18 0 1.123
10 Energy conservation by stopping 2N23ABC, 2N23BBC, 2N22RA & 2N28BF
16 - 17 0 14.68
11 Reduction of false air in coal mills 16-17 0 4.79
12 Removed 2N33BF fan & its RAL from the circuit 17-18 0 2.139
Trusted Technology - Solid Strength
Projects With Cost Benefits
S.No Project Description SavingRs Lac or Kcal
1 Compressor air line integration between U-3 to U-2. 19.8 Lacs
2 Installation of 75 KW VFD Drive for PC Firing ROS Blower (Unit II Kiln Section)
4.75 lacs
3 Main PA fan 132 KW motor replaced with existing spare 90KW motor. (Unit 3 Kiln)
5.180 lacs
4 Replacement of Unit-1 Cooler fan-2 motor with energy efficient motor
1.40
5 Avoid the running of higher capacity compressor for Raw mill 1&2 hopper top bag filter top bag filters
5.52
6 Provided VFD Drives for Packer bag filters. 4.90
7 Reduction in pressure drop across damper in CM – 4 HR, BH & Sepol fan
82.2 Lacs
Duo Flex Burner tip life enhancement in Unit – 3 & 4.
Innovative Project-1
Theme : Duo Flex Burner tip life enhancement in Unit – 3 & 4.
Trusted Technology – Solid Strength
Before:
➢ Lot of Pits observed on burner tip, even after maintenance of burner as
given by OEM recommendation (annular gap) after few days in operation &
also there was observation that flame was off centre.
➢ To correct the flame, inner pipe of burner was retracted to make the flame
positioned at centre. The deformation in flame i.e off centre was increasing
with increasing in operation time & burner tip life was around 30-45 days
only.
Idea:
Maintain the uniform annular gap across the periphery of
burner tip in between inner & outer pipe, wedge to be
provided in all four quarters of burner.
After installation of wedges(April’18 U-4), burner tip was kept at Zero
position, flame was observed on daily basis for any deviation from
centre. Even after operating the same burner for three months
(checked in U-4 stoppage), tip was found to be in good condition.
Trusted Technology – Solid Strength
Benefits:
1. No deformation in flame shape
2. Burner flame in center.
3. Increase in Flame momentum by maintaining Burner tip
at zero position.
4. Reduction in Sp Fuel consumption & better clinker
quality.
5. No frequent adjustment inner pipe to make the flame
center.
6. Burner tip life enhancement.
7. Reduction in SEC at the time of Cooling, ramp-up &
pickup.
8. Reduction in Kiln Thermal shocks.
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Savings:I) In terms of coal consumed to restart the plant after Burner pipe
replacement (8-10Hrs)
Coal Consumed for plant heat-up 15-20MT
Coal Cost - Rs. 5700/MT(including grinding cost)
Saving - Rs 5700 x 18MT Coal consumed
- Rs. 102600 for one burner pipe
Considering two burner replacement due to tip wear in Unit – 3 & 4
which accounts to four stoppages to replace burner pipe
Net Saving - 4no x Rs102600
= Rs. 4,10,400
II) Welding material & man power cost for rebuild up.
For One Burner pipe - Rs 65000 x 4no
= Rs. 260000
III) Total saving annually = 410400 + 260000
= Rs 6,70,400
Trusted Technology – Solid Strength
RABH below mass flow conveyors (MFC) are getting over loaded during module cleaning.
Innovative Project-2
Description Before After Remarks
* Main air valve close time 8 sec 10 sec
* Lag between Main air valve close and
reverse air valve open
8 sec 10 sec
* Reverse air valve open 35 sec 25 sec
* Settling time 5 sec 40 sec
* Dwell time 10 sec 120 sec
* Cycle time for one module 56 sec 85 sec
* Total cycle time for 14 module 924sec(15.4
min)
2870sec(4
7min)
Brain storming session carried out and decided RABH
module cleaning sequence and timings to be modified.
RABH Cleaning Sequence chamber wise:
Trusted Technology – Solid Strength
1 3 5 7 9 11 13
2 4 6 8 10 12 14
Gas In
CHAMBERSBefore
1 8
2
3
4
5
6
7
9
10
11
12
13
14
1
13
3
5
7
9
11
2
4
6
8
10
12
14
After
Gas outMFC Discharge
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RAL
Reverse Air bag house
Mass flow conveyorMFC
RABH END VIEW RABH FRONT VIEW
RH side modules-7Nos LH side modules-7 nos
Gas
inlet
Gas
out
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1 2 3 4 5 6 7
MFC-1
Reverse Air purging
Dust Dislodging from Filter bag
Dust accumulation
Before :Modification
RALHopper
Filter
bags
Reverse air valveOutlet valve
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1 2 3 4 5 6 7
MFC-1
Reverse Air purging
Dust Dislodging from Filter bag
No Dust accumulation
After : Modification
Benefits:
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• No MFC over loading after module cleaning.
• No MFC tripping.
• No frequent hopper high level alarm during module
cleaning.
• Maintained stack emission level resulted in clean
environment.
• Reduced cleaning cycle in increase of bag life.
Savings:
• Reduced RA fan start / stops from 6 to 4 times.
• Reduced run hours of RA fan resulted in power saving
90KW/day 90*4.9*330=Rs,1,45,530.
• Avoided manpower for dust spillage
Power Reduction in Unit-3 Bag House Fan.
Innovative Project-3
Theme : Power Reduction in Unit-3 Bag House Fan.
Trusted Technology – Solid Strength
After checking the operating parameters of RABH & fibre
glass bags, with I/L temp 240 Deg C continuously & peak
value of 260 Dec C, we have consulted different major
suppliers of Bags regarding the observation, all the
suppliers had given clearance to raise the temperature
against present operation. With this the matter was raised
with OEM.
OEM has accepted our observation & given consent to
revise the setting of RABH I/L Temp.
Before:
1. Two fresh air dampers are
operating in PID to control
RABH I/L temperature as
per set point of 175 Deg C
(as defined by OEM)
2. Third damper is provided to
further control the
temperature, if these two
dampers are in open
condition & temperature is
going beyond 175 Deg C.
Setting of Temperature was
as given below.
Full open at 180 Deg C &
Close at 160 Deg C
Trusted Technology – Solid Strength
After:
➢ Fresh Air Dampers 1 & 2
Operating in PID, Set Point
Increased From 175 to 195
Degree Celsius.
➢ Interlock Provide to third
damper to Open @ 208 Deg C &
Close @ 195 Deg C Instead of
Operating @ 180 & 160 Deg C
Respectively.
Benefits:
➢ Power Saving.
➢ Improvement in Existing System.
➢ Before Modification:
May-2018 Specific Power of BH Fan:2.74
KWH/MT Clinker.
➢ After Modification:
June-2018 Specific Power of BH Fan:2.48
KWH/MT Clinker.
➢ Power Saving:
1. 0.26 KWH/MT of Clinker.
2. BH Fan Power Earliear:549.46 KWH.
3. BH Fan Power After:489.74 KWH.
4. Saving:59.72 KWH.
Trusted Technology – Solid Strength
Investm
ent:
---
ZE
RO
--
-
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1. Feasibility study conducted & Techno – economic feasibility reportsubmitted by Ms. Holtec for WHR system for line 1,2,3 & 4.
2. Increase in injection of Limestone % from 4% to 4.5%.
3. Use of 0.5% CPP bed ash in clinker coolers.
4. Up gradation of Unit -1 cooler.
5. Use of Membrane bags in all Bag filters.
6. Replacing all motors by Energy Efficient Motors.
7. Few more Instillation of Wind mills at Out let of Bag filters.
8. Planned for solar project, under initial study.
9. Use of Day light Pipes wherever possible.
10. Use of Turbo Ventilators for TG Building of CPP.
Projects in Pipe Line
Trusted Technology - Solid Strength
IS/ISO 9001/2008 IS/ISO 14001/2004 IS/ 18001/2007
ISO / 50001:2011
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MANDATORY REQUIREMENT ENERGY POLICY
Awareness & Training to
Employees. Periodic Energy Audit, Continuous monitoring, Bench Marking . Identify Energy potential areas for energy conservation. Purchase energy efficient equipment. Process optimization to minimize SEC. Utilization of RE & AFR.
Last Reviewed Date : April - 2018
Next Review Due On : Oct - 2018
Frequency : Every 6 Months
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ENERGY MANAGEMENT CELL FORMED UNDER ISO 50001
System Co-ordinator Mr. C M Bagwan
TEAM-1 MINES
HMODr. CHANDAR KUMAR JAIN
No of Members- 05
TEAM-2 MINES
CRUSHER
No of Members-08
TEAM-3, 4 RAW MILL -1&2 COAL MILL-1&2
No of Members-12
TEAM-5 & 6 KILN-1&2
No of Members- 12
TEAM-7& 13 CEMENT MILL-1, 2
3&4
No of Members- 15
TEAM-8 & 14 PKG PLANT-
1,2,3 &4
No of Members- 09
TEAM-9, 10 RAW MILL-3&4 COAL MILL-3&4
No of Members-14
TEAM-11 & 12 KILN-3&4
No of Members-13
TEAM-15 AUTO GARAGE
No of Members-04
TEAM-16 & 17TPP-1 2 3 4 & 5
No of Members-19
PURCHASE
No of Members-02
HRD
No of Members-02
Management Representative Mr G Raja Rao
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ENERGY MANAGEMENT CELL & ENERGY MANAGERS
LIST OF ENERGY CONSERVATION COMMITTIES
WATER MANAGEMENT
COMMITTEE
PACKING PLANT-POWER
CONSUMPTION REDUCTION COMMITTEE
CEMENT MILLS-POWER
CONSUMPTION REDUCTION COMMITTEE
IDLE RUNNING EQUIPMENTS DETECTING
COMMITTEE
STEAM LEAKAGES DETECTION
COMMITTEE AT THERMAL POWER
PLANTS
TEAM LEADER : Mr. S.S. Rao
(VP Civil)
TEAM LEADER:Mr. Revankumar Patil
(GM PP)
TEAM LEADER:Mr. K. Srinivasu
(GM Elect)
TEAM LEADER:Mr. Alibin Mohammed
(DGM PROCESS)
TEAM LEADER:Mr. Chandrashekhar Ujja
Team Members :1) Mr. Ravindra L2) Mr. Rajarao3) Mr. Shankar
Rao Patil4) Mr. K. Srinivasu5) Mr. N.P. Singh
Team Members :1) Mr. NP Singh2) Mr. Y. Srinivasa Rao3) Mr. Venkatesh
Marla4) Mr. Jaganath Adki5) Mr. V. Nagesh
Team Members :1) Mr. Udaykumar Mugli2) Mr. Rabbani3) Mr. Vijender Janib4) Mr. B. Praneeth5) Mr. D. Kranti6) Mr. Sanket K7) Mr. Ganapati8) Mr. Rajkumar
Team Members :1) Mr. Sriram Arsid2) Mr. Manjunath3) Mr. V. Madhukrishna
Team Members :1) Mr. Vishveshwarayya
Hiremath2) Mr. K.V. Ramana3) Mr. R.D.B. Patil
Trusted Technology - Solid Strength
1.1 REVIEW PERTAINING TO ENERGY EFFICIENCY.
FREQUENCY REPORT/SYSTEM RESPONSIBILITY
24 Hrs X 7days
➢ “Prevention is better than Cure” So On line SP power Monitoring facility provided for Unit-3 & 4 at CCR.
➢ Energy consumptions reviewed in Production Meeting headed by HMO.
➢ Daily review meeting with power plant O & M teamby HOD to optimize plant performance by monitoringand controlling of parameters like auxiliary power,coal, water and plant heat rate.
➢ Energy consumptions reviewed in Cross functional Meeting headed by HMO.
➢ Stoppage , OEE & Benchmark Presentation (Specific Power Consumption, Details of Stoppages, Heat Balance ,Power plant performance )
CCR Operator
Daily HMO
HOD
HMOWeekly
Monthly
Daily
HMO
Trusted Technology - Solid Strength
1.1 REVIEW PERTAINING TO ENERGY EFFICIENCY.
FREQUENCY REPORT/SYSTEM RESPONSIBILITY
➢ Review of Energy Management System ISO-50001Section Wise.
➢ Review of Packing Plant Power consumption.
➢ Review of Cement Mills Power consumption.
➢ Review of equipments running Idle.
➢ Review of steam leakages detection
➢ Review of Water consumption trends.
➢ Review of AOP headed by President/ HMO.
➢ Review of Energy Management System ISO-50001 with Top management , MR & Team Leaders .
➢ Surveillance Audit by external Auditor.
TEAM LEADER
Half Yearly HMO
Monthly
PRESIDENT / HMO
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AMOUNT SPENT ON ENERGY EFFICIENCY PROJECTS
FOR LAST THREE YEARS
Sl NO YearAmount Spent In
Rs.Crores
1 2012-13 57.21
2 2013-14 46.38
3 2014-15 31.69
4 2015-16 60.30
5 2016-17 74.58
6 2017-18 43.6
Trusted Technology - Solid Strength
Employees and team work1. Suggestion Scheme
2. Brain Storming
3. 5s Activity
4. Kaizen Mela
5. Fugai Finding
6. Leakage Detection
Leakage Detection Area Points Detected Points Attended
Power Plant 1110 1002
Cem Mills and Pack Plant
980 948
Crusher 520 482
YearTotal
SuggestionsSuggestions
ImplementedSuggestions
Rejected
2014-15 580 318 70
2015-16 599 451 101
2016- 17 685 414 23
2017-18 860 838 22
YearNo Of
Kaizens Registered
No Of Kaizens Completed
No.of Best Kaizens
2014-15 463 451 54
2015-16 563 497 57
2016-17 613 542 56
2017-18 684 666 62
• Energy Conservation week.
• Door to Door campaign.
• Distribution of pamphlets.
• Organizing Competitions.
• Training class to near by villages
• No Vehicle Day Celebration
• Safety Gate Meeting.
• Attending all External Trainings
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ENERGY WEEK KICK START BY HMO BY WAVING FLAG
DRAMA ON ENERGY SAVING BY VVV SCHOOL
ENERGY OATH AT ENERGY CONSERVATION DAYINAUGRATION OF EC WEEK BY HMO
ENERGY CONSERVATION WEEK -2017
Energy saver Rath
On line Electrical SP Power Monitoring at CCR
Trusted Technology - Solid Strength
•Every 15 Days
• Every 15 days
•Monthly•Monthly
Heat Balance / Radiation
Loss
False Air Monitorin
g
Cement Circuit
Sampling / Crash
Sampling
HT Fans Performance Monitoring
• Quarterly
• Half Yearly
• Half Yearly
• Half
YearlyBag
Filters Audit
Compressor Audit
Ball Mill
Audit
Comprehensive
Heat Balance
Monitoring Schedule Mini audits
Trusted Technology - Solid Strength
➢Continuous Increase of Blended Cement share in total production shows our eco- friendly nature.
➢35.0 % of fly ash injection is achieved by continuous trials in our Laboratory and by Installing Roto
Scale for Accurate Feeding.
➢Addition of performance improvers in cement, resulting in fuel and natural resources
conservation.
➢Hot Disc Installed at Unit -3 Pre heater, First in India, to consume wastes like Tyre , Paper , plastic ,
Coconut shell, and Segregated Municipal waste.( Full Fledged AFR feeding system at Unit -4 PH to
consume more and more AFR is under progress)
➢Lab trials for composite cement is being taken, which can reduce clinker factor drastically.
➢First Cement Plant to Participate in GREENCO rating Project actively conducted by M/s CII and
awarded as First GREENCO PLATINUM cement company in India.
Our Commitment Towards Green Tomorrow
Trusted Technology - Solid Strength
FLY ASH INJECTION
Trusted Technology - Solid Strength
Utilization of renewable Energy sources1. Solar heating system for Industrial Canteen.2. Installed Steam Cooking in our Canteen3. Solar Lightening at New ADM building.4. Wind Mill for Bag filters installed for two bag filters
1. Techno-feasibility studies completed for Installation of Wasteheat recovery system on cooler and PH exit gases.
2. There is possibility of 17MW power generation with WHRS.3. In Advanced stage for installation of 5MW solar power
generation.
Initiative
implemented
Action
Planned
For future
Trusted Technology - Solid Strength
Environmental Projects
Initiatives
On
Environment
Conservation
1. Obtained Authorization From CPCB & KSPCB For Burning OfHazardous waste /Non Hazardous Waste , like Tire Chips, PlasticWaste etc.
2. Fly ash transportation by rail.
3. Reduced the bauxite consumption percentage by optimizing theraw mix.
4. Planted Huge number of trees with 53 % of survival.
5. Rain water storage capacity of 40.00 Lac cu.mt at Mines & 4.00Lac cu.mt at Power plant pit.
6. Majority % of water requirement is full filled by Rain Water.
7. Installed Two On line Ambient Air Quality Equipment in Up Wind& Down Wind Direction.
8. Recorded 96 % of plant water requirement is managed with Rainwater Harvesting. Planning to reach 100 %.
9. Signed MOU with Goa Government for Supply of Plastic Waste.
10. Signed agreement with Ramkey for supply of 75 Tons/Day waste
Still Long way to go …………. Let us Start now with new Aim
THANK YOU