UltraTechUltraTech Cement LimitedCement Limited

(Unit: (Unit: KotputliKotputli Cement WorksCement Works--Power Plant)Power Plant)

Welcome to CII

13th National Award for Excellence in

Energy Management 20121

We are going to shareWe are going to share……

�Company Profile

�Unit Profile

�Plant Configuration and Flow diagram

�Energy Management System Policy

�Methodology of Energy monitoring

�Plant Performance over the years

�List of ENCON Projects/Major ENCON Projects

�Environment Projects/Renewable Energy Sources

�CSR initiatives

�Best Practices

�Innovative Projects

�Awards & Accolades

�Way forward

2

Company ProfileCompany Profile

UltraTech Cement…………

� An Aditya Birla Group Company

� Best Employer in India and Asia Pacific

� Only Cement company having Double Super brand

� Leader in India ,Largest in Asia, 7th largest Globally

� Ranked 4th Globally &1st in Asia-Pacific in the top companies for Leaders

2011 study

3

Unit ProfileUnit Profile

Kotputli Cement Works………..

� 2X23 MW Captive Power Plant

� 3.3 MTPA capacity Green field Cement

plant.

� First CDM Certified Captive Thermal

Power Plant in the Globe

� Environment friendly due to less CO2

emission.

� Certified with ISO 9001-2008 & 14001-

2004

� Adopted World Class Manufacturing

Excellence Model

KotputliKotputli

Cement Cement

WorksWorks

4

Plant ConfigurationPlant Configuration

Boiler

Type : IR-CFBC

Make : M/s Thermax

Rating : 2X102TPH

Pressure : 98.5 Ata

Temp. : 540+/-5 Deg C

Turbine

Type : Impulse- reaction

Make : M/s HTC China

Rating : 2X23 MW

Pressure : 96 Ata

Temp. : 535Deg C

5

Process FlowProcess Flow

EEnergy nergy MManagement anagement SSystem Policyystem Policy

7

Methodology adopted for Energy MonitoringMethodology adopted for Energy Monitoring

8

Flow Chart for Energy monitoring SystemFlow Chart for Energy monitoring System

Energy AuditEnergy Audit

Recommendations of AuditRecommendations of Audit

Evaluation & Action Plan

Operational Control

Programme

Operational Control

ProgrammeManagement Programme

Work order Generation Top Management Approval

Suggestions/

Kaizens

(Employees

/ Vendors )

Completion of Work Review of ResultsReview of Results

Energy management Cell

Systematic

Improvement

& Innovation

Committee

Systematic

Improvement

& Innovation

Committee

9

Plant PerformancePlant Performance

10

Sustainable Plant PerformanceSustainable Plant Performance

GOOD

GOOD

11

Comparison with cluster unitsComparison with cluster units

12

List of ENCON ProjectsList of ENCON Projects

13

Energy Savings Projects (2009Energy Savings Projects (2009--10 & 1010 & 10--11)11)

Sl.No. Energy saving ProjectsSaving Achieved

(Rs. Lacs)

Investment

(Rs. Lacs)

2009-10

1Petcoke firing in Boilers for increasing

boiler Efficiency. 175.9 NIL

2Operation of CHP & Lime Stone Plant in

group1.5 NIL

2010-11

1To eliminate of Dry Type transformer

from ACC Fan VFD Drives.1.41 NIL

2Reduction in LOI at Boiler for

increasing Boiler efficiency85.3 NIL

3Reduction in Heat rate by inter connection

of both TG condensate Lines8.8 0.2

14

Sl.

No.Energy Saving Projects

Saving Achieved

(Rs. Lacs)

Investment

(Rs. Lacs)

1To reduce auxiliary power by operating

BFP through PID logic-BFP-1&230.80 NIL

2 Operation of CEP through PID logic 18.00 NIL

3Reduction in auxiliary power consumption by

reducing inst air pressure (7.2 BAR TO 6.0 BAR)3.20 NIL

4Optimization of Aux. Power Consumption of

ESP of Boiler-1 & 2.1.40 NIL

5Energy saving by interconnection of

both CBD tank.1.60 0.2

Energy Savings Projects (2011Energy Savings Projects (2011--12)12)

15

Sl.

No.Energy saving Projects

Saving Achieved

(Rs. Lacs)

Investment

(Rs. Lacs)

6To optimize air consumption of coal

Handling & Lime stone Circuit 4.00 NIL

7

Reduction in auxiliary power consumption by

replacing new ACC tube bundle rear to front

side.

55.40 30

8Reduction in Heat rate consumption by replacing

new ACC tube bundle rear to front side.190.0 40

9Reduction of power consumption by installing

VFD in CEP - 1&211.50 6

10Reduction of power consumption Aux. Cooling

Water Pump # 1&3 by installing of VFD.1.40 6

Total Saving 590.21 82.4

Energy Savings Projects (2011Energy Savings Projects (2011--12)12)

Major ENCON ProjectsMajor ENCON Projects

17

ThemeTheme--1 # 1 # Operation of BFP through PIDOperation of BFP through PID

Opportunity:

� Operating BFP at constant RPM through

VFD

Approach:

� PID logic made and set point given to VFD

from discharge pressure

Results:

� Saving of 50 KWH/Pump achieved

� Saving of Rs. 30.8 Lacs/Annum

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ThemeTheme--2 #2 # Installation of VFD in CEP &PID controlInstallation of VFD in CEP &PID control

Opportunity:

� Both Units CEP’s (110KW rating) were running

on DOL mode

Approach:

�Installed the VFD in one pump for energy

conservation.

�PID logic made and set point given to VFD from

discharge pressure.

Results:

� Saving of 30 KWH/Pump achieved

� Saving of Rs. 18.0 Lacs/Annum

19

20

BEFORE (Photo / Sketch)

AFTER (Photo / Sketch)

DearatorDearator--11 DearatorDearator--22

BFPBFP--11 BFPBFP--22 BFPBFP--33

BFPBFP--11 BFPBFP--22 BFPBFP--33

CEPCEP--11 CEPCEP--22

CONDENSATE

EXTRACTION LINE

DearatorDearator--11 DearatorDearator--22

INTERCONNECTION OF CONDENSATE LINE

CEPCEP--11 CEPCEP--22

Opportunity:

� Due to individual deaerator for the

Boilers, Heat Rate was getting increased

by cross Operation of TG & Boiler.

Approach:

� Both Units Condensate lines

Interconnected

Results:

� Heat rate decreased by 20Kcal/kwh

� Saving of Rs. 8.8 Lacs/Annum

ThemeTheme--3 # 3 # Improvement in Heat Rate by Improvement in Heat Rate by

interconnection of CEP discharge linesinterconnection of CEP discharge lines

Environmental ProjectsEnvironmental Projects

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ThemeTheme--1 # 1 # CDM ProjectCDM Project

� Boilers registered in UNFCCC (United Nations Framework

Convention on Climate Change) for Carbon Credit.

� First time in Globe, CFBC Boilers selected for CDM benefit.

� Total Credit of CO2 will be 21509 Ton/Year

� M/s UTCL will get benefit of Rs. 1.50 Crores/year for next 15

Years.

22

This type of Boiler, first in the Globe to earn Carbon This type of Boiler, first in the Globe to earn Carbon

Credits by using CFBC Technology Credits by using CFBC Technology

Kotputli cement Works

BEFORE (Photo / Sketch)

AFTER (Photo / Sketch)

Baffle Pot

OMF

OMF

Main Oil Tank

Exhaust

ExhaustOpportunity:

� From Turbine Vapor Extraction fan,

oil

particle was going to atmosphere

with fumes.

Approach:

�Installed Baffle pot in discharge line.

�Connected Baffle pot drain directly

to MOT.

Result:

�Saving of Turbine oil of 1.6 Liters/day

�Saving of Rs 0.76 Lacs/Annum

ThemeTheme--2 # 2 # Saving of Turbine OilSaving of Turbine Oil

24

Valve

Valve

Main Oil Tank

Green Belt development / Green Belt development / Rain water harvestingRain water harvesting

3416 4026

15564 1608613267

0

5000

10000

15000

20000

2007-08 2008-09 2009-10 2010-11 2011-12

Rich plantation area as 110.4 Hectare

Renewable Energy Sources/Waste Renewable Energy Sources/Waste

UtilisationUtilisation

26

Solar Power PlantSolar Power Plant

Utilization of Renewable

Energy through installation

of 100 KW Solar Power Plant

27

Utilization / Recycle of WasteUtilization / Recycle of Waste

1. Use of effluent Water (Boiler blow down,

CT blow down & DM plant backwash

water)– for Greenbelt and Dust

suppression. Water recycled & saved

70000 M3 in last 03 Years.

3. Power Plant total Fly Ash is used by Cement Plant.

4. Power Plant Bed Ash is used by Cement Plant as a Chemical Gypsum.

2. Cooling Water –Using Side stream

sand filter to reduce blow down

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Corporate Social Responsibility…..Corporate Social ResponsibilityCorporate Social Responsibility……....

STRIVING FORSTRIVING FOR…………

Societal Change ……29

Corporate Social ResponsibilityCorporate Social Responsibility

Corporate CSR Corporate CSR

CSR Vision CSR Vision

CSR Policy CSR Policy

Focus AreaFocus Area

30

Education� Emphasis on girls education.

� Felicitation Program for students.

� Formation of 06 Self Help Groups.

� Awareness Campaign for personal hygiene, Family

Planning, Immunization - SHGs Meeting.

� Infrastructure development for Hospitals/Schools

nearby.

� Discussion with NABARD for livelihood project

Corporate Social ResponsibilityCorporate Social Responsibility

Best PracticesBest Practices

32

Examples are as under –

� IR-CFBC Boilers selected in place of AFBC to achieve better Thermal

Efficiency.

� Intelligent MCC for better monitoring.

� First time Boiler Feed Pumps & Fans taken on VFD

� Screw type Air Compressors with VFD.

� Energy efficient motors & Illumination System

� 12-Pulse VFD, in view of harmonic reduction

Best Practices since inception of the projectsBest Practices since inception of the projects

33

Innovative ProjectsInnovative Projects

34

ThemeTheme--1 # 1 # Centralized Communication for Intelligent MCCCentralized Communication for Intelligent MCC

35

Opportunity:

Installed ACC was not performing as per design due to heat transfer problem from Tubes to fins.

OEM Recommendation:

To erect newly ALE tube bundles at last stage of existing ACC.

Our Experience:

At our other group units , new bundles were erected at last stage of ACC.

Brainstorming and Decision:

A brainstorming session was conducted with TPP team, looking the Aluminiummetal heat transfer characteristics, the decision was taken to erect new ALE bundles at front and existing old bundles at last stage of ACC as it gives advantage during summer as well as in winter season.

It was discussed with M/s Greenesol and they also agreed with the above advantages.

ThemeTheme--2 # 2 # Extension and Modification of ACC Extension and Modification of ACC

36

Results Achieved (Winter Season):

� After E&C (Unit-2), we have operated both the turbines at same vacuum with all six fans at running condition, we found load on TG 2 - 23 MW and TG 1 - 18 MW i.e. benefit of 5 MW load.

� Again we have operated both the Turbines at same load and vacuum i.e. 21 MW and -0.78 Kg/cm2 by stopping the ACC fans and got benefit of 2400 KW/Day/ACC (Margin of two fan/ACC).

Results Achieved (Summer Season):

� After E&C (Unit-1&2), we found load increment on single TG 6-6.5 MW after operation of all modules at design ambient temperature i.e. 42 Deg C, thus total load increment with both the TG’s found 12-13 MW.

� If we were erected new ALE Bundles at rear side as per recommendation of OEM, then we will benefited only 7-8 MW with both the TG’s.

Thus we got benefit of 5-6 MW with both the units by installation of new ALE Bundles at front side.

Extension and Modification of ACC Extension and Modification of ACC

37

Benefits:

� Benefit due to increased load – Rs. 1.44 Cr./annum

(2*2500Kwh*Rs 1.0 (Cost difference)*24hrs*120 days - Summer)

� Benefit due to reduction in APC – Rs. 0.46 Cr./annum

(2*200Kwh*Rs 4.0 (Gen.cost)*24hrs*120 days - Winter)

TOTAL BENEFIT – Rs. 1.90 CRORES/ANNUM

�And also we are able to run the Cement Plant at Full Capacity.

�Resulting benefit due to Cement production – Rs. 34.86 Cr./annum

Extension and Modification of ACC

38

Theme-3 # Synchronization of 21 Nos Breakers

Opportunity:

� No. of Synchronization Breakers are

more & chances of Mis-operation.

Approach:

� Auto synchronization scheme

prepared through redundant PLC

operation and implemented.

Result:

� System can be synchronized from

single location i.e. CCR.

� Plant reliability increased due to auto

Load shedding

� No Black out since last two years

even after 400 islanding.

� Plant sustained at the time of

Northern Grid failure on dated 30 &

31.07.12

Theme-4 # Online Energy Monitoring System

Approach:

� Online Energy monitoring system

implemented.

� All auxiliary transformers connected

with system.

Opportunity:

� No online Energy monitoring

system for Aux. equipment.

Result Achieved:

� Identification of inefficient equipment

( i.e. ACW Pumps, BFP & CEP).

� Optimisation of Auxiliary Power

Consumption ( i.e. APC reduced from

17% to 13.5%).

� Report is being generated on daily basis

for study & analysis of Power.

Efficiency Monitoring & Daily report

TPP Daily Report

Today MTD YTD

Parameters Units Unit-1 Unit-2 Total Unit-1 Unit-2 Total Unit-1 Unit-2 Total

A Plant Performance

2STG Running

HoursHrs 24.0 24.0 48.0 192.00 192.00 384.0 3092.7 2749.1 5841.8

3 Plant Load Factor % 79.74 70.87 75.31 81.16 82.62 81.89 78.34 74.28 76.31

4 Gross Generation KWh 440141 391227 831368 3584205364869

4

723289

9

5572241

0

4696576

3

1026881

73

5 Aux Consumption % 12.52 13.79 13.12 13.01 12.90 12.95 13.29 13.32 13.30

8 Average Load MW 18.34 16.30 34.64 18.67 19.00 37.67 18.02 17.08 35.10

10 Sp. Steam Cons Kg/Kwh 4.35 4.31 4.33 4.38 4.26 4.32 4.40 4.32 4.36

11 Turbine Heat RateKcal/KW

H2721 2683 2703 2733 2642 2687 2741 2693 2719

12 Station Heat RateKcal/KW

H3127 3084 3107 3141 3038 3089 3160 3105 3135

13 SFC Kg/Kwh 0.38 0.71 0.53 0.38 0.71 0.55 0.48 0.62 0.55

B Generation Cost

1On Gross

GenerationRs/Kwh 2.75 3.52 3.11 2.76 3.45 3.11 2.81 2.80 2.80

2 On Net Generation Rs/Kwh 3.14 4.08 3.58 3.17 3.96 3.57 3.24 3.23 3.23

Energy Efficiency

Auxiliary Power Monitoring

August-2012S No. Particulars Aug 1, 12 Aug 2, 12 Aug 3, 12

1 BLR # 1 33882 33658 310952 TG # 1 2958 2957 29893 ACC # 1 16842 16781 147884 ESP # 1 1147 1152 1142

Power Consumption for Boiler # 1 54829 54543 50019

5 BLR # 2 33498 33670 322126 TG # 2 2656 2597 27767 ACC # 2 16661 17264 177468 ESP # 2 1056 1026 1036

Power Consumption for Boiler # 2 53871 54557 53760

9 AHP 3380 3381 335010 WTP 2957 3321 344011 CHP 2337 2594 194112 AC 3229 3864 404413 Fire Fighting 30 35 2814 Misc(MLDB/APDB) 1298 1086 1297

Total Consumption 123230 126019 118806

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Awards & AccoladesAwards & Accolades

43

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

Commendation Certificate for Energy ConservationCommendation Certificate for Energy Conservation

44

� ISO 9001:2008 - Quality Management System

� ISO 14001:2004 - Environment Management System

ISO Certification ISO Certification

COMMITMENT COMMITMENT

TOWARDS QUALITY TOWARDS QUALITY

& ENVIRONMENT& ENVIRONMENT

45

Way ForwardWay Forward

46

Energy Saving Projects for next 03 YearsEnergy Saving Projects for next 03 Years

Sl. No. Energy Saving projects Proposed Saving Target date

1 Installation of 6X100 KW Solar Plant Under RE 30.03.2013

2Installation Higher Capacity Aux.

Cooling Water Pump.50 KWH 30.11.2012

3Installation Lower capacity

Condensate extraction Pump.2X 15 KWH 31.12.2012

4Installation of Smart Air flow

Controller in Air compressors.20 KWH 30.09.2012

5PRS for the utilization of Turbine Ist

extraction Steam for Ejector & Gland.10 Kcal/Kwh 31.10.2012

6FRP fans in Air Cooled Condensers in

place of Aluminium/GRP fans12 X 15 KWH 31.03.2013

7 Firing of Alternate fuels Under RE

After

modification in

feeding system 47

Presented By:Presented By:UltraTechUltraTech Cement LtdCement LtdKotputliKotputli Cement WorksCement WorksPower PlantPower Plant