UltraTech Cement Limited (Unit: Kotputli Cement Works-Power Plant)
Welcome to CII 18th National Award for Excellence in
Energy Management 2017
Content Company Profile
Plant Configuration and Flow diagram
Energy Management System Policy
List of EnCon Projects
Plant Performance over the years
Innovative Projects
Environment Projects / Initiatives
Renewable Energy Sources/ Waste utilization
Methodology of Energy monitoring
Best practices/ Involvement of Employees
CSR initiatives
Awards & Accolades
Way forward
Company Profile • UltraTech Cement…………
Kotputli Cement Work
An Aditya Birla Group Company.
2X23 MW Captive Power Plant
3.3 MTPA capacity Green field Cement plant.
Environment friendly due to less emissions.
Certified with ISO 9001, 14001, OHSAS 18001 , ISO 27001, ISO 50001 & ISO 17025.
Adopted World Class Manufacturing Excellence Model
Kotputli Cement
Works
Energy Savings Projects Summary
SN Financial
Year Investment/
No Investment No. of Projects
Electrical Energy Savings (MWH)
Heat Energy Savings
(Ton/Year)
Savings in Rs. Million
Invested Amount in Rs. Million
1 2016-17 No Investment 18 7253 85.35 16.44 -
Investment 9 490 357 3.9 3.7
2 2015-16 No Investment 12 1924 313 8.39 -
Investment 4 226 1342 7.84 3.0
3 2014-15
No Investment 10 4046 426 11.5 -
Investment 1 2781 2004 9.26 102.8
Total 54 16720 4527.35 57.33 109.5
Energy Savings Projects with No Investment (2016-17)
SN Energy Saving Projects
Saving Achieved
Electrical Energy (MWH)
Thermal Energy
(Ton/Year)
(Rs. Million)
1 Reduction of BFP power by developing discharge pressure biasing. 330 1.09
2 Reduction in Boiler PA Fan KW by optimizing the PA Air flow according the boiler load
264 0.87
3 Condensate interconnection to reduce heat loss (From Aug-16 to Mar-17)
4.12 0.03
4 Reduction in SAC running hours through ESP hopper level by Draft transmitter.
165 0.54
5 Utilising lower CFM & KW compressor for Fly ash conveying 66 0.22
6 Usage of 90% Pet coke in fuel mix & Reduction in CHP power by increasing through put
66 0.22
Energy Savings Projects with No Investment (2016-17)
SN Energy Saving Projects
Saving Achieved
Electrical Energy (MWH)
Thermal Energy
(Ton/Year)
(Rs. Million)
7 Reduction in AC & lighting power 33 0.11
8 Reduction in ID fan power consumption due low bed ash cooler running hour
33 0.11
9 Reduction in BLR SA fan KW by optimizing the SA air pressure. 31.68 0.10
10 Reduction in instrument air compressor power by optimizing the air flow in BLR MDC sealing
31 0.10
11 Silo bag filter purging air pressure reduction 26.4 0.09
12 CEP power cons. reduction by inter connecting condensate line during unequal loads on TG.
8.25 0.03
Energy Savings Projects with No Investment (2016-17)
SN Energy Saving Projects
Saving Achieved
Electrical Energy (MWH)
Thermal Energy
(Ton/Year)
(Rs. Million)
13 Reduction of RO Degasser transfer pump power consumption by utilising old CT sump as storage
3.56 0.01
14 Reduction of raw water pump running hours by continuous make up of cooling tower
1.81 0.01
15 ACW pump power reduction by optimizing the CW flow of equipment's according the ambient temp.
39.6 0.13
16 Use of Raw Mill dust to reduce sensible heat loss due to bed drain & Usage of High GCV fuel in the boiler to achieved higher boiler efficiency.
81.22 0.52
17 Reduction in import of Grid power ( Diff. @ Rs 2.8 in Power generation cost against Grid Power)
896 2.50
18 Power Sale to other group units ( Difference @ Rs 1.86 in Power generation cost against Grid Power)
5257 9.78
Energy Savings Projects with Investment
SN Energy Saving Projects
Saving Achieved
Investment (Rs. Million)
Pay back
Month Year Electrical
Energy (MWH)
Thermal Energy
(Ton/Year)
Rs. Million
1 TG 1 ACC fan 2 VFD installation 115.5 0.38 0.42 13 16-17
2 Replacement of TG 1 MOP with high efficiency pump
79.2 0.26 0.16 7 16-17
3 Bed ash cooler fan outlet duct inter connection 69.3 0.23 0.1 5 16-17
4 Boiler-1 BAC fan VFD installed 69.3 0.23 0.42 22 16-17
5 Cooling tower fan VFD installed 33.99 0.11 0.15 16 16-17
6 Power reduction by Installation of submersible pump in main effluent pit for transfer to mines.
11.88 0.04 0.038 12 16-17
Energy Savings Projects with Investment
SN Energy Saving Projects
Saving Achieved
Investment (Rs. Million)
Pay back
Month Year Electrical
Energy (MWH)
Thermal Energy
(Ton/Year)
Rs. Million
7 Utilisation of TG-2 1st extraction steam in PRDS for ejector (From Nov-16 to Mar-17)
4.8 50.05 0.33 0.45 16 16-17
8 Lighting power optimisation. 6.6 0.02 0.02 11 16-17
9 LOI reduction in fly ash by U beam straightening to improve ash circulation rate & by MDC replacement
307.31 1.96 0.63 4 16-17
10 Up keepment of steam turbine-2 to improve heat rate
- 1342 7.07 2.61 4 15-16
11 Reduction in power consumption of air conditioners by using Nano technology & installing water cooled condensers
203.6 - 0.69 0.20 4 15-16
Energy Savings Projects with Investment
SN Energy Saving Projects
Saving Achieved
Investment (Rs. Million)
Pay back
Month Year Electrical
Energy (MWH)
Thermal Energy
(Ton/Year)
Rs. Million
12 Installation of separate energy efficient side stream filter pump (Grundfos Make) for cooling tower to reduce power from existing ACW pump.
17.3 - 0.06 0.05 10 15-16
13 Usage of renewable (solar)energy for lighting at HSD area .
5.6 - 0.02 0.14 88 15-16 015-16
14 Operation of TG-2 ACC with ALE fins tube bundles & Auto PID operation of all ACC fans with VFD.
2781 2004 9.26 102.8 133 14-15
Energy Savings Projects with No Investment (2015-16)
SN Energy Saving Projects
Saving Achieved
Electrical Energy (MWH)
Thermal Energy
(Ton/Year)
(Rs. Million)
1 Improved heat rate of TG-2 by operating with higher vacuum - 313 1.65
2 Intermittently stopped service air compressor to avoid idle running during pet coke usage & DP level in ESP hoppers.
340.5 - 1.25
3 Developed a logic (Auto set point calculation) for BFP discharge pressure w.r.t. steam drum pressure.
320.2 - 1.19
4 Developed a logic (Auto set point calculation) for CEP discharge pressure w.r.t. deaerator pressure.
268.6 - 0.96
5 Reduction of both boiler ESP field power by changing charging ratio with respect to fuel types.
278 - 0.93
6 Adiabatic cooling system for inlet air of ACC Fans in unit-1 216 - 0.73
Energy Savings Projects with No Investment (2015-16)
SN Energy Saving Projects
Saving Achieved
Electrical Energy (MWH)
Thermal Energy
(Ton/Year)
(Rs. Million)
7 Through put increased & run hours reduction of CHP by using Belt power feedback display on DCS.
164.3 - 0.55
8 Indigenous development of auto import -export logic during power export.
150.7 - 0.50
9 Reduced Instrument air pressure set point from 6.5 kg/cm2 to 5.8 kg/cm2 (gradually in two phase).
72.6 - 0.26
10 WTP running hours reduction by commissioning & utilising dump steam system.(Savings of 06 Months)
48.4 - 0.16
11 Reduction in BAC fan air flow from 22 to 19 TPH 46.2 - 0.15
12 Reduction in idling hours by implementing remote operation of Fly ash compressors.
18.2 - 0.06
Energy Savings Projects with No Investment (2014-15)
SN Energy Saving Projects
Saving Achieved
Electrical Energy (MWH)
Thermal Energy
(Ton/Year)
(Rs. Million)
1 Improved Boiler Efficiency by increasing pet coke percentage in fuel mix.
- 1643 10.09
2 Boiler operated at lower bed height. Reduced by 200mmwc,power savings @90Kwh.
1188 - 4.40
3 Optimization of steam venting by taking Raw mill initial drive start feed back through PI system.
- 372 2.29
4 Operation of TPP at Island mode operation. 561 - 2.09
5 Power generated from TG-2 during ACC bundle replacement with ACC single stream operation. ( Difference Rs 0.93/Kwh of TPP vs Grid Power).
2221 - 2.08
Energy Savings Projects with No Investment (2014-15)
SN Energy Saving Projects
Saving Achieved
Electrical Energy (MWH)
Thermal Energy
(Ton/Year)
(Rs. Million)
6 Improved TG vacuum by arresting leakages in TG exhaust path through Helium check.
53.5 0.37
7 Optimised CHP bag filter purging air through DP transmitter instead of timer mode.
69.96 - 0.26 8 Reduced power consumption of bag filter fan by parallel circuit operation of CHP & LSHP.
9 Modified CHP Start & Stop logic to reduce idle hour.
10 Reduced Hot well transfer pump running hours of unit-1 by rerouting of LP Heater drain to CRT tank.
5.81 - 0.02
Key Performance Indicators
3.78 3.70
3.33 3.29
3.00
3.50
4.00
2013-14 2014-15 2015-16 2016-17
75.02 75.85 75.41 76.57
65.00
75.00
85.00
2013-14 2014-15 2015-16 2016-17
12.49
11.36
9.54
8.99
8.50
10.50
12.50
2013-14 2014-15 2015-16 2016-17
9 % reduction
16 %
reduction
5.8 %
reduction
3095
3049 3036 3041
3000
3100
2013-14 2014-15 2015-16 2016-17
Under Performance of ACC of Unit-1
GOOD
GOOD
PLF (%) Heat Rate (Kcal/Kwh)
Power Cost (Rs./Kwh) Auxiliary Power (%) GOOD
GOOD
Benchmarking With UTCL Units 2016-17
3224 3188 3144 3143 3118
3080 3067 3045 3041 2998
2700
3000
3300
HCW ACW RWCW RC APCW GCW AC SCW KCW VC
Heat Rate (Kcal/Kwh)
12.26 11.65 11.71
11.30 11.06 10.73
10.20 10.14 10.04
8.99
8.00
9.00
10.00
11.00
12.00
13.00
HCW RWCW VC GCW AC ACW SCW RC APCW KCW
Auxiliary Power (%) Best Across UTCL
units
Benchmarking With UTCL Units 2016-17
90.5 86.8 80.1 78.4 78.4 76.9 76.9 76.0 73.0 64.8
0.0
20.0
40.0
60.0
80.0
100.0
RC GCW APCW HCW SCW ACW KCW AC RWCW VC
Plant Load Factor (%) Less Demand of Load
Project-1 # Reducing heat loss in Aux. steam for Ejector
Reason for Selection:
• The Aux. steam for Ejector was supplied from main steam line by reducing its pressure & temperature from 100 Kg/cm2 & 535°C to 11 kg/cm2 & 350°C respectively by spraying feed water resulting heat loss in the system.
Technology Adoption:
• Installed a pressure reducing station & utilized Turbine 1st extraction steam of lower pressure & temp.(22 kg/cm2 & 360 °C) in ejector & reduced heat loss in Aux. steam
Cost of Implementation: Rs. 0.45 Million
Benefits:
• Total Savings in Coal : 50 MT/Annum • Total Savings in Power:4.8 MWH/Annum • Total Savings : Rs. 0.33 Million/Annum
Uniqueness: Single PRS being utilized for two TG’s
Before: Main Steam Utilisation in Ejector
After: Extraction Steam Utilisation in Ejector
Project-2 # Reduction in LOI of Fly ash by Ash Recycle
Reason for Selection:
• At 90% Pet-coke in fuel mix LOI in Fly ash was higher resulting lower boiler efficiency.
Technology Adoption:
• Modified the fly ash conveying line of ESP & APH and diverted it to existing bed material bunker of the boiler.
• Recycled the fly ash again to the boiler and reduced the LOI %.
Benefits:
• Reduction in LOI by 0.8 %
• Total Savings : Rs. 2.5 Million/Annum
Before: Without Ash Recycle Line
After: With Ash Recycle Line
APH Conveying System
APH Conveying System
ESP Conveying System
ESP Conveying System
Project-3 # Reduced Bed Ash Cooler fan power consumption
Reason for Selection:
• Higher Power consumption of boiler-2 Bed ash cooler fan due to DOL drive.
Technology Adoption:
• Fabricated & Interconnected bed ash cooler fan discharge duct of both the boiler with pneumatic operated isolation valves.
• Operated both bed ash cooler with single fan with VFD.
Cost of Implementation: Rs. 0.05 Million
Benefits:
• Total Savings in Power : 69.3 MWH/Annum
• Total Savings : Rs. 0.23 Million/Annum
Uniqueness: Single VFD being utilized for Both boiler BAC.
BAC duct without Interconnection
BAC duct with Interconnection
Project-4 # Intermittent stoppage of service air compressor
Reason for Selection: • Earlier ash conveying system of ESP was operated by hopper
level switches in timer & probe mode resulting idle running of service air compressor due to malfunctions.
• Stoppage of service air compressor was carried out based on manual checking of hopper levels.
Technology Adoption:
• Installed DP transmitter in hoppers with online display on DCS for continuous monitoring.
• Intermittently stopped the compressor with respect to Draft level at hoppers to optimized power consumption.
Benefits:
• Total Savings in Power: 340 MWH/Annum
• Total Savings : Rs. 1.25 Million/Annum
Reason for Selection: • Air Cooled Condensers are supplied with multi row HDG(Hot Dip Galvanized) Fin material of low
heat transfer coefficient, resulting higher heat & power consumption.
• ACC’s under performance de-rating TG loading during peak ambient temperature.
• Replacement of air cooled condenser was initiated. But the cost of it was higher.
Complexity: • The Capital for new ALE multi row tube bundle replacement had higher cost (10 Cr) & had higher
return in investment (>8 Yrs.).
Approach: • Brainstorming within team & explored opportunity for low cost & efficient alternative technology
within & outside India.
Technology Adoption: • Approached new technology supplier having ACC- Single Row Condenser (SRC) technology at low
cost & high heat transfer efficiency resulting lesser heat & power consumption.
Way Forward # Technology Up gradation of ACC (SRC)
Benefits: • Procured at Capital cost to 4.42 Cr with ROI of 3.95 yrs. • Proposed savings : 62 Kcal/Kwh & 8.5 Lacs Kwh / Annum. • Proposed Savings: Rs. 7.8 Million/Annum
Uniqueness: First time installation being carried out in India.
Way Forward # Technology Up gradation of ACC (SRC)
PAT Status GtG energy consumption status (Cement & Power Plant)
993 937
711 670 641
400
600
800
1000
1200
2009-10(Baseline year)
Target SEC for PAT cycle1
ActualPAT Cycle 1
BaselinePAT Cycle 2
TargetPAT Cycle 2
Kcal
/kg
PP
C E
qu
iv.
No. of Energy Saving Certificates 37153
Target for reduction
4.32%
28.40 % reduction
5.6% reduction target
Unit is registered as Designated Consumers (DC) under PAT scheme. Target given for 5.6 % reduction in GtG Specific Energy Consumption for PAT Cycle-1 (FY14-15) Implementation of ENCon projects in the unit reflects 28.40 % reduction in SEC in PAT cycle-1. Now entitled
for 37153 Nos. of Escerts costing about Rs.37 Crores
GHG Inventorisation
Year tCO2 Emission Sp. CO2 Emission
2014-15 319290 1.18
2015-16 331119 1.17
2016-17 348690 1.18
Environmental Initiatives Green Belt development
Saplings Planted in last 09 Years: 137683 nos. Green belt area developed : 110.35 hectare
Environmental Initiatives
Ground water recharging through injection well Rain Water Harvesting Ponds
Green Belt in Colony Sapling Distribution to Villagers
98549
120934
108126 100136
50000
75000
100000
125000
2013-14 2014-2015 2015-16 2016-17
Solar Unit Generation (kwh)
Renewable Energy Utilisation
Usage of renewable energy for lighting at TPP HSD Area: • Installed Solar Power Generation at HSD area : 1000Watts • Solar energy : 0.04 % of total power share
Solar Unit Generation (kwh) 100 KW Solar Power Plant
Utilisation / Recycle of Waste
TPP Bed ash – 100 % Bed ash being used in Cement plant.
a) While using 100% Petcoke in boiler and generating 18-20 TPD bed ash which was creating problem of reuse. Discussed with Cement plant Quality Control Deptt. and after detailed analysis & coordination started using in cement plant.
b) Recycle of TPP bed ash & fly ash again in boiler to recover un-burnt carbon during pet coke usage.
PPF for boiler Light up – Usage of Petro Polymer fuel in place of Diesel for every Boiler light-ups, replacing the convectional fuel
Methodology adopted for Energy Monitoring
Well Established energy management cell headed by FH-TPP.
Daily monitoring of Heat rate and Aux. power deviation report.
Analysis of equipment performance for deviation.
Identification of energy conservation scope.
Theme base suggestions/Kaizens scheme under “Energy Saving ”.
Feasibility study of suggestions & submit proposal for sanction.
Preparation of detail action plan.
Weekly review to monitor project progress.
Benefits analysis after project implementation.
Sustainability of the project
Journey Towards Excellence
ISO
9001
2011
ISO
14001
2011
OHSAS
18001
2013
2014
ISO
17025
2015 2015
ISO
27001
ISO
50001
NA
BL
accr
ed
itat
ion
En
erg
y M
anag
em
en
t
Info
rmat
ion
Se
curi
ty
Occ
up
atio
nal
H
eal
th &
Saf
ety
Envi
ron
me
nt
Man
age
me
nt
Qu
alit
y M
gmt.
WCM
2010
WC
M
Init
iate
d
WCM
2013
WC
M B
ron
ze
Aw
ard
WCM
2015
WC
M G
old
Aw
ard
Exce
llen
t En
erg
y
Aw
ard
2016
Energy
Award
No
te w
ort
hy
Wat
er
effi
cie
nt
un
it
2016
Water
Award
ISO 50001,9001 &14001 for FY 2016-17
S.No
Findings Corrective Actions Standard Status
1 Acceptance criteria may be defined against various variable identified for significant energy use.
Acceptance criterion is defined in OCP prepared respective sections. ISO 50001
Completed
2 No findings
.
ISO 9001
3 No findings OHSAS 18001
Corrective Action against finding related to ISO 50001, 9001 & 14001 for FY 16-17
Team Work for EnCon
SN EnCon idea Idea originated
(Year) Team involved Status
1 Reduction in power by Installation of submersible pump in main effluent pit for transfer to mines.
2016 O&M and E&I Team Completed
2 Optimization of heat loss by utilising TG-2 1st extraction steam in PRDS for ejector
2016 O&M and E&I Team Completed
3 Replacement of TG 1 MOP with high efficiency pump
2016 TPP (O&M) Team Completed
4 Pressure biasing for BFP discharge pressure 2016 O&M and E&I Team Completed
5 Increase the power generation during the summer season by adiabatic cooling system for inlet ambient air in ACC Fans in unit-1
2015 FH-TPP/TPP( O&M) & TPP (E&I) team/ M/s Greensole power
Completed
Team Work for EnCon
SN EnCon idea Idea originated
(Year) Team involved Status
6 Reduction of Raw water consumption of by utilization of Boiler blow down water for cooling tower make up
2015 TPP (O&M) Team Completed
7 Replacement of ACC HDG tube bundles with ALE tube bundles.
2014 O&M, E&I Team and M/s Greensole Power
Completed
8 CEP discharge pressure droop mode operation with reference to Deaerator pressure
2014 O&M and E&I Team Completed
9 CHP power optimization by increasing through put according to fuel types
2014 O & M and E&I Team Completed
10 Blow down water Heat recovery system 2014
O & M and E&I Team & M/s Forbes Marshall
Completed
Replication Arising Out of Best Practices
SN Name of service provided to vendor Replicating Unit Name of associate
/ vendor
1 Replacement of ACC HDG tube bundles with ALE tube bundles.
Aditya Cement, Rajshree cement & new projects at
UTCL
M/s Greenesol Power
2 ACC Power Reduction by operating all fans with VFD & Vacuum with auto PID control
Aditya Cement, Rajshree cement & new projects at
UTCL
M/s Greenesol Power
3 Island Mode operation of Thermal power plant Rawan cement, Aditya
Cement, Rajshree cement -
4 Utilisation of Boiler blow down water as cooling tower make up.
Rajshree cement M/s Chembond & Ion Exchange
Best Practices Shared to Vendors
SN Name of
associate / vendor
Name of service provided to vendor
Energy cons.
before
Energy cons. After
Gain Type of inputs / projects provided to the vendor/
associate
1 M/s Greenesol Power
Hotwell transfer pump running hours optimization by modification of LP Heater drain direct to CST.
79 Mwh/ month
62 Mwh/ month
22% Applicable in all existing units & new projects.
2 M/s Thermax Modification in Ejector motive steam line
10 Kcal/Kwh In all Plants where Thermax has supplied the Boilers
3 M/s Greenesol Power
Energy efficient ACC fans 100 KW/Fan
80 KW/Fan
20% Installation of these fans in new projects
4 M/s Greenesol Power
Replacement of ACC HDG tube bundles with ALE tube bundles.
232 Mwh/month
112 Mwh/month
Installation of ALE bundles in new projects
Corporate Social Responsibility
Education
Sustainable Livelihood
Social Causes
Infrastructure Development
Health Care
Corporate CSR
CSR Vision
CSR Policy
Focus Area
Awareness campaign for Personal hygiene, Family
planning, Immunization camps.
Infrastructure development for hospitals/
schools nearby.
Skill Up gradation Training for Black Marble Stone Sculptures
Corporate Social Responsibility
Corporate Social Responsibility
Coaching classes & felicitation programs for students.
Conducting free eye camps to extend hand of help to communities.
Formation of Self Help Groups (SHG)
Awards & Accolades
Kotputli Cement Works –TPP team receiving award for “Excellent Energy Efficient Unit “ in year 2016.
Kotputli Cement Works –TPP team receiving certificate for “Noteworthy water efficient unit “ in year 2016.
Awards & Accolades
Kotputli Cement Works –TPP team receiving award for “Excellent Energy Efficient Unit “ in year 2015.
Kotputli Cement Works –TPP team receiving award for “Excellent Energy Efficient Unit “ in year 2014.
Awards & Accolades
Kotputli Cement Works –TPP team receiving award for “Energy Efficient Unit “ in year 2013.
Kotputli Cement Works team receiving award for “Rajasthan Energy Conservation’’ in year 2014.
Awards & Accolades
Kotputli Cement Works –TPP team receiving award for “Water Efficient Unit “ in year 2012.
Commendation Certificate by the Ministry of Power, Government of India in recognition of efforts made to conserve the energy for year 2012-13.
Awards & Accolades
Commendation Certificate by the Ministry of Power, Government of India in recognition of efforts made to conserve the energy for year 2011 -12.
First prize by dept. of energy, Govt of Rajasthan for sincere efforts towards energy conservation & efficient use.
Way Forward: Energy Saving Projects
Replacement of existing ACC tube bundles with upgraded SRC technology tube
bundles with APC savings of 8.5 Lacs Kwh / Annum.
Overhauling of TG-1 for Heat Rate improvement.
Installation of waste Heat Recovery boiler from Kiln PH & cooler outlet gases.
1) For power generation 2) For heat utilization.
Existing ETP Pump replacement with Grundfos make energy efficient pump.
Installation of VFD drive in bed ash cooler fan-2.
Impeller trimming of Raw water pump for power optimization
Installation of Energy efficient 3 phase rectifiers for ESP.
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