“Bureau of Energy Efficiency” Knowledge Exchange Platform …Obtained ISO :14001 in 1997....
Transcript of “Bureau of Energy Efficiency” Knowledge Exchange Platform …Obtained ISO :14001 in 1997....
UltraTech Cement Limited Unit: Vikram Cement Works
“Bureau of Energy Efficiency”“Bureau of Energy Efficiency”Knowledge Exchange Platform
2015
23rd June’15
Vikram Cement WorksVikram Cement Works
ABG ABG -- Largest Cement Producer in India.Largest Cement Producer in India.
1010thth Largest in the World.Largest in the World.
Capacity : 4.0 MTPA Capacity : 4.0 MTPA
Win T P M award : JIPM, Japan in 1992.
First ‘Cement Plant’ in India to :First ‘Cement Plant’ in India to :
Obtained ISO :14001 in 1997.
Obtained ISO : 27001 ISMS certification in 2009
Obtained ISO : 50001 Energy Management System (EMS) in 2013
Use MSW as ‘alternate fuel’ – since July 2007.
Use 100% high sulfur pet coke as fuel in kilns.
Achieved lowest annual kiln shut down period.
Achieved + 350 days of continuously kiln run.
WHY Energy Conservation ?WHY Energy Conservation ?
• Cement Industry is the one of the largest Energy Intrinsic Consumer.
• Energy cost is 50 - 52 % of Cement manufacturing cost
• Own Power Cost increased from Rs. 3.36 to 4.23 per unit in last four years
Need For Energy ConservationNeed For Energy Conservation
• Own Power Cost increased from Rs. 3.36 to 4.23 per unit in last four years
• Higher Energy Consumption as compared to competitors with New
Technology.
• Increasing trend of energy cost due to fossil fuel depletion.
• Energy audit once in two year.
• Specific energy audit for compressors, water pump etc.
• Pyro process audits from OEM’s like, KHD, FLs etc.
• Suggestions.
Energy Conservation Energy Conservation Initiatives Initiatives
• In-house improvements & Kaizens.
• Literature review.
• Participation in Awards & Seminars.
� CII has done “Resource Study” for energy efficiency improvement in Line-2 Kiln.
� Under this study 36 energy improvement was identified and almost 30% short term
projects has completed and Capex projects under implementation in phase manner
Energy Conservation (Energy Conservation (EnCONEnCON) )
ProjectsProjects
Maximum utilization of Alternate Fuel
Project No-1
Reduction of fossil fuel consumption
Description:
� Use of Alternative Fuel (AF) as thermal energy substitute to replace the conventional fossil fuel for pyro-processing.
� Vikram Cement line-3 kiln has alternate fuel feeding system. Till 2009-10, Vikram Cement achieved 0.77% Thermal Substitute Rate (TSR) through AF consumption i.e. Municipal Solid Waste (MSW) and Agro waste.
� Line-1 & 2 kiln there was no any alternate fuel feeding system. Plastics waste used by manual feeding into the calciner through a hopper, waste used by manual feeding into the calciner through a hopper, hence very low TSR%.
� VCW is committed to improve upon TSR and achieve up to 4.0 % TSR.
Goal: Maximum utilization of alternate fuel on consistent basis with high
calorific value alternate fuel and without involve capital expenditure.
Approach:
� Identified the bottlenecks to improve TSR%
o Inconsistent feeding due to frequent problem of concrete hopper jamming of
MSW feeding System
o CO generation in the system
o Identify the new source of alternate fuel
� Carbon dust was identified as high calorific value alternate fuel for line-� Carbon dust was identified as high calorific value alternate fuel for line-1& 2, which is available at vicinity area.
� Feasibility study in existing storage and feeding system.
Alternate Fuel Feeding System for Line-3 Kiln
Action:
� Modification in A-29 screw conveyor discharge
Belt A36 Belt A34
Screw Conveyor A29
Belt A36 Belt A34
Screw Conveyor A29
Slide gate
Before After
Screw Conveyor A29 Slide gate
� At AF discharge chute air blaster & dispersion air provided.
Power consumption save 34kwh by above modification
Action:
Line-1 & 2 Kiln
� Installation of carbon dust unloading system form bulker to storage hopper.
� Installation of compressed air line for bulker unloading.
� Mix grinding with the Petcoke and fired with fine Petcoke in calciner.
Manual feeding system
Plastic Feeding Hopper
KILN
A
F
E
L
E
V
A
T
O
R
KILN
INLET
KILN
RISER DUCT
ALTERNATE
FUEL
BELT
CONVEYOR PLASTIC FEEDING CHUTE
CHUTE PNEUMATIC SHUT OFF GATE FOR SAFETY
PLASTIC FEEDING HOPPER
HOPPER FEEDING COVER
INSTRUMENT SWITCHS FOR SAFETY
Manual feeding system
Tyre dust unloading system
Results:Alternate fuel consumption (MT) year wise in Line-3
Description (L-III) 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15
MSW 3397 3555 4092 5498 4772 3673
SOYA HUSK 638 0 0 0 0 0
SARSO HUSK 558 793 1210 1309 1742.9 4.60
TYRE CHIPS(INDIAN /IMP) 198 559 421 228 161.7 181.35
PLASTIC WASTE 146 400 646 284 211.35 64.57
WOODEN DUST 21 1398 1659 150 1.97 0
GROUND NUT HUSK 1643 2959 3884 180 0 0
PAINT SLUDGE 0 38 305.07 85.02 78.19 43.49
AFSGRI WASTE ( Doda Chura) 0 14.80 46.17 35.22 26.04 3165.98
OPIUM MARC 0 199.20 0.00 0 108.14 0
ISABGHOL HUSK 0 0 1493.00 2475 0 0
DHANIA HUSK 0 0 1550.00 3197 1000.4 0
AFMIXAGROWASTE 0 0 0 7724 11985 9184AFMIXAGROWASTE 0 0 0 7724 11985 9184
MSWRDFFLUFF 0 0 1884.00 3570 1028.6 330.25
DATESEEDS 0 0 5.00 0 0 0
TYRE DUST 0 0 0 991 1493 2674
ETP SLUDGE 0 0 0 2.50 0.86 277
AF Pyrolysisoil 0 0 0 0.00 0.00 11.82
TOTAL QTY (MT) In Line-III 6601 9916 17195 25729 22610 19610
1.8
5 3.6
2 5.9
7 9.2
8
9.3
0
8.7
7
0.7
7
1.5
0 2.7
8 4.5
4
4.1
2
4.0
2
0
2
4
6
8
10
2009-10 2010-11 2011-12 2012-13 2013-14 2014-15
Year wise Alternate fuel TSR%
Kiln-3 Combined
Results:
0.5
0
0.2
3
0.2
5
0.1
4
0.0
4
0.3
1
0.1
9
0.4
2
0.1
0 0.7
4
2.4
5
0.4
5
0.8
2
3.9
5
0.5
3
0.3
7
0.5
5
0.1
1
0.0
6
0.3
0
0.0
1
0.4
5
0.0
0
2.4
2 3.0
9
6.2
3
6.5
7
5.2
5
1.00
2.00
3.00
4.00
5.00
6.00
7.00 Monthly: Alternate fuel TSR%
� Vikram Cement achieved more than 4.0% TSR on consistent basis.
0.2
3
0.2
5
0.1
4
0.0
4
0.3
1
0.1
9
0.1
0
0.3
7
0.1
1
0.0
6
0.3
0
0.0
1
0.0
0
0.00
1.00
Kiln -1 Kiln - 2
Installation of Energy Efficient Screw Compressors
Project No-2
Screw Compressors
Description: Higher power consumption of old and low efficiency
Reciprocating air compressors which is sp. power consumption 14-17kW/100m3/hr. Due to it’s low efficiency, higher power consumption, frequentmaintenance & higher maintenance cost. Replacement of reciprocating typecompressors into the high efficiency compressors.
Goal: To reduction of specific energy consumption of compressors.
Approach: Identification of low efficient compressors.
Compressor No Measured FAD Atual kW SPC /100m3
800.51 612.0 107.00 17.48
800.52 589.0 84.00 14.26
800.53 560.5 82.50 14.72
800.01 270.8 40.00 14.77
800.11 502.9 86.00 17.10
Total 2535.1 399.50
Actual kwh
Action: Replacement of low efficiency 8 nos. compressors with new 2 Nos.
energy efficient Screw compressor of 2500 m3/hr (GA 110) capacity with specific power consumption of 10kW/100m3/hr.
Results:POWER SAVING STATEMENT FOR Line-1 SCREW
COMPRESSOR
POWER SAVING STATEMENT FOR Line-2 SCREW
COMPRESSOR
Old
Compressors
KWH
consumption
from 1.10.13
to 31.12.13
Run
Hours
Avg.
kwhMF
Actual
kwh
Old
Compressors
Kwh
20.05.14 at
10.30 to
24.00hrs
Run
Hours
Avg.
kwhMF
Actual
kwh
COMPRESSOR
NO. 01 1,43,485 1832.2 78.3 1 78.3
COMPRESSOR
NO. 011,037 13.5 76.8 1 76.81
COMPRESSOR
NO.-02 4,97,170 2207.7 225.2 0.33 74.3
COMPRESSOR
NO. 023,280 13.5 243 0.33 80.18
COMPRESSOR
NO. 04 4,34,283 2205.2 196.9 0.4 78.8
COMPRESSOR
NO. 03317 13.5 23.5 3.15 73.97
COMPRESSOR COMPRESSOR COMPRESSOR
NO. 03 2,76,779 1803.9 153.4 0.5 76.7
COMPRESSOR
NO. 04172 13.5 12.7 6.25 79.63
Average Kwh of all
compressors 308.1
Average Kwh of all
compressors 310.59
New Screw
Compressor
KWH
consumption
from 13.02.14
to 18.03.14
Run
Hours
Avg.
kwhMF
Actual
KW
New Screw
Compressor
Kwh
19.06.14 at
00.00
to 24.00hrs
Run
Hours
Avg.
kwhMF
Actual
KW
Screw
compressor 189248.7 789.2 239.8 1 239.8
Screw
compressor 5789 24 241.2 1 241.21
Total Power saved 68.3 Total Power saved 69.4
Net power saving annually:
� Power saving
Line-1 = 68.3 kwh
Line-2 = 69.38 kwh
� Annual power saving = 137.68kwh X 24hrs X 330days = 1090425.6 kWh
� Cost saving 4.19 INR/ kW = 1090425.6 X 4.19 = Rs. 45.68 Lacs.
Results:
� Cost saving 4.19 INR/ kW = 1090425.6 X 4.19 = Rs. 45.68 Lacs.
Payback period:
� Total cost including equipment, civil, mechanical, electrical, instrument is = Rs. 77.5 Lacs.
� Pay back period = Total cost / Net saving yearly.
=Rs. 77.5 Lacs / Rs. 45.88 Lacs
= 1.68 YEAR
Provide Quality & Reliable
power to Kilns by TPP
Project No-3
power to Kilns by TPP
Description:
� Grid is a vast system & likely to have fault.
� Power system frequency & Voltage floating with grid because, TPP
follow the variation in grid voltage/frequency to remain parallel with grid.
� Whenever any Grid disturbance occurs plant severely affected.
Goal:
� Provide quality & reliable power to plant (kiln) without impacting of grid
disturbance (voltage & frequency).
Approach:
� Feasibility study to provide isolated power from TPP to plant.
� Most critical process Kilns load are suitable for TPP one unit capacity.
Previous distribution (before TPP )
GRID
132 KV BUS
Tr-
G G G
Kiln &,
CO/M section
RM, CM
6.6kV BUS VC-3VC-2VC-1
DG Generator
Tr-
1 Tr-
2Tr-
3
Kiln &,
CO/M section
RM, CM Kiln &,
CO/M section
RM, CM
Previous distribution (after TPP)
GRID TPP- 1 TPP- 2
132 KV BUS
Tr-
G G G
6.6kV BUS VC-3VC-2VC-1
DG Generator
Tr-
1Tr
-2Tr-
3
Kiln &,
CO/M sectionRM, CM
Kiln &,
CO/M sectionRM, CM Kiln &,
CO/M section
RM, CM
Action: Install additional transformer
GRID TPP- 1 TPP- 2
Trafo-4
Sync.
Present distribution
132 KV BUS
G G G6.6kV BUS
VC-3VC-2VC-1
DG
Sync.
BkrTr-
1Tr-
2Tr-
3
Kiln &,
CO/M sectionRM,
CM
Kiln &,
CO/M sectionRM, CM Kiln &,
CO/M sectionRM, CM
Results:
� We have taken trial of all thee kiln on TPP-2 (Without grid) at optimized
voltage & frequency from 26.04.2015 to 30.04.2015.
� At the time of voltage dip or any Grid disturbance all kilns remains
unaffected.
� Plant run at optimized frequency & voltage.
� Efficiency of Plant is improved.� Efficiency of Plant is improved.
� Saving expected in kiln power by 0.33 kwh/ton of material and actual
achieved – 0.60 kwh/ton of material
Saving
Previous
calculation & study
Description:
Bag house fan was running at higher speed (800 – 830rpm) and
consuming more power (430-460kw) to maintain required draught at PH fan outlet.
Bag house fan power consumption reduction
Project No-4
PH fan outlet.
Goal:
Reduction in power consumption & optimise the fan speed by reducing
pressure drop and minimise false air ingress in system.
Approach:
• Pressure drop across damper checked and it was found on higher side (50mmWg) in full open condition.
• Fan inlet suction eye gap checked.
• Repair/replacement of bag house inlet duct to reduce false air entry.
Fan inlet damper: Pressure drop reduction across damper
Fan inlet damper vanes repairing.
BeforeBeforeInlet
Damper
AfterAfter
Inlet
Damper
Action: 1st Improvement
Damaged Inlet Damper
Open
Vanes
Vanes
not fully
open
Repaired inlet damper
All open
Vanes
Fan inlet suction eye: Eye gap optimise
Replaced fan inlet suction eye
BeforeBeforeAfterAfter
Suction Suction
EyeEye
Suction
Eye RotorRotor
Action: 2nd Improvement
Suction eye
GapGap 15 mm
New Suction Eye
OverlapOverlap 7, 25
mm
Bag house inlet duct: To reduction of false air
Replacement of Bag house inlet duct
• Replace bag house inlet duct of Dia. 3450 mm and Length 37 Mtr.Before After
Action: 3rd Improvement
Damage Duct New Duct*To reduce corrosion ceramic resistance coating was done
Benefit of Improvement
1) Power consumption- 438 KW
438X24X330=3468960 KW
2) Maintenance on duct-high risk job
3) Cleaning of spillage material-
1) Power consumption- 403 KW
403X24X330=3191760KW
Before After
3) Cleaning of spillage material-extra manpower required
Loss-Saving
Bag house fan motor: Resizing to utilize SPRS
Before After
1. Motor Power :- 1060 KW 1. Motor Power :- 550 KW
� Bag house fan SPRS is designed for 70 to 95% RPM So fan was running at
700 rpm and further control was being done by Inlet Damper.
� So Motor replaced with low RPM( 990 to 743 RPM) and KW (1060 to 550 KW)
now control of RPM below 700 was possible that resulted in power saving
Further 4th Improvement
1. Motor Power :- 1060 KW
2. Fan RPM :- 990
3. Running RPM: 700+
1. Motor Power :- 550 KW
2. Fan RPM :- 743
3. Running RPM: 535 to700
Power consumption- 400 KW
400X24X330=3168000 KW
Total cost- 3168000 X4.75= Rs. 15048000
Power consumption- 340 KW
340X24X330=2692800KW
Total cost- 2692800 X4.75= Rs. 12790800
Description:� Presently low efficiency Chinese pumps are installed for feeding the
water into boilers.� Maintenance expenditure as spare parts cost of these Chinese
Project No-5
Replacement of Boiler Feed Pumps with high efficiency indigenous pumps
� Maintenance expenditure as spare parts cost of these Chinesepumps are very high & no service support is available in India.
Goal:Replacement of low efficiency water pump with high efficiency indigenouspumps to save the energy.
Approach: Two boiler feed pump were identified as low efficiency
pump.
Action: Installation of Indigenous KSB pump
Before After
Chinese Pump Indegnious Pump
Results:
S.No.Load
(TPH)Amps
KSB
Pump
Power
cons. kw
KSB Pump
average
Power
cons. kw
Chinese
Pump power
cons. (kw)
Chinese Pump
average power
cons. (Kw)
Net
saving
in Kw
Net average
saving in Kw
1 102 37.86 615 790 175
2 118 40.2 675 790 115
3 109 41.97 683 790 107
Saving analysis:
643 790 147
3 109 41.97 683 790 107
4 98 39.58 630 790 160
5 94 39.76 632 790 158
6 94.5 40.06 635 790 155
7 89 38.7 630 790 160
Before pump installation After pump installation
Energy consumed = 18960 kwh / day Energy consumed = 15432 kwh / day
Net average saving per day = 3528 kwh
Net average saving per annum = 1287720 kwh
In term of Rupees = 1287720X3.45X = Rs 4442634/ annum
Saving for two nos pump installed = 4442634 X 2 = Rs 8885268 / annum
Thank YouThank You