Ltd. … · RMX Plants : 72 Cement Plants : 6 Aggregate Plants : 2. Date | 5 Mejia Cement Plant...
Transcript of Ltd. … · RMX Plants : 72 Cement Plants : 6 Aggregate Plants : 2. Date | 5 Mejia Cement Plant...
3Date |
Acquisition of Tata Steel’s Cement Business.
Acquisition of Raymond Ltd’s Cement division
Launch of ConcretoCement
Mejia plant commissionedSonadihCement plant Line 2 addedAcquisition of L&T’s RMX business
Cement business expansion in North
East GU, Clinker de-bottlenecking,
Further expansion projectsLafarge India Limited becomes part of NirmaLimited following divestment from LafargeHolcim
Lafarge India Limited is rebranded
NuvocoVistas Corp. Ltd. (continues to sell products under the Lafarge Brand names
2006-11
2016
20022001
1999
2013-14
2017
RMX Plants : 72
Cement Plants : 6
Aggregate Plants : 2
5Date |
Mejia Cement PlantCement Grinding1.65 MT
OUR HISTORY❖ Mejia cement plant is the
first green field project of our earlier company (Lafarge India Ltd.), it is a grinding unit with present capacity of 1.65 Million Tons per annum.
AREA
❖ 62.26 acres
MANPOWER STRENGTH❖ Permanent Employee Approx 56 Nos❖ Contract manpower Approx 436 Nos
RAW MATERIAL❖ Clinker – Received by rail from
Sonadih cement Plant and Arasmeta Cement Plant
❖ Chemical gypsum – Received by rail from various sources.
❖ Fly-ash – Through Pipeline from DVC
PRODUCTS❖ Duraguard❖ Duraguard MF❖ Infracem
MODE DISPATCH ❖ 45 % despatch by rail
❖ 55% by road.
• Inking of Agreement with DVC
• Start of Project
• Commissioning of Project
• First Cement Dispatch by Road
• First Cement Dispatch by Rail
• Consent to enhance from 1.0MTPA to 1.5 MTPA obtained from WBPCB
• Consent to enhance from 1.5MTPA to 1.65 MTPA obtained from WBPCB
• Awarded with National FICCI CSR Special Jury Award (on Women Empowerment)
• Awarded with Golden Peacock for Health and Safety
• Certified with ISO 14001 : 2015
• Awarded with CII SHE Excellence Award
• Awarded with CII Energy Efficient plant
• MOU with DVC
• Consent to establish for
1.0 MTPA obtained from WBPCB
2001
2006
2009
2012
2015
2016
2017
2018
Temperature
Pressure
Air/Gas flow
Sample
kW
kW
kW
kW
kW
rpm
clinker Gypsum
Fly ash
Reject SFM
Separator
Mill vent fan
Recirculation duct
Separator fan
Mill vent BH
Separator BHFresh air damper
Cement Silo
Stack
Cement mill9.23 Tph
122.1 Tph
62.0 Tph
95 Deg C
Equipment Capacity Make
Ball Mill 150 TPH KHD
Mill Motor 2*2550 KW C.G.
Packer 3*180 TPH Enexco
Clinker Storage 22000 Ton KHD
Cement Storage 12000 Ton KHD
Gypsum Storage 2*4000 Ton KHD
Wagon Tippler 20 Tips Per Hr Elecon
FY 15-16 FY 16-17 FY 17-18
29.86
29.21
28.04
OVERALL PLANT SPC Plant Section FY 15-16
FY 16-17
FY 17-18
Grinding SEC 28.18 27.58 26.59
Fly Ash BulkerHandling
1.64 1.47 1.46
Packing SEC 1.67 1.62 1.19
Overall Mejia Plant SEC
29.86 29.21 28.04
6.01% over FY 15-16
FY 15-16FY 16-17
FY 17-18
28.18
27.59
26.85
Overall PPC Grinding SEC Section FY 15-16
FY 16-17
FY 17-18
Mill Main Drive
22.79 22.20 21.81
Separator & Bag house Fan
1.28 1.42 1.50
Mill Auxiliary 2.66 2.48 2.41
Mill Utility 1.44 1.48 1.11
Overall PPC Grinding SEC
28.18 27.59 26.85
4.71% over FY 15-16
FY 15-16 FY 16-17FY 17-18
1.681.62
1.19
Overall Packing & Shipping SEC
PLANT SECTION
FY 15-16
FY 16-17
FY 17-18
Packing Plant MCC
0.908 0.897 0.585
Packing Plant Utility
0.768 0.725 0.603
Overall Packing SEC
1.676 1.622 1.188
29.16% over FY 15-16
PLANT Plant-1 Plant-2 Plant-5 Plant-6 Plant-7 DCW-Durgapur
UTCL-Durgapur
Ambuja-Sakrail
NVCL-Mejia
Ball Mill Closed Circuit
Rated Capacity
TPH 133 200 - - 200 150 130 90 150
Operating Capacity
TPH 143/186
225 195 205 200 155 192 105 204.5
Overall Plant
SEC/MT
27.8 28.7 30.4 30.8 31.9 38 29.5 36.5 28.04
27.81 28.74 30.4 30.78 31.9238
29.536.5
28.04
❖ Second Best at National level as per CII Benchmark
2.b. National Benchmark (Cement Grinding SEC)
27.16 27.59 29.13 29.37 30.536.05
27.14
35
26.85
❖ Best at National level as per CII benchmark
PLANT Plant-1 Plant-2 Plant-5 Plant-6 Plant-7 DCW-Durgapur
UTCL-Durgapur
Ambuja-Sakrail
NVCL-Mejia
Overall Grinding
SEC/MT 27.2 27.6 29.1 29.4 30.5 36.1 27.1 35 26.85
2.b. National Benchmark (Packing & Shipping SEC)
0.65
1.15 1.27 1.41 1.42
1.952.35
1.51.19
❖ Top 3 at National level as per CII Benchmark
PLANT Plant-1 Plant-2 Plant-5 Plant-6 Plant-7 DCW-Durgapur
UTCL-Durgapur
Ambuja-Sakrail
NVCL-Mejia
Overall Packing
SEC/MT 0.65 1.15 1.27 1.41 1.42 1.95 2.35 1.5 1.19
❖ Bench marking done with other plant in Group & National Level.❖ Conducted Energy Audit through CII and got good action points for implementation❖ Prioritized and formulated plant overall SEC target with Management Steering
Committee.❖ Objective set to optimize SEC , Stretched SEC target included in KPI of all concerned
and taken as plant’s one of the primary objective.❖ Energy committee formulated and members are empowered to take decision on any
operational points related to power optimization.❖ Dynamic monthly SEC target set and monthly SEC tracking done by Management
Steering Committee in cost meeting.❖ Priority discussion on shop wise power consumption in Daily Operational meeting.❖ Formulated special task force team for identification and rectification of
compressed air leakages.❖ Specific inspection done as per power mastery guideline.e.g:
✓ Major fan efficiency, separator efficiency, mill volume loading,✓ compressor performance test, Particle size analysis by different samplings
etc.❖ Compressor run hour management supervised by shift in charge, tracking of
compressor loading / unloading hour.❖ Energy Management training conducted at Group Level for key personnel.
Sl Action Plan Energy Saving
kWH/Yr
Savinsgin mINR
Investment mINR
SEC reduction
1. Installation of VFD in Aux. Bag filter Fan to avoid pressure loss across the damper
235,205 1.29 0.35 0.151
2. DP Mode operation of Vent bag house & optimizing compressed air consumption
120,000 0.66 0.15 0.077
3. Addition of low rating Process Pump for Shutdown duration
10,920 0.06 Zeroinvestment
0.007
4. Modification & de-rating of auxiliary circuit motors
50,616 0.028 Zeroinvestment
0.033
5. Optimization of Process water pump power by rerouting of water pipeline
23,760 0.13 0.30 0.015
6. Blade angle optimization & motor de-rating of Cooling tower fan
10,560 0.06 Zeroinvestment
0.007
Total no. of Projects : 32
Project with Zero Investment : 21
Project with Investment : 11
Total Energy savings : 44,43,675 kWh
Total Cost Savings : 25.12 mINR
Sl Action PlanEnergy Saving
kWH/YrSavinsg in
mINRInvestment
mINRSEC
reduction
1.Modification of Wagon Tippler lighting system with DCS control
8,856 0.05Zero
Investment0.006
2. Adding Flyash at Cement Mill outlet 545,892 3.00Zero
Investment0.399
3.Optimization and review of raw material transport circuit idle running during clinker and gypsum unloading
109,178 0.57Zero
Investment0.079
4.Optimization of Packing Plant Compressoroperation as per Packer operation to reduce Packing power
24,000 0.11Zero
Investment0.017
5.
Optimizing of Compressor load to minimize the loading hours by tuning the load/unload settings as per actual requirement
64,000 0.29Zero
Investment0.046
6. Installation of Process Optimizer LUCIE 436,714 2.28 0.15 0.319
Sl Action PlanEnergy Saving
kWH/YrSavings in mINR
Investmentin mINR
SEC reduction
7.Modification of de-dusting line for Clinker Extraction conveyors with installation of shut-off gates & selective operation
35,640 0.16Zero
Investment0.026
8.2nd chamber media gradation done withHigh Chrome Grinding Media
237,180 1.18 9.6 0.173
9.
Dose optimization Mill performance enhancer (Grinding Aid) resulting to higher Fly-ash addition & improvement in SPC
650,000 3.30Zero
Investment0.476
10.Optimization of Bag Filter purging ON/OFF time in Finished grinding & Packing
12,300 0.50Zero
Investment0.009
11.Optimizing of excess illumination in specific high mast tower area by switching of alternate fittings
8,856 0.4Zero
Investment0.006
Sl Action PlanEnergy Saving
kWH/Yr
Savings in mINR
Investment in mINR
SEC reduction
1.Optimization of Plant High Mast Tower lighting and achieved energy saving
77,186 0.41Zero
Investment0.052
2.Replacement of conventional office lightings with LED lights
59,206 0.33 0.38 0.040
3.Replacement of WT Main Bag Filter FanImpeller with High efficiency impeller
34,970 0.18 0.35 0.023
4.Modification in Air Slide Blower pipeline to stop Air Slide Fan 416FA25A
23,680 0.13Zero
Investment0.016
5.Retrofitting of wagon tippler twins Fan to increase the efficiency
14,210 0.08 0.10 0.009
6.Optimizing FA Silo top Bag Filter Fan VFDwith Auto control loop
13,530 0.07Zero
Investment0.009
Sl Action PlanEnergy Saving
kWH/Yr
Savings in mINR
Investment in mINR
SEC reduction
7.Installation of Frequency Drive for Wagon Tippler Bag Filter Fans
42,900 0.23 0.08 0.029
8.
Connection of Air Slide 543AS02 with Cement Bin Aeration Blower 543AB01,02resulted stopping543FA02 Air Slide Fan
7,316 0.39Zero
Investment0.005
9.Modification of MF Feeding Air Slide toMF Elevator by Connecting Air Slide Fan 512FA13 resulted stopping of 543FA01 fan
6,458 0.03Zero
Investment0.004
10.
Connection of VAC Elevator feeding blower 543FA04MT10 with Silo Extraction AS Blower resulted in stoppage of 512FA15A
14,481 0.08Zero
Investment0.009
Sl Action PlanEnergy Saving
kWH/Yr
Savings in mINR
Investment in mINR
SEC reductio
n
1.Optimization of cooling tower fan operation with temperature control
1,670 0.01Zero
Investment0.001
2.Optimizing the pressure setting of Compressors in plant to reduce compressor running in load
42,000 0.22Zero
Investment0.028
3Replacement of existing process water pump with High Efficiency Pump for Cooling water circulation
95,040 0.50Zero
Investment0.064
4.Replacement & Upgradation of obsoletepackage Air Conditioning system withSplit Air Conditioner and occupancy sensors.
223,072 1.18 1.2 0.150
5.Replacement of conventional Plant lightings,Street Lights and High Mast Area light fittings with LED lights
486,910 2.58 2.4 0.328
Sl Action PlanEnergy Saving
kWH/Yr
Savinsgin mINR
InvestmentmINR
SEC reduction
6.Improve Distribution Transformers Loading by using one transformer at a time
12,176 0.06Zero
Investment0.008
7. De-rating of Air slide Fan motors 15,725 0.63Zero
Investment0.010
8Installation of Automatic star-delta converter for under loaded motors
380,160 2.01Zero
Investment0.256
9.De-rating of Motors in Packing Plant Loading Belt conveyor circuits
97,152 0.53 1.50 0.065
10.Installation of Frequency Drive for Packing Plant Bag Filter Fans
475,200 2.61 1.30 0.320
PROJECT – 1
Title :❖ Reduction in Cement Grinding SEC by Automatic Delta Star Motor Controller
Implementation :❖ As some Screw conveyors are running below 40% load but need high torque at starting.
we develop a Current base Functional Block at Distributed Control System to forChange over from Delta to Star as per running load.
❖ Fixed Current Transformer & current transducer in the circuit to measure line current and communicate with DCS.
❖ Making panel with 2 nos contactor for star and delta and brought all the six terminals of the motor to panel and arranged proper way for star-delta operation and Logic developed as per requirement .
❖ Step-1- Motor always stars with Delta mode to reach the starting torque after a certain time limit it will start observing line current for star – delta operation.
❖ Step-2-If Current Transformer( Sensing the line current) is below 50% of full load current then motor will run with star mode (energy saving mode) otherwise it will run with delta mode.
❖ Step-3-If it was running with Star mode after sensing line current and suddenly line current increased more than 40% of F.L current for any process deviation it will convert to delta mode even if any fault in current transformer, motor will operate in delta mode as per logic. (Default value set more than 50% of full load current).
Implementation :
Block developed in DCS (ABB library), ease to implement as & when requirement
Advantages :
❖ Innovative development of DELTA-STAR-DELTA Mono Block in ABB DCS System (STAR-DELAT Block does not exist in ABB DCS Library)
❖ Energy Saving (Reduction in KW and KWH).
❖ Improvement in power factor.
❖ Reduction in line current so it will minimize copper loss and reduces motor temperature and it leads to increase motor life.
Cost benefits in our case:
❖ Saving for in-house development of the energy saver unit (2 nos) : 1.5 Lakhs
❖ Total expected Energy Saving : 23,996 Kwh/Year(Considering Mill running for 330 days)
❖ Total expected cost saving : 1.35 Lakhs/Year(Considering Power Cost – 5.60 Rs./Unit)
PROJECT – 2Title :❖ Energy saving by replacement of existing obsolete package AC system with individual
Split AC units & optimizing the operations.
Implementation :❖ There are conditions that all the cabins & halls are not occupied continuously & all at a
time during the General shift duty hours. Also as per our study the average occupancy of the rooms is for maximum 5 hrs a day & 24 days a month.
❖ But it is required to keep the package AC units continuously on for Servers Room, DCS Room, CCR Room & Lab Room continuously on 24x7 basis to maintain the equipment & system reliability.
❖ Thus there is huge Power consumption due to running of packages for cooling of few areas & even the other areas remain unoccupied.
Benefits :
❖ Individual AC units could be switched off when not required & when there is no occupancy in the rooms or cabins.
❖ AC temperature could be controlled individually as per comfort level.
❖ Gives Energy savings with low Energy consumption. Savings of 217,226 units/year.
❖ New generation AC units are less in maintenance & much more reliable.
PROJECT – 3Title :❖ Temperature Control Start-Stop of Cooling Tower Fan.
Implementation :
❖ It was observed that process water cooling tower Fan (11 kW motor) runs continuously 24x7 even through the process water temperature is very less & does not require further cooling.
❖ Avoided un-wanted running of cooling tower fan, by introducing a temperature control interlock to stop the fan with target temperature Set point.
❖ Thus saved the running power of cooling tower fan during entire 4 months of Winter season when ambient temperature is very low
Cooling Tower fan operation with temp control
Temperature Controller Water Cooling Tower
Temp ControllerRTD
Cooling Tower Fan:❖ It was observed that process water cooling tower Fan (11 kW motor) runs
continuously 24x7 even through the process water temperature is very less & does not require further cooling.
❖ Avoided un-wanted running of cooling tower fan, by introducing a temperature control interlock to stop the fan with target temperature Set point.
❖ Thus saved the running power of cooling tower fan during entire 4 months of Winter season when ambient temperature is very low.
Benefits:❖ Total Energy Saving = 34,830 kWh❖ Total Cost Saving @ 5.60 Rs/Unit = 1.50 Lacs/Yr
❖ In NUVOCO, management is committed to utilise renewable energy source, at first phase, Chittorgarh Unit , Rajasthan, 0.5MW Solar plant is under commissioning stage.
❖ In Mejia, Plant Roof-top 20 KW Solar stations installation project has been proposed for office lighting.
Solar Panels at Chittorgarh Unit
YEAR SCOPE 1 EMISSIONS
SCOPE 2EMISSIONS
TOTAL REDUCTION
(KG)
2014-15 234521000 191513 234712513
2015-16 236880000 2075198 238955198
2016-17 252530000 732030 253262030
2017-18 263817000 1217254 265034254
SCOPE 1 Reduction in Emission due to less consumption of clinker (higher CK ratio)
SCOPE 2 Reduction in Emission due to Savings in kwh
FY 2014-15
FY 2015-16
FY 2016-17
FY 2017-18
FY 2014-15 FY 2015-16
FY 2016-17 FY 2017-18
❖ Total plant area: 25.19 Ha.❖ Green belt developed inside plant: 6.83 Ha.❖ Green belt developed at social forestry
in community : 9.09 Ha.❖ No of sapling planted inside plant : 3550 nos❖ No of sapling planted in community : 11000 nos
Green Belt At Mejia
Plantation Near Workshop
Water Harvesting Pond Plantation Programme at Mejia
❖ Nuvoco Vistas Corp. Ltd is committed for Green Supply Chain Management initiative.
❖ Mejia has already initiated the process to adopt Green purchasing practices in the plant to get benefits like… ✓ To conservation of energy, water and other natural resources.
✓ To lowering of costs incurred towards waste management. ✓ To compliance with the environmental regulations. ✓ To improve brand image & reputation among customers as the organization is focusing
towards greener product.✓ To improve employee health due to lesser environmental impact.
❖ Further to development of green purchase/procurement Novoco is aiming at…✓ Reducing the usage of hazardous (toxic) products / chemicals in their manufacturing facilities &
phasing out toxic chemicals use in a phase manner.✓ The major purchasing like - capital goods, raw materials, maintenance consumables (electrical,
mechanical, oils), building materials, & other consumables will be initiated with green procurement guidelines.
❖ As a initiative towards Green Supply Chain Management implementation at Mejia Cement Plant, is reflecting through its following actions..
✓Mejia is Certified as ISO 14001 : 2015 compliance cement manufacturing unit in 2018.
✓ Environmental Objective and Targets shows the commitment to achieve the Green Supply Chain Management.
Monthly Energy committee MetingEnergy awareness Programme among Shop floor People
Productivity Capex Approved in Last two Finacial Year :
❖ Capex Budget Approved for FY – 2017-18 = 16.5 mINR
❖ Capex Budget Approved for FY – 2018-19 = 10.5 mINR
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Mill kWh VS TPH
Mill Motor KW TPH
Hourly Tracking Through EMS systemSystematic Monthly tracking
Thank You
8/29/2018 43