UltraTech Cement Limited: Unit-Sewagram Cement Works
Transcript of UltraTech Cement Limited: Unit-Sewagram Cement Works
CII-20th National Award for Excellence in
“Energy Management System-2020”
UltraTech Cement Limited: Unit-Sewagram Cement Works
Presenters:1.Sajeesh G.-FH-Technical2.R M Sahu-HOD Technical Services3.Krishna Sharma-SH Technical Services
Contents
2
Implementation of ISO50001/Green Pro/IGBC rating
01 Brief Introduction on company/Unit
02
03
04
05
Energy consumption overview
Sp.Energy consumption- Last 03 Years
National and Global Benchmarking
ENCON-Last 03 Years
06 Innovative projects Implemented
07
08
09
10
Utilization of renewable Energy Sources
GHG Inventorisation and Green Supply chain management
Team Work Employee Involvement and Monitoring
11 Implementation of ISO50001/Green Pro/IGBC rating
Other Innovative technologies and Long Term Vision on EE
Waste utilization and Management.
12
3
1.Business Overview-UltraTech Cement Limited
Sewagram Cement Works
Symbol Plant Nos
Integrated Units 23
Grinding Units 27
White Cement & Putty Units 03
Jetty
Under Commissioning
1.Sewagram Cement Works
4
Units Month & Year of Commissioning Installed Capacity
Clinkerization Line I-Sept’09/Line II-Feb’11 3.60 MTPA
Cement grinding CM1-Mar ’09 /CM2-Dec’10 /CM3- May’12 3.10 MTPA
Packing Plant Packing Plant 1-Mar ’09 /Packing Plant 2- Jul’10 4 Nos. x 180 TPH
Thermal power Plant TPP 1-Sept’09 /TPP 2-Jul’11 TPP1-35 MW, TPP2-22.5MW
Desalination Unit Jul’09 6600 M3/Day
Solar Power Plant Aug’18 5MW
PPC PPCSOPC PPCWR
55.45% 1.77%1.68%41.10%
OUR PRODUCTS
1.Sewagram Cement Works-Journey So Far….
5
• Clay Lease execution & opening of mines• Transfer of Baranda Laterite Mining lease to UTCL• Major use of Lignite coal started using in Kilns for the first time.• Clinker silo of 70,000 MT commissioned.• PPCS grade manufacturing started.
• Initial Jetty manual operation started in a small way.
• Transfer of all EC’s pertaining to Mines in the name of UltraTech
• 12th June UTCL took over from Jaypee.2014-15
2015-16
2018-19
2017-18
2016-17
2019-20
• Started Manufacturing of PPCWR Cement.
• Finally mining lease transferred in the name of UTCL (ML1-659 & ML2- 2832 Hac.
• 5 MW solar plant commissioned.• Baranda Laterite mines expansion project approved from
MOEFCC
6
2.Energy consumption & Summary of saving Initiatives- last 03 Years
7
Year No of Proposals Investments Savings
2017-18 23 81.82 63.78
2018-19 44 119.07 41.79
2019-2020 14 32.58 27.04
Summary of EnCON-Last 03 Year
Energy Consumption Summary-TOE
16774
182155820182172594
TOE
Electrical energy (TOE)
Thermal Energy (Solid & Liguid Fuel)-TOE
TOTAL-TOE
3.Specific power Consumption
8
63.9660.09
57.11 59.44
20
40
60
80
FY 2016-17 FY 2017-18 FY 2018-19 FY 2019-20
Pre-clinkerisation (kWh/MT Clinker)
32.37
30.87
29.30 28.96
20
25
30
35
FY 2016-17 FY 2017-18 FY 2018-19 FY 2019-20
Cement grinding (kWh/MT Cement)
-Up to clinkerization power increased in last FY as Line-1 Kiln stopped for 69.11 Days and Line -2 Kiln stopped 90.26 days in excess clinkertill Feb ’20 & this lead to increase in Misc./Utility power by 3.0-3.5 units.Production of high C3S clinker also lead to increase in sp.power consumption.Power consumption also increased due to increase in bypass% from 13% to 24% t consume high SO3 and Chloride Limestone.Utilization of high moisture and low CV coal also lead to increase in sp.power consumption.
6.1
9 %
Re
du
ction
3.Specific Power Consumption (kWh/T Cement)
9
1.401.36
1.18
1.00
0.80
0.90
1.00
1.10
1.20
1.30
1.40
1.50
FY 2016-17 FY 2017-18 FY 2018-19 FY 2019-20
Packing Plant
15
.25
% R
ed
uctio
n
86.2880.45
75.51 77.06
20
40
60
80
100
FY 2016-17 FY 2017-18 FY 2018-19 FY 2019-20
Overall Specific power consumption
4.2
1 %
Re
du
ction
3.Section-wise Specific Power Consumption (kWh/T Mat)
10
15.8115.54
14.92
15.75
14.00
14.50
15.00
15.50
16.00
FY17 FY18 FY19 FY20
Raw Mill
29.65 29.13
32.73
25.76
15.00
20.00
25.00
30.00
35.00
FY17 FY18 FY19 FY20
Coal Mill
29.39
27.2625.68
26.44
22.00
24.00
26.00
28.00
30.00
FY17 FY18 FY19 FY20
Kiln 3.41
2.82 2.913.37
0.00
1.00
2.00
3.00
4.00
FY17 FY18 FY19 FY20
Utility Services
-Raw mill sp.power consumption increased due to high rain fall (1038 mm in FY20).-Utilization of high moisture coal also lead to high sp.power.-kiln sp.power consumption increased due to increase in bypass% from 13% to 24-25%.
3.Grade-wise Specific Power Consumption (kWh/T Mat)
11
34.09
32.21
29.59 29.69
26.00
28.00
30.00
32.00
34.00
36.00
FY17 FY18 FY19 FY20
OPC Cement
30.53
29.06
28.1827.35
24.00
26.00
28.00
30.00
32.00
FY17 FY18 FY19 FY20
PPC Cement
38.05
36.85
35.57
34.00
36.00
38.00
40.00
FY18 FY19 FY20
PPCS Cement
-Overall cement grinding power reduced by 6.19 % in last 3 FY.-We started production of weather plus cement Sept’19onwards which also resulted in increase of power consumptionto maintain high quality of cement.
3.Specific Heat Consumption wrt Bypass %
12
706.40
700.67
697.43
690.21
14.36%
13.23%
17.58%
23.45%
0.00%
5.00%
10.00%
15.00%
20.00%
25.00%
680
690
700
710
FY 2016-17 FY 2017-18 FY 2018-19 FY 2019-20
Specific heat consumption (Kcal/Kg clinker)
Sp.Heat cons. (Kcal/Kg.Clk) Chloride Bypass (%)
• Avg. SO3 in mines limestone 1.16% and Avg. chloride 0.18%.
• Avg.SO3 0.78% and Avg. chloride 0.08% in mines limestone used in last three years @bypass of 13-14%.
• To sustain the mine life SO3 and chloride being planned to use limestone having Avg. SO3:1.0% and Avg.Cl:0.16% and bypass increased up to 23-24%.
• 1% Chloride bypass result in heat loss of 2.2 kcal/kg clinker and which is equivalent to loss of 52.8 kcal/kg clinker as well as 2.75-2.90 kWh/T clinker
additional power loss due to this bypass system.
1.0
4 %
Re
du
ction
13
4.Roadmap to achieve National/Global benchmark-Electrical
Energy
01
0203
04
Replacement of High efficiency impellers-Upgradation of Bag house Fans
Kiln outlet seal modification
Fan inlet box modification-(Raw mill, Alkali bag house fan, KS and CS fan ) Removal of louvre dampers from KS and CS and Raw Mill fan inlet
Application of ceramic grinding media in Roll press and Ball Mill
National /Global Benchmark-62 kWh/T cement
Current Level: 75.51kWh/T cement
GCW NJFD SCW
Pre clinkerization Sp.Power
53.90 50.63 59.44
Post Clinkerization 32.23 30.64 30.96
Overall Sp.power 77.33 76.72 77.06
Sp.heat consumption 705.18 759 690.21
Cluster Comparison
14
4.Roadmap to achieve national/Global benchmark-Thermal
Energy
01
0203
04
Installation of Coriolis coal feeding system- 2.5-3 Kcal/kg clinker
Reduction in Alkali bypass, Process optimization and False air reduction in preheater up to 5%.-10-12 kcal/kg clinker
Utilization of Fuel catalyst for heat consumption reduction 5-6 Kcal/kg clinker
Application of heat resistant paint in preheater, Kiln and Cooler- 8-10 kcal/kg clinker
Target-675 kcal/Kg clinker
Current Level: 690 kcal/kg clinker *All data reported are without bypass loss
4.Future Energy Saving Projects
15
Sr. N. ProposalAnnual Elect. Saving
(kWh)Annual Cost Saving
(Rs. Million)Annual Thermal SavingQuantity Rs Million
Total Annual Savings (Rs Million)
Investment Made (Rs Million)
1 Replacement of High efficiency impeller in RABH-1 Fan 255840.00 1.07 - - 1.07 5.00
2 Replacement of High efficiency impeller in RABH-2 Fan 255840 1.07 - - 1.07 5.00
3 Ceramic Grinding media for cement mill 315000 1.32 - - 1.32 3.00
4 Pressure drop reduction in Line-1 Preheater (Cyclone modification) 196200 0.82 - - 0.82 6.00
5 Fan inlet box modification in line-1 Kiln sting and Calciner string fan 489600 2.06 - - 2.06 0.45
6 Fan inlet box modification in line-2 Calciner string fan 331200 1.39 - - 1.39 2.2
7 Installation of coroilis feeding system in line-2 311740 1.31 480 3.85 5.16 34.7
8
Energy Saving by reduction of pressure drop across the Cyclone and ducting in the Line-1 Raw Mill Circuit by application of CFD analysis and Modification.(Cyclone riser modification, baffle plates installation as per CFD OFIs)
1660000 6.30 - - 6.30
9 Line-2 Mill operating Dp to be reduced to 670 mmWg, 264000 1.11 - - 1.11 0.5
10 Raw Mill Fan inlet box modidifcation in both line 377200 1.58 - - 1.58 0.3
11 Alkali Bypass Bag House Fan inlet box modidifcation in both line 192000 0.81 - - 0.81 0.8
12 Alkali Bypass Bag House Fan inlet damper removal in both line 144000 0.60 - - 0.60 0.2
13Inlet box modification to reduce fan power consumption in Cement Mill-2 Bag house fan (Sepax fan).
157500 0.66 - - 0.66 0.8
14Inlet box modification to reduce fan power consumption in Cement Mill-3 Bag house fan.
150000 0.63 - - 0.63 0.8
15 Compressed Air Optimisation & Leakage Reduction with automation 230400 0.97 - - 0.97 3.5
16 Radiation reduction in preheater & TAD with surface coating 0 0.00 1535 12.33 12.33 8.0
17Power reduction in bag filter fans by VFD/Energy efficient motors & Damper removal (15 Fans)
375000 1.58 - - 1.58 2.0
18 Power reduction in utility water pumps by efficiency improvement 480000 2.02 - - 2.02 1.5
Total Savings 6185520.00 25.31 2014.32 16.18 41.48 74.75
5.List of Encon-2017-18
16
Sr. N. ProposalAnnual Elect.
SavingAnnual Cost
Saving
Annual Thermal Saving Total Annual Savings Investment Made
Payback
kWh Rs. Million Quantity Rs. Million Rs. Million Rs. Million Months
1Energy saving by replacement of the GRR control with MV drives In Line 1 Kiln String Fan (Aug'17)
789848 3.16 - - 3.16 7.48 28
2Energy saving by replacement of the GRR control with MV drives In Line 1 Calciner String Fan (Aug'17)
3365427 13.46 - - 13.46 10.33 9
3Energy Saving by Reduction of Air Infiltration across K-String of the line -1 SCW
460000 1.75 - - 1.75 - -
4Energy Saving by reduction of air infiltration across Raw Mill-1 fan and there by reduction of Raw Mill-1 fan power consumption
920000 3.47 - - 3.47 - -
5Energy Saving by increasing the Line-2 Kiln Feed Temperature and thereby reducing the specific heat consumption for Clinker Production. 58 to 70 °C
- - 666.5 MT 4.13 - -
6
Energy Saving by improving the cooler-1 recuperation efficiency through replacing the static grate with modified ABC static grate (Make-FLS) (Nov'17)
- - 1083 MT 6.50 17.9 33
7
Energy Saving by reduction of air infiltration across line-2 Alkali Vent by-pass bag filter and thereby reducing line-2 alkali bypass fan power consumption.
29000 1.1 - - 1.1 - -
8Energy Saving by replacement of the Line-2 Calciner String Fan and also installing new MV Drive in place of GRR in (Nov'17). 1538797 6.16 - - 6.16 16.3 31.78
9Energy Saving by replacement of the Line-2 KS Fan and also installing new MV Drive in place of GRR.(Dec'17)
773315.38 3.09 - - 3.09 9.8 38.02
10 Replacement of conventional lights with energy saving LEDs. 19500 0.078 - - 0.078 - -11 Reduction in Raw Mill Dam ring height by 15mm. 378496 1.51 - - 1.51 - -
12Raw Mill nozzle veloctiy optimization by blocking nozzles behind Roller
504661 2.02 - - 2.02 - -
13 Damper removal in cooler fan 32000 0.128 - - 0.128 - -
5.List of Encon-2017-18
17
Sr. N. Proposal Annual Elect. Saving
Annual Cost Saving
Annual Thermal SavingTotal Annual
Savings
Investment Made Payback
14Energy Saving by Reduction of Air Infiltration of the line -2 Coal mill Circuit 130000 0.49 - - 0.49 - -
15 Energy saving in CM2 Ball Mill bag house fan by reduction in air infiltration across the bag house
13000 0.05 - - 0.05 - -
16TA duct area decreased from 3500mm to 2800 mm to increase the gas velocity and reduction in TAD dropping. 276.48 MT 1.714 - -
17Reduction in Idle run Hour of RMHS(Limestone, Additive and Coal Circuit) 1182717 4.731 - - 4.73 - -
18VRM table and Roller liner changed from HighChrome to SinterCast.
563024 2.25- - - - -
19Bag House operation with Differential Pressure (DP) inplace of timer in Roller Press Mill (CM2) and VRM Bag House
22521 0.09- - - - -
20 Alkali dust usage in cement Mill 225210 0.90 - - - - -
21Installation of New generation NOVAFLAME five pilaard burner in Line-2 - -
480.0 MT 2.98 10 40
22 Use AF Carbon black and Coal dust as a ulternative fuel in Kiln - - 431 MT 2.67
23 Line1 Burner Replacement in May'17 (Swirlex to Pillard) - - 766 MT 4.60 10 26
Total No of Projects-23 10947515 63.78 81.82
5.List of Encon-2018-19
18
Sr. N. Proposal Annual Elect. Saving Annual Cost Saving Annual Thermal Saving Total Annual Savings Investment Made kWh Rs. Million Quantity Rs. Million Rs. Million Rs. Million
1 Installation of 5 MW Solar power plant 5295000 3.71 - - 3.712 Line-2 ABC cooler installation 74127 0.31 384 3.07 3.38 17.903 Installation of Expert optimizer in Kiln-1 175404 0.74 - - 0.74 2.804 Installation of Expert optimizer in Kiln-2 201353 0.85 - - 0.85 2.805 Reduction in false air In Kiln Section 183600 0.77 - - 0.77 0.03
625-30 mmWg Pressure drop reduction in calciner string cyclone 3 and 4 through roof lifting (Line-2)
74127 0.31 - - 0.31 6.00
7 Installation of MV drive in Line-1 Raw Mill Fan 440134 1.85 - - 1.85 11.84
8Installation of aerofoil nozzle ring for pressure drop reduction
77486 0.33 - - 0.33 3.30
9 Installation of MV drive in Line-2 Raw Mill Fan 458611 1.93 - - 1.93 10.00
10Classiifer skirting and optimization of dam ring height in Raw Mill
38743 0.16 - - 0.16 0.025
11 Reduction in false air In Raw Mill Section 214621 0.90 - - 0.90 0.02512 Installation of Expert optimizer in Raw Mill-1 372995 1.57 - - 1.57 2.4013 Installation of Expert optimizer in Raw Mill-2 330562 1.39 - - 1.39 2.4014 Installation of Expert optimizer in Coal Mill-1 38153 0.16 - - 0.16 2.4015 Installation of Expert optimizer in Coal Mill-2 49849 0.21 - - 0.21 2.4016 Installation of MV drive in Line-1 Coal Mill Fan 70505 0.30 - - 0.30 7.9117 Installation of MV drive in Line-2 coal Mill Fan 93299 0.39 - - 0.39 6.0618 Reduction in false air In Coal Mill Section 40502 0.17 - - 0.17 0.025
19CM-2 RP Feeding of Separator reject fines at the bottom of V-Separator instead of Roller Press Bin
108020 0.45 - - 0.45 0.03
20CM-2 RP Optimization of Grinding media charge with several trials with different loading 295666 1.24 - - 1.24 0.02
21 CM-2 RP Stud Roller Installation in place of CHF roller 1404259 5.90 - - 5.90 2.20
22 Expert optimizer for Mill Operation- CM2 293677 1.23 - - 1.23 2.40
5.List of Encon-2018-19
19
Sr. N.Proposal
Annual Elect. Saving
Annual Cost Saving Annual Thermal SavingTotal Annual
Savings Investment Made
kWh Rs. Million Quantity Rs. Million Rs. Million Rs. Million23 Expert optimizer for Mill Operation- CM3 415668 1.75 - - 1.75 2.4024 CM-2 Fan flow optimization with fan speed reduction 75951 0.32 - - 0.32 025 CM-3 Removal of Fan inlet damper to reduce the pressure drop 88329 0.37 - - 0.37 0.1026 Reduction in Dam ring height to reduce the main drive load 325410 1.37 - - 1.37 0.02
27Compressed air to be isolate during mill stoppage by providing the SOV in main line of header.
95490 0.40 - - 0.40 0
28 Compressor to be taken into auto mode and start stop from DCS. 63660 0.27 - - 0.27 029 Raw Mill single start stop 10200 0.04 - - 0.04 030 coal mill single start stop 4800 0.02 - - 0.02 031 CM-2 Single start stop 7520 0.03 - - 0.03 032 CM-3 Single start stop 6640 0.03 - - 0.03 033 VFD Installation in bag filter fan 651FN1 (651BF1)
610 1.9
- - 1.90
9.68
34 VFD Installation in bag filter fan 651FN2 (652BF1) - - 0.0035 VFD Installation in bag filter fan 642FN4 (642BF1) - - 0.0036 VFD Installation in bag filter fan 642FN9 (642BF3) - - 0.0037 VFD Installation in bag filter fan 642FN5 (642BF2) - - 0.0038 VFD Installation in bag filter fan 642FNA (642BF4) - - 0.00
39Lighting timers to be replaced by Astro timers in MLDB
29700 0.12 - - 0.12 0.08
40 70W HPSV light to be replaced by 24W LED in phased Manner. 510 nos 83720 0.35 - - 0.35 0.6
41 CCR lightings to be replaced by 20W against 36W (360Nos) 33920 0.14 - - 0.14 0.2842 VFDs for 3 x 75 kW Pumps 109200 0.46 - - 0.46 0.45
43Township area switching OFF Lights of Non Critical Areas Between Mid Night to morning Hours. Or Alternate street light to be switched OFF
24130 0.10 - - 0.10 0
44 Installation of stud roller in CM-2 Roll press 1474190 6.19 - - 6.19 22.50
Total Savings 13179830 38.72 384 3.07 41.79 119.07
5.List of Encon-2019-20
20
Sr. N. ProposalAnnual Elect. Saving
(kWh)Annual Cost Saving
(Rs. Million)Annual Thermal SavingQuantity Rs Million
Total Annual Savings (Rs Million)
Investment Made (Rs Million)
Payback(Months)
1Coal Mill-1 fan Louvre damper removal & inlet box modifiaction
167631.36 0.80 - - 0.80 0.65 9.80
2Coal Mill-2 fan Louvre damper removal & inlet box modifiaction
197147.12 0.94 - - 0.94 0.65 8.33
3Line-1 Cooler fans silencer & inlet damper removal (8 Fans)
167771.52 0.80 - - 0.80 0.06 0.83
4 Idle run hour reduction in RMHS circuits. 376300.00 1.79 - - 1.79 0.07 0.50
5Line-2 Kiln string fan impeller replacement with High efficiency impeller (>82%)
784704.00 3.73 - - 3.73 4.50 14.49
6 CM-2 Speax fan changed with high efficiency fan (>82%) 208440.00 0.99 - - 0.99 2.80 33.94
7 Classifying thin liner installation Cement Mill-2 969246.00 4.60 - - 4.60 7.10 18.51
8Coriolis firing system & VFD blower installation for coal conveying in Line-1
226008.00 1.07 481.86 3.87 4.94 16.00 38.84
9 Optimization of TG frequency from 50 Hz to 49.5 Hz 933240 4.43 - - 4.43 0 0
10Optimization of compressed air consumptionby reducing leakages in all sections
363000 1.72 - - 1.72 0 0
11Power saving through reduction of idle running of bag house (both main bag house as well as Alkali bag house and ESP) RALs.
239250 1.14 - - 1.14 0 0
12 Air slide blower air optimization in Raw mill circuit 77000 0.37 - - 0.37 0 0
13 Installation of low pressure blower for cloth cleaning 21600 0.10 - - 0.10 0.15 17.54
14Colony and plant lightning power consumption optimization through timer and LED lights installation
146000 0.69 - - 0.69 0.6 10.38
Total Savings through EnCons in FY19-20 4877338.00 23.17 481.86 3.87 27.04 32.58
6.Theme-1 Installation of high efficiency impeller in KS Fan
21
Issues :
Low efficiency (71-73%) of Line-2 Kiln string fan.
High pressure drop in Line-2 wrt Line-1 Kiln.
High Specific power consumption due to low efficiency
and High pressure drop.
Approach:
A cross functional task force team formulated with fan consultant.
It was found that the efficiency of the fan was lower-71-73%
Pressure drop was also higher side in comparison of Line-1.
6.Theme-1 Installation of high efficiency impeller in KS Fan
22
Results :
Kiln String Fan efficiency was increased from 71-73% to 80-81% which resulted in power saving of 100 kW.
Energy saving by 0.8 Kwh /MT clinker.
Total annual savings achieved: Rs 38.74 Lacs in current FY. ROI achieved in less than 6 months. Horizontal
replication will be done in Line-1 also.
6.Theme-2 Pressure drop reduction by cyclone roof lifting6.
23
Problem Statement : high pressure drop across 3rd and 4th cyclones in Preheater (106 & 100 mmwg respectively).
Issues :
High pressure drop in 3rd and 4th cyclone ie.106 & 100 mmWg.
High specific power consumption due to high pressure drop.
BEFORE
AFTER
6.Theme-2 Pressure drop reduction by cyclone roof lifting
24
Approach:
A detailed CFD analysis done for reduction of pressure drop.
After CFD analysis it was decided for lifting the cyclone roof by 500 mm which lead to reduce the pressure
drop by 20-25 mmWg.
Results :
By cyclone roof lifting project there was a pressure drop reduction by 20-25 mmwg which resulted in
savings of 45 kWh.
Total annual savings achieved: Rs 24.74
Lacs in current FY.
6.Theme-3 Coal mill fan inlet box enlargement and louvre damper removal
25
Issues :
After installation of MV drive Coal mill fan still having louvre dampers having a pressure drop of 30 and 32
mmwg across the damper in Line-1 and Line-2 respectively.
Also it was found that the fan inlet velocity was also at higher side it was in the range of 19-22 m/sec.
A potential identified for removal of damper and fan inlet velocity reduction by inlet box modification.
Feed
Classifier
Grinding table
Grinding rollers
Hot air
Ground material
+ Outlet gas
Bag House
Raw Coal Feed
Hot gases from PH outlet
Recirculated Gas
Fine Coal BinGround Product + Outlet gas
To Stack
--Gas Flow
Material flow
Coal Mill MILL
Before
After
6.Theme-3 Coal mill fan inlet box enlargement and louvre damper removal
26
Approach:
A cross functional team including wage board staff formulated for power consumption reduction.
It was found that the energy consumption reduced by removal of fan inlet damper and fan inlet boxmodification
Fan inlet velocity was also reduced by fan inlet box enlargement.
Results :
Saving of 54 KW without zero investment and in terms of sp. power consumption it was 1.50 kWh/T mat.
Reduction in fan inlet velocity from 19-22 m/sec to 14-15 m/sec. which also reduce the pressure in coal millcircuit.
Due to reduction in pressure drop coal mill fan efficiency increased from 71-73% to 80-83%.
Total Savings achieved 17.05 Las Rs in current FY.
6.Theme-4 Installation of thin classifying liners
27
Issues :
CM-2 roll press with ball mill now converted in mono chamber mill from double chamber mill.
After conversion to mono chamber the liners are still earlier one having thickness of 90mm which lead to
increase the sp. power consumption.
Higher Sp. power consumption due to high weight liners installation.
Old Liners New Thin classifying Liners Before Modification After Modification
28
Approach:
To reduce the specific power consumption a plant level cross functional team formulated which analyse the
detailed power consumption with productivity data.
After that in consultation with OEM and our TPMC cell it was decided to replace the existing liners (150 mm) with
thin classifying liners.
Replacement of old liners with new thin classifying liners having the thickness of 38-42 mm only.
Results :
Cement Mill power consumption reduced by 0.98 kWh/T cement.
Total annual savings achieved 24.67 Lac Rs in current FY.
6.Theme-4 Installation of thin classifying liners
6.Theme-5 Installation of aerofoil nozzle ring
29
Issues :
Line-1 Raw mill having high specific power consumption and high pressure drop.
Pressure drop in the era of nozzle ring was the major concern.
Higher sp.power consumption due to high weight liners installation.
Old Nozzle Ring New Aero foil Nozzle Ring
30
Approach:
To reduce the pressure drop after cross functional teams detailed analysis and OEM reference, it was decided to
replace the nozzle ring armor ring and separator blanketing to be done.
As the material leaves the table at different velocities depending on the table diameter. This is compensated for
the new nozzle ring by having a different inclination of louvres for different diameter; try to match the horizontal
velocity of the material leaving the table with the air velocity.
LNVT nozzle is designed with different inserts in the different areas of the nozzle ring locations, where the
resistance through the nozzle is different for the air entry, as well as louvres of different inclinations, depending
on table diameter.
Results :
Sp. power consumption reduced by 0.15 kWh/T Mat.
6.Theme-5 Installation of aerofoil nozzle ring
31
7.Utilization of Renewable Sources
32
Capacity is 5.0 MWp (DC) / 4.0
MWp (AC)
Approximate Land Requirement: 25
Acres
Type of System: Fix-Tilt
Expected Life Of Solar Plant: 22 Years
Details of Solar Plant
Expected Generation- 22287 kWh/Day
First Year Power Generation - 85.0
(Lacs Units)
First Contract year adjusted - 2.5%
degradation
Each subsequent Year degradation -
0.7%
Efficiency- 19.4%
Proposed Power Generation& Efficiency
%Share:4.64MkWh:8.50
%Share:3.97MkWh:8.26
%Share:2.23 MkWh:5.3
FY18-19FY20-21(Target)FY19-20
Utilization of Solar Energy
8.Waste Utilization & Management - AFR
33
Sl.No
Year (2019-20)
Waste DetailsQuantity
(MT)GCV
(kcal/Kg)
Heat value (kcal)
Waste as Percentage of total fuel (%)
1 AFCOALDUST 118.0 2109.1 248876 0.01
2 AFEMBROIDERYWASTE 7.0 5309.1 37164 0.003 AFCARBONBLACK 64.0 3157.7 202090 0.01
4 AFMSWDERIVEDFUEL 10.5 4106.0 43114 0.00Total 199.5 2662.9 531243 0.03
Waste material (AF) used as Fuel
Sl.No Waste MaterialQuantity Used
FY 2017-18 FY 2018-19 FY 2019-20
1 AFCOALDUST 780.0 0.0 118.0
2 AFEMBROIDERYWASTE 0.0 0.0 7.0
3 AFCARBONBLACK 45.0 0.0 64.0
4 AFMSWDERIVEDFUEL 0.0 0.0 10.5
Total 825.0 0.0 199.5
34
8.Waste Utilization & Management
Waste material used as Alternative Raw Material (Additive)
Sl.No Waste MaterialQuantity Used (MT)
FY 2017-18 FY 2018-19 FY 2019-20
1 Fly Ash 246683 285874 259758
2 Fly Ash TPP 9550 13987 6434
3 Chemical Gypsum 4462 3350 8433
4 Red mud 509 - -
5 Pond ash 59043 80801 48608
6 TPP Bed ash 11076 14239 11014
7 Fly ash TPP 32657 24556 28431
Total 363980 422807 362677
9.PAT Cycle-II Status
35
Gate to Gate Sp. Energy Cons. (Kcal/Kg Cement)
1000
1075
1150
1225
1300
1222 1148 10701032 1029 1011
Unit registered as Designated Consumers (DC)under PAT scheme. Base line year FY2014-15.
Target given for 1104 kcal/kg of equivalentcement in GtG Specific Energy Consumption atthe end of PAT cycle (2016-2019)
FY18-19 is assessment year so performanceassessment by BEE and achieved 1029.21 inGtG SEC achieved with 13611 Energy savingEscert's.
9.GHG Inventorisation
36
0.9493
0.92940.9227
0.9170
0.90
0.92
0.94
0.96
FY17 FY18 FY19 FY20
OPC-Conversion Factor
0.6774
0.6550
0.6266 0.6265
0.60
0.64
0.68
0.72
FY17 FY18 FY19 FY 2019-20
PPC Conversion Factor
29.11%
31.87%
33.99% 33.89%
25.00%
30.00%
35.00%
FY17 FY18 FY19 FY20
Fly Ash Consumption in PPC (%)
744 744
680
656
640.00
665.00
690.00
715.00
740.00
FY17 FY18 FY19 FY20
CO2-Emissions-kgCO2/MT Cement
3.5
3%
Re
du
ction
0.6
0 %
Re
du
ction
0.0
2%
Re
du
ction
10.Sustainability Strategy- Our Public Commitments
37
EP 100- Double the energy productivity in 25 yrs.(2010/2035 -107/214)
Reduce CO2 emission intensity by 25% (05/06 -20/21)
Water Positivity – 4 times water positive by 2021 (Current level 2.88)
•WHRS - 15% (9.17)
•Solar - 10% (1.9)
Share of Green Energy 25% by 2021 –(Current level 12.20%)
Thermal Substitution Rate- 10% by 2021( internal)–(Current level 3.7%)
Comprehensive Biodiversity Assessment of all the IU by 2024.
Internal Carbon Price of $10 per ton of CO2 emitted.
Supply Chain
Operations
Product
Customers
People
CSR
Climate Change
Communication & BrandingGovernance & Disclosures
10.Sustainability Strategy- Action Plan
38
Supply Chain
Operations
Product
Customers
People
CSR
Climate Change
Communication & BrandingGovernance & Disclosures
Aspect Target Current state Key actions
Climate Change25% reduction in CO2 intensity by 2021
19.14%- Focus on blended cement- Increase share of alternate fuel (AFR%)
WaterBecome 4 times water positive
2.88
- Implementation of two ongoing large integrated watershed project
- Watershed potential assessment at 4-5 locations- Water demand reduction projects- 2 large integrated Water shed projects Tadipatri &
Rajshree
Waste (Alternate Fuel)
10% 3.7%- Implement AFR handling systems- Secure tie-ups for long term fuel availability- Build strong network
Energy (Renewable Energy + WHR)
25% of total electrical demand
12.20%- Implementation of 118 MW WHR projects- Third party + Group captive solar projects (300+
MW)
Biodiversity
Biodiversity assessment and management plan for all integrated Units
5- Implementation of BMP at Sewagram and Raj shree- BMP under process for 3 more plants- Aditya, Balaji,
Kotputli
10.Green Supply Chain-Cement Bulker %
39
Bag/Bulk
FY17-18 FY18-19 FY19-20
Dispatch Quantity
Avg.Distance
Dispatch Quantity
Avg.Distance
Dispatch Quantity
Avg.Distance
Bag 2085279 440 2260199 439 1987549 444
Bulk 160881 372 233803 341 287981 368
Total 2246160 435 2494002 430 2275530 435
Cement dispatch increased through Bulker :54178 MTFuel Savings :51469.1 Liters 72 Rs/Liter DieselCost Savings :37.06 Lakh Rs.
10.Green Area Development
40
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Tree Plantation
2008-14 2015-16 2016-17 2017-18 2018-19 2019-20
52515
65890
78020
8227583315
85315
To
tal
Tre
es
Pla
nte
d
2
Garden
Development
at SCW
10.Sustainability-Mines Life Enhancement
41
Optimized reserves (ML-1 + ML-2) @ 5.40 MTPA)
Actual FY’19(Apr’18-Mar 19)
SO3 : 0.77 CL : 0.11LSF : 244.61
Actual Quality (April 19 to Mar-20)
SO3 : 0.83Cl : 0.12LSF : 235.34
Actual Quality (Apr 20 to June-20)
SO3 : 0.91Cl : 0.12LSF : 253.80
Remarks
Criteria for calculation of Life of deposit
142.40 Million T
Mine life 26.37 years
225.11 Million T
Mine life 41.69 years
225.23 Million T
Mine life 41.71 years
Clinker Production : 4.0 MTPALST required @ 1.35 conversion factor = 5.40 MTPAThe production from Apr’18 to 9th June’20 is 7.4 MTPA.
Mineable Reserve(Million T)
As on 31.05.2020
Average Quality of Overall Limestone Deposit (%)
SO3 CL MgO LSF Life @ 5.40 MTPA
620.77(ML-1 & ML-2)
1.15 0.18 2.04 188.20 114.96
1% Bypass lead to loss of 2.2 kcal/kg clinker but all are compensated to enhance the mines life by utilization of high SO3 and Chloride limestone.
42
01 02 03 04 05 06
SAFETY QUALITY
CONTROLRELIABILITY
PROCESS
IMPROVEMENT
COST
REDUCTION
Main focus onsafety started withsafety pause
Analysis of sectionwise performancewrt budget andbest achieved
Analysis of pre andpost clinkerisationquality norms wrtABG& BIS Standard
Analysis of each andevery stoppage toavoid its reoccurrence.
Processimprovementidentification and itsimplementation.
Cost analysis andreductionmeasures
11.Team Work Employee Involvement & Monitoring
PRODUCTIVITY
& ENERGY
Process ImprovementDaily Co-Ordination MeetingValue Month
Raw Mill-1 21.90 21.64 11.83 23.94 23.81 2.30 22.36 June'18
Coal Mill-1 3.51 3.49 5.33 3.21 2.40 -0.28 2.59 Feb'20
Kiln-1 24.34 24.77 18.83 36.19 26.82 11.42 23.87 Nov'17
Misc. Services-1 3.29 3.78 3.00 2.27 -0.78 1.29 Dec'17
Other Utilities Line-1 (Desalination) 0.91 0.82 1.23 0.72 0.41 0.63 Jan'20
Shutdown Power 0.76 3.52 0.00 0.00 -3.52 - -
Power Up to Clinkerization U-1 54.71 58.02 67.56 56.01 9.54 52.33 May'18
Raw Mill-2 21.61 21.49 17.17 24.35 24.28 2.86 21.85 July'18
Coal Mill-2 3.51 3.50 7.08 2.65 2.67 -0.86 2.89 Feb'20
Kiln-2 25.12 25.29 24.00 26.72 26.15 1.43 25.96 Feb'19
Misc. Services-2 3.29 3.78 3.00 2.27 -0.78 1.67 Jan'18
Other Utilities Line-2 (Desalination) 0.91 0.82 1.23 0.72 0.41 0.63 Jan'20
Shutdown Power 0.83 0.00 0.00 0.00 0.00 - -
Power Up to Clinkerization U-2 55.27 54.88 57.95 56.08 3.06 55.70 May'18
Combined power upto clinkerisation 54.99 56.24 61.37 56.05 5.13 53.96 May'18
Best
Parameters Budget / Clk
March'2020
Run
Hrs
ATD
/ Clk
MTD/
ClkDiff
Budget / clk
FY20
11.Team Work Employee Involvement & Monitoring
43
ROBUST ENERGY
MONITORING &
REVIEW
MECHANISM
Online Energy Management System
Energy Consumption monitoring through CCR Desk
Daily Production Report and Power consumption Report.
Daily monitoring of water consumption.
Resource
Line-1 Combined
TODAY PDN( MT )
Monthly PDN
TODAY SP POWER CLK
Monthly SP POWER CLK
TODAY SP POWER CLK
Monthly SP POWER CLK
RAW MILL 5997 135499 25.99 24.90 25.99 24.90
COAL MILL 548 10153 2.54 2.53 2.54 2.53
KILN 4990 94639 25.94 26.53 25.94 26.53
COMMON POWER (KWH) 12731 266536 2.55 2.82 4.82 5.11
Desal 0.33 0.69 0.66 1.34
OVER All CLINKERISATION POWER
57.34 57.46 60.40 61.38
Over All Cement Power/Cement
83.67 82.29 75.49 80.57
11.People Engagement-No of Kaizen and Savings
44
NO OF KAIZEN NO OF SUGGESTION ANNUAL SAVING KPE
4151
1050
1.80
CR.
5.15
Champions of Champion Team award Best KAIZEN Team awardExternal Training on EE
11.People Engagement
01
02
03
04
Theme: Installation of self inertia lump separation wheel for reduction of unplanned stoppages due to lumps and boulders in raw mill.Increase in reliability reduction in unplanned stoppages and power saving of 0.15 kWh/T Mat and Saving impact:25.56 LPA.
Theme: Removal of silencers and fan inlet damper in Line-1 Cooler after installation of slide gate. Savings:0.07 kWh/MT clinker having cost impact of 4.08 LPA.
Theme: Power optimization by stopping stand by blowers in raw mill product transport group.Savings: 2.37 LPA.
Theme: Removal of coal mill fan inlet damper for reduction in pressure drop by 30-32 mmWgSavings:0.30 kWh/MT Mat
05
06Theme: Increase of the life of lighting power JB through modification in JB nut bolt type in place of screw type JB Impact: Increased lighting JB life and reliability.
Theme: Reduction in bag brustage and dust emission by smoothening of bag discharge chute.Savings: Improvement in reliability and reduction in bag brustage
40
6 N
os.
K
aize
ns/
Sugg
est
ion
12System Accreditations so far…..
46
SCW has got “Certification from International organization for standardization for Integrated Management systems for QualityManagement System (ISO 9001:2015), Environment Management System (ISO 14001:2015) , Energy Management System (ISO50001:2018) and Occupational Health and Safety Management System (ISO 45001:2018),Information management System (ISO270001:2013) from certification agency DNV.
47
12.Implementation of Energy Management System
ISO50001:2018 &Green Products
Energy Policy
Gap Identification
Review Mechanism
National Workshops
&REPRISM
Well defined Energy Policy
Formation of Energy cell-Cross functional Team comprising various levels.
Gap analysis with respect to target and systematic action plan to achieve the target
Monthly review by TOP ManagementNew return base CAPEX approved on top priority-ROI<3 Yrs.
Daily review by Technical Head along with all Departmental Head .
Time to Time participation in different energy saving initiative national as well as group level workshop
REPRISM-Implementation of other unit best practices at respective units
Task force teams formation for different sections.
SCW has got “Certification from International organizationfor standardization for Integrated Management systems forEnergy Management System (ISO 50001:2018) fromcertification agency DNV.
GreenPro and LCA studies helped assessed various initiatives taken by the company for reducing the environmental impact of manufacturing cement at every stage of its lifecycle.
13.Other Innovative Technologies
48
CBA
PI-Online Monitoring System
XRDExpert Optimizer
CBA
14.Long Term vision on EE
49
To be the Most Energy Efficient Cement Unit
OperationalEfficiency
Supply Chain Technological Upgradation
Capacity Utilization
Optimizing Fuel Mix cost by utilizing costeffective coals.Increase Clay usage to minimize other additives in Raw Mix.Explore use of AF including carbon black, spent pot liners etc.Working on design parameters of PH cyclones to reduce the pressure drop across tower.
Jetty mechanized system revamping.Higher efficiency fans.New coal firing systems.Cross country belt conveyor for LS Transport.(OLBC)Increase in Solar Powerutilization.Alternate Fuel feeding system.
Increased Jetty UtilizationClinker export.Cement export.More Clinker dispatch to WCW & MGD,RTN via Jetty.Increase PPC-WR Volume
Most economical supply of fuel which possible through Jetty.Inward & outward material logistics integration.Increased share of loose cement.Sourcing of AFR -MSW/RDF.Enhance pond ash usages.New source of gypsum.
48
50
Awards & Accolades
ANY OTHER
Awards &Accolades
51
Sewagram Cement works received 1st
Rank in Kaizen Award underEnvironment- Large Category in 12th
CII National Competitiveness and ClusterSummit 2019 for Lignite based TPP Fly AshUtilisation
SCW received second prize in CII KaizenAward under 5S & Safety at 12th
National Competitiveness & Cluster Summit2019
52
SCW received Third Championship
Award under Digitization/NewTechnology at 12th CII National
Competitiveness & Cluster Summit2019 at New Delhi
Awards &Accolades
Sewagram Cement Works awarded as“ Gold Medal “ under the category of
NAMC Awards-2019 by Intl’ Research
Institute for Mfg. on 18th Oct’19 atMumbai.
53
Awards & Accolades
Sewagram Cement works Best practices recognized at IMC, Mumbai :
1. A giant step towards Green & Clean clinker production.
2. Utilization of AFBC boiler Flyash as fuel in CFBC Boiler(TPP).
The same Best Practices were also published in their Annual Magazine with a Introduction of SCW Plant.
Sewagram Cement Works received
Second prize in CII-GreenConclave-Pune for Water
consumption reduction kaizen, awardceremony held on 6th Dec’18 at CII-Pune.
54
CII-National Kaizen Award-Energy Consumption Reduction
Sewagram Cement Works received
First prize in CII Kaizen Awardunder Energy optimizationCategory at 11th National
Competitiveness & Cluster Summit2018 which was held on 21st Nov’18 atNew Delhi.
Sewagram Cement Works received Gold rating at3rd CII National 5S excellence awards which
was held at India habitat center, New Delhi.
Other-Awards
55
Sewagram Cement Works won IndustrialSafety Excellence Award- 2018 by Center forSocial Development and Ahmedabad TextileAssociation
SCW (Only Cement Plant) have wonNational Kaizen Award (Top -18) forUtilization of Alkali-Chloride Bypass dustin Cement under Environment Category.
Unit won “Certificate of Merit” inManufacturing Category presented atMumbai on 16th March 2017