Upload
others
View
1
Download
0
Embed Size (px)
Citation preview
The Ramco Cements Limited
Jayanthipuram
Best practices for Energy
conservation
CementReady Mix ConcreteCement Fibre ProductsCotton and Synthetic YarnSoftware SystemsTotal Employees : 15,000
RAMCO GROUP
Shri P.A.C.
Ramasamy Raja
Founder
(1894 - 1962 )
Shri.P.R.
Ramasubrahmaneya Rajha
Former CMD (1935 – 2017)
The Ramco Cements Limited, (formerly known as Madras Cements Ltd.)- Second Largest in South India.- One of the most Reputed Cement Companies in India.- Sixth largest Cement Producer in India- Single largest Cement Brand in South
Plants :1. RR Nagar Plant near Virudhunagar, TN (2.0MTPA) (Established in 1959)2. KSR Nagar Plant, Jaggaiahpet near Amaravathi, Andhra Pradesh (3.65 MTPA) (Estd. in1986)3. Alathiyur near Vridhachalam, Tamil Nadu (3.0 MTPA) (Established in 2002)4. Mathodu near Chitradurga, Karnataka (0.3 MTPA) (in Operation since 2000)
5. Ariyalur, Tamil Nadu (5.5 MTPA) (Established in 2009).
Cement Grinding Units :
1. Kattuputtur (0.75MTPA)
2. Valapadi (2.0 MTPA)
3. Kolakhat (1.0 MTPA)
4. Vizag (0.95 MTPA)
Wind FarmsResearch & DevelopmentDry Mortar PlantsCotton TextilesSurgical.Turnover : Rs. 5,500 crores
Well diversified Group:
Packing Unit :
Nagercoil, TN
Shri.P.R. V. Raja
CMD
Management System Certificates
Energy Policy
4
Energy Road Map
5
Sl. No. Name Designation
01 Sri N Ravi Shankar President - Mfg.
02 Sri S Rajasekharan Sr. GM – Process & Quality Control
03 Sri AV Satyanarayana Asst. GM - Mech.
Sl. No. Name Designation
01 Sri D Sitaramaiah Sr. Dy. GM - Mech.
02 Sri S Kesavaperumal Sr. Dy. GM – Electrical & Inst.
03 Sri P Raghuram Dy. GM – Elec.
04 Sri I.Hariprasad Asst. GM - Env.
05 Sri SVSN Raju Asst. GM - Mech.
06 Sri P Sreekanta Reddy Manager – Inst.
07 Sri R Venkatapathi Gupta Manager - Mech.
08 Sri Chandan Kumar Parasar Dy. Manager - Process
09 Sri M Sreedhar Asst. Manager - Elec.
Apex committee
Core committee
Energy Conservation Organization
Energy Performance Improvement
9
Sl. No Description Units 2016-17 2017-18
1 MTOE reduction MTOE -- --
2 Kiln Thermal SEC kCal/kg cli 684 736
3 Specific Electrical Energy - clinkering kWh/T of clinker 58.14 60.46
4 Specific Electrical Energy – Grinding kWh/T of cement 79.75 82.10
5 CPP Heat rate kCal/kWh 3876 3706
6 CPP auxiliary consumption % 13.63% 12.29%
7 Thermal Substitution Rate % 0 0
8 Clinker factor % 77.89 78.75
9 Blended cement *%) of total cement % 61.62 57.63
10 Renewable Energy (RPO) -- --
11 REC Purchased – Solar REC -- --
12 REC Purchased – Non Solar REC -- --
13 Specific CO2 emission Kg CO2/ kg cement 0.66 0.67
10
Top Ten Energy Projects in 2017-18
S.No Project DetailsSavings In
KW
KWHRs (@ INR 4.62/KWH
1
To avoid the Line-1 Preheater compressors (75 kW)tripping due to high lube oil temperature and to minimize the power Consumption by reducing the suction air temperature with Exhaust fan and duct arrangement (2.8*3497*4.62)
2.80 9792 45239
2
Reducing power consumption in CF Silo aeration Standby Blowers by replacing existing VR4 model 18.5 kW -3nos with GR22 model 37 kW single blower (15*7169*4.62)
15.00 107535 496812
3
Reduction of Power consumption in Packing plant by optimizing the compressors ( running PP3CP02 -55 kw compressor for Packers operation and P1X21-110 kW compressor for Flyash bulk tankers unloading. Savings=129.9 kWh/day ( 129.9*365*4.62)
129.90 47414 219052
4Reduction of fuel consumption per hour in BH 40 Ton Dumpers-2nos. by reducing the engine RPM from 2100 to 1900 ( 200)- (1.42*2672*62.4)
1.42 lphHSD
3794 236761
5Avoiding Idle running of Slag mill Bag house fan motor GRR Blowers by giving interlock (1462*6*4.62)
6.00 8772 40527
Top Ten Energy Projects in 2017-18
11
6Replacement of timer based auto drain valves with zero energy loss auto drain valves -8nos.in line-1 compressor Receiver tanks ( 96kW* 365*4.62)
96 35040 161885
7
Power reduction in STP tank aeration blowers by stopping one blower (7.5 kW ) through interconnecting both aeration Pipe lines and replacing blower motor with 9.3 kW (6*3600*4.62)
6.00 21600 99792
8Power reduction in Line-2 Kiln bag house fan by modification with Fuzzy New PID system (43*3417*4.62)
43.00 146931 678821
9
Power reduction in 132 kw dewatering pumps of North band mines by providing suitable head pump(higher discharge) in place of existing pump.(lower discharge). 450 cum/hr to 650 cum/hr during Pit levels high. (11.7*123*24*4.62)
11.70 34538 159566
10Slag bag house purging Compressor optimization by reducing the Pr. by replacing the In-Built PLC controllerNeuron (5.5 to 3.8 kg/cm2) (9.8*2500*4.62)
9.8 24500 113190
Journey to ISO : 50001-2011
Implementation
We have started the Energy Conservation activity in the year 2011-12.
In the starting, we have divided the whole plant into 11 Teams.
There was a Review meeting being conducted on monthly basis.
In the meeting Each team has to present their Working on Energy Conservation in front of Management.
There by the project was being implemented.
Again in the next month of Meeting the project status will be reviewed.
The consolidated Annual Achievement has shown in the next slide.
Year Savings(Lakh KWH)
2012-13 10.50
2013-14 7.25
Savings Achieved…
We have implemented the ISO : 50001-2011 EnMS in the year
2013-14 with the External Certification Agency BSI.
It has taken approx 6 months for completion of all the
Documentation.
In the month of August’2014, we had the Certification Audit.
After successful completion of the Audit, we have certified for
EnMS (ISO:50001-2011) in August’2014.
The Old Energy Teams were continued (with addition of 2
more teams) on the way of Energy Conservation with this
Management System.
ISO : 50001-2011
Implementation/Certification
Energy Conservation Activities…
The Energy consumption & deviation is being monitored by
individual team members on daily basis .
Review of the same with Corrective Actions (If any) is being
discussed in meeting with HOD’s & Management on daily
Basis.
Monthly Once we will have the meeting of Energy
Consumption & Conservation with all the Team Members.
There is also a Competition being conducted twice in a year on
Energy Conservation Day & Our Founder’s Day.
Energy Conservation Activities…
This Competition will consist of several activities like Energy
Conservation Projects Presentation, Slogans, Essays, Painting &
Skit programs.
In this competition we are involving the Ladies Club members &
School Children also along with the Regular and contract
employees.
This competition will be followed by the Award distribution for
the Best Presentation in each area.
The LED Bulbs also being distributed as gift to the All the Energy
Team members as a part of Energy Conservation.
Re-certification audit conducted in Aug.2017 and certificate
issued.
Savings Achieved…
Year Savings(Lakh KWH)
2014-15 40.84
2015-16 17.91
2016-17 4.42
2017-18 10.83
Best Practices for Energy ConservationIn2017-18
Best Practices for Energy Conservation in 2017-18
Project details -Reducing power consumption in CF Silo aeration Blowers by replacing existing VR4 model 18.5 kW -3nos. with GR22 model 37 kW single (available )blower of equalent capacity.
Savings (KWH) : 15
Annual Cost Savings (INR) : Rs . 4.96Lakhs (15*7169*4.62)
Project Investment : In House Works
Payback : -Nil-
GR22 Blower VR4 Blower
Best Practices for Energy Conservation in 2017-18
Project details -Reduction of fuel consumption per hour in BH 40 Ton Dumpers-2nos. by reducing the engine RPM from 2100 to 1900 ( 200)
Savings (L/h) : 1.42 HSD L/h
Cost Savings (INR) : Rs . 2.37Lakhs (1.42*2672*62.4)
Project Investment : In House Works
Payback : -Nil-
BH 40 Dumper
Best Practices for Energy Conservation in 2017-18
Project details -Replacement of timer based auto drain valves with zero energy loss auto drain valves -8nos.in line-1 compressor Receiver tanks
Savings (KWH) : 96 kWh/day
Cost Savings (INR) : Rs . 1.62 Lakhs (96*365*4.62)
Project Investment : Rs. 2.00 Lakhs
Payback : - 1.2 Years
Timer model Auto Drain Valve Zero Energy loss Auto Drain Valve
Best Practices for Energy Conservation
in 2017-18
Project details - Power reduction in 132 kw dewatering pumps
of North band mines by providing suitable head pump(higher discharge) in place of existing pump(lower discharge). 450 cum/hr to 650 cum/hr (Rainy season 4 monts-123 days)
Savings (KWH) : 11.7 kW/hr
Annual Cost Savings (INR) : Rs . 1.60 Laks (11.7*123*24*4.62)
Project Investment : Rs. 0.90 Lakhs
Payback : -7 months
Dewatering Pump at Mines
Best Practices for Energy Conservation in 2017-18
Project details - Power reduction by eliminating idle running
of refrigerated driers by giving interlock with compressors of-12 driers.
Savings (KWH) : 60kW/hr
Annual Cost Savings (INR) : Rs . 2.70 Laks (60*1000*4.6)
Project Investment : Rs. 1.2 Lakhs
Payback : -5 months
Driers interlock
Project details - Power reduction in Line-1 Compressors room
By reducing the room temperature by providing hot air vent duct with exhaust fan
Savings (KWH) : 2.80
Annual Cost Savings (INR) :0.45 Lakhs (2.8*3497*4.62)
Project Investment : Rs. 0.50 Lakhs
Payback :1 Year
Best Practices for Energy Conservation in 2017-18
Radiator Vent duct
Project details :Slag baghouse purging Compressor optimization by reducing the Purging Pr. by replacing the Compressor inbuilt PLC Controller Neuron (5.5 to 3.8 kg/cm2).Savings=9.8 kW
Annual Cost Savings (INR) : Rs .1.13 lakhs (9.8*2500*4.62)
Project Investment:0.50 Lakhs
Payback : 5.3 months
Best Practices for Energy Conservation in 2017-18
Best Practices for Energy Conservation
Project details -. Power savings in Line-1&2 process Bag filters-8nos. by changing the Bag house solenoid valves purging operation from Timer mode to DP mode .
Modifications carried out for all Process Bag filters (Total 9 nos ,Lime-1& 2 Coal mill Bag houses, Cement mill, Slag mill ,P/Plant Bag houses)
Savings (KWH) : 50 kW/hr
Annual Cost Savings (INR) : Rs .11.0Lakhs (50*4800*4.60)
Project Investment 0.90 lakhs
Payback : - 1 month
Rawmill-1 Bag house
Crusher kw 5
Raw Mill-1 kw 10
Coal Mill-1 kw 5
Coal Mill-2 kw 5
Slag Mill kw 5
Cement Mill Vent kw 5
Cement Mill O-Sepa Vent kw 5
VRPM Vent kw 5
VRPM Sep Vent kw 5
Total kw 50
Modified Bag filters to DP mode
Best Practices for Energy Conservation
Project details : Reducing of power consumption in Line-1 Kiln by stopping the 75 kW screw Compressor (20 hrs/day)by inter connecting the airline to Main 110 KW Compressor W1X11 airline which is running in more unload condition 70% with erection of additional Radiator of 11 kw fan. After modification Unloading reduced to 30%.
Net savings/day=1060 kWh
Savings (KWH) : 1060kWh/day
Cost Savings (INR) :9.75 lakhs (1060*200*4.6 )
Project Investment: 0.20 lakhs
Payback : 0.2 Months
Line-1 Kiln Compressor
Best Practices for Energy Conservation
Similar modification carried out for 5 Compressors i.e interconnecting of compressors which are running in more time in Unloading mode.(70-80%)
Ideal operation of Screw Compressors is 80% loading and 20%unloading.
Savings in 5 Compressors : 80 kW/hr
Annual savings (INR) : 17.7 Lakhs (80*4800*4.6)
Project cost : 1.0
Payback : 0.7 months.
Best Practices for Energy Conservation
Project details :Reducing of power consumption by interchange of product in Cement silos as Silos nos 1&2 -for Storage of OPC 43 grade cement from Slag mill and Silo nos.3&5- for Storage of PPC Cement from Cement mill .There by we can avoid running of Screw conveyors No.3,5 silos .(15+17 kW=32 kW)
Savings (KWH) : 32kW/hr
Annual Cost Savings (INR) :7.07 lakhs (32*4800*4.6)
Project Investment: In-House sources
Payback : NA
BU
CK
ET
EL
EV
AT
OR
INCLINEDSCREW
CONVEYOR-2
AIR SLIDE BLOWER
OPC SILO-4
PPC SILO-1
PPC SILO-2
OPC SILO-3
JUNCTION BOX
SCREW CONVEYOR
INCLINEDSCREW
CONVEYOR-1
SLAG MILL OUTPUT
BEFORE
53
Before QC we used to run one screw conveyor-1 for 3rd silo feeding and where as for 4th silo feeding we used to run screw conveyors -3 nos. During transportation
we are facing the following problems 1.Frequent breakdowns of screw conveyors,2.High maintenance cost 3.High power consumption.
Cement Mill :PPC:1 and 2 silosSlag Mill :OPC :3 and 4 silos
INCLINEDSCREW
CONVEYOR-2
AIR SLIDE BLOWER
PPC SILO-4
OPC SILO-1
OPC SILO-2
PPC SILO-3
JUNCTION BOX
SCREW CONVEYOR
INCLINEDSCREW
CONVEYOR-1
BU
CK
ET
EL
EV
AT
OR
SLAG MILL OUTPUT
AFTER
54
To overcome above experienced problem based on suggestions given by our team members, we have interchanged the storage of product from 3rd and 4th silos to
1st and 2nd silos. By this we have avoided running of 2 screw conveyors. After changing our previous problems are solved
Cement Mill :PPC:3 and 4 silosSlag Mill :OPC :1 and 2 silos
Energy saving proposals
Sno.Area Project Details
Power
Savings
Kw/hr
Projected
Annual
Power
Savings
kWh
Projected
Annual
savings
Rs. Project cost Rs Payback
1 Pumphouse
Pumphouse pumps automation a) Plant
incoming pumps, b)Colony utility water
pumpc) Cooling water Pumps by
providing level sensors and auto on/off
.savings =160-110=50 kW /hr ( for 160
days )
50 kW 192000 960000 10,00,000 1 Year
back
Energy saving Proposals
TPP TANK
WATER FLOW
CRUSHER
WATER SPRAY
MK. PUMP No.3
T
AN
K
T
AN
K
T
AN
K
No.5 No.7
MG FILTERS
NRV
NRV
VALVE
VALVE
MOTORISED
VALVEVALVE
(10 “ )WATER LINE FROM MINES TO TPP TANK
IN
No
1&2
FLYASH SILO
BULK TANKER
RE
CE
IVE
R
TA
NK
Flyash Bulk Tanker unloading
COMPRESSOR
Low pressure Compressor
RAMCO CEMENTS LTD., JAYANTHIPURAM.
Section : Compressors
Project No. Date 10/8/2018
Area of the Project Flyash handling
Project details
To replace the existing 110 kW old High pressure Screw compressor with 55kW Godrej make low Pressure Compressor
Present condition
110 kW old high pressure KG Khosla Compressor is in operation .Its specific power consumption is =10 kwh/cum/min
Proposed scheme and Projected savingsPlanned to replace with 55kW low pressure Godrej make Screw Compressor ,Specific power consumption = 3 kWh/Cum/min . Flyash avg.yearly Consumption= 2,20,000 MT,
No of trucks @ 30 T/each(with 110 kW compressor) = 1.20,000/30=4000 No.of hrs with existing 110 kW high pressure compressor@45min = 3000hrs No.of hrs with proposed 55 kW low pressure compressor@30min = 2000hrs , Power consumption with the existing 110 kW Screw compressor = 90 kW* 3000 =270000 kWh Power consumption with the proposed 55 kW Godrej compressor =55*2000 = 110000 kWh
Annual Power savings = 160000 kWh = Rs 8,00,000/-
Maintenance cost reduction = Rs 1,00,000/-Total savings = Rs.9,00,000/-Project cost (Compressor+Drier) = Rs 14,00,000/-
Payback = 1.5 years
Remarks