CII – Energy Excellence Award 2017

UltraTech Cement, GICW, Ginigera

The Team:

Mr. Mahendra P Singh – Asst. General Manager

Mr. Hanumanthappa. C - Dy. Manager - E&I

Mr. Pradeepkumar C K - Manager - Process

2

▪ Plant capacity(Cement) - 1.3 MTPA

▪ Products - OPC, PPC,PSC and GGBS

▪ Market - North Karnataka & Goa

UltraTech Cement, GICW, Ginigera

(Commisioned on Sept-2008)

Process View , GICW, Ginigera

Clinker Silo

35000 Tons

capacity

Wagon tippler

20 boxes/hr4000 Tons/rake

Cement Mill

LM 53.3.3

175 TPH @ 350 blains

Cement Silo

3-compartments

5000 x 3 =15000

Tons

Bulk cement

loading

Cement packer

6-Spouts, 4-nos of 90

TPH

Truck

loading

6-nos

Wagon

loading

8-nos

Gypsum

Fly ash

Slag

Clinker

Coal

Clinker From APCW

Clinker hopper-1000 Tons

Slag hopper-1000 TonsGypsum Hopper: 350

Tons

4

UltraTech Cement, GICW, Ginigera

5

Energy Conservation Projects Completed 2014-16

Sl.

No.Title of Project

Annual

Electrical

Saving (kWh)

1 Timer interlock for tripping on idle running for Cement Mill Auxiliary equipment 8541

2Provided interlock for cement mill stack monitoring system purging air blower to avoid idle

running1000

3 Installed 55 kw compressor with VFD drive in place of 90 kw compressor 262800

4 Installed Air dryer for new 55kw compressor 63360

5 Replaced Conventional Lamps with LED Lamps.73563

6 Installing VFD drive for Packer No-1 & 3 De-dusting fan 128480

7 Improving Fly ash blain at source by modification in the circuit 114000

8 Installing LED lights instead of HPSV for various location 18188

9 Mechanical system for Fly ash Unloading 24400

6

Energy Conservation Projects completed 2014-16

Sl.

No.Title of Project

Annual

Electrical

Saving (kWh)

10 Replacing fluorescent lamps with 18 W LED lamps at various locations 19523

11 Single Button start command for Cement Mill (Start up time reduced from 15min. To 8.0min.) 47460

12 Installation of VFD for cement mill reject circuit bag filter fan(22KW) in place of DOL starter. 23142

13 Single Blower for Fly ash feeding air slides instead of two blowers 9375

14To avoid idle running of compressors by providing control valves for cement mill and packing plant and

operating from CCR300000

15 Packer discharge conveying line was connected with 1.1 KW motor for diverter which was consuming

power, hence it is decided to install power less diverter and save power11680

7

Energy Conservation Projects completed 2014-16

16Raw coal feeding conveyor belts were having delayed start for each belt, hence analyze the

start time and reduced idle run hours about 7 minutes on every start.949

17stacker conveyor belts were having delayed start for each belt, hence analyze the start time

and reduced idle run hours about 3 minutes on every start.440

18

Packer floor all lights were working continuously irrespective of working of Packers,

modified lighting circuit to switch on lighting for individual packers and control given at

CCR.

18396

19

Packing plant P&V system operational control made in auto mode and interlocked with

packing plant operation, since packing plant operates only two shifts avoided idle

running.

20075

2090 KW water cooled compressor was working for running 2 packers, which was consuming

more power, hence modified the air line to work 55 KW compressor for running 2 packers292000

Total in Lacs kwh 14.37

Sl.

No.Title of Project

Annual

Electrical

Saving

(kWh)

8

Energy Conservation Projects 2017-18

Action plan for reducing power consumption 2017-18

Sl. No. Title of Project

Estimated Annual

Electrical Savings

(kWh/year)

1 Elimination of 2 Nos. Mill feed conveyor belts by Circuit Modification 90000

2Modification of Reject circuit by including intermediate Bin

90000

3 Replacement of Venture in Mill Fan circuit 126000

4 Mill Fan Inlet Box Modification 180000

5 Replacing Old AC s with new Energy efficient ACs 43800

6 Changing lighting circuit in packing plant 5000

7 Replacing Conventional Lamps with LED Lamps 10775

Total in kwh 545575

10

10

Planned to purchase solar power to fulfill total power

requirement about 90% from renewable energy

Future plan for purchasing renewable energy

SourceABG renewable

power project

Expected

units/annum100 Lacs

Expected price 5.00 Rs./kwh

11

OPC Grinding Specific power (U/T)

12

26.06

25.27

25.07 25.05

24

25

26

27

2013 - 14 2014 - 15 2015 - 16 2016 - 17

Target - 25.00

Reduction – 3.9%

PPC Grinding Specific power (U/T)

13

28.78 28.82

25.9625.62

20

22

24

26

28

30

2013 - 14 2014 - 15 2015 - 16 2016 - 17

Reduction – 11.10%

141414

42

.34

42

.1

39

.05

37

.32

35

.84

2012-13 2013-14 2014-15 2015-16 2016-17

Reduction – 15.35%

15

15

26.4%29.7% 30.8%

0.0%

10.0%

20.0%

30.0%

40.0%

50.0%

2014-15 2015-16 2016-17

Consumption of dry fly ash Target = 33 %

Year Comments

2014-15 100% pond ash with high moisture.

2015-16 Commissioned dry fly ash system in Apr-2015.

Comparison of specific power consumption with other grinding units on monthly basis – Bench Marking

171717

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1. Zero Fuel for Cement Grinding

Year Comments

2012 -13 100% HFO utilization

2013-14 Commissioned coal HAG during Jun-13

2014-15 100% coal HAG

2015-162016-17

Eliminated hot gasses for OPC &PPC in July-15Sustained Zero fuel for Cement Grinding

19

Benefits

1. Zero Coal Consumption during Cement Grinding.

2. Reduced Coal Handling Quantity.

3. Reduced Coal mill run hours.

4. Reduction in process water consumption.

5. Increase in HAG refractory life.

6. Conservation of natural resources

Coal : 4800 MT/Year

Water : 21 Lakh M3/Year

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2. Optimizing Lighting Power

➢ Replacing Sodium Vapor Lamps by LED

Lamps

➢ Switching OFF Excess fittings based on

Lux levels

➢ By Utilizing natural light during Day

Time

46101

33525

-12576-20000

-10000

0

10000

20000

30000

40000

50000

2014-15 2017-18 Reduction

Variance

Saved >400 kwh/day

(27%)

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3. Mill Fan Venture replacing by Annubar Flow meter

-570mmWG

-555mmWG

Back Ground of the Project :Venture Meter was used for Mill Fan flow measurement which was

leading to a pressure drop of 15-20mmWG across the duct .Project expected to complete by August’17

-30mmWG

= Pressure Drop

Total Pressure rise

X Power Consumption

Pressure Drop = -570 – (-555) = -15

Pressure Rise = -30- (-570) = -540

= 15/540 *1520

Power Consumed = 1520 KW

= 42.2 KW

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AfterBefore

3. Mill Fan Venture replacing by Annubar Flow meter

Modification work in Progress

23

4. Installation of VFD`s for fans & pumps

By this principle

reduced the RPM

Of fans & Pumps after

analyzing

the requirements and

process by using

VFD Drives.

Carried out 6 small projects under this Category and Saved

204000 kwh/Annum

24

5. Compressed air optimization

Problem definition:

Utility power was on higher side due to the un controlled compressor

operation and leakages in the circuit and compressor dedicated for packing

& Cement mill separately. Entire Compressors were operated from locally,

and there are no isolation valves to separate the Air lines to Wagon Tippler,

coal mill etc. whenever it is not in operation.

We have four 90KW Compressors, one 55KW air cooled compressor and one 132KW air cooled compressor as follows

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5. Compressed air optimization

CompressorAvailable Compressed air

(M3/hr)

Required as per design for the operation of entire Plant(M3/hr)

1 (90KW) 1026

5578

2 (90KW) 10263 (90KW) 10264 (90KW) 1026 (Dedicated for Fly ash Unloading)

5 (55KW) 4596 (132KW) 1443 (Dedicated for Fly ash Conveying)

Total 6006

As per the study regarding availability and requirement we have made an

operation matrix for the compressors other than dedicated ones.

Installation against requirement:

26

5. Compressed air optimization – Action Plan

Sl.No.

Activity Description FPR Target Date Status

1 Operation of all compressors to be made from CCR CH 30.04.2016 Completed

2Compressor Operation to be synchronized for both

packing & Mill operation instead of dedicated operation.CKP 30.04.2016 Completed

3Survey for identifying the leakages as well miss usages of

compressed air in the entire circuit of plant operation.JSR 30.04.2016 Completed

4Pneumatic Isolation valves to be provided at Wagon Tippler & Coal Mill circuit. These valves can be operated from CCR

as per the requirement.ADK 15.05.2016 Completed

5After studying the compressed air requirement for each

section ,operation matrix of compressor to be provided to CCR Operator.

CKP 15.05.2016 Completed

6Mechanical system for Fly ash unloading through existing

Bucket Elevator to be doneMM 15.04.2016 Completed

7 Operation of Bag Filters in DP Mode PVM/JSR 30.06.2016 Completed

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5. Compressed air optimization

Condition-1

Condition-2

Condition-3

Condition-4

Condition-5

Condition-6

Condition-7

Condition-8

Packer-1 a a a a a a aPacker-2 a a a a aPacker-3 a aPacker-4 a aCement

Mill a a a aWagon Tippler a a

Coal Mill

COMPRESSOR OPERATIONCompress

or-1

1&2 or 1&3 or

2&3

a a a aCompress

or-2 aCompress

or-3 aCompress

or-5 a a a

Operation matrix and logic MIMIC

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5. Compressed air optimization - Results

Particulars Before After

Cement mill &

packing plant operation

4 x 90kW 2 x 90 kW

Wagon loading

operation with

4-packers

2 x 90 kW 1 x 90 kW

Truck loading

with 2-packers1 x 90 kW 1 x 55 kW

Specific power

consumption

for compressed

air

2.27 1.64

29

6. Renewable Power Purchase (Wind power)

Made long term Agreement with

M/s Sembcorp Green Infra from April 2016

and started availing power from September 2016

236.57

80.46

43 39.618

49.2

0

50

100

150

200

250

2016-17 2017-18(Till July'17)

Wind Power Utilization

Total power Wind power % age utilisation

30

GUH Vice President

Cement Mill Packing plantRaw material Handling

and Wagon Tippler

Energy

co-ordinatorTechnical Head

ENCON – Organization Chart

Energy Management Committee

S no Name Designation 1 T.K.M.Reddy UH

2 Mahendra P Singh TH3 Hanumanthappa.c SH (E&I) Co-ordinator4 Pradeepkumar.CK SH (Process)5 Srinivasarao J SH (Mech)6 PSN. Murthy SH (Comercial)7 Dada Khalandar Mechanical (FLE)8 Krishnaprasad B IT9 Balasreenivasareddy Electrical (FLE)

10 Ravindrareddy.V Instrument (FLE)11 Ravi Firangi HRD

12 Thatchinamurthy N SH - QC13 Prasad Danial Stores14 Nageshwara Rao Security

Agenda:

1) Review of previous

meeting points

2) Review of action plan

3) Generation of new ideas

4) Any specific issues

5) Conclusion with action

plan

Online Energy Monitoring-Section wise

Section wise Energy Monitoring on daily basis

Energy Monitoring in SAP

Energy Management System (EnMS)-Policy

36

Rewards & Recognitions

Received Energy Efficient unit award from CII - 2015

Environment Practices

Development of pond for rain water harvesting & Greenery

39.8

13.115.7

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

40.0

45.0

Total Area Gree bel to be covered Coverd till today

Hectares

Green belt is to

be covered 33.0% ie. 13.1

Hector