Penna Cement Industries Limited - qcfihyderabad.com

Penna Cement Industries LimitedTalaricheruvu , Ganeshpahad, Boyareddypalli,Tandur & Captive Power Plant

Captive Thermal Power Plant &Best Energy Efficiency Practices

Ganeshpahad Cement

Plant

TandurCementPlant

Boyareddypalli Cement

Plant

Talaricheruvu Cement

Plant

Captive Power Plant (2x38.5 mw)

1

PENNA CEMENT INDUSTRIES LTD

POWER PLANT

77 MW Captive Power Plant

WELCOMES YOU

Penna Cement Industries LimitedTalaricheruvu , Ganeshpahad, Boyareddypalli, Tandur & Captive Power Plant

Vision, Mission and Values

Our Vision:

TO CREATE SUSTAINABLE VALUE & GROWTH FOR ALL

STAKEHOLDERS

Our Mission:

TO CREATE ENERGIZED, COMPETITIVE, INNOVATIVE AND A WINNING

ENVIRONMENTFOR ALL STAKEHOLDERS

Our Values:

FOCUS ON CUSTOMER ||

PURSUE EXCELLENCE ||ACT WITH INTEGRITY || NURTURE EMPLOYEES || CARE FOR SAFETY || CARE FOR COMMUNITY

3


Key Milestones:

In 1994 -

0.2

mTPA

Commiss

ioned at

Talariche

ruvu, AP

2002 - New

plant

Commission

ed at

Ganeshpaha

d, TG

& capacity

reached to

1.3 mTPA

2005 -

Crosses the

milestone

of 2.1

mTPA

2008 - New

Plant

Commissio

ned at

Boyareddy

palli, AP

&

capacity

crosses the

4.0 mTPA

2010 - New

Plant

Commission

ed at

Tandur, TG

with a

capacity of

2.0 mTPA &

CPP of 77.0

MW Commissioned

at Ganeshpahad,

Penna

Crosses the milestones

of 7.0 mTPA

Cement Capacity with 4

cement plants

Future

expansion of 3.0 mTPA of

cement and crosses

the 10. mTPAcapacity in

the year 2018

4


Energy Policy & Energy Committee Review Structure:

Energy Policy:

“PENNA CEMENT INDUSTRIES LTD is committed

to all applicable legislation and other

requirements related to Energy Management

System. We are committed to improve energy

efficiency as a continuous improvement process

in all our business processes and ensuring the

availability of information and resources to meet

the energy objectives andtargets.

We are committed to incorporate energy

efficiency as a key component for new

equipment, major innovation, new design and to

promote energy saving awareness to our staff

and stake holders.”

`

Monthly Operation & Energy

review by Director - Technical

Review by Corporate Energy

Audit Cell

Review by Plant Head

Review In Energy Cell Meeting

by Energy Manager & HOD's

5

Sustainability Excellence of Indian cement industry- Energy Management

6

Awards: 2nd Prize in National Energy Conservation Award 2016.

7

company profilecompany profile

• Plant Profile

Plant performance indices

Plant performance indices • Summary of Energy Savings

Innovative projectsInnovative projects • Innovative Projects

Energy conservation implementations

Energy conservation implementations

• Energy Conservation Implementations

ENCON Projects ENCON Projects

• ENCON Projects

ENCON Projects based on new

operational strategy

ENCON Projects based on new

operational strategy

• ENCON Projects based on new operational strategy

8

9

Plant Profile

Power Plant

Located at Ganeshpahad village, Damarcherla Mandal of Nalgonda District in Telangana State.

➢Plant Capacity : 2 x 38.5 MW

❖ 160TPH /CFBC boiler /106kg pr./540 deg.

❖ Project Established in year : 2008

❖ Plant Commissioned in year : 2010

10SA FAN

PA FAN

COAL BUNKER

LIME STONE

HP , LT SUPER HEATER

ECONOMISER

APH

E.S.P

FEED PUMP

ID FAN

11

Summary of Energy Savings

S.No Details of Energy Saved Achievement

ElectricalEnergy

(Million Units)

Equivalent Thermal Energy

(Millionkcal)

1 Units Generated in FY:2017-18 289

2Electrical energy savings achieved by reduction in APC when compared to FY:2016-2017

1 % 28.598473

3

Plant Heat rate reduced by when compared to FY:2016-17Based on No of units generated

during FY2017-18 thermal energy saved

24 kcal/

kwh NA

6936

4 Total Thermal Energy Saved (2 +3) 15409

5Thermal energy saved in terms of Tonnes of Oil Equivalent ( TOE) 1540.9

12

SI.NO

Project Type

TitleSavings In units

1 Innovative Running of one SA fan in each Boiler at low loads 2,72,100

2Innovative Isolation of Cooling Water for bed ash cooler during

idle condition80,400

3Innovative

Air pressure /RPM reduction for Inst. Air Compressor 75,375

4Innovative

Reduction of BFP discharge Pressure 11,88,000

5Innovative

Installation blow valve for ESP hoppers 42,600

6 EnconInstallation of low pressure high volume j-seal

blower37,620

7 Encon replacement of sec. crusher motor with lower rating 93,440

8Energy

conservation Improved Throughput in Coal Extraction system 1,01,286

Details of Energy Savings

13

S.NoProject

TypeTitle

Savings ( units)

9 Encon replacement of CEP with energy efficient pump. 2,19,000

10 EnconInterconnection of AC units water line to ACW

pumps common header3,00,960

11 Enconreplacement of BC-9 bag filter fan with lower

capacity5,83,935

12 EnconRetrofitting of conventional light fittings with LED

lightings93,440

13 EnconReduction of water cooled AC’s power consumption

2,19,000

14Operational

strategyOptimization of ESP Aux. Consumption in

according to TG loading94,050

15Operational

strategyReduction of fly ash & bed ash conveying air

pressure by installing low pressure air compressor3,00960

16Energy

conservationTurbine-2 servicing for heat rate improvement

24 kcal/kwh

17Energy

conservationPlant overall Heat rate Improvement

Total Savings 31,58,351

**

** Up to September

Generation ( million units)

14

mil

lio

n u

nit

s

Financial Year

50

100

150

200

250

300

350

400

450

2016-17 2017-18 2018-19

419

289

170

**

Power Export ( million units)

15

mil

lio

n u

nit

s

Financial Year

50

100

150

200

250

300

350

2016-17 2017-18 2018-19

369

257

152

** Up to September

** Up to September

**

APC Percentage

16

aux.

%.

Financial Year

10.00

10.20

10.40

10.60

10.80

11.00

11.20

11.40

11.60

11.80

12.00

2016-17 2017-18 2018-19

11.83

10.84

10.57

Innovative Projects

Implemented

17

Activities Carried Out1. Optimized SA and PA Air Flows and stopped one SA Fan during low loads.2.Seal proof Dampers are provided

in the fan outlet in each Fan and logic implemented in DCS.

Benefits Achieved:1.Total Energy saving per Annum:

=37.79kw x 24 x 150 x 2

=272100 Units

Seal proofDamper

18

Installed seal proof dampers to stop one SA Fan during low loads

Innovative Project-1: Boiler Operation with single SA Fan

Existing Damper

Innovative Project-2

Isolation of Cooling Water circulation through bed ash cooler during Idle condition .

BEFORE:Continues Cooling water circulation

through bed ash coolers even in off condition.

Activities Carried OutON/OFF butterfly valve installed at

water Outlet of each bed ash cooler and logic implemented in DCS.

Benefits Achieved:

Bed ash cooler idle time: 12 HrsSavings Achieved : =20kw/Hrs Total savings annum

= 20kw x 12hrs x 335 days

= 80400units

ON/OFF Butterfly

valve

19

Before: Instrument Compressor Energy Consumption : 1750 units/dayActivities Carried Out

VFD arranged and established optimum RPM of Instrument Air Compressor at required Air Pressure .Identified 2300 RPM is optimum against design RPM of 2975 .

Accordingly replaced the 230mm dia pulley with 180 mm dia pulley on motor.

Benefits Achieved:

Energy Consumption after modification = 1495 units/day

Net energy saving per day =255 units/day

Total savings annum = 225 units x 335 days

= 75375 units

230mm Dia Pully

180mm Dia Pully

Optimization of Instrument Air Compressor RPM


20

Reduction of BFP Discharge Pressure

BEFORE:BFPs ran with Full RPM in both units and

discharge pressure was maintained very high which resulted higher energy consumption in Boiler Feed Water Pumps

Activities Carried OutBFPs Discharge Pressure Control PID

Loop created in DCS to maintain required discharge pressure. BFPs speed controlled by set discharge pressure given by Operator

Benefits Achieved:

Energy saving per Annum = 75 kw x 24 Hrs x 330days x 2 no,s=11,88,000

260 KW MOTOR

160 KW MOTOR

21

PID LOOP IMPLEMENTED


Before: Fluidization Air is provided continuously for ESP hoppers.

Activities Carried OutBlow valve installed in fluidization line and

made open/close of this valve according to dome valve open/close respectively.

Benefits Achieved:

Reduction of fluidizing air consumption = 4000 M3/day

Total Energy Savings Annum = 142units x 300 days = 42600 units

Installation blow valve for ESP hopper fluidization


22

Energy conservation

Activities implemented

23

1.Plant Heat Rate Improvement

24

2900

2930

2960

2990

2016-17 2017-18 2018-19

2,983

2,964

2,959

1.Overhauling of Turbine-2 carried out

2.Improvement of vacuum from 0.84 to 0.91

a)Condenser cleaning carried outb) Helium test conducted & leakages arrestedc) cooling tower efficiency improved

3.Boiler air flows optimized and excess air controlled .

4.Air infiltration points identified and arrested5.Improved APH efficiency by replacing spiral tubes in place of plain tubes

6. Cyclone design changed and installed segment type there by

improved in cyclone efficiency resulted in less LOI.

7.Expansion bellows at ID fan replaced with New bellows for controlling

False air entering, there by ID fan RPM

8.APH to Economizer Expansion Bellow Modified .

25

1a). Activities Carried Out :

Boiler-1

26

APC reduced by 0.44%

3.3

3.4

3.5

3.6

3.7

3.8

3.9

4

Before After

3.98

3.54

3.3

3.4

3.5

3.6

3.7

3.8

3.9

4

Before After

3.92

3.53

Boiler-2

APC reduced by 0.39%

Reduction APC in Boilers

27

2.Enhancing Coal Extraction system output and

Reduction of specific power consumption

0.00

0.50

1.00

1.50

2.00

2.50

3.00

2016-17 2017-18 2018-19

2.68

1.67 1.63

Sp. Power Consumption

0

50000

100000

150000

200000

2016-17 2017-18 2018-19

164381 161004

96308

Coal Transfer to the bunker

Tones

0

500

1,000

1,500

2,000

2,500

2016-17 2017-18 2018-19

2,0921,631

1,038

Running Hours

28

Before: Coal Plant Throughput is low and Consuming high Specific Power .

Activities Carried OutProcured 10mmx15mm Screen Decks and

replaced top 3 Decks in place of 8mmx15mm Screen Decks.

Benefits Achieved:

coal plant out put tonnage increased around 110 to 115 TPH. ( 20 to 25 TPH improvement)

8mmx15mm Screen Mesh

10mmx15mm Screen Mesh


Reduction of specific power consumption3a) Secondary screen output improvement

29

Before: 100% Coal was feeding to secondary crusher from Stock file through short belt conveyors

Activities Carried Out1.Sieve analysis carried out and found more than 60% product found in Stock file .

2.Hence Bypass chute arranged for crusher and Fed Coal directly to screen and only rejects Fed to the crusher there by load on crusher is reduced.

Benefits Achieved:

Total savings annum (a & b) = 101286 units


reduction of specific power consumption3b) Secondary Crusher bypass chute arrangement

ENCON PROJECTS IMPLEMENTED

30

Installation of Energy efficient new J-seal blower in place of 2 no’s of same KW roots blowers

BEFORE

2 No’s 75kw J-seal blowers are running

Power Consumption:

J-seal-1 (50amps), running kw=35

J-seal-2 (55amps), running kw=39

Total running kw= 74

Activities Carried Out

Low pressure and high volume energy efficient blower with same kw motor

installed

Power Consumption:

J-seal-New (65amps), running kw = 46

Benefits Achieved:

1.Total Energy saving = 74kw-46kw

= 28kw

2.Total savings per annum

= 28kw x 24hr x 330

=221760 units

31

Encon Project-1

Replacement of Coal secondary crusher with lower size motor 260kw to 160kw with the same output

BEFORE:Coal Secondary crusher 260Kw

Power Consumption: 99kw(140amps)

Activities Carried Out260kw motor replaced with 160kw motor

Benefits Achieved:

Crusher running load = 79kw(112amps)

Savings Achieved = 99kw-79kw=20kw

Total Energy saving annum

= 20kw x 12hrs x 330 days= 79200 units

260 KW MOTOR

160 KW MOTOR

32

Encon Project-2

Replacement of Existing CEP with Energy Efficient Pump

BEFORE:

Motor Power Rating : 160kw Avg.Power Consumption = 110kw

Activities Carried OutMotor Power Rating : 90kw

Avg. Power Consumption = 80kwPower Saving = 110 – 80 = 30kwh

Benefits Achieved:

1.Total Energy savings per annum=30kw x 24Hrs x 330 x 2 = 475200 Units

260 KW MOTOR

160 KW MOTOR

33

Old Pump160 kw

New Pump 90KW

Encon Project-3

Interconnection of AC units cooling water line from ACW pump header

34

BEFORE:Water circulation pumps 2 x 11kw used for Centralized AC units of 16.5 tons which were mounted on TG floor

Activities Carried OutAC circulating water line connected ACW pump header and removed cooling Water pumps . Further ACW pump controlled from VFD through pressure control PID.

Benefits Achieved:

1.Total Energy savings per annum = 11kw x 24Hrs x 365= 96360 Units

Encon Project-4

Replacement of BC-9 bag filter fan motor with lower size motor 15kw to 5.5 kw

BEFORE:Bag filter fan motor :15Kw

Activities Carried Out15kw motor replaced with 5.5kw

motor

Benefits Achieved:

Bag filter fan running load: 5.5kw

Energy Savings Achieved = 15kw-5.5kw=9.5kw

Total Energy saving per annum

= 9.5kw x 12hrs x 330 days

= 37620 units

Encon Project-5

35

Retrofitting of conventional light fittings HPMV/SV/MH lamps with LED lighting fixtures

S. NO DISCRIPTIONTOTAL

NOSUSED NOS

LOCATIONREPLACED WITH

SAVING

NET SAVING

IN WATTS

1 70W LED FITTINGS 55 55STREET

LIGHTS150W 80W 4400

2 40W LED FITTINGS 67

15BOILER 1

150 110W 1650

7 70 30W 210

15BOILER 2

150 110W 1650

5 70 30W 150

10STREET

LIGHTS150W 110W 1100

5BC - 4

TUNNEL150W 110W 550

6 RO PLANT

AERA

150W 110W 660

4 70W 30W 120

340W WELL GLASS

FITTINGS6 6 ESP 1,2 70W 30W 180

4 20W LED BULBS 3115 UNIT-1 36W 16W 240

16 UNIT-2 36W 16W 256

525W CEALING

FIITNGS30 30

OFFICE AND

VFD36W 11W 330

6 150W LED FIITNGS 10 9 TG HALL 3* 250 600W 5400

7100W LED FLOOD

LIGHTS20

10BOP

250W 150W 1500

10 400W 300W 300036

Benefits Achieved:

Total saving per day

= 21.4kw x 12hrs

=256 units

Total savings annum

= 256 x 365 days

= 93440 units

Encon Project-6

37

Reduction of water cooled AC’s power consumption

BEFORE:VFD drives room Air conditioning

consumption : 2600 units/day

Activities Carried Out1.Running status of individual AC units

indication provided in VFD room2.Requirement of the No. of AC units schedules

prepared according to the TG sets in operation and according to the loading on the TG sets.

Benefits Achieved:

AC conditioning consumption

=2000 units/day

Total savings annum =2600-2000

=600 x 365days

=2,19,000 units

Encon Project-7

ENCON PROJECTS BASED ON NEW OPERATIONAL STRATEGY

38

39

Before: 1.ESP field Current maintaining constant at all Load conditions. 2.All ESP fields kept on at low loads also.

Activities Carried Out1. Switched off some fields at low load

conditions 2.Reduced ESP Field currents wrt Load changes

i) One ESP field kept in OFF & ONE field current reduced up to 10%, Loads between 25 - 30MW

ii) TWO E.S.P fields kept in OFF & TWO fields current reduced up to 10 %, Loadsbetween 20 – 25 MW

Benefits Achieved:

Energy Savings Per Day = 285 UnitsEnergy Saving Per Year

= (285kwh X 330Days) = 94,050 Units

1200

1700

30.19 30.72 22.5 22.56

1810

1520

1780

1495

E.S

.P A

ux

(KW

)

Generation (MW)

E.S.P Aux(Kwh)

0

2

4

6

30.19 30.72 22.50 22.56

5 4 5

3

No

of

fiel

ds

Generation (MW)

Number of Fields

Optimization ESP Aux. ConsumptionProject-1

Reduction of fly ash & bed ash conveying air pressure

❖Fly ash& bed ash conveying air pressure reduced from 5.5kg to 4.2 kg

Activities Carried OutInstallation of 110 kw New LP air

compressor in place of existing 160 kwHP air compressor for Ash Handling for Energy Saving.

Benefits Achieved:

1.Total Energy saving per Annum: = 38kw x 24 Hrs x 330 days= 300960 Units

260 KW MOTOR

160 KW MOTOR

40

160 kw

110 kw

Project-2

41

BEFORE:During boiler light up we are using diesel oil of 3.3KL per each light up

Activities Carried Out1.Installed separate tank & transfer

pump for polymer oil usage2. Oil burner system modified

suitable for polymer oil usage

Benefits Achieved:

Total Polymer Oil used

FY: 2017-18= 45 KL

Cost at price Rs.35 per liter = 15,75,000

Cost of diesel at avg. price Rs.70/- ltr

= 316,55,34

Net Saving per annum

=15,90,534

Promoting non conventional fuel usage in Boiler during light up

Project-3

Benefits: 1.Each area wise power consumption can be monitored 2. Customization reports available on each day3.Any abnormal consumption can be tracked on day to day basis 4. Daily efficiency report will be generated based on EMS reports

Daily Auxiliary Report Date: 11/06/2017A) BOILER-1 B) BOILER-2

SI.No

Description Meter No.Units(Kwh)

SI.No


1 CT-1 M3 0 1 CT-2 M8 13267.01

2 CT-3 M2 0 2 CT4-(MCW4+MCW5) M10-(M61+M62) 18697.57

3 BOILER MCC-1-(ESP1) M28-M42 0 3 BOILER MCC-2-(ESP2) M44-M58 893.6

4 AUX MCC-1 - (MLDB1) M29-M41 0 4 AUX MCC-2 M45 3399.3

TOTAL 0 TOTAL 36257.48

C) TURBINE-1 D) TURBINE-2

SI.No


SI.No


1 TG MCC-1 M33 144.22 1 TG MCC-2 M49 2805.2

2 CTMCC1-(AC UNITS) M31-M43 615 ACW-1 M55 3050.59

3 ACW-2 M34 0 3 ACW-3 M56 0

4 MCW-1

M6 0

4 MCW-4 M61 5055.01

5 MCW-2 5 MCW-5 M62 5366.4

6 MCW-3 6 CTF-1

M38 07 CTF-4

M52 2175.2

7 CTF-2

8 CTF-5 8 CTF-3

9 CTF-6

10 CTF-7 TOTAL 16277.2

TOTAL 2934.42

E) WATER SYSTEM F) COAL HANDLING PLANT

SI.No


SI.No


1 PUMP HOUSE M4 1512.99 1COAL UNLOADING MCC

M53 198.56

2 RO PLANT MCC-2 M36 927.5 2 COAL CRUSHER-1 M40 0

3 FIRE FIGHTING MCC M39 391.97 3 COAL CRUSHER-2 M54 198.95

TOTAL 2832.46 4 COAL EXT MCC-1 M30 331.08

TOTAL 728.59

G) ASH HANDLING SYSTEM H) INSTRUMENT COMPRESSOR

SI.No


SI.No


1ASH HANDLING MCC2(Ash Comp-B,C& Mics)

M51 477.05 1 INSTRUMENT COMP-1 M63 1200.8

2 LP COMPRESSOR M37 0 2 INSTRUMENT COMP-2 M64 0

3 ESP-1 M42 0 3 INSTRUMENT COMP-3 M65 1780.9

4 ESP-2 M58 1776.1

TOTAL 2253.15 TOTAL 2981.7

Installation of Energy Management System

42

Project-4

Greenery Development

43

Photos of Greenery development

44

Coal Handling Plant Area

Fly ash Silo Area Coal Unloading Area

used for dust suppression

47

Waste Water Utilization

48

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Penna Cement Industries Limited - qcfihyderabad.com