UltraTech Cement Limited - greenbusinesscentre.comgreenbusinesscentre.com/energyaward2017presentations/Power/CII... · Reduction in Boiler PA Fan KW by optimizing the PA Air ... LOI

UltraTech Cement Limited (Unit: Kotputli Cement Works-Power Plant)

Welcome to CII 18th National Award for Excellence in

Energy Management 2017

Content Company Profile

Plant Configuration and Flow diagram

Energy Management System Policy

List of EnCon Projects

Plant Performance over the years

Innovative Projects

Environment Projects / Initiatives

Renewable Energy Sources/ Waste utilization

Methodology of Energy monitoring

Best practices/ Involvement of Employees

CSR initiatives

Awards & Accolades

Way forward

Company Profile • UltraTech Cement…………

Kotputli Cement Work

An Aditya Birla Group Company.

2X23 MW Captive Power Plant

3.3 MTPA capacity Green field Cement plant.

Environment friendly due to less emissions.

Certified with ISO 9001, 14001, OHSAS 18001 , ISO 27001, ISO 50001 & ISO 17025.

Adopted World Class Manufacturing Excellence Model

Kotputli Cement

Works

Process Flow Diagram

Energy Management System Policy

List Of EnCon Projects

Energy Savings Projects Summary

SN Financial

Year Investment/

No Investment No. of Projects

Electrical Energy Savings (MWH)

Heat Energy Savings

(Ton/Year)

Savings in Rs. Million

Invested Amount in Rs. Million

1 2016-17 No Investment 18 7253 85.35 16.44 -

Investment 9 490 357 3.9 3.7

2 2015-16 No Investment 12 1924 313 8.39 -

Investment 4 226 1342 7.84 3.0

3 2014-15

No Investment 10 4046 426 11.5 -

Investment 1 2781 2004 9.26 102.8

Total 54 16720 4527.35 57.33 109.5

Energy Savings Projects with No Investment (2016-17)

SN Energy Saving Projects

Saving Achieved

Electrical Energy (MWH)

Thermal Energy

(Ton/Year)

(Rs. Million)

1 Reduction of BFP power by developing discharge pressure biasing. 330 1.09

2 Reduction in Boiler PA Fan KW by optimizing the PA Air flow according the boiler load

264 0.87

3 Condensate interconnection to reduce heat loss (From Aug-16 to Mar-17)

4.12 0.03

4 Reduction in SAC running hours through ESP hopper level by Draft transmitter.

165 0.54

5 Utilising lower CFM & KW compressor for Fly ash conveying 66 0.22

6 Usage of 90% Pet coke in fuel mix & Reduction in CHP power by increasing through put

66 0.22



Saving Achieved


Thermal Energy

(Ton/Year)

(Rs. Million)

7 Reduction in AC & lighting power 33 0.11

8 Reduction in ID fan power consumption due low bed ash cooler running hour

33 0.11

9 Reduction in BLR SA fan KW by optimizing the SA air pressure. 31.68 0.10

10 Reduction in instrument air compressor power by optimizing the air flow in BLR MDC sealing

31 0.10

11 Silo bag filter purging air pressure reduction 26.4 0.09

12 CEP power cons. reduction by inter connecting condensate line during unequal loads on TG.

8.25 0.03



Saving Achieved


Thermal Energy

(Ton/Year)

(Rs. Million)

13 Reduction of RO Degasser transfer pump power consumption by utilising old CT sump as storage

3.56 0.01

14 Reduction of raw water pump running hours by continuous make up of cooling tower

1.81 0.01

15 ACW pump power reduction by optimizing the CW flow of equipment's according the ambient temp.

39.6 0.13

16 Use of Raw Mill dust to reduce sensible heat loss due to bed drain & Usage of High GCV fuel in the boiler to achieved higher boiler efficiency.

81.22 0.52

17 Reduction in import of Grid power ( Diff. @ Rs 2.8 in Power generation cost against Grid Power)

896 2.50

18 Power Sale to other group units ( Difference @ Rs 1.86 in Power generation cost against Grid Power)

5257 9.78

Energy Savings Projects with Investment


Saving Achieved

Investment (Rs. Million)

Pay back

Month Year Electrical

Energy (MWH)

Thermal Energy

(Ton/Year)

Rs. Million

1 TG 1 ACC fan 2 VFD installation 115.5 0.38 0.42 13 16-17

2 Replacement of TG 1 MOP with high efficiency pump

79.2 0.26 0.16 7 16-17

3 Bed ash cooler fan outlet duct inter connection 69.3 0.23 0.1 5 16-17

4 Boiler-1 BAC fan VFD installed 69.3 0.23 0.42 22 16-17

5 Cooling tower fan VFD installed 33.99 0.11 0.15 16 16-17

6 Power reduction by Installation of submersible pump in main effluent pit for transfer to mines.

11.88 0.04 0.038 12 16-17



Saving Achieved


Pay back


Energy (MWH)

Thermal Energy

(Ton/Year)

Rs. Million

7 Utilisation of TG-2 1st extraction steam in PRDS for ejector (From Nov-16 to Mar-17)

4.8 50.05 0.33 0.45 16 16-17

8 Lighting power optimisation. 6.6 0.02 0.02 11 16-17

9 LOI reduction in fly ash by U beam straightening to improve ash circulation rate & by MDC replacement

307.31 1.96 0.63 4 16-17

10 Up keepment of steam turbine-2 to improve heat rate

- 1342 7.07 2.61 4 15-16

11 Reduction in power consumption of air conditioners by using Nano technology & installing water cooled condensers

203.6 - 0.69 0.20 4 15-16



Saving Achieved


Pay back


Energy (MWH)

Thermal Energy

(Ton/Year)

Rs. Million

12 Installation of separate energy efficient side stream filter pump (Grundfos Make) for cooling tower to reduce power from existing ACW pump.

17.3 - 0.06 0.05 10 15-16

13 Usage of renewable (solar)energy for lighting at HSD area .

5.6 - 0.02 0.14 88 15-16 015-16

14 Operation of TG-2 ACC with ALE fins tube bundles & Auto PID operation of all ACC fans with VFD.

2781 2004 9.26 102.8 133 14-15



Saving Achieved


Thermal Energy

(Ton/Year)

(Rs. Million)

1 Improved heat rate of TG-2 by operating with higher vacuum - 313 1.65

2 Intermittently stopped service air compressor to avoid idle running during pet coke usage & DP level in ESP hoppers.

340.5 - 1.25

3 Developed a logic (Auto set point calculation) for BFP discharge pressure w.r.t. steam drum pressure.

320.2 - 1.19

4 Developed a logic (Auto set point calculation) for CEP discharge pressure w.r.t. deaerator pressure.

268.6 - 0.96

5 Reduction of both boiler ESP field power by changing charging ratio with respect to fuel types.

278 - 0.93

6 Adiabatic cooling system for inlet air of ACC Fans in unit-1 216 - 0.73



Saving Achieved


Thermal Energy

(Ton/Year)

(Rs. Million)

7 Through put increased & run hours reduction of CHP by using Belt power feedback display on DCS.

164.3 - 0.55

8 Indigenous development of auto import -export logic during power export.

150.7 - 0.50

9 Reduced Instrument air pressure set point from 6.5 kg/cm2 to 5.8 kg/cm2 (gradually in two phase).

72.6 - 0.26

10 WTP running hours reduction by commissioning & utilising dump steam system.(Savings of 06 Months)

48.4 - 0.16

11 Reduction in BAC fan air flow from 22 to 19 TPH 46.2 - 0.15

12 Reduction in idling hours by implementing remote operation of Fly ash compressors.

18.2 - 0.06



Saving Achieved


Thermal Energy

(Ton/Year)

(Rs. Million)

1 Improved Boiler Efficiency by increasing pet coke percentage in fuel mix.

- 1643 10.09

2 Boiler operated at lower bed height. Reduced by 200mmwc,power savings @90Kwh.

1188 - 4.40

3 Optimization of steam venting by taking Raw mill initial drive start feed back through PI system.

- 372 2.29

4 Operation of TPP at Island mode operation. 561 - 2.09

5 Power generated from TG-2 during ACC bundle replacement with ACC single stream operation. ( Difference Rs 0.93/Kwh of TPP vs Grid Power).

2221 - 2.08



Saving Achieved


Thermal Energy

(Ton/Year)

(Rs. Million)

6 Improved TG vacuum by arresting leakages in TG exhaust path through Helium check.

53.5 0.37

7 Optimised CHP bag filter purging air through DP transmitter instead of timer mode.

69.96 - 0.26 8 Reduced power consumption of bag filter fan by parallel circuit operation of CHP & LSHP.

9 Modified CHP Start & Stop logic to reduce idle hour.

10 Reduced Hot well transfer pump running hours of unit-1 by rerouting of LP Heater drain to CRT tank.

5.81 - 0.02

Plant Performance & Benchmarking

Key Performance Indicators

3.78 3.70

3.33 3.29

3.00

3.50

4.00

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

75.02 75.85 75.41 76.57

65.00

75.00

85.00

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

12.49

11.36

9.54

8.99

8.50

10.50

12.50

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

9 % reduction

16 %

reduction

5.8 %

reduction

3095

3049 3036 3041

3000

3100

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

Under Performance of ACC of Unit-1

GOOD

GOOD

PLF (%) Heat Rate (Kcal/Kwh)

Power Cost (Rs./Kwh) Auxiliary Power (%) GOOD

GOOD

Benchmarking With UTCL Units 2016-17

3224 3188 3144 3143 3118

3080 3067 3045 3041 2998

2700

3000

3300

HCW ACW RWCW RC APCW GCW AC SCW KCW VC

Heat Rate (Kcal/Kwh)

12.26 11.65 11.71

11.30 11.06 10.73

10.20 10.14 10.04

8.99

8.00

9.00

10.00

11.00

12.00

13.00

HCW RWCW VC GCW AC ACW SCW RC APCW KCW

Auxiliary Power (%) Best Across UTCL

units

Benchmarking With UTCL Units 2016-17

90.5 86.8 80.1 78.4 78.4 76.9 76.9 76.0 73.0 64.8

0.0

20.0

40.0

60.0

80.0

100.0

RC GCW APCW HCW SCW ACW KCW AC RWCW VC

Plant Load Factor (%) Less Demand of Load

Innovative & EnCon Projects

Project-1 # Reducing heat loss in Aux. steam for Ejector

Reason for Selection:

• The Aux. steam for Ejector was supplied from main steam line by reducing its pressure & temperature from 100 Kg/cm2 & 535°C to 11 kg/cm2 & 350°C respectively by spraying feed water resulting heat loss in the system.

Technology Adoption:

• Installed a pressure reducing station & utilized Turbine 1st extraction steam of lower pressure & temp.(22 kg/cm2 & 360 °C) in ejector & reduced heat loss in Aux. steam

Cost of Implementation: Rs. 0.45 Million

Benefits:

• Total Savings in Coal : 50 MT/Annum • Total Savings in Power:4.8 MWH/Annum • Total Savings : Rs. 0.33 Million/Annum

Uniqueness: Single PRS being utilized for two TG’s

Before: Main Steam Utilisation in Ejector

After: Extraction Steam Utilisation in Ejector

Project-2 # Reduction in LOI of Fly ash by Ash Recycle


• At 90% Pet-coke in fuel mix LOI in Fly ash was higher resulting lower boiler efficiency.


• Modified the fly ash conveying line of ESP & APH and diverted it to existing bed material bunker of the boiler.

• Recycled the fly ash again to the boiler and reduced the LOI %.

Benefits:

• Reduction in LOI by 0.8 %

• Total Savings : Rs. 2.5 Million/Annum

Before: Without Ash Recycle Line

After: With Ash Recycle Line

APH Conveying System

APH Conveying System

ESP Conveying System

ESP Conveying System

Project-3 # Reduced Bed Ash Cooler fan power consumption


• Higher Power consumption of boiler-2 Bed ash cooler fan due to DOL drive.


• Fabricated & Interconnected bed ash cooler fan discharge duct of both the boiler with pneumatic operated isolation valves.

• Operated both bed ash cooler with single fan with VFD.

Cost of Implementation: Rs. 0.05 Million

Benefits:

• Total Savings in Power : 69.3 MWH/Annum


Uniqueness: Single VFD being utilized for Both boiler BAC.

BAC duct without Interconnection

BAC duct with Interconnection

Project-4 # Intermittent stoppage of service air compressor

Reason for Selection: • Earlier ash conveying system of ESP was operated by hopper

level switches in timer & probe mode resulting idle running of service air compressor due to malfunctions.

• Stoppage of service air compressor was carried out based on manual checking of hopper levels.


• Installed DP transmitter in hoppers with online display on DCS for continuous monitoring.

• Intermittently stopped the compressor with respect to Draft level at hoppers to optimized power consumption.

Benefits:

• Total Savings in Power: 340 MWH/Annum


Reason for Selection: • Air Cooled Condensers are supplied with multi row HDG(Hot Dip Galvanized) Fin material of low

heat transfer coefficient, resulting higher heat & power consumption.

• ACC’s under performance de-rating TG loading during peak ambient temperature.

• Replacement of air cooled condenser was initiated. But the cost of it was higher.

Complexity: • The Capital for new ALE multi row tube bundle replacement had higher cost (10 Cr) & had higher

return in investment (>8 Yrs.).

Approach: • Brainstorming within team & explored opportunity for low cost & efficient alternative technology

within & outside India.

Technology Adoption: • Approached new technology supplier having ACC- Single Row Condenser (SRC) technology at low

cost & high heat transfer efficiency resulting lesser heat & power consumption.

Way Forward # Technology Up gradation of ACC (SRC)

Benefits: • Procured at Capital cost to 4.42 Cr with ROI of 3.95 yrs. • Proposed savings : 62 Kcal/Kwh & 8.5 Lacs Kwh / Annum. • Proposed Savings: Rs. 7.8 Million/Annum

Uniqueness: First time installation being carried out in India.

Way Forward # Technology Up gradation of ACC (SRC)

Environmental Projects / Initiatives

PAT Status GtG energy consumption status (Cement & Power Plant)

993 937

711 670 641

400

600

800

1000

1200

2009-10(Baseline year)

Target SEC for PAT cycle1

ActualPAT Cycle 1

BaselinePAT Cycle 2

TargetPAT Cycle 2

Kcal

/kg

PP

C E

qu

iv.

No. of Energy Saving Certificates 37153

Target for reduction

4.32%

28.40 % reduction

5.6% reduction target

Unit is registered as Designated Consumers (DC) under PAT scheme. Target given for 5.6 % reduction in GtG Specific Energy Consumption for PAT Cycle-1 (FY14-15) Implementation of ENCon projects in the unit reflects 28.40 % reduction in SEC in PAT cycle-1. Now entitled

for 37153 Nos. of Escerts costing about Rs.37 Crores

GHG Inventorisation

Year tCO2 Emission Sp. CO2 Emission

2014-15 319290 1.18

2015-16 331119 1.17

2016-17 348690 1.18

Environmental Initiatives Green Belt development

Saplings Planted in last 09 Years: 137683 nos. Green belt area developed : 110.35 hectare

Environmental Initiatives

Ground water recharging through injection well Rain Water Harvesting Ponds

Green Belt in Colony Sapling Distribution to Villagers

Renewable Energy Sources / Waste Utilisation

98549

120934

108126 100136

50000

75000

100000

125000

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

Solar Unit Generation (kwh)

Renewable Energy Utilisation

Usage of renewable energy for lighting at TPP HSD Area: • Installed Solar Power Generation at HSD area : 1000Watts • Solar energy : 0.04 % of total power share

Solar Unit Generation (kwh) 100 KW Solar Power Plant

Utilisation / Recycle of Waste

TPP Bed ash – 100 % Bed ash being used in Cement plant.

a) While using 100% Petcoke in boiler and generating 18-20 TPD bed ash which was creating problem of reuse. Discussed with Cement plant Quality Control Deptt. and after detailed analysis & coordination started using in cement plant.

b) Recycle of TPP bed ash & fly ash again in boiler to recover un-burnt carbon during pet coke usage.

PPF for boiler Light up – Usage of Petro Polymer fuel in place of Diesel for every Boiler light-ups, replacing the convectional fuel

Energy Monitoring

Methodology adopted for Energy Monitoring

Well Established energy management cell headed by FH-TPP.

Daily monitoring of Heat rate and Aux. power deviation report.

Analysis of equipment performance for deviation.

Identification of energy conservation scope.

Theme base suggestions/Kaizens scheme under “Energy Saving ”.

Feasibility study of suggestions & submit proposal for sanction.

Preparation of detail action plan.

Weekly review to monitor project progress.

Benefits analysis after project implementation.

Sustainability of the project

Efficiency Monitoring & Daily report Efficiency Energy

Aux. Power Monitoring

Online Energy Monitoring System

ISO & Accreditations

Journey Towards Excellence

ISO

9001

2011

ISO

14001

2011

OHSAS

18001

2013

2014

ISO

17025

2015 2015

ISO

27001

ISO

50001

NA

BL

accr

ed

itat

ion

En

erg

y M

anag

em

en

t

Info

rmat

ion

Se

curi

ty

Occ

up

atio

nal

H

eal

th &

Saf

ety

Envi

ron

me

nt

Man

age

me

nt

Qu

alit

y M

gmt.

WCM

2010

WC

M

Init

iate

d

WCM

2013

WC

M B

ron

ze

Aw

ard

WCM

2015

WC

M G

old

Aw

ard

Exce

llen

t En

erg

y

Aw

ard

2016

Energy

Award

No

te w

ort

hy

Wat

er

effi

cie

nt

un

it

2016

Water

Award

http://www.presentermedia.com/index.php?target=closeup&id=11749&categoryid=115&maincat=animsp

ISO 50001,9001 &14001 for FY 2016-17

S.No

Findings Corrective Actions Standard Status

1 Acceptance criteria may be defined against various variable identified for significant energy use.

Acceptance criterion is defined in OCP prepared respective sections. ISO 50001

Completed

2 No findings

.

ISO 9001

3 No findings OHSAS 18001

Corrective Action against finding related to ISO 50001, 9001 & 14001 for FY 16-17

Team Work for EnCon

SN EnCon idea Idea originated

(Year) Team involved Status

1 Reduction in power by Installation of submersible pump in main effluent pit for transfer to mines.

2016 O&M and E&I Team Completed

2 Optimization of heat loss by utilising TG-2 1st extraction steam in PRDS for ejector


3 Replacement of TG 1 MOP with high efficiency pump

2016 TPP (O&M) Team Completed

4 Pressure biasing for BFP discharge pressure 2016 O&M and E&I Team Completed

5 Increase the power generation during the summer season by adiabatic cooling system for inlet ambient air in ACC Fans in unit-1

2015 FH-TPP/TPP( O&M) & TPP (E&I) team/ M/s Greensole power

Completed

Team Work for EnCon

SN EnCon idea Idea originated

(Year) Team involved Status

6 Reduction of Raw water consumption of by utilization of Boiler blow down water for cooling tower make up

2015 TPP (O&M) Team Completed

7 Replacement of ACC HDG tube bundles with ALE tube bundles.

2014 O&M, E&I Team and M/s Greensole Power

Completed

8 CEP discharge pressure droop mode operation with reference to Deaerator pressure


9 CHP power optimization by increasing through put according to fuel types

2014 O & M and E&I Team Completed

10 Blow down water Heat recovery system 2014

O & M and E&I Team & M/s Forbes Marshall

Completed

Replication Arising Out of Best Practices

SN Name of service provided to vendor Replicating Unit Name of associate

/ vendor

1 Replacement of ACC HDG tube bundles with ALE tube bundles.

Aditya Cement, Rajshree cement & new projects at

UTCL

M/s Greenesol Power

2 ACC Power Reduction by operating all fans with VFD & Vacuum with auto PID control

Aditya Cement, Rajshree cement & new projects at

UTCL

M/s Greenesol Power

3 Island Mode operation of Thermal power plant Rawan cement, Aditya

Cement, Rajshree cement -

4 Utilisation of Boiler blow down water as cooling tower make up.

Rajshree cement M/s Chembond & Ion Exchange

Best Practices Shared to Vendors

SN Name of

associate / vendor

Name of service provided to vendor

Energy cons.

before

Energy cons. After

Gain Type of inputs / projects provided to the vendor/

associate

1 M/s Greenesol Power

Hotwell transfer pump running hours optimization by modification of LP Heater drain direct to CST.

79 Mwh/ month

62 Mwh/ month

22% Applicable in all existing units & new projects.

2 M/s Thermax Modification in Ejector motive steam line

10 Kcal/Kwh In all Plants where Thermax has supplied the Boilers


Energy efficient ACC fans 100 KW/Fan

80 KW/Fan

20% Installation of these fans in new projects


Replacement of ACC HDG tube bundles with ALE tube bundles.

232 Mwh/month

112 Mwh/month

Installation of ALE bundles in new projects

Corporate Social Responsibility

STRIVING FOR……

Societal Change ……


Education

Sustainable Livelihood

Social Causes

Infrastructure Development

Health Care

Corporate CSR

CSR Vision

CSR Policy

Focus Area

Awareness campaign for Personal hygiene, Family

planning, Immunization camps.

Infrastructure development for hospitals/

schools nearby.

Skill Up gradation Training for Black Marble Stone Sculptures



Coaching classes & felicitation programs for students.

Conducting free eye camps to extend hand of help to communities.

Formation of Self Help Groups (SHG)

Awards & Accolades

Awards & Accolades

Kotputli Cement Works –TPP team receiving award for “Excellent Energy Efficient Unit “ in year 2016.

Kotputli Cement Works –TPP team receiving certificate for “Noteworthy water efficient unit “ in year 2016.

Awards & Accolades



Awards & Accolades

Kotputli Cement Works –TPP team receiving award for “Energy Efficient Unit “ in year 2013.

Kotputli Cement Works team receiving award for “Rajasthan Energy Conservation’’ in year 2014.

Awards & Accolades

Kotputli Cement Works –TPP team receiving award for “Water Efficient Unit “ in year 2012.

Commendation Certificate by the Ministry of Power, Government of India in recognition of efforts made to conserve the energy for year 2012-13.

Awards & Accolades

Commendation Certificate by the Ministry of Power, Government of India in recognition of efforts made to conserve the energy for year 2011 -12.

First prize by dept. of energy, Govt of Rajasthan for sincere efforts towards energy conservation & efficient use.

Way Forward

Way Forward: Energy Saving Projects

Replacement of existing ACC tube bundles with upgraded SRC technology tube

bundles with APC savings of 8.5 Lacs Kwh / Annum.

Overhauling of TG-1 for Heat Rate improvement.

Installation of waste Heat Recovery boiler from Kiln PH & cooler outlet gases.

1) For power generation 2) For heat utilization.

Existing ETP Pump replacement with Grundfos make energy efficient pump.

Installation of VFD drive in bed ash cooler fan-2.

Impeller trimming of Raw water pump for power optimization

Installation of Energy efficient 3 phase rectifiers for ESP.

Energy Simply Burns or Earns, Choice is Ours!

Sincere Thanks..

UltraTech Cement Ltd Kotputli Cement Works

Power Plant

Documents

UltraTech Cement Limited - greenbusinesscentre.comgreenbusinesscentre.com/energyaward2017presentations/Power/CII... · Reduction in Boiler PA Fan KW by optimizing the PA Air ... LOI