UltraTech Cement Limited (Unit: Kotputli Cement Works .
UltraTech Cement Limited(Unit: Kotputli Cement Works-Power Plant)Welcome to CII19th National Award for Excellence inEnergy Management 2018Participants Pintoo Dodiya (Assistant Manager) R.N.Tripathi (Assistant Manager) Harish Mittal (Assistant Engineer) Confederation of Indian Industry
Contents Company profile and Flow diagram Specific energy consumption data in last 3 years Information on competitor and Bench marking Energy saving projects implemented in consecutive 3 years Major i o ati e proje ts i ple e ted i FY’ 7-18 Utilization of renewable energy GHG Inventorisation Team work employee involvement & monitoring Implementation of ISO 50001 Awards & Accolades Confederation of Indian Industry
ProfileKotputliCementWorks UltraTech Cement Kotputli Cement Work An Aditya Birla Group Company. 2X23 MW Captive Power Plant 3.3 MTPA capacity Green field Cement plant. Certified with ISO 9001, 14001, OHSAS 18001 , ISO 27001, ISO50001 & ISO 17025. UltraTech-Kotputli TPP o First prize i Natio al E ergConservation Award7 by Ministry of Power Awarded byhonourable President of India. The continual Energy improvements by KCW TPP have beenre og ized a ardi g CII – Excellence Energy Efficient Unita ard for last o se uti e four ears at CII –Hyderabad Adopted World Class Manufacturing Excellence Model Confederation of Indian Industry
Process flow diagram Confederation of Indian Industry
Specific Energy consumptionOVERALL PLANT APC (%)10PLANT HEAT RATE (KCAL/KWH)9.54Higher due toTG SSC 30008200071000FY'15-16FY'16-17FY'17-180FY'15-16BOP APC ( %)ACC-1 AUXILIARY POWER CONS. '16-17FY'17-18FY'15-16 Confederation of Indian IndustryFY'16-17FY'17-18
National f- For International Benchmark BEE presentation during interactive workshop on normalization factor in AhmedabadRef. For National Benchmark Data Best Thermal energy efficiency award byfor FY2014-15. NCCBMConfederationof Indian Industry
Benchmarking With UTCL Units 2017-1833503320Heat Rate (Kcal/Kwh)318031483143312931283113Second bestAcross VCKCWSGAuxiliary Power (%)Best Across 99.629.589.359.008.928.398.00HCAPCWACACWGCWRWCW Confederation of Indian IndustryVCRCSGKCW
Road map for Benchmarking Plant Digitalization and installation of Optimax software for boiler efficiencyimprovement (saving in HR 26 kcal/kwh ). Overhauling of TG-1 for Heat Rate improvement ( saving in HR 67 kcal/Kwh) Improvement of PLF by power wheeling to other sister units in group. Existing ETP Pump replacement with Grundfos make energy efficient pump. Installation of Energy efficient 3 phase rectifiers for ESP. Installation of VAM in place of existing package AC. ACC-1 all fan replacement with Energy efficient fan blade (Encon.) Confederation of Indian Industry
Energy Savings Projects with No Investment (2015-16)SNEnergy Saving Projects1 Improved heat rate of TG-2 by operating with higher vacuumSaving AchievedElectrical ThermalEnergy(Rs. ly stopped service air compressor to avoid idlerunning during pet coke usage & DP level in ESP hoppers.340.5-1.253Developed a logic (Auto set point calculation) for BFPdischarge pressure w.r.t. steam drum pressure.320.2-1.194Developed a logic (Auto set point calculation) for CEPdischarge pressure w.r.t. deaerator pressure.268.6-0.96Reduction of both boiler ESP field power by changing charging5ratio with respect to fuel types.278-0.936 Adiabatic cooling system for inlet air of ACC Fans in unit-1216-0.73 Confederation of Indian Industry
Energy Savings Projects with No Investment (2015-16)SNEnergy Saving ProjectsSaving AchievedElectrical ThermalEnergy(Rs. Million)Energy(Ton/Year)(MWH)7Through put increased & run hours reduction of CHP by usingBelt power feedback display on DCS.164.3-0.558Indigenous development of auto import -export logic duringpower export.150.7-0.509Reduced Instrument air pressure set point from 6.5 kg/cm2 to5.8 kg/cm2 (gradually in two phase).72.6-0.2610WTP running hours reduction by commissioning & utilisingdump steam system.(Savings of 06 Months)48.4-0.1646.2-0.1518.2-0.0611 Reduction in BAC fan air flow from 22 to 19 TPH12Reduction in idling hours by implementing remote operation ofFly ash compressors. Confederation of Indian Industry
Energy Savings Projects with Investment (2015-16)Saving AchievedElectrical ThermalEnergyEnergy(MWH) (Ton/Year)SNEnergy Saving Projects1Up keepment of steam turbine-2 to improve heatratePayInvestmentbackRs.(Rs. Million)MonthMillion-13427.072.614Reduction in power consumption of air2 conditioners by using Nano technology & installingwater cooled condensers203.6-0.690.204Installation of separate energy efficient side3 stream filter pump (Grundfos Make) for coolingtower to reduce power from existing ACW pump.17.3-0.060.05105.6-0.020.14884Usage of renewable (solar)energy for lighting atHSD area . Confederation of Indian Industry
Energy Savings Projects with No Investment (2016-17)SNEnergy Saving ProjectsReduction of BFP power by developing discharge pressurebiasing.Reduction in Boiler PA Fan KW by optimizing the PA Air flow2according the boiler load13Condensate interconnection to reduce heat loss(From Aug-16 to Mar-17)4Reduction in SAC running hours through ESP hopper level byDraft transmitter.5 Utilising lower CFM & KW compressor for Fly ash conveying6Usage of 90% Pet coke in fuel mix & Reduction in CHP power byincreasing through put Confederation of Indian IndustrySaving AchievedElectrical ThermalEnergy(Rs. 31650.54660.22660.22
Energy Savings Projects with No Investment (2016-17)SNEnergy Saving Projects7 Reduction in AC & lighting power8Reduction in ID fan power consumption due low bed ash coolerrunning hour9 Reduction in BLR SA fan KW by optimizing the SA air pressure.10Reduction in instrument air compressor power by optimizingthe air flow in BLR MDC sealing11 Silo bag filter purging air pressure reduction12CEP power cons. reduction by inter connecting condensate lineduring unequal loads on TG. Confederation of Indian IndustrySaving AchievedElectrical ThermalEnergy(Rs. 31.680.1026.40.098.250.03
Energy Savings Projects with No Investment (2016-17)SNEnergy Saving ProjectsReduction of RO Degasser transfer pump power consumption byutilising old CT sump as storageReduction of raw water pump running hours by continuous14make up of cooling tower13ACW pump power reduction by optimizing the CW flow ofequipment's according the ambient temp.Use of Raw Mill dust to reduce sensible heat loss due to bed16 drain & Usage of High GCV fuel in the boiler to achieved higherboiler efficiency.Reduction in import of Grid power ( Diff. @ Rs 2.8 in Power17generation cost against Grid Power)Power Sale to other group units ( Difference @ Rs 1.86 in Power18generation cost against Grid Power)15 Confederation of Indian IndustrySaving AchievedElectrical ThermalEnergy(Rs. .1381.220.528962.5052579.78
Energy Savings Projects with Investment (2016-17)SNSaving AchievedPayInvestmentElectrical (MWH) (Ton/Year)Energy Saving Projects1 TG 1 ACC fan 2 VFD installation115.50.380.4213Replacement of TG 1 MOP with high efficiencypump79.20.260.1673 Bed ash cooler fan outlet duct inter connection69.30.230.154 Boiler-1 BAC fan VFD installed69.30.230.42225 Cooling tower fan VFD installed33.990.110.151611.880.040.0381226Power reduction by Installation of submersiblepump in main effluent pit for transfer to mines. Confederation of Indian Industry
Energy Savings Projects with Investment (2016-17)Saving AchievedElectrical ThermalEnergyEnergy(MWH) (Ton/Year)SNEnergy Saving Projects7Utilisation of TG-2 1st extraction steam in PRDS forejector (From Nov-16 to Mar-17)8 Lighting power optimisation.4.850.056.6LOI reduction in fly ash by U beam straightening to9 improve ash circulation rate & by MDCreplacement Confederation of Indian Industry307.31PayInvestmentbackRs.(Rs. Million)MonthMillion0.330.45160.020.02111.960.634
Energy Savings Projects with No Investment (2017-18)SNEnergy Saving ProjectsCooling tower fan temperature control PID set point increasedfrom 30 to 30.5 deg C for power saving.Boiler feed pumps pressure biasing set point reduction from 72kg/cm2 to 6.3 for power reduction.13Stopped root blower for fluidizing in fly ash silo & used itsservice air for silo fluidization.4 CHP bag filter damper throttling for power reduction.5CEP discharge Condensate line interconnection to reduce heatloss due to make-up water.6Installation of low pressure compressor for feeding Raw mealpowder in to bunker. Confederation of Indian IndustrySaving AchievedElectrical ThermalEnergy(Rs. .0627.60.121620.7.15.09
Energy Savings Projects with Investment (2017-18)SNSaving AchievedPayInvestmentElectrical ThermalbackRs.(Rs. Million)EnergyEnergyMonthMillion(MWH) (Ton/Year)Energy Saving ProjectsReplacement of ACC-1 HDG tube bundles with SRCtube bundles & Improved heat rate of both TG by1operating with higher vacuum. (Commissioned inthe month of Dec-17)296.782563.6442322 Installation of VFD in Bed ash cooler fan of 211841.680.540.150.161302 Nos Fan blade change in ACC-2 with energyefficient fan blade(Encon.)Interconnection of Instrument Air with service air4& utilizing instrument air compressor with VFDFly ash recycle to bunker line erection of ESP -15filed in both boilers.36 Energy efficient lube oil pump33.12 Confederation of Indian Industry
Project -1# ACC HDG Tube bundle replacement with SRC bundleApproach: Brainstorming within team & explored opportunityfor low cost & efficient alternative technologywithin & outside India.Technology Adoption: Approached new technology supplier having ACCSingle Row Condenser (SRC) technology at lowcost & high heat transfer efficiency resulting lesserheat & power consumption. Heat transfer co efficient: MRC-HDG- 26.79 Kcal/M2 Hr deg SRC ALE- 36.18 Kcal/M2 Hr deg Confederation of Indian Industry
Project -1# ACC HDG Tube bundle replacement with SRC bundle Result Achieved:ResultsTangible Benefits Savings of Rs. 24.25 Lacs due to savings inFuel(for 3 month Jan-March). Savings of Rs. 5.26 Lacs due to savings in Aux.Power.Intangible Benefits Able to run TG on full load at Peak ambienttemperature. Capable to fulfil the power requirement ofCustomer. Wheeled Power to Sister Unit. Higher Vacuum operation of Mar-18SavingsSp. Steam condense (Kwh/MT)Sp. Power Cons. (MT/Kwh) Power requirement for Steam condensing reducedby 1.06 Kwh/MT. Steam condensation increased by 0.29 MT/Kwh. Confederation of Indian Industry
Project-2 # Instrument and service air Inter connection for Utilizationof maximum VFD drive compressor. Theme: Capacity Utilization of VFD drive compressorinstead of DOL operated service air compressor . Approach:Brainstorming within team & explored opportunityfor: Change DOL drive compressor with VFD drive. How can get maximum out put of VFD operatedand partial loaded instrument compressor. Technology Adoption:Inter connected both air supply line with controlvalve and further air pressure obtained for both byindividual smart flow controller as according torequired process. Confederation of Indian Industry
Project-2 # Instrument and service air Inter connection forUtilization of maximum VFD drive compressor.Individual Auxiliary powerconsumption by compressor.(%) Result Achieved:0.5Tangible Benefits Savings of Rs. 15.6 Lacs due to savings inauxiliary power.Intangible Benefits Able to minimize surrounding area noiseby running single compressor instead oftwo.0.50.40.290.30.20.10FY'16-17 Confederation of Indian IndustryFY'17-18
Project-3 #ACC fan blade replacement with energy efficient fan blade Theme: ACC fan replacement with energy efficient fan. Approach: by Optimizing Fan dia. & no. of Blades Efficiency ղ Q x TPOld Design:Q Airflow (M3 / Second) Dimensions of Fan blades at shoulder(590mm), Tip (590mm) The blade Tip angle (31 Deg), shoulder(45 Deg)TP Total pressure (Pascal) Technology Adoption:1-Selection of High-Grade FRP2- UV Degradation (Epoxy Resin) Composites3-Higher dampening property4-Uniform air flow causing less turbulence and avoidflickering forces on the structure Confederation of Indian IndustryNew Design: Dimensions of Fan blades at shoulder(820 mm) and Tip (290 mm) The blade Tip angle (20 Deg),shoulder (40 Deg)
Project-3 #ACC fan blade replacement with energy efficient fan blade Action Taken: Replaced Existing ACC Fan blades with new energy efficient fan blade in Fan 1 and 4 of Unit-1. Benefit Achieved: Conducted Pre and post flow measurement of ACC Fan in which bladesreplaced. Achieved power consumption reduction by 25% and improvement in flow by10 % at full speed. Resulting saving of Rs. 1.68 Lacs per annum per ACC fan. Confederation of Indian Industry
Utilization of renewable energy sourcesUsage of renewable energy for lighting atTPP HSD Area:125000120934111997108126100136100000 Installed Solar Power Generation at HSDarea : 1000Watts Solar energy : 0.04 % of total powershare75000500002014-152015-162016-17Solar Unit Generation (kwh)Solar Unit Generation (kwh)100KW Solar Power Plant Confederation of Indian Industry2017-18
GHG 014-152015-162016-17TONS OF CO2 EMMISSION Confederation of Indian Industry2017-18
Green Belt Development (Plant, Colony & 137500050000856976873825000092%2012-1391%2013-14No s. of sampling vival rateDeveloped 34% area at Plant/Colony and 61% area at Minesas Green Belt against the statuary requirement of 33%.Cumulative Survival rate 91% Confederation of Indian Industry
Green Belt Development & environment initiativesSapling Distribution to VillagersGround water recharging through injection wellGreen Belt DevelopmentRecognition of student by UH on occasion of Environment day Confederation of Indian Industry
Daily monitoring systemKCW TPP Daily ReportDate 15-Aug-18BudgetUnits Unit-1 Unit-2 Unit-1ParametersTodayUnit-2Total Unit-1 Unit-2Total4/1/2018YTDUnit-2Unit-1TotalA Plant Performance1Avaialbility 95.089.92STG Running 3009.85795.83Plant Load 77.4178.444Gross GenerationKWh13868966 13347360463488437064900552 7465921 65648721403079350919425 535876631045070885Aux ConsumptionKWh1241272 7.657.557.607.347.877.5918.388.628.5026Shut Down PowerKwh000000129726756802054067Aux. Power from Cement Plant Kwh6565130-28-28-56-18183-18183-363668Aux. power including SD7.657.557.607.347.877.5918.638.768.6999Net GenerationMWh428015404071832086 6917588 60481381296572646523486 488927639541624910 Average 817.8036.0811 TG I/L 226812446101aSteam from eam from 12627694 12186140548361 51676212 Sp. Steam 4.2713 Turbine Heat RateKcal/KWH 2643261226322647263926222653263626742631265214 Station Heat RateKcal/KWH 30152980300130173009299030243005.6830533000302615 .4316 71-0.78-0.77-0.78Energy calculation sheetOn line boilers losses calculation Confederation of Indian Industry
Daily monitoring systemOn line Efficiency monitorOn line drive efficiency calculation Confederation of Indian Industry
Review meeting chaired by Well Established energy management cell headed by FH-TPP.FH(TPP) Daily monitoring of Heat rate and Aux. power deviation report. Analysis of equipment performance for deviation. Identification of energy conservation scope.HOD(O&M)HOD(E&I)SH (MECHMAINT.)SH(OPERATION) The e ase suggestio s/Kaize s s he e u der E ergSa i g .MAINTENANCEENGG.PROCESS ENGG. Feasibility study of suggestions & submit proposal for sanction.ELECTRICALENGG. Preparation of detail action plan. Benefits analysis after project implementation. Confederation of Indian IndustryDAILY MEETING STRUCTURESH(E&I)
Methodology for identification of improvement projectsOpportunityidentificationEnergy mappingBench markingLost cost matrixSuggestionIdea generationIdea screeningFeasibility studyTeamformationandallocationof projectteam Confederation of Indian IndustryProjectExecution &review ofprogress ResultAchieved Reward&Recognition
Project implementation through KaizenFIELD OPERATOR AND WORKMANCONCERN (dpt) ENGINEERSAPPROVER COMMITTEEEVALUATION TEAM761100075715001368Suggestion and kaizen steps5000Manthan program for idea sharingKaizen Award Confederation of Indian IndustryKaizen Submission
Project Implemented through workers and supervisorSNIdea1Reduction of boiler bottom ash loss by provided extra air pressureto spreading air for uniform fuel spreading in to furnace.Completed2MDC RAV shaft sealing cold air provided by PA fan out let in placeutilization of compressed. So power saving of compressor.Completed345Coal circuit stand by stream suction damper isolation duringrunning of main circuit. Power saving of bag filter.Pushing air provided to Fly ash conveying system for avoiding linejamming and avoiding continuous utilisation of service air.Utilization of ESP fist field Ash to coal bunker for recycle andreduction of LOI Confederation of Indian IndustryStatusCompletedCompletedCompleted
Implementation of ISO 50001ISO50001Energy Management2015 Confederation of Indian Industry
Energy Management System Policy Confederation of Indian Industry
Awards & Accolades Confederation of Indian Industry
Awards & AccoladesNatio al E erg o ser atio A ard In E elle t E erg Effi ie t U it Iyear 2017.year 2017.Note orth ater effi ie t u itIn year 2017.E elle t E erg Effi ie t U itin yearof 2015. ConfederationIndian IndustryE elle t E erg Effi ie t U itIn year 2016.Note orth ater effi ie t u itIn year 2016.
Awards & AccoladesRajastha E ergCo ser atio ’’ i ear4.E elle t E erg Effi ie t U itIn year 2014.E erg Effi ie t U itIn year 2013.Water Efficient U itin year 2012.Commendation Certificate by the Ministry of Power,Government of India in recognition of efforts made to conservethe energy for year 2012-13 Confederation of Indian Industry
The less you burn, the more you earn.Sincere Thanks.UltraTech Cement LtdKotputli Cement WorksPower Plant Confederation of Indian Industry
UltraTech Cement YYYY Kotputli Cement Work An Aditya Birla Group Company. 2X23 MW Captive Power Plant 3.3 MTPA capacity Green field Cement plant. Certified with ISO 9001, 14001, OHSAS 18001 , ISO 27001, ISO 50001 & ISO 1
Mar 01, 2008 · MSDS: Lafarge Portland Cement Material Safety Data Sheet Section 1: PRODUCT AND COMPANY INFORMATION Product Name(s): Product Identifiers: Lafarge Portland Cement (cement) Cement, Portland Cement, Hydraulic Cement, Oil Well Cement, Trinity White Cement, Antique White Cement, Portland Cement Type I, lA, IE, II, 1/11, IIA, II
Plant Capacity RWCW is the largest unit of UltraTech Cement Ltd. in Eastern Cluster of India RWCW. Integrity Commitment Passion Seamlessness Speed . Conversion of Coal Mill & Cement Mill ESP to Bag house to reduce emissions to 20 Mg/N
Effect of Fineness on Hydration of Cement: 1. When the fineness of cement is more i.e. the size of cement particles is very small; then the all the cement particles gets covered with water film easily. Hence the hydration of cement takes place very quickly with added water. 2. When the fineness of cement is less i.e. the size of cement
Jaypee Cement Groups” . 12500 crores of loans on the books of Jai Prakash associates ltd will move to Ultratech. From being classified as a non-performing asset the debt will be upgraded to AAA status. ICICI Bank played a crucial role in
supplies cement in North Karnataka, Coastal Karnataka, Goa and some parts of Maharashtra The company owns three very renowned regional brands of cement "Jyoti Power" "Jyoti Gold" & "Keshav Cement". Keshav Cement" is a premium brand of the company. 100 % USE OF GREEN POWER 25 YEARS EXPERIENCE 1,100 TPD CEMENT CAPACITY REASONABLE PRICING FY22
Note: This SDS covers many types of Portland cement. Individual composition of hazardous constituents will vary between types of Portland cement. Intended Use of the Product Cement is used as a binder in concrete and mortars that are widely used in construction. Cement is distributed in bags, totes and
3.2.3. Cement Industry Clinker Process and Electricity Use 3.2.4 Fuel Use and Total Energy Consumption in the Cement Industry 3.2.5 Cement Industry Pollutant Releases: CO2, NOX and Toxics 3.2.6 Cement Industry Waste Management 3.3 Regulatory Structure for Waste and Emissions Management 3.3.1 Emission Controls 3.3.2 Cement Kiln Dust Management
Here are a few suggested references for this course, [2,19,22]. The latter two references are downloadable if you are logging into MathSci net through your UCSD account. For a proof that all p{ variation paths have some extension to a rough path see, [21] and also see [9, Theorem 9.12 and Remark 9.13]. For other perspectives on the the theory, see [6] and also see Gubinelli [10,11] Also see .
