19th National Award for Excellencein Energy Management 2018
UltraTech Cement Limited
Unit: Kotputli Cement Works
Presenting Team Members :–
Mr. Rajnish Roshan (Manager Electrical)
Mr. Neeraj Pundir (Asst. Manager WCM/ ISO)
Equipment Make Rated Capacity Benefits
Raw Mill Loesche GMBH 735 TPH Improved energy
efficiency, Easy
maintenanceCoal Mill Loesche GMBH
50 TPH for Pet
Coke
First Vertical
Cement Mill in
UTCL
Loesche GMBH 2 X 215 TPH
Kiln KHD GMBH
8000 TPD on
100% Pet coke
Mechanically
designed for
10000TPD
Six- Stage Pre-
heater twin stringKHD GMBH -
Enhanced heat &
mass transfer
Pyro floor clinker
cooler with roller
crusher
KHD GMBH -
High heat
recuperation
efficiency
Online Cross Belt
Analyzer, XRF (02
nos.), XRD (01 no.)
Thermoscientific,
PAnalytical-
Efficient Quality
Control System
Company Profile
KCW was
commissioned in
the year 2009 with
clinker production
capacity of 3.3
MTPA (10,000
TPD)
GOOD
670
675
680
685
FY16 FY17 FY18
680.4
675.5 675.4
Cement Dispatch (Million MT)Specific Heat Consumption
9300
9500
9700
9900
FY16 FY17 FY18
9494
9753 9772
Cement Dispatch (Million MT)Kiln TPD
Unit Performance – Last Three Years
GOOD
50
52
54
56
58
FY16 FY17 FY18
57.0155.33
53.65
Cement Dispatch (Million MT)Sp. Power Upto Clinkerisation (KWH/MT Clk)
72
74
76
FY16 FY17 FY18
74.43
75.57
73.53
Cement Dispatch (Million MT)Overall Sp. Power Cons. (KWH/MT cement)
GOOD
GOOD
Unit Energy Performance Comparison: At A GlanceWith benchmark/cluster units performance (Year 2017-18)
Overall sp. Power Consumption (Kwh/MT cement)
Sp. Heat Consumption (Kcal/kg clinker)
647
675 677 675
687
650
660
670
680
690
International Benchmark
National Benchmark ACC Cement Kotputli Cement(UTCL)
Vikram Cement(UTCL)KCW
64.00 65.05 64.50
73.53
65.70
40
60
80
100
International Benchmark
National Benchmark Reddipalyam(UTCL)
Kotputli Cement(UTCL)
J K Cement
Ref- For International Benchmark report of Industrial Energy Efficiency Benchmarking Report for Cement Sector by United Nations Industrial Development Organization. Ref. For National Benchmark Data Best Thermal energy efficiency award by NCCBM & CII Energy benchmarking for cement Industry Ver-2 May-15
GOOD
GOOD
➢ Adopting Digitization by Installation of plant optimizer in Raw Mill, Cement Mill
operation for performance improvement.
➢ Installation of WHR (16 MW)
➢ Retrofitting/ replacement of Energy efficient fans at Major Fans.
➢ Increasing TSR by executing CAPEX for AFR feeding system.
➢ Modification in Pre heater by increase in height of stage –II cyclone roof along
with riser duct, cyclone inlet portion modifications for both Strings for pressure
drop reduction.
➢ Replacement of existing Cooler with high efficiency cooler
Road Map for Benchmarking
GtG energy consumption status
993
937
711670 641 656
400
600
800
1000
1200
2009-10(Baseline year)
Target SEC forPAT cycle 1
ActualPAT Cycle 1
BaselinePAT Cycle 2
TargetPAT Cycle 2
Status PATCycle 2
Kcal
/kg
PP
C E
qu
iv.
No. of Energy Saving Certificates 37153
Unit is registered as Designated Consumers (DC) under PAT scheme.Target given for 4.32 % reduction in GtG Specific Energy Consumption for PAT
Cycle-2 (FY18-19)
28.40 % reduction
PAT Status
SN. Energy Saving theme
Energy Saved/yr Savings(Rs.Lac/yr)
Elect (MWH)
Thermal (Mkcal)
1Start of cold meal injection system for eliminating coating formation & reducing cleaning process by water jet
- 6499 67.5
2 Raw Mill cyclone dip tube modification 231.9 - 67.5
3Heat of formation reduction by Raw Mix optimization
- 2559 22.1
4
Reduction in Limestone, Additives & Coal transport Idle run hours for power optimization by DCS interlocking w.r.t to load (KW).
850 - 34.0
5Maintaining A/S ratio for enhanced petcokeutilization with stable operation by Raw Mix optimization
- 2973 25.6
Energy saving initiatives with Zero Investment
SN. Energy Saving theme Energy Saved/yr Savings(Rs.Lac/yr)
Elect (MWH)
Thermal (Mkcal)
6Pressure drop reduction of cooler fans (11 Nos.) by removing louvre dampers
643 - 22.50
7Removal of all Flow regulators(MFR) from chamber-2 ,3,4 & 5 of cooler resulting in chamber pressure reduction
428 4284 53.30
8Optimization of 2 coal firing blowers by line modification &running at low air to material ratio
257 - 9.0
9Cement mills power reduction by optimizing the reject circuit running hrs
82.2 - 2.90
10Reduction in packing plant bag filter fan power by change in drive system
576 - 20.20
11 Reduction in idle running of cooling tower fan 12.96 - 0.50
Energy saving initiatives with Zero Investment
SN. Energy Saving theme Energy Saved/yr Savings(Rs.Lac/yr)
Elect (MWH)
Thermal (Mkcal)
12Optimization of preheater water spray system
362 18.10
13Optimization of coal firing blower RPM after burner modification
161 8.0
14Stopping of cooling air fan after burner modification
137 6.80
15Reduction in Gypsum feeding circuit idle running hrs
21 1.0
16Scoop plate installation to enhance cement mill productivity
27 1.40
17Power reduction by changing 56 nos. motor connection from delta to star
113 5.60
Total 3902 16315 366
Energy saving initiatives with Zero Investment
SN. Energy Saving theme
Energy Saved/yr Savings(Rs.
Lacs/yr)
Invest(Rs. in Lacs)
Payback (months)Elect
(MWH)Thermal (Mkcal)
2015-16
1Fuzzy logic installation for Kiln /Cooler
269 584 15.8 47.0 36
2Installation of castableretainer in DSC toenhance refractory life
- 1038 8.90 3.0 4.0
3
Increased therecuperation efficiencycooler by airflowmodification
- 6225 28.9 1.0 0.42
4
Modification in cooler water spray for minimizing water cons. & cooler outlet temp.
- 6225 53.7 0.5 0.11
Energy saving initiatives with Investment
SN. Energy Saving theme
Energy Saved/yr Savings(Rs.
Lacs/yr)
Invest(Rs. in Lacs)
Payback (months)Elect
(MWH)Thermal (Mkcal)
5
Reduction in pressuredrop by installing baffleplate in all 4 nos. topcyclones of Preheater
1345 - 53.8 1.0 0.22
6
Preheater top cyclone water spray system installation for reducing power
721 - 28.9 94 39
7Installation of Static synchronous compensator (STATCOM)
591 - 23.6 18.7 9
8Replacement of kiln firing root blower with screw compressor
232 - 9.3 5.4 70
Energy saving initiatives with Investment
SN . Energy Saving theme
Energy Saved/yr Savings(Rs.
Lacs/yr)
Invest(Rs. inLacs)
Payback (months)Elect
(MWH)Thermal (Mkcal)
9Removed venturi from Cement Mill 1 Bag House fan inlet duct
221 - 8.8 5 7
10Removed venturi from Raw mill fan inlet ducts
311 - 28.0 3 1.28
118 Watt CFL in colony replaced by 5W LED lamps
1.4 - 0.1 0.5 105
Energy saving initiatives with Investment
SN . Energy Saving theme
Energy Saved/yr Savings(Rs.
Lacs/yr)
Invest(Rs. inLacs)
Payback (months)Elect
(MWH)Thermal (Mkcal)
2016-17
12Pressure drop reduction of cooler fans (11 Nos.) by removing Silencers
279 - 9.70 1.50 2
13Optimization of compressor run hrs by various modifications
236 - 8.20 8.0 12
14PH Fan inlet duct enlargement
300 - 10.50 11.0 13
15Removal of venturi from Cement Mill-2 Fan inlet duct
198 - 6.10 0.50 1
Energy saving initiatives with Investment
SN . Energy Saving theme
Energy Saved/yr Savings(Rs.
Lacs/yr)
Invest(Rs. inLacs)
Payback (months)Elect
(MWH)Thermal (Mkcal)
16Raw Mill table liners & rollers replacement
3342 - 117 107 11
17
Radiation losses reduction by attending all areas of refractory wear & tear
- 2142 19.10 1.0 1
18Extending the Thermal wall(Null point) by 800mm for retaining heat
- 3213 28.70 1.0 0.4
19Installed PID based VFD at Post clinker compressor house
277 - 9.70 8.50 11
20Installed PID based VFD at Pre Clinker compressor house
149 - 5.20 8.50 20
Energy saving initiatives with Investment
SN . Energy Saving theme
Energy Saved/yr Savings(Rs.
Lacs/yr)
Invest(Rs. inLacs)
Payback (months)Elect
(MWH)Thermal (Mkcal)
21Installed Energy Efficient Pump at Pre Clinker Pump House
30.5 - 1.10 11.0 124
22Cement Mill -1 Bag house Fan Inlet Box enlargement
95.13 - 3.30 0.50 2
23Cement Mill -2 Bag house Fan Inlet Box enlargement
94.18 - 3.30 0.50 2
24Reduction in separator power of cement mills by removing slave roller
113 - 4.0 2.80 8
25Energy saving by replacing existing conventional light fittings with LED light
53 - 1.90 21.0 136
Energy saving initiatives with Investment
SN . Energy Saving theme
Energy Saved/yr Savings(Rs.
Lacs/yr)
Invest(Rs. inLacs)
Payback (months)Elect
(MWH)Thermal (Mkcal)
2017-18
26VFD installation in Raw mill bag filter fans
237 - 11.90 1.50 2
27Lower RPM motor installation in bag filter fan
119 - 5.90 1.50 3
28Installation of VFD in Pyro-1 coal firing blower
241 - 12.10 4.50 4
29Raw Mill fan inlet duct enlargement
151 - 7.50 10.0 16
30Installation of energy efficient pump in post Clinkerisation pump house
257 - 12.90 4.20 4
31Usage of AFR in place of petcoke
- 7277 20.20 3.06 2
Energy saving initiatives with Investment
SN . Energy Saving theme
Energy Saved/yr Savings(Rs.
Lacs/yr)
Invest(Rs. inLacs)
Payback (months)Elect
(MWH)
Thermal (Mkcal)
32Energy saving through change drive system of packer bag filter fans.
346.6 - 16.04 3.28 2.5
32Power saving by replacing existing conventional light fittings with LED light fitting.
85 - 4.20 24.20 68
33Enhancement in burner pipe castable life by using new generation hasle castable
- 455 24.4 8.0 4
34Classifier area reduction of cement mill separator
544 - 2.70 4.0 18
Total 10839 27159 605.44 426.14 9
Energy saving initiatives with Investment
Project 1 – Energy saving through change drive system
Objective:-
Energy saving through change drive system of packer bag filter fans (8 nos fan)
Project Description
➢ Packer bag filter fans was direct coupled drive and run at 1500RPM consuming
around 35-37 KW per fan
➢ All the fans were damper controlled
➢ We worked out the optimum RPM to control the dust emission and resulting
power reduction.
➢ Changed the drive system from coupling to belt drive, installed 265 PCD pulley
at motor and 315 PCD pulley at fan side.
Before
After
Results:-
1. Reduction in fan RPM from 1485 to
1260
2. Power saving of 12 KW per fan.
3. Cost Saving of 16.08Lacs/annum
Project 1 – Energy saving through change drive system
Project 2 - Energy Saving by installing energy efficient Pump
Objective:-Installing energy efficient pump at Post Clinker Pump house to minimise power consumption of parallel pumping system.
Project Description:-For post clinker cooling water system two pumps are operating in parallel and supplies cooling water from underground water tank mainly to compressor house, Cement Mill-1 & 2.
Parallel operating efficiency of pumps 531WP-1 & 2 is 67.4%. It is less than design value of 76%. Individual pump efficiency is measured 68%. (less than design).
Considering above energy efficient pump of 45KW (2 no’s) at 531WP-1 and 531WP-2 is installed.
Post clinker – Cooling water system layout
Results:-
1. Saving of 32.0 KW achieved on overall loading of post clinker pumping system
2. Cost Saving of 12.90Lacs/annum
Project 2 - Energy Saving by installing energy efficient Pump
Project 3 - Energy saving through by modification in identified bag filters fans
Objective:-
Energy saving through by modification in identified bag filters fans at Raw Mill.
Project Description:-➢ 331BF1 bag filter fan was running with 60% damper opening to have effective
purging and pressure loss across the damper is 300mmwc.
We Installed VFD for above bag filter fan, and removed damper control
➢ 331BF2 bag filter fan was running with 60% damper opening but pressure loss across the damper is 310mmwc.
We Installed VFD for above bag filter fan, and removed damper control
Results:-
➢ Total reduction of 60KW achieved.
➢ Cost Saving of 16.5Lacs/annum
Project 3 - Energy saving through by modification in identified bag filters fans
➢ 361BF5 bag filter fan was running with 60% damper opening to have effective purging and pressure loss across the damper is 380mmwc.
Installed Lower KW (37 to 30KW) and RPM (1500 to1000) Motor.
S.N. Energy Saving theme
Potential Energy Saving Target For
CompletionElect (MWH)
Thermal (Mkcal)
1. Installation of expert optimizer in Raw mill 1200 - Jun-18
2.Installation of expert optimizer in Cement Mills
1350 - Jun-18
3.Installation of VFD in raw mill transport bag filter fan
59 - Nov-18
4.Incorporating the baffle plates in stage IV cyclone riser duct for both the strings
950 - Jul-18
5.To increase the height of stage –II cyclone roof along with riser duct, cyclone inlet portion modifications for both Strings
634 - Jul-18
6.VFD installation in Clinker silo top bag filter fan
95 - Dec-18
Plan matrix for Future ENCon Projects
S.N. Energy Saving theme
Potential Energy Saving Target For
CompletionElect (MWH)
Thermal (Mkcal)
7.Retrofit of bag house fan (kiln bag house) with high design operating efficiency fan
836 - July-19
8.Improve efficiency of Pre heater fan-2
514 - July-18
9.Installation of VFD at compressor (Pre and Post clinker)
524 - Dec’18
10.Optimising efficiency of pre and post pumping system
296 - Mar-19
11.VFD installation in Pyro-2 coal firing blower
238 - Jul-18
Plan matrix for Future ENCon Projects
S.N. Energy Saving theme
Potential Energy Saving Target For
CompletionElect (MWH)
Thermal (Mkcal)
12.VFD installation in cement mill bag filter fans
198 - Dec-18
13.Retrofit of cement mill bag house fans due to low efficiency of fans
1350 - Jan-19
14. Installation of WHR system 3960 - Mar-19
15.Installation of modular lining (Hasle) in all feed pipes of cyclones.
- 4148 Jul-18
16. Usage of AFR upto 1.0% TSR - 22000 Mar-19
Total 12204 26148
Plan matrix for Future ENCon Projects
Utilization of Renewable Energy sources/ Waste Material
➢ Solar Power Generation (kwh)
0
50000
100000
150000
2015-16 2016-17 2017-18
10
81
26
10
01
36
11
19
97
Utilization of waste material
➢Use of Fly ash up to 34.2 % in PPC production
➢Use of Rubber chips, Plasticwaste,FMCG Waste in fuel firing
➢Use of wet Flyash about 10% of total PPC production.
➢ REC purchased 12499 solar certificates under RPO
2000400060008000
1000012000
FY15 FY16FY17
FY18
4543 4762 5792
11715GOOD
Municipal Solid Waste PLANT : JAIPUR
102% increase over last year Production
Utilisation of Waste Material as Fuel
0
0.2
0.4
0.6
0.8
% TSR
2017-18 2018-19 (YTD-July'18)
Enrichment in TSR by increasing usage of AFPLASTICWASTE, AFRUBBERCHIPS and AFFMCGWASTE as an AFR
Proposed AFR feeding arrangement .
Capacity - 3000 Tons Per
TSR - 25%
Status:
• Proposal prepared and submitted,
• Capex proposal to be submitted by 10th
Sept’18
• Estimated cost Rs. 1800 lacs.
Utilisation of Waste Material as Fuel
GOOD
CO2 Emissions (kg CO2/ton of Cementitious product)
660
670
680
690
700
FY15-16 FY16-17 FY17-18
677.00
699.00
680.00
GHG Inventorisation
Green Supply Chain
❖ While procuring the Motors, AC’s, luminous products & refrigerators we are incorporating the Clause of Energy efficient Products needs to be supplied with ratings mentioned.
❖ Implemented usage of Day light in Main Stores/Brick go down there by decreasing the Power consumption.
❖ Implementation of RTGS/NEFT for making online payment instead of Cheque Process there by reducing the Paper Consumption.
❖ Increasing the Vendor Management inventory to save multi packing & Shipments.
❖ Re-use of incoming boxes for outgoing materials.
❖ Reduction of carbon foot print by developing the reverse logistics & reduce the Co2 emissions.
Unit Head
FH(Tech)
Crusher & RMCH Raw Mill
Kiln & Coal Mill
Cement Mill
Packing Plant
S.No. Monitoring and reporting
1 Daily Power Report
2Daily Section Performance Review Report
3 Daily Compressor Power Report
4 Daily HOF Optimization Report
5 Daily Idle run hrs report
Opportunity identification
Energy mapping
Bench marking
Lost cost matrix
Suggestion
Idea generation
Idea screening
Feasibility study
Returnable CAPEX
proposal and
sanction
Separately budgeted
Team formation
Project Execution
Review of progress
Result Achieved
Reward & Recognition
Methodology for identification of improvement projects
EVALUATION TEAMAPPROVER
COMMITTEECONCERN (dpt)
ENGINEERSFIELD OPERATOR AND
WORK MAN
Suggestion and kaizen steps
Kaizen Award
13001350140014501500
13
68 14
26 14
84
Approved Kaizens
Manthan program for idea sharing
Celebration of Energy conservation month
Training program on Energy Conservation and efficiency / ISO-
50001 system
ISO 50001-2011 Energy Policy Carbon Policy
Major Achievements
Reduction in sp. water consumption by proper monitoring & metering in each Section
➢ Water Balance Index of Ultratech Cement Limited - 2.18 (Positive)
➢ Water Balance Index Kotputli Cement Works - 2.46 (Positive)
Result declared on Apr’30 2018 by External agency DNV.GL
Consequently won second cycle of ABG WCM Gold award in 2017 (Previous -2015)
38
Under category of Thermal Power Stations
(Less than 100MW Coal & Gas) Sector.
Award received on 14th Dec 2017 at Vigyan Bhavan, New Delhi by honorable
President of India
National Energy Conservation Award 2017 (First Prize)
NCCBM National Award for Best Thermal Energy Performance
Received on 08th Dec 2017 At New Delhi in 15th NCB International Seminar
National Benchmark in Specific Heat Consumption
CII Energy Efficient AwardConsecutively 6th year..
