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1 Hirmi Cement Works Energy Management
ABG : Business Diversity
2
Hirmi Cement Works
Jafrabad Cement
Works
Magdalla Cement
Works
Ratnagiri Cement
Works
Andhra Pradesh Cement
Works
Arrakonam Cement
Works
Awarpur Cement
Works
Jharsuguda Cement
Works
West Bengal Cement
Works
Bathinda Cement
Works
Aditya Cement
Vikram
Cement
Gujarat Cement
Works
Kotputli Cement
Works
Hotgi Cement Works
Rajashree Cement
Works
Ginigera Cement
Works
Panipat Cement
Works Dadri Cement
Works Aligarh Cement Works
RWCW
Reddipalayam Cement
Works
Integrated plant
Grinding unit
Bulk terminals Mangalore Cement
Unit BSBT-
Dodballapur
Shankarapally Bulk
Terminal
Navi Mumbai Cement
Unit
3
Hirmi Cement Works
HCW Clinker contributes 7 %
Of UltraTech
Hirmi Cement Works
ABG - Largest Cement Producer in India.
5
Introduction
• Plant Clinkerization capacity is 2.75 Million tons.
• Plant is a single line Kiln, two VRMs for Limestone Grinding, One
VRM for Coal Grinding and two closed circuit Cement mills. All
major equipment's are supplied by FLS.
• High Kiln Volumetric loading – 7.35 TPD / M3 @ 8000 TPD.
• Most of the capacity enhancement through Kaizens, modifications
& optimisation without any major Capex.
• Rated 4 Star by Whitehopleman International benchmark.
• BCE Green Plant and won Chairman WCM Gold award in 2015.
OPC- 43 [IS : 8112-2013]
PPC- (UltraTech PPC) [IS : 1489-Part-I 1991]
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Plant Performance
0
1
2
3
4
5Kiln Productivity
Sp. Heat consumption
Sp. Electrical energyconsumption
Safety
IMS muturity
BCE
WCM
Quality
Environment
Variable cost
Target Actual- 2014-15 Actual 2015-16 Projected 2016-17
Rated 4 * by Whitehopleman International benchmarking
“CII-ITC sustainability award 2009”
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Awards
“CSR Planet Award 2012”
“DL Shah National Quality Award-2013”
“CII Energy award 2013”
“WCM Silver Award 2013”
“FIMI Award 2014”
“CII-ITC sustainability award 2014”
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Awards
“CSR Planet Award 2014”
“NSC Safety Award 2016”
“CG State Energy award 2014”
“IMC RBNQA- Performance excellence Trophy 2014”
“WCM Gold Award 2015”
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Energy Cell Structure (HCW)
Joint Executive President (Unit Head)
FH (CPP) FH (F&C) FH (Tech) FH (MIN) FH (HR)
HOD (TS) Energy Manager HOD-TPP
GRT
Energy Cell Leader HOD- Electrical
Members-Process, Mechanical, Electrical. Instrument, Technical
Services, CPP
Energy Policy
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UltraTech Cement Limited Hirmi Cement Works
Energy Management Policy
We are committed to conduct our operations by utilizing various forms of energy in the most cost effective and efficient manner so as to conserve energy resources and to make cleaner environment for our future generation. Our emphasis is to: Adopt energy conservation measures to enhance energy
efficiency. Monitor & control the consumption of energy through effective
energy information system & through periodic reviews. Create awareness through training amongst all Employees as
part of Mass Energy Conservation Movement Carry out regular energy audits through internal / external
resources / agencies to identify areas of improvement.
Unit Head
• To create a unit wide awareness and practical understanding of energy efficiency improvement opportunities.
• To remove the energy losses through problem solving tools, and to increase overall plant effectiveness.
• To motivate employees for continuous improvements in energy efficiency.
• To develop robust system for data measurement and analysis which leads to improvement.
• To develop effective & systematic knowledge management system.
Objectives
Energy Cell- Focus Area
Energy Cell Functioning Focus Area
Restoring basic condition of equipment
Effective PM07 / PM01
Process/energy optimisation
Technological up-gradation
Awareness / Champaign
Knowledge management
Focus Area- • Crusher- Granulometry • Raw Mill- RM Fan and Table
Power, Separator performance • Coal Mill- Fan & Table \ ,
Separator performance • Kiln-KS, CS & CV Fan, False air • Cement Mill- MD Power,
Separator & Fan performance • Compressor- Volumetric
efficiency, Leakage
Energy Cell- Focus Area
Energy Cell Functioning Focus Area
Restoring basic condition of equipment
Process/energy optimisation
Technological up-gradation
Awareness / Champaign
Knowledge management
Focus Area- • Crusher- Hopper empty, Idle
running • Raw Mill- Start/Stop, Feed rate • Coal Mill- Start/Stop, Feed rate • Kiln- TPD, False air, Heat
consumption • Cement Mill- Start/Stop, Feed
rate, Fly ash quality, Grinding aid • Packing plant- TPH • Compressor- Running hr, Leakage
Energy Cell- Focus Area
Energy Cell Functioning Focus Area
Restoring basic condition of equipment
Process/energy optimisation
Technological up-gradation
Awareness / Champaign
Knowledge management
Focus Area- • External energy audit- Once
in a three year • Internal energy audit-
Annual • Technology benchmarking
Focus Area- • Kaizen Mela • Competition
Focus Area- • Participation in conference/
seminar • KIP
Annual Business
Plans
Technical Journals,
Consultants etc.
KIP Visit, Best practices
Energy mapping
Plant performance
Report
Audit process
Bench- marking
report Loss & Cost
Report
Problems / Opportunities
for Improvement
Identified
Identification of Opportunities
Project Execution
Project Identification
Review & Approve Project, issue project charter
Form the team for execution of Project
Prepare action plan for implementation of Project
Execute as per the Action Plan
Monitor the results of the Project with target, take necessary action if deviation observed
Complete the Project, submit project report for final review, establishment of results & sharing of Learning
Review of Projects on periodic basis for
necessary changes
Energy Mapping
Approach- • Capturing and reviewing drive wise power consumption for each
section. • Real time data made available to all employees & HO through PI
and PG. DEPARTMENT PARTICULARS
ON DATE
PROD.
ON DATE R
Hrs ON DATE TPH ON DATE UNITS
ON DATE
UNITS/Hrs
ONDATE/MT
MAT
TARGET /MT
MAT DEVIATION
MONTH TO
DATE/MT MAT
LS CRUSHER
A.LSCR1 MAIN DRIVE 16,218.00 13.69 1185 6,280 459 0.39 0.32 0.07 0.4
B.LSCR1 AUX 0 0 17,052 0 1.05 1.06 - 0.01 1.15
SUBTOTAL : 16,218.00 13.69 1185 23,332 1,704 1.44 1.38 0.06 1.55
RAW MILL-1
A.RM1 MAIN DRIVE 6,909.00 23.42 295 60,720 2,593 8.79 8.7 0.09 8.88
B.RM1 FEED 4,211 180 0.61 0.57 0.04 0.61
C.RM1 FAN 49,180 2,100 7.12 7.22 - 0.10 7.29
D.RM1 AUX 3,014 129 0.44 0.5 - 0.06 0.49
E.RM1 AIR LIFT/BBE 2,211 94 0.32 0.33 - 0.01 0.33
F.RM1 WATER SUPPLY 322 14 0.05 0.06 - 0.01 0.06
G.RM1 COMPRESSOR 1,612 69 0.23 0.2 0.03 0.23
SUBTOTAL : 6,909.00 23.42 295 1,21,269 5,178 17.55 17.58 - 0.03 17.87
RAW MILL-2
A.RM2 MAIN DRIVE 7,062.00 24 294 63,390 2,641 8.98 8.7 0.28 8.99
B.RM2 FEED 4,305 179 0.61 0.57 0.04 0.61
C.RM2 FAN 55,150 2,298 7.81 7.22 0.59 7.78
D.RM2 AUX 2,501 104 0.35 0.44 - 0.09 0.39
E.RM2 AIR LIFT/BBE 2,259 94 0.32 0.33 - 0.01 0.33
F.RM2 WATER SUPPLY 329 14 0.05 0.06 - 0.01 0.06
G.RM2 COMPRESSOR 1,647 69 0.23 0.2 0.03 0.25
SUBTOTAL : 7,062.00 24 294 1,29,581 5,399 18.35 17.52 0.83 18.42
RAW MILLS TOTAL : 13,971.00 47.42 295 2,50,850 5,290 17.96 17.55 0.41 18.17
COAL MILL
A.MAIN DRIVE 1,129.82 16.34 69 8,820 540 7.81 9.11 - 1.30 8.31
B.FAN 8,640 529 7.65 8.95 - 1.30 8.41
C.AUX 3,208 196 2.84 5.8 - 2.96 4.01
D.COMPRESSOR 4,345 266 3.85 2.75 1.10 3.37
SUBTOTAL : 1,129.82 16.34 69 25,013 1,531 22.14 26.61 - 4.47 24.09
KILN
A.KILN MAIN DRIVE 8,186.00 24 341 12,150 506 1.48 1.5 - 0.02 1.49
B.KILN FAN J1J01 27,260 1,136 3.33 3.05 0.28 3.43
C.CALC FAN J1J03 54,020 2,251 6.6 6.35 0.25 6.38
D.MAIN ESP FAN 22,030 918 2.69 2.7 - 0.01 2.71
E.KILN FEED 10,294 429 1.26 1.51 - 0.25 1.3
F.COAL XPORT 12,120 505 1.48 1.42 0.06 1.53
G.COOLER&CLKR
XPOR 52,369 2,182 6.4 6.65
- 0.25 6.63
H.W1P21 ESP FAN 1,150 48 0.14 0.32 - 0.18 0.33
I.WIP31 ESP FAN 2,285 95 0.28 0.35 - 0.07 0.36
J.WATER SUPPLY 1,301 54 0.16 0.2 - 0.04 0.17
K.COMPRESSOR 3,259 136 0.4 0.29 0.11 0.36
L.DUST TRANSPORT 9,530 397 1.16 1.46 - 0.30 1.27
SUBTOTAL : 8,186.00 24.000 341 2,07,767 8,657 25.38 25.8 - 0.42 25.97
Review- • Review of Power
Consumption done in the daily production meeting, energy meeting and MPR meeting.
Bottleneck Analysis of HCW
4000 4500 5000 5500 6000 6500 7000 7500 8000 8200 8500 9000 9500 10000
Cooler
Clinker DBC
Coal Firing
Tertiary Air Duct
PH Fan
Kiln PH
Kiln Feed B.E.
Silo Extraction
Coal Mill
Raw Mill
Stacker
Crusher
4000 4500 5000 5500 6000 6500 7000 7500 8000 8200 8500 9000 9500 10000
Design potential of HCW
Bottleneck removed through Systematic Improvement
Bottleneck to be removed
Loss & Cost Matrix
Deployment- Developed Loss matrix for each area.
Approach- • Team wise SQCDIP for each section captured and analysed on
monthly basis through online software Confluence. • Monthly team level competition is done and best teams are
recognised.
SQCDIP Monitoring
Approach-
• Monthly heat balance.
• Quarterly audit for fan system.
• Weekly review of false air in RM and Kiln.
• Quarterly audit of Cement Mills.
• Six monthly audit of Raw Mills, Coal Mill and Kiln.
• Six monthly assessment for Compressors and blowers.
• External audit through CTES or other reputed party on once in a
three years.
Energy audit
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Project – 1- Turbo Blower
Baseline Power- 115 KW
Present power- 55 KW
Saving- 60 KW
Project – 2- Compressor Optimisation
Before After
Loading Pressure 6.6 Kg/cm2 6.1 Kg/cm2
Unloading Pressure 7.0 Kg/cm2 6.3 Kg/cm2
Before After
No of compressor in operation
4 at Pre + 3 at Post
2 at Pre + 2 at Post
Power saving -
5000 kWh per day = Rs 80 lacs
annually
EQUIPMENT Saving, kWh
CALCINER FAN 99.57
RAW MILL ESP 92.34
COAL MILL 6.47
COOLER ESP 26.36
COOLER ESP 31.95
Project 3- Cone Correction
Cone gap correction Cone replacement in RM-2
RM-2 Fan efficiency improved by 5.5% with new cone and anti swirl plate
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Project 4- Raw mill 1 Energy Efficiency
SN Action Point
1 Raw material size optimised by optimising Grinding path in Crusher.
2 Fan flow optimized with Separator vis a vis required residue.
3 RM 1 & 2 Separator top seal gap modified.
4 Water spray optimised- 12 m3/hr to 8 m3/hr.
5 Dam ring height reduction.
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Separator Seal Gap
Modifications done in Separator Inner Seal Plate – Increased by 150mm
Before After
• Coal Mill out put increased by 2 TPH- Sp. Power reduced by 0.1 kWh/T of Coal
• Cement Mill by Pass reduced by 3 %. Saved 0.2 kWh/T of material.
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Reduced Dam ring Height
Before After
185mm 195mm
RM Dam ring
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Benefits
286.7
291.3 295
280
285
290
295
300
Mill, TPH
Mill 1 and 2 TPH
2013-14 2014-15 2015-16
Good
18.23
17.99
17.82
17.6
17.8
18
18.2
18.4
Sp. Power, kWh/MT
Mill 1 & 2 Sp. Power, kWh/T
2013-14 2014-15 2015-16
Good
Annual gain in 2015-16 is more than Rs 60 Lacs.
Project 5-Sp. Power consumption reduction in Coal Mill- Stopped Booster Fan
• Installed a by-pass
duct to pass hot
gas directly to Mill.
• Stopped Booster
Fan except during
rainy season.
• Saving 60 kWh.
• Annual saving
potential- 50 X 22 X
(330- 45) days X 4.5
Rs/kWh = Rs 14.1
Lacs
• Saving 0.1 unit/ MT
Clinker.
Project -6 - Cement Grinding Optimisation
Before
After
• Grinding media filling reduced from 29% to 25%. Mill rate reduced by
5 TPH from baseline of 195 TPH.
Drying chamber removal
BEFORE AFTER
Mill with drying chamber Mill without drying chamber
• Sp. Power reduced by 1.35 kWh/MT of Cement in PPC Grade.
• Saving is equivalent to Rs 109.3 Lacs annually
Project -7- Fly Addition
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Better
Improved conversion factor in PPC -
• By usage of Pet coke in Kiln.
• By improvement in clinker C3S .
• By improvement in fly ash quality.
• Use of GA
29.4 30.2
33.3
5.0
10.0
15.0
20.0
25.0
30.0
35.0
2013-14 2014-15 2015-16
Fly ash % in PPC
Operating 800 KW Solar plant to meet RP Obligation
Year Lac Units
Generated
2013-14 9.68
2014-15 9.28
2015-16 9.67
Project 8- Renewable Energy Initiatives
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Way Forward
Sustenance of Kiln up time & OEE.
Enhancing fly ash usage factor up to 34.5% in PPC.
Reduction of Top Stage Preheater Cyclones Pressure Drop.
Installation of new burner for partial reduction of NOx and PA.
Installation of Turbo Blower in Calciner firing.
Inlet Cone and anti swirl plate replacement in RM-1 Fan.
Pressure drop reduction in KS Fan inlet box.
Thanks !!
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