UltraTech Cement Limited Hotgi Cement Works€¦ · Hanumanthappa - Manager 3. Mr. Viwek Zode...

UltraTech Cement LimitedHotgi Cement Works

Team Members

1. Mr. Kasi Viswanadham – Deputy General Manager

2. Mr. Hanumanthappa - Manager

3. Mr. Viwek Zode – Asst. Manager

August 2020

1.a. Unit Introduction – Plant Details

ULTRATECH CEMENT LIMITED, HOTGI CEMENT WORKS

Land Acquisition – 265 Acres 1994

Line-1 commissioned – Capacity 1.2 MTPA Products – OPC 43, OPC 53, PPC & PPCS

23 July 1995

Introduction of PPC at Line 1 - Capacity enhanced by 0.8 MTPA Total Capacity 2 MTPA

2008

Line-2 commissioned with Capacity – 2.0 MTPA Products – OPC 43, OPC 53 & PPC

20th March 2013

Total Plant Capacity is 4.0 MTPA

Located at South Solapur, Maharashtra on Mumbai – Hyderabad broad gauge line Caters market of entire South-West Maharashtra.

1.b. Unit Introduction – Process Overview

Clinker from RCW

BCCW Rake

2. Energy Consumption Overview

Overall Energy consumption data

YearElectrical Energy

(kwh)Thermal Energy

(Kcal)Total Energy

(TOE)

2017-18 70619000 0 6072.14

2018-19 61646000 0 5300.60

2019-20 68315000 0 5874.03

100

0

Total Energy (%) Consumed 2019-20

Electrical Energy (kwh)

Thermal Energy (kcal)

100% Electrical Energy consumption

3.a. Sp. Energy Consumption – Product Specific(FY 2017-20)

26.28

26.0726.03

25.9

25.95

26

26.05

26.1

26.15

26.2

26.25

26.3

2017-18 2018-19 2019-20

OPC Grade Sp. Power kwh/MT

2017-18 2018-19 2019-20

25.4525.31

24.58

24

24.2

24.4

24.6

24.8

25

25.2

25.4

25.6

2017-18 2018-19 2019-20

PPC Grade Sp. Power kwh/MT

2017-18 2018-19 2019-20

Grade Improvement %

OPC 0.95

PPC 3.42

Reasons for improvement

Installation of Thin classifying Liners

C-194 Seperator fan impeller replaced.

Installation of Expert Optimizer

Grinding Media Regradation

3.b. Sp. Energy Consumption – Section Wise(FY 2017-20)

25.95

0.7522.81

25.74

0.7542.88

25.55

0.6652.57

0

5

10

15

20

25

30

Total Grinding Power Packing Power Misc. Power

Sp. Power – Section Wise

2017-18 2018-19 2019-20

Section Improvement % Reason for variationGrinding Power 1.54 Thin classifying liners, Expert Optimizer, C-194 Impeller

replacement, Grinding Media Regradation, VFD operated bag filters, Roller profiling in every six months etc.

Packing Power 11.57 Wagon loading bay extension, VFD operated bag filters, Increase in Packer speed, Increase in BCCW dispatches, installation powerless bag diverters etc.

Misc. Power 8.54 VSD compressors in place of IR, AC energy savers, reduction of idle running of equipment's, Installation of LED lights utilization of only one cooling tower in monsoon etc.

4.a. Benchmarking(RP +Ball Mill Circuit)

Internal Benchmarking

Line Present Sp. Power Kwh/MT

External Benchmark kwh/MT

CM 1 25.09 24.37

CM 2 26.49 25.90

Grade Present Sp. Power Kwh/MT

Internal Benchmarkkwh/MT

OPC 25.30(Lowest across UTCL)

25.30

PPC 26.27(3rd lowest across UTCL)

25.68

** Normalized SPC (kWh/MT) of PPC in RP+ Ball Mill Circuit at 380 m2/kg cement Blaine, 30 % fly ash & 300 m2/kg fly ash Blaine

Benchmarking Source: UltraTech Technology & Performance Monitoring Cell Benchmarking report

External Benchmarking

Benchmarking Source: In reference to CII Energy benchmarking report for Indian Cement Industry (May 2019, V-4).

Short term & Long Term Target


Short Term Target (Mar’21)kwh/MT

Long Term Target (Mar’22)kwh/MT

CM 1 25.09 24.71 24.37

CM 2 26.49 26.20 25.90

4.b. Encon initiatives planned in 2020-21

S.No Encon projects planned in 2020-21Approx. SavingsLac units/annum

1 Installation of separate Kaiser compressor for Line-2 bulk Loading operation. 1.08

2 Direct coupling of bag filter fans (4 Nos) at line 1 0.69

3 Direct coupling of bag filter fans (4 Nos) at Packing plant 0.43

4Installation of Powerless diverters in place of motorized diverters (3 no's) in Packing plant

0.18

5Replacement of 70 watts conventional lights with 18 watts LED lights in phase manner (60 no's)

0.13

6Replacement of 400 watts conventional lights with 200 watts LED lights in phase manner. (24 Nos)

0.19

7Modification of K22 BC7 discharge so that direct feeding of limestone is done to its hopper at Line 2

0.11

8Reduction in Separator Power consumption by installing Vortex plate in SKS Separator.

0.32

9Installation of Proxy sensor device on the belt to identify the bags on the belt and accordingly should trip for delay in no bags on belt.

0.08

10Optimization of Bag filter fan speed by modifying cleaning cycle with reference to differential pressure of bag filter in Packing Plant

0.14

Total energy Savings expected (Lac Units/annum) 3.35

5. Energy Saving projects implemented (FY 2017 -20)

613 11

166.60

60.71

138.86

160.71

51.41

121.1

0

20

40

60

80

100

120

140

160

180

2017-18 2018-19 2019-20

Summary

Proposals (Nos) Investment (Rs in Lacs) Savings (Rs in Lacs)


Sl. No Project DetailsInvestments(Rs in Lacs)

Savings per annum(Rs in Lacs)

Payback(Years)

1Installation of Thin Classifying Liners at line 1 (2019-20)

105 74.24 1.41

2Installation of Expert Optimizer at Line 1 & 2(2019-20)

52.00 30.00 1.73

3Installation of energy efficient impeller for C-194 Seperator fan. (2019-20)

21.34 15.59 1.37

4Installation of Airtron energy conservation units for AC's (2019-20)

9.43 5.86 1.61

5Direct Coupling of C142 & C318 Bag Filter Fans (2019-20)

0.35 1.85 0.19

6 Installation of VFD for P&V system (2019-20) 1.10 1.77 0.62

7Installation of air control valves for segregating compressed air lines of PP from CM at line 1 & 2 (2019-20)

2.20 1.71 1.29

8Temperature interlocking of VFD Panels with their inverter cooling fans - 8 Nos (2019-20)

0.05 1.59 0.03

9Silo top BE3 discharge chute modification thereby eliminated the usage of 2.2 KW blower (2019-20)

0.20 0.78 0.26


Sl. No Project DetailsInvestments(Rs in Lacs)

Savings per annum(Rs in Lacs)

Payback(Years)

10Replacement of Water Cooled fixed speed Compressor with VSD air cooled compressor. (2018-19)

16.32 20.27 0.81

11Installation of 1 HT VFD & 5 LT VFD’s in CM 1 & Packing Plant (2018-19)

45.61 22.09 2.06

12BCN rake loading bay extension to reduce the loading hours (2018-19)

4.80 3.91 1.23

13Reduction in Solar Deemed Generation by connecting solar power to Line 2 Cement Mill (2018-19)

1.15 5.28 0.22

14Replaced Conventional lighting 70 Watt SV lamp into LED 18 Watt in Cement Mill 1 & 2 area.(450 Nos) (2018-19)

1.43 5.20 0.28

15Replaced fluorescent lights 72 watts with 18 watts LED tubes at offices & load center areas (250 Nos) (2018-19)

1.00 3.00 0.33

16Regradation & Optimization of Grinding Media.(Weight of Grinding Media Before - 235MT; After 220MT) (2017-18)

18.00 86.94 0.21

17Cement transfer from line-1 to line-2 by providing air slide. (2017-18)

91.75 55.41 1.66

1. Thin Classifying Liners:Line-1 Hotgi Cement Works was installed in 1995 is of Polysius make containing Polycom + Ball mill

circuit. The Ball mill has bolted normal class shell liners, which were in use since inception except for

minor replacement for normal wear and tear. Entire liners need to be replaced for smooth running of

mill as life of existing is completed.

Instead of going for bolted normal class shell liners again, we installed thin classifying liners of AIA

make, which gave us additional benefit of reduction in specific power consumption by 1 kwh/MT.

Installation Month & Year: Aug’2019.

Investment Cost: Rs. 105 Lacs

Savings expected per annum: Rs. 74.24 Lacs

Replication potential: Yes, can be replicated in all ball mills.

6. Innovative Projects implemented


2. Installation of Expert Optimizer at both line 1 & 2: Expert Optimizer is a hybrid intelligent-system product developed by ABB for expert closed-loop process control and

optimization of cement grinding processes. It possesses human-like knowledge within specific domain. It makes

decisions and takes actions to improve plant performance & to reach profitability and sustainability goals.

Main benefits of Expert Optimizer:

Increase in output & Reduction in power consumption.

* Estimated savings in 0.4 kwh/t

Installation Month & Year: Feb’2019

Investment Cost: Rs. 52 Lacs

Expected Annual Savings: Rs. 30.00 Lacs

Replication potential: Yes, can be replicated in all cement plants.

3. Airtron Control Units for Packaged AC (AC Energy Savers): At Line 2, AC systems - 8 Nos (24 Nos AC compressors) at MCC/ substation are being continuously operated 24 hours a

day for maintaining the healthy condition of Equipment's. Estimated Electrical Consumption per Day - 1030 kwh.

Resulting in running expenses around Rs. 21.05 Lacs / annum.

Installed Airtron Controller units (ON/OFF duty cycle ratio) with Frigitech Solution

for AC systems to obtain 20 % savings in power consumption. Average electrical

consumption per day after installation is 731 kwh (23.65%).

Installation Month & Year: Dec’2019

Investment Cost: Rs. 9.43 Lacs




4. Reduction in Solar Deemed Generation by connection Solar power to Line 2:

Issue: Earlier solar power was connected to line-1 load, whenever line-1 was stopped, the generation was considered

under deemed. Hence we were incurring loss by compensating non-utilised solar power.

Work carried out: Spare HT capacitor feeder used as Solar incomer 2 for line 2 load and configured the reverse power protection with the help of M/s Siemens on 6.6 KV panel. Provided reverse power option for line-2 incomer. Provided castle interlocking keys for solar breaker 1&2 with new drive box arrangement thereby reduced the changeover time & increased the human safety.

Benefits: Solar power can be utilized for both line 1 & 2 thereby reduced the solar deemed generation.

Avoided stoppage of packing plant, cement transfer circuit from line-2 to line-1 during change over

Installation Month & Year: Nov’2018


Expected Annual Savings: Rs. 3.51 Lacs (0.63 lac units)

Replication potential: Site Specific.


5. Enhancement of Truck Loaders capacity (In house): Issue: Truck loading machines 2 and 3 of packer-1 has a limitation for loading up to 27 MT. More retention of 32MT

trucks due to unavailability of infrastructure (32 MT trucks had to wait till the loading of other 32 MT trucks is finished

on TLM 1 & 4).

Work carried out: In house modification done by increasing the length of luffing by 750 MM & feed trolley by 1500 mm.

Now all 4 Nos truck loaders of Packer 1 can be used for loading 32MT vehicles.

Benefits:

• Shift out put increased by 228MT by loading 32MT trucks continuously thereby eliminated 1.5 Hours of Packer 1 &

its loading belts operation. Approximate savings of 0.86 Lac units/annum - Rs 4.78 Lacs

• Purchase of new higher capacity machine is avoided thereby saved Rs 40.00 Lacs.

• Meets the Logistic requirement. Gain from market by increase in shift output is Rs 16.40 Lacs per annum.

• Avoided retention time (idle hours) of 32MT trucks.

Month & Year: Jul’2017



Replication potential: Yes, can be replicated in all packing plants where truck loading capacity is 27 MT.

Before After

6. Cement transfer from Line 1 to Line 2 by air slide: At Hotgi Cement Works, average Sp.Power Consumption of line-2 is more than line-1. There was a huge

difference of 3 Kwh/MT. Cement transport through belt conveyors was available from line-2 to line-1

but there was no infrastructure to transfer cement from line-1 to line-2. Wagon bulk loading system is

available at line 2 only.

Provided an air slide duct between line-1 to line-2 along with bag filters to transfer cement from line-1

to line-2 thereby reduced the Specific Power by 2.4 kwh/MT by increasing the utilization of line-1

Month & Year: Aug’2017



Replication potential: Site Specific


7. Utilisation of Renewable Energy sources

YearInvestment(in million)

Onsite/OffsiteGeneration

Installed Capacity / Enhanced Capacity

(MW)

Power Generation (million kWh)

% of overall electrical

energy

2018-19 52.96 Onsite 1.00 1.03 1.67

2019-20 Nil Onsite - 1.34 1.96

• Solar power generation was started from 20th June 2018 with installed capacity of 1 MW.

• Achieved 2.81 MU against RPO target of 1.83 MU in 2 years.

• RPO obligation – Yes (Solar obligation is fulfilled against wheeling power).

Environment Compliance status

8. GHG Inventorisation

HOCW

PM Limit

as per

MoEF

PM Cement mill

NOXLimit as

per MoEF

NOX

SOXLimit as

per MoEF

SOX

UOM mg/Nm3 2017 2018 2019 µg/M3 2017 2018 2019 µg/M3 2017 2018 2019

Line 1 Cement Mill ESP

30 29.83 21.48 16.76 - NA NA NA - NA NA NA

Line 2 Mill Vent Bag

House30 24.01 22.47 16.11 - NA NA NA - NA NA NA

Line 2 Seperator Vent

30 27.05 23.34 16.21 - NA NA NA - NA NA NA

AAQM - NA NA NA 80 12.87 9.96 8.61 80 27.61 28.10 25.11

Public disclosure


Environment display board displays

daily monitoring results of Air

Emissions & control, STP, Hazardous

waste generation etc.

Continuous monitoring & display of

ambient Air quality from AAQMS &

data transfer to MPCB & CPCB.


S.No InitiativesAmount Invested

Rs. In Lacs

1. Installation of Ambient Air Quality Monitoring System (3 Nos)Stack

Monitoring124.82

2. Construction of Rain Water Harvesting Pits – 2 NosWater

conservation1.48

3 290 trees were planted under tree plantation scheme. Green Belt

development0.32

4 Water tanker used for suppression of dust emission Dust control

initiative0.36

5Cement Mill outlet, Seperator Bag house, other bag filters inspection & bags replacement at CM, WT, PP & RMH areas

Dust control initiative

6.34

6Spiral chute installation, Vent line modifications, discharge chute modifications, skirt board modifications at CM, WT, PP & RMH areas.

Dust controlinitiative

5.97

7Stopped usage of plastic bottles, plastic covers inside the plant.

Environment 0.18

Total (Rs in Lacs) 139.50

Safeguarding Environment


Green Belt Development

265

87.45124.55

0

50

100

150

200

250

300

Total Area (Acres) Area to be developed (Acres) Green Belt area till date

Green Belt

Total Area (Acres) Area to be developed (Acres) Green Belt area till date

Green belt should cover 33.0% of entire area

47%

Environmental thinking in Supply Chain Management:

• Clinker is sourced from Rajashree Cement Works, where AFR used as partial fuel in clinkerisation process thereby conserving fossil fuel reserves and reduce greenhouse gas emissions. Rajashree Cement Works is ISO 14001 & ISO 50001 certified plant.

• Dry Ash which is waste product of power plant is used in making blended Cement. 35% dry ash is used in PPC whenever there is availability of dry ash from nearby NTPC which is a ISO 14001 certified plant.

• Dry Ash is also obtained in jumbo bags through rake from distant sources in large quantities (bulk transport) & increased the PPC production to meet the market requirements. Road transportation is eliminated thus reducing GHG emissions.

• Pond Ash which is also a waste product of power plant is used while making blended Cement. Increased the Pond Ash utilisation from 5% to 15% to cater the market requirement.

• Chemical Gypsum which is a waste product of chemical industry is used at 50% for production of all grades of cement.

• Replaced CFC truck with Diesel tanker (2500 L capacity) for procuring the diesel for plant operations.The result is that quantity of Diesel required in a month for plant operations is obtained in 6 trips through diesel tanker compared to 12 trips of CFC truck thereby reducing GHG emissions.

9. Green Supply Chain Management

Monitoring system of Energy Consumption: 1) Daily Performance Review meeting chaired by Unit Head

2) Monthly Performance Review meeting chaired by Cluster Head

Sections covered during daily & monthly review meetings related to energy:

a) Specific Power consumption of all grades. b) Packing Plant Power Consumption.c) Miscellaneous Power Consumption (Lighting, Material handling, utilities, Wagon Tippler).d) Power Wheeling – Wheeling lossese) Solar Power (renewable energy) generation – Deemed Generationf) Initiatives to be taken/action plan for reduction in power consumption.g) Comparison of specific power & flyash consumption with other grinding units in UltraTech.

• Brainstorming sessions are conducted every quarter involving all the employees to generate ideas/suggestions for reducing the power consumption. Cross functional Task force teams are formed to implement the identified power saving initiatives.

Budget for Energy Conservation: System in UltraTech Cement business:

• All the energy conservation proposals from integrated plants, grinding units & bulk terminals will be sent to TPMC (Technology & Performance Monitoring Cell – includes SME’s) & Projects department at Head Office under Capex for review & finalisation. Proposals get sanctioned/approved based on the savings, investment, pay back, availability of cash flow etc.

• TPMC will also have separate budget for implementing the new energy conservation initiatives across UltraTech (POC will be done at single/multiple units) & approved initiative will be implemented/ recommended to applicable units in UltraTech.

10. Teamwork, Employee Involvement & Monitoring

Projects implemented from suggestions given by workers and supervisor - Kaizens

• Bucket Elevator 3 discharge chute modified thereby eliminated the usage of 2.2 KW blower for transferring of

material into silo. Estimated Annual Savings: 0.78 Lac units

• Local start stop push button provided for all flyash compressors at flyash

unloading area. Operator can stop compressor immediately after

completion of unloading. Idle run hours are minimized.

Estimated Annual Savings: 0.57 Lac units

• Temperature interlocking of VFD Panels with their inverter cooling fans.

Provided temperature interlock with converter and inverter cooling fan,

whenever VFD panel become idle after stopping the motor, cooling fans

will stop after attaining desired temperature.

Estimated Annual Savings: 0.22 Lac units

• Installed 11 no's body cleaning blowers covering all the locations in plant thereby eliminated usage of compressed

air for body cleaning & reduced the load on compressors.

• Operation of bore wells through mobile starter thereby eliminated idle running hours, saved water & time.

• Provision of hooter at wagon loading machines for diversion of bags towards desired wagon loading machine

without stopping the belt & bag diverting operating panel is also placed near the loaders

10. Teamwork, Employee Involvement & Monitoring

11. Other Innovative technologies implemented

ONLINE ROLLER PRESS GEAR BOX MONITORING SYSTEM: Objective: To avoid unplanned stoppages by detecting Gear and bearing failures of Gearbox in earlier stage.

Technology Adoption: Installed the Dalog system for continuous online monitoring of critical Gearbox internal parameters and to carry out offline root cause analysis. Alarms will be triggered & email will be sent to responsible persons if there is any abnormality observed.

Benefits: 1.Optimize Production Process. 2. Stable Mill Operation. 3. Detect Wear in Early Stage. 4. Avoid Subsequent Damage

Installation Month & Year: Sep’2018



SERVER ANTENNA WITH TORQUE SENSOR FIXED ROLLER

SPEED SENSOR

TORQUE SENSOR

Long Term Target of Energy Efficiency

12. Long Term Vision on EE


Long Term Target (Mar’22)kwh/MT

CM 1 25.09 24.37

CM 2 26.49 25.90

S.No Initiatives to be taken Support required Remarks

1To increase the PPC production by using more dry flyash (up to 35%) thereby reducing the Sp. Power & clinker factor.

Supplier engagement

Availability of fly ash from nearby source (NTPC) gotreduced.

2Upgradation of Packers at line 1 to increase productivity & decrease power consumption. (12 spouts to 16 spouts)

FinancialCapex sanctioned in FY21 for Rs 110 Lacs. Planned to complete in FY22.

3Replacement of conventional rollers with stud rollers in Polycom / Roller Press at line 1 & 2.

Technical & Financial

Technical & cost benefit discussions are in progress.

4Replacement of Pneumatic slide gate with Hydraulic at Line 2 Roller Press

FinancialReplacement planned in next year.

5Installation of Low Pressure compressors in place of IR compressor at Line 2 for fly ash unloading.

FinancialCapex Proposed – Rs 14 Lacs (ROI is > 2.5 Years)

6Replacement of Overloaded, under loaded & inefficient motors with IE3/IE4 motors.

FinancialCapex Proposed – Rs 26 Lacs (ROI is > 4 Years)

Accomplishments

• Hotgi Cement Works Bagged a “Certificate of Merit” from NSCI Maharashtra Chapter for achieving “ZERO” Accident frequency rate for the year 2018.

• In 2019-20, Hotgi Cement Works is the unit with least grinding specific power in OPC grade (RP + Ball Mill Circuit) across the UltraTech which includes integrated & grinding units. (Source – UTCL TPMC Benchmarking report)

• Hotgi Cement Works is the highest pond ash consuming grinding unit (RP + Ball Mill Circuit) across the UltraTech. We have Increased the Pond Ash usage from 5% to 15% and increase the PPC Production thereby reducing the clinker factor.

• UltraTech has received Green Pro certification from Confederation of Indian Industry’s (CII) Indian Green Building Council for its Portland Pozzolana Cement and Composite Cement products.

Any other relevant information

Thank You

[email protected]+91 7744051100
mailto:[email protected]

Date post:	20-Oct-2020
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