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Wadi Cement Works 15th Oct. 2018
Best Practices Towards Energy Excellence
1
ACC Limited, Wadi Cement Works
ACC Wadi Geographic Location
KARNATAKA
STATE
Plant Site
Clinkering : 5.83 MTPA, Cement - 6.03 MTPA Power - 125 MW
Wadi-1
Wadi-2
2
ACC Limited, Wadi Cement Works
Genesis of the plant...............Wadi Cement Works
1978 1983 1995 2001 2006 2010 2014
1968
1968: Wadi I set up with installed capacity of 0.4 MTPA
Kiln 1 & 2 1978: MFC Installation
1983: Ist 1.0 MTPA Indigenous
Plant in India & 25 MW
CPP installed
1995: CPP expanded to 50 MW
Wadi-2 Commissioning
2.0 MTPA
2006 With in house
modification at Wadi II total capacity of Wadi- 4.2 MTPA
WD 2Expansion
clinkering & CPP(50 MW)
Total capacity 6 million Tons &
125 MW CPP
CommissioningAFR platform
(16 TPH)
India’s Ist 1.0MTA Plant
2018-19
Expansionof AFR platform
(20% TSR)
ACC Limited, Wadi Cement Works
Plant layout_Wadi-2
L&T make impact bar crusher Crusher 1 – 1000 TPHCrusher2 – 1200 TPH
Raw Mill-1 (Atox 50)Capacity – 450 TPHRaw Mill-2 (Pfeiffer 5600 B)Capacity – 560 TPH
Raw Meal Silo1 Nos. CF SiloCapacity – 21000 T
Complex SLC & ILC Combination of
6 stage PH
ILC Height –182 mSLC Height - 120 m
Kiln : Size – 6 m Dia X 96 m Length,BDP – 12500 TPD, Make –FLS, Inclination – 4%, RPM – 5 max. ,Drive – Twin Drive
RM1 RM2
Coal Mill-1 (Atox KM25)
Capacity – 50 TPH
Coal Mill-2 (Loeshe LM43.4 D)
Capacity – 93 TPH
Cr1 Cr2
SLC
ILC
K4
KM1 KM2
CM (Ball Mill)– 2 Nos.Capacity – 220 TPHx 2Make - FLS
VRPM – 2 Nos.Q –230 TPHMake- AMCL
Clinker SiloQ. – 1.15 LT
Cement SiloCap.- 10000t Tx 3
Packer- 4 Nos.Cap. -180 TPHX 4Double discharge
ACC Limited, Wadi Cement Works
Energy performance improvement over one year
5
Sl. No Description Units 2016-17 2017-18
1 MTOE reduction TOE/Ton 0.0811 0.0761
2 Kiln Thermal SEC kCal/kg cli 718.73 718.37
3 Specific Electrical Energy - clinkering kWh/T of clinker 62.62 59.61
4 Specific Electrical Energy – Grinding kWh/T of cement 37.57 37.09
5 CPP Heat rate kCal/kWh 3375 3359
6 CPP auxiliary consumption % 13.32 12.83
7 Thermal Substitution Rate % 6.32 11.2
8 Clinker factor % 0.72 0.68
9 Blended cement *%) of total cement % 83.54 89.76
10 Renewable Purchase Obligation (Solar+ Non Solar) REC 27017 41517
11 REC Purchased – Solar REC 1542 0
12 REC Purchased – Non Solar REC23744
26000
13 Mitigation of RPO through Solar Power Consumption REC 1700 15517
ACC Limited, Wadi Cement Works
SEC Performance Clinkering in last 3 - Years
In Year 2016, both SEC & STEC have been increased from previous years due to;
✓ Low PRI of Kiln; 83.79% in Y’16 from 93% in Y’15 after 100% pet coke firing.
✓ Increased AFR consumption from 4.17 % - TSR in Y 2015 to 6.23 % -TSR in Y 2016.
✓ Low PRI of Kiln due to TA Duct failure in Dec 2016 (PRI-50%) and Jan 2017 (PRI-48%)
57.50
58.00
58.50
59.00
59.50
60.00
60.50
61.00
61.50
62.00
62.50
Y'15 Y'16 Y'17 Y'18
60.06
62.19
60.6
59.35
Clinkering SEEC KWh/Tcli. Including 70% NP Power
685.0
690.0
695.0
700.0
705.0
710.0
715.0
720.0
725.0
Y'15 Y'16 Y'17 Y'18
697.6
709.7
722719.6
STEC K Cal/ Kg Clinker
Including 70% Non Process Power
ACC Limited, Wadi Cement Works
SEC Performance Grinding/Total in last 3 - Years
72.00
74.00
76.00
78.00
80.00
82.00
84.00
Y'15 Y'16 Y'17 Y'18
79.47
82.6
78.86
76.48
Total SEEC KWh/T cem including NP Power
36.2
36.4
36.6
36.8
37
37.2
37.4
37.6
Y'15 Y'16 Y'17 Y'18
36.73
37.47
37.33
37.05
Grinding SEEC KWh/T cem. Including 30% NP power
ACC Limited, Wadi Cement Works 8
Road map to achieve benchmark/global best SEEC
Sr. No.
Title of Project Saving
1 Expansion of Alternative Fuels project TSR increase from
12 to 20%
2 Replacement of Beumer pan conveyor with Aumund 1.7 KWh/T Cem
3 PIT navigation system - Intelligent optimization software for
Cement Kiln 1 KWh/T Cem
10 K Cal/Kg Clic.
4 Replacement of DC drive of Kiln String Fan with MV Drive0.4 KWh/T Cem
5 Replacement of DC drive of old Baghouse Fan with MV Drive0.57 KWh/T Cem
6 Replacement of DC drive of old Cooler ESP Fan with MV Drive0.2 KWh/T cem
7 Replacement of Cross bar cooler with IKN Cooler 1.5 KWh/T Cem
10 K Cal/Kg Clic.
8 Installation of double flap damper below Coal mill #2 BH
discharge0.1 KWh/T cem
ACC Limited, Wadi Cement Works 9
Road map to achieve benchmark/global best SEEC
Sr. No.
Title of Project Saving
9 Tapping heat from Cooler & Kiln exhaust gases by installing
waste heat recovery system13.2 MW Potential
10 Replacement of Cement Mill & Raw Mill separator DC drive with
LV drive0.17 KWh/T Cem
11 Replacement of Coal Crusher & Lime stone crusher Apron feeder
DC drive with LV drive 0.11 KWh/T Cem
12 Replacement of calciner string fan impeller with lower sized
impeller in order to improve operating efficiency 0.14 KWh/T Cem
4 Kcal/Kg Cli.
13 Replacement of existing three way separator with V separator0.7 KWh/T Cem
14 Maximization of fly ash absorption from current level of 33.5%
to 35% 0.8 KWh/T cem
Total 7.39 KWh/T Cem
24 K Cal/Kg Clic.
ACC Limited, Wadi Cement Works
INNOVATIVE PROJECT -1 Page 1 of 4
Plant : WD` Title of the measure :
Reduction in primary air in firing burner
from 9.73 % to 6.7% by modification of jet air nozzle
Category A Known concept with Unique Application
❑ Description of the energy conservation measure:
The Wadi2 Kiln operates with KHD pyrojet burner commissioned in Oct 2017. The jet air nozzles diameter was reduced from 27 mm to 17mm.
There are total 16 holes for jet air. The area is reduced from 9156 mm2 to
3632 mm2
❑ Problem Faced:
✓ Higher Primary Air intake
✓No any significant reduction in NOx emission
✓ Higher Fuel consumption
✓ Poor Nodulisation of clinker
✓ Lower C3S & Higher C2S
ACC Limited, Wadi Cement Works
Problem Analysis and action taken Page 2 of 4
Problem Action taken
1. Higher PA
consumption & Low Burner momentum
1.Replaced FLS duplex burner to KHD pyro jet burner
2. Jet air nozzle dia. reduction from 27 mm to 22 mm3. Replacement of PA fan with Blower
2. Formation of
coating in raiser duct.
1.Started using high alkali content material in raw meal
corrective to maintain A/S in clinker.2.Installation of Cardox socket in kiln raiser duct to
dislodge the coating.
3.Cyclone / Raiser duct air blaster sequence changed to auto mode.
3. Flushing of
clinker in pan conveyor tunnel
due to fine clinker.
1. Increased alumina ratio for better nodulization.
2. Cooler operation mode changed from random to shuttle.
3. PC discharge chute modification
4. Higher NOx
Emission
1. Reduction in PA Air
2. Jet air nozzle dia. reduction from 27 mm to 22 mm
ACC Limited, Wadi Cement Works
Picture/ sketch before modification Picture/ sketch after modification
PRODUCTIVITY IMPROVEMENT POTENTIAL Page 3 of 4
22 mm Dia.
ACC Limited, Wadi Cement Works
TANGIBLE IMPACT OF THE PROJECT Page 4 of 4
Result & Benefit
•The jet air blower operating speed is reduced from 1260 rpm to 860 rpm
•NOx reduction from 905 mg/Nm3 & 1027 mg/Nm3 to 730 mg/Nm3 & 887 mg/Nm3
respectively. (reduction by 175 mg/Nm3 and 140 mg/Nm3)
•The reduction in primary air from 9.6% to 6.7% - Savings of 4.1 Kcal/Kg
Clinker
ACC Limited, Wadi Cement Works
INNOVATIVE PROJECT -2 Page 1 of 4
Plant : WD Title of the measure : Improvement in RM#2
PRI from 560 to 570 TPH by internal modification
in Raw Mill #2 (Pfeiffer 5600 B)Category B New concept (risks taken/self driven / beyond OEM)
❑ Description of the energy conservation measure:
Problem Faced:❖Mill body vibration high 16 to 18 mm/sec & air Separator was running in the range
of vibration levels 20-22 mm/sec. There was no any oil cooling arrangement for the
hydraulic system. This causes following problems–•Mill buffer seal & Pull rod failure frequently
•Buffer & it’s side liner got damage .•Cracking of mill surrounding Platform
•Damage of hydraulic Cylinder top bush & seal
•Not Able to increase the Feed more then 560 tph
❑ Identification of problem and root Cause Analysis
✓ Continuous studies by OEM Since 2010 but no solution was provided✓To reduce the oil temperature we have installed separate oil cooling arrangement
✓ Carried out brainstorming session & also taken ideas from sister Works i.e. Chanda
Works
ACC Limited, Wadi Cement Works
Picture/ sketch before modification Picture/ sketch after modification
Electrical Energy Conservation Case Study Page 2 of 4
Before dam ring increase Material empty After dam ring increase material height
ACC Limited, Wadi Cement Works
Picture/ sketch before modification Picture/ sketch after modification
Innovative Project 2 Page 3 of 4
Oil Tank
Pump
Filter 10 µ
Valve Block
Hydraulic
Cylinder 3 Nos
Pump
Oil Tank
Pump
Hydraulic Cylinder
3 Nos
Valve Block
Filter 20 µ
Filter 20 µ
Heat Exchanger
Pump
ACC Limited, Wadi Cement Works
Electrical Energy Conservation Case Study Page 4 of 4
❑ Execution & Implementation
Dam ring height & feed chute height has been increased & mill body vibration & separator vibration reduced drastically
❑ Result & Benefit
✓ Decreased mill internal recirculation of material resulted in lower mill DP caused
increase in feed by 15-20 TPH.
✓MILL vibration Reduced from 20- 22 mm/sec to <7 to 8 mm/sec
✓Silo feed bucket elevator load increase around 15 to 20 Amps
✓Buffer seal & Liner plate life has been increased
✓Cracking of Mill surrounding platform eliminated
✓Hydraulic Cylinder top bush life increased
✓Reduction in frequent mill breakdown due to seal damage & pump failure
✓Reduction in oil temperature resulting in reduction in seal damage, solenoidmalfunctioning & oil consumption.
Total reduction of around 1 KWh/T mat has been achieved
ACC Limited, Wadi Cement Works 18
Energy Saving projects implemented in FY 2017-18
Sr. No.
Title of Project
Annual SavingElectrical(KWh) Thermal (Mio. K
Cal)
Total Annual Saving (Mio. INR)
Investment made (Mio. INR)
1 Improvement in RM#2 PRI from 560 to 570 TPH by1) Arresting false air from 25 % to 13 %2) Modification in Mill feed chute3) Maintaining crusher output size 90% passing 75 mm
561250 2.81 0
2 Interlocking of crusher hopper level sensor with apron feeder RPM to reduce idle running & reliability of lamella plate
99000 0.495 0.05
3 Old stacker travel drive converted from Rdol to VFD 79200 0.396 0.05
4 Replacement of soft starter with VFD in old high grade & shale reclaimer 217661 1.1 0.2
5 Reduction in rake (coal & Gypsum) unloading time from 9.6 hrs to 7 hrs 449000 2.25 0
ACC Limited, Wadi Cement Works 19
Energy Saving projects implemented in FY 2017-18
Sr. No.
Title of Project
Annual Saving
Electrical(KWh)
Thermal (Mio. K Cal)
Total Annual Saving (Mio. INR)
Investment made (Mio. INR)
6 Cooling tower Hot water pumping system modification & replaced 75 KW motor with 45 KW motor. 144000 0.7 0.05
7 Replacement of Conventional lights with LED lights 171915 0.86 2
8 Reduction in clinker cooler Temperature by 1) replacement of cooler fan FA 4 & 5 with motor 2) Replacement of impeller of Cooler fan FA 6 & FA 7 3) Replacement of Cooler 3rd compartment plates
11467.94 (T) 13.76 8.2
9 Reduction of avoidable electrical energy loss in GRR by replacing GRR with SPRS in RM#1 fan (3400 KW & 6.6 KV)
1222000 6.11 7.5
ACC Limited, Wadi Cement Works 20
Energy Saving projects implemented in FY 2017-18
Sr. No.
Title of Project
Annual SavingElectrical(KWh) Thermal (Mio. K
Cal)
Total Annual Saving (Mio. INR)
Investment made (Mio. INR)
10 Improvement in NAI of both VRPM to ensure 100% Cement Mill running with Pre-grounded material by carrying out following jobs 1) Replacement of separator rotor & stator 2) Replacement of impeller of Sepax fan3) installation of chillers unit for gearbox
oil cooling
2245000 11.23 5.6
11 Reduction in primary air in firing burner from 9.9 % to 6.7% by replacing the existing fan with high pressure& low volume blower.
13696 (T) 15.89 20
ACC Limited, Wadi Cement Works
Utilisation of waste for replacing the conventional energy
Pre-processing: Capacity- 200 M3/Hr
Co-processing: Capacity- 150M3/Hr
❑ Consists of Metso M&J 4000 S
hook shredder, REMA belt
conveyors, Steinert Magnetic
Separator & Eco-star screen.
❑ Suitable for material with bulk
density= 0.1 to 0.6 t/m3
❑ Suitable for material having
moisture range= 0 to 70 %
❑ Facility to handle both HZ & NHz
Waste
ACC Limited, Wadi Cement Works
Utilisation of waste for replacing the conventional energy
ACC Limited, Wadi Cement Works 23
0.02
4.09
6.43
9.69
11.39
10
71
70
15
51
62
23
94
66
16
79
30
2994242340
62530
40521
0
50000
100000
150000
200000
250000
300000
Y'14 Y'15 Y'16 Y'17 Y'18
0.00
2.00
4.00
6.00
8.00
10.00
12.00
TSR (%) TSR (m Kcal) TSR (MT)
Plan to increase TSR % from 12% to 20% by the year 2020 by
adding another Pre-processing line of having investment of Rs. 70 Cores – In progress
AFR Performance
ACC Limited, Wadi Cement Works
Green Procurement & Green mission Policy
1. Optimization of natural resources
2. Installation waste heat recovery system to produce green energy
3. Sustainable reduction in Plant Energy consumption
4. Reduction in plant water consumption
5. Cement manufacturing with Zero harm to Environment
6. Our slogan “Manufacturing of Green Cement”
ACC Limited, Wadi Cement Works
Projects implemented in Green mission Policy
1. Dispatch of Bulk Cement to bulk terminal at Mumbai via rail transportation (16% of total dispatch- 359730.8 MT)
2. Major portion of Cement Bag dispatch through rail to reduce GHG emission (53% rail & 47% road)
3. Major portion of Clinker dispatch through rail to reduce GHG emission (82% rail & 18% road)
4. Finalizing the order of electrical equipments based on efficiency & BEE star rating.
5. 100 % own fly ash transportation through pumping. Bulker movement has been eliminated.
6. Zero waste discharge from the boundary of the plant.
7. Major portion of fly ash transportation through rail transportation.
ACC Limited, Wadi Cement Works
Organization Chart for Energy & Environment Dept.
ACC Limited, Wadi Cement Works
Involvement of Employees, Team work in ENCON, ….
✓To achieve our objective of manufacturing of Green Cement we have formed various cross functional team to improve the performance by enhancing energy Efficiency & minimum harm to environment✓Identifying the gap in performance and develop Roadmap for bridging the GAP✓Monitoring progress in weekly review meeting along with functional manager chaired by unit head for improving operational excellence
ACC Limited, Wadi Cement Works
Online monitoring of electrical energy – EMS
Hourly Tracking of section wise SEC through auto generated SMS
ACC Limited, Wadi Cement Works
2
9
Energy Management System & Energy Policy
ACC Limited, Wadi Cement Works
PAT Cycle Performance
Baseline SEC Target SEC Assessment year Normalized SEC
0.0922
0.0874
0.0829
GtG
SEC
(to
e/t
on o
f eq.
Cem
)
Nos. of ECerts: (+) 23426 Nos.
ACC Limited, Wadi Cement Works
Major Investment for Energy Conservation
# Project Description AmountRs. Cr.
Current Status
1 Replacement of SF Bar Cooler fans 0.82 Implemented
2 Bed Ash Coolers for AFBC & CFBC Boilers 6, 7 at CPP 4.1 Implemented
3 New PYROJET Burner 1.5 Implemented
4 CPP – Zero Liquid discharge project 8.25 Implemented
5 Online condenser cleaning system 0.82 Implemented
6 Replacement of GRR with SPRS in RM#1 fan. 0.93 Implemented
7 Up gradation of CM inlet fly ash feeding system 0.70 In progress
8 To increase TSR % from 10% to 20% in Y’2020 by adding another Pre-processing line.
70 In progress
9 Air cooled condenser for TG4 & TG5 50 In progress
10 Replacement of PH ILC string fans with high Efficiency fan 2 In progress
11 Replacement of 3-way separator to standard separator 5 In progress
12 Up gradation of DCS Operating 3 In progress
13 Replacement of Condenser Tubes TG5 1.5 In progress
14 PIT navigation system - Intelligent optimization software for Cement Kiln
2.5 In progress
Total 151.08 cr. (10% of turnover)
ACC Limited, Wadi Cement Works
National Energy Conservation Day Celebration (Awareness Drive)
ACC Limited, Wadi Cement Works
National Energy Conservation Day Celebration (Awareness Drive)
ACC Limited, Wadi Cement Works
ACC Limited, Wadi Cement Works
Mr. Piyuesh Goyal, Hon’ble Minister of State (Independent Charge) forMines, Power, Coal & New Renewable Energy GOI awarded the trophy toDr. S B Singh, Cluster Head South, ACC Limited
FIMI – Health & Safety Award
35
Wadi Cement works bagged the FIMI – Health & Safety Award Y15-16
ACC Limited, Wadi Cement Works 36
19th National Award for Excellence in Energy Management by CII
National Award as “Excellent Energy Efficient Unit” by CII in year 2018
ACC Limited, Wadi Cement Works
National Award for Excellence in Energy Management by CII
National Award as “Energy Efficient Unit” by CII in year 2017, 2016 & 2015
ACC Limited, Wadi Cement Works
Awards & Accolades
Green Manufacturing Excellence Gold Award - 2012
National Award for Excellence in Energy Management- 2011
India Manufacturing Excellence Gold Award - 2012
Green Manufacturing Excellence Award- 2014
ACC Limited, Wadi Cement Works
▪ National Award for outstanding performance in promoting rural and agriculturaldevelopment – by ASSOCHAM
▪ Indira Priyadarshini Vrikshamitra Award - by The Ministry of Environment andForests for "extraordinary work" carried out in the area of afforestation
▪ FICCI Award - for innovative measures for control of pollution, waste management& conservation of mineral resources in mines and plant
▪ Subh Karan Sarawagi Environment Award - by The Federation of Indian MineralIndustries for environment protection measures
▪ Drona Trophy - By Indian Bureau Of Mines for extra ordinary efforts in protectionof Environment and mineral conservation in the large mechanized mines sector
▪ Indo German Greentech Environment Excellence Award
▪ Golden Peacock Environment Management Special Award - for outstandingefforts in Environment Management in the large manufacturing sector
▪ Indira Gandhi Memorial National Award - for excellent performance inprevention of pollution and ecological development
Awards And Accolades
ACC Limited, Wadi Cement Works
Thank You
40