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BEST PRACTICES TOWARDS ENERGY BEST PRACTICES TOWARDS ENERGY
EFFICIENCYEFFICIENCY
UltraTech Cement Limited.UltraTech Cement Limited.UltraTech Cement Limited.UltraTech Cement Limited.
(Unit (Unit (Unit (Unit –––– Narmada Cement, Jafarabad Works)Narmada Cement, Jafarabad Works)Narmada Cement, Jafarabad Works)Narmada Cement, Jafarabad Works)
Narmada Cement-Jafarabad Works was established in 1982 with aninstalled capacity of 1 MMTPA clinker and has been graduallyincreased to 1.50 MMTPA (4,300 – 4,500 TPD). Cement capacity is0.50 MMTPA (1,150 TPD). The Unit is ISO 9001:2008, ISO14001:2004, OHSAS 18001:2007, ISMS 27001:2005 & SA8000:2008, ISO-50001:2011certified
It is India's first split location dry process cement plant with Fuller
Overview of NCJW
It is India's first split location dry process cement plant with Fullertechnology having four-stage suspension pre-heater, in-line flashcalciner, reverse air bag house dust collector, vertical roller millsbesides to be the first to unload imported South African coal at plantjetty. It transports 100% clinker to grinding units is in bulk by searoute. The special feature of this plant is 'Just in Time‘ design for rawmill circuit. As against conventional norms of 20,000 MT silo for rawmeal storage it has 2,000 MT silo.
The grinding units associated with Jafrabad Cement Works are Magdalla CementWorks having capacity of 0.80 MMTPA and Ratnagiri Cement Works havingcapacity of 0.50 MMTPA. All three coast-based split location units have Jetties formarine transportation. Narmada Cement was the prime supplier of fly ash basedPortland Pozzolana Cement (PPC) to Sardar Sarovar Dam on river Narmada,which is the World's second largest concrete gravity dam (by volume). Wecreated a benchmark in Indian cement industry with installation of SF 3 X 6 cross
Overview of NCJW
created a benchmark in Indian cement industry with installation of SF 3 X 6 crossbar cooler supplied by FLS, in record 41 days.
With the hand holding of DuPont Sustainable Solutions, we are marching towards"Zero Accident" goal and articulating "Safety " as fundamental core belief withthe theme "Life is precious, We care for it" as advocated by Shri O PPuranmalka, Business Director. Moving ahead in the safety journey, we achievedlost time injury frequency rate (LTIFR) 0.00 in the year 2014-15.
ENERGY SAVING PROJECTSENERGY SAVING PROJECTS
4
1. Problem Statement: Dust settling in separator inlet duct.
2. Impact of Problem : Higher power consumption of separator fan to maintain the velocity in duct and maintain the DP in separator.
3. Action taken :� Separator all duct pressure readings were taken.� Dust settle point identified� Velocity measured in the separator inlet duct & found velocity was
lower than desired.
1.0 Case Study-Elimination of material settling at separator
inlet duct by providing hump to increase air velocity.
lower than desired.� It was decided to provide the hump in the inlet duct to increase the
velocity.� Hump size & location decided in the duct & provided.
Dust accumulation in duct
Before
Area Measurement UOM
Sep I/L Duct
Radius(Rb)1.5 Mtr
Duct Area 1.7671 M2
Flow 26.578 M3/Sec
Flow 95680 M3/Hr
Velocity 15.04 M/Sec
After
Area Measurement UOM
Radius (Ra) 1.25 Mtr
Duct Area 1.23 M2
Flow 26.578 M3/Sec
Flow 95680 M3/Hr
Velocity 21.66 M/Sec
Calculation for Hump size
Velocity 15.04 M/Sec Velocity 21.66 M/Sec
250mm
a532mm
Ø
Cos = (Height Of hump)/(a/2)
Height of hump = Rb-Ra
Cement angle of repose( )= 20
deg
Base of hump (a ) = 532mm
Ø
Ø
Before After
Separator Inlet Duct
Profile of dust settling inside duct
8
Hump in
separator inlet
duct
Hump view in separator
9
BEFORE AFTER
Previous fan power in KW 96Existing Fan running KW
84
Run Hrs 24 Run Hrs 24Power/Day 2304 Power/Day 2016Power per month 69120 Power per month 60480
Power Saving Calculation
Saving
Saving in energy KWh per year 103680
Saving in Lacs / Year (considering unit rate @ 4.85) 5.03
1. Problem Statement : High Pressure drop across the Preheater , High velocity at orifice because of high velocity difference in short span, Puffing occur at orifice.
2. Impact of Problem : High heat consumption across Preheater.
3. Action taken : Brought down the velocity at orifice to reduce
2.0 Reduction in heat losses across Preheater
3. Action taken : Brought down the velocity at orifice to reduce pressure drop across calciner
Existing
21.23
m/sec
21.23
m/sec
41.35
m/sec
Velocity 30m/Sec after orifice modification
21.23
m/sec
21.23
m/sec
30m/sec
Velocity at orifice at different location
12.09
m/sec
m/sec
12.09
m/sec
875 850
688650
902 880
600
700
800
900
1000
Kiln Feed PH Fan Speed PH O/L Temp
PH O/L Draft Calciner Exit Temp Calciner Exit Draft
Kiln feed Hood draft Kiln Riser DP Calciner Inlet Draft
Result
300 304382 386
11369
28 2784
4251 49
0
100
200
300
400
500
600
Before After
84
60
70
80
90
Kiln Riser DPBefore After
Result
42
0
10
20
30
40
50
60
Before After
2310
2157 2159 2152
906
899
894 893895
893
886
885
890
895
900
905
910
2150
2200
2250
2300
2350
KWH SG Fan RPM
Result
2157 21592143 2143 2152
20942062
877
860
865
870
875
880
885
1900
1950
2000
2050
2100
Nov-14 Dec-14 Jan-15 Feb-15 Mar-15 Apr-15 May-15 Jun-15
Month
Saving in Orifice Modification
Saving Average 280KWH of PH Fan
Kiln Running hours =345*24=8280
Result
=8280Total Saving in KWh =8280*248
=2053440Saving of Rs = 2053440 *4.67Rs/Unit
=95.89Lacs/Annum
•Increased insulation thickness in TAD from 65 to 100mm in 20m lining area
AFTERAFTERBEFOREBEFORE
3.0 Reduction in heat by increasing insulation in TA duct
•Backup Insulation of 35mm provided in Stage IV feed pipe.
AFTERAFTERBEFOREBEFORE
Result
•Before radiation losses with castable : 2.91 kCal/Kg of clinker
•After radiation losses with Brick lining : 2.22 kCal/Kg of clinker
Benefit in kCal/Hour : 129312.65Total Benefit in kCal kG/Clinker : 0.69
18
SNo. Title Action TakenSaving
KW/Month
1
Grinding aid motor running
with constant speed without
considering variation in Cement
mill Feed.
For optimizing Grinding Aid system
VFD installed. Now Motor speed is
varied with TPH.136.80
2
Pre grinder dust collector
material conveying air slide
blowers were running
Interlock provided such that if pre
grinder stopped two blowers stopped 1367.81
4. Various energy saving projects
2 blowers were running
continuously even if pre grinder
is kept stop condition.
grinder stopped two blowers stopped
after 10 min.
1367.81
3
Separator fan was running on
RPM basis so power is not
monitored, also due to material
settling in duct it was difficult
maintain the draft in circuit.
1) Sep. Fan control changed from
RPM base to KW base.
2) Trommel screen was taken in
operation to reduce the nibs
settling in duct
3) One hump is provided to increase
the velocity in duct.
17561.84
SNo. Title Action TakenSaving
KW/Month
4 Reduction in Mill fan RPM To maintain the mill discharge Blaine mill
fan rpm maintaining from 400 to 460.688.03
5Mill taking more power with
considering TPH.
Mill power optimized with maintaining the
media size & qty.7495.20
6
Pre grinder running hrs was
more because fresh feed was
Close loop system was developed and
feed was controlled w.r.t. reject .Through
put set point to be kept manually by 13200
4. Various energy saving projects
6 more because fresh feed was
monitoring manually.
put set point to be kept manually by
monitoring the crusher load.
13200
7
Separator motor was of old
version i.e. DC motor and taking
more power to operate.
Converted sep motor from DC to AC. 8208.00
Our Goal is to achieve Excellence in Our Goal is to achieve Excellence in
21
Energy ConservationEnergy Conservation
Thank You
Saving calculation of G-Aid motor after VFD.
Earlier motor KW----------A 0.37
After VFD motor running KW------B 0.18
Difference(A-B)---------C 0.19
Normal Day Run Hrs---------D 24Normal Day Run Hrs---------D 24
Saving in KW/Day (C X D)-------E 4.56
Saving in KW/Month (E X 30)-------F 136.8
Calculation-Earlier Condition
Motor rated KW 3.7
Operating KW 2.74
No. of blowers 2
Pre grinder running Hrs 15
Calculation-Existing Condition
Motor Rated KW 3.7
Operating KW 2.74
No. of blowers 2
Pre grinder running Hrs 15
Idle running for each stoppage 0.17
Saving calculation of Pre grinder blower
running hours
Pre grinder running Hrs 15
Idle running 9
Power/Day of both blowers 131.52
Idle running for each stoppage
of pre grinder0.17
Total start stop of Pre grinder 4
Total idle running Hrs 0.68
Power/day of both blowers 85.93
Saving in energy KWh per day 45.59
Saving in energy KWh per Month 1367.81
Power calculation on Last year performance
Operating current in
Amps 198.42
Operating KW 108.39
Power calculation on current year
performance
Fan running KW 84
Running Hrs 24
Saving calculation Cement Mill Separator fan
Operating KW 108.39
Running hours 24
Power/day in KWh 2601.395
Power per month in
KWh78041.84
Running Hrs 24
Power/Day in KWh 2016
Power per month in KWh 60480
Saving of KWh per month 17561.84
Saving calculation Cement mill fan
Power calculation on Last year performance
Operating current in Amps 8.8
Operating KW 4.81
Running hours 24
Power/day in KWh 115.37
Power per month in KWh 3461.18
Power calculation on current year performance
Operating current in Amp 7.05
Operating KW 3.85
Running hours 24.00
Power/day in KWh 92.43
Power per month in KWh 2772.88
Saving of KWh per month 688.30
Power calculation on Last year performance
Operating KW 1363.63
Running hours 24
Power/day in KWh 32727.12
Power per month in KWh 981813.6
Power calculation on current year performance
Operating KW 1353.22
Running hours 24
Power/day in KWh 32477.28
Power per month in KWh 974318.4
Saving calculation Mill main Motor KW
Saving of KWh per month 7495.20
Power calculation on Last year performance
Operating KW 140.00
Running hours 14
Power/day in KWh 1960
Power calculation on current year
performance
Operating KW 95.00
Running hours 16
Power/day in KWh 1520
Saving calculation of Pre grinder circuit
Power/day in KWh 1960
Power per month in KWh 58800
Power/day in KWh 1520
Power per month in KWh 45600
Saving of KWh per month 13200.00
Power calculation on Earlier performance
2 Nos DC Motor Cooling fan operating
KW5.4
DC Motor operating KW 13.00
Total Power drawn by the separator
drive system.18.40
Power calculation on current year performance
No Cooling fan for AC Motor. 0
Sep AC motor Operating KW 7.00
Total Power drawn by the Separator drive
system.7.00
Saving calculation of Cement mill separator
Motor from DC to AC
drive system.18.40
Running hours per day 24
Daily Power Consumption in KWh 441.6
Monthly Power Consumption in KWh 13248
Total Power drawn by the Separator drive
system.7.00
Running hours per day 24
Daily Power Consumption in KWh 168
Monthly Power Consumption in KWh 5040
Saving of KWh per month 8208.00