Green Co Best Practice Award 2016

Presented by

Mr. Ankit Nagar

Mr. Jitendra Lakhwani

Shree Cement profile

GreenCO Journey

Tangible & Intangible Benefits

Challenges faced and their resolution

Manufacturing process brief layout

Project detail – Waste Heat Recovery System

Involvement of team for accomplishment of project

Methodology for developing project

Uniqueness of Project

Outline of Presntation

Shree Cement Profile

� Largest cement player of North India and has

diversified into power business including Green

power

� Operations at ten locations at Beawar, Ras,

Raipur, Khushkhera, Roorkee, Jaipur, Suratgarh,

Aurangabad, Panipat & Bulandshahar

� Cement Production capacity of 25.6 MTPA and

Power Generation Capacity of 612 MW which

includes 111 MW Waste Heat Recovery Systems.

� Selected as New Sustainability Champion- 2011

by World Economic Forum

Green Co Journey

• Energy conservation

• Water conservation

• Emmision reduction

• Resource conservations

• Green supply chain

• Waste management

• LCA

• Product imorovement

Training programme ( Internal & External)

Idea Sharing

Inhouse innovations

Rewards

National & International Benchmarking Activities

Action Plan &Target Setting

Formulation of Green Co teams

Green Company

Gold rating,

2014

5

Cement Process

PackingWagon &

trucks

Cement silo Roller press cum

Cement mill

Cement Mill

hopperClinker stock

yard

KilnPreheater

Raw mill

silo

Raw mill Raw mill hopper Reclaimer

StackerMines

Waste heat recovery system

• Pyro processing / Clinkerization takes place at

1450 °C

• Approx 45% of total energy released into

environment

• Hot gases are released from Air quenched

cooler approx 400 °C

• From Pre heater approx 300 °C

WHR system traps this waste heat and

utilize for power generation

Without

WHRB

With

WHRB

Hence WHR plant is named as GREEN POWER

PLANT in Shree Cement Ltd.

Pre project scenario Post project scenario

Waste Heat Recovery Plants: Technology Introduction

Waste heat recovery system

Waste heat recovery system in

Cement Industry

Methodology adopted for

developing project

• Incorporation of WHR

in 2001 was failure

• Regular introspection and

reviews resulted in success

� Reduce consumption of resources

� Re-use waste materials

� Replace conventional fuel

� Release less emissions

� Restore to nature what one takes

from it

� Rethink and relearn

� Research and Development

7 R Philosophy

Driving force for Implemantation

�Management Philosophy based

•A sustainable Energy Solution

•Proactive approach toward climate change

�Business based

•Protects from fuel price volatility

•Reliable power supply source

�Environment based

•Water conservation

•Fuel conservation SCL installed 111 • SCL installed 111 MW WHRP covering

all cement plants • Largest in World

Cement Industry except China

As a philosophy all new cement plants will have WHRP

units

Uniqueness of Project

• Lower temperature heat utilization

• Dual pressure steam cycle selected for maximum heat recovery

• WHRS with 2 gas strings – Kiln string & pyro string

• Project commissioned time is approx. 15 months

• WHRS with air cooled condenser for minimum water consumption

• Project registered in Limca book of world record for its exceptionally faster execution

• Project is under consideration of CDM at UNFCCC

Involvement of team

• Regular meeting with suppliers for optimum plant

installation

• Thorough research for type of boiler, cycle selection

etc

• Figures like saving for 1 day early commissioning of

WHRS were displayed for motivation of Project &

O&M team.

• Innovative layout were explored for installation within

running cement plant and keeping space for existing

equipments maintenance

• Innovative idea by brainstorming sessions.

Challenges and their resolution

Technical Challenges– Type of Boiler selection – Vertical type boilers for less

space usage

– Dust separation – Dedusters were installed

– Layout - Existing cement plant (Pre Heater & Raw Mill foundation) - Vertical boilers for less space usage

– Existing equipment use - Use of existing fans of cement plant

– Hookup - Readiness of WHR plant & hookup within 5 days of plant stoppage

– Air cooled condenser required additional huge area in cement plant and location of dust free area in cement plant - Location in least dusty area

– Maximum possible cost effective Heat recovery – Dual pressure system, optimum mid tap location

– Less PLF & less availability – Changing size, orientation of ducts, de-duster , modification in super heaters

Challenges and their resolution

Maintenance challenges •Height of boiler – Lifts for easy approach

•Lumps formation inside boiler due to high dust content-

Hammering system , Vibrators, Sonic Horns , de-dusters

•False Air ingressment in Boilers – Smoke test, Expansion

bellows for expansion, Proper gap sealing, Online O2

analyzers for continuous false air monitoring

•Pressure drop in Gas path – Effective hammering system

•High Erosion– Proper metallurgy, Gas velocity, refractory

selection, dummy objects installation

And many more….

Challenge- Layout (Space)

Resolution-Vertical Boiler Installation

Challenge- False Air

Resolution- Sealing by Rubber Caps

Challenge- False Air

Resolution-Online Oxygen analyzers

Challenge-Dust Content in Gases

Resolution- Hammering System

Challenge- Water Consumption

Resolution- Air Cooled Condenser

• Reduced GHG emission reduction of approx 0.81 Lac Ton CO2

• Reduced consumption of fossil fuel by approx 0.26Lac MT

• Reduced water consumption approx 6527 KL/yr

• Reduced NOx and SOx

Tangible Benefits

342361

413700

504376

104220 105971

81084

0

100000

200000

300000

400000

500000

600000

2012-13 2013-14 2014-15

CO2 reduction by WHR

(Tones /year) SCL

CO2 reduction by WHR

(Tones /year) Beawar Plant

Second Best company world wide in field of CarbonReduction and Disclouser project 2015 by CDP publishedreport 2016

Intangible Benefits

• Social well being

– Employment generation for labors and professional

• Economic well being

– Created business opportunities for technology consultant,

contractors

• Environmental well being

– Replaced electricity generation from petcoke

• Technology well being

– Handling highly dusty gases require unique system

Shree Cement as Green Cement

Company Green

Globe Green

Thank You !