Penna Cement Industries LimitedTalaricheruvu , Ganeshpahad, Boyareddypalli,Tandur & Captive Power Plant
Captive Thermal Power Plant &Best Energy Efficiency Practices
Ganeshpahad Cement
Plant
TandurCementPlant
Boyareddypalli Cement
Plant
Talaricheruvu Cement
Plant
Captive Power Plant (2x38.5 mw)
1
PENNA CEMENT INDUSTRIES LTD
POWER PLANT
77 MW Captive Power Plant
WELCOMES YOU
Penna Cement Industries LimitedTalaricheruvu , Ganeshpahad, Boyareddypalli, Tandur & Captive Power Plant
Vision, Mission and Values
Our Vision:
TO CREATE SUSTAINABLE VALUE & GROWTH FOR ALL
STAKEHOLDERS
Our Mission:
TO CREATE ENERGIZED, COMPETITIVE, INNOVATIVE AND A WINNING
ENVIRONMENTFOR ALL STAKEHOLDERS
Our Values:
FOCUS ON CUSTOMER ||
PURSUE EXCELLENCE ||ACT WITH INTEGRITY || NURTURE EMPLOYEES || CARE FOR SAFETY || CARE FOR COMMUNITY
3
Penna Cement Industries LimitedTalaricheruvu , Ganeshpahad, Boyareddypalli, Tandur & Captive Power Plant
Key Milestones:
In 1994 -
0.2
mTPA
Commiss
ioned at
Talariche
ruvu, AP
2002 - New
plant
Commission
ed at
Ganeshpaha
d, TG
& capacity
reached to
1.3 mTPA
2005 -
Crosses the
milestone
of 2.1
mTPA
2008 - New
Plant
Commissio
ned at
Boyareddy
palli, AP
&
capacity
crosses the
4.0 mTPA
2010 - New
Plant
Commission
ed at
Tandur, TG
with a
capacity of
2.0 mTPA &
CPP of 77.0
MW Commissioned
at Ganeshpahad,
Penna
Crosses the milestones
of 7.0 mTPA
Cement Capacity with 4
cement plants
Future
expansion of 3.0 mTPA of
cement and crosses
the 10. mTPAcapacity in
the year 2018
4
Penna Cement Industries LimitedTalaricheruvu , Ganeshpahad, Boyareddypalli, Tandur & Captive Power Plant
Energy Policy & Energy Committee Review Structure:
Energy Policy:
“PENNA CEMENT INDUSTRIES LTD is committed
to all applicable legislation and other
requirements related to Energy Management
System. We are committed to improve energy
efficiency as a continuous improvement process
in all our business processes and ensuring the
availability of information and resources to meet
the energy objectives andtargets.
We are committed to incorporate energy
efficiency as a key component for new
equipment, major innovation, new design and to
promote energy saving awareness to our staff
and stake holders.”
`
Monthly Operation & Energy
review by Director - Technical
Review by Corporate Energy
Audit Cell
Review by Plant Head
Review In Energy Cell Meeting
by Energy Manager & HOD's
5
Sustainability Excellence of Indian cement industry- Energy Management
6
Awards: 2nd Prize in National Energy Conservation Award 2016.
7
company profilecompany profile
• Plant Profile
Plant performance indices
Plant performance indices • Summary of Energy Savings
Innovative projectsInnovative projects • Innovative Projects
Energy conservation implementations
Energy conservation implementations
• Energy Conservation Implementations
ENCON Projects ENCON Projects
• ENCON Projects
ENCON Projects based on new
operational strategy
ENCON Projects based on new
operational strategy
• ENCON Projects based on new operational strategy
8
9
Plant Profile
Power Plant
Located at Ganeshpahad village, Damarcherla Mandal of Nalgonda District in Telangana State.
➢Plant Capacity : 2 x 38.5 MW
❖ 160TPH /CFBC boiler /106kg pr./540 deg.
❖ Project Established in year : 2008
❖ Plant Commissioned in year : 2010
10SA FAN
PA FAN
COAL BUNKER
LIME STONE
HP , LT SUPER HEATER
ECONOMISER
APH
E.S.P
FEED PUMP
ID FAN
11
Summary of Energy Savings
S.No Details of Energy Saved Achievement
ElectricalEnergy
(Million Units)
Equivalent Thermal Energy
(Millionkcal)
1 Units Generated in FY:2017-18 289
2Electrical energy savings achieved by reduction in APC when compared to FY:2016-2017
1 % 28.598473
3
Plant Heat rate reduced by when compared to FY:2016-17Based on No of units generated
during FY2017-18 thermal energy saved
24 kcal/
kwh NA
6936
4 Total Thermal Energy Saved (2 +3) 15409
5Thermal energy saved in terms of Tonnes of Oil Equivalent ( TOE) 1540.9
12
SI.NO
Project Type
TitleSavings In units
1 Innovative Running of one SA fan in each Boiler at low loads 2,72,100
2Innovative Isolation of Cooling Water for bed ash cooler during
idle condition80,400
3Innovative
Air pressure /RPM reduction for Inst. Air Compressor 75,375
4Innovative
Reduction of BFP discharge Pressure 11,88,000
5Innovative
Installation blow valve for ESP hoppers 42,600
6 EnconInstallation of low pressure high volume j-seal
blower37,620
7 Encon replacement of sec. crusher motor with lower rating 93,440
8Energy
conservation Improved Throughput in Coal Extraction system 1,01,286
Details of Energy Savings
13
S.NoProject
TypeTitle
Savings ( units)
9 Encon replacement of CEP with energy efficient pump. 2,19,000
10 EnconInterconnection of AC units water line to ACW
pumps common header3,00,960
11 Enconreplacement of BC-9 bag filter fan with lower
capacity5,83,935
12 EnconRetrofitting of conventional light fittings with LED
lightings93,440
13 EnconReduction of water cooled AC’s power consumption
2,19,000
14Operational
strategyOptimization of ESP Aux. Consumption in
according to TG loading94,050
15Operational
strategyReduction of fly ash & bed ash conveying air
pressure by installing low pressure air compressor3,00960
16Energy
conservationTurbine-2 servicing for heat rate improvement
24 kcal/kwh
17Energy
conservationPlant overall Heat rate Improvement
Total Savings 31,58,351
**
** Up to September
Generation ( million units)
14
mil
lio
n u
nit
s
Financial Year
50
100
150
200
250
300
350
400
450
2016-17 2017-18 2018-19
419
289
170
**
Power Export ( million units)
15
mil
lio
n u
nit
s
Financial Year
50
100
150
200
250
300
350
2016-17 2017-18 2018-19
369
257
152
** Up to September
** Up to September
**
APC Percentage
16
aux.
%.
Financial Year
10.00
10.20
10.40
10.60
10.80
11.00
11.20
11.40
11.60
11.80
12.00
2016-17 2017-18 2018-19
11.83
10.84
10.57
Innovative Projects
Implemented
17
Activities Carried Out1. Optimized SA and PA Air Flows and stopped one SA Fan during low loads.2.Seal proof Dampers are provided
in the fan outlet in each Fan and logic implemented in DCS.
Benefits Achieved:1.Total Energy saving per Annum:
=37.79kw x 24 x 150 x 2
=272100 Units
Seal proofDamper
18
Installed seal proof dampers to stop one SA Fan during low loads
Innovative Project-1: Boiler Operation with single SA Fan
Existing Damper
Innovative Project-2
Isolation of Cooling Water circulation through bed ash cooler during Idle condition .
BEFORE:Continues Cooling water circulation
through bed ash coolers even in off condition.
Activities Carried OutON/OFF butterfly valve installed at
water Outlet of each bed ash cooler and logic implemented in DCS.
Benefits Achieved:
Bed ash cooler idle time: 12 HrsSavings Achieved : =20kw/Hrs Total savings annum
= 20kw x 12hrs x 335 days
= 80400units
ON/OFF Butterfly
valve
19
Before: Instrument Compressor Energy Consumption : 1750 units/dayActivities Carried Out
VFD arranged and established optimum RPM of Instrument Air Compressor at required Air Pressure .Identified 2300 RPM is optimum against design RPM of 2975 .
Accordingly replaced the 230mm dia pulley with 180 mm dia pulley on motor.
Benefits Achieved:
Energy Consumption after modification = 1495 units/day
Net energy saving per day =255 units/day
Total savings annum = 225 units x 335 days
= 75375 units
230mm Dia Pully
180mm Dia Pully
Optimization of Instrument Air Compressor RPM
Innovative Project-3
20
Reduction of BFP Discharge Pressure
BEFORE:BFPs ran with Full RPM in both units and
discharge pressure was maintained very high which resulted higher energy consumption in Boiler Feed Water Pumps
Activities Carried OutBFPs Discharge Pressure Control PID
Loop created in DCS to maintain required discharge pressure. BFPs speed controlled by set discharge pressure given by Operator
Benefits Achieved:
Energy saving per Annum = 75 kw x 24 Hrs x 330days x 2 no,s=11,88,000
260 KW MOTOR
160 KW MOTOR
21
PID LOOP IMPLEMENTED
Innovative Project-4
Before: Fluidization Air is provided continuously for ESP hoppers.
Activities Carried OutBlow valve installed in fluidization line and
made open/close of this valve according to dome valve open/close respectively.
Benefits Achieved:
Reduction of fluidizing air consumption = 4000 M3/day
Total Energy Savings Annum = 142units x 300 days = 42600 units
Installation blow valve for ESP hopper fluidization
Innovative Project-5
22
Energy conservation
Activities implemented
23
1.Plant Heat Rate Improvement
24
2900
2930
2960
2990
2016-17 2017-18 2018-19
2,983
2,964
2,959
1.Overhauling of Turbine-2 carried out
2.Improvement of vacuum from 0.84 to 0.91
a)Condenser cleaning carried outb) Helium test conducted & leakages arrestedc) cooling tower efficiency improved
3.Boiler air flows optimized and excess air controlled .
4.Air infiltration points identified and arrested5.Improved APH efficiency by replacing spiral tubes in place of plain tubes
6. Cyclone design changed and installed segment type there by
improved in cyclone efficiency resulted in less LOI.
7.Expansion bellows at ID fan replaced with New bellows for controlling
False air entering, there by ID fan RPM
8.APH to Economizer Expansion Bellow Modified .
25
1a). Activities Carried Out :
Boiler-1
26
APC reduced by 0.44%
3.3
3.4
3.5
3.6
3.7
3.8
3.9
4
Before After
3.98
3.54
3.3
3.4
3.5
3.6
3.7
3.8
3.9
4
Before After
3.92
3.53
Boiler-2
APC reduced by 0.39%
Reduction APC in Boilers
27
2.Enhancing Coal Extraction system output and
Reduction of specific power consumption
0.00
0.50
1.00
1.50
2.00
2.50
3.00
2016-17 2017-18 2018-19
2.68
1.67 1.63
Sp. Power Consumption
0
50000
100000
150000
200000
2016-17 2017-18 2018-19
164381 161004
96308
Coal Transfer to the bunker
Tones
0
500
1,000
1,500
2,000
2,500
2016-17 2017-18 2018-19
2,0921,631
1,038
Running Hours
28
Before: Coal Plant Throughput is low and Consuming high Specific Power .
Activities Carried OutProcured 10mmx15mm Screen Decks and
replaced top 3 Decks in place of 8mmx15mm Screen Decks.
Benefits Achieved:
coal plant out put tonnage increased around 110 to 115 TPH. ( 20 to 25 TPH improvement)
8mmx15mm Screen Mesh
10mmx15mm Screen Mesh
3.Enhancing Coal Extraction system output and
Reduction of specific power consumption3a) Secondary screen output improvement
29
Before: 100% Coal was feeding to secondary crusher from Stock file through short belt conveyors
Activities Carried Out1.Sieve analysis carried out and found more than 60% product found in Stock file .
2.Hence Bypass chute arranged for crusher and Fed Coal directly to screen and only rejects Fed to the crusher there by load on crusher is reduced.
Benefits Achieved:
Total savings annum (a & b) = 101286 units
3.Enhancing Coal Extraction system output and
reduction of specific power consumption3b) Secondary Crusher bypass chute arrangement
ENCON PROJECTS IMPLEMENTED
30
Installation of Energy efficient new J-seal blower in place of 2 no’s of same KW roots blowers
BEFORE
2 No’s 75kw J-seal blowers are running
Power Consumption:
J-seal-1 (50amps), running kw=35
J-seal-2 (55amps), running kw=39
Total running kw= 74
Activities Carried Out
Low pressure and high volume energy efficient blower with same kw motor
installed
Power Consumption:
J-seal-New (65amps), running kw = 46
Benefits Achieved:
1.Total Energy saving = 74kw-46kw
= 28kw
2.Total savings per annum
= 28kw x 24hr x 330
=221760 units
31
Encon Project-1
Replacement of Coal secondary crusher with lower size motor 260kw to 160kw with the same output
BEFORE:Coal Secondary crusher 260Kw
Power Consumption: 99kw(140amps)
Activities Carried Out260kw motor replaced with 160kw motor
Benefits Achieved:
Crusher running load = 79kw(112amps)
Savings Achieved = 99kw-79kw=20kw
Total Energy saving annum
= 20kw x 12hrs x 330 days= 79200 units
260 KW MOTOR
160 KW MOTOR
32
Encon Project-2
Replacement of Existing CEP with Energy Efficient Pump
BEFORE:
Motor Power Rating : 160kw Avg.Power Consumption = 110kw
Activities Carried OutMotor Power Rating : 90kw
Avg. Power Consumption = 80kwPower Saving = 110 – 80 = 30kwh
Benefits Achieved:
1.Total Energy savings per annum=30kw x 24Hrs x 330 x 2 = 475200 Units
260 KW MOTOR
160 KW MOTOR
33
Old Pump160 kw
New Pump 90KW
Encon Project-3
Interconnection of AC units cooling water line from ACW pump header
34
BEFORE:Water circulation pumps 2 x 11kw used for Centralized AC units of 16.5 tons which were mounted on TG floor
Activities Carried OutAC circulating water line connected ACW pump header and removed cooling Water pumps . Further ACW pump controlled from VFD through pressure control PID.
Benefits Achieved:
1.Total Energy savings per annum = 11kw x 24Hrs x 365= 96360 Units
Encon Project-4
Replacement of BC-9 bag filter fan motor with lower size motor 15kw to 5.5 kw
BEFORE:Bag filter fan motor :15Kw
Activities Carried Out15kw motor replaced with 5.5kw
motor
Benefits Achieved:
Bag filter fan running load: 5.5kw
Energy Savings Achieved = 15kw-5.5kw=9.5kw
Total Energy saving per annum
= 9.5kw x 12hrs x 330 days
= 37620 units
Encon Project-5
35
Retrofitting of conventional light fittings HPMV/SV/MH lamps with LED lighting fixtures
S. NO DISCRIPTIONTOTAL
NOSUSED NOS
LOCATIONREPLACED WITH
SAVING
NET SAVING
IN WATTS
1 70W LED FITTINGS 55 55STREET
LIGHTS150W 80W 4400
2 40W LED FITTINGS 67
15BOILER 1
150 110W 1650
7 70 30W 210
15BOILER 2
150 110W 1650
5 70 30W 150
10STREET
LIGHTS150W 110W 1100
5BC - 4
TUNNEL150W 110W 550
6 RO PLANT
AERA
150W 110W 660
4 70W 30W 120
340W WELL GLASS
FITTINGS6 6 ESP 1,2 70W 30W 180
4 20W LED BULBS 3115 UNIT-1 36W 16W 240
16 UNIT-2 36W 16W 256
525W CEALING
FIITNGS30 30
OFFICE AND
VFD36W 11W 330
6 150W LED FIITNGS 10 9 TG HALL 3* 250 600W 5400
7100W LED FLOOD
LIGHTS20
10BOP
250W 150W 1500
10 400W 300W 300036
Benefits Achieved:
Total saving per day
= 21.4kw x 12hrs
=256 units
Total savings annum
= 256 x 365 days
= 93440 units
Encon Project-6
37
Reduction of water cooled AC’s power consumption
BEFORE:VFD drives room Air conditioning
consumption : 2600 units/day
Activities Carried Out1.Running status of individual AC units
indication provided in VFD room2.Requirement of the No. of AC units schedules
prepared according to the TG sets in operation and according to the loading on the TG sets.
Benefits Achieved:
AC conditioning consumption
=2000 units/day
Total savings annum =2600-2000
=600 x 365days
=2,19,000 units
Encon Project-7
ENCON PROJECTS BASED ON NEW OPERATIONAL STRATEGY
38
39
Before: 1.ESP field Current maintaining constant at all Load conditions. 2.All ESP fields kept on at low loads also.
Activities Carried Out1. Switched off some fields at low load
conditions 2.Reduced ESP Field currents wrt Load changes
i) One ESP field kept in OFF & ONE field current reduced up to 10%, Loads between 25 - 30MW
ii) TWO E.S.P fields kept in OFF & TWO fields current reduced up to 10 %, Loadsbetween 20 – 25 MW
Benefits Achieved:
Energy Savings Per Day = 285 UnitsEnergy Saving Per Year
= (285kwh X 330Days) = 94,050 Units
1200
1700
30.19 30.72 22.5 22.56
1810
1520
1780
1495
E.S
.P A
ux
(KW
)
Generation (MW)
E.S.P Aux(Kwh)
0
2
4
6
30.19 30.72 22.50 22.56
5 4 5
3
No
of
fiel
ds
Generation (MW)
Number of Fields
Optimization ESP Aux. ConsumptionProject-1
Reduction of fly ash & bed ash conveying air pressure
❖Fly ash& bed ash conveying air pressure reduced from 5.5kg to 4.2 kg
Activities Carried OutInstallation of 110 kw New LP air
compressor in place of existing 160 kwHP air compressor for Ash Handling for Energy Saving.
Benefits Achieved:
1.Total Energy saving per Annum: = 38kw x 24 Hrs x 330 days= 300960 Units
260 KW MOTOR
160 KW MOTOR
40
160 kw
110 kw
Project-2
41
BEFORE:During boiler light up we are using diesel oil of 3.3KL per each light up
Activities Carried Out1.Installed separate tank & transfer
pump for polymer oil usage2. Oil burner system modified
suitable for polymer oil usage
Benefits Achieved:
Total Polymer Oil used
FY: 2017-18= 45 KL
Cost at price Rs.35 per liter = 15,75,000
Cost of diesel at avg. price Rs.70/- ltr
= 316,55,34
Net Saving per annum
=15,90,534
Promoting non conventional fuel usage in Boiler during light up
Project-3
Benefits: 1.Each area wise power consumption can be monitored 2. Customization reports available on each day3.Any abnormal consumption can be tracked on day to day basis 4. Daily efficiency report will be generated based on EMS reports
Daily Auxiliary Report Date: 11/06/2017A) BOILER-1 B) BOILER-2
SI.No
Description Meter No.Units(Kwh)
SI.No
Description Meter No.Units(Kwh)
1 CT-1 M3 0 1 CT-2 M8 13267.01
2 CT-3 M2 0 2 CT4-(MCW4+MCW5) M10-(M61+M62) 18697.57
3 BOILER MCC-1-(ESP1) M28-M42 0 3 BOILER MCC-2-(ESP2) M44-M58 893.6
4 AUX MCC-1 - (MLDB1) M29-M41 0 4 AUX MCC-2 M45 3399.3
TOTAL 0 TOTAL 36257.48
C) TURBINE-1 D) TURBINE-2
SI.No
Description Meter No.Units(Kwh)
SI.No
Description Meter No.Units(Kwh)
1 TG MCC-1 M33 144.22 1 TG MCC-2 M49 2805.2
2 CTMCC1-(AC UNITS) M31-M43 615 ACW-1 M55 3050.59
3 ACW-2 M34 0 3 ACW-3 M56 0
4 MCW-1
M6 0
4 MCW-4 M61 5055.01
5 MCW-2 5 MCW-5 M62 5366.4
6 MCW-3 6 CTF-1
M38 07 CTF-4
M52 2175.2
7 CTF-2
8 CTF-5 8 CTF-3
9 CTF-6
10 CTF-7 TOTAL 16277.2
TOTAL 2934.42
E) WATER SYSTEM F) COAL HANDLING PLANT
SI.No
Description Meter No.Units(Kwh)
SI.No
Description Meter No.Units(Kwh)
1 PUMP HOUSE M4 1512.99 1COAL UNLOADING MCC
M53 198.56
2 RO PLANT MCC-2 M36 927.5 2 COAL CRUSHER-1 M40 0
3 FIRE FIGHTING MCC M39 391.97 3 COAL CRUSHER-2 M54 198.95
TOTAL 2832.46 4 COAL EXT MCC-1 M30 331.08
TOTAL 728.59
G) ASH HANDLING SYSTEM H) INSTRUMENT COMPRESSOR
SI.No
Description Meter No.Units(Kwh)
SI.No
Description Meter No.Units(Kwh)
1ASH HANDLING MCC2(Ash Comp-B,C& Mics)
M51 477.05 1 INSTRUMENT COMP-1 M63 1200.8
2 LP COMPRESSOR M37 0 2 INSTRUMENT COMP-2 M64 0
3 ESP-1 M42 0 3 INSTRUMENT COMP-3 M65 1780.9
4 ESP-2 M58 1776.1
TOTAL 2253.15 TOTAL 2981.7
Installation of Energy Management System
42
Project-4
Greenery Development
43
Photos of Greenery development
44
Coal Handling Plant Area
Fly ash Silo Area Coal Unloading Area
used for dust suppression
47
Waste Water Utilization
48