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BEST PRACTICES TOWARDS ENERGY

EFFICIENCY

UltraTech Cement Limited.


(Unit – Narmada Cement, Jafarabad Works)
Overview of NCJW

Narmada Cement-Jafarabad Works was established in 1982 with an


installed capacity of 1 MMTPA clinker and has been gradually
increased to 1.50 MMTPA (4,300 – 4,500 TPD). Cement capacity is
0.50 MMTPA (1,150 TPD). The Unit is ISO 9001:2008, ISO
14001:2004, OHSAS 18001:2007, ISMS 27001:2005 & SA
8000:2008, ISO-50001:2011certified

It is India's first split location dry process cement plant with Fuller
technology having four-stage suspension pre-heater, in-line flash
calciner, reverse air bag house dust collector, vertical roller mills
besides to be the first to unload imported South African coal at plant
jetty. It transports 100% clinker to grinding units is in bulk by sea
route. The special feature of this plant is 'Just in Time‘ design for raw
mill circuit. As against conventional norms of 20,000 MT silo for raw
meal storage it has 2,000 MT silo.
Overview of NCJW

The grinding units associated with Jafrabad Cement Works are Magdalla Cement
Works having capacity of 0.80 MMTPA and Ratnagiri Cement Works having
capacity of 0.50 MMTPA. All three coast-based split location units have Jetties for
marine transportation. Narmada Cement was the prime supplier of fly ash based
Portland Pozzolana Cement (PPC) to Sardar Sarovar Dam on river Narmada,
which is the World's second largest concrete gravity dam (by volume). We
created a benchmark in Indian cement industry with installation of SF 3 X 6 cross
bar 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 with
the theme "Life is precious, We care for it"as advocated by Shri O P
Puranmalka, Business Director. Moving ahead in the safety journey, we achieved
lost time injury frequency rate (LTIFR) 0.00 in the year 2014-15.
ENERGY SAVING PROJECTS

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1.0 Case Study-Elimination of material settling at separator
inlet duct by providing hump to increase air velocity.
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.
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
Calculation for Hump size

Before After
Area Measurement UOM Area Measurement UOM
Sep I/L Duct
1.5 Mtr Radius (Ra) 1.25 Mtr
Radius(Rb)
Duct Area 1.7671 M2 Duct Area 1.23 M2

Flow 26.578 M3/Sec Flow 26.578 M3/Sec


Flow 95680 M3/Hr Flow 95680 M3/Hr
Velocity 15.04 M/Sec Velocity 21.66 M/Sec

Cos Ø = (Height Of hump)/(a/2)

Height of hump = Rb-Ra


250mm

Ø Cement angle of repose(Ø )= 20


deg

a Base of hump (a ) = 532mm


532mm
Profile of dust settling inside duct

Before After
Separator
Inlet Duct

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Hump view in separator

Hump in
separator inlet
duct

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Power Saving Calculation

BEFORE AFTER
Existing Fan running
Previous fan power in KW 96 84
KW
Run Hrs 24 Run Hrs 24
Power/Day 2304 Power/Day 2016
Power per month 69120 Power per month 60480

Saving

Saving in energy KWh per year 103680

Saving in Lacs / Year (considering unit rate @ 4.85) 5.03


2.0 Reduction in heat losses across Preheater

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


pressure drop across calciner
Velocity at orifice at different location

Existing Velocity 30m/Sec after orifice modification

21.23 21.23
m/sec m/sec

41.35
m/sec 30m/sec
21.23
m/sec
21.23
m/sec

12.09 12.09
m/sec m/sec
Result

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
1000
875 902 880
900 850
800
688
700 650
600
500
382 386
400
300 304
300
200
113 84
51 69
100 28 27 42 49
0
Before After
Result

Kiln Riser DP
Before After
90 84
80
70
60
50
42
40
30
20
10
0
Before After
Result

KWH SG Fan RPM


2350 906 910
2300 905
2310 899
2250 895 900
894 893 893
895
2200
886 890
2150
2157 2159 2152 885
2100 2143 2143
877 880
2050 2094
2062 875
2000 870
1950 865
1900 860
Nov-14 Dec-14 Jan-15 Feb-15 Mar-15 Apr-15 May-15 Jun-15
Month
Result

Saving in Orifice Modification

Saving Average 280KWH of PH Fan

Kiln Running hours =345*24


=8280
Total Saving in KWh =8280*248
=2053440
Saving of Rs = 2053440 *4.67Rs/Unit
=95.89Lacs/Annum
3.0 Reduction in heat by increasing insulation in TA duct
•Increased insulation thickness in TAD from 65 to 100mm in 20m lining area
BEFORE AFTER

•Backup Insulation of 35mm provided in Stage IV feed pipe.


BEFORE AFTER
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 : 129312.65


Total Benefit in kCal kG/Clinker : 0.69

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4. Various energy saving projects

Saving
SNo. Title Action Taken
KW/Month
Grinding aid motor running For optimizing Grinding Aid system
with constant speed without VFD installed. Now Motor speed is
1 136.80
considering variation in Cement varied with TPH.
mill Feed.
Pre grinder dust collector
material conveying air slide Interlock provided such that if pre
2 blowers were running grinder stopped two blowers stopped 1367.81
continuously even if pre grinder after 10 min.
is kept stop condition.
1) Sep. Fan control changed from
Separator fan was running on RPM base to KW base.
RPM basis so power is not 2) Trommel screen was taken in
3 monitored, also due to material operation to reduce the nibs 17561.84
settling in duct it was difficult settling in duct
maintain the draft in circuit. 3) One hump is provided to increase
the velocity in duct.
4. Various energy saving projects

Saving
SNo. Title Action Taken
KW/Month
To maintain the mill discharge Blaine mill
4 Reduction in Mill fan RPM 688.03
fan rpm maintaining from 400 to 460.
Mill taking more power with Mill power optimized with maintaining the
5 7495.20
considering TPH. media size & qty.
Close loop system was developed and
Pre grinder running hrs was feed was controlled w.r.t. reject .Through
6 more because fresh feed was put set point to be kept manually by 13200
monitoring manually. monitoring the crusher load.

Separator motor was of old


7 version i.e. DC motor and taking Converted sep motor from DC to AC. 8208.00
more power to operate.
Our Goal is to achieve Excellence in
Energy Conservation
Thank You

21
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 24
Saving in KW/Day (C X D)-------E 4.56
Saving in KW/Month (E X 30)-------F 136.8
Saving calculation of Pre grinder blower
running hours

Calculation-Earlier Condition Calculation-Existing Condition


Motor rated KW 3.7 Motor Rated KW 3.7
Operating KW 2.74
Operating KW 2.74
No. of blowers 2
No. of blowers 2
Pre grinder running Hrs 15
Pre grinder running Hrs 15 Idle running for each stoppage
0.17
Idle running 9 of pre grinder
Power/Day of both blowers 131.52 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


Saving calculation Cement Mill Separator fan

Power calculation on current year


Power calculation on Last year performance
performance
Operating current in
198.42 Fan running KW 84
Amps
Operating KW 108.39 Running Hrs 24

Running hours 24 Power/Day in KWh 2016

Power/day in KWh 2601.395 Power per month in KWh 60480


Power per month in
78041.84
KWh

Saving of KWh per month 17561.84


Saving calculation Cement mill fan

Power calculation on Last year performance Power calculation on current year performance
Operating current in Amps 8.8 Operating current in Amp 7.05
Operating KW 4.81 Operating KW 3.85
Running hours 24 Running hours 24.00
Power/day in KWh 115.37 Power/day in KWh 92.43
Power per month in KWh 3461.18 Power per month in KWh 2772.88

Saving of KWh per month 688.30


Saving calculation Mill main Motor KW

Power calculation on Last year performance Power calculation on current year performance
Operating KW 1363.63 Operating KW 1353.22
Running hours 24 Running hours 24
Power/day in KWh 32727.12 Power/day in KWh 32477.28
Power per month in KWh 981813.6 Power per month in KWh 974318.4

Saving of KWh per month 7495.20


Saving calculation of Pre grinder circuit

Power calculation on current year


Power calculation on Last year performance
performance
Operating KW 140.00 Operating KW 95.00

Running hours 14 Running hours 16

Power/day in KWh 1960 Power/day in KWh 1520

Power per month in KWh 58800 Power per month in KWh 45600

Saving of KWh per month 13200.00


Saving calculation of Cement mill separator
Motor from DC to AC

Power calculation on Earlier performance Power calculation on current year performance

2 Nos DC Motor Cooling fan operating


5.4 No Cooling fan for AC Motor. 0
KW

DC Motor operating KW 13.00 Sep AC motor Operating KW 7.00


Total Power drawn by the separator Total Power drawn by the Separator drive
18.40 7.00
drive system. system.
Running hours per day 24 Running hours per day 24
Daily Power Consumption in KWh 441.6 Daily Power Consumption in KWh 168
Monthly Power Consumption in KWh 13248
Monthly Power Consumption in KWh 5040

Saving of KWh per month 8208.00