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Wadi Cement Works 29- 31 st Aug 2018 Best Practices in Energy Efficiency & Energy Optimization Presented at :- 19th National Award for Excellence in Energy Management 2018 Presented by: Vikas Kumar Lokesh Rao 1

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Page 1: Best Practices in Energy Efficiency & Energy Optimization ... · Cement Kiln 1 KWh/T Cem 10 K Cal/Kg Clic. 4 Replacement of DC drive of Kiln String Fan with MV Drive 0.4 KWh/T Cem

Wadi Cement Works 29- 31st Aug 2018

Best Practices in Energy Efficiency & Energy Optimization

Presented at :-19th National Award for

Excellence in Energy Management 2018Presented by: Vikas Kumar

Lokesh Rao

1

Page 2: Best Practices in Energy Efficiency & Energy Optimization ... · Cement Kiln 1 KWh/T Cem 10 K Cal/Kg Clic. 4 Replacement of DC drive of Kiln String Fan with MV Drive 0.4 KWh/T Cem

ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

Plant Overview – Wadi Cement Works

Agenda

2

Renewable Energy sources, utilization of waste for replacing the conventional energy

Energy Efficiency & Benchmarking with Global best SEC

Innovative Projects – Case Studies in EE

Involvement of Employees, Team work in ENCON, Monitoring & Reporting, Implementation

Energy Saving Projects

Page 3: Best Practices in Energy Efficiency & Energy Optimization ... · Cement Kiln 1 KWh/T Cem 10 K Cal/Kg Clic. 4 Replacement of DC drive of Kiln String Fan with MV Drive 0.4 KWh/T Cem

ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

ACC Wadi Geographic Location

KARNATAKA

STATE

Plant Site

Clinkering : 5.83 MTPA, Cement - 6.03 MTPA Power - 125 MW

Wadi-1

Wadi-2

3

Page 4: Best Practices in Energy Efficiency & Energy Optimization ... · Cement Kiln 1 KWh/T Cem 10 K Cal/Kg Clic. 4 Replacement of DC drive of Kiln String Fan with MV Drive 0.4 KWh/T Cem

ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

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

IndigenousPlant 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)

Page 5: Best Practices in Energy Efficiency & Energy Optimization ... · Cement Kiln 1 KWh/T Cem 10 K Cal/Kg Clic. 4 Replacement of DC drive of Kiln String Fan with MV Drive 0.4 KWh/T Cem

ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

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

Page 6: Best Practices in Energy Efficiency & Energy Optimization ... · Cement Kiln 1 KWh/T Cem 10 K Cal/Kg Clic. 4 Replacement of DC drive of Kiln String Fan with MV Drive 0.4 KWh/T Cem

ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

Reduction in SEC Performance 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%)

660.0

670.0

680.0

690.0

700.0

710.0

720.0

730.0

Y'15 Y'16 Y'17 Y'18 GAP Top 10 NationalBest

697.6

709.7

722 719.6

702

686

17.6

STEC K Cal/ Kg Clinker

0.00

10.00

20.00

30.00

40.00

50.00

60.00

Y'15 Y'16 Y'17 Y'18 GAP Top 10 NationalBest

56.6158.23 56.92 56.37

4.57

51.843.9

Clinkering SEC KWh/T cli.

Page 7: Best Practices in Energy Efficiency & Energy Optimization ... · Cement Kiln 1 KWh/T Cem 10 K Cal/Kg Clic. 4 Replacement of DC drive of Kiln String Fan with MV Drive 0.4 KWh/T Cem

ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

SEC of Cement Grinding in year 2018 has been increased from previous years due to;

✓ Change in product portfolio

✓More Concrete C+ production instead of PPC;

✓ Less throughput & High grinding SEC during concrete + production

✓ High clinker temperature leads to poor availability of VRPM – Pregrinder.

Reduction in SEC Performance in last 3 - Years

0.00

10.00

20.00

30.00

40.00

Y'15 Y'16 Y'17 Y'18 GAP Top 10 NationalBest

34.26 34.95 34.9235.12

4.62

30.5 28.8

Grinding Energy KWh/T Cem.

0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

80.00

Y'15 Y'16 Y'17 Y'18 GAP Top 10 NationalBest

74.55 77.2273.93 72.58

1.39

71.1963.13

Total Energy KWh/T Cem

Page 8: Best Practices in Energy Efficiency & Energy Optimization ... · Cement Kiln 1 KWh/T Cem 10 K Cal/Kg Clic. 4 Replacement of DC drive of Kiln String Fan with MV Drive 0.4 KWh/T Cem

ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

SEEC - Comparison with Global Best SEC

1.6 2.1 1.98 1.83 0.7

16.97 18.3 16.64 16.4711.1

38.69

49.0741.84

48.86

23.9

20.5

21.85

20.3919.15

17.05

34.26

34.95

34.9235.12

27.07

4.92

5.38

4.933.9

0

20

40

60

80

100

120

140

2015 2016 2017 2018 Global Best

General Consumption

Cement Grinding

Clinker Production

Solid Fuel Preparation

Raw Meal Preparation

Raw Material Preparation

72.5877.22

73.93

63.91

8.67

74.55

Page 9: Best Practices in Energy Efficiency & Energy Optimization ... · Cement Kiln 1 KWh/T Cem 10 K Cal/Kg Clic. 4 Replacement of DC drive of Kiln String Fan with MV Drive 0.4 KWh/T Cem

ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt. 9

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 Cem10 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 Cem10 K Cal/Kg Clic.

8 Installation of double flap damper below Coal mill #2 BH discharge

0.1 KWh/T cem

Page 10: Best Practices in Energy Efficiency & Energy Optimization ... · Cement Kiln 1 KWh/T Cem 10 K Cal/Kg Clic. 4 Replacement of DC drive of Kiln String Fan with MV Drive 0.4 KWh/T Cem

ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt. 10

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 system

13.2 MW Potential

10 Replacement of Cement Mill & Raw Mill separator DC drive with LV drive

0.17 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 Cem4 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.

Page 11: Best Practices in Energy Efficiency & Energy Optimization ... · Cement Kiln 1 KWh/T Cem 10 K Cal/Kg Clic. 4 Replacement of DC drive of Kiln String Fan with MV Drive 0.4 KWh/T Cem

ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt. 11

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

Page 12: Best Practices in Energy Efficiency & Energy Optimization ... · Cement Kiln 1 KWh/T Cem 10 K Cal/Kg Clic. 4 Replacement of DC drive of Kiln String Fan with MV Drive 0.4 KWh/T Cem

ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt. 12

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 in 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

Page 13: Best Practices in Energy Efficiency & Energy Optimization ... · Cement Kiln 1 KWh/T Cem 10 K Cal/Kg Clic. 4 Replacement of DC drive of Kiln String Fan with MV Drive 0.4 KWh/T Cem

ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt. 13

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 Replaced ILC tertiary air duct damper to enable operation at oxidizing kiln conditions to reduce CO and improve clinker quality (C3S)

1100000 5.5 6

11 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

12 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

Page 14: Best Practices in Energy Efficiency & Energy Optimization ... · Cement Kiln 1 KWh/T Cem 10 K Cal/Kg Clic. 4 Replacement of DC drive of Kiln String Fan with MV Drive 0.4 KWh/T Cem

ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt. 14

Energy Saving projects implemented in FY 2016-17

Sr. No.

Title of Project

Annual Saving

Electrical(KWh)

Thermal (Mio. K Cal)

Total Annual Saving

(Mio. INR)

Investment

made (Mio. INR)

1Reduction in false air ingress in Coal Mill#1 from > 35% to < 15% 60000 0.27 0

2Reduction in false air ingress in Coal Mill#2 from 35% to TARGET < 15%

90000 0.41 0

3

Reduction in false air ingress in Raw Mill#1 (mill inlet to fan outlet) from ≈ 17% to Target < 10%

207740 0.94 0

4Improved thermal substitution rate (TSR) from 5.69% to 6.32%

7648 13.33 0

5Improvement of Throughput from 52 TPH to 60 TPH in coal mill # 2 during PetcokeGrinding

176538 0.8 0

Page 15: Best Practices in Energy Efficiency & Energy Optimization ... · Cement Kiln 1 KWh/T Cem 10 K Cal/Kg Clic. 4 Replacement of DC drive of Kiln String Fan with MV Drive 0.4 KWh/T Cem

ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt. 15

Energy Saving projects implemented in FY 2016-17

Sr. No.

Title of Project

Annual SavingElectrical(KW

h) Thermal (Mio. K Cal)

Total Annual Saving

(Mio. INR)

Investment

made (Mio. INR)

6Replacement of new cooler ESP duct to reduce false air ingression 360000 1.8

1

7

To maintain L/S crusher output size, R 75mm in the range of 5-10% in order to improve throughput and SEEC in Raw Mill VRM

339270 1.54 0

8

Skew correction in old high grade reclaimer by installing LVDT in place of skew pot

72000 0.36 0.05

9

Optimisation of CM#1 & CM#2 throughput by 95 % and 90% respectively in case of PPC grinding by:a) Increasing mill ventilation rateb) grinding media optimisation andc) 100% petcoke fired Clinker quality

optimisation.

935193 4.68 1

Page 16: Best Practices in Energy Efficiency & Energy Optimization ... · Cement Kiln 1 KWh/T Cem 10 K Cal/Kg Clic. 4 Replacement of DC drive of Kiln String Fan with MV Drive 0.4 KWh/T Cem

ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt. 16

Energy Saving projects implemented in FY 2015-16

Sr. No.

Title of Project

Annual Saving

Electrical(KWh)

Thermal (Mio. K Cal)

Total Annual Saving

(Mio. INR)

Investment

made (Mio. INR)

1

Reduction in SEEC in Raw Mill -1 by1) Improving Raw Mill#1 Fan efficiency

from 70% to 78% by maintaining optimum axial and radial cone overlap.2) Reducing False Air from 30% to 12%

across the mill circuit.3) Increasing PRI by optimizing mill feed size.(earlier R75 ~ 25 to 30% and present R 75~ 5 to 10%).4) Strengthening of daily walk by

inspection, Preventive Maintenance and CBM activities; resulting improve in MTBF

1647652 7.12 0.5

2

Reduction in clinker cooler discharge temp by 20 deg C (By Raw mix design modification)

12792 15.65 0

Page 17: Best Practices in Energy Efficiency & Energy Optimization ... · Cement Kiln 1 KWh/T Cem 10 K Cal/Kg Clic. 4 Replacement of DC drive of Kiln String Fan with MV Drive 0.4 KWh/T Cem

ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt. 17

Energy Saving projects implemented in FY 2015-16

Sr. No.

Title of Project

Annual SavingElectrical(KW

h) Thermal (Mio. K Cal)

Total Annual Saving

(Mio. INR)

Investment

made (Mio. INR)

3

Improvement in TSR to 5.69% by enhancing usages of AFR at kiln (PCPF facility - Pre- and Co-processing facility

commissioned on Dec 2014)

12752.84 156 700

4

Reduction in SEEC of Raw Mill -2 by1) Improving Raw Mill#2 Fan efficiency

from 79% to 83% by maintaining optimum axial and radial cone overlap. 2) Reducing False Air from 25% to 11% across the mill circuit.3) Strengthening of daily walk by inspection, Preventive Maintenance and CBM activities; resulting improve in MTBF 4)Installing SPRS in place of GRR for Raw Mill#2 System Fan

4099980 17.71 9.35

Page 18: Best Practices in Energy Efficiency & Energy Optimization ... · Cement Kiln 1 KWh/T Cem 10 K Cal/Kg Clic. 4 Replacement of DC drive of Kiln String Fan with MV Drive 0.4 KWh/T Cem

ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt. 18

Energy Saving projects implemented in FY 2015-16

Sr. No.

Title of Project

Annual SavingElectrical(KWh

) Thermal (Mio. K Cal)

Total Annual Saving

(Mio. INR)

Investment

made (Mio. INR)

5 “War on Waste” To Improve the housekeeping and Reduce the waste generation i.e. Reduction in spillages, compressed air & water leakage, Lubricants etc.

198000 (E)

1200 (T)2.32 0

6 Improved in throughput & reduction of idle running hour of mines LS crushers by 2-shift operation of mining activities instead of 3 - shift operation.

115500 0.5 0

7 Cooler static inlet modification to ABC

5816 6.96 35

7.1 Improving the cooler recuperation efficiency from 65% to 69 % .

7.2 Reduction in cooler vent gas temperature from 302 oC to 298 oC

7.3 Reduction in clinker exit temperature from 220 oC to 170 oC

Page 19: Best Practices in Energy Efficiency & Energy Optimization ... · Cement Kiln 1 KWh/T Cem 10 K Cal/Kg Clic. 4 Replacement of DC drive of Kiln String Fan with MV Drive 0.4 KWh/T Cem

ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

INNOVATIVE PROJECT -1 Page 1 of 4

Plant : WD` Title of the measure :

Reduction in primary air in firing burner from 9.6 % 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

Page 20: Best Practices in Energy Efficiency & Energy Optimization ... · Cement Kiln 1 KWh/T Cem 10 K Cal/Kg Clic. 4 Replacement of DC drive of Kiln String Fan with MV Drive 0.4 KWh/T Cem

ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

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 burner2. 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 NOxEmission

1. Reduction in PA Air2. Jet air nozzle dia. reduction from 27 mm to 22 mm

Page 21: Best Practices in Energy Efficiency & Energy Optimization ... · Cement Kiln 1 KWh/T Cem 10 K Cal/Kg Clic. 4 Replacement of DC drive of Kiln String Fan with MV Drive 0.4 KWh/T Cem

ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

Picture/ sketch before modification Picture/ sketch after modification

PRODUCTIVITY IMPROVEMENT POTENTIAL Page 3 of 4

22 mm Dia.

Page 22: Best Practices in Energy Efficiency & Energy Optimization ... · Cement Kiln 1 KWh/T Cem 10 K Cal/Kg Clic. 4 Replacement of DC drive of Kiln String Fan with MV Drive 0.4 KWh/T Cem

ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

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

Page 23: Best Practices in Energy Efficiency & Energy Optimization ... · Cement Kiln 1 KWh/T Cem 10 K Cal/Kg Clic. 4 Replacement of DC drive of Kiln String Fan with MV Drive 0.4 KWh/T Cem

ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

INNOVATIVE PROJECT -2 Page 1 of 5

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. ChandaWorks

Page 24: Best Practices in Energy Efficiency & Energy Optimization ... · Cement Kiln 1 KWh/T Cem 10 K Cal/Kg Clic. 4 Replacement of DC drive of Kiln String Fan with MV Drive 0.4 KWh/T Cem

ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

Picture/ sketch before modification Picture/ sketch after modification

Electrical Energy Conservation Case Study Page 2 of 5

Before dam ring increase Material empty After dam ring increase material height

Page 25: Best Practices in Energy Efficiency & Energy Optimization ... · Cement Kiln 1 KWh/T Cem 10 K Cal/Kg Clic. 4 Replacement of DC drive of Kiln String Fan with MV Drive 0.4 KWh/T Cem

ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

Picture/ sketch before modification Picture/ sketch after modification

Innovative Project 2 Page 3 of 5

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

Page 26: Best Practices in Energy Efficiency & Energy Optimization ... · Cement Kiln 1 KWh/T Cem 10 K Cal/Kg Clic. 4 Replacement of DC drive of Kiln String Fan with MV Drive 0.4 KWh/T Cem

ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

Electrical Energy Conservation Case Study Page 4 of 5

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 materialresulted in lower mill DP caused increase in feed by15-20 TPH.

✓MILL vibration Reduced from 20- 22 mm/sec to<7 to 8 mm/sec

✓Silo feed bucket elevator load increase around 15to 20 Amps

✓Mill power consumption comes down around 1.33Unit/ton of cl.

✓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 sealdamage & pump failure

✓Reduction in oil temperature resulting in reductionin seal damage, solenoid malfunctioning & oilconsumption.

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ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

Monetary and Non Monetary benefits Page 5 of 5

Parameter UoM OEM design

Before modification

After Modification

Output Tph 560 560 575-585

Product fineness Residue-90µ

% 25 27 27

Product fineness Residue-212µ

% 3 6 6

Mill Body Vibration mm/sec 20-25 <7

Separator vibration mm/sec 22-28 <8

SEEC MD KWh/T Mat 9.3 8.9 8.1

SEEC Fan KWh/T Mat 10.24 8.3 7.4

Total SEEC KWh/T Mat 19.4 18.9 17.8

Total reduction of around 1 KWh/T mat has been achieved

Page 28: Best Practices in Energy Efficiency & Energy Optimization ... · Cement Kiln 1 KWh/T Cem 10 K Cal/Kg Clic. 4 Replacement of DC drive of Kiln String Fan with MV Drive 0.4 KWh/T Cem

ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

INNOVATIVE PROJECT -3 Page 1 of 3

Plant : WD Title of the measure : Reduction in Clinker

temperature by replacing 4 Nos. Cooler fan & 1 compartment cooler platesCategory A Known concept

with Unique Application

Description of the energy conservation measure:

The clinker cooler recuperation zone has 4 fans (4,5,6,7) for first moving compartments .These fans are replaced with higher pressure ratings. Design pressure of fan 4&5 is changed from 88 mbar to 120 mbar whereas of fan 6&7 is changed from 88 mbar to 112 mbar. The cooler plates (350) of compartment 2 were also replaced during the shutdown.

Problem Faced:

✓ Higher Clinker Exit temperature

✓ Higher Thermal Energy Consumption✓ Restriction in Fan Flow

Page 29: Best Practices in Energy Efficiency & Energy Optimization ... · Cement Kiln 1 KWh/T Cem 10 K Cal/Kg Clic. 4 Replacement of DC drive of Kiln String Fan with MV Drive 0.4 KWh/T Cem

ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

TANGIBLE IMPACT OF THE PROJECT Page 3 of 3

•The grate speed is reduced from 14-16 ST/min to 10-12 ST/min. There is improvement in clinker bed height and clinker cooling. •The ESP inlet temperature on finer clinker side is around 320 deg C and on coarser side is around 240 deg C. •The measured clinker temperature was in the range of 145 -155 deg C. This reduction in clinker temperature from earlier 175-180 deg C corresponds to reduction in cooler losses by ~ 4.0 kcal/kg Clic.

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ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

Renewable Energy sources & Compliance of RPO

30

Solar Delineators @ all curve ant intersection

Solar Powered Zebra crossing with flasher & buzzer

Solar Street Lights installed at Plant & various location

Particulars Units Y'2013-14 Y'2015-16 Y'2016-17 2017-18 Total

REC's Liability (Solar & Non-Solar) Nos. 20782 23010 27017 41517 112326

REC's Purchased (Solar & Non- solar) Nos. 20615 23083 25286 26000 94984

Purchase of solar power MWh 0 0 1700 15517 17217

Short / Excess Purchased (Solar & Non-Solar)

Nos. -167 73 -31 0 0

To promote Renewable Energy we have consumed 19106 MWh of

solar power at Wadi Cluster during Y2017-18.

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ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

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

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ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

AFR Performance

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

Utilisation of waste for replacing the conventional energy

0.02

4.09

6.43

9.69

11.39

10

71

70 1

55

16

2

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)

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ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

GHG Inventorisation

33

Scope -1 : Emissions from Kiln fuel, CPP fuel, Own vehicle fuel consumption, Calcination, fuel for drying if any

Scope -2 : Emissions from Grid electricity consumptionSpecific GHG (KG CO2/T cem) increased in the year 2015 due to higher clinker production

✓Various Energy Efficiency measures taken for reduction of SEEC & STEC, resulting reduced GHG Emission

✓ Increased in TSR from 6.43% in 2016 to 9.69% in 2017

✓ CPP SHR has been reduced from 3448 Kcal/kWh in Y 2014-15 to 3363 Kcal/kWh in Year 2017-18

✓ CPP, APC has been reduced from 13.3 % to 12.8% due to various energy efficiency measures taken like VVFDs in BFW, ACWP, CEP, SA fan in STGs .

✓ Way forward - Potential to be tapped for additional reduction in GHG Emission by WHRS – 13.2 MW & Improve TSR up to 20%

0

200

400

600

800

1000

1200

1400

1600

1800

2015 2016 2017 2018

1651

1394 13961354

992939 916 904

Sp. Net CO2 (Kg CO2/T Cem) Sp. Net CO2 (Kg CO2/T Clic.)

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ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

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”

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ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

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.

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ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

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

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ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

Involvement of Employees, Team work ….

37

Project methodology1. Problem Identification 2. Observation3. Analysis 4. Action 5. Check (Saving

validation by Plant FICO

6. Standardization7. Conclusion

Basic problem solving tools1. Check Sheet2. Stratification/ Classification3. Pareto Diagram4. Cause & Effect Diagram

4a. Brain Storming4b. Cause & Effect Analysis4c.Cause Analysis Table4d. Why-Why Analysis

5. Histogram6. Scatter Plot & Correlation7. Graphs & Control Charts

S.No Section Wadi

1) Quarry/Mines 42) Production 53) Electrical Energy 104) Quality 55) Maintenance 56) CPP 107) Geocycle 68) Packing Plant 39) Plant logistics/GIGO 4

Total Projects 52

Project of Year 2017

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ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

Online monitoring of electrical energy – EMS

Hourly Tracking of section wise SEC through auto generated SMS

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ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

3

9

Energy Management System & Energy Policy

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ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

PAT Cycle Performance

Baseline SEC Target SEC Assessment year Normalized SEC

0.0922

0.0874

0.0829

GtG

SEC (

toe/t

on o

f eq.

Cem

)

Nos. of ECerts: (+) 23426 Nos.

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ACC Limited, Wadi Cement Works 19h National Award for Energy Excellence in Energy Mgmt.

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)

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ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

ENVIRONMENT POLICY

42

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ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

SD 2030 action Plan for Water :-“Target for Water Y 2020 – 32% reduction in specific fresh water withdrawal vs 2015”

Key Initiatives

▪ Conservation of Rain water at mines pitsof capacity 40 Lakh m3 used to run theplant.

▪ “RO” Plant for drinking water at plant &colony

▪ Monitoring of water consumption on dailybasis.

▪ Zero water discharge from plant.

▪ 100% utilization of CPP cooling towerand DM plant blow down water, Boilerblow down, RO discharge, Sand filterback wash water etc. “ZLD concept”.

43

Initiative - Water ManagementLits/

t cem

Specific Water consumption

0

100

200

300

400

500

600

2014 2015 2016 2017 Target

2020

524

405

337 318276

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ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt. 44

Environmental ProjectsE

nv

iro

nm

en

tal

Pro

ject

s /

Be

st P

ract

ice

s ▪ Continuous Emission monitoring system for ILC & SLC string has beeninstalled for online monitoring of flue gases and reporting to SPCB/CPCB.▪ Online ambient Air Quality monitoring Station has been installed formonitoring the quality of ambient air.▪ ROC-F9 & L-8 Drill Machine with dust collector is used at mines for reducing the fugitive emission during drilling.▪ Nonel technology is being used for ground vibration monitoring analysis and redesigning of Blasting pattern.▪ Eco- friendly Electric Shovel is being used for dumper loading inside the mines. ▪CPP ZLD project has been commissioned to reduce water consumption▪ESP transformers has been replaced from single phase to 3 phase to improve ESP performance▪ TSR (Thermal substitution rate) has been increased up to 12% by commissioning Pre & Co-processing platform (PCPF). ▪New water tanker with spray nozzles has been procured at mines to reduce fugitive emission

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ACC Limited, Wadi Cement Works 19h National Award for Energy Excellence in Energy Mgmt.

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ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

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

46

Wadi Cement works bagged the FIMI – Health & Safety Award Y15-16

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ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

National Award for Excellence in Energy Management by CII

National Award as “Energy Efficient Unit” by CII in year 2018, 2017 & 2016

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ACC Limited, Wadi Cement Works 19h National Award for Energy Excellence in Energy Mgmt.

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

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ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

▪ 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

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ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.

Thank You

50