cii national award for excellence in energy management...

Nalagarh

CII National Award for Excellence in Energy ManagementAmbuja Cement Ltd., Nalagarh

Vision: To be the most sustainable and competitive company in our industry

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Nalagarh

Presentation Contents/Take Aways❖Company Profile

❖Plant Profile & Major Process Equipment

❖Energy Saving Projects with no investment

❖Status of Last three years Energy Conservation Projects

❖Electrical Energy Optimization

❖Three years Roadmap for Energy conservation projects

❖Specific Energy Consumption figures & Comparison with Competitors

❖Innovative projects

❖Project Implementation methodologies.

❖Implementation of ISO 50001

❖GHG Initiatives

Nalagarh

Company Profile

❖Ambuja Cements Ltd, a part of the global conglomerate LafargeHolcim.

❖Total cement capacity of 29.65 million tonnes.(05 IPs and 08 GUs).

❖Cement Products: OPC, PPC & Ambuja Plus Roof Special.

❖Certified five times water positive and is India's only water positive

cement company.

❖Also plastic positive, by burning as much as over 50,000 tonnes of plastic

waste in its kilns, equivalent to 1.54 times of total plastic used.

❖Company generates 6.5% of its energy from renewable resources.

❖CSR arm ACF(Ambuja Cement Foundation) with presence in 21 locations

spread across 11 states.

Nalagarh

Plant Profile

❖ A Grinding Unit situated in Nalagarh, Himachal Pradesh (India) at an

altitude of 334 mtr’ .Commissioned in March’2010.

❖Plant rated capacity is 1.50 Million Ton per annum.

❖VRM : Make Loesche -LM56.3+3C; Capacity 250TPH.

❖Classifier; Make Loesche –LSKS 102 CS r.

❖Bag House: Make Redycam; Designed Flow 869000 M3 /hr; Dust Loading

348 gm/M3;

❖Packer: Make EEL; Two Nos; 16 Spouts double discharge 240 TPH each.

❖Plant connected load :15MW; Contract Demand: 9MVA

❖First cement plant in India certified as ISO 50001-2011.

Nalagarh

Performance

Parameter

2012 2013 2014 2015 2016 2017

YTD

Lag Indicators :

Fatality 0 0 0 0 0 0

LTIFR 6.72 3.70 2.94 7.3 0

LTI 0 01 + 02*01* 01+01

*

02 0

MTI 9 2 1 03 06 0

First Aid 3 4 8 03 6 0

Lead Indicators :

Near miss 76 79 75 29 56 24

Hazard’s 476 506 575 880 596 282/ 363

SOT’s 491 643 786 669 481 256

Health & Safety Performance

LTIFR : LTI Frequency Rate (per million man hrs)

LTI : Lost Time Injury

MTI : Medical Treatment Injury

* Indicates offsite incident

Nalagarh

Awards & Certifications

CII Green Tech Award

for Water Positive

Best Plant Performance

Award-ACL

FICCI Award for

Health & SafetyCII CSR Award

Cement Budget Champion

Award-ACL“Most Clean” Unit

Award-ACL

-OHSAS 18001:2007 ; QMS (ISO 9001:2008),

-EMS (ISO 14001:2004); EnMS (ISO 50001:2011)

Nalagarh

Cost -effective Energy Saving Projects- NIL Investment

Sr.

No.

Initiative Name Power

Saving

KW

Annual

Saving

INR Lakh

1 Optimize operating pressure(Grinding roller

pressure) in VRM*

125 22.5

2 Controlling of plant Lights and package AC

operation from PLC

85 19

3 Change in process –operation of BH Fan after

HAG firing to avoid idle running.

2000 19

4 Stopped recirculation of fly ash to silo through

process modification

140 10

5 Max operation of VRM in high level control

(fuzzy logic)

50 9

6 Optimized distribution transformer loading to

avoid no load losses. Spare 03 transformers

15 6.6

*CII recommendations

Nalagarh

Sr.

No.


Saving

KW

Annual

Saving

INR Lakh

7 Optimized capacity of lightly loaded motors

converting them from delta to star.*

30 5.4

8 Stopped idle running of GRR cooling blowers. 22 4

9 Change in process –operation of product group

only after VRM grinding mode.

220 2.1

10 Modification in clinker silo extraction chute logic to

get homogenous temperature material reduced

vibration breakdown by 50%.

2300 0.5

11 Avoid Idle running of gypsum crusher vent bag

filter fan.*

15 0.3

Total 93

Cost -effective Energy Saving Projects- NIL Investment


Nalagarh

Last three years Major Energy Conservation Projects

Sr.

No.Initiative Name Power

Saving

KW

Annual

Saving

INR Lakh

Invest-

ment

INR Lakh

1 Arresting of false air in VRM grinding section

closed loop system from 25 % to 15%.250 46.8 15

2 Installed 3000KW SPRS (Slip Power

Recovery System) for VRM Fan*150 27 86.4

3 Pressure setting regulation along with VFD

installation in compressor and making

common header line for all.

102 11.7 5

4 Optimized two PD blower for aeration in fly

ash silo and cement silo system*30 11 0.3

5 Reject group running optimization by

installing a small hopper & level sensor in it.60 10.8 0.7

6 Installation of Honeycomb air washer system

in place of pressurized water spray nozzle

system

25 5.4 3


Nalagarh

Sr.


Saving

KW

Annual

Saving

INR Lakh

Invest-

ment

INR Lakh

7 Increasing of feed chute by 75mm to

take the feed at the center of table.

50 5.4 0.4

8 Installed correct head high efficiency

pump for process water pump.*

23 4.1 3

9 VFD installation for clinker unloading

hopper vent to avoid damper losses*

20 3.7 3

10 Use of FRP blade for cooling tower and

motor cooling fan.

20 2.7 3

11 LED light installation of different wattage

in plant*

10 2.1 8

Total 130.7 127.8

Last three years Major Energy Conservation Projects


Nalagarh

Sr.

No

.


Saving

KW

Annual

Saving

INR Lakh

Invest-

ment

INR Lakh

Status

1 Optimize Bag House & Other

bag filter purging cycle from 12

cycle/minute to exiting 9 cycle/

minute

50 9.0 0 Done

2 To stop fly ash tippler unloading

bag filter while bulker unloading

in process

50 7.3 0 Done

3 Simultaneous unloading of fly

ash from two bulkers at a time

53 3.9 1.5 Done

4 Optimization of Mill Parameters

to increase the TPH

250 50 0 2017(In

progress)

5 Installation of Waste Air Wind

Mill 9 KW

8.6 1.8 8 Sep’17(Material

Received)

Roadmap for Energy conservation_2017-19

Nalagarh

Sr.


Saving

KW

Annual

Saving

INR

Lakh

Invest-

ment

INR

Lakh

Status

6 LED light installation of different

wattage in plant

10 2.2 8 2017-19

7 Elimination of venturi from bag house

fan duct to eliminate pressure drop.

60 10.8 13 Feb’18(PO Issued)

8 VFD installation for clinker unloading

hopper vent to avoid damper losses*

20 3.7 5 2018

9 Installation of Light Pipes in Packing

plant

5 1.0 2.0 2018

10 Direct feeding of clinker from tippler to

Hopper building

150 16.8 80 2019

11 To conduct Energy Audit from CII 2017

Total 106.5 116.3

Roadmap for Energy conservation_2017-19


Nalagarh

Reduction in Specific Energy(Power) Consumption figures

44.4

40.8

34.0 34.7

30.5 30.4 30.6 30.3 29.5

30

.4

30.2

33

.6

32

.0

0

5

10

15

20

25

30

35

40

45

50

2010 2011 2012 2013 2014 2015 2016 2017 Asp.'17

KWH/T

Total PPC Roof Special KWH/T

14.1

Nalagarh

36.2

31.1

28.3 28.5

26.5 26.4 26.5

30.8

20.0

22.0

24.0

26.0

28.0

30.0

32.0

34.0

36.0

2010 2011 2012 2013 2014 2015 2016 OEM

VRM Section KWH/T

VRM Section Performance

Nalagarh

Reduction in Specific Energy(Thermal) Consumption figures

5356

4817

1572

0 00

1000

2000

3000

4000

5000

6000

2014-15 2015-16 2016-17 2017-18 Asp.-17-18

Millon'Kcal

Nalagarh

Reduction in CO2 Emission

1649

1229

418

0 00

200

400

600

800

1000

1200

1400

1600

1800

2014-15 2015-16 2016-17 2017-18 Asp.-17-18

Ton of CO2

Nalagarh

312 11

29

5448

74

106

125

0

20

40

60

80

100

120

140

2010 2011 2012 2013 2014 2015 2016 2017 Asp.'17

MTBF (Rolling Hrs)

Energy Reduction Contributing Factor - Improvement in Plant MTBF

Nalagarh

0.2 0.2

0.4

0.7

0.8

0.90.9

1.0

0.0

0.2

0.4

0.6

0.8

1.0

1.2

2010 2011 2012 2013 2014 2015 2016 Bugt'17

Producton (Million' MT)

Plant Utilization

Nalagarh

SEC Benchmarking with peers(GU ACL & ACC power comparison)

30.5 30.6 30.8

38.6

43.8

0

5

10

15

20

25

30

35

40

45

50

ACLNalagarh

ACC, Kolar ACL, Dadri ACC, Bellari ACC,Sindri

KWH/T

Nalagarh

Innovative Project-1

Initiative: Coverage of VRM Nozzle Ring to Achieve Higher Gas

Velocities.

Modification: Louver area reduced from 4.27m2 to 3.95m2 by 20 mm

blocking louvers ring12

1110

09

08

07

06

05

04

03

02

01

48

47

46

45

44

43

42

4140

39 38 37 3635

34

33

32

31

30

29

28

27

26

25

24

23

22

21

20

19

18

1716

151413

Louver area

covered

Saving: 300KWH

Parameters UOM Before After

Velocity m/sec 49.4 54

Dust Load g/m3 348 400

Gas Flow m3/kg 2.81 2.37

Air Flow m3/hr 7.60 7.10

TPH t/h 270 290

Fan Power KWH 2700 2400

Benefit = INR 54 Lakh /annum;

Investment: INR 0.3 Lakh

Nalagarh

Modification Snapshot

Aspects of closing

nozzle Rings:

❖ Uniform material

distribution on the

rotor circumference

❖ Regulation in

airspeed

❖ Uniform air

distribution all around

the table

Modification: Iron rod

placed to reduce open

area of nozzle ring

area

Nozzle-Ring –

Guide Vanes

Nalagarh


Impact:

❖ R45 decreased from 11% to 5%.(Best PSD in ACL & ACC accredited by

CSG )

❖ 2.5% Increase of fly ash consumption from 29% to 31.5%.

❖ Reduction in Mill Department Power Consumption by 0.8KWH/Ton

(around 200KWH) or saving of around INR 36 Lakh per year

Initiative: Reduction in dynamic seal gap of VRM separator

Modification: Reduction in dynamic seal gap from 15mm to ZERO mm by

using “Felt”.

➢ First ever modification done in VRM separator in the history of cement

industry.

Benefit = INR 36 Lakh /annum;

Investment: INR 0.1 Lakh

Nalagarh

Modification Snapshot

Gap 15 MM

After Modification: Felt

inserted

Before Modification:

Seal Gap in Separator

Nalagarh

Round Robin Test Results- Best R45

Test 01 Test 02 Test 03ACL, Ropar 10.24 13.98 10.3

ACL, Darlaghat 9.02 10.84 8.20

ACL, Bathinda 9.10 12.44 11.2

ACL,Nalagarh 8.82 7.50 3

ACC Limited, Gagal 10.68 10.68 10.2

Grasim Industries, Lehra

Mohabbat10.26 10.40 7.90

Shree Cement Limited, Beawar 12.36 10.20 8.50

JP Cement Limited, Bagheri

Nalagarh Solan HP9.90 16.58 14.5

Achievements:

❖ Innovation well appreciated by OEM and taken the design of

modification to replicate this design in their future separators.

❖ Design replicated at 05 other plants of ACL & ACC and achieved similar

results

Nalagarh


Initiative: Reduction of fuel consumption for preheating VRM (grinding)

operation

Operational Requirement of HAG:

❖ VRM Grinding is started only >90 degree C as general practice.

❖ Temperature drop of 15-20 degree C in closed circuit due to false air entrance

>25%.

❖ To avoid dehydration of final cement product.

❖ To avoid condensation of cement in transport circuit and silo.

❖ To avoid boulder formation and deterioration of final cement material.

Initiatives taken to optimize HAG Operation:

❖ OEM & Techport recommendation to operate VRM grinding above dew point.

❖ Blocked all false air sources and reduced it to design level of 15%.(CII 13.2%)

❖ Online temperature monitoring of final cement discharge to silo.

❖ Auto controlling of water spray with above temperature.

❖ Modified clinker silo extraction chute logic to get homogenous temperature

material during plant operation

❖ Utilized required heat from grinding energy and Clinker temperature.

Benefit = INR 1.5 Crore /annum;

Investment: INR 10 Lakh

Nalagarh

604

450

153

00

100

200

300

400

500

600

700

2014-15 2015-16 2016-17 Asp.'17-18

HSD/HFO Consumtion (K Litres)

INR 1.3 Crores.

Initiatives Impact & Saving

Added benefits achieved :

❖ Power saving of 2500KWH in one running or INR 22.5 Lakh per annum

as idle running of Mill Fan , Classifier, transport group and HAG stopped.

❖ Reduction in the boulder formation in cement silo at reduced temp. 70-75

degree C.

❖ Minimum handling of hazardous material like HSD/FO in plant

❖ Increased production as idle heating time of 2hrs stopped .

Nalagarh

Innovative Project-4(Planned)

Initiative: Waste Air Recovery System which covert waste air velocity and flow

to convert it into electrical energy

Modification: Installation of 8.6KW Waste Air Recovery System at our packing

bag filter vent and utilize it for packing plant lighting.

Benefit = INR 2 Lakh/annum;

Investment: INR 8 Lakh

GA Drawing of System:

Waste Air

Wind Mill

System

Alternator

Bag Filter

BF Fan

Nalagarh

Technical Data Sheet

Velocity 19 m / Sec

Velocity Pressure (Static Pr.) 35 mm of W. G.

Duct area 0.79 sq.m

Outlet flow in M3 / hrs. 54036

Fan Actual Consumption in Kw. 34 / 23

Capacity Of Alternator9 KW, 1500 rpm, 440 V, 3ph,

specially designed alternator.

Power available(Potential Saving) in outlet flow:

Outlet flow in per min X Velocity Pr.

KW = ------------------------------------------------------- = 8.6KW6120 X Effi. Of bag filter fan

Yearly Saving Potential : 8.6X 12X365= 37668 KWH or INR 1.8 Lakh

Investment = INR 8Lakh

Technical Data Sheet & Saving Potential

Nalagarh

Project Implementation methodologies-Energy Management Division

Alok Sharma

(Certified Energy Manager

DGM-E&I)

Raj Garg

(SI-Operation

Exp-20yrs)

Deepak Dhiman

(CEM-Electrical

Exp-10yrs)

Ravinder Gill

(SI-Automation

Exp-10yrs)

Manish Tandon

(SI-Mechanical Exp - 9yrs)

Manohar Lal

(SI- Electrical

Exp-9 years)

Aasheesh Kumar

(Planner-Mech.

Exp-9 years)

Durga Verma

(Head-Env.

Exp-20 yrs)

❖ Perform daily power analysis

❖ Conduct internal audits

❖ Evaluate new ideas,

❖ Implement new initiatives

❖ Ensure compliance of energy audits points

Nalagarh

Project Implementation methodologies-Energy Circles

VRM Mill Section

Raw Material Handling Section

Utilities & Lighting Section

Packing Section

Energy

Circle -1

Energy

Circle -2

Energy

Circle -3

Energy

Circle -4

04 Members(02 MS; 02 WB)




❖ Daily Energy Observation Tour(EOT) to observe any abnormality

❖ Ensure timely compliance of points identified

❖ Analyze idle running of equipment operation

Nalagarh

Baseline &

Aspiration

Setting

Evaluation

& Approval

Implementa

tion &

tracking

Dream Run

Idea

Generation

Practices

Identification

Data

Collection &

analyses

Weekly War Room Reviews & MIS tracking

▪ Technical

Modules

training at

Bootcamp

▪ Wave team

finalization

▪ Wave

planning

▪ Trend

Analyses

▪ Benchmarking

with other

plants

▪ Finalization of

equipment and

sub-equipment

targets

▪ Idea

generation

sessions with

wave teams,

operators,

junior

engineers &

wageboard

▪ Identification of

SOP/SMPs

critical for

achieving wave

targets

▪ Binder

evaluation

▪ Identifying

deep-dive

areas for study

▪ Idea

prioritization on

the basis of

potential and

ease of

implementation

▪ Signoffs on

prioritized

ideas in Idea

evaluation

template

▪ Idea

implementation

templates and

signoffs.

▪ Tracking

progress on

ideas

▪ Trainings for

the

SOPs/SMPs

identified

▪ Branding and

communication

s

▪ Adherence to

practices

▪ Tracking and

review of

progress

Boot camp

& Wave

Planning

▪ Baseline

Data

Collection

▪ Aspiration

Setting

Workshop

▪ BH & Unit

Head

approval for

the

aspirations

The systematic 4-month wave process

1 Week 1 Week 2 to 3 Weeks 3 to 4 Weeks 2 to 4 Weeks 6 to 8 Weeks 4 to 8 Weeks

1 2 3 4 5 6 7

Project Implementation methodologies-People Power Initiative

Nalagarh

YTD’17 JAN’17 FEB’17 Mar’17 Apr’17

Sr.No.

SECTION / EQUIPMENT OWNER Target KWH/T KWH/T KWH/T KWH/T KWH/T

A CEMENT GRINDING 25.42 26.82 26.35 26.70 27.59 26.11MAIN DRIVE M.Sharma 15.4 17.18 16.14 17.39 17.96 16.72

CLASSIFIER M.Sharma 0.6 0.47 0.58 0.48 0.41 0.47

BAG HOUSE FAN M.Sharma 8.4 8.13 8.60 7.71 8.17 7.99

AUXILIARIES M.Sharma 0.98 1.04 1.04 1.12 1.05 0.93

B PRE PROCESS 2.00 2.03 2.19 2.26 1.76 2.09

GYPSUM HANDLING R Garg 0.15 0.17 0.16 0.14 0.18 0.18

FLYASH HANDLING Vijay Verma 0.8 0.89 1.10 1.21 0.59 0.84

CLINKER HANDLING Raj Kumar 0.2 0.24 0.26 0.24 0.23 0.22

CLINKER SILO FEEDING R Garg 0.8 0.74 0.68 0.68 0.77 0.85

C UTILITY 2.05 1.86 2.08 2.01 1.49 2.09

PLANT COMPRESSOR Harjeet 0.5 0.78 0.93 0.90 0.66 0.67

FACTORY LIGHTING Manohar 82168 72044 66308 64929 78516 78424

WATER PUMPS Pritam 0.12 0.10 0.14 0.09 0.09 0.10

STP1 (Plant) Durga Verma 1541 1523 1664 1496 1637 1297

STP2 (Guest house) Durga Verma 1541 1433 1664 1425 1519 1224

DTotal Grinding Consumption

29.5 30.71 30.62 30.97 30.85 30.30

Main Reporting Format- Sample

Nalagarh

Reporting Format-Section-I Sample

Nalagarh

Reporting Format-Section-II Sample

Nalagarh

CII Energy Saving Proposal Compliance

No. of

proposal

Proposal

Executed

(Nos)

Annual

Savings

Achieved

(Rs Lakh)

Cost

Incurred in

(Rs Lakh)

Planned

proposal

( Nos)

Potential

Saving

(Rs

Lakh)

Investm

ent

Require

d (Rs

Lakh )

17 14 183 102 3 8 10

Implementation of ISO 50001 & Investment on Encon Projects

Nalagarh

GHG Initiative _ Plantation Data

6063

866

0

1000

2000

3000

4000

5000

6000

7000

Trees PlantedTill'17 (Nos)

Avg. Tree plantedper year(Nos)

34031

4862

0

5000

10000

15000

20000

25000

30000

35000

40000

Shrubs Till'17 (Nos) Avg. shrubs planted peryear( Nos)

Nalagarh

GHG Initiative _ Plant Area: 29Hectare ; Green Area : 34 %

Views: Central Area

Nalagarh

GHG Initiative _ Plant Area: 29Hectare ; Green Area : 34 %

Views: Truck Yard

NalagarhThanks !!!

cii national award for excellence in energy management...

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