implementing energy savings with automation - aia … kulkarni_acc_6thnov09_ai… · implementing...

6th November 2009, Mumbai

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Implementing Energy Savings with Automation

Gururaj KulkarniHead, Electrical Engineering

ACC Limited


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Topics• Electrical Power and Energy requirement of a

Cement Plant

• Role of Automation in Energy Efficiency in Cement Industry

• Various Energy Efficiency Systems utilizing Automation in Cement Industry

• New Systems/tools being used in ACC/Holcim Plants


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Energy Consumption and Energy cost in Cement Industry

• Thermal Energy :• Best in India –around 680 kCal/Kg of Clinker• Best in World –around 650 kCal/Kg of Clinker

• Electrical Energy :• Best in India –around 63 kwh/t of Cement• Best in World –around 65 kwh/t of Cement

• Energy cost :• *Electrical energy cost (Grid power) around Rs. 300 / t • *Thermal energy cost around Rs. 500-700 / t• *Note :- These are approx costs and also depends on Energy

sourcing, Plant location, Sale Agreement, transportation cost etc.,


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Energy Consumption pattern in Cement Industry

• The Electrical energy consumption in Cement Industry is reduced by around 27% in last decade

• and • Thermal energy consumption by 11% during last one

decade.

• The Energy cost has reduced from 60% of the total cost in 2005 to 50% in 2009.

• CMA & NCB have proposed Energy consumption Norms to BEE for adherence by Cement Industry.


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Electrical Power and Energy requirement of a Cement Plant


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Electrical Power and Energy requirement of a Cement Plant

• Cement Industry is a Energy Intensive industry (both Electrical & Thermal).

• Therefore Energy Efficiency is very vital in Cement Industry.

• The Medium Voltage (6.6 KV/11 KV) form around 65 % of total loads.


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Quantity Powerover 250kW50-250kW10-50kW

3-10kW

up to 3kw

High voltage

Low voltage

1%6%

14%

17%

62%

65%

19%

9%3%4%

Distribution

Power range and distribution profile of drive applications in a cement plant


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Motors in a Cement Plant

Motor Type

Slipring Squirrel Cage Direct current

Fixed Speed

Mills, Crushers

Pumps, Belt Conveyor, Fans, Blowers, Compressors etc.,

Variable Speed

Fans with GRR or SPRS

Fans, Separators, Kilns, Belt Conveyors with VFD’s

Kiln, Separator (not recommended now)


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Motors in a Cement Plant

Constant Torque Loads KilnMillsSeparatorsConveyorsElevatorsCompressorsCrushers

Variable Torque Loads FansBlowersPumps


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Conveyor Belt

Fan or pump

Torque

Ball Mill

Kiln

Winder

Speed

Md

n

n

Md

Md

n

Md

n

Torque/speed profile of process equipment


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Typical power distribution structureUtility Power Supply

High VoltageSwitchgear

TransformersHigh / Medium Voltage

Medium Voltage Switchgear

Transformers Medium / Low Voltage

Motor Control Centers

Medium / Low Voltage MotorsPLANT

AUTOMATION

PROCESS

EmergengyPower


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kW = Electrical Power

kWh = Electrical Energy

For Plant of 3000 t you need ~ 30’000 kW = 30 MW

of Installed power to be able to run the plant electrical equipment

Rule of Thumb:P = t × (7…10) kW/t

Power and EnergyPower = Energy /

Time


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• Specific Electrical Energy Consumption ~ 100 kWh/t

• Electrical Energy Consumed during 24 Hours:Econs = 3’000 t × 100 kWh/t = 300’000 kWh

Average Daily Power Demand:Paver = 300’000 kWh / 24 h = 12’500 kW

• Peak Power Demand: ~ 1.2 - 2 × Average Daily Power Demand~ 25’000 kW (to size electrical equipment)

Power Demand:


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Special consumers

Legend:HV = High Voltage = Charging measuring pointMV = Medium Voltage = Measuring pointLV = Low Voltage = Consumer (drives, …..)P = ProcessNP = Non Process

M

Main incomer

M=

Department

Non-Process

MV

HV

DispatchCement

MillKilnRawMill

Crusher

P NP

LV

P NP P NP

LV

M M M

P NP P NP

LV

M M M

M

M M M

LV

M M M

M

M M M

LV LV

M M M

Electrical energy and power metering


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Packing & Shipping

Cement GrindingClinker ProductionRaw Meal Preparation

Raw Material Preparation

Raw Material Extraction

Electrical Energy Consumption per Cost Center 2003

0.8 2.5

25.5

32.9

47.4

2.9

05

101520253035404550

10 Raw Material Extraction 20 Raw Material Preparation 30 Raw Meal Preparation 40 Clinker Production 50 Cement Grinding 60 Packing and Shipping

Plant Cost Center

kWh/

t cem

1%

2%

22%

3%

30%

42%

Plant Cost Center kWh/t cem %

10 Raw Material Extraction 0.8 120 Raw Material Preparation 2.5 230 Raw Meal Preparation 25.5 2240 Clinker Production 32.9 3050 Cement Grinding 47.4 4260 Packing and Shipping 2.9 3

Total 112 100


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Total Production costs

63%

19%

18%

Energy Cost

Total production costs:Electrical Energy = 18%-20%Thermal Energy = 18%-30%


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Role of Automation in Energy Efficiency


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• Automation plays major role in :

• Collation of Information/data on Energy consumption.

• Provides real-time information about Energy usage

• Analysis of Energy consumption pattern / trends

• Optimization of the operating parameters / philosophy or the equipment/system based on the above analysis.


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• Automation has boosted performance of Drives and therefore now widely accepted system for Energy efficiency in Cement Industry

• Seamless flow of information across units

• Load Shedding Scheme

• Islanding operation of CPP


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• Increase in productivity

• Decrease in Breakdown

• Reduction in per tonne of Energy cost

• The Electrical energy consumption in Cement Industry is reduced by around 27% and Thermal energy by 11% during last one decade


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• Protection of environment

Costsavings

Benefits of Automation

• Uniform and automated operation

• Energy saving

• Increasing manpower efficiency

• More efficient maintenance

Best Cement

in the World

• Stable quality of products

• Fast, reliable information

• More reliable operation

• Personnel safety and equipment protection


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Cost Reduction – how can automation contribute?

Cost Reduction Measures Control Requirements

multiples types and higher amount of AFR

accurate dosing, stable mix of raw materials & fuels

lower e-energy consumption variable speed drives (fan)optimized sequence control

higher equipment availability,less stops

proper interlocking, correct trip values, adequate alarming

maximum production rate accurate measurement & actuators(high level control: expert optimizer)

rationalization (better use of manpower)

high degree of automation (release people from repetitive tasks)


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Areas of Automation: From Quarry to Shipping

Quarry

Raw Material

PreparationCement

Mill

Shipping

Quarry: quarry management

Raw Material Preparation: pre-blending control, stock pile management

Raw Mill: process control, material feed and homogenisation

Fuel Preparation: process control, fuel preparation (coal, oil, AFR) & feed

Kiln & Cooler: process control, quality control

Cement Mill: process control, mix and quality control

Shipping: dispatch/ logistic management

Fuel / AFR

Raw Milling Kiln & Cooler


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Automation: One Integrated System which Covers all Tasks in the Whole Plant (Quarry to Shipping)

Raw Material

Preparation

Quarry

Raw Milling Kiln & Cooler Cement

Mill

Shipping

Finance, Administration, Maintenance, Logistic, …


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Automation Trends in a Cement PlantYear Complexity of control. Plant size Signals

1940 local control of individual machine, local pneumatic/mechanical indication.

50 motors,20 instruments

65

1960 central control rooms (CCR), relay control of motors, some remote indication of instruments.


600

1975 first use of programmable controllers,monitoring- or process computers.


1'900

1985 first use of PC's in CCR, full graphic displays, communication links. decentralized inputs & outputs


3'000

1990distributed control systems, optical cables,automated documentation tools, integration ofmanagement information. full use of PC's….

1000 drives500 sensors

5'500

1995 optimized human machine interface,fuzzy logics, high level control.

1050 drives600 sensors

7'000

2000 field bus, soft PLC based on PC's 1100 drives1000 sensors

9'000

2006 WLAN throughout the plant, increased complexity, new projects 12'000

FutureWAN controlled factory/wireless maintenance, fully integrated information flow, increased complexity More instruments More

signals


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TIS (PIMS/LIMS): 350’000 USD

mechanical equipment:68 mio. USD = 100 %for 1 mio t/d plant

EO: 1ki ln & cooler : 250’000 USD1kiln & cooler , 3 mills: 310’000 USD

auto lab & sampler:2 – 3 mio USD

instr. & sensors: 1.5%advanced instr. : 1.5%

of mech. equip.

PCS: 2.8 mio USD per plant or 3 - 5 % of mech. equip.

Specific / typical Cost (system, engineering, installation)

TIS (PIMS/LIMS): 350’000 USD

mechanical equipment:68 mio. USD = 100 %for 1 mio. t/d plant

auto lab & sampler:2 – 3 mio USD

instr. & sensors: 1.5%advanced instr. : 1.5% of mech. equip.

PCS: 2.8 mio. USD per plant or 3 - 5 % of mech. equip.

EO: 1kiln & cooler : 250’000 USD1kiln & cooler , 3 mills: 310’000 USD


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Investment & Lifetime Comparison

• Lifetime of an equipment and system (years)

• Investment cost– 1 mio. t/a plant =170 mio. USD– mechanical equipment = 68 mio. USD (40 % of plant)

– electrical equipment = 21 mio. USD (30 % of mech., 12% of plant)

– PCS = 2.8 mio. USD (4 % of mech., 1.6 % of plant)

40 + : mechanical equipment20-35 : electrical equipment8 - 16 : automation

3 - 5 : office automation


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Level of Automation in Cement Plants

Very High

+ high level control on all mills+ full-size auto lab+ auto raw/cement-mix control+ automatic shipping station (link to SAP)

High+ high level control on kiln+ TIS for process and lab

Adequate+ master group control+ recipe, silo selection, auto feed

Very Lowstart/stop of individual motors (relay logic)alarm announcer panelsindividual indicators for analog values/loop

MinimumPCS for sequence control, analog indication, loop control and alarming system

Lowmotor sequence on PLCseparate (computer) system of analog/loop

equalcosts

risingcosts


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Various Energy Efficiency Systems utilizing Automation in Cement Industry


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Various Energy Efficiency Systems utilizing Automation in Cement Industry• 1. Variable Frequency Drives :• Electrical rotating m/cs (Motors) form 90% of Electrical Loads

which is highest of all industries.

• Variable Speed Drives with Frequency converters reduce energy consumption of Pumps & Fans by up to 70%.

• LV drives are common now and MV drives are becoming acceptable now in India. We should promote these in Cement Industry as 65% of the energy consumption is from MV motors.Other industries may also take clue from this.

• Kiln main drive which was predominantly a DC drive, is replaced by VFD now.


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Drive train efficiency consideration


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Variable Speed Drives


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Variable Speed Drives


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Compressors


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Fan Drive


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Fan Drive


37

Pump


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Various Energy Efficiency Systems utilizing Automation in Cement Industry• Medium Voltage Variable Frequency Drives :

• Common in Europe & North America

• It was not very popular in India due to very high capital cost.

• Now due to high energy cost & power shortage, MV drives are being considered for variable speed applications.

• Large Process Fans in Cement Plant consume major part of Electrical energy and MV drives contribute in energy savings for this applications.

• Water cooled MV drives have higher energy saving potential than the Air cooled.


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• Slip Power Recovery System (SPRS) :

• This system is more suitable where the speed variation required is between 70 % to 90%

• Mostly used for Process fan.

• In this system the Slip power from the rotor is fed back to the Grid thus reducing the energy losses.


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• Energy Management Systems • Waste Heat Recovery systems• Expert systems• Optimizers• Particle size analysers• Cross belt analysers• Auto sampling system and Robo lab• Auto Sample transportation


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New Systems/tools being used in ACC/Holcim Plants


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New Systems/tools being used in ACC/Holcim Plants

• Technical Information System (TIS)

• Energy Management Systems

• MV VFD’s

• Waste Heat Recovery systems

• Green building concept for Offices, CCR & Residential Colony


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Technical Information System (TIS)

• Storage, analysis and reporting of technical data for Holcim cement plants


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What data and information do YOU need?

• Management: How are we doing this day/week/month/ year?• Production: what is the production rate, consumption,

stock?• Process: Is the process optimized? why not? Where can

we improve?• Maintenance: runtime, machine conditions, failure rates,

reasons?• Quality: what is the quality of my products, why is it

in/out of spec? Which influence do AFRs have?• Energy: what are my specific energy numbers, what is

our AFR usage? • Environment: what are the emissions, are we endangered to

exceed limits ?


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Data flow in a cement plant

PMPP

MM / SDLIMS

BW

SAP R/3

HIP

TIS

I/O

HMI

measuring

logic

storage

confirmcompilation

display &

control

transmission

The physical signal e.g. Temperature is converted to an electrical Signal e.g mA

Short tern data storage threshold values for alarm and/or interlocking

Automation networktransmission

Data collection forhigher level data storage(OPC-Server)

Reporting and storage

HMI:1 value display value and trend2. Warning and Alarm3. Control (interlock or PID

Signal transmission4-20 mA or BCD-Signal (Profibus)

Business administration

[ ms ]

[ s ]

[ min,Hr,d,

weeks,y ]

consolidate Management information


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Specific indicators(x/t) online

Spanningdata analysis

Information availablefor everybody

OnlineCorrelations

Many sources - one hub - several

destinations

LIMS

PCSProcess Control System

CrossBeltAnalyser

EnergyMonitoringSystem

OnlineParticleSizeAnalyser

ContinuesEmissionMonitoring

XRFXRDLaboratory

I/O

Process Measurements


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Specification for an plant information system

• One source for all technical data (process, quality, production, environment,…)

• Easy, reliable and fast access to data• Interfaces to source system: control systems, laboratory

systems• Interface to SAP system• Calculation of indicators• Correction of data (incl. automatic recalculations)• Possibility for ad-hoc reporting


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Integration of TIS into Plant Networks

LAB PCS HLC EMS DISP

Link to Corporate HQSAP

TISServer

Plant Admin.

Plant Operation

LINKman

Automation Network

Office Network

Firewall


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Data consolidation and storage

Minute dataStorage period 1.5 years

Hour dataStorage period 1.5 years

Shift dataStorage period 1.5 years

Day dataStorage period 5 years

Week dataStorage period 5 years

Month dataStorage period 10 years

Year dataStorage period 10 years

Laboratory dataStorage period 10 years


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Electrical Energy Report• Energy reports according HARP and plant requirements

supports a close monitoring and analysis of energy consumption.


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TIS Mission Statement

• Provide a proven solution to Holcim cement plants for – online process data acquisition – long-time data storage– comprehensive process data management– analysis of process performance– support of sustainable process optimization

• With the definitions of the TIS Global Concept a standard scope and functionality as well as a systematic implementation will be achieved for every TIS implementation in Holcim.


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Energy Management System

• The Main functions of the proposed EMS are :

Load Monitoring

Load Shedding Assistance

Analysis & Reporting

Remote access to the Energy Management Systems information

Load Optimization


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Overview of proposed overall metering system configuration


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*****Thank You*****

implementing energy savings with automation - aia … kulkarni_acc_6thnov09_ai… · implementing...

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