9-Ambuja Cement PDF

14th National Awards for Excellence In Energy Management -2013
Ambuja Cements Limited Unit : Rabriyawas
Agenda
Company Profile Manufacturing Process Encon Projects With Cost Benefit Focus on Last 03 Years Encon Efforts Reduction In Energy Consumption Global Norms / Bench Mark : Road Map Innovative Projects
Ambuja Cements Limited, Unit Rabriyawas
Agenda
Rabriyawas Location
8/23/2013 4:12 PM
Company Profile
4200 TPD Cement Plant ( Make FLS) consisting One Raw Mill (340 TPH) & Coal Mill ( 40 TPH) and Cement Mills ( 2X120 TPH OPC) along with 15 MW Power Plant , was set up by M/s DLF Group in1996. DLF Cement was acquired by Gujarat Ambuja Cements Ltd. in December, 1999 Kiln upgraded from 4200 to 6000 TPD in 2007 New 6th Stage SLC String New 260 TPH Raw Mill New 25 TPH Coal Mill (2008) New CPP of 18.7 MW in July 08. 500 TPD Synthetic gypsum manufacturing plant (Aug2011) Environmental clearance obtained for 3.6 million TPA capacity & consent to operate for 7000 TPD clinker
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IMS Certified Company
8/23/2013 4:12 PM
IMS & Energy Policies

Ambuja Cements Limited Unit: Rabriyawas
Energy Policy
We are committed to conserve energy in cement manufacturing, power generation and related activities by optimization and efficient use of resources in a cost effective manner. We are committed to reduce our specific energy consumption on a continual basis year over year. To accomplish this we shall: 1. 2. 3. 4. 5. 6. 7. 8. Create awareness and impart training to employees for energy conservation. Monitor energy consumption regularly in various departments, analyze the information and take necessary steps for continual improvement through an effective energy management information system. Comply to all applicable legal requirements & strive to go beyond compliance. Conduct Energy Audit to further identify potential areas and equipments for energy conservation. Consider energy efficiency performance for all procurements of energy consuming equipments Implement innovative ideas / modifications for improvement and upgradation of the equipments. The policy shall be communicated to all stakeholders both internal & external. Carry out on-going process optimization and diagnostic studies to maintain high productivity and capacity utilization to minimize specific energy consumption.
J. C. Toshniwal Business Head-North
Vallabh Tank Unit Head Date: 01.01.2013 Rev.: 00
8/23/2013 4:12 PM
EARN : An Systematic Energy Reduction Plan by 2015 to achieve PAT Targets
8/23/2013 4:12 PM
EARN : An EnCon Initiatives in the South Asia Pacific Region

TML SML MML
EE Sanjeev Singh TE Rajendra Sharma
Unit Head
Head Works
Pillar Champions
CF Jaiprakash Vrati Coal Anil Chordia Geo Mukul Grag
Academy Co-ordination
Yogesh Nagayach Pushpanjali Rawat Nikhil Handa Vikas Sharma Rajat Mukherjee
FML Excecution Team

Project Team Line Team
Roles & Responsibilities
Head Works
To ensure the achievements of set EARN targets for each year Include EARN pillars targets as a part of yearly KPIs Ensure hurdle free working in coordination with all plant EARN Champions Ensuring implementation of various ideas / practices / projects in a timely manner
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Pillar Champion
Timely submission of any information in relation to EARN for respective
pillar
Meeting the deadlines as decided by corporate PMO office Work in coordination with Academy coach to work out any innovative ideas
/ practices for achieving set reduction targets

Work in coordination with Project / Line team for implementation of any
ideas / practices / project

Update top management about the progress in respective pillar on
fortnightly / monthly basis in given formats
Include EARN pillars targets as a part of yearly KPIs

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Project Team
Execution
Line Team
Academy
of projects in relation to EARN
Implementation of
To
ideas
Follow
up the best practices
work in coordination with EARN champion for achieving set reduction target for respective pillar EARN targets as a part of wave & tracking of same
Include
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Ambuja Cements Limited, Rabriyawas Note Unit Execution part will be done jointly by Project & Line team
Awards and Recognization

Rabriyawas Unit has been awarded Second National Safety Award (Performance Year 2009) by Ministry of Labour, Govt. of India. Rabriyawas Unit has been awarded National Award for Excellence in Energy Management 2011 by CII, (Confederation of Indian Industry), Hyderabad on 25th August, 2011. Rajasthan State Productivity Council, Jaipur has adjudged Rabriyawas Unit in Cement Industry (Gray) for Productivity Appreciation Certificate 20092010.
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Two National Safety Awards (Performance year 2010) by Ministry of Labour, Govt. of India. WINNER I/12: frequency rate Lowest Average
RUNNER-UP-II/12: Accident free year
Rabriyawas Unit was adjudged for Productivity Merit Award 2010-2011 by Rajasthan State Productivity Council, Jaipur. The Award was given by the Hon'ble Industry Minister on 4th April, 2013.
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National Award for Excellence in Water Management 2012 under the category Within the Fence by CII Hyderabad. Last year we got Award in Beyond the Fence Category. Received award for Excellence In Improving Performance Leadership. Presented by the Indiasgreatest.com (The Greatest Corporate Leaders of India) Powered by DNA.
Regional Leadership Retreat ( RLR) - 2013 Holcim EARN Regional Award for Most Improved Plant in Electrical Energy Pillar
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8/23/2013 4:12 PM
Agenda
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Cement Manufacturing Process
Quarrying Raw Material Preparation
Raw Meal Preparation Clinker Production
Cement Grinding Dispatch
Implementation of ISO 50001: 2011 by Oct 2013

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Production (Million MT)

Kiln Equipments Modification
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Agenda
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Encon Projects with Cost Benefit

Enlargement of kiln inlet chamber and rotary kiln inlet part from 4.55 to 5.2 m diameter (6.4 mtr. length) Elimination of conical kiln outlet section (3.4 m length) Cooler extension by additional 22 RFT grate rows in cooler Benefit Observed: Reduction in Kiln Tube velocity from existing > 13.5 m/sec to < 10m/sec @ 6000 TPD. Reduction in overall Kiln pressure drop from 90100 mmWG to 45-50 mmWG. Reduction in ILC PH exit gas temperature from earlier 370-380 Deg.cen to 320-330 Deg. cen. ILC TA Duct damper made operational, which was non operational since Sep'2007 Kiln upgradation from 4200 to 6000 TPD.
Enlargement from 4.55 to 5.2 m dia shell length 6.7 m Orifice net cross section ~7m2, 30 m/s
New kiln inlet housing for 5.2 m kiln
New lamella seal
Kiln Inlet Chamber Modification
Additional waste air take-off duct
New roller crusher 4 rolls 3.6 m Adding 22 rows of RFT grates (6.6 x 3.6 m) Existing hammer crusher
Clinker Cooler Enlargement
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8/23/2013 4:12 PM

Installation of MF HRB -12 for clinker crushing
Benefits Observed: Kiln MTBF reduced on account of Hammer crusher inlet chute jamming with big coating pieces & clinker balls. Consistency observed in kiln running
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8/23/2013 4:12 PM

Modification of Cyclone tangential gas duct entry in both string of ILC cyclones- 6th & 5th as per CFD Analysis.
Benefit Observed: Improvement in bottom stagescyclone efficiency and reduction in preheater exit gas temperature by 20-30 Deg Cen. ( Saving of approx. 5-8 Kcal/ Kg-cl)
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8/23/2013 4:12 PM

Installation of New Transport air blower ( VVFD ) for Kiln coal firing. Benefit Observed: To facilitate 100% petcoke usage in main burner and reduction in Primary air quantity.
Installation of new coriolis coal feeding system. Benefit Observed: Expected Kiln MTBF Improvement due to facilitity of fine coal feeding in existing all three Coriolis system to meet any emergency. Also introduce second fuel in all the three system of coal firing lines.
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8/23/2013 4:12 PM
Agenda
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Energy Conservation Initiatives 2011

Sr. No 1 2 3 4 5 6 Energy Conservation Measures Installation of GRR for raw mill # 1 fan Inlet Box modification Raw Mill # 2 fan Direct drive with VVVF & removal of damper for cooler fan 471 FA-7 & FA-E Installation of VVVF & removal of damper for cooler fan 471 FA-4 & 5 Capcity enhencment & Direct drive operation of two nos IKN -KIDS fan (471 FA-2&3) Installtion of GRR In Coal mill-1 Shortening of cement mill # 1 chamber length by 0.5 mtr. (present 3.8 mtr.) & Optimisation of grinding Media pattern as per HGRS Standard Optimisation of Raw Mill-1 & 2 with optimum dam ring height, Armor ring angle changed to 15 Deg from previous 10 deg to make fines interactions towards mill centre, change of separtor guide vans angle towards centre shaft by maitaining the lourve gap from 55mm to 65mm. Energy & Water audit for Plant & CPP by CII Investm ent (Rs. Lac) 20 Nil Due to Unstable Kiln operation , Lower NAI & PRI , raw mill operation with lower raw meal residue (12 % on 90 Micron) , Proposed saving could not be achieved as planned in 2011, However the same will be monitored in 2012 specially changes of Kiln Operating Parameters after MPR modifications . Savings (Rs. Lac) Yr. 2011 Yearly Potential 12.76 10.21 6.81 6.81 1.70 5.58 Modification was carried out in Oct-11 and afterwards Kiln Stopped for MPR modification jobs hence Mill operation with seasoned clinker . Proper evaluation will be carried out in Jan'12 onwards. Due to reduction on raw meal residue from 13 % to 12 % on 90 Micron as per Kiln operation requirement.
72
Nil 8
7.5
Nil
Nil
Nil
12.00
Final report received in Dec'11 . Job will be initiated from Jan'12 onwards
Nil 25

Sr. No Energy Conservation Measures Savings (Rs. Lac) Investment (Rs. Yearly Lac) Yr. 2012 Potential
1 2 3 4 5 6
2000 kW SPRS Retrofitting from SLC Fan to Bag House Fan 3 no. mono block pumps replaced with submersible pump in raw mill-1 Stop one blower from Raw Mill-1 product air slide without affecting the operation Installtion of VVFD for Coal Mill -2 Booster Fan there by reduction in Bag house fan specific power consumption. Removal of CCRD motors from coal stacker and coal reclaimer Transparaent Sheet on workshop roof for using day light
0.5 0.4 Nil 7.5 0.4 0.4
26.93 0.08 0.32 2.42 0.86 0.47
80.784 1.26 1.29 26.86 3.43 1.86
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Sr. No
Energy Conservation Measures
Investment (Rs. Lac)
Savings (Rs. Lac) Yr. 2012 Yearly Potential
Thermal Energy Raw Mix & Fuel mix optimisation in Kiln , Thereby 100 % Petcoke usage in Kiln as well as SLC (around 65 % fuel basis). Budgeted Petcoke taregt was 31 % in 2012 . In Acutal it was achieved 49.86 % resulted saving in fuelmix cost. Short dip tube installtion in ILC Lower stage cyclones ( 6th Stage) of KS-1 & KS-2 string . Also modification in ILC Cyclone 6th & 5th both the stings gas duct. tangential entry based on CFD analysis there by Saving of 8-10 Kcal/Kg-cl achieved Maximise AFR usage by installtion of AFR burnout chamber in SLC TA duct.
Nil
2,193.00
2,193.00
90.00
88.00
176.00
7.50
108.30
118.80
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Raw Mix Optimization with Low ash fuel
Key Issues Intricate type of deposits with marginal grade of lime stone (Avg. 43.5% CaO from Mines). In order to maintain consistent quality of cao 44.0%, we have to procure around 6-8 % high grade limestone. Higher percentage of rejects 47-48 % Main operational measures (incl. costs & benefits) Raw mix optimization to enhance mines life by usage of max. usage of low ash fuel ( Petcoke & Lignite) .
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Kiln & Calciners : Fuel Mix Optimisation
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Current Alternative Fuels
Carbon Black
Trade Rejects
Cow-Dung
Biomass
Paint Sludge
BF Flue Dust
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Maximum AFR Utilization AFR Performance
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Sp. Actual Cost of Thermal Energy (Rs./t Clin)
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Agenda
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Sp. Power Consumption Profile
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Sp. Thermal Energy Consumption Profile
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Clinker Factor & Fly Ash Consumption
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Agenda
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Cost Saving Initiatives Planned -2013

Sr. # Description Operating Full Load Saving KW (KW) KW 24.00 24.00 46.00 76.00 48.00 15.00 11.00 24.00 37.00 37.00 55.00 160.00 110.00 22.00 22.00 37.00 17.00 17.00 13.00 13.00 20.00 13.00 16.00 16.00 Investment (Rs. Lacs) 2.78 3.00 3.85 6.00 5.00 2.50 2.50 2.78 Pay Back (Yearly) 0.5 0.5 0.9 1.4 0.7 0.6 0.5 0.5
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1 VFD in CM-1 main bag filter fan (561FN2) VFD in cement mill-2Bag filter fan 2 (562FN2) 3 VFD in CM-2 ESP fan -(562FN3) 4 VFD in coal firing blower for Kiln (481BL2) 5 6 7 8 VFD in coal firing blower SLC Firing (451BL5) VFD in cement Mill-1 Feed belt JPF Fan (531-FN1) VFD in cement Mill-2 Feed belt JPF Fan (532-FN1) VFD in Packing plant JPF fans (664 FN-1 to FN-4)
Cost Saving Initiatives Planned-2013

Sr. # Description Operating Full Load Saving KW (KW) KW 1450.00 400 2000 675 247.00 100.00 Investment (Rs.) 85.00 85.00 Pay Back (Yearly) 1.0 2.5 9 SPRS in Kiln BH FAN 10 VFD in Cooler ESP fan 11 Screw compressor instead of reciprocating compressor - 10 Nos Replaced with 05 Nos New Screw Compressors. (Capex Not Approved hence taken in PMP-2014 Capex) 12 VFD in CCP-1 Boilor feed pump 13 VFD in CPP-2 FD Fan 14 SPRS for RM-1 Fan 15 VFD for IKN Fan 471 FA1,FA2 and FA3 16 VFD for Cooler RFT Fan 471FA-A and FA-B 17 SPRS for RM-2 Fan Total Investment Saving -> KWH Saving -> kWh/ton of cement
672
958
400.00
250.00
1.9
320 320 2180 200 320 1600
400 400 2600 354 360 2000
80.00 80.00 180.00 50.00 40.00 120.00 1422 5.68
75.00 75.00 91.00 35.00 25.00 75.00 824.41
2.8 2.8 1.5 2.1 1.9 1.9 < 1.5 yrs.

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Continual Efforts to Achieve Global Target

Global Norm: 68 kWh/TC
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8/23/2013 4:12 PM
Agenda
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Conversion of Kiln /Raw Mill RABH to Jet Pulse Filter

Project Started 16th Nov2011
Date of completion : 31st Dec2011.

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Conversion of RABH to Jet Pulse Filter Kiln/Raw mill RABH

High mechanical losses across the bag house> 240-260 mmWG
Losses in the plenums
Losses across dampers
Losses through Filter bags
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Conversion of RABH to Jet Pulse Filter RABH Internal ( Before Modification)

4.2 m * 3.5 m Reverse air Plenum Outlet Plenum 2.814 m * 3.5 m
Inlet Plenum
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Conversion of RABH to Jet Pulse Filter RABH Internal (After Modification)

Reverse air Plenum 5.77 m * 3.5 m
Outlet Plenum 5.77 m * 3.5 m
Inlet Plenum
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Conversion of RABH to Jet Pulse Filter
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Plant Performance RABH Vs Jet Pulse Filter

Particular Bag house DP Bag House Fan power Unit mmWG kWH RABH @ 6017 TPD 250 1802 Jet Pulse @ 6017 TPD 100-110 1354 Remarks Reduced by 56 % Reduced by 448 kWH. RA Fan 132 KWH drive also stopped Reduced by ~ 150 rpm Saving by ~ 220 kWh Increased by 58 kWH.
Bag House Fan speed Installation of SPRS in place of GRR Compressed air cons. (upto clinkerisation) Filtration area Air to cloth ratio (Designed) Overall Saving
rpm Damper % kWH m2 M3/min/m2 kWh/tcl
950-980 70-100 2.17 Gross: 23182 Net: 20866 0.91
780-830 90-100 % 2.40
Gross: 22206 * 62 Nos. Bags holes dummy New: 21983 * 0.98 0.87
448 + 90 + 220 58 = 700 KWH = 700 X 24 / 6017 = 2.80 kWh/ T-Cl
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Reduction in BH Fan Power (kWh/ton of clinker)
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THANK YOU

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14th National Awards for Excellence In Energy Management -2013

Ambuja Cements Limited Unit : Rabriyawas

Ambuja Cements Limited, Unit Rabriyawas

Ambuja Cements Limited, Unit Rabriyawas

Ambuja Cements Limited, Unit Rabriyawas

Ambuja Cements Limited, Unit Rabriyawas

IMS Certified Company

Ambuja Cements Limited, Unit Rabriyawas

IMS & Energy Policies

J. C. Toshniwal Business Head-North

Vallabh Tank Unit Head Date: 01.01.2013 Rev.: 00

Ambuja Cements Limited, Unit Rabriyawas

EARN : An Systematic Energy Reduction Plan by 2015 to achieve PAT Targets

Ambuja Cements Limited, Unit Rabriyawas

EARN : An EnCon Initiatives in the South Asia Pacific Region

FML Excecution Team

Ambuja Cements Limited, Unit Rabriyawas

Roles & Responsibilities

Ambuja Cements Limited, Unit Rabriyawas

Roles & Responsibilities

Timely submission of any information in relation to EARN for respective

/ practices for achieving set reduction targets

ideas / practices / project

fortnightly / monthly basis in given formats

Include EARN pillars targets as a part of yearly KPIs

Ambuja Cements Limited, Unit Rabriyawas

Roles & Responsibilities

of projects in relation to EARN

up the best practices

Awards and Recognization

Ambuja Cements Limited, Unit Rabriyawas

Awards and Recognization

RUNNER-UP-II/12: Accident free year

Ambuja Cements Limited, Unit Rabriyawas

Awards and Recognization

Ambuja Cements Limited, Unit Rabriyawas

Ambuja Cements Limited, Unit Rabriyawas

Cement Manufacturing Process

Quarrying Raw Material Preparation

Raw Meal Preparation Clinker Production

Cement Grinding Dispatch

Implementation of ISO 50001: 2011 by Oct 2013

Ambuja Cements Limited, Unit Rabriyawas

Production (Million MT)

Ambuja Cements Limited, Unit Rabriyawas

Ambuja Cements Limited, Unit Rabriyawas

Encon Projects with Cost Benefit

New kiln inlet housing for 5.2 m kiln

New lamella seal

Kiln Inlet Chamber Modification

Additional waste air take-off duct

Clinker Cooler Enlargement

Ambuja Cements Limited, Unit Rabriyawas

Encon Projects with Cost Benefit

Ambuja Cements Limited, Unit Rabriyawas

Encon Projects with Cost Benefit

Ambuja Cements Limited, Unit Rabriyawas

Encon Projects with Cost Benefit

Ambuja Cements Limited, Unit Rabriyawas

Ambuja Cements Limited, Unit Rabriyawas

Energy Conservation Initiatives 2011

Ambuja Cements Limited, Unit Rabriyawas