UltraTech Cement Limited. (Unit Narmada Cement, Jafarabad Works)

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1 BEST PRACTICES TOWARDS ENERGY EFFICIENCY UltraTech Cement Limited. (Unit Narmada Cement, Jafarabad Works)

2 Overview of NCJW Narmada Cement-Jafarabad Works was established in 1982 with an installed capacity of 1 MMTPA clinker and has been gradually increased to 1.50 MMTPA (4,300 4,500 TPD). Cement capacity is 0.50 MMTPA (1,150 TPD). The Unit is ISO 9001:2008, ISO 14001:2004, OHSAS 18001:2007, ISMS 27001:2005 & SA 8000:2008, ISO-50001:2011certified It is India's first split location dry process cement plant with Fuller technology having four-stage suspension pre-heater, in-line flash calciner, reverse air bag house dust collector, vertical roller mills besides to be the first to unload imported South African coal at plant jetty. It transports 100% clinker to grinding units is in bulk by sea route. The special feature of this plant is 'Just in Time design for raw mill circuit. As against conventional norms of 20,000 MT silo for raw meal storage it has 2,000 MT silo.

3 Overview of NCJW The grinding units associated with Jafrabad Cement Works are Magdalla Cement Works having capacity of 0.80 MMTPA and Ratnagiri Cement Works having capacity of 0.50 MMTPA. All three coast-based split location units have Jetties for marine transportation. Narmada Cement was the prime supplier of fly ash based Portland Pozzolana Cement (PPC) to Sardar Sarovar Dam on river Narmada, which is the World's second largest concrete gravity dam (by volume). We created a benchmark in Indian cement industry with installation of SF 3 X 6 cross bar cooler supplied by FLS, in record 41 days. With the hand holding of DuPont Sustainable Solutions, we are marching towards "Zero Accident" goal and articulating "Safety" as fundamental core belief with the theme "Life is precious, We care for it"as advocated by Shri O P Puranmalka, Business Director. Moving ahead in the safety journey, we achieved lost time injury frequency rate (LTIFR) 0.00 in the year

4 ENERGY SAVING PROJECTS 4

5 1.0 Case Study-Elimination of material settling at separator inlet duct by providing hump to increase air velocity. 1. Problem Statement: Dust settling in separator inlet duct. 2. Impact of Problem : Higher power consumption of separator fan to maintain the velocity in duct and maintain the DP in separator. 3. Action taken : Separator all duct pressure readings were taken. Dust settle point identified Velocity measured in the separator inlet duct & found velocity was lower than desired. It was decided to provide the hump in the inlet duct to increase the velocity. Hump size & location decided in the duct & provided.

6 Dust accumulation in duct

7 Calculation for Hump size Before Area Measurement UOM Sep I/L Duct Radius(Rb) 1.5 Mtr Duct Area M2 Flow M3/Sec Flow M3/Hr After Area Measurement UOM Radius (Ra) 1.25 Mtr Duct Area 1.23 M2 Flow M3/Sec Flow M3/Hr Velocity M/Sec Velocity M/Sec Ø Cos = (Height Of hump)/(a/2) Ø 250mm a 532mm Height of hump = Rb-Ra Cement angle of repose( Ø)= 20 deg Base of hump (a) = 532mm

8 Profile of dust settling inside duct Before After Separator Inlet Duct 8

9 Hump view in separator Hump in separator inlet duct 9

10 Power Saving Calculation BEFORE AFTER Previous fan power in KW 96 Existing Fan running KW 84 Run Hrs 24 Run Hrs 24 Power/Day 2304 Power/Day 2016 Power per month Power per month Saving Saving in energy KWh per year Saving in Lacs/ Year (considering unit 4.85) 5.03

11 2.0 Reduction in heat losses across Preheater 1. Problem Statement : High Pressure drop across the Preheater, High velocity at orifice because of high velocity difference in short span, Puffing occur at orifice. 2. Impact of Problem : High heat consumption across Preheater. 3. Action taken : Brought down the velocity at orifice to reduce pressure drop across calciner

12 Velocity at orifice at different location Existing Velocity 30m/Sec after orifice modification m/sec m/sec m/sec m/sec 30m/sec m/sec m/sec m/sec

13 Result Kiln Feed PH Fan Speed PH O/L Temp PH O/L Draft Calciner Exit Temp Calciner Exit Draft Kiln feed Hood draft Kiln Riser DP Calciner Inlet Draft Before After

14 Result Kiln Riser DP Before After Before After

15 Result KWH SG Fan RPM Nov-14 Dec-14 Jan-15 Feb-15 Mar-15 Apr-15 May-15 Jun-15 Month

16 Result Saving in Orifice Modification Saving Average 280KWH of PH Fan Kiln Running hours =345*24 =8280 Total Saving in KWh =8280*248 = Saving of Rs = *4.67Rs/Unit =95.89Lacs/Annum

17 3.0 Reduction in heat by increasing insulation in TA duct Increased insulation thickness in TAD from 65 to 100mm in 20m lining area BEFORE AFTER Backup Insulation of 35mm provided in Stage IV feed pipe. BEFORE AFTER

18 Result Before radiation losses with castable : 2.91 kcal/kg of clinker After radiation losses with Brick lining : 2.22 kcal/kg of clinker Benefit in kcal/hour : Total Benefit in kcal kg/clinker :

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

20 4. Various energy saving projects SNo. Title 4 Reduction in Mill fan RPM 5 Mill taking more power with considering TPH. Pregrinder running hrs was 6 more because fresh feed was monitoring manually. Action Taken To maintain the mill discharge Blaine mill fan rpm maintainingfrom 400 to 460. Mill power optimized with maintaining the media size & qty. Close loop system was developed and feed was controlled w.r.t. reject.through put set point to be kept manually by monitoring the crusher load. Saving KW/Month Separatormotor was of old version i.e. DC motor and taking more power to operate. Converted sep motor from DC to AC

21 Our Goal is to achieve Excellence in Energy Conservation Thank You 21

22 Saving calculation of G-Aid motor after VFD. Earlier motor KW A 0.37 After VFD motor running KW------B 0.18 Difference(A-B) C 0.19 Normal Day Run Hrs D 24 Saving in KW/Day (C X D) E 4.56 Saving in KW/Month (E X 30) F 136.8

23 Saving calculation of Pre grinder blower running hours Calculation-Earlier Condition Motor rated KW 3.7 Operating KW 2.74 No. of blowers 2 Pre grinder running Hrs 15 Idle running 9 Power/Day of both blowers Calculation-Existing Condition Motor Rated KW 3.7 Operating KW 2.74 No. of blowers 2 Pre grinder running Hrs 15 Idle running for each stoppage of pre grinder 0.17 Total start stop of Pre grinder 4 Total idle running Hrs 0.68 Power/day of both blowers Saving in energy KWh per day Saving in energy KWh per Month

24 Saving calculation Cement Mill Separator fan Power calculation on Last year performance Operating current in Amps Operating KW Running hours 24 Power/day in KWh Power per month in KWh Power calculation on current year performance Fan running KW 84 Running Hrs 24 Power/Day in KWh 2016 Power per month in KWh Saving of KWh per month

25 Saving calculation Cement mill fan Power calculation on Last year performance Operating current in Amps 8.8 Operating KW 4.81 Running hours 24 Power/day in KWh Power per month in KWh Power calculation on current year performance Operating current in Amp 7.05 Operating KW 3.85 Running hours Power/day in KWh Power per month in KWh Saving of KWh per month

26 Saving calculation Mill main Motor KW Power calculation on Last year performance Operating KW Running hours 24 Power/day in KWh Power per month in KWh Power calculation on current year performance Operating KW Running hours 24 Power/day in KWh Power per month in KWh Saving of KWh per month

27 Saving calculation of Pre grinder circuit Power calculation on Last year performance Operating KW Running hours 14 Power/day in KWh 1960 Power calculation on current year performance Operating KW Running hours 16 Power/day in KWh 1520 Power per month in KWh Power per month in KWh Saving of KWh per month

28 Saving calculation of Cement mill separator Motor from DC to AC Power calculation on Earlier performance Power calculation on current year performance 2Nos DC Motor Cooling fan operating KW 5.4 No Cooling fan for AC Motor. 0 DC Motor operating KW Total Power drawnby the separator drive system Running hours per day 24 Daily Power Consumption in KWh Monthly Power Consumption in KWh Sep AC motor Operating KW 7.00 Total Power drawn by the Separator drive system Running hours per day 24 Daily Power Consumption in KWh 168 Monthly Power Consumption in KWh 5040 Saving of KWh per month