ULTRATECH CEMENT LIMITED

(UNIT: REDDIPALAYAM CEMENT WORKS)

19th National Award for Excellence in Energy Management 2018: 29, 30 & 31 August 2018, Hyderabad

Team Members:

Mr. Praveen Kumar (HOD TS & WCM)

Mr. N Srinivasan ( SH TS)

1

Hirmi Cement Works

Jafrabad Cement Works

Magdalla Cement Works

Ratnagiri Cement Works

Andhra Pradesh Cement Works

Arrakonam Cement Works

Awarpur Cement Works

Jharsuguda Cement Works

West Bengal Cement Works

Bathinda Cement Works

Aditya Cement

Vikram Cement

Gujarat Cement Works

Kotputli Cement Works

Hotgi Cement Works

Rajashree Cement Works

Ginigera Cement Works

Panipat Cement WorksDadri Cement Works

Aligarh Cement Works

Location of Integrated Plants,

Grinding Units and Bulk Terminals

RWCW

Reddipalayam Cement Works

Integrated plant

Grinding unit

Bulk terminals

Mangalore Cement Unit

BSBT- Dodballapur

Shankarapally Bulk Terminal

Navi Mumbai Cement Unit

Cochin Bulk Terminal

Sewagram Cement

Works

Wanakbori Cement

Works

Patliputra Cement Works

Dankuni Cement Works

Jhajjar Cement Works

Magdalla Terminal

Units SymbolNumber of

Units

Integrated

Plants19

Grinding Units 25

Bulk Terminals 7

UltraTech Cement Ltd Overview

Area of spread (RDCW) RDCW Unit

Plant capacity 1.6 MTPA

Area of mines 188.62 Ha

Area of plant 125 Ha

Nearest air port Trichy

(75 km)

2

CEMENT – MANUFACTURING PROCESS

3

MILESTONES

▪ Preheater upgraded

from IV to V stage

▪ Cooler up gradation

▪ GCT vessel height increased

▪ Three cooler fans replaced with high

efficiency fans

▪ Modified Pre-heater twin cyclone Aero-

vane

▪ Clinker breaker Upgradation

▪ Kiln speed

increased from 3.2

to 5.5 RPM

▪ TA duct dia

increased from 2.1

M to 2.5 M

▪ Cooler grate area

increased from

52m2 to 72m2

▪ Kiln Inlet

modification

▪ Kiln feed bucket

elevator speed

increased from

1.5 to 1.7m/Sec

▪ New Plant

Commissioned

FY2016-17

Feb 2000

Apr 2002

Feb 2003

Jun 2004

Sep 2006

Apr 2012

3250 TPD

3150 TPD

3000 TPD

2800 TPD

2400 TPD

1800 TPD

3294 TPD

▪ By continuous

improvement &

optimization

4

▪ State of the art Cement Plant commissioned in the millennium year 2000

▪ 1st Unit in UTCL having Robo lab for total quality control from sampling to

analysis

▪ State of art testing laboratory for Alternative fuels

▪ Designed for using multiple fuels

▪ Pioneer in using alternate fuel with pre-processing system

▪ Pioneer in Using alternate raw material

▪ First Plant in the World to get CDM credit for use of Agro waste alternate fuel

▪ Packing facility with Centralized discharge from cement silo

▪ No fatal accident since last 16 years

UNIQUE FEATURES

5

6

SL NO. DESCRIPTION MAKE SIZEDESIGN

CAPACITYOPERATING CAPACITY

PHOTO

1Limestone Crusher

with Secondary crusher

L&T,

MMD APPM 1615,

MMD 500700 TPH 800 TPH

2 Raw Mill Loesche LM 35.4 180 TPH 230 TPH

3 Coal Mill Loesche LM 21.2 18 TPH 25 TPH

4 Kiln Fuller 3.75 M X 57 M 2400 TPD

3250 TPD

(5 – stage Pre-Heater)

Major process equipment

7

SL NO.

DESCRIPTION MAKE SIZEDESIGN

CAPACITYOPERATING CAPACITY

PHOTO

5 Cooler FLSCross Bar :

10X48 M, HRB3500 TPD 3300 TPD

6

Cement Mill

(Close circuiting

with V-

Separator)

KHD 3.8 Dia X 11.8 M 135 TPH 200 TPH

7

Electronic

Packer ENEXCO 12 Spouts 2 X 180 TPH 2 X 180 TPH

8

Thermal Power

Plant - 12.5 MW

DG - 6.25 MW (2 Nos)

Boiler- CVPL,

Turbine- BHEL

Boiler-55 TPH,

AFBC, CVPL,

Turbine – Triple

extraction cum condensing turbine

TPP

12.5 MW

DG

12.5 MW

TPP

13.5 MW

DG

12.5 MW

Major process equipment

MANAGEMENT SYSTEMS

ISO :18001 -Safety ISO :14001 EnvironmentISO : 9001 - Quality ISO :27001 ISMS ISO :50001 EnMS

8

Reduction in specific energy consumption

746715

733

724691 689

676658

641613

500

600

700

800

Kcal/kg equivalent Cement

Better

Total 3554 No's of EScerts credited for PAT cycle-1

22.92

18.16

13.00

10.94

9.62

9.60

8.34

18-19 Q1

17-18

16-17

15-16

14-15

13-14

12-13

AF

R S

ubstitu

tion %

TS

R

31.52

31.90

30.61

28.47

27.79

26.89

18-19 Q1

17-18

16-17

15-16

14-15

13-14

Fly

ash a

dditio

n in

PP

C

9

Action Plan to Achieve PAT cycle –II Target

Sr. No. Energy efficiency improvement measures

Investme

nt

Rupees in

Lacs

Date of

completion of

measure/ likely

completion

Energy Consumption

Annual Energy saving(TOE)

BeforeAfter

Measures

Electricity

(kWh)

Coal

Measures (Tonne)

1Pressure drop reduction in Preheater 4th stage

cyclone14 completed 1067 1016 583680

2Reduction of pressure drop through junction

box & duct modification at RM ESP32 Completed 176 166 109440

3Replace CFL lamps,HPSV lamps and Tube lights

with LED lamps10.6 Completed 8.39 4.94 40171

4Installation of Aerzen Turbo blower for Kiln coal

firing in place of existing Twin lobe blower 34.89 Completed 32 21 124032

5 Substitution of alternate fuel from 11 % to 15% 45 Completed 48621 48370 321

6 To enhance fly ash addition up to 30% 124 Completed 60639 60342 151614 364

7 Replacement of HVMP lamps with LED in TPP 3 Completed 138 119 224400

8 VFD for BF pump in TPP 25 Completed 175 161 163200

9 Overhauling of TG in TPP 70 Completed 25851 25753 196

10 Heat recovery from rotary kiln 100 Mar-19 33978 33880 196

Total 242186 241239

10

Specific Power Consumption – kWh/MT Clinker

Better

0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

CII NationalBenchmark

2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19 Q1

16.28

59.89 60.3263.43

59.86 58.30 58.5157.48

11

Specific Power Consumption – kWh/MT Cement

Better

50.0

60.0

70.0

80.0

CIINational

Benchmark

2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19 Q1

65.0

71.8 72.0 71.1

66.763.9

64.3 63.5

12

13

Energy Performance Indicators Vs National Benchmarking

S.NO Section Electrical Energy Consumption (kWh/Mt)

CII Benchmark

FY 2015

Achieved

(FY15-16)

Achieved

(FY16-17)

Achieved

(FY17-18)

Achieved

(FY18-19) Q1

1 Single stage Crusher 0.70 0.78 0.75 0.78 0.88

2 Double stage crusher 0.65

3 Raw Mill - VRM 13.3 14.87 14.66 14.78 14.11

4 Raw Mill – Ball mill 16.5

3 Coal Mill 23.90 49.75 52.96 48.01 44.90

4 Pyro – 5th Stage 16.28 27.01 26.23 26.31 27.09

5 Pyro – 6th Stage 17.05 NA

6 Shut Down 0.69 0.46 0.69 0.19

7 Misc 3.91 3.43 3.43 3.26

8Up to Pyro (kWH/MT of

Clinker)38.43 59.86 58.30 58.51 57.48

14

S.NO Section Electrical Energy Consumption (kWh/Mt Cement)

CII Benchmark

FY 2015

Achieved

(FY15-16)

Achieved

(FY16-17)

Achieved

(FY17-18)

Achieved

(FY18-19) Q1

9Cement Mill- Ball mill with

HPRG23.75 22.84 22.92 23.00 22.34

10Cement Mill- Ball mill with

Close circuit27.16 - -

11 Packing Plant 0.65 0.70 0.66 0.72 0.62

12 Overall 69.13 66.72 63.91 64.31 63.49

S.NO Section Thermal Specific Energy (kcal/kg clinker)

CII Benchmark

FY 2015

Achieved

(FY15-16)

Achieved

(FY16-17)

Achieved

(FY17-18)

Achieved

(FY18-19) Q1

1Thermal SEC for 5 stage

Preheater707 735.43 734.86 735.35 734.67

Energy Performance Indicators Vs National Benchmarking

Energy saving proposals under implementation

15

Sl.No. Descriptions Status Target Date

Proposed

energy savings

(Lac kWh)

Expected

Monetary Gain

(Lacs/annum)

Investment

( Rs Lakh)

Payback

(Months)

1Refurbishment and overhauling of Raw Mill Fan (Impeller

change)In progress

30/10/2018

(S/D Req.)11.76 46 35.00 11

2To reduce pressure drop in Raw mill through nozzle ring/

armor ring modificationIn progress

30/10/2018

(With S/D)5.71 22.4 27.65 15

3 Reduce pressure drop across PH down comer duct In progress30/10/2018

(S/D Req.)4.73 18.54 50.00 33

4

Replacement of Cement Mill area Cooling tower pump

with EE 60 m3/hr., 60 meter head and 65% efficiency to

save energy.

In progress 30.09.2018 0.41 1.60 1.00 8

5 Arrest air ingress in Boiler APH outlet to ESP outlet Completed 15.06.2018 0.32 1.26 1.00 10

6Install Boiler blow down heat recovery system to recover

blow down water heatPlanned 30.10.2018 0.68 2.67 4.00 18

7

Revamp the insulation on the main steam pipeline from

boiler to turbine to bring down the temperature drop

below 5 Deg C.

Completed 15.06.2018216.3 MT Coal

saving/yr10.5 10.00 11.00

8 Maintain TG vacuum to improve TG heat rate In progress15.06.2018 (a)

30.09.2018 (b)

511 MT Coal

saving/yr24.8 40.00 19.00

Future Energy Saving Projects

Sl no Location & Equip Modification Suggested

Expected

Saving KW

1 PH Stage III Cyclone

Existing cyclone cap of 6300 mm size is to be replaced with 6900 mm size

without changing the original roof height. Minor modification will be done at

the outlet duct to match with the existing arrangement.

119

2 PH Stage V Cyclone

Existing cyclone roof will be lifted by 500 mm along with the similar

modification to the connecting duct. Inlet duct dimension will change from

4477 x 2545 to 4977 x 2545 ii) Existing immersion tube length is to be

increased.

64

3 Raw mill

Installation of New generation classifier (LSVS) along with inbuilt Vortex

rectifier in Raw Mill to reduce power consumption 194

4 Alternate Fuel AFR Pre processing & Feeding system capacity encasement to save fossil fuel7452Mkcl /Year

saving of Fossil fuel

16

Summary of Energy saving Initiatives ( FY 2015 to 2018)

Sl NoYear of

Implementation Number of projects Savings In Rs Million

Total Annual Energy

Savings TOE

1 2015-16 6 3.25 66.62

2 2016-17 10 9.51 382.46

3 2017-18 5 9.94 446.06

Total 21 22.70 895.14

17

Energy saving Initiatives

18

Year Title of Energy Saving projectAnnual Savings

Rs (Million)

Energy saving

(MTOE)

2015-16

❖ Installation of VFD in 1st RO HP pump 0.16 3.19

❖ Installation of VFD in TPP Drag Chain Feeder 0.02 0.41

❖ Optimization in coal unloading & operation of crushing 0.30 6.17

❖ Installation of Turbo Blower for PC firing 1.00 20.50

❖ Kiln Auxiliary power reduction 1.76 36.06

2016-17

❖ Use of TPP fly ash in the pre-calciner having high Calorific value 7.98 351

❖ Removal of Pre collector Cyclone in the Coal Mill Circuit during Bag house conversion 0.14 3.39

❖ Coal mill nozzle ring modification 0.09 2.30

❖ Installation of Raw Mill Reject Handing System 0.17 1.01

❖ Installation of Cement Mill Reject Handing System 0.13 0.44

❖ Power optimization of RM BH rotary air lock 0.01 0.33

❖ pressure drop reduction in Pyro circuit by modifying PH cyclone-04 & PH fan inlet box

modification0.17 4.22

❖ Raw mill fan inlet box modification to reduce pressure drop reduction 0.13 3.14

❖ Reduction of pressure drop through Junction box & duct modification 0.18 4.29

❖ HPMH & HPMV lamps replaced with LED lamps provided in plant areas, truckyard,coal

tippler, CCR building and Colony areas.0.51 12.34

Energy saving Initiatives

19

Year Title of Energy Saving projectAnnual Savings

Rs (Million)

Energy saving

(MTOE)

2017-18

❖ Air ingress reduction in Raw mill 0.18 3.87

❖ Overhauling of TG 2.45 274.5

❖ Power factor improvement 7.39 162.97

❖ Install energy efficient fan for Packing plant Bag filter fan 612BF2 0.05 1.20

❖ Install correct size Raw mill Bag house fan ( Fan impeller Tipping) 0.16 3.52

20

Installation of In-House fabricated secondary & tertiary shredder with accessories

Challenge➢ As the source and type of Alternate fuel is changing unpredictably

in vide range, So the requirement of universal shredder machine capable to process different types of alternate fuel was felt.

Approach➢ Secondary & Tertiary shredder In-House fabricated and installed in

line with the primary shredder

Investment: Rs.28.0 Lac Savings : Rs. 60 Lac

Benefits :➢ Availability of processed alternate fuel to achieve AFR substitution

up to 40% ➢ Increase in % TSR from 13 % to 18% . Now Consistently sustaining

above 22 % by TSR AFR Shredder

Improvement Project :-01

Increasing Alternate Fuel Consumption

Problem statement :High pressure drop in Preheater Cyclone No :04

Preamble: RDCW have 5 stage ILC Preheater system having pressure

drop around 722 mmwc across preheater with PH fan power of 12.04

kWh/ton clinker.

During upgradation first and second stages cyclones were upgraded to

new design, where as other three cyclones are old with pressure drop

of 120-130 mmwg pressure.

Action Taken : Detailed study conducted and modified the cyclone

inlet area and Diameter of cyclone for pressure drop reduction and

power saving

Benefit : PH fan power reduced by 40 Kwh

Replication potential : YES

Pressure drop reduction across Cyclone-04

Improvement Project :-02

21

Installation of Turbo blower for kiln coal firing

Improvement Project :-03

22

Problem statement: High power consumption & High Noise level

Background : Twin lobe blower was installed for kiln coal firing It is belt driven

system & water circulation for cooling is required continuously. It consumes 70 Kw

power at rated flow of 33000m³/hr @ 0.5 bar.

Based on the performance of Turbo blower installed for PC firing and consultation

with OEM It was decided to replicate the same for kiln firing.

Execution:

Installed the Godrej turbo blower in place twin lobe blower for Kiln firing. It is direct

driven system & air cooled cooling system. It consumed power of rated flow

3300m³/hr @ 0.5 bar is 35kw.

Benefit : Tangible : 35 Kw per hour

{Source of idea : Presentation of M/s Godrej & Boyce on Turbo Blower during

Green Cementech 2014 at Hyderabad on 15 th -16 th May 2014}

Turbo blower

Utilization of Renewable Energy

2051093

1844096

1592363

20291432192542

1000000

1200000

1400000

1600000

1800000

2000000

2200000

2400000

Wind Power (Units)

Installed Capacity (5*225) KW

144974

136527

138791

142949

136624

132000

134000

136000

138000

140000

142000

144000

146000

Solar Power (Units)

100 KW Solar Plant

23

Utilisation of waste material as fuel

24

Alternate fuelAlternate fuel Consumption (MT)

2015-16 2016-17 2017-18

AFCARBONPOWDER 1819 3618 2764

AFETPSLUDGE 130 57 147

AFFIBREWASTE 439.07 81 159

AFFOOTWEARSCRAP 517 483 473

AFFMCGWASTE 2305 1057 780

AFMSWRDF 999 2233.1

AFOILSLUDGE 13

AFOILYCOTTONWASTE 274.54 334 610

AFPAINTSLUDE 1602 1370 1566

AFPLASTICWASTE 6430 7979 10669

AFSPENTCARBON 69 52 35

AFWASTEFUELTYRES 640.86 712 1326

AFWOODENDUST 9.49 1465

AFPHWASTELIQUID 38 12

AFCHARCOAL 88

8.349.6 9.62

10.94

13.00

18.16

22.94

6

8

10

12

14

16

18

20

22

24

12-13 13-14 14-15 15-16 16-17 17-18 18-19 Q1

Alternate Fuel Substitution % TSR

➢ Capex of Rs. 2643 lakh. sanctioned for Alternate fuel pre handling

and feeding system to achieve AFR substitution ( mainly Industrial

waste & municipal waste ) by 40 % TSR. Expected Simple payback

2.5 years

RECOGNITION FOR AFR utilization

MOU made Between M/S. 'UltraTech cement Ltd (UTCL) & Municipal Corporation of Tiruchirappalli (TMC) For “Disposal of Plastic waste from Municipal Solid Waste (MSW) through Co – processing in Cement Kilns”

159

MOU made with following Municipalities for MSW Supply at plant site

S. No Municipalities1 ARIYALUR

2 JAYANKONDAM

3 PERAMBALUR

4 PUDUKKOTTAI

5 KUMBAKONAM

6 SRIRANGAM

7 MAYILADUTHURAI

8 CUDDALORE

9 CHIDHAMBARAM

10 PANRUTI

11 NELLIKKUPPAM

12 VIRUDHACHALAM

13 KARAIKUDI

14 TRICHY CITY CORPORATION

15 AVADI

16 POONAMALLE

17 THIRUVERKADU

18 THIRUVALLUR

19 Chengelpet

20 Madurantakam

21 Manapparai

Net CO2 Emissions

601

577

565556

541

500510520530540550560570580590600610

2013-2014 2014-15 2015-16 2016-17 2017-18

Kg CO2/MT Cementitious Material

The First Cement Company in the World to earnCarbon Credits by using alternate fuels and earned52 million selling credits to Europe already part ofthe Aditya Birla Group in 2007

26

Green Supply Chain

INITIATIVES

Green Supply Chain Policy rolled out

Reverse Logistics

Development new Material sources – Nearby area…Lead Reduction

ARC’s & AMC’s…..Supplier engagement

Procurement of Energy Savings Motors (IE-3) & appliances(5 Star

Rating electronic products & LEDs etc.)

Green Packaging :Developed Returnable Boxes (GI Box ) for

packaging in place of Carton Wooden Box (within the lead distance

of 100 Km

On-line payment system

Development of Supplier Portal (Emptoris.)

Vendor Managed Inventory (VMI)

Implemented sending soft order copies to all supply vendors instead

of hard copies.

Procuring of 75 GSM paper instead of 80 GSM

38

Awareness for vendors

39

By HOD (Mtrls.) on GSC Co2 emission Energy conservation Water conservation

Interaction with vendors

29

ENERGY MONITORING & REVIEW SYSTEMS

29

To measure, monitor, trend & compare power consumption of all major

systems/ sub systems/ auxiliaries for improving Sp. Energy Consumption

Energy monitoring System

❖ Online monitoring

❖ Report generation and archiving is possible

❖ PI system available in all PC and every engineer can monitor all

parameters.

❖ Daily Report on Utilization of Various Fuels.

❖ Useful for analysis of operational deviation

Energy Optimization

❖ EO system results in optimized and smooth operation of the plant and

very minimal operator intervention is required in plant operation.

Plant performance Review Mechanism

❖ Daily Power & Production variance review meeting {FH(T)+DH+SH}

❖ Monthly Plant performance review meeting {UH +FH+DH+SH}

❖ Monthly Communication meeting {UH +all employees}

30

Budget for Energy saving projects

Note : Capex for the Projects having energy saving potential is raised through UH at any point of time & energy savings projects are

given priority.

31

Plant Colony

Workers colony

Govt.School, Reddipalayam

Plant

Vallalar Middle School

Thelur Govt. High School Awareness Street Play

Awareness & Training

Energy & Water Conservation

▪ Creating awareness by celebrating Energy conservation Week

▪ In-house training conducting to all employees

▪ Awareness creating to all Colony residents

▪ Awareness creating to workmen's through pep talks

▪ Awareness through various competitions to Staff, Workmen, School

children and Colony residents

In-house training for employeesEmployee recognition

32

Awareness & Training

Energy & Water Conservation

Green Belt Development

39 % of total area covered with tree

plantations as against 33% of statutory

norms

Survival rate - 96%

33

Green Initiatives

On the eve of World Environment day a Green Walk along with “swachh bharat abhiyan” was organized at surrounding

areas to create awareness among villagers. The whole work force was divided in four groups headed by Function

heads and cleaned the common public places. A large number of villagers also joined Voluntarily to make the area

clean. Program was concluded with sibling plantation at plant and honoring the hygiene workers of municipality

34

Swachh bharat abhiyan outside of the plant & market

AWARDS & ACCOLADES

35

RDCW has been awarded the “ Green Co” - Gold

Certification by Confederation of Indian Industry in

accordance with the Green Company rating system.

This award recognize the significant contribution of

RDCW in the area of energy reduction, environment

and sustainability performance.

RDCW is among few companies in India and first in

our cement business to be certified under Green Co.

RDCW was measured on ten parameters and

environmental practices. The Green Co drivers for

excellence are- Energy Efficiency, Water

conservation, GHG emission, Waste management,

Material conservation, Recycling, Recyclability,

Green supply chain, Renewable Energy, Product

Stewardship and Life Cycle Assessment.

AWARDS & ACCOLADES

RDCW has been awarded “Most Innovative Project” for the Best Practices in Waste

Management by CII GreenCo Best Practices Award 2016.

36

State Government Safety Award Greentech Safety Award

AWARDS & ACCOLADES : Safety

❖First place for best safety practices “SAFECON 2015” by CII

❖State Level Safety Award from Tamil Nadu Government (1999,2000, 05, 06 & 08)

❖Safety Appreciation Award from NSC Tamilnadu Chapter 2003

❖Greentech Safety Award - Bronze in 2006 , Silver in 2007 & Silver in 2010.

❖Two First Prizes State Level Safety Award from Tamilnadu Government (2005 & 2006)

❖Global Cement Awards Lowest Injury Incidence Rate – First prize ($1000).(2006)

❖Golden Peacock Award GPOHSA 2009 & 2010 .

SAFECON 201537

❖“GreenCo Gold’’ certification by CII-Green Company Rating System – 2015

❖National Excellent Energy Efficient Unit Award by CII – (2009, 2010, 2011, 2013, 2014, 2015, 2017 & 2017)

❖National Energy Efficient Unit Award by CII (2004, 2006,2007, 2008 & 2012)

❖Global Cement Awards, Lowest Specific Energy consumption, raw meal & clinker grinding – 2006

❖NCCBM Best Electrical Energy Performance Award 2008-09

❖NCCBM Second Best Improvement in Thermal Energy Performance Award 2008-09

CII Energy Awards

AWARDS & ACCOLADES : Energy

38

❖ Green Manufacturing Excellence Award by Frost & Sullivan 2013,2014,2015,2016,2017

❖Tamil Nadu Pollution Control Board - Green Award 2012

❖ FIMI National Award in Environment -2014

❖ GreenTech Environment Excellence - Silver Award 2006 & 2009 & Gold -2012

❖ Global Cement Award Lowest specific CO2 emission - 2006

❖ Most Innovative Scheme for environmental impact abatement - 2006

❖ FICCI Environment Sustainability of Business Award 2006 – 2007

FIMI National AwardTNPCB GREEN AWARD Frost and Sullivan GMEAFrost & Sullivan Leader award

for Sustainability 4.0

AWARDS & ACCOLADES : Environment

39

Thank you

40