ULTRATECH CEMENT LIMITED (UNIT: …

1 ULTRATECH CEMENT LIMITED . ( unit : reddipalayam CEMENT WORKS). 18th National Award for Excellence in Energy Management- 2017 . 30- Aug 2017 to 01-Sep 2017 , Hyderabad. Team Members: Mr. Praveen Kumar (HOD TS & WCM). Mr. ( HOD Project). 1. ULTRATECH CEMENT Ltd Overview Location of Integrated Plants, Grinding Units and Bulk Terminals Number of Units Symbol Bathinda CEMENT Works Units Panipat CEMENT Works Dadri CEMENT Works Jhajjar CEMENT Works Aligarh CEMENT Works Integrated 18. Plants Kotputli CEMENT Works Aditya CEMENT Wanakbori CEMENT Vikram CEMENT Patliputra CEMENT Works Grinding Units 25. Works West Bengal CEMENT Works Sewagram CEMENT Works Hirmi CEMENT Works Dankuni CEMENT Works Bulk Terminals 7.

2 Gujarat CEMENT Works Magdalla CEMENT Works Jharsuguda CEMENT Works Jafrabad CEMENT Works Magdalla Terminal Awarpur CEMENT Works RWCW. Navi Mumbai CEMENT unit Hotgi CEMENT Works Ratnagiri CEMENT Works Shankarapally Bulk Terminal Area of spread (RDCW) RDCW unit Rajashree CEMENT Works Andhra Pradesh CEMENT Works Plant capacity MTPA. Ginigera CEMENT Works Mangalore CEMENT unit Arrakonam CEMENT Works Area of mines Ha Integrated plant Area of plant 125 Ha BSBT- Dodballapur Grinding unit Trichy reddipalayam CEMENT Works Bulk terminals Nearest air port (75 km). Cochin Bulk Terminal 2. CEMENT MANUFACTURING PROCESS.

3 3. MILESTONES. 3294 TPD. 3250 TPD. 3150 TPD FY2016-17. Apr 2012 By continuous 3000 TPD improvement &. Sep 2006 optimization 2800 TPD Preheater upgraded Jun 2004 from IV to V stage 2400 TPD Cooler up gradation Feb 2003 GCT vessel height increased 1800 TPD Three cooler fans replaced with high Apr 2002 Kiln speed efficiency fans increased from Modified Pre-heater twin cyclone Aero- Feb 2000 Kiln Inlet to RPM vane Clinker breaker Upgradation modification TA duct dia New Plant Kiln feed bucket increased from Commissioned elevator speed M to M. increased from Cooler grate area to increased from 52m2 to 72m2.

4 4. UNIQUE FEATURES. 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 15 years 5. MANAGEMENT SYSTEMS. ISO : 9001 - Quality ISO :18001 -Safety ISO :14001 Environment ISO :27001 ISMS ISO :50001 EnMS.

5 6. Management System - Certification ISO 50001:2011. CII Green Co - Gold Certification Energy Management 7. Management System Energy Policy implemented in Dec 2013. Energy Policy states unit 's commitment to achieving energy performance improvement Energy policy is communicated at all levels. Energy policy is regularly reviewed. Next review of energy policy : Jan -2018. 8. Energy consumption 9. Reduction in specific energy consumption AFR Substitution % TSR. 12-13 Kcal/kg equivalent CEMENT 13-14. 14-15 15-16 800 746 733. 715. 724 13. 16-17. 691 689. 700 676 17-18 Q1. 658. 616. Better 600. Fly ash addition in PPC.

6 13-14 500 14-15 15-16 16-17 17-18 Q1 Total 3554 No's of EScerts credited for PAT cycle-1. 10. Specific Power Consumption kWh/MT Clinker 64 62. 60. 58. 56. 54. 52. Target FY2014-15 FY 2015-16 FY 2016-17 FY 2017-18 Q1. FY 2017-18. Kwh/Clinker 11. Specific Power Consumption kWh/MT CEMENT 80. 72 72 71. 67. 70. 65. 64. Better 60. 50. CII National 2012-13 2013-14 2014-15 2015-16 2016-17. Benchmark 12. Energy saving Projects 13. Methodology for Identification of Improvement Projects Opportunity Identification Suggestion Energy Mapping Idea Generation Benchmarking Results Achieved Team formation Idea Screening Project execution Rewards Lost Cost Matrix Feasibility Study & &.

7 &. OEE & VOC. Allocation of project team Recognition Review of Progress 14. Action Plan to Achieve PAT cycle II Target Energy Consumption Date of (TOE) Annual Energy saving Investme completion of Sr. No. Energy efficiency improvement measures nt Rupees measure/ likely Before Coal in Lacs After Electricity completion Measures (Tonne). Measures (kWh). Pressure drop reduction in Preheater 4th stage 1 14 completed 1067 1016 583680. cyclone Reduction of pressure drop through junction box &. 2 32 Completed 176 166 109440. duct modification at RM ESP. Replace CFL lamps,HPSV lamps and Tube lights 3 Completed 40171.

8 With LED lamps Installation of Aerzen Turbo blower for Kiln coal 4 Mar-18 32 21 124032. firing in place of existing Twin lobe blower 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 Mar-18 175 161 163200. 9 Overhauling of TG in TPP 70 Mar-18 25851 25753 196. 10 Heat recovery from rotary kiln 100 Mar-18 33978 33880 196. Total 242186 241239. 15. Increasing Alternate Fuel Consumption Purpose: To increase the thermal substitution rate from 10 % to 25%.

9 Types of Industrial waste Moisture Size (mm) % of Usage Al ternate Fuel Challenges used in RDCW (%). Carbon Powder 16. FMCG 33 4. Foot ware 4 Ballast Inhomogen Size Circulation (Cl, (Water, Ash) eous variation S, alkali ). Paint Sludge 32 400 Plastics 53 68. Poor Plugging Spent Carbon 40 High heat consumption Combustion Technical Approach: Poor availability Production loss Granulometry of AF improved after double shredding Spike rollers installed in hopper discharge chute to improve Increase in OEE down Poor clinker the flowability production cost quality Optimizing AF feed bucket elevator speed to improve output.

10 16. Installation of Multi purpose Shredder Purpose: Shredder Machine Capacity enhancement of Alternate fuel feeding system through size reduction. Technical Approach: Installed Multi-purpose shredding machine Double shredding of Alternate fuels Investment: Lac Savings : Rs. Lac Benefits : Size reduction from 500 MM to 50 MM (Plastic, HDPE bags, Tarpaulin, Foot wear waste, Agro waste, wood and other miscellaneous waste. Shredded HDPE bags & Tarpaulin 17. Increasing Alternate Fuel Consumption Shredder Machine 12-13 13-14. 14-15 TSR %. 15-16 13. 16-17. Alternate Fuel - Samples 17-18 YTD . 6 8 10 12 14 16 18.)