BEST PRACTICES TOWARDS ENERGY

EFFECIENCY

UltraTech Cement Limited.

(Unit -Kotputli Cement Works)
 Best Practices towards Energy
Efficiency
1. Selected Vertical Mills installed at Raw Mill, Cement Mills & Coal mill
instead of Ball Mills, looking to energy efficiency.
2. Selected High recuperation Efficiency Hydraulic Cooler instead of
Mechanical Cooler, which is having 72% Efficiency, whereas
Mechanical Cooler is having 60-65%.
3. Adopted High Efficient Screw Compressor instead of reciprocating
compressor.
4. Adopted CFBC boiler even at small capacity of 2X102TPH because of
its efficiency compared to AFBC boiler i.e. (having efficiency of 85%
instead of AFBC boiler efficiency 81-82%).
5. All Major Process Fans are with Medium Voltage 6.6KV, 36 Pulse VFD
(8 Nos).
6. All other Cooler Fans with Low Voltage (690 V) 12 Pulse VFD.
 Best Practices towards Energy
Efficiency
7. Having Intelligent MCC (ABB-MNSIS) with the facility of monitoring of power,
even for a smallest motor.
8. Adopted intermediate voltage of 690V for motor rating between 200-1000KW to
reduce rated current and hence I2r losses.
9. Adopted 11KV instead of 6.6KV medium system which reduced distribution
losses at MV system.
10. Started 100% Petcoke Firing in Kiln since Nov14.
11. Installed 100KWp solar power plant to promote green energy.
12. Replacing conventional lightings with LED lightings in phased manner.
13. Installed movement cum occupancy sensor for reduction of lighting running
hours.
14. TPP bed ash usage in raw mix .
15. Provided baffle plate (guide plate) inside twin cyclone top duct which is going to
down comer duct.
 Best Practices towards Energy
Efficiency

16. To reduce the power consumption and increase the mill stability through
Cement mills hydraulic line modification.
17. Hydraulic cooler lane DP optimization with cooler lane CPM.
18. Reduction in LOI at Boiler for increasing Boiler efficiency
19. Reduction in Heat rate by inter connection of both TG condensate Lines
20. Smart Air Flow Controller in Air network for Power saving in Compressors
 Medium Voltage Drives
for all major process fans

Objective:
1. Reduction in overall power consumption for cement manufacturing.
2. Constant process parameters for stable operation by close loop speed control.
Background:
In cement manufacturing Fuel/power cost is
very significant (55-60% of total cost). Hence
over all cost can be optimized by optimizing
flow and speed of process fans like PH fans,
BH fans, Cement Mill Fans etc.
Fan power is directly proportional to cube
time of its speed, hence by optimizing the
speed of drives by close loop speed control
with process parameters, a significant amount
of power can be saved.
 Medium Voltage Drives
for all major process fans

Activities:
Installation of 8 Nos MV Drives in all process Fans since project stage and also
controlling the process parameters in close loop auto control of drive speed.

Additionally, KCW is also having 690 V Drives for all cooler fans.

Benefits:
Less power consumption due to wide speed control
Less maintenance as compare to slip ring motor + SPRS.
Low Harmonics
Almost unity Power Factor (Better efficiency of electrical system).
 Slip Power Recovery System
for Raw Mill Fans

Objective:
Raw Mill Fan 2 Nos Motors of 3400 KW each, when run in GRR at between 87% to
90% speed and there are losses of power across the GRR (Around 200 to 250
KW), are recovered through SPRS.
HT Bus (Grid)

( HT
Breaker * HT Isolator

(
SPRS
ISOLATOR
Motor *
(

M
LRS / GRR ROTOR SPRS Feedback
CONTACTOR TRANSFORMER CONTACTOR PWM PWM Transformer
Rotor Source
Converter Converter

Rotor
Resistance
& Starter
Panel*
 Slip Power Recovery System
for Raw Mill Fans

Activities:
Installation of SPRS to recover power loss in slip

Benefits:
SPRS will increase in stability of process, as it will operating in close loop and
no effect of change in grid frequency and mill stability will improve
Total power saving approx. 245.3 KW for each fan at 90% operating speed of
fan.
 Replacement of MH street Lights
by LED lights in Township

Benefits:
Low Power Consumption (90 W instead of
150W)
Higher Burning Life (>1,00,000 Hrs in LED and
10,000 Hrs in MH Lamps)
Low Maintenance Cost.
Low Start / Restrike Time (almost zero in LED
and 2-4 minutes in MH Lamps)
Lumen Maintenance at the end of Life LED
gives 90% output, whereas in MH Lamps it
reduces upto 60%
 CFBC Boiler for Captive Power Plant

Objective:
2X102TPH Boilers selected as per load
requirement.
In this range earlier AFBC Boilers were
installed in group units.
CFBC Boilers considered in Place of
AFBC because of its higher efficiency as a
new technology (having efficiency of 85%
instead of AFBC boiler efficiency 81-
82%)..
 100 kwP Solar Power Plant (Colony Side)

Objective:
Promotion of green energy
Activities:
Solar Power of 100 KWp Mono crystal
type cells (437 cells of 230 Wp) technology
supplied by M/s Tata BP Solar Ltd.
Investment: Rs. 117.19 Lacs

Benefits:
Approx 1,40,000 KWh/Year to be
generated.
Subsidy of Rs. 57 lacs from MNRE (Govt
of India)
 Power saving in Compressed air system

Objective:
Power saving in Compressed air
by installing compressed air
controller.
Investment: Rs. 16.59 Lacs
Movement Sensor at Toilets
 Provided baffle plate inside twin cyclone
top duct going to down comer duct

Before After

P 45 mmWg P 25 mmWg

Issues:
High Pressure drop across the top bend portion
High sp. power consumption of Preheater fans
 Provided baffle plate inside twin cyclone
top duct going to down comer duct

Activities:
Installation of baffle plates (750*800*12 mm) at twin cyclone top duct
which is going to down comer duct.
Four plates in a duct at 90 degree angle.

Benefits:
Fan motor power saved of 681.49 MWh/annum

Annual savings for Rs. 26.0 Lac/annum

Payback time calculated as 0.1 months

 To reduce the power consumption,
increase Cement mill stability
through hydraulic line modification

common HSLM

Three separate HSLM

Issues:
Hydraulic disturbances due to separate hydraulic system for each roller
 To reduce the power consumption,
increase Cement mill stability
through hydraulic line modification

Activities:
Installation of a common HSLM unit for all the 3 master Rollers & soon after this
implementation, pressure deviation became nil between all rollers
Benefits:
Due to Mill stability improvement
Mill output increased by 5 TPH
Mill Vibration reduced from average 7.8 to 5.5mm/sec
Reduce water consumption by average 40KL/day
Total potential saving of Rs123.8 Lac/annum
Power saving of 3240 Mwh/annum
 Power saving through reclaimer
harrow drive modification
Before After

Issues:
High power drawn by reclaimer harrow drive and Pivot point failure.
Load of harrow drive at peak was 70 amp.
Material scrapping not proper
 Power saving through reclaimer
harrow drive modification

Activities:
Replacement of spike rods by 150 mm flat leading to uniform extraction of
material.

Benefits:
Load of harrow drive reduced drastically from 70 amps (Peak) to 45 A (Peak)
Annual savings for Rs. 3.7 Lac/annum
 Optimization of air slide blowers
in cement transport

Issues:
Excess transport air consumption resulting into higher mill sp. Power
consumption
Bag House

To Cement
Silos

Approach:
Interconnection of air blower lines to make common for all blowers delivery
04 nos. of blowers out of 08 stopped under air optimization process
Results :
Total 30 kw/hr energy saved resulting into Rs. 12.6 Lac / anum savings
Zero investment project
 Power saving through kiln coal
conveying line modification

Issues:
High pressure drop along excess length of kiln coal conveying line
High power drawn by conveying blower due to pressure loss to deliver coal at
firing point
9 mtr.
Coriolis feeder

160 kw blower

Approach:
Conveying line layout changed to reduce 18 mtr. of pipe length
Results :
Total 09 kw/hr power saved in blower resulting into Rs. 3.6 Lac/anum
Payback period calculated as months
 Ejector line modification at TPP

Opportunity : At the time of Project Ejector motive steam lines were erected as per
design with 3 inch dia from PRDS to Ejector for both the Units separately, after
commissioning of the plant we were facing problem of Low steam temperature at
Ejector inlet i.e. 250 Deg C without de superheating at PRDS while design pressure
temperature is 11Ata and 350 Deg C
Approach:
A brain storming session has organized with TPP all team members and various
suggestions have come. In those suggestions team has taken decision for
implementation of one suggestion i.e. 6 Inch dia headed from PRDS to near ejectors
then 3 inch line to individual ejectors.
New 6 inch header erected and connected with existing PRDS and ejectors
Results:
We have got desired temperature i.e. 350 Deg C and also started de superheating.
Ejector efficiency increased and vacuum increases by 0.02 kg/cm2
Saving of 10 Kcal/kwh achieved i.e. Saving of Rs. 26.30 Lacs/annum
 Auto set point of BFP with
Drum Pressure - TPP

Opportunity:
In Boiler feed Pump we have installed VFD
since starting and set point of discharge
pressure to VFD is giving manually
Approach:
Looking to the variable load demand One
logic made for auto set point to VFD from
Boiler drum pressure.

Results:
Reduction in Power- 40Kwh/day/pump

Saving of Rs. 22.80 Lacs/Annum

THE JOURNEY CONTINUES
UltraTech