8-UltraTech Vikram Cement PDF

8/23/2013
sio Vi
ission , Values & Strat n, M e gy
n, Creativity & Cont ratio nspi in uo s-I us am Le Te
ulture & Passion et, C inds M
Market & Customer Orien tation
$ltra%ech Cement &imited $nit' (i)ram Cement *or)"
CII National Award for Excellence in Energy Mangement2013 19th 20th A!g!"t2013#
Visio
ion , Values & Str ate n, Miss gy n, Creativity & Con ratio tin nspi uou s-I am s Le Te
!" # $ar%est Cement Prod&cer in India. 10t' $ar%est in t'e (orld.
Mar)et s'are C&rrent *12# *12#1+, : 22 -
.i)ram Cement (or)s Ca/acit0 : 1.0 M2P
First Cement Plant Plant in India to :
obtain ISO : 27001 ISMS certification in 2009.
arn
ing
(i)ram Cement *or)"
set, ind M
& Culture Passion
arn
ing
8/23/2013
sio Vi
Cement Man!fact!ring +roce""
AF
Visio
EnC,N +ro-ect" ' witho!t In.e"tment
set, ind M
& Culture Passion
arn arn
ing ing
8/23/2013
sio Vi
Visio
set, ind M
& Culture Passion
arn arn
ing ing
8/23/2013
sio Vi
Visio
EnC,N +ro-ect" ' with In.e"tment
set, ind M
& Culture Passion
arn arn
ing ing
8/23/2013
sio Vi
Visio
set, ind M
& Culture Passion
arn arn
ing ing
8/23/2013
sio Vi
Visio
61#72 60#38 99#86
99#69
09210
10211
11212
12213
)*h 5 % of Cement
4o!rce'NCC;M /ear 0 A1r2Mar3 09210 10 211 11212 12213 41ecific Elect Energy Con"# )*h 5 % Cement 61#72 60#38 99#86 99#69
arn
ing
:ed!ction in 41ecific +ower Con"!m1tion
set, ind M
& Culture Passion
arn
ing
8/23/2013
sio Vi
:ed!ction in 41ecific =eat Con"!m1tion

990 990
990 988
09210
10211
<cal 5<g of Clin)er
11212
12213
4o!rce'NCC;M /ear 41ecific %hermal Energy Con"# )Cal 5 <g of Clin)er 990 990 990 988
09210 10 211 11212 122 13
Visio
Development and Commercial Production of new product like Active Belite Cement, Portland Composite Cement and Portland lime stone Cement after getting approval from BIS. By 2 !"#!$ Installation of %&' System ! (%. By 2 !$#!) )"#* + production of ,lended cement. By 2 !-#!" Increase t.e percentage fly as. from 2- to 2)+ in Blended Cement. By Dec 2 !/ P&#! 0 2 1p gradation to increase t.e plant capacity from / 2PD in consultation wit. 3&D . By 2 !"#!$ 2PD to /"
Installation of roller press in Cement (ill#! 0 Cement (ill#2. By 4ov 2 !"
arn
ing
:oadma1 to Achie.e ;enchmar)
set, ind M
& Culture Passion
arn
ing
8/23/2013
sio Vi
5C#/ raw material 0 cement ,all mill in closed circuit along wit. 5#separator 0 roller press in closed circuit. By 2 !-#!" $ Stages pre.eater wit. 6P cyclones in all t.ree kilns. By 2 !-#!" (odification in 5C#/ pre.eater cyclones#2,/,- as per C7D in ,ot. stream. By 2 !-#!" 'eduction in pressure of 5'( ,y C7D modeling.By Dec 2 !/ Installation of online particle si8e analyser for optimi8ation of 9uality and product mi: cement; By 2 !-#!" Installation of new !$< water transport system from S3! and S32 mines to Plant for power saving ,y 2* 3%; By Dec 2 !/ Installation of rotoscale for fine coal 0 kiln feed feeding system; By 2 !-#!"
Visio
'eduction in power consumption and Capacity en.ancement of feeding System of Alternate fuel in (S% feeding System.
arn
ing
+ro-ect ' 1 Modification in Alternate >!el >eeding 4y"tem
Problem Statement
set, ind M
& Culture Passion
arn
ing
:oadma1 to Achie.e ;enchmar)
8/23/2013
sio Vi
>&,* ?IA@:AM ,> A&%E:NA%I(E >$E& >EE?IN@ 4/4%EM
Visio
A&%E:NA%I(E >$E& >EE?IN@ 4/4%EM 2 ;efore

;elt A39 ;elt A3A
set, ind M
& Culture Passion
4crew Con.eyor A29
arn arn
ing ing
8/23/2013
sio Vi
Belt A36
;elt A3A
Slide gate
Screw Conveyor A29
Visio
set, ind M
:e"!lt"
2angi,le !.Power saving of 2"." 3%. Saving in terms of 'upees =2"." :2- &rs : // Days : 's. -.$/ =>./" 6acs per annum /.(aintenace cost reduced . -.Increased (S% consumption from 2$ to -" 2?day.
& Culture Passion
arn arn
ing
Action" to eliminate the Ca!"e0after Modification3
ing
8/23/2013
sio Vi
Visio
Problem faced during feeding at various point of plant

Material Feeding in Agriculture hopper at AF system (1)Material Flush at discharge point. (2)Effect on Plant Cleanliness (Black particle layer on floor) (3)Increased fugitive dust emission in plant area. Feeding at old coal transport system with Imported Coal. (1)Difficulty in continuous feeding. (2)Safety Issues. (3) Material Flushing at discharge point. (4)Storage problem.
arn
ing
Reason for Improvement Techniques
set, ind M
& Culture Passion
arn
ing
+ro-ect ' 2 $tiliBation of %yre ?!"t in <iln >iring and de.elo1ment of >eeding 4y"tem
8/23/2013
sio Vi
>ine coal =o11er
Visio
set, ind M
4a.ing" Achieved
Name of Alternati.e >!el Act!al @C( of Material A.ailaCility 0M%3
!
& Culture Passion
%otal &anded co"t +M% %otal Material co"t 0In :"3 0A?;3
3700 "#!
Tyre dust/ Carbon Black
68
Calc!lation of re1lacement co"t of %yre d!"t with +etcoc)
+artic!lar"
Act!al @C(
:e1lacement %otal landed %otal Material co"t Dty co"t +M% 0In :"3 0A?;3
A08 8021 32# 6#$
+etco)e
8338
Net 4a.ing
172096A
arn arn
ing
>eeding 4y"tem after Modification
ing
8/23/2013
sio Vi
Installation of air receivers at VC-I and VC II Kiln common header line. We utilized the receiver available in Inert gas plant . Saving Achieved = 18KW (which is 3% of total power consumption) In terms of Rs. = 4.6 Lacs / annum
Visio
set, ind M
& Culture Passion
We were having 5 nos. of low efficiency compressors having high specific power consumption of 14-17 KW/100m3
Com1re""or No
800.51 800.52 800.53 800.01 800.11
Total
Mea"!red >A? 6"2% !89% !6 %! 2# %8 ! 2%9 2!3!%"
At!al )*
107.00 84.00 82.50 40.00 86.00
4+C 5100m3
17.48 14.26 14.72 14.77 17.10
399%!
arn
ing
+ro-ect ' A In"tallation of 4crew Com1re""or to meet ;a"e &oading reF!irement of the "y"tem re"!lting "a.ing in energy
arn
ing
+ro-ect ' 3 $tiliBation of old Air :ecei.er" of inert ga" a" ;!ffer 4toc) for control airE re"!lting in red!ction of 1ower con"!m1tion d!e to fl!ct!ation in control air line 1re""!re#
8/23/2013
sio Vi
We have installed energy efficient compressors of 2500 m3/hr (ZR 250-7.5) resulted in reduction of specific power consumption from 17 to 10KW/100m3
:e"!lt
Reduction in electrical energy consumption : 150KWh In terms of Rs. : 150 x 24hr x 330 days x Rs. 4.63 / Unit = 55.1 Lacs
Visio
arn
ing
En.ironment +ro-ect" Cement 4!"tainaCility Initiati.e"
set, ind M
& Culture Passion
ing
Action %a)en
arn
8/23/2013
sio Vi
Alternate >!el Con"!m1tion

2!%#2
2"
"#% " ""%$"

""
"#%"9
9%28 #%2! 3%62 !%9#
9%9"
"
& AF weig't
2 " -""
& TS(
2 ""-"2
)ty% T'ousand *+T,

2 "2-"3
Visio
>ir"t time in India .se o/ 0on 1a2ardous 3aste in Ce4ent 5iln 6rocess o/ +S3 7 use o/ (8F 6lastic 7 6olyt'ene *Below 2 +icron Si2e, 9ovt% Sei2ed 8oda C'ura *6o::y Straw, 1a2ardous 3aste ;:iu4 +arc o/ ;:iu4 Alkaloid Factory< 0ee4uc' 6aint sludge *Auto4obile =ndustries, .se o/ Alternate /uelState o/ art environ4ental /riendly dis:osal syste4 >nergy (ecovery wit' e//ective utili2ation >4ission reduction Conservation o/ 0atural (esources
AF( /eeding syste4 at ?C3
arn
ing
$"e of =aBardo!" and Non =aBardo!" *a"te a" Alternate >!el in Cement <iln
set, ind M
& Culture Passion
arn
ing
8/23/2013
sio Vi
Cost Bene/its-
?e"cri1tion )uantity o/ AF( .sed *+T, T'er4al Substitution (ate *TS( &, Cost Saving *(s% =n lak's, Fuel Saving *+T, Material 6aint Sludge ;:iu4 +arc
2009210 66 " "%8! *-, "36% 2#26 D!antity 0M%3 $$"%26 3 #%3$
2010211 99"6 3%62 23%#! $662
2011212 "#"9! !%9# "#!%66 8$8$
2012213 2!#28 9%28 26"%!8 "28!"
201321A D1 3##8 #%39 3#%39 "9!! %otal Negati.e Co"t till G!ne 13 0In &a)h"3 3!%3 !!%32
Negati.e Co"t 0:"5M%3 8 "8
>nergy Saving on account o/ @(eduction in Coal +ill (unning 1rs (eduction in >nergy Consu4:tion by !%$ Aacs k3'
Visio
set, ind M
& Culture Passion
+A% ;enefit Cy !"ing A>

Year Qty. of Alternative Average CV Fuel Consumed Value of (MT) Alternative fuel (Kcal/Kg) 17195 25729 3778 3608 3641 3860 PAT Benefit (MToE)
2011-12 2012-13 2013-14(Q1)
6204 9368 1443
* MToE- Metric tons of oil equivalent
arn arn
ing
%angiCle ;enefit"
ing
8/23/2013
sio Vi
C;2 5g/ton o/ Ce4ent
2010211 #$3
2011212 6!
2012213 632
Environmental Projects for carbon emission reduction 1.Consumption of MSW is 3555,59 ! " 9#!$ M% in last 3 &ears. '.Consumption of ()ro Waste is 3 ! , 19! " $1$3 M% in *ast 3 &ears. 3. +se of Copper sla) as a alternate ra, material actin) as minerali-er. .. /ncreased t0e production of 1lended Cement from !$ to 1 2. 5./ncreased in t0e 2 of 3l4 as0 Consumption from'. to '!2. !./ncreased t0e Performance /mprover from ..5 to 5 2 in 5PC .3 and 53 6rade Cement.
Visio
Societal Bene/its- Better 3aste +anage4ent Syste4 Co-:rocessing o/ (8F in Ce4ent 5iln is bene/icial to 'u4an 'ealt' 6lastic 7 6olyt'ene is a//ecting to >nviron4ent 7 1ealt' 8is:osal o/ Sei2ed 8oda C'ura in 5iln solved t'e :roble4 o/ 6olice 8e:art4ent 8is:osal o/ ;:iu4 +arc in 5iln% 6aint Sludge-8is:osal % (ecognition 7 a::reciation /ro4 8istrict Collector and S%6%
arn
ing
IntangiCle Cenefit"
set, ind M
& Culture Passion
arn
@reen =o!"e @a"e" Emi""ion :ed!ction
ing
8/23/2013
sio Vi
Partial s&bstit&tion of fossil f&el in 3iln 4it' MS(5 %ric&lt&re 4aste etc.
Stat&s : &dited in /ril /ril12 Pro8ect desi%n doc&ment *P66, : In Pro%ress
Visio
1se of 2PP Bed As. as @ypsum an.ydrite 1se of Copper Slag as raw mi: component acting as minerali8er 1tili8ation of 6ow @rade 6imestone 1tili8ation of Apium (arc, t.e .a8ardous waste of Apium Alkaloid Plant 1tili8ation of paint Sludge, t.e .a8ardous waste of Automo,ile Industries
arn
ing
$tiliBation of *a"te Material
set, ind M
& Culture Passion
arn
ing
Clean 6e7elo/ment Mec'anism
8/23/2013
sio Vi
Rally Poster
Quiz
600000 500000 400000 300000 200000 100000 0

2004-05
%ree +lantation
3<39< 8 3< 9<$"3 2<#!<9$2
!<2!< 6" $<9$<33" $<6$<8!$ $<2#<#22 3<98<398 3<6#<3$8
2005-06
2006-07
2007-08
2008-09
2009-10
2010-11
2011-12
Visio
arn
ing
%heme of the month >eC13 Energy Con"er.ation
set, ind M
& Culture Passion
2012-13
arn
Acti.itie" on En.ironment >ront
ing
8/23/2013
sio Vi
Energy Awarene"" Mea"!re"

"% 2% 3% $% !% 6% #% 8% 9% =n-'ouse 7 eBternal Training /or all% Attending Se4inars on >0C;0 Attending >Bternal 6rogra4s on >0C;0 .:dates /ro4 =nternet =nteractions wit' >0C;0 Co4:anies% Training by >nergy Auditing Agencies like@ C==< CT>S etc%%
?arious co4:etitions on >nergy Conservation 6rogra4 *6oster< Slogan< etc%%, involving all Co4:any e4:loyees< Contract e4:loyees< 1ouse wi/e< Sc'ool c'ildren etc%% 6oster 8is:lay su::lied by B>> ?ideo dis:lay letters%
" % (ecognition 7 a::reciation by distribution o/ Awards< token gi/t and a::reciation ""% Suggestion Sc'e4es%
Visio
arn
Management of Energy Con"er.ation +rogramme"
set, ind M
& Culture Passion
arn
ing ing
8/23/2013
sio Vi
Visio
CA6>C /or 2 +3 Solar :ower :lant :ro:osed /or t'e year 2 "$-"! % To increase AF( substitution at Aine-3 /ro4 9%3! to "!& and its eBtension to line " 7 2 =nstallation o/ 31( Syste4 " +3% (oller 6ress =nstallation in C+ " 7 2 To en'ance t'e :roduction o/ Blended Syste4% =ncrease t'e :ercentage /ly as' /ro4 2#& to 3 & in Blended Ce4ent
arn
ing
EnCon +ro-ect" for next 3 year"
set, ind M
& Culture Passion
arn
ing
>nergy Conservation Target Setting 7 +onitoring
8/23/2013
sio Vi
61-" 7 2 .: gradation to increase t'e :lant ca:acity /ro4 3 3! T68 in consultation wit' 518
T68 to
=nstallation o/ new "6D water trans:ort syste4 /ro4 S5" and S52 4ines to 6lant /or :ower saving by 28 53 8evelo:4ent o/ new :roduct like Active Belite Ce4ent< 6ortland Co4:osite Ce4ent and 6ortland li4e stone Ce4ent% =nstallation o/ (oto scale /or /ine coal 7 kiln /eed /eeding syste4
Visio
Steps taken to reduce SOx and NOx emission in the stack to meet the proposed norms.
arn
&dit findin%s ISO 11001:2001
set, ind M
& Culture Passion
arn
ing
EnCon +ro-ect" for next 3 year"
ing
8/23/2013
sio Vi
Energy Monitoring >ormat
Daily Power Report Through SAP
Power Summary Report Through SAP
Visio
9ner%0 Monitorin% Format Sa7in%s :&antification

& Culture Passion
set, ind M
EN 5 - Total energy saved due to conservation and efficiency improvements. Sr. Sources of Energy Savings Unit FY 2010-11 No. Process Optimization 1 Energy savings due to process re-design Modification in cyclone 1.1 1A 1! " #A $#! as per %&' recommendation. E,uipment -pgradation . modification - /avings due " to conversion and retrofitting of e,uipment Modification of 0iln-1 ".1 %ooler E/P Modification in Pyro Outlet "." duct ".* 3&' 4nstallations at &ans 7educed energy usage due * to c8anges in employee 9e8avior *.1 0aizens *." /uggestions # Ot8ers Total FY 2012-13 Apr-11May-11 Jun-11 Jul-11 Aug-11 Sep-11 Oct-11 Nov-11 Dec-11 Jan-12 Feb-12 Mar-12 TOTAL
()
5#*+
() () () 2157 +2 52 162 1"1 1*#
31
1""
1#1
1#1
12+
619
152
1+6
1+1
12"
125
1365
() () () ()
"5
*6
*"
*5
*2
55
+"
+2
1+
5"
16+
1"#
751
255*
"5
*6
55
1*"
1##
11*
15+
"55
*+1
#61
#"+
#25
"2*5
arn arn
ing ing
8/23/2013
sio Vi
Bnergy Audits carried out ,y; Central 2ec.nical and Bnergy Services CC2BSD in t.ree years
5ikram Cement %orks is accredited wit. ISA " !;2 !! ,y D45.
Visio
5nowledge s'aring on co :rocessing o/ waste wit' steel< :ower 7 and Ce4ent =ndustries%
5nowledge s'aring on :rocessing o/ +S3 at Eai:ur
arn
ing
!est Practices S'arin% <Im/lementation Adoption of Best Practices
set, ind M
& Culture Passion
arn
ing
9ner%0 &dits ; Certificate
8/23/2013
sio Vi
5nowledge s'aring on 9reen Tec'nologies /or Sustainable Concrete Construction
.se o/ 8ay lig't Syste4
Use of Solar Heaters for Water Heating
Visio
Bducating t.e suppliers?5endors?Contractors and customers on energy reduction measure. 2ransporters; 2o transport t.e fly as. in "2 (2 Bulker instead of / (2 ,ulker leading to ,ot. reduction in energy and cost. 2o transport all ot.er raw materials like red oc.re ,,au:ite,laterite and pet coke in ,ig trailer instead of mini trucks. 2ankers carrying fly as. is ,eing utilised for transporting of cement during return trip.
arn
ing
Best practices implemented on energy front among the Associates .
set, ind M
& Culture Passion
arn
ing
=se of of >ene4able 9ner%0 Adoption Best Practices
8/23/2013
sio Vi
(aFiv 9and'i 0ational )uality and >nviron4ent Award
Visio
CII Bnergy and Bnvironment Award 2 !2
arn
ing
Awards and Accolades
set, ind M
& Culture Passion
arn
ing
Award" and Accolade"
8/23/2013
sio Vi
Thank You!
Visio
7u88y 6ogic controller for 3iln and Cooler Circuit. 2emperature rise in Primary and Secondary Air. S.ifting of 7eed Bo: In Centre of 6ine to a,sor, more .eat ;Pre.eater /. Bliminate Air Ingress ,y improving Sealing. Pre.eater Duct replacement in 6ine /
arn
Measures for Specific Heat Reduction
set, ind M
& Culture Passion
arn
ing ing

8-UltraTech Vikram Cement PDF

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

8-UltraTech Vikram Cement PDF

Uploaded by

Copyright:

Available Formats

8/23/2013

ission , Values & Strat n, M e gy

n, Creativity & Cont ratio nspi in uo s-I us am Le Te

ulture & Passion et, C inds M

Market & Customer Orien tation

$ltra%ech Cement &imited $nit' (i)ram Cement *or)"

!" # $ar%est Cement Prod&cer in India. 10t' $ar%est in t'e (orld.

Mar)et s'are C&rrent *12# *12#1+, : 22 -

.i)ram Cement (or)s Ca/acit0 : 1.0 M2P

First Cement Plant Plant in India to :

obtain ISO : 27001 ISMS certification in 2009.

(i)ram Cement *or)"

& Culture Passion

Market & Customer Orien tation

ission , Values & Strat n, M e gy

n, Creativity & Cont ratio nspi in uo s-I us am Le Te

Cement Man!fact!ring +roce""

ulture & Passion et, C inds M

Market & Customer Orien tation

EnC,N +ro-ect" ' witho!t In.e"tment

& Culture Passion

Market & Customer Orien tation

ission , Values & Strat n, M e gy

EnC,N +ro-ect" ' witho!t In.e"tment

n, Creativity & Cont ratio nspi in uo s-I us am Le Te

ulture & Passion et, C inds M

Market & Customer Orien tation

EnC,N +ro-ect" ' witho!t In.e"tment

& Culture Passion

Market & Customer Orien tation

ission , Values & Strat n, M e gy

EnC,N +ro-ect" ' witho!t In.e"tment

n, Creativity & Cont ratio nspi in uo s-I us am Le Te

ulture & Passion et, C inds M

Market & Customer Orien tation

EnC,N +ro-ect" ' with In.e"tment

& Culture Passion

Market & Customer Orien tation

ission , Values & Strat n, M e gy

EnC,N +ro-ect" ' with In.e"tment

n, Creativity & Cont ratio nspi in uo s-I us am Le Te

ulture & Passion et, C inds M

Market & Customer Orien tation

EnC,N +ro-ect" ' with In.e"tment

& Culture Passion

Market & Customer Orien tation

ission , Values & Strat n, M e gy

n, Creativity & Cont ratio nspi in uo s-I us am Le Te

61#72 60#38 99#86

:ed!ction in 41ecific +ower Con"!m1tion

& Culture Passion

Market & Customer Orien tation

EnC,N +ro-ect" ' with In.e"tment

ulture & Passion et, C inds M

Market & Customer Orien tation

ission , Values & Strat n, M e gy

n, Creativity & Cont ratio nspi in uo s-I us am Le Te

:ed!ction in 41ecific =eat Con"!m1tion

ulture & Passion et, C inds M

Market & Customer Orien tation

09210 10 211 11212 122 13

Installation of roller press in Cement (ill#! 0 Cement (ill#2. By 4ov 2 !"

Mar)et s'are C&rrent 12# 12#1+, : 22 -