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    Udaipur Cement Works Limited

    Uploaded by

    Bülent Bulut
    This document presents two case studies from Udaipur Cement Works Limited (UCWL) on optimizing energy usage and productivity: 1. VRM power optimization through upgrading the mill from 270TPH to 330TPH capacity and modifying components, reducing specific power consumption by 23.62%. 2. WHRS power performance improvement through modifications like bypass ducts and dampers, reducing auxiliary consumption below 5% and increasing power generation to 6.2MW. Overall the case studies showcase UCWL's efforts to improve energy efficiency and reduce costs through innovative technical upgrades to their vertical roller mill and waste heat recovery systems.

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    © All Rights Reserved
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    Udaipur Cement Works Limited

    Uploaded by

    Bülent Bulut
    95 views17 pages
    This document presents two case studies from Udaipur Cement Works Limited (UCWL) on optimizing energy usage and productivity: 1. VRM power optimization through upgrading the mill from 270TPH to 330TPH capacity and modifying components, reducing specific power consumption by 23.62%. 2. WHRS power performance improvement through modifications like bypass ducts and dampers, reducing auxiliary consumption below 5% and increasing power generation to 6.2MW. Overall the case studies showcase UCWL's efforts to improve energy efficiency and reduce costs through innovative technical upgrades to their vertical roller mill and waste heat recovery systems.

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    Cement

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    4. Udaipur Cement Works Limited

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    This document presents two case studies from Udaipur Cement Works Limited (UCWL) on optimizing energy usage and productivity: 1. VRM power optimization through upgrading the mill from 270TPH to 330TPH capacity and modifying components, reducing specific power consumption by 23.62%. 2. WHRS power performance improvement through modifications like bypass ducts and dampers, reducing auxiliary consumption below 5% and increasing power generation to 6.2MW. Overall the case studies showcase UCWL's efforts to improve energy efficiency and reduce costs through innovative technical upgrades to their vertical roller mill and waste heat recovery systems.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    95 views17 pages

    Udaipur Cement Works Limited

    Uploaded by

    Bülent Bulut
    This document presents two case studies from Udaipur Cement Works Limited (UCWL) on optimizing energy usage and productivity: 1. VRM power optimization through upgrading the mill from 270TPH to 330TPH capacity and modifying components, reducing specific power consumption by 23.62%. 2. WHRS power performance improvement through modifications like bypass ducts and dampers, reducing auxiliary consumption below 5% and increasing power generation to 6.2MW. Overall the case studies showcase UCWL's efforts to improve energy efficiency and reduce costs through innovative technical upgrades to their vertical roller mill and waste heat recovery systems.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 17

    A Case Study Presentation

    at 15th Green Cementech


    2019 on Optimization of
    Energy & Productivity
    @

    Udaipur Cement Works Limited


    (a subsidiary of JK Lakshmi Cement Limited)
    UCWL: Snapshot

    UCWL is a subsidiary of JK Lakshmi Cement Ltd.

    Located in Dabok near Udaipur

    Installed Production Capacity of 3750 TPD

    Brand Name: Platinum Heavy Duty Cement


    Case Study

    01
    VRM POWER
    OPTIMIZATION
    VRM Performance

    Production Production
    Capacity: 270 Capacity: 330
    TPH TPH

    Specific Power Specific Power


    Consumption: 25.0 Consumption: 14
    kWh/MT kWh/MT

    EARLIER PRESENT
    VRM Performance
    S.N
    Description Unit Designed / Upgraded Operating Data* % Change
    o.

    1 Capacity TPH 330 302 8.48

    2 Residue % R @ 90 µ 12 12 0

    Specific Power Consumption

    3 Mill Main Drive U/T 6.6 6.0 10

    4 Classifier U/T 0.5 .09 82

    5 Mill Fan U/T 7.1 4.7 33.80

    Others (Bag House fan +


    6 U/T 4 3.2 20
    Reclaimer +Aux)

    7 Overall U/T 18.2 13.9 23.62

    8 Emission Level Mg/Nm3 20 14 30

    *As per Energy Benchmarking Study conducted by CII for UCWL, we are the
    country best in VRM power.
    Background

    The designed clinker production


    capacity of kiln is 3750 MT / Day. To
    cater designed clinker production
    requirement Raw Mill is 6975 mt/day
    330tph for 21 running hour

    The then old mill capacity was 270


    TPH, Hence it was decided to
    increase the VRM capacity to
    330TPH by innovative technique

    It was decided to retrofit the VRM


    with new classifier & Gearbox
    VRM Performance by Modification

    12 nos. (03 nos. after each Roller)


    12 nos. (03 nos. before each Roller) 5 partial inserts “Plate" removed.
    partial inserts “Plate" removed.
    4
    6 Reduced Nozzle Ring Velocity from
    61.2 m/s to 58.3 m/s
    Water Lance slot opening
    increased from 2 mm to 5 mm. 3

    7 Further Reduced N2 Pressure


    from 45 bar to 40 bar

    Roller Position Calibration 2

    Reducing N2 Pressure
    from 50 bar to 45 bar
    1
    Upgradation: Mill Feed from 270 TPH to
    300 TPH

    Gear Box from 1850 Kw / 27 RPM to 2500Kw / 30 RPM

    Mill Motor from 2200 Kw to 2700 Kw

    New louver Ring & Armor Ring with Hard Faced Material,
    Dam Ring, Scatter Ring, Wear/lining Ring

    Classifier LKS 67 to LSKS 71

    Mill fan with VFD

    RABH from ESP

    Hydraulic line open loop to close loop


    Installation of

    Reject Re-circulation

    Additive Circuit Belt Bucket


    elevator for silo
    filling
    Case Study

    02
    WHRS POWER
    PERFORMANCE
    WASTE HEAT POWER

    Contribution of WHR in total


    Power Consumption is around Power Generation is 36-40
    35% Unit/ton Clinker

    Average generation is 6.2 MW


    Auxiliary Consumption is
    below 5%

    WHRS of UCWL is one of the best performing WHRS in the country as per CII Energy
    Benchmarking Study.
    WASTE HEAT POWER
    WHRS MODIFICATION FOR IMPROVED POWER PERFORMANCE

    AQC- Boiler By pass of


    Booster fan and
    Erection of New
    AQC- Boiler Repairing
    Bypass Duct.
    of Dust Separator with
    Hard Facing
    Installation of New
    Damper in ESP Bypass
    Duct
    SP Boiler BY Pass
    Damper Flap Sealing
    Work

    Logic Modification

    Reduction of Auxiliary
    Power
    WHRS –Modification Performance
    Sr. Before After
    Modification Unit Gain/ Improvement
    No Modification Modification
    1 WHRS Power Generation KW 5800 6200 400
    2 AQC- Boiler By - Pass Duct Modification
    3 AQC-Boiler Outlet Draft mmwc 100 150 50
    4 AQC- H.P Steam Pressure kg/cm² 14.6 16.8 2.2
    6 AQC- H.P Steam TPH 13.3 15.0 1.7
    5 AQC- L.P. Steam Flow TPH 2.7 3.01 0.31
    7 E.S.P. Fan Power KW 250 150 100

    8 S.P. Boiler By- Pass Damper Sealing Work


    9 SP-Boiler H.P. Steam Pressure kg/cm² 16.0 18.0 2.0
    10 S.P. Boiler H.P.Steam Flow TPH 14.7 15.2 0.5
    11 S.P. Boiler L.P.Steam Flow TPH 4.9 6.0 1.1
    12 S.P Boiler Flue Gas Inlet Temp. °C 374 347 27
    13 Pre Heater Fan Inlet Temp. °C 205 180 25
    14 Pre Heater Fan Power KW 1050 880 170
    15 Total H.P Steam Generation TPH 28.0 30.2 2.2
    16 Total L.P Steam Generation TPH 7.6 9.0 1.4
    17 Total Power Saving KWH 670*

    *GHG Emission reduction to the tune of 538.8 Kg CO2e


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