Experience of Energy Management System
and Monitoring
in Hatien-1 Cement Company
(Vicem Hatien)
Presented by Hoang Kim Cuong
Deputy General Director
Hatien-1 Cement JSC.
www.efficiency-from-germany.info
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Experience of Energy Management
System and Monitoring
in Hatien-1 Cement Company
(Vicem Hatien)
Presented by Hoang Kim Cuong
Deputy General Director
Hatien-1 Cement JSC.
23.3.2015 Ho chi Minh City
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Outline
General
Kinds of used energy
Energy cost
Management
Implementation
Long-term plan
Conclusion
Energy
cost
Kinds
of used
energy
Energy
Effect
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General
•
•
•
•
Since 1964
2 plants, 4 cement grinding terminals
Employees: 2.870
Production capacity:
– Clinker: 4,5 million tpy
– Cement: 7 million tpy
• Standards ISO 9001: 2008; ISO 14001:
2004; OHSAS 18001: 2007
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SITE MAP
CAMRANH GRINDING
TERMINAL
BINHPHUOC CEMENT PLANT
PHUHUU GRINDING
TERMINAL
KIENLUONG CEMENT PLANT
LONGAN GRINDING
TERMINAL
THUDUC GRINDING
TERMINAL
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Kinds of energy using
Oil from
cashew HFO, 3%
nut shell,
6%
DO, 1%
Other, 2%
Electricity
32%
Coal
55%
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Energy Cost
Product
Energy cost / ex-work cost
Clinker
Cement
60% … 70%
5% … 10%
Energy type
Consumption
rate
Target
better cost
Electrical energy for
producing clinker
64 … 85
kWh/T
65
60 … 65 kWh/T
Anthracite Coal
760 … 900
kCal/kg clinker
760
720 kCal/kg
33 (VRM)
40 (BM)
33 (VRM)
40 (BM)
Electrical Energy for
34 … 45
producing cement kWh/T cement
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Frequency
Power consumption
Frequency
55
Heat Consumption
110
50
Min
max
Avg
Median
45
57.8
76.7
69.0
69.0
Min
max
Avg
Median
100
90
40
606
975
774
767
80
35
70
30
60
25
50
20
40
15
30
10
20
5
10
0
0
950
925
900
875
850
825
800
90
775
kWh/T clinker
85
750
80
725
75
700
70
675
65
650
60
625
55
600
50
kCal/kg clinker
Histogram of energy consumption of Binhphuoc Cement Plant for
clinker production - 2014
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Power consumption for
Cement Grinding &
frequency
Despatch
55
Min
max
Avg
Median
50
45
17.0
65.6
33.7
32.5
Power price (average), at
110 kV for production
vnd
us
cent
40
35
1 600
30
1 400
25
1 200
20
1 000
15
800
10
5
0
Loesche’s Vertical Roller Mill
Binhphuoc Cement Plant
Histogram 2014
55
50
45
40
35
30
25
20
kWh/T cement
7
6
5
4
600
3
400
2
200
1
0
0
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Management
Awareness of energy saving to
all employees
Upgrading technology
Optimizing operation
Modern technology during
project time
Looking other fuels as
alternative fuels for combustion,
Reducing fossil fuels
Making products with low
energy consumption
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Solutions
• Establish energy management system in each
plant
• Monitoring energy consumption of production
lines by daily report, studying abnormal things to
solve
Entry
Result
Report
Chart
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Solutions
• Executing energy audit by independent service
following government regulation, training for
internal energy audit
• Establishing energy management team in each
plant.
• Starting ISO 50001 from 2015
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Implementation
Measurement
• Making category of loads according to the energy
unit
• Installing power meters for recording
• Connect to the control system for online
monitoring in each plant
“If you can’t measure it,
you can’t manage it”
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Implementation
Optimizing and improving the operation
 Keep equipment operating at designed capacity or more,
not running at no-load or low load, avoid to start / stop
many time.
 Increase the productivity of the ball mill by optimization
of the ball quantity.
 Select the materials with good and correct quality.
 Produce Portland Cement Blended (PCB-40 PCB-50) to
reduce clinker.
 Mixing the components of raw materials in a correct
proportion to reduce heat energy (coal) for combustion.
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Implementation
Control operation
 Assure that equipment operating properly,
avoid operation in rush hour for some
equipment.
 Shut down the bag filter if production line
stops. Establish the bag filter operates in
automatic according to pressure difference
 Assure that power factor above 0,9 in order to
reducing the inactive power
 Optimize the compressed air system by
centralizing the control system and monitoring
losses
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Implementation
Optimize the operation parameter
 Study experience among internal departments, with other
cement plants frequently in order to find the optimized parameter.
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Implementation
Enhancement of innovation
 Encourage everyone give ideas for
upgrading equipment.
 Improving the cooling water of
air compressor at cement grinding
and packing area, change the
electrical motor from 37 kW to 5,5
kW for a pump.
 Redesign the chute, not use chain
conveyor under the chute (7,5kw),
lengthen the rubber conveyor
instead.
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Implementation
Enhancement of innovation
Installing the variable frequency converter for conveyor
2E1BC1. The power reduces from 120 kW to 66 kW. Saving
energy and keep the thickness of material layer to be stable for
PGNAA, ensure the analysis exactly
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Implementation
Increase the maintenance skill
 Training to the maintenance team in order to
decreasing the maintenance time.
 Apply preventive maintenance, solve all the repeated
problem thoroughly
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Implementation
Lighting and air conditioner
 Lighting: reduce the number of lights reasonably, assembly the
automatic equipment for turning on / off the lighting.
 Office: open window for sun light, turn off the equipment in the
room when no anyone in the room.
 Air conditioners: set at 25oC .. 26oC for people and for
equipment room.
 Step by step to change lighting with energy saving lamps
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Implementation
Solution for cost saving
Alternative fuels that are using in Ha Tien 1:
 Using a part of Indonesia anthracite coal
(high/medium volatile substance, cheaper price)
for producing clinker.
 Oil from cashew nut husk to replace HFO for
combustion in the kiln at Kienluong Cement
plant
Using FO-R (recycle product from wasted
rubber) to replace DO at Binhphuoc cement plant
 Using cashew nut husk (after extracting oil) as
an alternative fuel in Binhphuoc cement plant
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Implementation
Solution for cost saving
 Using rice husk to replace HFO
at Phuhuu grinding Terminal.
 Use wasted heat from kiln to heat
the coal mill instead of HFO at
Kienluong cement plant
These do not save energy but
reduce energy cost and contribute
to reduce CO2 emissions.
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Implementation
Typical unit price of some fuels - 2015
unit: vnđ/kCal, including logistic cost, no VAT
HFO
DO
FO-R
Cashew
oil
Rice
husk
Coal
3c
Indo.
Coal
Cashew
nut
shell
1.3
1.6
1.4
1.1
0.57
0.44
0.38
0.3
1.9
2.3
1.8
1.3
HCM
City
Binh
Binh
phuoc phuoc
Kien
luong
0.4
HCMC
Phuhuu
Binh
phuoc
Binh
phuoc
Binh
phuoc
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Long-term plans
 Continue to study “Variable frequency converter”
to regulate the flow of the fans instead of dampers.
 Optimize the production process, Looking for the
optimization software for operation of the rotary
kiln.
 Upgrade technology: replace planet cooling
system with clinker grate cooler. Improving the
preheater of old kiln, use high efficiency burner
for old clinker production line at Kienluong plant.
 Study of mineral additives to use for combustion
in the kiln to reducing the heat consumption.
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Long-term plans
 Study to burn other wastes.
 Implement the project of
waste heat recovery system
to generate electricity for
new kiln at Kienluong plant
and Binhphuoc plant. This
will save about 15%
electrical energy for each
plant.
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Conclusion
 Cost saving is different from energy saving,
but both of these are directed to use energy
efficiently
 Hatien-1 always thinks about energy saving
and efficiency, gradually optimizing and
improving energy efficiency
 Use energy saving and efficiency will be increasing the
competitiveness of enterprises. It also contributes to reducing
CO2 emissions, towards the goal of sustainable development of
enterprises.
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