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Dalmia Cement (Bharat) Limited, Kadapa

Founded in 1935 by Shri Jaidayal Dalmia. The Group established Indias first Cement Plant with 250 TPD in 1939. The Group interests includes Cement, Sugar, Power and Refractory. Put up Cement Plants in Tamil Nadu and Andhra Pradesh. Kadapa Unit Commissioned in Mar 2009 with a Capacity of 2.5MTPA Cement. Overall Cement Manufacturing Capacity 17.9 MTPA.

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We Manufacture:
OPC 53 PPC

OPC 43

SRPC

ISO 9001:2008,ISO 14001:2004,OHSAS 18001:2007

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We are committed to produce cement of required Quality & Quantity, by Continuous Improvement on Energy Performances through effective implementation of Energy Management System, also by Effective utilization of available Energy resources by Optimization and alternates. Enhancing the Energy efficiency, Reduction in Energy Wastage Strive to be a bench marking organization in the Cement Industry. Abide to all the applicable legal requirements and other requirements M.C. Gautam Date : 10/07/2013 Executive Director

1. 2. 3.

Current Plan & Actions EnMS 50001 Enhancement of Alternative Fuel Feeding Development of Renewable Power

3rd Year Operation Stage Improved Energy Saving : 43.88 Lakhs Units/Annum 2nd Year Operation Stage Improved the Equipt Perfor. Energy Saving : 114.77 Lakhs Units/Annum 1st Year Operation Stage Optimized Startup Time, Idle Run Solar Heaters & Solar Lights at Mines Energy Saving by Case Studies : 11.5 Lakhs Units/Annum Commissioning Stage Developed EMS Software in Plant Automation Energy Saving by Efficient Eqpt. & Energy Savers: 85.5 Lakhs U/Annum Plant Execution Stage Considered Energy Saving Equipments Plant Ordering Stage Took Initiative for Energy Efficient Equipments

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MV Drive for Pre Heater Fan & Bag House Fan Damper less Process Fans with Variable Speed Drive AC Variable Speed Drive for Coal Mill Main Drive AC Variable Speed Drive for Kiln Main Drive Cross Country Belt Conveyor for Lime Stone Transportation

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Expert Optimizer for Efficient Operation Intelligent MCC for the Motors Energy Efficiency Series Motors for the Complete Plant P20 Lighting Energy Saver Panels Energy Management System in DCS through Digital Meters Particle Size Analyser Cross Belt Analyser Robo Lab

Lowest Pressure Drop for 6 Stage Pre Heater (460 to 480mmwg) Lowest Specific Power Consumption of PH Fan (4.6 U/T of Clinker) Lowest False Air levels

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We do not use any natural mineral resources except Limestone AFR We use Red mud Fly ash Petcoke & AF : As corrective in Raw mix : As additive in PPC Material : As fuel

Chemical Gypsum : As Additive in Cement Grinding

Unit Head Technical Head Task Force Leader Dalmia - Ariyalur Task Force Leader Dalmia - Trichy Task Force Leader OCL, Rajganpur

Unit Energy Task Force Leader

Unit Energy Manager Team Members (from) Mechanical Electrical Process Instrumentation Utilities (Engineers & Technician Categories)

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Unit Total No. of Projects No.

Without With Investment Investment 35 26

Electrical Energy Saving Million / Annum Units Fuel Energy Saving / Annum Cost Saving / Annum Million Kcal Rs. Million

6.2
6200 31.2

6.84
100 33.74

No Investment

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No Investment
Sl. No. Energy Saving Projects Annual Electricity Saving Achieved Units in Rs. In Million Million 0.35 0.06 0.84 1.75 0.3 4.2

Daily Monitoring and control of Section 1 Wise Idle Power Consumption through DCS 2 3 Cement Mill Transport group stopped during the Mill Heat up. Reduction of Cement Heat up Idling time duration from 2 Hours to 45 Minutes

No Investment
Sl. No. Energy Saving Projects Annual Electricity Saving Achieved Units in Rs. In Million Million

Relocation of VFD for Compressor from 4 Pyro to Cement Mill and avoided the unloading operation of the Compressor Increased the Electrical System Power 5 Factor from 0.97 to 0.98 by Auto Operation of HT Bus Capacitors 6 Kiln Shell Cooling Fans Operation with Temperature Interlock

0.16

0.81

0.14 0.18

0.72 0.9

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No Investment
Sl. No.

Energy Saving Projects

Annual Electricity Saving Achieved Units in Rs. In Million Million 0.01 0.015

Coal Mill Hydraulic Pump Operation interlocked with Oil Temperature after 7 Mill Stoppage and reduced the Idle Running.

8 Star Connection for Shell Cooling Fans

9 GRR Cooling Fan Stop Interlock at 100% Speed & SPRS Mode

0.07
0.38

0.36
1.90

No Investment
Sl. No. Energy Saving Projects Annual Electricity Saving Achieved Units in Rs. In Million Million

Reduction of Raw Mill Power 10 Consumption by Dam Ring & Nozzle Ring Modification Modification in LS Crusher Wobbler Ribs 11 to reduce the gap and achieved Reduction in Lime Stone Size 12 Reduction of Idle Power in RMH Section by No Material Sensors

1.46
1.13 0.16

7.31
5.63 0.80

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No Investment
Sl. No. Annual Electricity Saving Achieved Units in Rs. In Million Million Reduction of Bore well Power by using STP Water for Cement Mill Bag House in DP Mode and Reduction of BH Fan & RA Fan Power Intermittent Timing Operation for LS Crusher Spillage Conveyor 0.06 0.50 0.02 0.30 2.52 0.12

Energy Saving Projects

13 14 15

No Investment
Sl. No. Energy Saving Projects Annual Electricity Saving Achieved Units in Rs. In Million Million 0.11 0.01 0.15 0.56 0.05 0.73

Packing Plant Dust Collector Fans Speed Interlocked with Packer Main Drive. 16 (Reducing Speed to 20% when Packer Stops) Conducted Compressor Leak Test & 17 Reducing the Leak of Compressed Air. Auto Start Stop Time Interlock for Office 18 Area Centralised AC

10

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No Investment
Sl. No. Energy Saving Projects Annual Electricity Saving Achieved Units in Rs. In Million Million 0.03 0.01 0.01 0.17 0.06 0.07

Switching Off the Distribution 19 Transformers & Drive Transformers during Plant Shutdown Time Delay Interlock for RABH Rotary Air 20 Locks Operating of Plant Lighting according to 21 the Seasonal Variations

No Investment
Sl. No. Energy Saving Projects Annual Electricity Saving Achieved Units in Rs. In Million Million 0.01 0.01 0.01 0.05 0.07 0.06

Auto Stop Interlock for Circular Stacker Slew with respect to the Material Flow Auto Stop Interlock for Coal Stacker & 23 Additive Stacker Travel with respect to the Material Flow Automatic Speed Reduction of Blending 24 Silo Top Bag Filter with respect to the Raw Mill Operation
22

11

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No Investment
Sl. No. Energy Saving Projects Annual Electricity Saving Achieved Units in Rs. In Million Million Operating the Raw Mill Hopper Bag Filter Fan with respect to material property Auto Start Stop Interlock for Water Fountain Pumps with Office Timing Optimized the Wagon Loading Time duration from 15Hrs. to 8 Hrs. 0.13 0.005 0.01 0.69 0.025 0.06

25 26 27

No Investment
Sl. No. Energy Saving Projects Annual Electricity Saving Achieved Units in Rs. In Million Million 0.01 0.003 0.07 0.013

Switching OFF Alternative Street Lights at Plant & Colony after late Night Reduction of Distribution Transformer 29 Voltage from 435V to 415V by Tap Changing Operating the LS Crusher during Day time and minimizing the Lighting requirement. 30 Also, Stopping the Mine Haulage Road Lighting according to the LSC Operation
28

0.01

0.05

12

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No Investment
Sl. No. Energy Saving Projects Annual Electricity Saving Achieved Units in Rs. In Million Million 0.02 0.13 0.12 0.66

31 32

Intermittent Operation of Truck Tippler Spillage Conveyor By reducing the False Air Level (3% Reduced), Coal Mill Fan Power reduced

No Investment
Sl. No. Energy Saving Projects Annual Fuel Saving Achieved / Annum Fuel Rs. In Qty. Million 17 Kcal/Kg Clinker 450 KL 14 KL/Start 2.23

Reduction of Fuel Consumption in Pyro Section (False Air, Outlet Temp., O2 33 Optimization, Exhaust Gas Volume, Insulation Bricks) Reduction of Specific Diesel 34 Consumption in Cement Mill Reduction of Diesel Consumption during 35 Kiln Start-up.

26.1 9.75

13

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With Investment

Sl. No.

Energy Saving Projects

Pay Invest Back ment in (Rs. Mont Units in Rs. In Million) hs Million Million 0.11 0.53 1.58 0.13 0.18 0.70 16

Annual Electricity Saving Achieved

Installed VFD for VRM 1 Reject belt & Reduction of Idle Power

Modification of PH Down 0.32 2 comer Expansion Joint and 1 Sustained Lowest False Air Kcal/Kg 3 Silo Aeration Blower Drive Pulley size Reduction 0.04

0.1 0.01

1 1

14

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Sl. No.

Energy Saving Projects

Annual Electricity Invest Saving ment Pay Achieved (Rs. Back in Millio Months Units Rs. In n) in Million Million

Tower AC Installed for Robo 4 Lab and Optimized Centralised AC Temp. Operation of STP Water 5 Pumps through Mobile Phone Starter 6 Installed Air Control Module for Flyash Unloading System

0.29
0.01 0.03

1.46
0.03 0.15

0.20
0.01 0.1

2
4 8

Sl. No.

Annual Electricity Invest Pay Saving ment Back in Energy Saving Projects Achieved (Rs. Month s Units in Rs. In Million) Million Million Raw Mill Inlet duct modification with chute 0.66 3.3 0.1 1 and improved productivity Packing Plant Blower Capacity Reduced from 0.07 0.35 0.04 2 30KW to 22 KW

15

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Sl. No.

Energy Saving Projects

Annual Electricity Invest Saving ment Pay Achieved (Rs. Back in Millio Months Units Rs. In n) in Million Million

Installed HT Bus Capacitor 9 and Improved the PF from 0.98 to 0.992 Speed Reduction of Coal 10 Crusher Belt Conveyors Replacement of Low Efficient old Pumps with Efficient 11 Pumps in Centralised AC System

1.5
0.05 0.07

7.3
0.25 0.35

0.7
0.08 0.04

2
4 2

Sl. No.

Energy Saving Projects

Annual Electricity Saving Achieved Units in Rs. In Million Million 2.80 14.00

Invest Pay ment Back in (Rs. Month Millio s n) 0.30 1

Optimization of Cement 12 Mill Power by rebuilding the Rollers & Table Decentralised 30KW 13 Compressors for Individual Packers Installed LED Street Lights 14 in Colony

0.39
0.01

1.96
0.03

2.80
0.19

18
80

16

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Sl. No.

Energy Saving Projects

Annual Invest Pay Electricity ment Back in Saving Achieved (Rs. Month Units in Rs. In Millio s Million Million n)

Installed Hydraulic Scrapper for unloading of Raw Material in Truck 15 Tippler and reduced the Truck unloading Time & Truck Tippler Group Operating Hours Converted of 200W Incandescent to 70W HPSV 16 Lamp in the SF Cooler Inspection Chamber

0.02

0.1

0.25

30

0.03

0.13

0.02

Sl. No.

Energy Saving Projects

Annual Electricity Saving Achieved Units in Rs. In Million Million 0.02 0.04

Invest Pay ment Back in (Rs. Month Millio s n) 0.01 3

Manual Switch Control for 17 Packing, Workshop, Silo Lightings Permanent Speed 18 Reduction of Raw Coal Hopper BF Fan Interconnected Bag Filter Suction & Stopped 2 Nos. 19 of 11KW BF Fan (491FN8 & 391FN9)

0.06

0.3

0.05

0.14

0.66

0.04

17

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Sl. No.

Energy Saving Projects

Annual Electricity Saving Achieved Units in Rs. In Million Million 0.03

Invest Pay ment Back in (Rs. Month Millio s n) 0.03 12

Usage of Hand Driven LED Torch Light for Securities, 20 0.006 in place of Inspection Hand Lamp for Maintenance Installation of Solar Water 21 Heaters for Athiti & 0.04 Swagath Guest Houses Installation of Solar Street 22 Lights with LED Light 0.01 Fittings at Mines Magazine

0.18 0.04

0.20 0.15

12 45

Sl. No.

Energy Saving Projects

Annual Electricity Saving Achieved Units in Rs. In Million Million 0.0025

Invest Pay ment Back in (Rs. Month Millio s n)

Installed Chute at Pre Heater to shift the Scrap 23 Material from 3rd /2nd /1st 0.0005 Floor to Ground. Hence, Lift Operation reduced. Occupancy Sensor for Load 24 Centre Lighting Auto 0.04 Control

0.05

240

0.19

0.01

18

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Sl. No.

Energy Saving Projects

Annual Electricity Saving Achieved Units in Rs. In Millio Million n 0.04 0.2

Invest Pay ment Back in (Rs. Month Millio s n)

Replacement of 60W Incandescent Lamp with 25 11W CFL Lamps at Colony & Guest Houses Replacement of 36W Fluorescent Lamps to T5 26 Lamps & CFL Lamps at Offices

0.05

0.08

0.4

0.05

Kcal / Kg Clinker
730 725 720 715 710 705 700 695 690 2010-11 2011-12 2012-13 2013-14 707 702 725 721

19

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Overall Units / Ton of Cement

84.45 86 84 82 80 78 76 74 72 70 68 66 64 2010-11 82.64

76.5 72.14

2011-12

2012-13

2013-14

KWH/T of Clinker
57 56 55 54 53 52 51 50 2010-11 2011-12 2012-13 2013-14 52.00 56.02 55.25 54.20

20

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KWH/T of Cement (OPC)

90 88 86 84 82 80 78 76 74 72 70 88.70 86.10 80.10 77.12

2010-11

2011-12

2012-13

2013-14

Kwh/Ton of Cement (PPC)

69 68 67 66 65 64 63 62 61 60 68.2 66.3

63.4

63.2

2010-11

2011-12

2012-13

2013-14

21

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Energy Savings (Million Units / Annum) Cumulative Trend

25 20 15 16.50 10.50 23.50 20.80

10
5 2009-10 2010-11 2011-12 2012-13

Explosives Kg/MT of Limestone

0.18
0.16 0.14 0.12 0.1 0.17 0.15 0.11

0.1

0.09

0.08

0.08
0.06 0.04 0.02 0 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14

22

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SEC Specific Energy Consumption Thermal (KCal/Kg of Clinker) Specific Energy Consumption Electrical (KWh/T of Cement)

National International DCBL Actual Benchmark Benchmark (FY 2012-13) *** *** 707* 76.5 667 67 660 65

*** Source of Information : 12th Planning Commission Report

*Specific heat consumption is : 686 Kcal/Kg Clinker

Kwh/Ton of Cement (PPC)

69 68 67 66 65 64 63 62 61 60 68.2 66.3 NB 63.4 63.2 INB

2010-11

2011-12

2012-13

2013-14

NB National Benchmark INB International Benchmark

23

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Installation of Waste Heat Recovery Power Plant. Generation Potential : 4.3 MW/Hr. Ordered to M/s Techpro Systems Ltd. Target : September 2014

Retrofitting of Cement Mill Fan Impeller for Energy Efficiency Improvement Study Completed. Saving Potential 250KW/Hr. Ordering Stage, Target : March 2014 Replacement of High Pressure Compressor to Energy Efficient Turbojet Blower for Flyash Handling Ordering Stage. Target : March 2014

Retrofitting of RABH Fan Impeller for Energy Efficiency Improvement Study Completed, Savings Potential 50KW/Hr. (Rs. 20 Lakhs / Annum) Target : June 2014 Reduction of Pressure Loss b/w Raw Mill Cyclone to Raw Mill Fan duct. Saving Potential 100mmwg. Study Completed. Saving Potential is 60KW/Hr. (Rs. 24 Lakhs / Annum) Target : September 2014 Improving the PPC Cement Dispatches Launched New PPC Product Dalmia Ultra to boost the PPC Sales. Shall reduce the SEC.

24

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IP - 1

Objective:

Reduction of Fuel Consumption from 721 kcal/kg to 700 kcal/kg

Approach:

2R principle that is Reduce Replace

25

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IP - 1
Limestone size High Silica 90mm >5% Limestone Segregation of material in Pile

Variation in Kiln Feed

Uneven Flow Of Correctives Silo Blending Efficiency Coal

Process
High False Air Low Burnability

High Loss through PH Exist Gases

Reduction of K.Cal/kg of Clinker

High Clinker Temp. Secondary Temp. Variation

Operation

IP - 1

Mines
Control the Fragmentation Size in Blast Muck Pile Two point Loading for better blending

Crusher
Reduction of output size less than 90mm Remove the clay in the Limestone to reduce Silica Variations

Stock Pile
Height of Fall in Limestone Stocking Pile Sequencing in Limestone Stocking Pile formation in Coal and correctives

26

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IP - 1

Raw Mill
Desired Flow of corrective material that is Red Mud. Optimum residue for good Burnability.

Pre Heater
Proper dispersion of raw meal into Pre-Heater False Air Management

IP - 1

Challenges:
High moisture up to 30% in the Red mud the corrective material affect the material flowability in the system.

Circular Stock Pile for Limestone which is having less blending efficiency
Limestone with relatively High Bond Index Used varieties of coal of origin Indonesia, South Africa, US and Petcoke

27

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IP - 1 Sl. No. 1 Area Problem Control the Fragmentation Size in Blast Muck Pile Improvement Actions

Optimising the Powder Factor (Explosive Energy Mines Consumed per MT of Limestone) Remove the clay in the Installation of Screening Limestone To reduce Plant in the Limestone Silica Variations crushing Circuit Wobbler Feeder Gap Crusher Reduce the crusher reduced from 85mm to output size less than 60mm by introducing the 90mm additional rib on the rollers

IP - 1
Sl. No. Area Problem Height of Fall in Limestone Stocking Improvement Actions Maintaining the Luffing Action of Limestone Stacker Interlocking the horizontal movement of Limestone Stacker with respect to the Material

Stock Pile

Pile Sequencing in Limestone Stocking

Linear Pile system for Pile formation in Coal correctives and coal and correctives instead of point stocking

28

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IP - 1 Sl. No. Area Problem Desired Flow of corrective material that is Red Mud. 4 Raw Mill Improvement Actions Additional Hopper for Red mud for quick change over and continuity of flow. Polymer Lining to the storage hoppers Conducted the Burnability studies and fixed the optimum residue for good burnability

Optimum residue for good Burnability. Raw mix residue optimized to 23% on 90 and 2.5% on 212

IP - 1
Sl. No.

Area

Problem

Improvement Actions Raw Meal silo extraction cycle pattern changed from normal to alternate cycle and timer changed from 3 minute to 2 minutes Blending Silo extraction Air Slide Cloth Changed Raw Meal silo top filling timer changed from 7 minutes to 3 minutes Filling of Silo more than 70%

Blending Silo

Blending Efficiency

29

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IP - 1 Sl. No.

Area

Problem

Improvement Actions

Pre Heater

Adjustment of the Proper dispersion dispersion plate in the feed of the raw meal box of cyclone 4 and 5 to into the Pre Heater optimize the Heat Transfer Profile

IP - 1
Retrofitting of Screening Plant in the Existing Crusher Circuit

30

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IP - 1

Benefits of Screening Plant Improved quality of limestone by separating the clay from limestone. Reduction in Reject of low grade limestone, hence the cost saving is Rs. 0.60/ton of material. (Saving Rs. 12 Lakhs / Annum) Life of the limestone mine Conservation) increased. (Mineral

IP - 1
Optimization of Preheater Exit Oxygen level from 3.0 %to 2.5% despite of using Petcoke by close & regular monitoring of all major expansion joints. Preheater down comer duct modified with telescopic design expansion joint to avoid thermal losses. Calciner Exit temperature optimised to the range of 880 to 885 deg C as against earlier of 900 deg C by consistent Raw mix quality. Installed Insulation Bricks (Alite Dalmia Refractory) in Calcination zone of kiln to reduce Kiln radiation.

31

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IP - 1 Because of all these actions, remarkable reduction in Preheater Exit temperature from 270 to 250 C to reduce the heat losses through PH exit gases. Cooler bed height increased from 600 to 720 mmwg, for better heat recuperation. Physical inspection and false air measurements every week in each section. Achieved Best Figure for False Air %, which is witnessed by CII Energy Audit Team during their visit in May-2013 Raw Mill : 7.2% Coal Mill : 6.2% Cement Mill : 7.4%

IP - 1

Improved the reliability and availability of kiln inlet analyser by increasing the probe length and by changing the angle. Reduction in diesel consumption for kiln light up from 12 KL to 4 KL per each light up. (Cost Saving 557 Lakhs / Annum)

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IP - 1

Our Focus are Liquid Alternate Fuel (from Pharmaceutical Industry) Dolachar (from Steel Rerolling Mills) Spent Carbon (from Pharmaceutical Industry)

IP - 1
Developed Inhouse system for the feeding of Liquid Alternative fuel.

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IP - 1 Alternative Fuels in TSR%

2.01

2.5 2 1.5 1 0.5 0

1.86

2012-13

2013-14

IP - 1

Installed VFD for Alternative Fuel Pump for effective combustion. Separate Feeding arrangement for Solid alternate fuel. Spent Carbon utilization by spreading in Raw Coal Pile.

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IP - 1 Result:
730 725 720 715 710 705 700 707 702 725 721

Kcal / Kg Clinker

695
690 2010-11 2011-12 2012-13 2013-14

IP - 1
Result: Current Status of Heat Consumption in Pyro Heat of Formation 410 Kcal/Kg Clinker

Heat loss through PH Exit gases

114 Kcal/Kg Clinker

Heat loss through Cooler Exit Gases 88 Kcal/Kg Clinker Heat Loss through Clinker Heat Loss through Radiation Total Heat Consumption 31 Kcal/Kg Clinker 43 Kcal/Kg Clinker 686 Kcal/Kg Clinker

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IP - 1

Formation

PH Exit 4.5

Cooler Exit 6.3

Clinker

Radiation

12.8

16.6

59.8

IP - 2

Objective:

Improve the Raw Mill Productivity from 370 to 400 TPH

Background: To maintain kiln feed quality consistently it is desirable to maintain the Raw Meal silo level more than 70%. To achieve this raw mill output requires 400MT per Hour for the Kiln output of 5200TPD. Achieved 6000TPD as highest Clinker Production, but optimized at 5200 TPD, keeping in view of Power & Fuel Economy

36

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IP - 2

Challenges: To maintain the Raw Meal residue 23% on 90 micron and 2.5% on 212 micron for better burnability. Designed capacity of mill is 375TPH at 23% residue on 90 microns Limestone with relatively High Bond Index Maximise the Alternative Raw Materials in place of minerals as correctives To avoid Running of Raw Mill in Peak Hrs

IP - 2

Lime Stone size is higher (5% more than 90mm Size) High Reject from the Raw Mill High Mill Main Drive load while increase Mill feed. Heavy Material deposition at Mill Inlet Duct.

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IP - 2

Reduction of Lime Stone Size Increase the Raw Mill Grinding Pressure Increase of Nozzle Ring Velocity Optimization of Dam Ring Height Optimization of Water Spray

IP - 2

Consistent feeding of Red mud. Solution for material accumulation at Mill inlet duct Optimization of Classifier Operation

38

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IP - 2

To reduce the Lime stone Crusher output size less than 90mm Blow Bar gap reduced from 90 mm to 80 mm. Extra Ribs provided in Wobbler Rollers to avoid any escape of higher size Lime Stones.

IP - 2
Additional Wobbler Ribs Provided to reduce the sieve size.

Before

Additional Ribs

After

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IP - 2 To maintain the consistent flow of Red Mud Stacker operation converted to auto linear stacking instead of point stacking. Iron ore hopper converted to stand by Red mud hopper for quick change over in case of jamming.

Provided Vibrator and Blasters for better flow of high moisture Red mud.
Polymer lining provided for better flow. Extra hopper for Red mud feeding, provided at reclaimer belt for dry Red mud during critical condition.

IP - 2

Optimized Nozzle Ring Velocity Nozzle Ring area between two Rollers of Raw Mill blocked. Total Nozzle ring area 7.99 M2 Blocked nozzle ring area 1.83 M2 (23%) Nozzle Ring Velocity : 36.21 M/Sec

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IP - 2

Nozzle Ring Blocked

Nozzle Ring Blocked

IP - 2
Dam Ring reduced from 65 mm to 25 mm in two phase, which reduced Mill Main Drive load from 3700 to 3400 KW. Optimized the Grinding Pressure. Raw Mill Separator Seal gap reduced by applying felt to avoid escaping of raw meal from separator seal. After increasing grinding pressure & applying felt for Separator, Separator speed optimized from 63% to 59% to achieve Raw Meal residue 22-23% on 90 & 2.8% on 212 .

41

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IP - 2

Raw Mill Feed chute length extended by 200 mm to avoid material rejection due to centrifugal force.
Raw Mill water spray nozzle location optimized to minimize the water consumption from 6 M3/Hr. to 2.5 M3/Hr.

IP - 2
Feed Chute Extended 200mm

Extended Chute

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IP - 2

Heavy Material Deposition

Inlet Duct Outer View

IP - 2

No Material Deposition

Installed Chute below the Inlet Duct to drain the deposition

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IP - 2 Raw Mill TPH

410 405 400 395 390 385 380 375 370 365 360 2011-12 2012-13 2013-14 382 388
Design Capacity 375 TPH

406

IP - 2
Raw Mill Specific Power
20 19
OEM Guaranteed 19 Units/Ton of Material

18
17 16 15 14

18

17.7 16.7

2011-12

2012-13

2013-14

Units / Ton of Material

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IP - 2 % Residue on 212
4
3.5 3 2.5 2 1.5 2011-12 2012-2013 2013-2014 3.5 3.0 2.8

IP - 3

Objective: Capacity Utilization of VRM (Raw Mill & Cement Mill) at all the Times and Reduction of VRM Power due to unexpected Tripping.

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IP - 3

Problem Faced: After the Unexpected Tripping of VRM, Mill unable to Operate at rated capacity due to Reject Bucket Elevator Overloading. (Due to Handling of Reject Hopper Material & VRM Reject Material). Hence, Mill Idle Power is High due to Operating at Under Capacity.

IP - 3

Action Taken :

Installed the Variable Frequency Drive for the Reject Handling Belt Conveyor. Reject Material in the Hopper is handled to the VRM at 10% Speed of the Reject Belt with the help of VFD.

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IP - 3
Benefits:

Overloading of Reject Belt Conveyor and Jamming of Reject Bucket Elevator avoided. Hence, avoided Mill Stoppage. VRM shall Operate at Rated Capacity with in a very short period. Idle Run Time, Productivity, Idle Power Consumption and Mill Performance were improved.

IP - 3

Summary: Investment : 3.5 Lakhs / VRM Unexpected Tripping : 2 Tripping per month / VRM Production Loss : 70 Tons Prod. / Trip / VRM i.e. 140 Tons Production Loss / Month in Raw Mill 140 Tons Production / Month in Cement Mill Idle Power Loss: Raw Mill Cement Mill Tentative Power Loss

: 1600 Units Loss / Trip : 1700 Units Loss / Trip : 6600 Units Loss / Month

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IP - 3

Results Achieved: Savings: Power Cost Saving : 6600 Units X Rs. 5.00 : Rs. 33,000 per Month

Total Power Cost Saving

Payback

: Rs. 4 Lakhs / Annum

: 2 Years

Note: Savings excluding the Truck Handling Charges

IP - 4

Objective: Optimizing the Cement Mill Operation with Minimum Hot Gas and Smooth Operation. Actions Taken: 1. Optimized the Temperature of Cement Mill VRM during Startup 2. Optimized the Water Spray able to retain the Temperature generated during the Grinding.

48

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IP - 4 Action Taken : 3. Optimizing the Recirculation Damper to avoid the heat loss. 4. Reducing the Start-up Idle Operation Time by One Hour due to Optimized with low temperature 5. Eliminated the requirement of Hot Gas during Operation (after Start up) 6. Stopped the Booster Fan Operation after Start up

IP - 4

2 1.8 1.6 1.4 1.2 1 0.8 0.6

1.98

1.4 Specific Diesel Consumption (Ltr./Ton of Cement) Cluster Specific Diesel Consumption (Ltr./Ton of Cement)

0.6 0.21 0.15 2012-13

0.4
0.2 0 2009-10 2010-11

2011-12

49

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IP - 5

Objective: Optimizing the KVAH Consumption by Improving the Power Factor from 0.975 to 0.990. Actions Taken: 1. Measured the Capacitor Requirement at the Individual Load Centres with the Help of Digital Multi Function Meter available in all the Feeders.

IP - 5

Actions Taken: 2. Provided Auto Start Stop Interlock for the HT Bus Capacitors through DCS 3. Arrived the Capacitor Requirement and Installed the additional HT Bus Capacitor 4. Controlled the HT Bus Capacitors operation through DCS as per the Mills Operation. 5. Ensured No Leading Power Factor all the Conditions

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IP - 5

Grid Power Factor

0.992 0.991 0.991 0.990 0.991 0.992 0.990
0.995 0.990

0.980

0.985
0.980

0.970

0.975 0.970 0.965

IP - 5
Continual Power Factor Improvement
0.995 0.99 0.985 0.98 0.99

0.98
0.975 0.97 0.965 0.96 2010-2011 0.97

0.970

0.972

0.980

0.987

2011-2012

2012-2013

0.990

51

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IP - 6

Objective: Reduction of Packing Plant Specific Power Consumption from 3.0 U/T of Cement to 1.2 U/T of Cement Actions Taken: 1. Installed & Operating 30KW Individual Compressor for Individual Packer instead of Operating 160KW Centralised Compressor

IP - 6
Actions Taken: 2. Arrested the Compressed Air Leakages & Optimized the Bag Filters Purging Frequency & Time 3. Monitoring & Controlling of Idle Power Consumption on daily basis 4. Reduced the Idling Time by Training given to Truck Loader Operators. 5. Optimised the Operating Speed of Bag Filter Fans through VFD. 6. Automatic Speed Interlocking to Bag Filter Fan with respect to Packer Main Drive Operation 7. Operation Interlock for Bag Cleaning Fans

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IP - 6

Result: Specific Power Consumption of Packing Plant reduced from 3.0U/T to 1.2 U/T of Cement Energy Saving of 2.5 Lakh Units / Annum

IP - 6

Sp. Power Reduction in Packing Plant

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Water

Reuse of STP water Water Conservation Task Force Rain Water Harvesting and Use of Mine Pumped out Water

Energy NonConvention al Energy

Energy Conservation Projects Solar Power Bio-Diesel Wind Power Jetropa Plantation Mass Tree Plantation on June 5th & providing sapling to neighbouring Department wise ownership

Plantation

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Environment

Stack Emissions Recycling of Floor Spills Gypsum Un loader Reuse of Waste

Community

Vermi-compost Common Vehicle for commuting in Plant & Colony Use of Bicycles by movement in the Plant Form pond Rain water harvesting structures Distribution of Solar lamps Practice of integrated Pest Management Awareness on Environment
Installation of Waste Heat Recovery Power Plant at Pyro Section Vent

CDM Project

Green Development

Neerium

Neem

Pungam Pungamia

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Green Development

Konocarpus

Tacoma Yellow

Green Development

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Green Development

Green Development

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Involvement of Employees, Families & Children

Involvement of Employees, Families & Children

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Green Development in the Plant & Colony 15000 16000

2009-10

10000

2010-11

15000

2011-12

2012-13

TARGET (2013-14)

1. Celebrated Energy Conservation Week during the National Energy Conservation Day 14th December 2012 2. Conducted Campaign at nearby Villages about the Energy Conservation and Methods to Save Energy 3. Sharing Energy Conservation Tips for the day during Energy Conservation Campaign

20000

59

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1. Utilizing 100% STP Generated Water to the Plant for VRM Water Spray. 2. Generated water storage pond for capacity 180000 M3 with an Investment of Rs.20.0 lakhs (Mines Pond Water)

3. Reduced Water Consumption in Clinker Cooler by improving the Heat recuperation from Cooler Fans (Fan No. 1, 2 & 3) and Optimized the fresh air entry by installing Fresh Air Damper at cooler ESP duct. Reduced Water consumption from 16 M3 to 3.5 M3.

Water Management Award received from CII

16
16 14 12 10 8 6 4 2 0 Before

3.5

At Present

Cooler Water Consumption (M3/Hr.)

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CIIs National Excellence in Water Management Award - 2012

Summary Electrical Energy Saving Projects 19505 Ton of CO2 Reduction / Annum 640 Tons of CO2 Reduction / Annum 56,000 Nos. of Plantation (Survived)

Thermal Energy Saving Projects

Greenary Development Major Future Plan

Waste Heat Recovery Plant Installation & Commissioning. Ordering Completed. Target for Commissioning : September 2014

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Employee Involvement & Opportunities for sharing Encon Ideas

1. Employee Suggestion Management Staff 2. Section wise Monthly Workmen to HOD Scheme from Workmen Meeting to

Performance

from

3. Employee Communication for Suggestions & Ideas to Corporate Management & Unit Management 4. Selection of Monthly Campaign for Energy Conservation, Environment, Health, Safetyggestion to Managing Director

Employee Involvement & Opportunities for sharing Encon Ideas

5. Capturing of Essays, Slogans, Essays from Workmen and awarding during Monthly Gate Safety Meeting 6. Weekly Section Wise Plant Review Meeting with Engineer Level to Top Management for the Improvement Jobs 7. Hotline Mail ID for Ideas & Suggestion to Managing Director

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Total No. of Suggestions (from Employees to Workmen) Suggestions Related to Energy Conservation Validated Suggestions related to Energy Conservation Total No. of Energy Conservation Suggestions Implemented Note : Including Minor Suggestions

No. No. No. No.

231 79 72 69

Sl. No. 1 2 3 4 5

Name of the Training Programme Energy Management Systems Energy Conservation & Audit Methods ENCON mission to world class energy efficient cement industries Energy Management Systems Training Program On Energy Management

No. of Training Total Man Employees days Days Participated 39 18 4 2 2 1 1 1 2 5 39 18 4 4 10

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Sl. No. 6

Name of the Training Programme

No.Of Training Total Man Employees days Days Particpated 5 2 10

Energy Conservation & Management in Cement Industry Energy Conservation & Energy Audits in Cement Plants

Energy Management in 8 Cement Industry

Idea Sl. Source of EnCon idea * originate No d in FY Power Factor 1 Improvement from 0.975 2012-13 to 0.992 Conversion of Delta 2 Conn. to Star Conn. for 2012-13 Shell & Tyre Cooling Fan

Silo Aeration blower 3 Speed Reduction by Changing Pulley

Completed. Project Identified during Section Review Meeting Completed. Project Identified during Encon Team Rounds & Encon Team Reviewed with Section 2012-13 & Section Meeting involved Engineer Foreman, Supervisor, CCR Operator & Engineers

Extent of man-power involved Shift Technicians & Engr. Elect. Technician & Engineer

Progress of implementation Completed & Achieved

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Sl. No

Source of EnCon idea * Relocated VFD from Pyro Comp. to Cement Mill Comp. (Avoided Unloading Operation of Comp.)

Idea Extent of originated man-power in FY involved

Progress of implementation

Installed VFD for VRM 5 Reject Belts and Improved Equipment Availability

Completed. Project Identified during Encon Section Team Rounds & 2012-13 Engineer & Reviewed with Section Section Head Meeting involved Foreman & Supervisor Completed. Project Identified during Section Fitter, Review Meeting involved 2012-13 Engineer & Foreman, Supervisor, Management CCR Operator & Engineers

Sl. Source of EnCon idea * No GRR Cooling Fan Stop 6 Interlock with 100% Speed Operation of Bag Filter in 7 DP mode instead of Timer Mode

Idea Extent of originate man-power d in FY involved 2011-12

Progress of implementation

2011-12

Regular Monitoring of 8 False Air Level in the Mills 2011-12 & Pyro section

Completed. Project Elect. Identified through Techncian & Employee Suggestion Engr. Scheme Section Engineer & Completed. Suggested Section by Section Engineer Head Fitters, Attenders, Continuous Process. Welders & Engineers

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Sl. Source of EnCon idea * No Plant Lighting Time 9 tuning as per the Seasonal Variation Coal Crusher Belt Conv. 10 Speed Reduced & Improved Belt Life

Idea Extent of originate man-power d in FY involved 2010-11

Progress of implementation

2012-13

Completed. Project Electrical Identified During Daily Technician Morning Meeting with Technicians Fitter, Completed. Identified & Welder, Proposed the Workmen Engr. & Team from RMH HOD Section

Sl. No.

Energy Saving Projects

Energy Investm Saving ent in Potential Rs. (Million Million Units/Annu m) 40 4 4 18.08 1.34 0.80

1 2

Installation of Waste Heat Recovery System for Pre Heater Exit Gas

Retrofitting of Cement Mill Fan to Save the Power of 250KW/Hr. Lower Cyclone Dispersion Box height 3 in riser duct and increase heat transfer

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Sl. No.

Energy Saving Projects

Energy Investm Saving ent in Potential Rs. (Million Million Units/Annu m) 1.5 0.5 0.5 0.56 0.27 0.12

Reduce Pressure drop across Cyclones outlet to fan inlet duct in Raw Mill Cooler Fan Silencer Pressure Drop is 5 more hence Replace with Less Pressure Drop silencer Load Center A/C Chillier Thermostat 6 to be replace with Electronic Thermostat 4

Sl. No.

Energy Saving Projects Replacement of High Pressure Compressor with High Eff. Turbojet Blowers for Flyash Handling Avoid air venting in packer Aeration blower by Providing VFD and Common Header Install New efficient Process Flow Pump Pumps at Water Treatment Plant Installation of Wind Power Generator at Pre Heater

Investm Energy Saving ent in Potential Rs. (Million Million Units/Annum) 0.8 0.5 0.2 1 0.09 0.02 0.02 0.01

7 8 9 10

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Non Conformities 3 Nos.

SL. NO

NON CONFORMITIES
Senior Engineer position defined but the authorities & Responsibilities not defined in the process manual reference doc no: F-1(SP-5, AM-5) Issue 02, Rev no:00 dated 12.08.11 Chain pulley 3 MT capacity (equipment id no: BR 60068) periodical testing details not evidenced

CORRECTIVE & PREVENTIVE ACTION

CORRECTIVE: Amend the format with respect to the responsibilities of Senior Engineer PREVENTIVE: Periodical Review Mechanism developed CORRECTIVE: The Chain Pulley will be tested. PREVENTIVE: List of Equipment's with their schedule to be made.

1.

2.

3.

Aspect of Generation and disposal CORRECTIVE: Aspects of generation & of E wastes during the Maintenance disposal of E waste will be identified of Instruments found not identified PREVENTIVE: Periodical Review of Aspect and evaluated. Register shall be followed.

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Dalmia Cement (Bharat) Limited. Kadapa Project Daily Power Consumption Report

132Kv Main Incoming Units DG Generation Units Peak Hour Consumption Sl. No. 1

Daily Power Consumption Report

374595 0 20715 Kwhr Kwhr Kwhr Avg PF: 0.990 (MD) KVA Prodn. Production Rate 707.79 22500 Avg Kw Units Consumption Running Hrs 16.17 3771 1938 2386 2060 10155 16.92 63158 44628 1523 1957 6936 327 1706 0 120235 14.33 5197 3577 272 2169 1349 12564 577 40.27 7105 419.92

Report Date: Consumption Date: OLTC Opn. Count Guaranteed U/T of Matl.

XX.06.2013 XX.06.2013 9 Actual U/T of Matl.

Section Description

LS Crusher LS Crusher Main Drive LS Crusher Auxiliaries 211BC2 Long Belt 211BC2A Long Belt LS Crusher & Transport-Total Raw Mill Raw Mill Main Motor Raw Mill Fan Motor Raw Mill Classifier MCC - 02 (LS Transport) MCC - 03 (RM Grinding Aux.) Additive Reclaimer LS Stacker & Reclaimer RM Fan SPRS Recovery Total Coal Mill Coal Mill Main Motor Coal Mill Fan Motor Coal Mill Classifier MCC - 07 (Coal Mill Grinding Aux.) RMH & Coal Crusher Total

11445

628 233 120 148 127

0.38 0.46 0.42 1.25

0.33 0.17 0.21 0.18 0.89

7106 3733 2638 90 116 410 19 101 0

17.42

2.07

19.49 877 363 250 19 151 94 25.51

8.89 6.28 0.21 0.28 0.98 0.05 0.24 0.00 16.92

25.51

9.01 6.20 0.47 3.76 2.34 21.77

16.73

Kiln & Cooler Kiln Main Drive Pre Heater Fan Cooler Fans & PA Fan VFD Bag House Fan MCC - 04 (RABH Dust Tpt.)

Daily Power Consumption Report

9244 385 25092 32221 5208 960 15257 2092 2597 5057 2461 100189 OPC 52877 26340 1296 909 0 1314 3841 -2942 83635 PPC 17305 5945 701 450 257 1303 963 0 26924 Total RH Total Prod. 14.66 4773 PPC RH PPC Prod. Prod. Rate 3.33 1034 311 OPC RH OPC Prod. Prod. Rate 11.33 3739 330 OPC KW 4667 2325 114 80 0 116 339 -260 7382 PPC KW 5197 1785 211 135 77 391 289 0 8085 32.20 5.20 27.00 1046 1343 217 40 636 87 108 211 103 27.54 9.33 2.61 15.60

24.00

5282

220.08

4175

1.75 4.75 6.10 0.99 0.18 2.89 0.40 0.49 0.96 0.47 18.97 OPC U/T PPC U/T 14.14 7.04 0.35 0.24 0.00 0.35 1.03 -0.79 22.37 16.74 5.75 0.68 0.44 0.25 1.26 0.93 0.00 26.04

MCC - 05A (CF Silo Ext. & Kiln Feed BE) MCC - 05B (Kiln Shell Cool & Lub) MCC - 08 (Coal Firing) MCC - 09 (SF Cooler, ESP & DPC) Utilities (Water Treatment) Total 5 Cement Mill Cement Mill Main Drive Cement Mill Fan Drive Cement Mill Classifier Drive MCC - 10 (Clinker Silo Ext.) MCC - 11 (Fly Ash Aux. & Comp.) Compressors MCC - 12 (Mill Grinding Aux.) CM Fan Recovery Power Total

Packing Plant MCC - 13 (Silo Extraction & Comp.) Compressors MCC - 14A (Packer - 1) MCC - 14B (Packer - 2) MCC - 14C (Packer - 3) Total 2343 0 831 797 1026 4997

24.00

4672.00

194.67

208 98 0 35 33 43 1.33 1.33 0.50 0.00 0.18 0.17 0.22 1.07

70

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Daily Power Consumption Report

7 Plant Services: Plant Lighting Plant Aux. Power (Welding) RMBH AC Power CCR AC Power CMBH AC Power Total 8 Distribution Losses Gross Units Consumption Total for Pre - Clinker Total for Post - Clinker 1469 2140 2082 4327 1153 11171 24.00 5282 220.08 465 61 89 87 180 48 2.50 2.50 0.28 0.41 0.39 0.82 0.22 2.11

2452 372143 243143 115556

24.00

5282

220.08

102

0.46

24.00 0.00

5282 0

10131 #DIV/0!

73.79

60.67 24.23

Daily Idle Power Consumption Report

ENERGY CONSERVATION (IDLE POWER CONSUMPTION REPORT)
XX.06.2013 SECTION SECTION DESCRIPTION OPTIMUM ACTUAL SATRT UP RUNNING TIME HOURS IDLE RUNING TIME ENERGY IN KWH IDLE /SHUT DOWN UNITS ACTUAL U/Ton WITHOUT IDLE RUNNING U/Ton Kwh

APRON FEEDER LS CRUSHER CRUSHER MAIN DRIVE 211BC2 211BC2A MINES DEWATERING PUMP IDLE/SHUT DOWN POWER 3.00 No of Start/ Stops WEIGH FEEDER MAIN DRIVE FAN LS RECLAIMER FEED GROUP AD. RECLAIMER FEED GROUP TOTAL DCS IDLE / SHUT DOWN POWER

0.00 0.17 0.50 0.50

16.17 17.67 17.92 17.92 66.00 1.33 0.00 1.25 106.40 0.00 181.25 287.65 0.89 0.86 80.00 145.00 145.00

Raw Mill

0.00 0.03 0.30 12.20 10.10 331.00 0.00 0.03 0.17 3.30 3.80

16.92 16.90 16.90 16.50 12.70

-0.05 -0.32 4.30 2.60

0.00 0.00 335.40 0.00 335.40

16.92

16.88

150.00 2600.00 78.00 49.00

No of Start/ Stops

0.00

Dcs Idle Power

Coal Mill

WEIGH FEEDER MAIN DRIVE FAN COAL STACKER FEED GROUP COAL RECLAIMER FEED GROUP RAW MATERIAL HANDLING TOTAL DCS IDLE / SHUT DOWN POWER

14.33 14.40 14.70 3.30 5.30

0.04 0.13 0.00 1.50

2.00 32.50 0.00 180.00 1349.00 214.50

19.44

19.06

50.00 250.00 54.00 120.00

No of Start/ Stops

4.00

Dcs Idle Power

75.00

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Daily Idle Power Consumption Report

KILN
24.00 KILN

COMPRESSOR

24.00

0.00

0.00

18.50

18.50

160.00

ALL DRIVES
TOTAL DCS IDLE / SHUT DOWN POWER

0.00

-24.00

0.00 0.00

No of Start/ Stops

0.00 WEIGH FEEDER MAIN DRIVE FAN CLASSIFIER SILO FEEDG ROUP COMPRESSERS BOOSTER FAN IDLE /SHUT DOWN POWER 0.00 0.08 1.00 1.00 1.00 1.00 1.00 Dcs Idle Power PACKER-1 621MD1 641FN1+641FN2 PACKER-2 622MD1 642FN1 PACKER3 BULK LOADING 623MD1 643FN1+643FN2 PACKING PLANT COMPRESSOR-CP1 PACKING PLANT COMPRESSOR-CP2 PACKING PLANT COMPRESSOR-CP3 PACKING PLANT COMPRESSOR-CP4 CEMENT MILL COMPRESSOR IDLE/SHUT DOWN POWER 1212.04 TON 3348.00 12.64 18.75 18.75 10.27 13.55 13.55 12.06 12.15 20.00 20.00 0.00 20.90 21.40 2.40 0.00 0.00 0.00 342.80 -2.42 0.00 0.00 6.11 6.11 0.00 3.28 3.28 0.00 0.00 -4.21 -4.21 0.00 61.10 183.30 0.00 32.80 65.60 0.00 0.00 0.00 0.00 1.07 1.00 10.00 20.00 38.00 10.00 30.00 6.00 10.00 20.00 14.66 14.90 15.90 16.00 15.30 16.60 2.00 0.00 -1.00 0.34 -0.60 0.30 0.00 0.00 0.00 71.06 0.00 52.80 0.00 123.86 23.16 23.14 1.24 250.00 2449.00 209.00 185.00 176.00 45.00

CEMNT MILL

No of Start/ Stops

2.00

PACKING PLANT

UTILITIES

UTILITIES
TOTAL UNITS

11171.00

FLY ASH

331.52

U/T

3.17

Daily Idle Power Consumption Report

Compressor 441CP1 441CP2 441CP3 441CP4 421CP1 421CP1 A K21CP1 K21CP2 K21CP3 K21CP4 K21CP5 K21CP6 621CP1 621CP2 621CP3 621CP4 R Hours 0.00 0.00 24.00 0.00 0.00 0.00 0.00 16.60 0.00 9.30 0.00 0.00 0.00 20.90 21.40 2.40 Units Comp. Energy Consumed for Pyro Comp. Energy Consumed for Cement Mill Comp. Energy Consumed for Fly Ash Comp. Energy Consumed for Packing Plant Total Compressed Air Energy Consumption 4171.00 1733.00 1050.00 1038.00 7992.00 Units Consumption 0.00 0.00 4171.00 0.00 0.00 0.00 0.00 1733.00 0.00 1050.00 0.00 0.00 0.00 249.00 708.00 81.00 Run Hours 24.00 16.60 9.30 44.70 24.00 Avg. KW #DIV/0! #DIV/0! 173.79 #DIV/0! #DIV/0! #DIV/0! #DIV/0! 104.40 #DIV/0! 112.90 #DIV/0! #DIV/0! #DIV/0! 11.91 33.08 33.75 Avg. KW 173.79 104.40 112.90 23.22 333.00 % Loading #DIV/0! #DIV/0! 98.47 #DIV/0! #DIV/0! #DIV/0! #DIV/0! 59.15 #DIV/0! 63.97 #DIV/0! #DIV/0! #DIV/0! 6.75 18.74 19.12

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Power units / MT of Material Description L S Crusher Raw Mill Coal Mill Coal Crusher Kiln & Cooler Power units / MT of Clinker Description L S Crusher Raw Mill Coal Mill & Crusher Kiln & Cooler Utilities & Others Power Upto Clinkerization Cement Mill OPC PPC Packing Plant Cement - Overall OPC PPC Overall

Monthly Energy Monitoring Report

XX-XX-13 XX-XX-13 XX-XX-13 XX-XX-13 XX-XX-13 XX-XX-13 XX-XX-13 XX-XX-13 Month Total 0.97 17.21 20.07 1.83 19.00 1.07 17.04 22.29 2.11 18.98 0.88 16.11 20.51 2.14 18.20 0.89 17.09 21.60 1.67 18.52 0.87 16.19 19.05 2.13 18.51 0.91 16.88 20.80 2.09 18.40 0.93 16.66 18.89 1.93 18.82 0.84 17.03 19.78 2.01 18.77 0.94 17.37 20.84 3.37 20.35 Pvs mnth May 0.95 16.43 19.89 2.89 18.48

6-17-13 1.36 26.16 2.41 19.00 2.16 51.09 26.11 27.07 23.65 1.15

6-18-13 1.50 25.91 2.66 18.98 2.17 51.21 23.84 23.73 0.00 1.21

6-19-13 1.24 24.49 2.60 18.20 2.28 48.82 24.16 24.66 23.27 1.07

6-20-13 1.25 25.98 2.58 18.52 2.09 50.42 24.74 24.67 0.00 1.17

6-21-13 1.22 24.61 2.37 18.51 2.24 48.96 27.37 28.28 26.78 1.12

6-22-13 1.28 25.66 2.48 18.40 2.29 50.11 25.40 24.92 26.36 1.15

6-23-13 1.30 25.32 2.30 18.82 2.17 49.90 26.37 26.13 0.00 1.24

6-24-13 1.18 25.89 2.50 18.77 2.13 50.47 25.53 21.86 26.12 1.20

Month Total Pvs mnth May 1.32 26.41 2.69 20.35 3.23 54.01 25.50 25.37 26.05 1.17 1.33 24.98 2.68 18.48 3.10 50.57 25.23 24.72 26.79 1.27

77.51 61.88 73.12

74.53 0.00 74.63

72.93 59.52 68.15

74.70 0.00 74.77

76.66 63.31 68.59

74.54 63.70 70.92

75.60 0.00 75.84

71.75 63.63 64.76

78.59 66.17 76.13

74.65 64.14 72.09

Plant DCS Report Formats

Section Specific Energy Consumption Data Idle Run Report

Online Specific Energy Consumption

Online Electrical SEC Online Thermal SEC

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Type of Renewable Energy Source

* Wind Power Portable Wind Power

Installed Capacity in KW
16525 1.5

Savings (Last 3 Years) Energy Generated (Lakhs Unit) 884 0.03 Cost Saving (Rs. Lakhs) 4420 0.15

Solar Power
Solar Water Heater

2
36

0.044
0.15

0.22
0.75

Note: * Wind Power Generation from the Dalmia Group (Dalmia Bharat Power)

Solar Water Heater

Solar Street Lights

Wind Power Generator Solar power Pack

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Wind Power Generator

Reminders

Slogans

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Pet Coke Red Mud Chemical Gypsum Alternate Fuels Flyash STP Water

Using 100% Petcoke for Clinkerization Waste From Alumina Industry as the Additive for Raw Mix, Which boost up utilization of Pet coke 100% Chemical Gypsum for Additive for Cement Grinding ( 2%) 2 % of Alternative Fuel for Clinkerization. By using the Hazardous Waste of Pharmaceutical Industry Utilization of Flyash 32% for Cement Grinding Utilizing the STP Water for the Cement Mill Water Spray

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Installation of Sewage Water Treatment Plant at Jammalamadugu (Near by Town) and Pumping Sewage the Treated water for Process Water Feasibility Study Completed. Under Engineering Stage Collection of Municipal Waste and use as Municipal alternative fuel in Pyro Waste Under Process with Pollution Control Board Identification of Waste (Agro Waste and Other Other Waste Generating from Industries). Industry Identified Waste & Pollution Control Board Waste Obtained

Vendor : Sri Sai Devine Mining Pvt. Ltd. Service: Supply of Lime Stone from Mines to Crusher Prior to Encon: Specific Fuel Consumption : 0.42/T of Lime Stone After Encon: Specific Fuel Consumption : 0.40/T of Lime Stone Improvement: 4.7% of Fuel Consumption Reduced. Encon Efforts : Reduced the Hauling distance by making straight haul road Controlled the Idle time of Loading Machine and Dumper

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Vendor : RR Transport & Sri Subramaniswar Transport Service: Logistics Services for Cement Dispatch by Road Prior to Encon: Specific Fuel Consumption : 0.33 Ltr./KM After Encon : Specific Fuel Consumption : 0.29 Ltr./KM Improvement: 14% of Fuel Consumption Reduced. Encon Efforts : Training to all Drivers on Defensive Driving Educating Drivers on Clutch / Brake Usage, Ramp up, Ramp down & Free Running Speed Utilization of Vehicle arriving with Red Mud for dispatching the Cements

Vendor : Meen Bahadhur Thakur Service: Maintenance of Guest House

Prior to Encon: Consumption of LPG Cylinders 25 Nos. / Month

After Encon : Consumption of LPG Cylinders 20 Nos. / Month Improvement: 20% of LPG Consumption Reduced / Month. Encon Efforts : Educated for avoiding the Idling of Gas Stove Educated on Preheating by Keeping the Vessels on the Vessels Usage of Pressure Cooker

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Distribution of Solar Lamps to the Surrounding Communities

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Won the following Mines Zonal Safety Competitions 2012

Drilling & Blasting Overall Performance 1st Prize 1st Prize

Mines Lighting & Electrical

Hazard Identification & Risk Assessment Mine Working

1st Prize
1st Prize 2nd Prize.

Photographs of Mines Award Ceremony Year 2012

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CIIs 5S Excellence Award - 2012

CIIs EHS Award - 2012

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Group Award
Go Green Award Safety, Environment & Housekeeping Award

Group Award
360 Value Feedback Award

CSR Award

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Save Energy - Save Money - Save the Planet.

83