HEARTY WELCOME

CII 18th EXCELLENCE IN ENERGY MANAGEMENT – 2017

Date : 30th, 31st August & 1st Sep’ 2017
Venue: Novotel & HICC Complex, Hyderabad

13 Varieties of Cement from one location

Operating 7 Management Systems

Presented by
M/s DALMIA CEMENT (BHARAT) LTD, DALMIAPURAM
 Presentation Coverage
I. Specific energy consumption and Key Parameters trend
II. Key Encon Projects (incld., 19 Nil Investment Projects)
III. Innovative projects in detail
IV. Carbon Emission Reduction
V. Team Work in Encon / Monitoring & Reporting / Employee
Involvement in Encon
VI. ISO 50001, Green Pro Certification
VII. Renewable energy sources
VIII.Waste Utilisation
IX. Replication of Best Practices
X. Benchmarking – Global Best & Roadmap to achieve Target
XI. Awards Accolades
 I. Specific energy consumption and
Key Parameters trend
Cement Production ( in Lakh MT) Line2 KILN HEAT RATE (Kcal/Kg) Line2 SPC – Kw/ton of clinker
1000
30 26.14 20.85 778 60
23.65 747 758 49.55 48.18
20.31 800 50 46.46
20
600 40
10
400 30
0
20
200
10
0 0
OPC
Fy'14-15 Fy'15-16 Fy'16-17 Fy' 14-15 Fy' 15-16 Fy' 16-17

AFR Consumption - % TSR Clinker Specific Power Consumption (KwH/Ton)

15 13.36 60 55.53
11.88 10.75 51.63 49.48
50
10
40
5 30
1.59
0.3 20
0
10

0
Fy'14-15 Fy'15-16 Fy'16-17
 II.ENCON PROJECTS WITH NIL INVESTMENT
Annual Annual Annual Thermal Saving Annual Total
Thermal Annual
Electrical Electrical
No Title of Project Year Unit of Cost Savings
Saving Cost Saving Quantity
(kWh) (Rs million) Measurement Saving (Rs (Rs
million) million)
Energy saving thro' clinker
1 subtitution by way of increased 2014-15 1057464 0.63 2133 Ton / Year 1.135 1.77
flyash utilisation in PPC

2 Maximization of Line 2 Operation 2015-16 3913 Ton / Year 20.82 20.82

3 Product Mix 2015-16 1956 Ton / Year 10.41 10.41

Commissioning of weigh bridge for
4 Bulk Loading of Cement at Line-II 2015-16 19667 0.12 0.12
Packing House
Optimisation of compressor air by
replacing 75 kw with 55Kw air
5 2015-16 87420 0.52 0.52
cooled compressor in line 2 Packing
House
optimizing bag filter fans operation
6 2015-16 28500 0.17 0.17
in line-2 Packing House
Power consumption reduced for
7 PPC & OPC Cement Grinding in 2015-16 4500000 27.0 27.00
CVRM-2
 ENCON PROJECTS WITH NIL INVESTMENT
Annual Annual Annual Thermal Saving Annual Total
Thermal Annual
Electrical Electrical
No Title of Project Year Unit of Cost Savings
Saving Cost Saving Quantity
(kWh) (Rs million) Measurement Saving (Rs (Rs
million) million)
Lastspecialcementgrindingshiftedfr
omBallmilltoGrindingOilWellcemen
8 tinCVRM- 2015-16 230720 1.38 1.38
1Toavoidruningtheoldballmill-
savings20Kwh/mt
Special cement grinding shifted
9 from CVRM-1 Grinding SRPC in 2015-16 546285 3.28 3.28
CVRM2 - savings 3 Kwh/mt
Change of SRPC production from
10 2015-16 802928 4.82 4.82
line 1 to line 2 - savings 4 Kwh/mt
Initiatives taken to reduce
compressed air power.
Arresting of all air leakages ,
Carrying out leakage test every
11 fortnight, VFD drive installation for 2015-16 11998172 71.99 71.99
compressor units and Modification
& rerouting of pipe lines In Line-2
Pyro, Cement Grinding and Packing
House
 ENCON PROJECTS WITH NIL INVESTMENT
Annual Annual Annual Thermal Saving Annual Total
Thermal Annual
Electrical Electrical
No Title of Project Year Unit of Cost Savings
Saving Cost Saving Quantity
(kWh) (Rs million) Measurement Saving (Rs (Rs
million) million)

Separate Firing of High CV

flyash and Carbon black
12 2015-16 100000 0.6 0.60
replaced with single blower
operation from 2 different bins

Energy saving thro' clinker

13 subtitution by way of increased 2015-16 1208963 0.73 2484 Ton / Year 1.321 2.05
flyash utilisation in PPC

Optimize Service air pressure

14 2016-17 71050 0.41 - - - 0.41
in 18 MW and 27 MW
 ENCON PROJECTS WITH NIL INVESTMENT
Annual Annual Annual Thermal Saving Annual Total
Thermal Annual
Electrical Electrical
No Title of Project Year Unit of Cost Savings
Saving Cost Saving Quantity
(kWh) (Rs million) Measurement Saving (Rs (Rs
million) million)
Optimize the phase density of
15 PC coal conveying blower in 2016-17 73728 0.43 - - - 0.43
Line 1

Arrest compressed air leakages

16 2016-17 179861 1.05 - - - 1.05
in the plant

Switch off idle running

17 compressed air dryers in line 2 2016-17 35971 0.21 - - - 0.21
compressors
Energy saving thro' clinker
18 subtitution by way of increased 2016-17 355566 0.21 746 Ton / Year 0.397 0.61
flyash utilisation in PPC
Reduce pressure drop in Line 1
19 PH Fan from downcomer to fan 2016-17 3 Ton / Year 355556 0.36
inlet
 ENCON PROJECTS WITH INVESTMENT
Total
Annual Annual Annual Thermal Saving Annual
Annual
Electrical Electrical Thermal Cost
No Title of Project Year Unit of Savings
Saving Cost Saving Quantity Saving (Rs
Measurement (Rs
(kWh) (Rs million) million)
million)
Kiln inlet & outlet
1 seal for both KHD & 2014-15 21.94 21.94
FLS
Optimize the
operation of coal
2 conveying blowers 2014-15 17.93 17.93
for KHD & FLS line
with Turbo Blowers
KHD Coal Mill, Raw
Mill pumping system
3 efficiency 2014-15 0.35 0.35
improvement(Water
pump)
Avoid unwanted use
4 of compressed air for 2014-15 0.39 0.39
packer bins aeration
Reduce bag filter DP
in Roto Packer 1 and
5 3 other Bag filters in 2014-15 0.96 0.96
DP Mode (DP
transmitter)
 ENCON PROJECTS WITH INVESTMENT
Annual Thermal Saving Total
Annual Annual
Annual Thermal Annual
Electrical Electrical
No Title of Project Year Unit of Cost Saving (Rs Savings
Saving Cost Saving Quantity
Measurement million) (Rs
(kWh) (Rs million)
million)
Beblec Lighting
6 2014-15 1.35 1.35
transformer
Improve heat
7 transfer in KHD line 2014-15 8.1 8.1
preheater
Reduce the
dispersion box
8 height in PH 2014-15 6.48 6.48
cyclone no. 1 & 2
in KHD
Reduce the
dispersion box
9 height in PH 2014-15 6.07 6.07
cyclone no. 2 & 3
in FLS
Improve top stage
10 cyclone efficiency 2014-15 4.05 4.05
in FLS
 ENCON PROJECTS WITH INVESTMENT
Total
Annual Annual Annual Thermal Saving Annual
Annual
Electrical Electrical Thermal Cost
No Title of Project Year Unit of Savings
Saving Cost Saving Quantity Saving (Rs
Measurement (Rs
(kWh) (Rs million) million)
million)
Upgradation of H & B, 3 2015-
11 400000 2.4 2.40
spout stationary packer 16
Energy efficient FRP 2015-
12 1193500 7.161 7.16
hollow bladed axial flow 16

Replacing existing less

efficient motors with 2015-
13 246813 1.480878 1.48
advanced energy 16
efficient motors.

Conversion of existing
mode of operation from 2015-
14 292307 1.753842 1.75
LRS and Damper to 16
GRR in VRM-2 Fan.
Variable Frequency
2015-
15 Drive For Compressor 121275 0.72765 0.73
16
Application
 ENCON PROJECTS WITH INVESTMENT
Total
Annual Annual Annual Thermal Saving Annual
Annual
Electrical Electrical Thermal Cost
No Title of Project Year Unit of Savings
Saving Cost Saving Quantity Saving (Rs
Measurement (Rs
(kWh) (Rs million) million)
million)
Up gradation of CVRM -1 2015-
16 490339 2.94 2.94
Mill fan SPRS 16
Coal (Ball) mill stopped in
Line-1 by pumping fine
coal from Line-2
(i) Line- 1 coal grinding
2015-
17 power 80 kWH/MT coal 720000 4.32 4.32
16
(ii) Line-2 coal grinding
power 36 kWH/MT coal
(ii) Pumping power 12
kWH/MT coal
PD Blower replaced with
2015-
18 Turbo Blower for Kiln and 516667 3.1 3.10
16
PC Firing
Optimize the operation of 2016-
19 332640 1.94 - - - 1.94
CEP by installing VFD 17
Optimize performance of HP
2016-
20 pump in RO plant by 7000 0.04 - - - 0.04
17
installing VFD
Install VFD in Instrument air 2016-
21 134050 0.78 - - - 0.78
compressors 17
 ENCON PROJECTS WITH INVESTMENT
Annual Annual Annual Thermal Saving Annual Total
Electrical Electrical Thermal Cost Annual
No Title of Project Year Unit of
Saving Cost Saving Quantity Saving (Rs Savings (Rs
(kWh) (Rs million) Measurement million) million)
AFR feeding system for
2016-
22 Line-2 and Shredder 60 MT 2689200 2.7
17
machine
ELGI Make screw
compressor integrated 2016-
23 65266.6 0.38 - - - 0.38
with VFD model (Line2 17
)
Replacement of Air
2016-
24 slide with screw 227168 1.32 - - - 1.32
17
compressor in old silo
Install VFD for line 1
2016- 21460.3
25 packing plant 0.12 - - - 0.12
17 2
compressor
Pyrojet Burner
2016- Kcal/Kg
26 installation in Line-1 4 2.4 2.41
17 clinker
kiln
Spent wash firing in 2016- Kcal/Kg
27 0.5 0.1 0.13
Line- 1 Pyro system 17 clinker
 ENCON ONGOING 2017-2018

Expected Savings
No Details
Rs. In Lakhs

Line-2 Heat Rate Reduction

1 Reduction in pressure drop in cyclone 3 & 1 to improve heat transfer 13
2 Cooler optimization 38
3 Reduction in Shell radiation by replacing upper transition zone bricks 51
4 Reduction in Shell radiation by replacing bricks in PC & cyclone 51
Line-1 Heat Rate Reduction
5 Optimization of Pyrojet burner & increase in output 35
6 Cooler optimization by IKN plates replacement 23
7 Reduction in Shell radiation by replacing upper transition zone bricks 29
8 Repairing / replacement of Cyclone feed pipe double flap 12
9 Cooler water spray system installation in cooler vent duct 12
 ENCON ONGOING 2017-2018
Expected Savings
No Details
Rs. In Lakhs

Maximising Low Cost fuels- Alternate Fuels

10 Installation of Spent Wash firing system
11 Installation of Shredder for AFR 159
Reduction in Power Consumption - Upto Clinker
12 Reducing size of Crusher output from max 75mm to max 65mm - Rawmill 35
13 Optimizing of Fuel mix depending on the physical characteristics - Coal Mill 23
14 Reduction in pressure drop in cyclone 3 & 1 to improve heat transfer - Kiln 12
15 Optimization of stoppage power in Pyro 87
Reduction in Power Consumption - Cement Grinding
16 Replacement of Master Roller tyre 15
17 Replacement of Table liner & dam ring
18 Stabilisation of above modifications 8
 ENCON ONGOING 2017-2018
Expected Savings Rs.
No Title of Project
In Lakhs
Replacement of Line-2 Pyro ELGI Compressor with energy efficent Gogrej
19 12.5
Compressor
Replacement of CVRM -2 ELGI Compressor with energy efficent Gogrej
20 10.9
Compressor
Replacement of CVRM -1 ELGI Compressor with energy efficent Gogrej
21 9.4
Compressor
Replacement of DFA Tanker unloading Water cooled Reciprcating Compressor
22 12.3
with energy efficient air cooled Screw compressor
Replacement of Timer operated auto drains valves with zero loss mechanical
23 6.9
type auto drain valves
24 Guillitione Dampers in place of Multilouver dampers for all fans 27.7
Guillitione Dampers in place of Flap dampers for all Compartments, Sealing of
10.1
25 air ( 22 nos )
26 Fanless Cooling Tower for 18 MW 5.6

27 Power consn reduction for running chiller during plant stoppage 1.4

28 Minimize air infiltration in boiler -27 MW 0.0

29 Minimize leakage in service air system of 27 MW 2.6

Up gradation of fly ash compressor with energy efficient compressor from
30 12.3
existing BDJL Compressor
 III. Innovative projects
III.1 Grinding Oil Well cement in CVRM-1
A. Purpose: So far Oil Well cement was ground with Oil Well clinker & Salt pan gypsum in cement Ball mills 2 & 3.
Since Ball mill is taking more power and it has been proposed to Grind Oil Well Cement in CVRM-1.
B. Action Plan:To grind Oil Well cement in CVRM1 with required quality Parameters of fineness (300 m2/Kg) and
Thickening Test (Cement setting time 90 to 120min).
C. Trial Details:The clinker hopper in CVRM-1 mill was emptied and filled with Oil Well clinker through manual
feeding hopper with Hitachi and JCB and one spare wet fly ash hopper was emptied out and the same hopper was
filled with salt pan gypsum through dump hopper.
SPECIFICATION AS PER OWC IN CVRM1
API 10A
Sp. Surface (M2/Kg) - 300
Thickening Time (Min) 90-120 96
Free Fluid (%) (Max) 5.9 4.2
CCS at 38*C (PSI) (Min) 300 600
CCS at 60*C(PSI) (Min) 1500 1650

A. Net Saving:= Power saving cost – Material Handling cost

=56887 – 21519 = Rs.35368/-
= Rs.57.5/MT of Cement (Power saving cost = 25unit * Rs.3.7 * 615MT)
➢The Indirect cost saving through manpower and spares cost not considered. EOT crane and Ball mill operation can
be stopped and Manpower utilized elsewhere in the plant.
B. Improvement Points: Clinker feeding arrangement to be modified to increase the mill output from 130 TPH to
160 TPH.
C. Conclusion:From this trial we could successfully overcome the constraints and explored the possibility of grinding
OWC in CVRM1 which is the last variety of Special cement ground in the Ball mill and thereby saved 25 units of
power per MT of Cement. (Considering 48,000 MT of OWC grinding). Potential Annual cost savings is Rs.28Lakhs
 III.2 Changing of SRPC clinker from Line-1 to 2

Challenges :
✓ High Sp.heat consumption
Energy Con.
✓ High Sp.Power consumption Proj.- 1
✓ Clinker Handling and Transportation
Action Taken :
✓ Shifting Special clinker production from Line1 to Line 2
Results :
✓ SHC -60 kcal/kg cli
✓ SPC – 4 Kwh/ton of cli
✓ Clinker handling and Transportation
reduced
✓ Annual Savings – 80 Lakhs

17
 III.3 AFR Thermal Substitution Rate of 10.75 % in 16-17

I.INTRODUCTION – AFR USAGE IN CEMENT PLANTS, AN IMPERATIVE

Our Dalmia Bharat Ltd., had also taken up AFR as a focus area, having got Sustainability
rooted in Our Corporate Vision viz. “Our vision is to become a leader in building
materials and evoke pride in all stakeholders through customer-centricity, innovation,
Sustainability and our values.”

In this Case study, a glimpse of the AFR Journey of our Dalmiapuram plant is dealt with,
highlighting the key actions from in-house team, leading to achieving a TSR of 10.75 % in
FY 16-17.

AFR utilized at our Dalmiapuram Plant with in-house developed feeding system –
Objective, Challenges, Actions and results. Several AFR materials identified and utilized
in 16-17 at our Dalmiapuram Plant with necessary approvals.

I.Objective:
Maximizing AFR consumption, with minimum investment
Reducing the operating cost
Reducing the Capital cost
ii) Challenges in the earlier system:
AFR Material was fed in to Line 1 Pyro clone , through winch bucket and handled manually,
The lifting Height was 45 mtr from Ground level
Handling the AFR material in bags was laborious
Low feed rate
Extra coal consumption due to false air entry
CO generation due to inconsistent feed
A proposal made to feed the AFR through proper conveying and measuring system had high
capital cost for (Rs.4.5 Crs for 4 TPH systems)
Team decided to go for an in house system, harnessing available resources, in view of high capital cost.
iii)Actions taken:
Old Passenger Lift available in adjacent building was modified with extended Height
To utilize this unused passenger lift in line-1 old pre-heater Building,
A motorized tippling chute arrangement was made in the ground level to fill the lift cabin.
The lift cabin was modified with bottom trap door arrangement, to unload material in to the storage
bin.
A 10Ton storage cum extractor bin was placed at 45 Metre level.
The extractor in the bin will feed the material to belt conveyor, which are controlled by VFD
The belt will feed to screw conveyor, which is connected to Raiser duct thru Double flap and shutoff
gates.

iv)Savings:
Project cost of new system is 4.5 Cr. This in House system cost 50 Lacs.
Net saving about 4.0 Cr
With Innovation …Creativity…Team work, this initiative was made to a success.
 III. 4 Water Conservation
– Our Innovative efforts resulting in
Conservation of 500 Cub. M/Day
Necessity is the Mother of invention. Facing an acute water shortage this summer, Our Team
Dalmiapuram plant had carried out a Water Audit in Dec’16, brainstormed and implemented several
conservation initiatives and achieved a conservation of about 500 Cub. M / Day.

I. PROOF OF THE NEED

Encountered Water shortage in our plant vicinity and low yield from our Captive Source, more so in view
of hot summer and less rain fall this year.

Team Dalmiapuram Plant felt the need for Water conservation, as there was a shortage in supply from our
Captive source / Rain water harvesting Ponds. Water conservation focus has been not just for the
necessity but also as our contribution towards Sustainability & Green cement, in line with our Corporate
Vision .“Our vision is to become a leader in building materials and evoke pride in all stakeholders through
customer-centricity, innovation, Sustainability and our values.”

The world’s population of about 7 billion is estimated to go up to 9.6 billion in 2050. Unless we adopt
judicious water conservation approach, we will not be able to meet our per capita requirement. Thus,
water becomes a precious resource and conservation is inevitable. Conserving water also saves energy
required for Pumping. The oceans, streams and lakes that are the lifeblood of so many local eco-systems
are to be protected. As a social cause, water conservation is everyone’s responsibility.

20
II. DIAGNOSTIC and REMEDIAL JOURNEY (Water Audit , Action Plan and Implementation)

To identify conservation potential, we have carried out a Structured Water Audit and an optimization Study.
Based on this, several ideas were generated thro’ brainstorming and implemented solutions / improvement
actions as below, achieving about 500 cum/day:

i. Capacity de-bottlenecking at our STP (Sewage Treatment Plant) to increase the yield
ii. Treated STP water usage for Plant process, replacing Raw Water
iii. Level sensors installation.
iv. Leakage Management- Major Leakage in an underground pipeline identified thro’ a meticulous
inspection/check and arrested by replacing 300 Metre pipeline.
v. Checking and repairing of Float Valves provided at Over Head Tanks to avoid overflow wastages.
vi. Optimization of Domestic Water usage in Plant thro’ awareness, pep talk and education.
vii. Re-utilization of RO Reject from CPP after treatment

21
II. DIAGNOSTIC and REMEDIAL JOURNEY (Water Audit , Action Plan and Implementation)

viii. Installation of automatic control system to Line-2 Domestic Water Over Head Tank.
ix. Cooling Tower Management.
x. Leakage of Water taps is arrested by Inspection, Repairing & Replacement in all Colony Houses, Schools
and Guest House.
xi. Creating awareness
xii. Installation of Flow meters to receipt/supply locations at our Plant
xiii. Provision of Flow meters to our Colony & School
xiv. Daily Water Monitoring and reports circulation to concerned ( water gets measured and gets controlled)
xv. Sprinkler system for Watering to Garden
xvi. Drip irrigation for tree saplings
xvii. Ideas involving investment were listed separately, Action Plan drawn with responsibility and time frame
(as given in Full Paper) and monitored with focus for quick implementation.

22
III. RESULTS / HOLDING THE GAINS

✓On implementations of the above measures close to 500 Cub. M/day of conservation achieved
and sustained thro’ daily Monitoring.

All diabetics know about – Exercise, Diet & Medication but the key however lies in action.

23
 III. Innovation in projects implemented

Annual Savings,
Sl.No Title of Project Brief Description of the Project Reason To Choose Rs million/ y
ear
Grinding Oil Well cement in OWC cement grinding shifted from To avoid running the old
1 2.80
CVRM-1 Ball mill to CVRM ball mill 20 Kwh/mt

Change of SRPC production SRPC Clinker Production in Line-1 SHC - 60.0 Kcal/ Kg.
2 SPC & SHC reduction SPC 4 kwh/ton
from line 1 to line 2 & Line-2 Kiln

Resizing of pipe line

Leakage reduction
Reduced compressor Specific Installation of VFD
3 SPC reduction -
Power LP screw Compressor
5 No’s 132 KW Compressor
stopped.
PD Blower replaced with Turbo Blower for Kiln and PC
4 SPC reduction 3.10
Turbo blower firing results in Power saving

AFR storage & feeding system Fossil fuel replacement &

5 Substitution of coal with AFR 20.00
installed COP reduction.
Replacing high cost coal with
6 Usage of High sulphur petcoke COP Reduction 150
low cost Pet coke

Inter-grinding of CPP ash &

7 Reduction in AFR firing power Power reduction 0.6
Petcoke. Dedicated blower stopped.
 IV. Carbon emission reduction –kg CO2 eq/Mt of cement
900
823
800

700 667
633 628 640
600

500

400

300

200

100

0
Base Line 2013-2014 2014-2015 2015-2016 2016-2017
 V.Team Work in Encon / Monitoring & Reporting /
Employee Involvement in Encon
✓ Suggestion Scheme
✓ Co-ordinated by Energy ✓ Good Work Award
Manager
✓ Long Service Award
✓ Energy conservation ✓ Employee of the Month
committee formed with ✓ EOM Training and Dinner
cross functional team
✓ Workers Education Class
members and best
energy saving initiatives ✓ Nomination for Tamilaga Arasin Uyarntha
discussed and Ulaipalar Virudhu
implemented.
✓ Safety Quizzes in Gate Meeting

✓ Best tracking system for ✓ Safety Messages Sharing in Gate Meeting

speedy implementation ✓ Productivity week/ Environmental Day
Celebrations Various Contests
✓ Quick fund allocation by
the management based ✓ National Safety Day Celebrations Various
on the pay back period Contests
✓ Safety Committee Meeting Members
✓ Best Energy saving
initiatives are awarded Participation
periodically. ✓ Various External Awards Participation
✓ Birthday Fiesta/Long service Mass Tree
Plantation.T rained for New Safety Approaches
 ENERGY POLICY
As energy intensive cement manufacturing company, We Our Energy Managers / Auditors
Dalmia Cement (Bharat) Limited, Dalmiapuram, Manufacturing in Dalmiapuram
varieties of cement are Committed to

❖ Reduce energy use per unit of production in our

Mr.T.Kandappan
manufacturing operations. EM1619
❖ Ensure Continual Improvement in our energy performance
❖ Analyze energy use and consumption with effective Mr.M.Senthil Murugan
monitoring and control.
EA18595
❖ Comply with all applicable legal and other requirements.
❖ Implement energy efficient technologies and operational
practices. Mr.P.Balaji
❖ Achieve energy targets with enhanced employee EA15525
participation, training and involvement
Date: 25.03.2014
R.A. Krishnakumar Mr.B.Madhu
Unit Head EA15526
 VI. ISO 50001, Green Pro Certification

Dalmia PPC - Green Pro Certified by CII

Energy Management SystemCertifiion
IS/ISO 50001:2011
 VII- Renewable Energy
Activities 2014-15 2015-16 2016-17 Overall Remarks
Bio Gas 02 07 10 112Tons of CO2 Have been evaded Thro
Plants this initiative)
Fuel efficient 300 222 401 3528.8Tons of CO2 Have been evaded
chullah Thro this initiative)

Solar lantern 200 300 500 2214Tons of CO2 Have been evaded
Thro this initiative r)
Solar Study Na 50 240 1326Tons of CO2 Have been evaded
lamp Thro this initiative
Solar Home Na 10 Na 2600Tons of CO2 Have been evaded
Light Thro this initiative
Solar Street 20 05 20 841Tons of CO2 Have been evaded Thro
Light this initiative

➢ Wind Mill
➢ We had installed windmill Farm - First in Cement Plant in the Tamil Nadu. Location
and Capacities are as mentioned as below:
➢ Site-I : In Muppandal,Kanyakumari District Capacity : 11.5 MW
➢ Site-II : In KarungulamVillage at Thirunelveli District Capacity : 5.025 MW
 VIII. Utilization of Waste material

CPP Fly Paper Coal Carbon PALM Spent TYRE Foot

AFR Dolachar GEPIL RDF
Ash Waste Dust Black Bunch Wash Fibres Wear

2015-2016

Qty. Consumed in MT 17235 25.45 361 8810 349.45 - - - - - 5.77

GCV(Kcal/Kg) 5685 4341 4926 6673 3516 - - - - - 5286

Heat Value (Million 97980.97 110.47 1778.3 58789 1228.66 - - - - - 30.5

Kcal)

TSR 8.08% 0.03% 0.04% 4.96% 0.06% - - - - - 0.00%

2016-17

Qty. Consumed in MT 18213 67 - 5943 - 146 79 830 9 15 378

GCV(Kcal/Kg) 6200 4926 - 6788 - 3400 3200 522 3300 7200 5500

Heat Value (Million 112920.6 330 - 40342 - 496.4 252.8 433.26 29.7 108 2079
Kcal)

TSR 8.0% 0.01% 2.49% 0.03% 0.02% 0.07% 0.00% 0.00% 0.12%
 IX- Replication of Best Practices
➢ Pyro Jet Burner in Line-1 & 2...

➢ Coriolis Feeding system in Line-1 & 2...

➢ Turbo Blowers in Line-1 & 2 - Coal Pumping...

➢ VFD for Plant Compressors...

➢ Spent wash Feeding System in both Lines...

➢ Inter Coal Pumping from both Lines...

➢ Higher Production in both Lines...

➢ Louver Velocity Optimzation in VRM's...

➢ Retrofitting of LED Light Fittings in both Lines...

 X- Benchmarking, Target &
Roadmap to achieve Target
Comparison with Benchmark Figures
National
Global Current
Description Unit Bench Our Target
Mark Best level
Thermal Kcal / 680 758 740
SEC kg. 707 (Line2)
clinker
Electrical Units/
SEC MT of
Clinker
49.9 45 48 45

National Benchmark – CII and CMA Energy Benchmarking for Cement Industry
Manual May 2015
International Benchmark -http://ietd.iipnetwork.org/content/cement#benchmarks