1 ID: 14 Title of measure Sector: Cement Industry

2 Survey Year: 2006 Cooler ESP Fan Drive modification Technology: Variable
Frequency Drive
3 Name of the Company : Ultratech Cement Limited, Awarpur Cement Works,
Chandrapur, INDIA
4 Agency that executed the project : In-house
5 Year of Implementation : 2004-05
6 Unit Profile:
Ultratech Cement Limited, a Grasim subsidiary has an annual capacity of 17 million tons. It
manufactures and markets Ordinary Portland Cement, Portland Blast Furnace Slag Cement and
Portland Pozzolana Cement. The unit has a turnover of nearly US$ 0.2 billion.
7 Description of Energy Conservation Measure:-
The cooler ESP fan was equipped with 425 kW, 6.6 kV HT Slip ring motor, with Liquid Rotor
Resistance (LRR), Slip Power Recovery System (SPRS), feedback transformer, which was running in
between 65-85% of the rated speed. Fan was drawing input power of 240 kW maximum. Since LRR
is one of the old and inefficient methods of varying speed of slip ring induction motors, the plant took
initiative to replace it with a VFD controlled Squirrel Cage motor.
Before Modification :
Motor Capacity = 425 kW, HT Slip ring , 6.6 KV
Air Handling Unit = Cooling system for HT Motor
Gear Box = 3.77 : 1
Power Drawn = 190 kW
After Modification :
Motor Capacity = 225 kW LT Squirrel Cage , 415 V
AHU = Cooling system eliminated
Gear Box = Existing GB
VSD = Installed Variable speed drive panel of 220 kW
8 Awarpur Cement Plant After Modification

9 Total investment: 31,250 US$

10 First year energy cost savings: 11,650 US$
11 First year additional savings beyond energy (i.e. water, raw materials etc.): Nil
12 Annual energy consumption before, MWh 1,286
13 Annual energy consumption after, MWh 885
14 First year energy savings, MWh 401
15 First year tons of CO2mitigated 401
16 Assumed sustainability, years 10
17 Expected tons of CO2 mitigated throughout life cycle 4,010

16
1 ID: 15 Title of measure Sector: Cement Industry
2 Survey Year: 2006 Installation of Lechler spillback water Technology: Water spray
spray system System
3 Name of the Company : Ultratech Cement Limited, Awarpur Cement Works,
Chandrapur, INDIA
4 Agency that executed the project : Lechler (India) Private Limited, Mumbai, INDIA
5 Year of Implementation : 2004-05
6 Unit Profile:
Ultratech Cement Limited is a part of Aditya Birla Group of Companies. Ultratech is the leading
cement major and the most reputed with premium brand in the country, with over 17 million tones
installed capacity, incorporating state of art technology, advanced instrumentation systems,
computerized control, online quality control by XRF & Computerized control. It manufactures and
markets Ordinary Portland Cement, Portland Blast Furnace Slag Cement and Portland Pozzolana
Cement. The unit has an annual turnover of nearly US$ 0.2 billion.
7 Description of Energy Conservation Measure:-
GCT was running with Enviro-Care system which requires compressed air for water spray
atomization. The requirement of air was 72 psig to maintain the P around 10-12. The plant took the
initiative to install a new system with Lechler spill-back water spray system with higher capacity water
pump and it eliminated one screw compressor of 200 kW.
Before Modification :
Compressor Capacity = 200 kW
Water Pump capacity = 55 kW
Power Drawn = 198 kW
After Modification :
Compressor = Eliminated
Water Pump = 110 kW
Power Drawn = 90-100 kW
8 Awarpur Cement Plant After Modification

9 Total investment: 175,000 US$

10 First year energy cost savings: 21,390 US$
11 First year additional savings beyond energy (i.e. water, raw materials etc.): Nil
12 Annual energy consumption before, MWh 3,208
13 Annual energy consumption after, MWh 2,495
14 First year energy savings, MWh 713
15 First year tons of CO2 mitigated 713
16 Assumed sustainability, years 10
17 Expected tons of CO2 mitigated throughout life cycle 7,130

17
 1 ID: 16 Title of measure Sector: Cement Industry
2 Survey Year: 2007 Modification in lubricating oil circuit Technology: Heat Exchangers
and HT water circuit
3 Name of the Company : Grasim Cement, Raipur, Chattisgarh, INDIA
4 Agency that executed the project : In-house
5 Year of Implementation : 2006-07
6 Unit Profile:
Grasim Cement, a certified company of Aditya Birla Group, is located in Raipur in Chattisgarh State.
Presently the unit has reached the capacity of 2.16 MTPA. The unit manufactures high quality
ordinary portland cement & blended cement. The unit produces blended cement by utilizing the
granulated blast furnace slag & flyash, the wastes of steel plants & thermal power plants respectively.
The annual turnover reported by the unit in the year 2006-07 is US$ 0.19 billion.
7 Description of Energy Conservation Measure:-
The in-house team identified that the lubricating oil circuit and high temperature water circuit can be
modified by providing plate heat exchangers. The engines could be interconnected to utilize the heat
energy of internal system water of the running DG set, to heat the lubricating oil of stand by DG sets.
The team took the initiative to interconnect the internal water system of all the DG sets in such a way
that lubricating oil of any standby DG set can be heated by using the heat of any one running engine.
8 Picture/ sketch/ drawing After Modification Picture/ sketch/ drawing After Modification

--
2

New connection

9 Total investment: 7,500 US$

10 First year energy cost savings: 10,425 US$
11 First year additional savings beyond energy (i.e. water, raw materials etc.): Nil
12 Annual energy consumption before, MWh 98
13 Annual energy consumption after, MWh 0
14 First year electricity savings, MWh 98
15 First year tons of CO2 mitigated 98
16 Assumed sustainability, years 10
17 Expected tons of CO2 mitigated throughout life cycle 980

18
1 ID: 17 Title of measure Sector: Cement Industry
2 Survey Year: 2006 Reduction of power by process Technology: Electrostatic
modification Precipitator
3 Name of the Company : Birla Super Cement, Solapur, Maharashtra, INDIA
4 Agency that executed the project : In-house
5 Year of Implementation : 2003-04
6 Unit Profile:
Birla Super Cement is a grinding unit of 1.5 million tons capacity with a modern technology
manufacturing process involves a level of sophistication & new to the cement industry. The annual
turnover of the unit for the year 2005-06 was US$ 80 million.
7 Description of Energy Conservation Measure:-
The Electrostatic Precipitator (ESP) in the plant is installed for de-dusting the grinding process. It
contains highly negatively charged electrodes, which attract dust in the system. An auto cyclic
hammering is initiated as per set time to dislodge the attracted particles. Thus the cement from ESP is
collected and re-routed into process, which led scope for conservation of energy. It was observed that
product outlet from ESP having characteristics similar to the final product, was sent for packing. An
alternate arrangement was done with system modification to avoid recirculation of material. A new air
slide with diverter gate was installed to divert ESP outlet product to finished product silos.

8 Picture Before Modification Picture After Modification

ESP

B/E

9 Total investment: 6,250 US$

10 First year energy cost savings: 58,925 US$
11 First year additional savings beyond energy (i.e. water, raw materials etc.): Nil
12 Annual electricity consumption before, MWh 29,749
13 Annual electricity consumption after, MWh 29,076
14 First year electricity savings, MWh 673
15 First year tons of CO2 mitigated 673
16 Assumed sustainability, years 10
17 Expected tons of CO2 mitigated throughout life cycle 6,730

19
 1 ID: 18 Title of measure Sector: Cement Industry
2 Survey Year: 2006 Process modification in Ball Mill to Technology: Ball Mill
reduce power consumption
3 Name of the Company : Birla Super Cement, Solapur, INDIA
4 Agency that executed the project : In-house
5 Year of Implementation : 2004-05
6 Unit Profile:
Birla Super Cement is a grinding unit of 1.5 million tons capacity with a modern technology
manufacturing process involves a level of sophistication and new to the cement industry. The annual
turnover of the unit for the year 2005-06 is US$ 80 million.
7 Description of Energy Conservation Measure:-
The cement grinding process consists of ball mill plus roller press as pre-grinder. The output of roller
press is fed to separator which separates fine and coarse material. The coarse material is fed to
cement mill for further grinding. This was again fed to separator for separation of fine and course
material. The fine being final product is sent for packing while coarse material is sent back to ball mill
for further grinding. The in-house team of the unit suggested sending the pre-grinder reject directly to
separator after ball mill as it contains appx. 30% of final product. The suggestions were implemented
with installation of additional system to transport the material. This modification has reduced burden
on ball mill and resulted in increased plant output.
8 Picture After Modification

PROCESS FLOW SCHEMATIC DIAGRAM

E.S.P.
WAGON
C.S.P.
TIPPLER

FINISH
PRODUCT
PACKING
PLANT
GYPSUM
CEMENT MILL SILO
FEEDER
1,2 &3

FLY
ASH SEPOL
HOPPERS
-CLINKER REJECT
-GYPSOM
-POZZO TRUCK WAGON
LOADING LOADING

CLINKER FEEDER L R V-SEP

9 Total investment: 2,500 US$

10 First year energy cost savings: 60,450 US$
11 First year additional savings beyond energy (i.e. water, raw materials etc.): Nil
12 Annual electricity consumption before, MWh 30,653
13 Annual electricity consumption after, MWh 29,931
14 First year electricity savings, MWh 722
15 First year tons of CO2 mitigated 722
16 Assumed sustainability, years 10
17 Expected tons of CO2 mitigated throughout life cycle 7,220

20
1 ID: 19 Title of measure Sector: Cement Industry
2 Survey Year: 2006 Compressed Air Optimization Technology: Compressor
3 Name of the Company : Mangalam Cement Limited, Rajasthan, INDIA
4 Agency that executed the project : Energy Logistics Pvt. Ltd., Mumbai
5 Year of Implementation : 2004-05
6 Unit Profile:
Mangalam Cement Limited was promoted in the year 1978. The company has recently commissioned
its state-of-the-art new cement plant with German technology at its existing site at Morak, Distt.
Kota in Rajasthan under the name of Neer Shree Cement. The annual turnover of the unit is
US$ 0.15 billion.
7 Description of Energy Conservation Measure:-
The unit installed three nos. of variable flow control (VFL) systems for compressors and replaced two
nos. heatless dryers with refrigeration type air dryers.
8 Picture Before Modification Picture After Modification

Refrigeration Type Air Dryer

Heat Less Dryer

VFC System

9 Total investment: 64,661 US$

10 First year energy cost savings: 27,016 US$
11 First year additional savings beyond energy (i.e. water, raw materials etc.): Nil
12 Annual electricity consumption before, MWh 1,883
13 Annual electricity consumption after, MWh 1,615
14 First year electricity savings, MWh 268
15 First year tons of CO2 mitigated 268
16 Assumed sustainability, years 10
17 Expected tons of CO2 mitigated throughout life cycle 2,680

21
 1 ID: 20 Title of measure Sector: Cement Industry
2 Survey Year: 2006 Close circuiting of cement mill Technology: Cement Mill

3 Name of the Company : Shree Cement Limited, Beawar, Rajasthan, INDIA

4 Agency that executed the project : KHD Humboldt Wedag GmbH, Germany
5 Year of Implementation : 2005
6 Unit Profile:
Shree Cement Limited is an energy conscious & environment friendly business organization. It is the
largest cement plant in northern India at single location with present cement producing capacity of
2.841 MTPA and annual turnover of US$ 0.15 billion.
7 Description of Energy Conservation Measure:-
The cement mill was installed with Ball mill in open circuit in year 1997. The cement grinding circuit
was installed as single chamber open circuit with V-Separator The fines classified from V-Separator
are then introduced in the battery of four cyclones where solids are separated from air stream and then
fed to ball mill. In order to increase the output of Shree Cement Limited, it was thought about of close
circuiting the ball mill. Study was conducted jointly by KHD Humboldt Wedag and Shree Cement on the
feasibility of increasing the production and the performance of cement mill II which was running in open
circuit. The agency suggested modification of close circuiting the mill with SKS Separator in S-type circuit.
By this, the fines classified from V-Separator are fed to SKS separator where fines are separated and
rejects are fed to ball mill. This reduces the load on the ball mill and the mill discharge is recirculated to SKS
separator which results in improved production with satisfactory energy consumption. The output
increased more than the expected figure of 6% (16 TPH) as envisaged to above 7.5 % (20 TPH) over the
present output.

8 Picture Before Modification Picture After Modification

FLOW:-28840 m3/hr V-SEP.FAN

V-SEP.FAN
Operating Design
A
Draught:- 34 mnwg RPM
KW
900
680
990
1110
0
Temp.:- 110 C 285 TPH
Stack CLINKER ELEVATOR
OPERATING 350 amp CYCLONE CYCLONE
DESIGN 380 amp
Flow:-248690 m3/hr. ESP
Temp.:- 980C Vent fan. V-SEP.FAN
8 SKS
Draught:- 268mnwg
Gyp Clinker
CLINKER GYPSUM 1000 TPH RPM -400-600 Op.
RPM -900 Design

Hopper Hopper ESP 2 Op - 50-100 amp.

Design -752 amp.
10
T
200 TPH S SE 585 TPH R
K P SKS Feeding elevator A
S Operating amp :- 150-200 S N
1 Design :- 285 amp. K S
S
V-SEP.
Capacity :- 700 TPH P 285 TPH
F O
330 TPH 20 TPH
E R
3 E T
D
I E
Legend PRE BIN
N L
Circuit
Nos G E
samples Roller press 5
Op.:- 1600-1700 kw C V
Flow Alphabet E

CEMENT MILL 800 TPH Design :- 2*1000kw A

L T
ESPOUTLET
Gas ROLLER PRESS 9 E O
ROLLER PRESS 4.6 mtr. DA14L mtr. Material
V
A
R

T
4
CEMENT MILL O
Op.:- 3000-3100kw R
500 TPH 6
650 TPH
Design:- 2*2400kw

150 TPH FILLER FLY ASH

CEMENT MILL-1 20 TPH 8 7 65 TPH

22
9 Total investment: 1,312,500 US$
10 First year energy cost savings: 207,500 US$
11 First year additional savings beyond energy (i.e. water, raw materials etc.): Nil
12 Annual electricity consumption before, MWh —
13 Annual electricity consumption after, MWh —
14 First year electricity savings, MWh 10,661
15 First year tons of CO2 mitigated 10,661
16 Assumed sustainability, years 10
17 Expected tons of CO2 mitigated throughout life cycle 106,610

23
 1 ID: 21 Title of measure Sector: Cement Industry
2 Survey Year: 2006 Installation of VFD for new cooler Technology: Variable Frequency
vent fan Drive
3 Name of the Company : Ultratech Cement Limited, Andhra Pradesh, INDIA
4 Agency that executed the project : L & T Limited, Mumbai, INDIA
5 Year of Implementation : 2004-05
6 Unit Profile:
Ultratech Cement Limited, a Grasim subsidiary has an annual capacity of 17 million tons. It manufactures
and markets Ordinary Portland Cement, Portland Blast Furnace Slag Cement and Portland Pozzolana
Cement. Ultratech has five integrated plants, five grinding units and three terminals — two in India and one
in Sri Lanka. The Andhra Pradesh Cement Works has a capacity of 2.3 million TPA and annual turnover of
US$ 0.13 billion.
7 Description of Energy Conservation Measure:-
In the plant, the ESP fan speed could not be reduced due to fan operating at low speed in slip power
recovery system(SPRS) mode. The damper was partially closed. The installation of the HT VFD made it
possible to reduce the speed further and opening of the damper fully.
Before Modification
ESP Fan power consumption/hour in SPRS mode of operation : 200 kW
SPRS saving/hour : 40 kW
Net power consumption : 160 kW
After Modification
ESP fan power consumption /hour in VFD mode of operation : 120 kW
Net saving/hour : 40 kW

8 Picture After modification

Input T/F Slim Inverter Output T/F

HT Breaker Fan HT Motor

9 Total investment: 100,000 US$
10 First year energy cost savings: 30,975 US$
11 First year additional savings beyond energy (i.e. water, raw materials etc.): Nil
12 Annual electricity consumption before, MWh 1,267
13 Annual electricity consumption after, MWh 950
14 First year electricity savings, MWh 317
15 First year tons of CO2 mitigated 317
16 Assumed sustainability, years 10
17 Expected tons of CO2 mitigated throughout life cycle 3,170

24
1 ID: 22 Title of measure Sector: Cement Industry
2 Survey Year: 2006 Reduction in separator area of raw Technology: Raw mill
mill 1 & 2 for efficiency improvement
3 Name of the Company : Ultratech Cement Limited, Andhra Pradesh, INDIA
4 Agency that executed the project : In-house
5 Year of Implementation : 2004-05
6 Unit Profile:
Ultratech Cement Limited, a Grasim subsidiary has an annual capacity of 17 million tons. It manufactures
and markets Ordinary Portland Cement, Portland Blast Furnace Slag Cement and Portland Pozzolana
Cement. Ultratech has five integrated plants, five grinding units and three terminals — two in India and one
in Sri Lanka. The Andhra Pradesh Cement Works has a capacity of 2.3 million TPA and annual turnover of
US$ 0.13 billion.
7 Description of Energy Conservation Measure:-
The in house team of the unit took the initiative to increase the separator velocity from existing 8 to 12
mtrs/sec by reducing 38% of the area in RM-1. The area was reduced by fixing the Tiscral plate 8 mm thick
(covered area is appx.32 %).
The mill specific power consumption was reduced by 0.2 kW/MT (85 kWh) and production was increased.

8 Ultratech Plant Picture After Modification

9 Total investment: 30,000 US$

10 First year energy cost savings: 77,500 US$
11 First year additional savings beyond energy (i.e. water, raw materials etc.): Nil
12 Annual electricity consumption before, MWh —
13 Annual electricity consumption after, MWh —
14 First year electricity savings, MWh 792
15 First year tons of CO2 mitigated 792
16 Assumed sustainability, years 10
17 Expected tons of CO2 mitigated throughout life cycle 7,920

25
 1 ID: 23 Title of measure Sector: Cement Industry
2 Survey Year: 2006 Dry fly ash storage and handling Technology: Ash Handling
system System
3 Name of the Company : Dalmia Cement (Bharat) Ltd., Dalmiapuram, Tamilnadu, INDIA
4 Agency that executed the project : In-house
5 Year of Implementation : 2005
6 Unit Profile:
Dalmia Cement (Bharat) Ltd. is a diversified 50 years old company. Its products include Portland
Cement, Portland Pozzolana and Slag Cements, Oil Well Cement, Dead burned magnesite, Basic
Monolights, Magnesia-Carbon Bricks, Sugar, Iron Ore, Electronic components etc.. The Dalmia unit at
Tamilnadu has a capacity of 3.5 T of cement with US$ 98 million as turnover in the year 2005-06.
7 Description of Energy Conservation Measure:-
The unit's existing fly ash handling and feeding capacity was only 15% of the total fly ash .The
moisture in the wet fly ash was as high as 25%. This required 14 Mkcal/hr of heat for drying and also
resulted in reduction in mill output. As an energy conservation measure the unit used an existing old
raw meal silo of 1000 T used as storage with:
– Pneumatic conveying from silo to intermediate hopper.
– Controlled feed from hopper to mill feed chute.
– Increase in dry fly ash addition from 15 to 40% on total fly ash.
The unit conducted trials by installing a small bin arrangement to feed 10 Tons of dry fly ash per hour
to study the performance of the system with dry fly ash which was found to be successful and it was
decided to go for a dedicated system for utilizing dry fly ash for the production of PPC. This resulted in
electrical and thermal energy savings.

8 Picture After Modification

26
9 Total investment: 37,500 US$
10 First year energy cost savings: 410,000 US$
11 First year additional savings beyond energy (i.e. water, raw materials etc.): Nil
12 Annual electricity consumption before, MWh 100
13 Annual electricity consumption after, MWh 0
14 First year electricity savings, MWh 100
15 Annual coal consumption before tons 4,000
16 Annual coal consumption after tons 0
17 First Year coal savings, tons 4,000
18 First year tons of CO2 mitigated 5,780
19 Assumed sustainability, years 10
20 Expected tons of CO2 mitigated throughout life cycle 57,800

27
 1 ID: 24 Title of measure Sector: Cement Industry
2 Survey Year: 2006 Optimization of Vertical Roller Raw Mill Technology: Vertical Roller Mill
3 Name of the Company : Madras Cement Limited, Alathiyur Works, Tamilnadu, INDIA
4 Agency that executed the project : In-house
5 Year of Implementation : 2004-05
6 Unit Profile:
Madras Cement Ltd., a flagship company of RAMCO group has four cement manufacturing units of
total capacity 6 MTPA. The main product of the company is Portland Cement. The company also
produces Ready Mix Concrete and Dry Mortar products. In addition, the company also operates one
of the largest wind farms in the country. The annual turnover of the Alathiyur Works unit is
US$ 77 million.
7 Description of Energy Conservation Measure:-
The plant has a Vertical Roller Raw Mill with high efficiency separator supplied by M/s.Loesche, Germany.
Mill
Make : M/s. Loesche, Germany
Mill size : LM 38.3
Drive : 1750 kW
The unit's in house team made the following modification in the Raw mill :
1. Classifier blades were changed to curved from flat surface.
2. Configuration of static blades were modified.
Result :
Increase in Mill Output by 5 TPH and Power reduced by 0.75 kWh/T of Raw Meal

8 Picture Before Modification Picture After Modification

28
9 Total investment: 37,500 US$
10 First year energy cost savings: 1,13,500 US$
11 First year additional savings beyond energy (i.e. water, raw materials etc.): Nil
12 Annual electricity consumption before, MWh —
13 Annual electricity consumption after, MWh —
14 First year electricity savings, MWh 1,296
15 First year tons of CO2 mitigated 1,296
16 Assumed sustainability, years 10
17 Expected tons of CO2 mitigated throughout life cycle 12,960

29