Saurashtra Cement Limited

Pond Ash v/s Dry Fly Ash in PPC Comparison

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Saurashtra Cement Limited

Glossery
 Comparison of Wet Fly Ash and Dry Fly Ash in PPC Cement
 In Base i.e. Dry Fly Ash material cost is Rs. 1590/MT, where as Wet Fly
ash Cost Rs.943/MT.
 In Wet fly ash, there is less spending of Rs. 4.59 Lacs due to lower
consumption and cement cost.
 In Dry Fly ash , due to return cement load there is estimated saving of
Rs. 24.74 Lacs compared to Wet fly ash.
 In Using Wet fly ash there will be loss of Rs. 20.14 with various reasons
as per working including return load.

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Saurashtra Cement Limited

Assumption
 Considered freight for Wet fly ash from GEB, G’nagar at Rs.750/MT in
place of Rs.940/ for cement.
 Cement mill output in Wet fly ash (Ground from CM-4) will be 44 TPH,
in dry fly ash 120 TPH (Ground from CM-1).
 Total Specific power consumption in wet fly ash will increase to 48.64
Kwh/MT from 36.25 Kwh/MT in dry fly ash
 Additional man power cost Rs.4.5/MT considered in Wet fly ash
 In PPC production from wet fly ash considered is 21.5%, dry fly ash
26.5% with a view to maintaining quality.
 Due to higher Clinker consumption in Wet fly, there is loss of Rs. 48/MT
 PPC Cement cost with wet fly ash is cheaper by Rs.15/MT compared to
dry fly ash
 There will be saving of Rs.4.59 Lacs on production of 30 KT PPC with
wet fly ash.

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Saurashtra Cement Limited

Assumption
 To meet the fly ash requirement of 7.9 KT fly ash, 98% is having return
load.
 Difference of Empty bulker and return load is Rs.0.79 per Ton per Km.
 Lead distance for dry fly ash is assumed 400 Km.
 With return load, there is saving of Rs. 24.74 Lac per month.

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Saurashtra Cement Limited

Working on Usage
Particular Wet Fly ash Cost Unit Dry Fly ash Empty
Basic cost of flyash 15 Rs /T 249
Transport cost 750 Rs /T 1317
Unloading cost 3 Rs /T 0
Total Delivered Cost 768 Rs /T 1566
Moisture Content 15 % 2
Dry Cost of flyash 903 Rs /T 1590
Material Handling cost 40 Rs /T 0
Total Flyash Cost 943 Rs /T 1590

Cement Mill output 44.00 TPH 120.00

Specific power consumption 43.18 Kwh/T 30.42
Specific Auxallaries 5.45 Kwh/T 5.83
Total Specific Power Consumption 48.64 Kwh/T 36.25

Power Cost 4.50 Rs /Kwh 4.50

PPC grinding Power Cost 218.86 Rs /T 163.13
Manpower cost 4.50 Rs /T 0.00
Flyash Utlisation 21.50 % 26.50
Clinker Cost 1900.00 Rs/T 1900.00
Difference in flyash Utlisation ( Dry- wet) 5.00 % 0.00
Contribution Loss 47.83 Rs /T 0.00

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Saurashtra Cement Limited

Working of Logistic
Monthly cement Dispatch Tons 15000.00
Flyash receipt per month Tons 7950.00
Return load % % 0.98
Return load qty Tons 7791.00

Empty Bulker Freight Rs /t / Km 2.80

Return load freight Rs /t / Km 2.01
Saving Rs/ T /Km 0.79
Lead Distance KM 400
Saving Lakh Rs RS / Month 2474422
Saving on account of Return load Rs /T 317.60

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Saurashtra Cement Limited

Working of Saving/Loss

Total Delivered cost of PPC Cement

Parameter Wet Flyash Dry Flyash
Clinker 1406.00 Rs/T 1311.00
Gypsum 45.00 Rs/T 45.00
Flyash 202.83 Rs/T 421.22
Power 218.86 Rs/T 163.13
Manpower Cost 4.50 Rs/T 0.00
Contribtuion loss clinker 47.83 Rs/T 0.00
Total Cost Of PPC cement Flyash 1925.03 Rs/T 1940.35
Difference of Cost between ( wet- Dry ) -15.32 Rs/T

SUMMARY

Rs /T Qty Cost Rs
Difference of Cost wet V/S Dry -15.32 30000 -459579
Savings on logisitcs cost on account of return load of cement & flyash 2474422
Net Saving Rs 2014843

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Saurashtra Cement Limited