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Jamul Cement Works

“National Award for Excellence in Energy Management 2017”

2

ACC Limited 20.08.2017

Plant location and salient features

Few facts

▪ Distance from nearest airport, Raipur ~60Km by road.

▪Jamul Cement Works established in 1965 & Renovated in 2016

▪ Plant clinkering capacity of 2.8 MTPA

▪ Plant grinding capacity of 2.6 MTPA

▪ Power from own CPP of 25 MW

▪ Power demand from CSEB of 30 MVA

▪ Limestone supplied from mines, namely

➢ Jamul [3 km]

➢ Pathariya [24 km]

3


Process Flow diagram – Jamul PlantRaw material extraction & preparation

Raw meal preparation

ClinkerizationCement Grinding

Jamul Mines

Pathariya Mines

60%

40%

L/S pile- Mixed Grade

Capacity : 35,000t X 2

L/S pile- High grade

Capacity : 5,000t X 2

L/S – Double impactcrusher

Capacity : 1500 tph

Roller Press

Capacity : 350 tph X 2

Blending silo

Capacity : 16,500 Tons

Kiln

Dia: 5.6 m X 82 m

Capacity : 9,000 TPD

6 stage, 2 string PH

In line calciner

Clinker silo

Capacity : 75,000 Tons

Hot air to RP

Hot air to Coal Mill

Cement VRM

Capacity : 175 TPH

OPC

6000 T

Slag

5000 T

Storage silo

16 X 1000 T

3 X 3000 T

Cement EDM

Capacity : 6 X 30TPH

Coal VRM

Capacity : 90 TPH

4


Plant achievement highlights ....

First plant in ACC Limited to be accredited for ISO 50001 (Energy Management System) in 2012

Reduction of 10.2 unit (11.5%) in specific Electrical Energy from 2016.

Significant improvement in reduction of thermal energy consumption by 252 MJ/t clinker (7.5%) from 2015 - 16

First plant in ACC- ACL group to maximize (up to 69%) slag absorption in PSC cement

First plant in Chhattisgarh State to use renewable energy(Solar power) from third party

5


Strategy House – a base for sustainable development

Sustainable development

Pillars

Results

Goal

Base

Reduction in Carbon

FootprintSEEC Reduction STEC Reduction

People & Innovation

Project implementation

Utilization of renewable

energy & AFR

Best Practice's & Methodology

ACC Benchmar

king

Adopt to EnMS & Green

supply chain

6


Energy Conservation Team Structure

Abhay Singh

Tapabrata Mallik

Amit Mishra

Sanjay Sharma

Core

Team

Team Members Circle area

Energy

Circles

Raw Material extraction

Raw Material crushing

Raw Mills

Homogenizing plant

Kilns

Coal Mills

Coal Handling plant

Cement Grinding

EOT Cranes

Packaging

CPP Boiler

CPP Turbine

Auxiliaries

S K Sharma

Ganesh Rathore

Rahul Jha

Kumund Sinha

Teekam Chandrakar

B.Kaushik

Sanjay Tiwari

Swapan Roy

Rajendra singh

Anil Sharma

Rajesh Pathania

Tulendra choudhary

Chandan Upadhay

1

2

3

4

5

6

7

8

9

10

11

12

13

Champions

G.Kewat

P Patil

7


Summary : ENCON Efforts

Energy Conservation Projects‰No fund investment

▪ No of project implemented : 15

▪ Saving Kwh/T of Cement : 2.1

▪ Saving in INR, Crore : 1.5

‰Medium Investment

▪ No of project implemented : 13

▪ Saving Kwh/T of Cement : 3.4

▪ Saving in INR, Crore : 2.5

54%

46%

No. projects

No fund investment

Midium investment

37%63

%

Savings, INR Cr

No fund investment

Medium investment

8


Major project Implemented for Energy Conservation

Replacement of reciprocating compressors with screw compressor. (cement mill & packing house)

Installation of capacitor bank to improve power factor

Installation of MV/ VFD Drive

Increase the PRI of Mills & kilns by grinding media optimization, liner replacing and process optimization.

Reduction in idle running of the equipments by providing the interlocks in DCS.

9


“Fail Fewer...Fail Fast…Fail Often” – Setting up of Innovation lab to churn out ideas for overall performance improvement

Methodology adopted..

Develop concept / Reference gathering

Experimentation / Adopting best

practice

System modification

Monitoring & tracking of result

Developing the concept of setting up of lab after studying the deficiencies of war room / mind mapping tools

Adopting the modern practices followed by the most innovative companies like Facebook, Google, Apple etc.

Creating a place where people experiments innovations

In house changes in the concepts suiting to the local environment

Carrying of ideations and tracking the result

In house compiled Innovation book - Pragati

Projecting aids and creative ambience

Innovation books New concept of reverse brainstorming

10


Optimization of roller press process by following initiatives-e

1. Optimize gap between feed control gate and fixed roller 2. Optimize feed chute deflector gap3. Monitor & reduce feed size < 40 mm4. Optimize pressure drop through V – separator by removing

restrictions for fan power reduction5. Reject belt operation modification to avoid idle running6. Not to operate single RP7. Nuisance dust collector fan speed optimization 8. PID control optimization

Action taken:

………………………………..………… 1.5

………………………………………………………………………………………………………. 0.4

0.2

……………………………………….… 0.4

Kwh/ T material

Feed size optimization Feed gate & cheek plate gap optimization

V separator pressure optimization

Reduction in specific power for Raw meal grinding through innovation

Total Savings: 1.3 INR, Cr

11


1.Cement VRM modifications carried out in mill internals (Central feed chute, dam ring & water spray nozzle)

2.Cement mill PID installation & optimization for feed, temperature, air flow regulations

Month +R45 (%) SEEC – Cement grinding (kwh/T)

Slag absorption target % (NJP – PSC)

Jan’17 7.3 47.0 64

Feb’17 8.1 42.2 66

March’17 7.7 39.5 68

8.0

1.5

Kwh/ T Cement

Initiatives Taken

Air profile optimization Feed chute modification Support ring & water lancer modification

Dam ring modification

Initiatives Result

Reduction in SEEC in VRM through innovation

Total Savings: 8 INR, Cr

12


Clinkering: Reduction in STEC

1. Following strict discipline of minimum limestone pile quantity from ~ 15Kt to 30kt which resulted in less variation in LS quality

2. Strict control in limestone pile quality in every 15% level3. Maintaining optimum clinker composition- Raw mix optimization4. Burner optimization with microscopy5. Clinker cooler performance improvement by minimizing losses-

optimizing cooler air flow, horse shoe modification

Month STEC – Kcal/ Kg Clinker Remarks

January’17 708 ▪ Horse shoe modification

▪ Cooler fan flow optimization

February’17 707

March’17 705

Initiatives Taken

Initiatives Result

Microscopic evaluation Cooler horse shoe modification Cooler fan flow optimization

Total Savings: 0.42 INR, Cr

13


Energy reduction through Water conservation

▪ Reduction in Cooling Tower Blow Down by

increasing the COC

▪ Stopping overflow from the GCT water tank by

providing control loops through flow control

valves.

▪ Change of mind set of topping up the waste

water tank with raw water for emergency

▪ Arresting of water pipe line leakages through

out the plant – 389 points attended

▪ Flow control valves installed in all the overhead

tanks

▪ Unique initiative of reducing the capacity of

flush tanks

▪ Stickers pasted near the water taps to reduce

leakages etc.

▪Zero water discharge

Provers

We are water positive

1700

424

819

-27%

1859

1399

4958

Water Cons-Mar14

CPP Plant

120

Domestic

3596

Water Cons-Mar16

Pla

nt

Do

mes

tic

CP

P

27% reduction in water consumption

Aspiration

of <3000

M3/Day

14


ENCON PROJECTS IMPLEMENTED IN 2016-17

Sl. No. Title of Project Annual

Electrical

Saving

(kWh)

Annual

Electrical

Cost

Saving

(Rs

million)

Annual

Thermal

Saving

(Million

Kcal)

Annual

Thermal

Saving (Rs

million)

Total

Annual

Savings

(Rs

million)

Investme

nt Made

(Rs

million)

Payback

(Months)

1

Carry out the maintenance and reduced

the pressure drop across compressor inlet

filters

115000 0.54 0.54 0.00 0.0

2

Reduced leakage and interconnect coal

mill and cement mill compressor to avoid

unloading

9000 0.04 0.04 0.10 28.4

3

Reduced generation pressure and use

cement mill 7 & 8 fluxo compressor only

for conveying purpose

120000 0.56 0.56 0.10 2.1

4Minimised the compressed air leakages in

the plant158000 0.74 0.74 0.10 1.6

5

Installed servo control voltage

transformers for lighting and maintain

lighting voltage at 210 V

22000 0.10 0.10 0.18 20.9

15




Electrical

Saving

(kWh)

Annual

Electrical

Cost

Saving

(Rs

million)

Annual

Thermal

Saving

(Million

Kcal)

Annual

Thermal

Saving (Rs

million)

Total

Annual

Savings

(Rs

million)

Investme

nt Made

(Rs

million)

Payback

(Months)

6

Improved mills ventilation for cement mill

1 to 6 and avoid over grinding 150000 0.71 0.71 0.00 0.0

7

Increased specific surface area of second

chamber in all cement mills by using

smaller size grinding media

1350000 6.35 6.35 0.00 0.0

8

Changed the pulley size and reduce

pressure drop across ca fan inlet damper –

coal mill 5

35000 0.16 0.16 0.01 0.7

9Replaced V-belt with cogged flat belt in

identified equipment104000 0.49 0.49 0.10 2.5

10

Adoptated new energy efficient

technology to meet out the our future PAT

target.

1530000 7.19 69499.00 57.96 65.15 18000.00 120.0

16




Electrical

Saving

(kWh)

Annual

Electrical

Cost

Saving

(Rs

million)

Annual

Thermal

Saving

(Million

Kcal)

Annual

Thermal

Saving

(Rs

million)

Total

Annual

Savings

(Rs

million)

Investment

Made (Rs

million)

Payback

(Months)

1Regrading & grinding media optimization

in mills168,000 0.81 0.81 1.00 14.9

2

Optimization of compressor running /

Enhanced the efficiency of compressor /

Leakages of compressed air.

140,000 0.67 0.67 0.00 0.0

3 Reduction in Idle running of equipments . 140,000 0.67 0.67 0.00 0.0

5 Controlling fine coal residue and moisture 0.28 0.25 0.25 0.02 1.0

6 Reducing false air ingress in the system 0.14 0.12 0.12

7Improve burning in kiln by arresting

infiltration air in the system0.26 0.25 0.25

17


Sl.

No.

Title of Project Annual

Electrical

Saving

(kWh)

Annual

Electrical

Cost

Saving (Rs

million)

Annual

Thermal

Saving

(Million

Kcal)

Annual

Thermal

Saving

(Rs

million)

Total

Annual

Savings

(Rs million)

Investment

Made (Rs

million)

Payback

(Months)

1 Better stalking of raw coal in monsoon and 14893 0.07 0.28 0.20 0.27 0

2Reducing the residue fine coal (kiln) from

22% to 18% 21276 0.10 0.32 0.30 0.4 0

3Addition of iron ore/Flue dust for improving

burnability of raw meal21276 0.10 0.32 0.30 0.4 0

4Installation of energy saver panel for colony

lighting63829 0.30 0.00 0.3 12 40.00

5Replacement of raw water pump with high

efficiency pump of mines.46808 0.22 0.00 0.22 3 13.64

6Shifting the load of TR6 to 1500 KVA TR No.

5 and switched off the TR No. 6.23400 0.11 0.00 0.11 0

7

K3 Cooler hot air slide zone fan

replacement for improving recuperation

efficiency.

0.98 0.93 8 8.60

8RM 1&3 Dust collector fans dampers to be

removed and run in PID loop.48960 0.23 0.00 0.23 0

9CM-7 DC fan damper to be removed as the

fan is running in vvf mode24480 0.12 0.00 0.12 0


18


Where we are………. overall Kwh/Ton of Cement

11%

▪ Challenging our best achieved and revising the targets

▪ Stoppage of Lepol grate, wet process Kilns.

▪ Total reduction in comparison to 2013 – 14 by 11%

Increased clinker factor

2013 2016

88.6 79.1

Impact(INR, Cr)

6.5

19


STEC – Kcal/Kg of Clinker

824.3 822.7 823.2

763.4

720.0

740.0

760.0

780.0

800.0

820.0

840.0

2013-14 2014-15 2015-16 2016-17

Kcal/

Kg

Clin

ker

Year

▪ Wet process kiln K1 and K2 stopped in 2016-17

7.5%

2016

824 763

Impact(INR, Cr)

6.7

2013

20


Energy reduction trend

90.9 90.6 89.072.8 72.0

48.6 48.4 49.8

49.1 48.3

43.7 44.4 46.6

39.8 36.8

50.0

70.0

90.0

110.0

130.0

150.0

170.0

190.0

210.0

2013-14 2014-15 2015-16 2016-17 Present YTD

Year

%Clinker factor Grinding power Kwh/T Cem Clinkering power, Kwh/T Clk

▪ %R 45 reduced from ~24% to ~22% in Ball mills in 2015-16 onwards

▪ With increase in slag % from 50 to 56 in 2016-17 further reduction in %R45 to ~18%

21


Achievement in PAT Target

936.0

890.0

802.0

754.0

631.0

600.0

650.0

700.0

750.0

800.0

850.0

900.0

950.0

1000.0

Baseline Target for PAT- I Achieved in PAT-I Target for PAT- II Achieved up to 16-17

Kcal/

Kg

Cem

en

t

9.8%

16%

1. BEE has issued 11295 REC of Rs.11.29 Crore to Jamul Cement Works for achieved the PAT cycle-I target.

2. Reduction of 9.88 & 16.31 % from target of PAT Cycle – 1 &2 respectively.

22


FUTURE ACTION PLAN FOR ENCON


Electrical

Saving

(kWh)

Annual

Electrical

Cost

Saving

(Rs

million)

Annual

Thermal

Saving

(Million

Kcal)

Annual

Thermal

Saving

(Rs

million)

Total

Annual

Savings

(Rs

million)

Investme

nt Made

(Rs

million)

Payback

(Months)

1 Upgradation of Slag Dryer Bag filter 90000 0.41 0.41 0.6 17.78

2Upgradation of Colony Power distribution system

from 3.3kv to 11 kv30000 0.14 0.14 0.54 48.00

3 Upgradation of Cement Mill main drive LRS 120000 0.54 0.54 0.45 10.00

4 Automation of Slag Dryer & Coal Mill 180000 0.81 0.81 0.4 5.93

5 Reject Handling System:Cement Mill 90000 0.41 0.41 0.2 5.93

6 Elevator Drive station for close circuit 30000 0.14 0.14 0.07 6.22

7 Repl of Girth Gear and Pinion for CM 1 30000 0.14 0.14 0.32 28.44

8Optimize operational efficiencies in RP & kiln and

cement grinding section 1500000067.50 67.50

9Improve plant power factor at import end from 0.92

to 0.97550000 2.48 2.48 5.00 24.24

10Thermal energy reduction by optimization of raw mix

0.00 16,000 13.60 13.60

23


Benchmarking within group

88

79

80

85

76

79

98

110

135

83

132

0.0 50.0 100.0 150.0

Plant 1

Plant 2

Plant 3

Plant 4

Plant 5

Jamul

Plant 6

Plant 7

Plant 8

Plant 9

Plant 10

Kwh/ Ton Cement

726

724

783

737

733

677

763

802

786

818

710

1,014

500.0 700.0 900.0 1100.0

Plant 1

Plant 2

Plant 3

Plant 4

Plant 5

Plant 6

Jamul

Plant 7

Plant 8

Plant 9

Plant 10

Plant 11

KCal/ Kg clinker

Aspirating to become best in the Company by 2017- 18 in SEEC (68 KWh/ Ton cement) &

STEC (675 Kcal/ Kg clinker)

SEEC STEC

24


Best practices…followed

Phase I Phase II Phase III Phase IV

Roller press

Kiln

▪ Installation of flow control gates for proper feeding to RP

▪ Roller speed optimization

▪ Separate air receiver for pneumatic shutoff gates.

Crusher

▪ Modification of pre bin overflow to maintain choke feed

▪ PID optimization for RP feed control

▪ Installation of DALOG

▪ Auto control of weigh feeders to maintain accurate raw mix- RAMOS software

▪ Fan speed optimization

▪ Velocity optimization for all nuisance dust collectors

▪ Optimization of raw meal residue based on Burnability study

▪ Extra blaster installation to avoid jamming

▪ Modification in kiln burner for better life-emergency cooling system, refractory

▪ Raw mix evaluation for 100% pet coke utilization

▪ Pet coke residue optimization

▪ Pre heater Cyclone flap counterweight adjustment for proper flapping.

▪ Auto operation of kiln shell cooling fans as per temperature

▪ Relocation of kiln I/L analyzer for increased reliability.

▪ Burner flame optimization

▪ Cooler horseshoe modification

▪ Fuel split ratio optimization

▪ Crusher dust transportation system in progress

▪ Installation of air blasters to avoid jamming

25


Cement VRM

Coal VRM

▪ Dam ring height adjustment considering pet coke clinker

▪ Installation of air blasters at mill inlet chute

▪ Installation of vibrators along with level sensors in slag chutes with frequent jamming

▪ Extra permanent magnet installed at reclaimer belt to eliminate metal before feed hoppers.

▪ Modification of mill central chute for better distribution of feed on table.

▪ Dam ring height optimized with support ring

▪ Separator dynamic seal gap reduced to “Zero” with felt packing.

▪ PID to regulate temperature & pressure by speed optimization

▪ PID installed with mill DP and fresh feed.

▪ Anti stick liner installation at feed chute

▪ Dam ring height increased to 150 mm from 90 mm for petcoke

▪ Separate Water spray nozzle installed on table for bed formation for pet coke

▪ Online mill fan “PROMEOCON” flow meter calibrated for better mill control.

Phase I Phase II Phase III Phase IV


26



▪ Regular testing of transformers (HT and LT) from certified vendors for condition monitoring

▪ Measuring of the contact resistance of all circuit breakers with Micro Ohm meter

▪ EMD test for critical HT motors by third Party.

▪ Harmonics study for all critical transformers from certified vendors

▪ Thermography of all critical E&I equipment with its analysis and planned corrective actions

System/ Technical

Behaviour

▪ PMO office for better monitoring and tracking

▪ Electronic Display (LED) board provided at prominent locations

▪ Dashboard corner for better awareness and update

▪ Unique initiative taken by Jamul as Energy officer tour (EOT ) done by assigned officers / Sr. NMS staff as per roaster. Attractive scheme of credit points and gifts

27


Substitution of Conventional Energy with Renewable Energy

Type of RES Installed

Capacity

Energy Generated

(MWh)

Annual Savings

(INR, Crores)

Solar photovoltaic– PPA 1.75 MW 3000 1.15

Building

Integrated

Photovoltaic

(BIPV)

7.5 KW 11.250 0.02

28


Sr. No Type of Waste Fuel usedQuantity of waste fuel used

(Tons)

2016-17

Waste fuel as % of total fuel

1 Bio Mass 27.6

16.79%

2 HUL 16.933 Spent Carbon 74.84 Saw Dust 12605 Mattel Toys 17.736 Acid Tar 42.257 CIL WASTE 2.248 ETP BIO MASS 119 Niva 1.94

10 Trade reject 5.411 Dolachar 19134

12 Coal fines, Washery rejects, Charcoal

24830

Utilization of Waste as Alternate Fuel

5.8 4.8

01

2.5 4

0

5

10

2015 2016 2017 2018 2019 2020

TSR future plan

Details of AFR used in 2016-17

No AFR in 2017 considered for new plant stabilization period & AFR feeding preparation

29


Team Work in Encon…

Ideations Energy circle formation Idea Implementation

▪ 2 ideation sessions wereconducted on “Electrical energy”involving 48 NMS and MS staff

▪ >80 ideas were generated

▪ Total 18 energy circles formedcovering 78 persons

▪ Working in small groups inrespective circles

▪ Total 10 ideas implemented

▪ 7 units reduction frombaseline

Monitoring & Tracking Training & Coaching

▪ TIS implemented

▪ KPI’s monitored through TIS & PDboards in every dept

▪ Awareness sessions conducted. People were made conscious about the energy

▪ Driven by people power

Step – 1.

Implementation

Step – 2

Sustainability

Reviews

▪ Weekly review started fromMay – 2016

▪ Total 10 reviews conducted

▪ Daily feedback to departments

Rewards EOT

▪Recognition for good work

▪ Celebrating quick wins

▪ Daily One Energy Officer

▪ Energy Observation tour of 4 hrs

▪ Sharing of observations in MIS meeting

Date Name of Energy Officer

02-Feb-16 D.Jena

03-Feb-16 Salim Sabry

04-Feb-16 V.K. Chhibber

05-Feb-16 Chandan Upadhayay

06-Feb-16 G.K. Agarwal

07-Feb-16 Aditya kumar (Elect)

08-Feb-16 D.datta

09-Feb-16 Pushkar Chandrakar

30


ISO 50001:2011 Certification…

Step – 3

Accreditation

In continue with our journey for energy efficiency improvement JamulCement Works is the first plant in ACC to accredited with ISO 50001:2011(Energy Management System) which helps us to achieve our aspiration withcomprehensive and structured approach.

31


Project Implemented For Environmental Improvement

Sr. No. Project TitleInvestment

in LakhsImplemented in

1 Renovation of four chamber Slag Dryer Bag filter 59.2 2015

2

Installation of Wet fog system at different transfer and

loading points, Water sprinkling system, Bobcat, Two no. of

hand driven sweeping machine 321.8 2016

3 Self Propelled Road Sweeping Machine 40 2016

4 Up gradation of Environment Lab 27.97 2016

5 Three stage Sewage Treatment Plant 113.89 2014

6 Continuous Ambient Air Quality Monitoring Station 26 2016

7 Dust Emission monitoring system for Stacks 8.74 2016

8Up gradation of Bag filters of Cement Mill , Raw Mill, Coal

Mill Etc. 93.43 2014

9 Stack and Ambient Air Monitoring system 8.76 2016

32


Sr. No. Project TitleInvestment

in LakhsImplemented in

10More than 30% Water Reduction under the special drive

5 2015

11

Every employ has been provided with “Carbometer Card” to

have in his pocket every time which will remind him about

his carbon footprint all the time. 2014

12 Bio Gas plant has been installed 3 2014

13Solar Cooker was distributed in the colony for the

promotion of Save Fuel 3.5 2014

14 7 KWh of Solar Power system was installed 8 2014

15ECO LAB was established and inaugurated for the training

and promotion of sustainable development 7 2014

16 Installation of new ID fan in Secondary Crusher Bag filter

has increased the dust collection capacity 8.5 2015

17 Promote the Solid waste management initiatives. 0 2015

Project Implemented For Environmental Improvement

33


ECO Lab has been developed to provide training regarding sustainable development

Glimpses of ECO LAB

34


We care…for our environment

Dust emission from Raw mill/VRM stack -15mg/Nm3

Dust emission from kiln ESP stack - 18 to 20 mg/Nm3

Water fogging at crusher LS dump hopper

Water spraying at LS stacker belt

Timer based water sprinkling system at weigh bridge area

Road swiping machine

Continues Ambient air Monitoring System (CAAQMS) for PM10, PM2.5, SO2 & NOX

Continuous Emission Monitoring System (CEMS) Installed at Kiln

35


Tracking of KPI’s- Single tool with multiple information

1. Daily tracking of all major KPI’s with TIS2. Monitoring of sectional power with individual equipment consumption

Review of daily performance

Analysis of problems

36


CO2 Emission Reduction Trend

1101 1096 1094

994

900

950

1000

1050

1100

1150

2013-14 2014-15 2015-16 2016-17

Kg CO2/ ton clinker

9%

Reduction in CO2 generation by 9% from last FY

37


CO2 Emission Reduction Trend- scope wise

1100 10951064

946

850

900

950

1000

1050

1100

1150

2013-14 2014-15 2015-16 2016-17

Co2 emissions for manufacturing of cement

Kg CO2/ Ton Clk

0.44 0.45

30.02

47.53

0

5

10

15

20

25

30

35

40

45

50

2013-14 2014-15 2015-16 2016-17

Co2 emissions from purchased Electricity

Kg CO2/ Ton Clk

0.3

0.4

0.3

0.1

0.0

0.1

0.1

0.2

0.2

0.3

0.3

0.4

0.4

2013-14 2014-15 2015-16 2016-17

Co2 emissions through diesel for Internal Transport & Vehicle

Kg CO2/ Ton Clk

38


Best Practices Implemented on Energy Front Amongst associates

S.No Name of associate /

vendor

Name of service provided to

vendor

% improvement Type of inputs / projects provided to the vendor/ associate

1 M/s EEL IndiaLimited

Encon 8.10% The acrylic sheets have been provided around thecement packers to eliminate the dust emission andincrease the suction intensity of the fan. Henceforthreducing the power consumption by 8-10%. Thisphilosophy was replicated by the supplier andimplemented in new packers supplying theircustomer as an energy efficient system

2 M/s RaviShrinarayan,M/s PrakashEnterprises,M/s Naneshtransport

Encon 10% Earlier our suppliers were using old trucks capacityof 15 ton to supply the raw material (i.e. Cement,coal, slag & lime stone etc.) which were not fuel andcost efficient and were requiring moremaintenance. Now as per our suggestion they havereplaced the old trucks with 25 tons capacity truckswhich are more efficient and cost effective.Therefore leading to reduction in dieselconsumption by 0.1 Ltr/Ton of material, henceforthconserving the natural resources.

39


Some acknowledge of our efforts

Green manufacturing excellence award in leader category - Frost & Sullivan

Indian manufacturing excellence award - Economics times.

Gold Award by Energy activation across regional networks (EARN) for best ideas & best pillars – Holcim

Excellent Energy Efficient Unit” Award in 2012-13 – CII

Three National awards (For Electrical,Thermal & Overall reduction in PSC cement manufacturing) – NCCBM

Two Nos State level awards for “Energy Conservation and Innovation in Energy conservation” – CREDA

“ Energy Efficient Unit” Award in 2013-14 – CII

40


For you an Idea could be a scrap but remember for me your one idea can make a difference

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