22-09-2019

PLANT PERFORMANCE ON ENERGY CONSUMPTION Presented on 20th National Award for Excellence in Energy Management 2019

RCCPL PVT LTD (MP BIRLA GROUP) 10,000 TPD PLANT , MAIHAR (M.P.)

AN INTRODUCTION : MP BIRLA GROUP OF COMPANIES. (1/2)

Birla Corporation Limited is the flagship Company of the M.P. Birla Group. Incorporated as Birla Jute Manufacturing Company Limited in 1919, it was Late Mr. Madhav Prasad Birla who gave shape to it. As Chairman of the Company, he transformed it from a manufacturer of jute goods to a leading multi-product corporation with widespread activities. Under the leadership of Mr. Rajendra S. Lodha, the Company posted its best ever results in the years ended 31.3.2006, 31.3.2007 and 31.3.2008. The Company continued to record impressive growth in 2008-09 and 2009-10. Mr Harsh V Lodha is now Chairman of the Company. The Company had a turnover of Rs 6,548.73 crores in 2018-19 and a net profit of Rs 255.70 crores. The Company is primarily engaged in the manufacturing of cement as its core business activity. The Company has acquired 100% shares of Reliance Cement Company Private Limited (Reliance Cement). This acquisition provides Birla Corporation Limited with the ownership of high- quality assets, taking its total capacity from 10 MTPA to 15.5 MTPA. M.P. Birla corporation – Cement Division has major units in mainly Central and Northern Region of India. S.No. UNIT CAPACITY 1 RCCPL Pvt LTD – Maihar, IU 3.3 MTPA Cement 2 Satna Cement Works, IU 2.2 MTPA Cement 3 Chanderia Cement Works, IU 4.00 MTPA, Cement 4 RCCPL Pvt LTD, Butibori, GU 0.58 MTPA, Cement 5 RCCPL Pvt LTD, Kundanganj, GU 3.2 MTPA Cement 6 Birla Corporation, Raebareli, GU 1.3 MTPA Cement 7 Birla Corporation, Durgapur, GU 2.30 MTPA Cement

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AN INTRODUCTION : RCCPL PVT LTD–10000 TPD CLINKER & 3.3 MTPA CEMENT PRODUCER (2/2)

SN Section Make/Supplier RCCPL PVT LTD is an entity of MP Birla Group, having per day installed production capacity of 10,000 TPD Clinker and 3.3 MTPA Cement. Plant was green field project 1 Crusher Double Roll, Impact Crusher, 1800 TPH, with 2000 TPH OLBC of 07 KMS commissioned on 26.01.2013. The plant is one of the largest 2 Raw Mill Roll Press (2 Nos) – 375 TPH, 400 TPH. POLYCOM – 2/12 8C Clinker Manufacturing Unit having all automatic controlled 3 Pyro 10,000 TPD Kiln with DOPOL 90 twin string, 6 stage, POLYTRACK operation with clinker capacity of 3.3 million tonnes per 13/4.0 – 2.5 Cooler & POLYFLAME VN Burner. annum. To monitor and control the quality of its product it has fully automated robotic lab including online particle size 4 Coal Mill FLSmidth make, ATOX 32.5, 90 TPH. analyzer. Maihar Unit has received prestigious "Greentech 5 Cement LOESCHE- LM56.3+3 Mill with 245 TPH PPC. Gold Award" for "HR Best Strategy” from Greentech Mill Foundation and “International Safety Award” from British Safety Council for demonstrating strong commitment to 6 Packing FLSmidth V – ROTOPACKER 210 tph X 4 Nos good health and safety.

AN OVERVIEW : OVERALL ENERGY CONSUMPTION 2018-19 (in TOE)

Overall Energy consumption (252226 TOE) 22800 265.18 Million KWH

THERMAL ENERGY ELECTRICAL ENERGY 229426

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AN OVERVIEW : SPECIFIC POWER CONSUMPTION - YEAR WISE

56.63 KWH/MT Cement KWH/MT Clinker KWH/MT Cement 55.03 74.73 53.50

51.50 33.13 68.97 30.15 29.36 66.63 66.3

16-17 17-18 18-19 bench mark 16-17 17-18 18-19 Bench mark 16-17 17-18 18-19

Clinkerization Overall Power Consumption Post Clinkerization

KWH/MT Clinker KWH/MT Raw Meal KWH/MT Cement KWH/MT Cement

29.79 2.14 13.7 25.24 13.37 1.88 24.13 27.28 12.89 23.69 26.76 1.63

16-17 17-18 18-19 16-17 17-18 18-19 16-17 17-18 18-19 16-17 17-18 18-19

Raw Meal Grinding Clinker Producing Cement Producing Cement Packing

IMPROVEMENT PROJECTS -2016-17 (1/3)

SN PRODUCTIVITY IMPROVEMENT INVESTME SAVINGS PAYBACK NT MONTHS

1 Limestone Grate basket modification to improve size of Limestone product in order Rs. 8 Lacs 0.2 KWH/MT LS 6.5 to increase input size for ROLLER PRESS in raw grinding output rate increase and consecutively reduction in Sp. Power of Raw grinding as well as LS crusher both.

Before Modification After Modification Curve radius of long belt conveyor

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IMPROVEMENT PROJECTS -2016-17 (2/3)

SN PRODUCTIVITY IMPROVEMENT INVESTME SAVINGS PAYBACK NT MONTHS

2 Replacement of Screw compressor of 8.5 bar with 4.5 bar flow discharge rating - Rs. 16 Lacs 0.15 KWH/MT CLK 4 1000 cfm remaining same for application requiring not more than 4 bar pressure.

3 Gravity take up of 291BC4 limestone conveying long belt conveyor is modified lead to Rs. 10 Lacs 0.12 KWH/MT LS 14 reduction in drawn power & Curve radius of 291bc4 and belt conveyors of Limestone belts were changed reducing friction occurrence and power drawn.

Curve radius of long belt conveyor

IMPROVEMENT PROJECTS -2016-17 (3/3)

SN PRODUCTIVITY IMPROVEMENT INVESTMENT SAVINGS PAYBACK MONTHS

4 Removal of All RPM controlling fan inlet dampers leads to saving of Pressure drop of Rs. 0.00 0.2 KWH/MT CM 10 mm WG to 12 mm WG.

5 Modification of Raw mill classifier guide vanes reduced pressure drop by 28 mmWG Rs. Zero 0.35 KWH/MT modified. RM 6 Substitution of Reversible belt with pneumatic diverter removing one drive from Rs. 6 Lacs 0.2 KWH/Mt RM 2.5 system. 02 Nos of such belts were removed.

7 Program Logics for various sections related frequent stoppages, while plant Rs. 0.00 0.5 KWH/MT CM production. Few of Program Logics : SN Program Logic 1 In case of VRMs, If any drive apart from air circuit trips, instead of tripping Mill, generate command to raise roller, this helped in avoiding 20 mins stoppage. 2 Running of Coal and Additive conveying belt w.r.t its feed belt current and stop circuit if running on No load after material empty out from complete circuit 3 Running Coal Mill in KW mode and Cement Mill in DP Mode.

4 Running reject belt conveyor as per feeding elevator load, to avoid tripping by over current.

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IMPROVEMENT PROJECTS -2017-18 (1/2) SN PRODUCTIVITY IMPROVEMENT INVESTMENT SAVINGS PAYBACK MONTHS

1 Situation : a) Manually it was difficult to fill all four Limestone hoppers, as stopping belt Rs. Zero 0.3 KWH/Mt conveyors and emptying out complete circuit was necessary to avoid motor stall. LS b) Complete capacity of 1000 TPH was not utilized. Action : A new Program logic was introduced in system, to run Complete Limestone reclaimer feeding circuit with 5 belt conveyor system. Feeding hopper as per weight and change automatically as per set point & priority. Initial feeding system is made to run with an empty patch, to avoid jamming of belt while change over, with reference to no load belt current and weigher. Benefit : 1) Motors start – starts were 50 to 60 times a day – eliminated. 2) Complete capacity of 1,000 tph was utilized. 3) Uninterrupted material flow. 4) Improved mill output by 5 TPH. 2 Modification of Armour ring angle from 25 deg to 10 deg of Loesche Mill for Cement Grinding, Rs. 0.5 Lacs 0.2 KWH/MT 5 there by reducing Pressure drop by 50mmWG CM

Online hopper change over logic Armour ring angle changed to 10 deg

IMPROVEMENT PROJECTS -2017-18 (2/2) SN PRODUCTIVITY IMPROVEMENT INVESTMENT SAVINGS PAYBACK MONTHS

3 Unloading of Fly ash bulkers directly to Cement Mill Double bin feeding hopper, 126 Lacs 1020 MWH. 21 avoiding operation of Dense Phase system when only one mill is running.

4 Added program Logics in DCS for various sections to avoid idle running of Material Zero 0.1 KWH/MT CLK feeding sections, Raw Mill, Coal Mill and Cement Mill sections when Production is not ON. 5 Addition of 2X2448 KVAR MV capacitor banks for power factor improvement Rs. 22 Lacs 261 MWH/ Year 24

SN Program Logic 1 Stopping of Raw Material conveying belts w.r.t running on no load current for span of 5 mins.

2 If Roll Press is not in operation than, Reduce circulating fan to min. RPM and stop mill and separator after 120 Secs. 3 Stopping additive, Coal & LS crushers with there succeeding and preceding belts are not running more than 5 mins. 4 Stopping of LS hopper feeding system is all Belts are running.

5 To Start and Stop Bag house dust bin reject circuit as per bin weight.

6 To stop Fly ash unloading & Dense phase compressors if running on unload condition more Unloading of Fly ash bulkers directly to Cement Mill than 5 mins Double bin feeding hopper

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IMPROVEMENT PROJECTS -2018-19 (1/3) SN PRODUCTIVITY IMPROVEMENT INVESTMENT SAVINGS PAYBACK MONTHS

1 Improving input power, escalating motor power from 1250 KW to 1500 KW as well as Rs. 120 Lacs 0.25 6 modification in Gear box, in order to apply additional pressure over material for grinding and KWH/MT RM reduce recirculation. 2 Inserted vertical and horizontal guide baffles in line of inlet duct of V- separator, improving Zero 0.1 KWH/Mt chamber air velocity. RM 3 Improved Coal Mill performance through optimization in pet coke, Rs. 0.2 Lacs 1.5 KWH/MT 3 a) Increasing Mill inlet chute by 200 mm from 50 mm. b) Modified complete water spray Mat nozzle over bed along with 10 deg angle for better water distribution over bed only. C) An additional seal ring in classifier added to avoid bypassing. D) Increased classifier Tailing chute 850mm downward toward table to avoid bypassing from return chute. 4 Introduction of VFD in Coal Firing PD Blower, optimizing air flow rate w.r.t quantity of coal Rs. 9.0 Lacs. 0.2 KWH/MT 7 dosing CLK

Improving input power, escalating Raw mill Additional Seal Ring Coal Mill Inlet Chute motor power from 1250 KW to 1500 KW in coal Mill Classifier Modified

IMPROVEMENT PROJECTS -2018-19 (2/3) SN PRODUCTIVITY IMPROVEMENT INVESTMENT SAVINGS PAYBACK MONTHS

5 Modified Width of Support ring of LOESCHE VRM for Cement Grinding. 20mm Block Rs. 0.75 Lacs 1.5 KWH/Mt CM 3 was initially welded over table maintaining gap between roller and Ring, however with due course of grinding, roller got worn out and gap increased to 33 mm. An additional block was added, and achieved 15000 Grinding of Mill, instead of 7500 Grinding hours as recommended by OEM for replacement. This was one of remarkable achievement in Industry. 6 Replacement of HPSV fixtures /fluorescent TL to LED fixtures Rs. 140 Lacs 1160MWH/ Year 21 7 Utilization of day light in Stores replacing artificial lights through light difractor Rs. 2.12 Lacs 0.0046 KWH/Mt 30 NOORICOOL CLK

Addition of Square block with existing Replacement of HPSV fixtures /fluorescent TL to Utilization of day light in Stores by light difractor NOORICOOL support ring. LED fixtures

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IMPROVEMENT PROJECTS -2018-19 (3/3)

SN PRODUCTIVITY IMPROVEMENT INVESTMENT SAVINGS PAYBACK MONTHS

8 Introduction of Demand Side Controller in line of compressed air delivery for Cement Rs. 26 Lacs 360 KWH/Day 12 Grinding and Pyro Processing system. 9 Reduce False air ingression from M-rollers of LOESCHE VRMs through sealing Zero 0.26 KWH/MT boundaries, by inner layer of scrap belt conveyor CM 10 Removal of alternate scoop plates of cement mill classifier to reduce pressure drop Zero 42KW/hr 55mmWG

Remedy for reduction in False air ingression Removal of alternate scoop plates of CVRM classifier helped in limiting pressure drop of 50mm WG. from M-rollers of LOESCHE VRMs

AN OVERVIEW : SPECIFIC HEAT CONSUMPTION – YEAR WISE

702 Kcal/Kg Clinker Improvement of Sp. Heat is by 4.5% within three consecutive year.

684 1. Increase in Kiln output rate by 13 %. 2. Increased plant MTBF by 65%. 676 671 In order to improve, sustainability of plant and productivity of plant, A set of programs & activities were performed in all aspects i.e introduction of new machines, modification of existing design, improvising conditions that led to energy loss, Optimizing plant equipment, 16-17 17-18 18-19 Benchmark Trend of Sp. Heat consumption. Avg. TPD clinker 10227 MTBF 243.14 TECHNIQUE ADOPTED FOR INITIATING IMPROVEMENT. 9635 124.71 Final conclusion through figures & conclusion. 8928 84.48 Distribution of project to team & Review by Management.

Formation of Quality Circle team, allocating UMANG 16-17 17-18 18-19 16-17 17-18 18-19 Projects to Multifunctional team Rate of Increase in Kiln Production Rate MTBF Presenting context to complete plant team with facts & Figures

Data Preparation and extracting areas of improvement

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IMPROVEMENT PROJECT – THERMAL CONSUMPTION (1/2) SN PRODUCTIVITY IMPROVEMENT SAVINGS 1 Improved Raw meal fineness from 5% to 3.8% on 212 mic. 3.5 Kcal/kg clk 2 Reduced False air from 9.5% to 6.5 % across Pre heater, by Reducing Cold air ingress from TAD expansion joints, through their 3 kcal/kg clk replacement. 3 Improved Fuel Combustion : 6 kcal/kg clk a) Pet coke addition to 55% along with Indian coal b) Optimize burner flame momentum from 1850 %m/sec to 2250 %m/sec through increasing Primary air pressure from 150mbar to 185 mbar & adjusting swirl nozzle to 17 Deg & - Divergent – Zero c) Kiln feed LSF reduced from 105 to 98. 4 Improved Fluctuations in Kiln feed bin 4 Kcal/Kg clk Reason – a) Variation in Quality B) Breakdown of feeding elevator due to surges. C) Fluctuation in Kiln feed – unstable Kiln operation. Actions – a) Changes in Program done : i) Operation timing of material dosing valve optimized, ii) Opening, closing timing and changeover program per cycle for pad aeration valves. b) Design of dosing valve from U shape to V shaped changed, controlling Material flow rate & avoiding surges. c) Additional air utilized from existing blower for different application, but being utilized for much lesser duration, hence no investment. d) Additionally added Heaters in line of aeration air for smooth flow and avoid lumps formation.

Changed Dosing Valve with V shaped profile than U shape in original Additional air added from existing blower Additional Heater added.

IMPROVEMENT PROJECT – THERMAL CONSUMPTION (1/2)

S.N. PRODUCTIVITY IMPROVEMENT SAVINGS

5 Introduction of VFD in PC Firing blower and optimization of conveying flow rate. Blower was designed for coal of 4250Kcal, 4 Kcal/kg clk Air/ Mat ratio = 296 M3/MT, however with pet coke NCV being increased, increased ratio to 410 M3/MT. Thus in order to limit False air addition through dosing air, as well as additional pumping heat, VFD is installed, which reduced sp. Power as well as sp. Heat consumption. 6 Operating Kiln through Online Free Lime analyzer. 1.5 kcal/kg clk 7 Improved Cooling air, through, 1.3 kcal/kg clk a) Removal of Flow regulators in cooler static grate, improving heat Quantum in secondary air, by improvement of Discharge air flow.

Free Lime Analyzer Flow Regulator of Cooler

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IMPROVEMENT PROJECT – THERMAL CONSUMPTION (2/2)

S. MTBF IMPROVEMENT BENEFIT N 1 In-house development of TAD damper which use to break down and stuck up in clinker closer. TAD Damper being assembled in 7 Kcal/Kg clinker two part, in due coarse of operation, bolts use to get shear and damper gets broken and stuck up in crusher. 2 Improved Cooling air, through, modification of aeration elements other than OEM design, for better aeration and lesser pressure drop across track and eliminated fine clinker fall through in air chamber. 3 Pre heater Feeding elevators, Pulley Lagging replacement with ceramic lagging, eliminating Kiln stoppage under Off Track.

4 Fine coal shortage due to Coal mill breakdown – Replacement Roller liner, Dam Ring & Pull Rod.

In-house development of TAD damper, led to elimination of Modified Cooler Aeration elements, Increased nozzle velocity on seal of conveying Kiln stoppage due to breaking from between. element & aeration pads by increasing air flow & marginal increase in under grate pressure in all 12 chamber.

IMPROVEMENT PROJECT – THERMAL CONSUMPTION (2/2)

S.N MTBF IMPROVEMENT 5 291BC3 Belt break/damage with Liner plate from crusher stuck – Installed metal detector, installation of grizzly in crusher discharge and feed chute, Installation of Belt rupture switch. 6 Kiln gear box internal damaged due to reverse run with excessive kiln loading. Problem : The existing centrifugal brake did not had much power to hold the kiln on excessive load, when kiln use to run in auxiliary and stops while changeover to main, as result, kiln use to reverse back with higher load, when loaded with material, This created excess load over main gear box, caused multiple damages inside.

Action: Replaced the centrifugal brake with modified design of 300 mm ring, connected by counter weight well conversed enough to sustain thrust and fixed the replacement frequency of brake wear parts once in a year 7 Improvement in Refractory of cooler Bull nose, Main burner, eliminating stoppage of failure. Also changing dense concrete concept laying with brick lining, lead to improvement in heat consumption.

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INNOVATIVE PROJECTS IMPLIMENTED IN 2018-19 (1/2)

1 Problems : Huge amount of false air ingression through Mill main master rollers. As an impact, Mill was made to run at higher fan speed, and as result was creating fluctuations in product quality too. a) Plant Process Team, who identified and presented area of opportunity. b) Plant Maintenance Team who created a Quality circle team, with shop floor workmen and came out with unique solution.

Remedial action : An in-house innovation of sealing with an expandable cloth, derived from inner layer of belt conveyor. Here a complete metallic frame was welded surrounded by rollers and fix flexible cloth of strong belt conveyor. This complete assembly helped in avoiding entrance of air into system.

Result : False Air of 8% got reduced to 6%, and improved, nozzle louver from 56 m/sec to 58 m/sec, as a result, fan speed was reduced by 20 RPMs and finally saving in Power, as well as reduced wear rate from inside.

BEFORE AFTER

INNOVATIVE PROJECTS IMPLIMENTED IN 2018-19 (2/2)

1 BENEFITS ACHIEVIED -

Project is an innovation, derived from Quality Circle group, of set of 6 People, having Engineers and shop floor level people, presented in National Level Quality circle Program, and certificate of PAR EXCELLENCE. Also Team has been selected to represent project at International level.

S.N. Description Cost (in Rupees)

A Expenses Manpower Cost for Implementation 1 23,400.00 (Rs.2600 * 9 gangs) 2 Material cost (45 mtr Angle + Reject belt) 20,000.00 Total Implementation cost 43,400.00 Benefits B Maintenance Cost of M-Rollers Lever 1 Rs. 91,200/ year seals (60 gangs X Rs. 1520) 2 Saving in Fan Power (KWh) 62 Savings in Power cost Rs. 36.54 Lacs 3 (62kwhx20hr/dayx300days/yr) /year

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INNOVATIVE PROJECTS IMPLIMENTED IN 2018-19

A challenge in operation of Vertical roller mill in clinker grinding is aging of grinding 2 rollers and gradual reduction in performance of mill in terms of output rate (TPH) and Sp. Power consumption. Issue prevailed in worn out liners were:- 1. Mill was experienced to run with high vibration and sudden collapsing of Clinker bed. 2. While starting of mill in grinding mode due to un even roller width material starts escaping from beneath Mill roller, Mill starts rejecting clinker, as a result, mill runs under heavy vibrations and consumption of mill bed water spray got increased. Also to avoid high vibration mill output rate got decreased and Sp. Power increased REMEDIAL ACTION - An additional hard faced stream lined profiled block of 16mm has been welded over table, along with original block of 35mm thick, keeping 22mm gap between worn out roller and ring. This hard faced block has profile pattern which prepared in line with current of material flowing over grinding track. This helped in reducing escape velocity of clinker and stable bed formation within 30 mins operation. Vibrations became normal, Water demand reduced from 8.5 M3/Hr to 6.5 M3/Hr & finally lead to increase in mill output rate and low sp. Power consumption.

Situation before Modification

INNOVATIVE PROJECTS IMPLIMENTED IN 2018-19

BENEFITS :

1. An improvement in Mill Output rate by 30 TPH & decrease in Mill Sp. Power consumption by 3.2 KWH /MT Cement. 2. Mill increased Table water spray system got decreased from 8.5 M3/Hr to 6.5 M3/Hr. 3. Plant was able to run Mill with 15000 Grinding Hours successfully, without effecting Cement despatch as well as Energy consumption 4. A benefit of Rs. 2.81 Crores (yearly) under investment of just Rs. 75000/-

This Improvement project was projected to CMA which was published in edition of Jan - June 2018

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UTILISATION OF RENEWABLE ENERGY SOURCES.

RCCPL being a freshly installed plant, didn’t had renewable energy sources utilization up-till 2018-2019 Perhaps, In Fiscal year 2019-2020, Plant has installed SOLAR PLANT, with expected power generation of 7.7 MW.

Technology Type of energy On site/Off Site Installed Generation Capacity (MWH) SOLAR ELECTRICAL On Site 7.7 MW 16710

UTILISATION OF WASTE MATERAIL AS FUEL (1/2) (CARBON BLACK)

RCCPL PVT LTD, has started utilization of AFR in form of Carbon Black & Rice Husk

Carbon black is being fed in two different arrangements

1. Through Bulkers, fed directly at Coal Mill outlet while operation, separating foreign material in order mix Carbon black with Fuel 2. Through Pressure vessel installed on ground, and feeding carbon black received in jumbo bags in Coal Mill inlet, only refine MT material is collected in coal firing. 1,802 1,365

223 Bulker unloading in Coal Mill 16-17 17-18 18-19

Carbon Black feeding

Pressure Vessel system for unloading Carbon black Jumbo bags

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UTILISATION OF WASTE MATERAIL AS FUEL (1/2) (RICE HUSK)

RCCPL PVT LTD, has started utilization of AFR in form of Carbon Black & Rice Husk

Rise Husk Feeding system is completely automated system. Rice feeding system has been installed in year of 2018-19. Thus material like Rice Husk, Mustard Husk, Fuel plastic waste, 1. Rise husk feeding is pneumatically to calciner, through system crushed briquette. which was discarded, for not in use. Quantity of 3.5 to 4 tph is easily being fed without much investment. In upcoming Financial Year, a conventional feeding system is proposed to feed AFR in higher Quantity. MT of AFR 553 206 15 20

Mustard Rice Husk Plastic Briquette Husk Waste

AFR consumption in 2018-2019

Rice Husk Feeding System

GHG INVETORISATION (1/2)

Kg CO2/ MT Cement Nos. of saplings % Hactares of Land 65 20,088 585 47 570 12,000 10,000 22 554

16-17 17-18 18-19 16-17 17-18 18-19 16-17 17-18 18-19

Trend for CO2 emission Trend of Sapling Plantation % Hectare of Land identified, converted in Green field

S.N ACTION PLAN % OPC Despatch Million MT PPC 20 31 30 19 1 Uninterrupted utilization of Fly ash as 34.5%. 25 14 2 % Increase of PPC Bulk production, more than OPC .

16-17 17-18 18-19 16-17 17-18 18-19 3 Improve Green belt in areas identified.

Trends of OPC & PPC Bulk Dispatch ACTION TO REDUCE CARBON FOOTPRINTS.

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GHG INVETORISATION (2/2)

FLY ASH UTILISATION / GREEN SUPPLY CHAIN

% FLY ASH ADDITION LACS MT FLY ASH CONSUMED % Fly Ash Addition Lacs MT Fly Ash consumed 7.02 34.53 34.42 6.54 4.58 32.30

16-17 17-18 18-19 16-17 17-18 18-19

GREEN SUPPLY CHAIN S.N ACTIONS 1 Utilization of Coal, pet coke and Gypsum rake reverse for clinker supply to GUs. 2 Utilization of incoming Fly ash tanker with outgoing Loose Cement in tanker

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TEAM WORK, EMPLOYEE INVOLVMENT & MONITORING

1. Daily Monitoring – Daily review meeting chaired by technical Head with Energy consumption record.

2. Review Meeting – Quarterly by Plant head through a complete presentation by process Engineers

3. Budget allocation – Separate budget of 20 to 25 Lacs is every year allocated for improvement.

4. Energy Awareness Program : Employees involved in consumption and monitoring Energy are sent on training and awareness program on site (knowledge sharing session) & Off Site (out station), acquiring information.

Employee involvement in Kaizen, Quality Circle, SGA Team with Plant Engineers & shop floor worker. Teams being awarded by Unit Head

TEAM WORK, EMPLOYEE INVOLVMENT & MONITORING (2/2)

Appreciation for work by UNIT HEAD & Management to Employees and Workers.

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KAIZEN PROJECT – FALSE TRIPPING FROM MOTION SENSOR.

Defining problem Problem Identification done Problem 1. Increase system reliability. with team, in different Identified to 2. Enhances safety. be 3. Reduced manpower cost. classes . false tripping 4. Operation improvement of Mill and Team Identified: of machine fly ash system Section head, from motion 5. Team buildup & knowledge Engineer & 4 nos of sensor enhancement. Electricians

Final Benefits

Our Team

Before Modification

Proxy locking Proxy locking without spring with spring washer washer After Modification

KAIZEN PROJECT - (ON SHOP FLOOR)

1. Project on high consumption Of Compressed air in Cement Mill bag house

Workers discussion Problem area Identified For problem

RECTIFICATION DECIDED: - 1. Poor threads of nipples: Decided to use only properly threaded nipples A, B & C which maintain assembly dimension after fitment. 2. Change in dimensions of GI & MS union: Decided to use only a standard sized MS union for all 19 assemblies of the headers so that the tension in the assembly with respect to each other can be eliminated. Final Result

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OTHER INNOVATIVE & LONG TERM PROJECTS UPCOMNG

S.N ACTION PLAN Investment Expected benefit 1 Co-generation of Power of 11.0 MW through Waste heat recovery system. Rs. 12784 Lacs Rs. 45.68 Cr.

2 Substitution of 110 L Air cannons with smart 70 L smart air cannons having higher pressure Rs. 27 Lacs Rs. 1.92 Lacs boosting. 3 Removal of reversible belt conveyor with a pneumatic diverter Rs. 6.5 Lacs Rs. 3.43 Lacs

4 Introduction of Motorized valves in Compressed air lines feeding air flow to both cement Mill. Rs. 0.5 Lacs Rs. 2.21 Lacs In case which ever Cement Mill is not in operation this isolation valves shall get closed, limiting air in circuit, and avoiding air loss. Thus Saving power in generation. 5 Addition of VFD in line of Compressor of Pyro & cement mill, improving consumption of Rs. 9 Lacs Rs. 6.5 Lacs. power spend idle while unloading of compressor while low demand. 6 Power generation through SOLAR, generating 7.7 MW voltage Rs. 4271 Lacs Rs. 10.2 Cr.

[email protected] ( 9152796285 ) [email protected] ( 9109113985 ) [email protected] ( 7303042550 )

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