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Group Profile 1. Promoted by Dalmia family in 1939. First cement plant of South India. 2. Strong promoters Mr. YH Dalmia has been past president of CMA Strong educational background of the promoters 3. Organization is known for its ethics, values & unblemished track record 4. Leading player in India in Cement and Sugar 5. Having a vision of growth, expansion and diversification, playing a role in National growth 6. Pioneer in cement in Tamil Nadu

Senior Leadership Team Focus

DETAILS
Technology Implementation Manufacturing Excellence Materials Management Marketing Co-ordination Activities Analyzing Competitors Profile Quality Management Eco Friendly Initiative Safety Energy Conservation Measures 15% 10% 10% 10% 10% 10% 15% 10% 10%

%BREAKUP

OUR VALUES We at DCBL believe in value creation for all stakeholders. Values for us are the means to our ends. We believe they are the core and the essence of doing things our way, the right way the Dalmia way. These values, for us, not only hold the threads of the present and keep us grounded, but are also the key to the future where the possibilities are endless. Our four core values are:

Learning Teamwork Speed Excellence

We have also coined an acronym to remember them easily by picking letters from each value LETS EXCEL!

Ariyalur Plant

Energy Policy We are committed to.. 9 Monitor, Control & upgrade technology and operational practices. 9 Comply with all applicable legal and other requirements. 9 Prevent Pollution, injury & ill- health. 9 Conserve energy and natural resources. 9 Optimize utilization of resources for sustainable development. 9 Create a work environment conducive for enhanced employee participation and involvement.
9 Utilization of waste & Hazardous material Unit Head

List of Energy Saving Projects 2011-12

Electrical Energy Saving project implemented (without investment) Innovative In house modification in Raw mill & Cement Mill Cooler Optimization & Reduction in preheater Fan Specific Power Consumption Review and Design modification of the Bag filter for the Packers Total Thermal Energy Saving project implemented (without investment) Reduction of heat rate from 799 to 730 Kcals /Kg of Clinker Reduction of diesel consumption 1.16 to 0.74 ltrs / ton of cement Total Grand Total Coal, Calorific Value (CV) - 6246 Kcal/Kg of coal
Annual Savings Lakh Units Saving Rs in Lakhs

54 22 10 86
Annual Savings In Tons of Coal

270 110 50 430

Saving Rs in Lakhs

8198 570 8769

639 44 683

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Quality Management Operation Friendly Equipment

MV AC Drives PH Fan, BH Fan. One of lowest preheater fan power consumption in India ( 3.4 unit/Mt of clinker) Siemens make EFF-1 motors Intelligent relays-MCCs SPRS in Raw mill fan and Cement mill fan Low NO ILC with High Efficiency, Low NOx Burner( Duo Flex Burner) Low Pressure Drop Pre Heater Cyclones(PH Exit Temp-255C for 5 Stage), SF Cross Bar Cooler VFD drives for all major motors Pfisters pumps in kiln & PC firing circuit

Online CBA for quality control , in the Incoming Feed Material from Crusher & Raw Mill Feeding Circuit. ABB expert optimizer for Raw Grinding, Pyro-Process & Clinker Grinding Sections. Robo Lab with Online sampling stations. X-Ray Analyzer, Online & Offline Particle Size Analyzer.

Technology Absorption

Eco Friendly Plant

High Efficiency Bag Filters & ESP (investment about 44 Cr.) Emission Level- Norms within the TNCPB Limits Go Green Implementation Alternative Raw Material Consumption 9

Energy Conservation Initiatives

Periodical Visit to Cement plants for Bench Marking, Learning and Effective implementation. Continuous up gradation of Process Logics in DCS. Productivity improvement. Factory within the factory divided into three Zones based on Cross Function Team (CFT) Daily Electrical Energy monitoring and Monthly Thermal Audit

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Specific Energy Consumptions Electrical Energy Consumption (kWh/Ton of Cement)

134

Thermal Energy Consumption (Kcals/ Kg of Clinker) 1842

87

72
799 730

2009-10

2010-11

2011-12

2009-10

2010-11

2011-12
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Comparison with National & International Benchmarks

Specific Energy Consumption

Achieved

National Benchmark *

International Benchmark **

Thermal (kCal/kg of clinker) Electrical kWh/T of cement

730

740

716

72.49

73

70

*As per Source-http://www.authorstream.com/Presentation/Perrin-49534-nccbm1ENERGY-CONSUMPTION-NORMS-CEMENT-SECTORUNDERENERGYCONSERVATION-nccbm[1-as-Entertainment-ppt-powerpoint/

** As per Source-http://www.chinaeci.com/admin/upload/20090817021600.pdf

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Road map for Energy Conservation Projects to meet Global Bench Mark

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Achievements (IP-1) Specific Power consumption for Clinker Production

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REDUCTION OF SPECIFIC POWER CONSUMPTION (IP-1)

Tremendous teething problems, especially in Raw Grinding circuit. A value based journey was started in April 10 bring down the power consumption from 80 units to 50 units by March 2012. Ultimately, Achieved the power consumption less than 50 units during kiln running condition and achieve an annual average of 54 units due to start & stop of Kiln.

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Optimization by In house Modifications (IP-1) Higher Raw mill Size requirement. and hence higher air volume In house modification was done in Dam ring to reduce the table power consumption in Raw Grinding Modification of Nozzle ring to reduce the air volume requirement and hence running the mill fan in SPRS mode, yielding to the reduction of fan power consumption

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Reduction in Breakdowns & Idle Running Hrs (IP-1) Cross function teams (CFT) formed in all sections to improve the availability. For every break downs, stoppage analysis done with WHY WHY analysis and corrective/preventive actions taken. Voice alarms/SMS facility provided to take instant action & to avoid the incidental stoppages. Continuous Improvement Approach (IP-1) Increase In Productivity in Crusher, Raw mill and Kiln through optimization Reduction of false air entry through periodical measurements & onset the conditions. Bench Marking and continuous improvement

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Achievements (IP-2) Specific Heat consumption for Clinker Production

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Steps to reduce the Thermal Energy Consumption (IP-2) Increasing the flame momentum in kiln. Online Thermal Energy Consumption indication - instant action. Running the kiln consistently at 4500TPD level. Monitoring the Thermal Efficiency- Monthly Heat Balance Exercise. Periodical Measurement & Corrective action Twice in a Month False air Entry. Reducing the variation in the quality/chemical parameters in the limestone pile and in kiln feed. Reducing the excess air in the preheater exit ( exit O2 less than 3%). Optimization of cooler for maximum heat recuperation ( TAD temp > 975 C).

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Thermal Energy Consumption (Kcals/ Kg of Clinker) (IP-2) 1842

799

730

2009-10

2010-11

2011-12

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Achievements (IP-3) Wet Fly Ash drying and Usage in cement mill

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Optimization by In house Modifications (IP-3) Mill originally designed for PPC with Dry fly ash only. Non availability of DFA used the mill as drier Consumption of wet fly ash SPC increased by 3 units/MT of cement. Dam ring modification to reduce the table power consumption of Clinker Grinding. Nozzle ring modification with dummy plates instead of inserts to reduce the air volume requirement. Mill fan in SPRS mode. Utilization of Wet fly ash in place of Dry fly ash started from Mar11 & achieved the consumption upto 68%.
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Dam ring modification

Nozzle ring modification

Utilization Of Wet Fly Ash (IP-3)

46%

8% 0%
2009-10 2010-11 2011-12

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Optimization of Crusher Operation (IP-4)

Batch Mode Operation of Crusher. Group starting sequence time reduced from 11.3 to 7.7 minutes. Auto tripping of Apron Feeder for maintaining the minimum bed thickness. Online Monitoring of Crusher Hopper through CCTV Camera. Automatic group Stop Command from DCS. Reduction in breakdowns through improved instrumentation for the belt conveyors.

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Power Consumption KWh/Ton Of Crusher (IP-4)

2.99

2.1 1.4

2009-10

2010-11

2011-12

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Packing plant bag filter suction lines modification (IP-5) Elimination of 37kW x 3 drives in Packing Plant: System was designed to use both the bag filters(75 kW & 37 kW) for individual packer during operation Now the suctions lines are modified and given to a common bag filter (75 kW) and the other bag filter load (37kW) completely eliminated for all the three packers Modification in suction lines without affecting environment. Result: Reduction in the Maintenance cost and Power Consumption in Packing Plant by 0.5 units/ton of Cement.

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BEFORE

AFTER

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Reuse of Treated trade effluent in Process (EP-1) As part of the initiative to conserve natural resources, Captive Power Plant effluent (waste water) is used for internal water spray in cement mill by which we are able to reduce the raw water consumption by approximately 80 KL water per day.

Investment Rs. 3 Lakhs.

h Results Conservation of Raw water

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Utilization of Alternate Fuels (EP-2) Usage of Alternative Fuel High CV Fly ash Availability: Substantial amount of High CV fly ash is available within the range of 130-200 km distance from Ariyalur plant. Result: Last year, a Break Through Environmental Project was taken on AF. Usage of 0.77 % AF in Pyro Processing. Focused on utilization of industrial waste from chemical, Steel, Sugar, pharmaceutical, Automobile and such other industries. Biofuels like Cashew nut shells, rice husk, Sawdust etc was also started.
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Utilization of Waste as fuel (Alternate Fuel Utilization) (EP-2)

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Utilization of Alternate Raw Materials (EP-3) Usage of Alternative Raw material Lime sludge from ETP/CETP. Availability: Around 6 Lakhs tons of Lime Sludge is available in and around of Tiruppur, Coimbatore, Erode, Karur and Salem all in the range of 150-200 km from Ariyalur plant. Result: Usage of 0.5% lime sludge in raw mix as part of alternate raw material which also yielded a economical benefit of 18 lakhs in 2011-12. This is an initiative as part of eco-friendly drive to use waste material as useful alternate raw material and appreciated by the Tamil Nadu Pollution Control Board (TNPCB) Government of Tamil Nadu.
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Linking to CARE Air centre (EP-4)

Stack emission data communication to TNPCB care centre - Chennai

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Other Environmental Improvements

Achieved plantation of 76465 trees inside the plant area with 97% sustenance rate. Remarkable initiative towards water conservation - Rain water Harvesting Pond with a capacity of 40000M3. CFL Energy Efficient lamps to our employee as birthday gift as part of GREEN INTIATIVE Initiative towards the Renewable Energy. Plantation by the visitors Donated Tree guard, Saplings in the city & near by villages

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Greenery development in the Plant area

Regional Training Centre

Colony Park

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Rain Water Harvesting Rain water harvesting Pond & Canals inside the plant

Rain water harvesting pond Capacity - 41,840m3

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Invested Cost for Pollution Control Equipments S.No

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Equipment Description
Bag filters - Bulk loading system Bag filters - Cement mill Bag filters - Coal mill Bag filters - Cement Silo Bag filters - Fly ash Silo Bag filters - Raw mill Bag filters - Roto packers Cement mill bag house Coal mill bag house Cooler Esp and fan Dust suppression system Raw mill reverese air bag house Small - Nusiance bag filters Water treatment plant

Supplier Name Cost in Lakhs

EEL GEBR GEBR EEL EEL GEBR EEL Himachal Env. Himachal Env. Himachal Env. PCE Himachal Env. Rieco & FLS Ion exchange 3.55 51.8 50.65 31.06 18.31 29.57 101.21 782.4 189.54 685.85 103.01 1881.06 167.44 362.77

Total Cost in Lakhs (Rs.)

4458.22
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Family involvement in Environment Initiatives We have conducted Essay writing contest for Spouses and children on BEST ECO-FRIENDLY PRACTICES We have also conducted Environmental Initiatives on BEST CRAFT

MATERIAL/ART MATERIAL PREPARED USING WASTE MATERIAL for Employee as well as family members.

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Saplings donated to near by villages

We are regularly buying and donating the saplings to near by villages. We are having our own nursery for producing and donating the saplings to near by villages on continuous basis. Donated the Tree guard to near by villages
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Installation of Damper in ESP Chimney

Reduction in SPM through the installation of Chimney Damper. Additional heat availability to Raw mill (2million kcal/hr) Lesser CO2 Emission due to reduced coal consumption in Raw mill HAG. Emission reduced by 3862 tons/annum

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Renewable Energy - Solar We are using solar water heater for our guest house purpose.

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Solar Energy We are using a solar energy lighting system for our two wheeler parking shed a purpose.

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MONITORING..Measure, Analyze and Improve Effective Functioning of Energy Committee In Unit level & In Group Level for continuous improvement Energy conservation committee formed with cross functional team members Energy saving initiatives discussed and implemented. Energy reports taken from Energy management system and analyzed in daily co-ordination meeting. Best Energy saving suggestions are awarded periodically. Quick fund allocation by the management based on the pay back period Speedy implementation
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People Involvement

Rewards Achieving Goals

Action Plan & Implementation Analyzing & Brain Storming Energy Conservation Monthly Review Meeting Daily Monitoring Responsibilities of Designated Energy Manager CFT Based Energy Team
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Sample Reporting Format

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Sample Reporting Format

Energy Conservation Projects for the Year 2012-2015 Future Plan to increase the usage of AFR. Optimization Of Cooler & False Air Entry Reduction Reducing the Variation in standard deviation of Kiln feed LSF Utilization of EO Optimizer in all section to reduce the Specific power Consumption. Classifier Modification in Raw mill & Cement mill Inlet Static Duct modification of all Process Fans. Optimization of Clinker quality to reduce Specific Power Consumption Utilization of Spent Wash in Cement & Coal grinding. Installation of Grizzly Bar in Crusher circuit

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Investments & Proposals for reduction in Energy Consumption For 2012-2013

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Awards and Accolades ISO 9001,14001 & OSHAS Certification Achieved In a Record time of 6 months

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ISO 9001 and ISO 14001 Certification

* Surveillance Audit done by M/s. DNV

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Awards and Accolades GREEN award from TNPCB for the year 2011-12. We have achieved consecutively BEST MANUFACTURING AWARD for the year 2010-11 & also 2011-12 among the groups. We have achieved BEST SHE UNIT AWARD for the year 2011-12 among the groups.

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THANK YOU

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