ULTRATECH CEMENT LIMITED

REDDIPALAYAM CEMENT WORKS

“16th National Award for Excellence

in Energy Management- 2015”
02-03 Sep 2015 , Hyderabad.

Team Members:
G. Suresh Kumar– General Manager (Mechanical)
Heera Kumar – General Manager (Electrical)
SC Samantaray- DGM (Technical Service & WCM)
 RDCW AT A GLANCE

Location of Integrated Plants, Number

Grinding Units and Units Symbol
of Units
Bulk Terminals
Integrated
12
Bathinda Cement Works
Plants
Panipat Cement Works
Dadri Cement Works

Aligarh Cement Works Grinding Units 12

Kotputli Cement Works

Aditya Cement
Bulk Terminals 05
Vikram
Cement West Bengal Cement Works

Gujarat Cement Works

Magdalla Cement Works
Hirmi Cement Works

Jharsuguda Cement Works

Area of spread Units
Awarpur Cement
Jafrabad Cement Works RWCW
Works Navi Mumbai Cement Unit

Hotgi Cement Works

Plant capacity 1.6 MTPA
Shankarapally Bulk Terminal
Ratnagiri Cement Works
Integrated plant
Rajashree Cement
Works
Andhra Pradesh Cement Works Grinding unit
Area of mines 188.62 Ha
Ginigera Cement
Works
Mangalore Cement
Unit
Arrakonam Cement Works Bulk terminals
Area of plant 125 Ha
BSBT- Dodballapur

Reddipalayam Cement Nearest air port

Works 75 km
Trichy
2
 REDDIPALAYAM CEMENT WORKS (RDCW)

UNIT VISION
TO BE RECOGNIZED AS THE “MOST INNOVATIVE COMPANY” IN MEETING
THE CUSTOMER REQUIREMENTS,USE OF RENEWABLE ENERGY &
CONSERVING RESOURCES BY THE YEAR 2015.
UNIT MISSION

• ADOPTING CREATIVITY & INNOVATIVE APPROACH IN CONTINUAL IMPROVEMENT

OF QUALITY, PRODUCTIVITY, SYSTEMS AND PROCESSES.

• ADOPTING STATE OF THE ART TECHNOLOGIES FOR CONSERVING THE RESOURCES

AND USE OF RENEWABLE ENERGY.

• CREATING VIBRANT WORK ENVIRONMENT TO ATTRACT,MOTIVATE & RETAIN

EMPLOYEES TO ACHIEVE THE ORGANIZATIONAL OBJECTIVES.

• BUILDING LONG LASTING CORDIAL RELATIONSHIP WITH SOCIETY AND THE

STAKE HOLDERS BY PRACTICING SAFE ENVIRONMENTAL STANDARDS.

• ADOPTING SAFETY FIRST APPROACH IN ALL OUR ACTIVITIES . 3

ENERGY POLICY

4
Management System - Certification

ISO :50001 2011

For Energy
Management
 GROWTH JOURNEY

Platinum Award
3250 TPD
+ (Brown Field)

2012-13

Gold & Planet award 2009-11

Silver award 3000 TPD

Upgraded Future Plan

3000 TPD 2004-05

Upgraded
Bronze Award 2800 TPD
2002-04
Instituted WCM
Upgraded
2400 TPD 2001 – 02

Installed
1800 TPD capacity
2000 - 01
Capacity 1998
CEMENT MANUFACTURING PROCESS
 Plant Unique Features

 State of the art Cement Plant commissioned in the millennium year

 Designed for using multiple fuels.
 Pioneer in using alternate fuel with pre-processing system
 First Plant in the World to get CDM credit for use of Agro waste alternate
fuel

 Robo lab for total quality control from sampling to analysis.

 Packing facility with Centralized discharge from cement silo
 No Fatal Accidents since Twelve years
 State of art testing laboratory for Alternative fuels
 PLANT – SALIENT FEATURES

Ripper dozer for mining Covered storage for raw

material and fuel Cross Belt Analyzer Robo lab for quality control

Energy efficient Roller Energy efficient single drive Micro processor based
ball mill for cement grinding Electronic Packer Captive Thermal Power plant
Press for Pre-Grinding

Shredder Machine for Alternate Fully equipped Alternate

Kiln with 5 stage Preheater fuel reprocessing fuel laboratory 9
 Reduction in specific energy consumption

Cement being an energy intensive sector, has been considered under the PAT
scheme to enhance its energy efficiency.

Kcal/kg equivalent Cement

746.17
714.99 732.66 724.46
750

700 668.97

Better
650

600
Base Line Target 2012-13 2013-14 2014-15

*After Normalization
 Specific Heat Consumption - kcal / kg clinker

739
743 734
750

700 665

CII National
650 Better
Benchmark
12-13
600 13-14

550

500
CII National 12-13 13-14 14-15
Benchmark

 12-13 – Preheater Upgradation from 4th stage to 5th stage & conventional
cooler replaced by CB cooler thereby reduced 50 kcal/kg clinker .
 Specific Power Consumption – kWh/MT Cement

72 72 71
80
60
70
CII National
60
Benchmark
50
12-13
40 Better
30 13-14
20
10 14-15
0
CII National 12-13 13-14 14-15
Benchmark

 Flyash consumption in PPC increased from 26 to 28%

 TPP Frequency reduced from 49.8 Hz to 48.8 Hz
 Implemented Energy Audit recommendations
 Flyash Consumption %

Flyash %
30
27.79
29
26.81 26.89
28
27
26
Flyash %
25
Better
24
23
22
21
20
12-13 13-14 14-15
 Methodology for Identifying Innovative Projects

Opportunity Suggestion PSS training

Identification Team Results
Project
formation Achieved
• Energy • Idea execution
Mapping Generatio Rewards
n &
• Benchmarki & &
ng • Idea
Screenin Allocation
• Lost Cost g of project
Matrix team Review of Recognition
• Feasibility Progress
• OEE & VOC Study
 Installation of Turbo Blower

Innovative Project -1
Objective: To reduce power consumption in PC Firing Blower.
Investment: 36 Lacs
Problem Faced:
 High power consumption (65 kW)
 High Noise level of existing blower in pyro section is 89 dB.
 Lobe element replacement – Every 3 years (Rs 6 Lacs each)

Twin lobe blowers for PC & Kiln

Firing Aerzen Turbo Blower
15
 Installation of Turbo Blower

The following modes can be selected,

a. Constant Pressure
b. Constant Current
c. Constant Volumetric Flow
d. Constant Oxygen
Savings Sheet
Godrej Aerzen Energy
Twin Lobe Blower
Purpose efficient Turbo Blower
451BL1 parameter
AT100 -0.6S Parameters
Operating data
Flow Rate: 4861m³/hr at Flow rate: 3980m³/hr at
Suction suction
Pressure: 0.325 bar Pressure: 0.26 bar
Pre calciner firing
Coal Feeding: 9.2 TPH Coal Feeding: 10 TPH
Power : 65 Kw Power : 26 Kw
Specific power: Specific power: 0.006
0.013Kw/(m³/hr) Kw/(m³/hr)
Power savings: (65kw-26kw) = 39kW
ROI 48 % 16
 Installation of Multi purpose Shredder
Objective: Innovative Project -2
 To increase the alternate fuel consumption from 9.5 % to 12 % TSR
 Size reduction from 500 MM to 50 MM (Plastic, HDPE bags, Tarpaulin, Foot
wear waste, Agro waste, wood and other miscellaneous waste.
Investment: 17 Lacs
Problem Faced:
Flowability was the major issue to increase the Alternate fuel quantity. Due to
jamming of bigger size of foot wear waste and HDPE bags.
Action taken:
Additional shredding machine installed with in house modification

Results:
Industrial waste feeding quantity increased from 50
MT per day to 90 MT per day
Helped to increase the consumption of plastic waste
by 1650 MT per annum.
 Enhancement of TPP capacity up to 13 MW

Innovative Project -3

Background : RDCW installed a 12.5 MW captive power plant to cater the power
requirement of cement plant. But due to plant capacity enhancement power
requirement increased up to 14.5 MW which was sourced from EB.

RDCW Team conducted a study along experts to assess the potential of power
generation from TPP. Study report recommended that with minor modification 14
MW can be generated from TPP.
Action Taken:
Fuel Mixed changed (80% Lignite + 20% SA Coal)
Steam pressure reduced from 66 kg/cm2 to 63 kg/cm2 & steam flow increased
from 55 TPH to 60 TPH.
 Enhancement of TPP capacity up to 13 MW

Benefits :
Power generation increased up to 13.5 MW
Boiler heat rate reduced from 3490 kcal/kWh to 3470 kcal/kWh
Cost saving: Shifting of 1MW load from EB to TPP will reduce TNEB
consumption 20000 Units/ Day
Net saving is = 20000*2.5 = Rs.50000 Per day
 Co-processing of ETP Sludge as an
Alternate Raw Material
Innovative Project -4

Issue – To support sustainable economic growth towards a low carbon future unit
not only focused on AFR but also search for alternate raw material.

The ETP sludge is a hazardous waste material of textile industries. This sludge is
openly dumped which leads to soil, surface water and ground water
contamination.

Co-processing ETP sludge in cement manufacturing is a scientifically proven

technology.
The sludge dumped at Landfill locations can be disposed as a value added
product as a Raw material in cement manufacturing.
 Co-processing of ETP Sludge as an
Alternate Raw Material
Action –
• We discussed with Textile Industries of Tamil Nadu and TNPCB for the environmental
friendly disposal of ETP Sludge.
• RDCW had conducted trial run of ETP sludge from 27.05.2013 to 31.05.2013 in
presence of CPCB & SPCB members, as per the “Guidelines on co-processing in
cement/Power/ Steel industry” published by CPCB in February 2010. The result was
encouraging .
• Unit received permission for regular use of ETP sludge from CPCB & SPCB.
Benefits:
Enhancement of mines life by 1 year, savings
in raw material cost by Rs 600 lakhs and
mines fuel cost by Rs 4.42 lakhs per annum.

Total scope for Energy saving by reducing

mining fuel cost is 78.93 MKCL/ANNUM
Trial Run in the presence of
CPCB and SPCB
 Alternate Fuel Handling System

Alternate fuel are collected from

different locations through different
suppliers, and stored as per allotted
space in closed yard. size 25X36 square
meters. Presently the unit has three
shed of same size.

Size 25X36 square meters. Presently the

Paint sludge Shredder machine
unit has three shed of same size.

Oversize material whose size is above 50 mm is

shredded through the shredder machine.

Plastic Shredder Machine

 Pre – Processing Equipments
Wood Chipping Machine Plastic Shredding Machine Shredder machine

Chaff Cutter for Agro Waste BobCat for AFR

Feeding
 AF Consumption – in % (TSR)

% on TSR

9.60 9.62
10.00

9.50

9.00
8.34
TSR %

8.50

8.00

7.50

7.00
12-13 13-14 14-15
ENERGY CONSERVATION INITIATIVE
 ENERGY SAVING PROJECTS IMPLEMENTED

WITH WITHOUT
PARTICULARS UOM INVESTMENTS INVESTMENTS
12-15 12-15
Total No of Projects
Nos 32 13
implemented

Total investment Rs in Million 87.37 Nil

Electrical Savings
Million units 36.97 1.55
achieved

Total Savings Rs in Million 155.65 6.54

 Energy saving projects with investment 2012-13

Electrical Savings Investment

Title of the Projects Implemented
achieved (kWh) (Rs. Million)
VFD For Bag filter fan 391 FN4 2.7 0.30
VFD For Bag filter fan 491 FN1 3.1 0.30
VFD For Bag filter fan 491 FN2 3.1 0.30
VFD For Bag filter fan 411 FN2 4.1 0.30
VFD For Bag filter fan 511 FN1 3.6 0.30
VFD For Bag filter fan 531 FN1 8.2 0.40
VFD For Bag filter fan 431 FN4A 3.6 0.30
VFD For Bag filter fan 491 FN10 3.6 0.30
Variable Frequency drive for screw compressor at power
226.0 4.50
plant
Replacement of Tubelights with LED lamps 2.7 0.30
Upgradation of Silo Feed Bucket elevators to increase
2513.9 58.50
cement mill output by 5 TPH.
 Energy saving projects with investment 2013-14

Electrical Savings Investment

Title of the Projects Implemented
achieved (kWh) (Rs. Million)
Install transparent sheet in workshop 4.8 0.1
CCR building centralized air conditioning system up
10 5.2
gradation
Replace aluminium blades with FRP blades for cooling
2.04 0.01
tower fan
Install automation system for kiln 0.5 5
Install adaptive predictive control system for ball mill
3.5
grinding 84
Replace HPMV lamps with CFL lamps in the packing plant 0.04
2.65
Replace HPMV Lamps with CFL Lamps in CPP 16 0.2
Replace HPMV lamp with Metal Halide Lamps in the CPP 0.03
1.5
Optimize the fly ash unloading system 30 0.1
 Energy saving projects with investment 2014-15

Electrical Savings Investment

Title of the Projects Implemented
achieved (kWh) (Rs. Million)
Replace HPMV lamps with CFL lamps in Packing plant, TPP
66 0.05
section
Flyash unloading through blower air instead of
40 0.05
compressed air
Overhead tank for colony water supply 233 0.30
Upgradation of ESP control panel for Coal mill ESP 6.11 0.66
Upgradation of ESP control panel for Raw mill ESP 20.80 1.00
Installation of turbo ventilators 14 0.012
Installation of transparent sheets 8 0.02
Cooler MFR Idle hole modification 1300 0.2
Upgradation of AC chiller 10 0.05
 Energy Saving Projects without Investment

Electrical Savings Investment

Title of the Projects Implemented
achieved (kWh) (Rs. Million)
Reduce pressure drop across cement mill vent fan inlet
damper(Damper removed to reduce pressure drop and 4 Nil
power saving)
Optimize the operation of cement silo top air slide fans 3.5 Nil
Minimize compressed air leakage in ash conveying area 5 Nil
Optimize the operating frequency of generators 74.54 Nil
Optimize the operation of DG distribution transformer 4 Nil
Optimize the operation of the instrument air compressor
6 Nil
(Captive Power Plant)
Optimize suction in raw meal silo top bag filter fan 4 Nil
ESP Transport group running optimization 7.1 Nil
GCT Transport group running optimization 11.16 Nil
By avoid water flow through idle equipment (Interlock the
4.72 Nil
operation of the pump with the group)
Optimize the Voltage of distribution transformer TR3 & 5 8.75 Nil
Arresting false air across Kiln inlet seal 55.16 Nil
False air leakages arresting in Raw mill & Coal mill 8.14 Nil
 Reduction of Auxiliary power consumption in
DG sets
Objective: To reduce auxiliary power consumption in DG sets through optimization.

Background: Usually DG set HFO fuel heaters were kept in ON condition to maintain the
temperature for immediate startup of the DG set. These heaters consumed 750 kWh per
day.
Action Taken: To reduce the power consumption, LDO circulation was given to the DG
set in place of HFO circulation. In emergency conditions, DG set can be started initially
with LDO then switched over to HFO in case of continuous operation.
Benefits:
1. Auxiliary consumption reduced by 300 unit per day.
2. DG power cost reduced.
3. Savings /Per Annum: 4.6 lacs
 Cooler MFR ID hole modification

Cooler Specific Power consumption was 5.5 kWh/

MT Clinker , we have increased the hole dia of
MFR plate so that pressure drop across plate is
reduced and power consumption reduced to 4.8
kWh/MT clinker

AFTER

BEFORE

Benefits:

1. Power saving = 0.70 KWH/ton of clinker

Cost savings = 0.70 x Rs.4.2 x 300 Days x 3250
TPD = Rs.31.53Lacks/Annum
 Up gradation of Air Conditioner Chiller

Replacement of Reciprocating Chiller by Screw Chiller

There are two air conditioner chillers reciprocating type having low efficiency &
higher power consumption with R22 refrigerant which is obsolete. These
chillers are replaced by screw chillers.
Before After

Benefits:
Savings in unit consumption 10KW*24 = 240 kWh/day
Saving in cost - Rs 3.11 lakhs per annum
Reduction in CO2 = 89 MT per annum
 Installation of Energy Efficient Lamps

We replaced HPMV/SV by CFL and LED lamps in plant and Guest house at colony.

Replaced CFL to LED Replaced CFL to LED

LED lightening at lightings at Packing lightings at Electrical
Materials Department Plant Department
 PH AIR BLASTER OPERATION MODIFICATION

Objective: To optimize the operation timing of the air blaster in Pre heater section.
Project Aim : To reduce power consumption.

Action Taken: Modified the program so that whenever the cyclone cone draft
reduce to minimum air blaster will operate.

Benefits:
Reduction in compressor air consumption.
Before Logic modification =6557.35 KW /day
After Logic modification =3945.48 KW /day

Total power saving = 2611.86 KW/day

Total Cost savings / Annum = 35.26 Lacks / Year

Reduction in CO2 - 966 MT per Annum

 Installation of Natural Day Light

Objective: Reduction of Power Consumption by using natural day light

Working principle of natural Day Light:
The Acrylic dome which captures sun-light. Spectra light tube transfers the sunlight
captures on the dome & sun light transferred through the spectra light tubing is
delivered through the diffuser.

Benefits:
1) Renewable form of energy, save huge energy cost and also reduces
carbon foot print on our environment.(Co2 Emission reduced – 6570
Kg/Annum)
2) The maintenance cost to Zero
3) No spares and maintenance
4) Cost Saving Rs 0.095 Lacs /Year
 Installation of Turbo Ventilators &
Transparent sheet

Project aim: To reduce power consumption

Benefits:
Eliminated use of electrical lamps during day time
Cost Saving Rs 5.74 Lacs /Year
 ENVIRONMENT
PROJECTS
“As a Group we have always operated and continue to
operate our businesses as Trustees with a deep rooted
obligation to synergise growth with responsibility.”
 ECO-Friendly Technological Features

• Ripper Dozer for environment friendly mining operation

• ESP & jet pulse bag filters
• Alternative/Hazardous Fuel Feeding System.
• Covered storage for Fuels.
Ripper Dozer
• Storage silos for raw meal, clinker, flyash and Cement.
• Covered belt conveyors for material transportation.
• Water sprinkler for dust suppression at Crushers.

Covered Limestone Shed

Covered Conveyors Storage Silos

Electro Static Precipitator
1
 Workshop on Co-processing hazardous wastes

TNPCB conducted Workshop on Co-Processing of Hazardous wastes in Cement Plants at

UltraTech –Reddipalayam on 21.01.2015
 Water Conservation Initiatives

Issue – Ground water with bore well is the only source of water for plant and
colony. Day by day the water table in the vicinity is depleting. In future it may lead
to severe water shortage.
Annual average rain
fall – 627 mm

About 500000m3 of
water is available in
abandoned mines. this
Drip irrigation at Colony & Plant
water started recycling
to power plant after
laying down a pipe line
of 6 km.

Rain Water harvesting at mines

Rain water harvesting at Truck
500000m3
yard
 WORLD ENVIRONMENT DAY CELEBRATION @ RDCW

On the eve of World Environment Day that fell on June 5, 2015, a Green Walk
has been organised to come to factory and back to colony, thereby avoiding
vehicle usage on that particular day.

We have issued to every house in the village, an “Environment Pack” which

comprised of one Jute bag with ‘UTCL RDCW’ logo, one Mango sapling, two
numbers of CFL lamps and Energy saving pamphlets and one children gift,
thereby covering 250 village residents.
 WORLD ENVIRONMENT DAY CELEBRATION @ RDCW

Environment Day pledge Green walk from colony Mass tree plantation by
to factory employees

Environment Pack for a villager Tree plantation at Village

 I am CO2 Positive-
Green concept Challenge Chain
 Green Belt Development

39 % of total area covered with tree plantations as against 33%

of statutory norms
150000 6960
13474
130000 15889
21769
110000
90000 121363 128323
107889
70000 92000

50000
2011-12 2012-13 2013-14 2014-15

year wise cummilative

Survival rate - 96%

45
 Reduction in CO2 Emission
kg CO2/MT Cement
610 610
620

600 583 578

580

560
2011-12 2012-13 2013-14 2014-15
kg CO2/MT Cement

The First Cement Company in the

World to earn Carbon Credits by
using alternate fuels and earned
52 million selling credits to
Europe already part of the Aditya
Birla Group
 Utilization of Renewable Energy

2012-2013 2013-2014 2014-15

Installed Annual Annual Annual
Energy Energy Energy
Type Capacity Savings Savings Savings
Generated Generated Generated
in kW (Rs.in (Rs.in (Rs.in
(kWh) (kWh) (kWh)
million) million) million)

(5*250)
Wind 1854000 7.69 2051093 7.19 1844096 9.78
KW
Solar
photo 100 KW 144000 0.61 144974 0.608 136527 0.548
voltaic

47
 INVOLVEMENT OF EMPLOYEES

Suggestion scheme in RDCW gives opportunity to employees for direct participation in

energy conservation & productivity improvement initiatives.

RDCW Team won

Kaizen Competition
Award for best
Communication
 ENERGY MONITORING & REPORTING SYSTEMS

EXPERT OPTIMISER

• Expert optimiser is an expert software package used

for optimisation of the plant operation.

• Used in Rawmill , Coalmill , Kiln ,Calciner , Cooler &

Cement mill sections for optimisation.

• EO system results in optimised and smooth operation

of the plant and very minimal operator intervention
is required in plant operation.

• After implementing EO system, all major plant

operation parameters are more stabilised and
consistent.

• Quality parameters like clinker free lime , rawmill

residue , cement mill blaine are more consistent.

49
ENERGY MONITORING & REPORTING SYSTEMS

KNOWLEDGE MANAGER SOFTWARE

 Individual MCC’s wise and section wise power

details.

 Speed, load, current and running hours of all

critical equipment's.

 Compressors, water pumps and bore wells

running hours.

 Start/stop power for all equipments

 Online monitoring of parameters in DCS.

 HT motors power and temperature details

 Plant stoppages are automatically booked in SAP

through PI system

50
 ENERGY MONITORING & REPORTING SYSTEMS

 Daily Vibration & Bearing Temperature Deviation Report

 PI system available in all PC and every engineer can monitor all parameters.
 Daily Report on Utilization of Various Fuels.
 Useful for analysis of operational deviation

51
 INTEGRATED MANAGEMENT SYSTEM CERTIFICATION

ISO : 9001 ISO :14001 ISO :27001 ISO :18001 ISO :50001 2011

Quality Environment ISMS Safety Energy

Sample - IMS audit 2014-15 report with few minor non-confirmative & corrective actions
Corrective Action to Eliminate Root Cause of Non-
Category of Description Correction to Eliminate the Analysis of Root Cause of Non-conformity, Distribution of conformity
Standard
Finding (Non-conformity description and evidence) Non-conformity Responsibility Within Organisation (For actions not implemented after 90 days a committed
date for implementation must be stated)

CAT2 (Minor) Requirement:- OHSAS Prposed changes to be 03.03.2015 incidence was thoroughly investigated and detailed THE my-sethu system needs coarse correction.
The organization shall establish, implement and maintain a procedure(s) 18001:2007 communicated to safety board . investigation results was submitted to the safety board through incident
for dealing with actual and potential nonconformity(ies) (non-accr.) investigation committee. The format need to revised since our system is
and for taking corrective action and preventive action. The centralised we will send our requisition to our corporate safety board for
procedure(s) shall define requirements for: suitable action
a) identifying and correcting nonconformity(ies) and taking action(s) to
mitigate their OH&S consequences;
Non Conformance:-
For the incident which happened on 03.03.2015, Corrective Actions are
not implemented as per the requirement of the standard.
Evidence: -
(i) Root cause analysis has not been carried out appropriately,
(ii) There is no provision for verification of the effectiveness of the
corrective action in the format for Incident Investigation.
(iii) HIRA has not been reviewed after implementing the corrective
actions.
CAT2 (Minor) Requirement:- OHSAS All the major Change & expasion All the major expanson project EIA assesment is done . How ever same Proactively all the risk and inventory register to be checked before
...For the management of change, the organization shall identify the 18001:2007 project seperate risk assesment was not included in the aspect impact & risk inventory register any new project start up
OH&S hazards and OH&S risks associated with changes in the (non-accr.) wil be done by project cell
organization, the OH&S management system, or its activities, prior to
the introduction of such changes.....
Nonconformance:-
Hazard Identification & Risk Assessment (HIRA) has not been carried for
certain changed or proposed activities before their introduction.
Evidence:-
HIRA has not been carried out for the following:-
(i) New Fly Ash Silo Erection & Commissioning,
(ii) Alternate Limestone Feeding System Erection & Commissioning, and
 REPLICATION ARISING OUT OF BEST PRACTICES
THROUGH ASSOCIATES

Best Practices Source

Technological Up gradation of Electronic packer Group Units
Reduce the Noise level of exhaust steam of deaerator Group Units
Installation of turbo ventilator CII conference
To make provision to lock end shield of drum motor Group Units
Fire resistant cloth fixing on hoses near engine turbocharger & exhaust Group Units

In house auto sample collection arrangement of additives. Group Units

To install continuous monitoring system for elevator belt position Group Units
Optimization of solvent for bag printing machines Group Units
Replaced of HPSV lamp with LED light. CII energy
audit
Mistake proofing in cement bags Group Units
Upgradation of air conditioner Chillers CII conference
Providing gate and interlock for bag lifting hoist Group Units

53
 Energy Saving Projects for Next Three Years

Sr. Annual Potential

Project Title
No Saving (Rs lakhs)
1 Heat Recovery from rotary kiln 400
2 MV drive for Preheater fan 55
3 VFD with Star Delta for 531FN8 bag filter fan 3.08
4 VFD with Star Delta for 531FN1 bag filter fan at clinker hopper circuit 2.31
5 Install expert optimization system for TPP 14.8
6 Optimize operation of blower of KILN 11.0
7 Installation of MMD Crusher 118
8 VFD for Coalmill main drive 34
9 HFO Firing System in Kiln 8.82
KNOWLEDGE SHARING

 We are already part of CSI - Switzerland

 Participating in benchmarking process
of Whitehopleman & others.

 Publishing best practices in Cement

sustainability report.

 Sharing best safety & environmental

practices

 Knowledge up gradation at all levels

 Participating in BEE’s PAT Scheme.
 AWARDS & ACCOLADES

• Tamil Nadu Pollution Control Board - Green Award 2012

• GreenTech Environment Excellence - Silver Award 2006 & 2009 & Gold -2012
• Global Cement Award Lowest specific CO2 emission - 2006
• Most Innovative Scheme for environmental impact abatement - 2006.
• FICCI Environment Sustainability of Business Award 2006 – 2007 .

FICCI Award received by Mrs. Rajashree Birla Green Award 2012 received by Mr. V Ganesan
from Dr. Man Mohan Singh, Former Honorable from Dr. J. Jayalalithaa, Honorable Chief
Prime Minister of India during the FICCI 80th Minister of Tamilnadu during the award
AGM at New Delhi ceremony in Chennai
 AWARDS & ACCOLADES

 National Energy Efficient Unit Award by CII (2004 & 2006,2007 , 2008 ,2012 & 2013)
 National Excellent Energy Efficient Unit Award by CII – (2009 , 2010 , 2011,2014)
 NCCBM Best Electrical Energy Performance Award 2008-09
 Frost and Sullivan Green Manufacturing Excellence Award – category - Aspirant
Award (2013), Challenger Award(2014,2015)
 Tamil Nadu State Safety Award- Ist Prize under Scheme II (Lowest Weighted Frequency
Rate, Compared with the other Industries.)
 Federation of Indian Mineral Industries (FIMI)
It is the small things that make for perfection
And perfection is no small thing
- Shri Aditya Vikram Birla