ULTRATECH CEMENT LIMITED REDDIPALAYAM

14th National Award for Exc ll nc in En r!" Mana! # nt$ %&1'( 1) * %& AU+ %&1' , H"d ra-ad.

T a# M #- r/0 Mr. N.1rini2a/a Rao * 3ic Pr /id nt 4 5H T chnical Mr. An6ra! 3"a/ * D+M 7Proc //8 Mr. +.9anardhana Rao* 1 nior Mana! r 7Pro: ct8

REDDIPALAYAM CEMENT ;<R=1 * A PI<NEER

1tat of th art C # nt Plant co##i//ion d in th #ill nni6# " ar D /i!n d for 6/in! #6lti>l f6 l/. 5ir/t Plant in th world to ! t CDM cr dit for 6/ of alt rnat f6 l? A!ro wa/t /. No fatal accid nt/ /inc t n " ar/. Pion r d in wa/t h at r co2 r" fro# cool r to dr" th w t fl" a/h 3ol6ntaril" >artici>atin! in C1I 1wit@ rland

REDDIPALAYAM CEMENT ;<R=1 7RDC;8 UNIT 3I1I<N

T< AE REC<+NIBED A1 THE M<1T INN<3ATI3E C<MPANY( IN MEETIN+ THE CU1T<MER RECUIREMENT1,U1E <5 RENE;AALE ENER+Y 4 C<N1ER3IN+ RE1<URCE1 AY THE YEAR %&1D.

UNIT MI11I<N
AD<PTIN+ CREATI3ITY 4 INN<3ATI3E APPR<ACH IN C<NTINUAL IMPR<3EMENT <5 CUALITY, PR<DUCTI3ITY, 1Y1TEM1 AND PR<CE11E1. AD<PTIN+ 1TATE <5 THE ART TECHN<L<+IE1 5<R C<N1ER3IN+ THE RE1<URCE1 AND U1E <5 RENE;AALE ENER+Y. CREATIN+ 3IARANT ;<R= EN3IR<NMENT T< ATTRACT,M<TI3ATE 4 RETAIN EMPL<YEE1 T< ACHIE3E THE <R+ANIBATI<NAL <A9ECTI3E1. AUILDIN+ L<N+ LA1TIN+ C<RDIAL RELATI<N1HIP ;ITH 1<CIETY AND THE 1TA=E H<LDER1 AY PRACTICIN+ 1A5E EN3IR<NMENTAL 1TANDARD1. AD<PTIN+ 1A5ETY 5IR1T APPR<ACH IN ALL <UR ACTI3ITIE1 .
3

ENER+Y P<LICY

CEMENT MANU5ACTURIN+ PR<CE11

PLANT * 1ALIENT 5EATURE1

Ri>> r do@ r for #inin!

Co2 r d /tora! for raw #at rial and f6 l

Cro// A lt Anal"@ r

Ro-o la- for total E6alit" control

En r!" ffici nt Roll r Pr // for Pr $+rindin!

En r!" ffici nt /in!l dri2 -all #ill for c # nt !rindin!

Micro >roc //or -a/ d El ctronic PacF r

Ca>ti2 Th r#al Pow r >lant

6

METH<D<L<+Y 5<R IDENTI5YIN+ INN<3ATI3E PR<9ECT1

IN H<U1E INN<3ATI3E PR<9ECT * 1 1TEAM HEATER1 5<R D+ LUA <IL 4 HT ;ATER

A6/in // ca/ 0

HEATER1 Hi!h A6x >ow r con/6#>tion in D+ which i/ con/6# d -" L6- <il and HT wat r h at r/ d6rin! /to>> d condition 7%D&& =wh8

Pro: ct ai# 0 To r d6c D+ a6x >ow r con/6#>tion fro# %D&& =wh? da" to 1%&& =wh ? Da" Steam line from turbine
Lube oil heaters

HT water heater
Lube oil separator Lube oil Skid HT Water skid

Diesel Generator #1

ondensate line

ondensate tank

1TEAM HEATER 5<R HT ;ATER

1t a# I?L

L6- <il I?L 1t a# cond n/at Drain <?L

L6- <il <?L

1TEAM HEATER 5<R LUAE <IL

HT wat r <?L

1t a# I?L H at Exchan! r 1t a# cond n/at Drain <?L Cold wat r I?L

1t a# H at r/ for D+ L6- oil 4 HT ;at r h at r/

AENE5IT10
!ower Sa"in#s $ 1%%3&'6 (nits)Da* !ower Sa"in#s ) +nnum , 3-. da*s of T!! /unnin# 0 $ 16.'1&- (nits)+nnum Sa"in# per +nnum Steam 3ost 4 3-. da*s Total Sa"in#s $ %2&. La3s $ -&6 La3s $ %.&- La3s

11

IN H<U1E INN<3ATI3E PR<9ECT * % IMPR<3E THE PR<DUCTI<N <5 5LYA1H DRIER

A6/in // ca/ 0 !resentl* the 3ooler "ent #ases are utili5ed for dr*in# the wet fl* ash& The fl*ash drier is presentl* deli"erin# an output of '&2 T!H of dr* fl*ash Pro: ct ai# 0 To in3rease the drier produ3tion from '&2 T!H to 11 T!H Action TaF n0 (tili5e the pre heater e6it hot air for dr*in# wet fl*ash durin# 3oal mill not in operation onne3t the oal 7ill booster fan to 8l*ash drier inlet

12

IMPR<3E THE PR<DUCTI<N <5 5LYA1H DRIER

In2 /t# nt 0 R/. 4& LaFh/ A n fit/ 0 The annual sa"in# potential will be R/. G.HH LaFh/. Pa"-acF > riod 0 '. months.

IN H<U1E INN<3ATI3E PR<9ECT $ ' LI+NITE DRYIN+ 1Y1TEM

A6/in // ca/ 0 Hi!h /> cific h at con/6#>tion 7'G&& Fcal?Fwh8 wa/ #a:or i//6 for -oil r o> ration at RDC;. Pro: ct ai# 0 To r d6c /> cific h at con/6#>tion -" I& =cl?=wh Anal"/i/0 ;hil d alin! with con/traint, 1ix /i!#a 7DMAIC8 a>>roach i/ an ff cti2 /trat !".

14

LI+NITE DRYIN+ 1Y1TEM

Anal"/i/0 Anal"/i/ r 2 al d that -oil r h at lo// i/ #axi#6# d6 to hi!h #oi/t6r cont nt in li!nit , th /tati/tical /ol6tion/ ar con2 rt d to n!in rin! /ol6tion/

5itt d lin >lot indicat / h at lo// d6 to #oi/t6r cont nt in f6 l ha/ >o/iti2 corr lation with total h at lo// in -oil r

1catt r >lot indicat / that h at lo// with f6 l ha/ >o/iti2 corr lation with #oi/t6r cont nt in th f6 l

LI+NITE DRYIN+ 1Y1TEM 5ollowin! action taF n0 R n!in rin! of -oil r circ6it 4 A6nF r Pr h at d hot air taF n -" 5D fan to r d6c #oi/t6r l 2 l aro6nd IJ.
E&e,ation )-. /eter $ro( 'op Appro0 160/'2

6( Pipe * 20 Nos it! "# Nos o$ Air No%%&e in eac! Air 'e(p pipe ECO *0 Deg C

APH

ESP

Lignite Bunker

Flue Gas

Hot air lin to -6nF r to>. T #>.1&& d !.C

Furnace

ID Fan *3000 /# 4Hr

PA FAN-A

Air 'e(p )"0 Deg C

PA fan di/char!

F&ui+i%ation Air 6.3000 /# 4Hr

PA FAN-B

FD Fan )3003000 /# 4Hr capacit5

16

LI+NITE DRYIN+ 1Y1TEM

Li!nit +C3
'4&& '%&& '%&& =cal
II I) II.ID IH

Aoil r Effici nc"

'&&&
IG ID.%D

%H&&

%I&&

ID

%G&& A for Aft r

I4 A for Aft r

16/taina-ilit" 4 A n fit/0 Achi 2 d r d6ction in Plant h at rat -" 1IG =cal?=wh Th 1> cific f6 l con/6#>tion r d6c d fro# 1.'4 to 1.&H 7F!?Fwh8 EE6i2al nt Li!nit 1a2in!/ 1%)&I TPA C<% R d6ction of 141)H TPA

MA9<R ACTI3ITY T< REDUCE ENER+Y C<N1UMPTI<N PRE HEATER UP +RADATI<N RDC; - li 2 / in attainin!, r tainin! and contin6o6/l" r for#in! it/ n r!" con/ r2ation Initiati2 / fro# ti# to ti# . Hi!h /> cific h at con/6#>tion 7IH1 =cal?=! of clinF r8 wa/ th #a:or i//6 . RDC; tooF initiati2 / -" 6>!radin! >r h at r fro# 4 /ta! / to D /ta! / with Calcin r. Thi/ co/t faciliti /. Mo/t of th ci2il x c6tion and r ction wa/ taF n 6> >arall ll" alon! with th >lant o> ration/. ff cti2 /ol6tion with th #axi#6# 6/ of th xi/tin!

PRE HEATER UP +RADATI<N

R >lac d th to> twin c"clon with /in!l /ta! and addition of c"clon 74th to Dth 1ta! 8 Ext n/ion of Calcin r to incr a/ r /id nc ti# fro# %.D to 4.D / c.
<ld 11t 1ta! 7Twin8 $ Dia 4.G M N w 1in!l c"clon $ Dia I.% M %nd 1ta! * Dia I.% M %nd 'rd 1ta! * Dia G.' M 1ta! * Dia G.' M %nd 1ta! #odifi d to 'rd 1ta! $ Dia G.' M 'rd 1ta! #odifi d to 4th 1ta! $ Dia G.' M 7Con Modification8 4th 1ta! #odifi d to Dth 1ta! $ Dia G.) M Pr Calcin r * Dia G.) K '& M Pr H at r 5an * 3ol6# D.) Lac #'?hr Pr //6r * H&H ##w! Down Co# r D6ct * Dia '1D& ## Tand # El 2ator $ Ca>acit" %GH TPH CTC * 44 M PA 5an * 3ol6# G)1' #'?hr

4th 1ta! * Dia G.' M Pr Calcin r * Dia I.% K 1I M Pr H at r 5an * 3ol6# 4.HH Lac #'?hr Pr //6r * DHH ##w! Down Co# r D6ct * Dia '&&& ## =iln 5 d A6cF t l 2ator * Ca>acit" %1& TPH CTC * HD.DM

PA 5an * 3ol6# D1G& #'?hr

PRE HEATER UP +RADATI<N

EKI1TIN+ 4 $ 1TA+E

EKTENDED D$1TA+E

A n fit0 R d6ction in h at con/6#>tion -" %& =cal?=! of clinF r Incr a/ clinF r o6t>6t -" 1&& TPD

MA9<R ACTI3ITY T< REDUCE ENER+Y C<N1UMPTI<N C<<LER UP +RADATI<N U>!radin! to ffici nt 5L1 Cro// Aar cool r with HRA
Separate 3linker 3on"e*in# 9 3oolin# s*stem Stationar*: sealed #rate line Self;ad<ustin# me3hani3al flow re#ulators
<ld T"> * C5+ 1&D4 with 1&&I CI1 +rat Ar a * I1.% #% Cool r 3 nt 5an * Ca>acit" 1&D #'?/ 1tatic Pr //6r 7* IH4 8>a 11 Cool r 5an/ ClinF r Ar aF r 7CC 11& K '&&8 Cool r E1P d6/t con2 "in! * % dra! chain/ N w T"> * CA 1& K 4H Cro// -ar cool r with AAC Inl t +rat Ar a * H1.4 #% Cool r 3 nt 5an * Ca>acit" 11) #'?/ 1tatic Pr //6r 7* 1D&& 8>a I Cool r 5an/ H a2" d6t" roll r Ar aF r 7M5 HRA '1&8 Cool r E1P d6/t con2 "in! * 4 dra! chain/ with Aa! 5ilt r

C<<LER UP +RADATI<N

A n fit/ R d6ction in h at con/6#>tion -" %& =cal?=! of clinF r Pot ntial to incr a/ clinF r o6t>6t -" 1&& TPD . 1> cific Coolin! Air C6antit" r d6c d fro# %.' to 1.H N#'?=! of ClinF r

REDUCTI<N IN THERMAL ENER+Y

1PECI5IC HEAT C<N1UMPTI<N7 =cal ? =!. ClinF r

H&& IH% IH& =cal ? =! ClinF rr IH4 IH' IH1

PH 4 Cool r U>!radation

IG& I4%.HD I4&

I%&

I&&
&H$&) &)$1& 1&$11 11$1% 1%$1'

IN1PIRATI<N 5R<M CHAIRMAN

As a Group we have always operated and continue to operate our businesses as Trustees with a deep rooted obligation to synergize growth with responsibility.

ALTERNATE 5UEL 5EEDIN+ 1Y1TEM

D<RA Ca/h w n6t 1h ll/ 1aw D6/t Aio * co#>o/t M6nici>al ;a/t Coir ;a/t ? D6/t Corn ;a/t +ro6nd n6t /h ll Pal# / d 1h ll Match /ticF wa/t ;ood 1tri>/ 1hr dd d T"r / T"r / Powd r R fin r" 1l6d! Paint 1l6d! T"r Chi>/

INN<3ATI3E METH<D 5<R 5EEDIN+ ALTERNATE 5UEL IN =ILN

1%.&& 1&.&&

ALTERNATE 5UEL C<N1UMPTI<N <N T1R AA1I1

1&.H) 1&.)%
Plant U>!radatio n

I.)' H.&& G.&& D.'& 4.&& %.&&

Paint 1l6d! 1hr dd r

H.11 G.HI

H.'4

&.&&
&G$&I &I$&H &H$&) &)$1& 1&$11 11$1% 1%$1'

%2

UTILI1ATI<N <5 RENE;AALE ENER+Y

T"> In/tall d %&1&$11 Ca>acit" En r!" Ann6al in F; + n rat d 1a2in!/ 7F;h8 7R/.in #illion8 7DL%D&8 1)G1&&& =; D&& ; 1&& Fw 1&4&& $ H.I4 &.&44 $ %&11$%&1% Ann6al En r!" 1a2in!/ + n rat d 7R/.in 7F;h8 #illion8 %&I%H4H 1&D&& 114D1 ).HD &.&4) &.&D4 %&1%$%&1' En r!" Ann6al + n rat d 1a2in!/ 7F;h8 7R/.in #illion8 %&G&&GI 1&4&& 144&HD 11.'I &.&D% &.I%

;ind

1olar >hoto 2oltaic

EN3IR<NMENT PR<9ECT +REEN AELT DE3EL<PMENT

D) acr / of >lant ar a co2 r d with tr 16r2i2al rat $ )%J

>lantation/

C6#6lati2 No/.

=.... 6.... 3%.23.... .2;.6 .6;.' 3'=2-

Tr
-'.22

Po>6lation
223-2 61'6% 61-16

=31.6

1.2%=3

.';.1

.1;.=

.=;1.

1.;11

11;1%

1%;13

EN3IR<NMENTAL INITIATI3E1

LIME 1T<NE 1T<RA+E YARD

C<3ERED C<N3EY<R1

CLIN=ER 1IL<

C<AL 1T<RA+E YARD

RIPPER D<BER

RAIN ;ATER HAR3E1TIN+ AT MINE1

C<NCRETE R<AD IN THE PLANT

%1

5ICCI * <6t/tandin! Achi 2 # nt in En2iron# ntal 16/taina-ilit" of A6/in // Award 5ICCI /a"/ RDC; ha/ >ion r d th 6/a! of alt rnat f6 l f din! /"/t # in India. Thi/ t chnolo!" r d6c / C<% #i//ion .U/a! of alt rnat f6 l al/o r d6c / co6ntr"M/ o2 rall d > nd nc on i#>ort d f6 l/.

Thi/ Award r c i2 d -" Mr/. Ra:a/hr Airla fro# Dr. Man Mohan 1in!h, Honora-l Pri# Mini/t r of India d6rin! th 5ICCI H&th A+M at N w D lhi

1PECI5IC P<;ER C<N1UMPTI<N IN PPC

Low Dr" 5l" a/h a2aila-ilit"

G) GI.'G GG =;H ? Ton of C # nt G' G& DI D4 D1 4H 4D

&I$&H &H$&) &)$1& 1&$11

GD.)4 G'.DG G'.14 G'.&%

GG.)G

11$1%

1%$1'

PR<9ECT1 IMPLEMENTED 1UMMARY

PARTICULAR1 Total >o of !ro<e3ts implemented ,>os0 ?le3tri3al Sa"in#s a3hie"ed ,million units0 Total in"estment ,/s in 7illion0 Total Sa"in#s ,/s in 7illion0

;ITH IN3E1TMENT1 &)$1' -1 31&.% 1.-'&31'1&.=

;ITH<UT IN3E1TMENT1 &)$1' ' 2&12 >il %6&33

31

En r!" /a2in! >ro: ct/ with o6t in2 /t# nt

Titl of th Pro: ct/ I#>l # nt d +rrestin# false air a3ross @iln inlet seal ompressor inter3ooler 3leanin# in !ower plant 8alse air leaka#es arrestin# in /aw mill 9 oal mill 8reAuen3* redu3tion from -=&=h5 to -=&2h5 /edu3tion of hi#h e63ess air in boiler in !ower !lant Belt interlo3kin# done in 3la* feedin# area& Cnterlo3kin# /! 3oolin# fans&

El ctrical 1a2in!/ achi 2 d 7F;h8 22&16 %&-3 1&111&2-&2= 1&13 1&-1

In2 /t# nt 7R/. Milion8 >il >il >il >il >il >il >il

En r!" /a2in! >ro: ct/ with in2 /t# nt %&&)$1&

Titl of th Pro: ct/ I#>l # nt d (se of ener#* effi3ient bearin#s& Cnterlo3kin# of pa3kin# plant ba# filters& /epla3ement of new "ersion S!/S in /aw mill fan& /epla3ement of normal pumps b* submersible pumps in /aw mill 9 oal mill& Cnstallation of D8D for !ower plant 3oolin# Tower fan & Cnstallation of !anel +ir 3onditioner 9 ?6haust fan in !ower !lant & /epla3ement of 12.W H!SD b* -2W 8L Waste #as utili5ation for dr*in# wet fl*ash ,Waste heat re3o"er* s*stem0&

El ctrical 1a2in!/ achi 2 d 7F;h8 .&11 =&3% %=&'= -&2' =&36 2&-1 %&=' 2&'6

In2 /t# nt 7R/. Milion8 .&.% .&.3 2&2. .&..&..&.% .&.% '&..

En r!" /a2in! >ro: ct/ with in2 /t# nt %&1&$11

Titl of th Pro: ct/ I#>l # nt d Bob3at C/ 7a3hine for remo"in# bri3k debris from kiln& ,shut down power redu3ed&0 7odifi3ation of ontrol !anel for 62. @W oal mill ?S! 8an & Cnstallation of S3rew ompressor in pla3e of /e3ipro3atin# air 3ompressor /epla3ement of H!SD,Hi#h !ressure Sodium Dapour0 Bulb to 8L, ompa3t 8luores3ent Lamp0 ooler Dent 8an /epla3ement& '%= 8>1 8an repla3ement& /epla3ement of Turbine Gland seal for better effi3ien3* in !ower plant& /epla3ement of re3ipro3atin# 3ompressor b* s3rew 3ompressor&

El ctrical 1a2in!/ achi 2 d 7F;h8 -1&.2 %-&66 2&1%&== 3-&1% 2&'1 36=&11 1&16

In2 /t# nt 7R/. Milion8 %&%. 1&3. .&=. 1&.. 36&=% 2-&%6

%.1&'

En r!" /a2in! >ro: ct/ with in2 /t# nt %&11$1%

El ctrical 1a2in!/ achi 2 d 7F;h8 1&13 -6&21 1&13 1&13 3&11 2&-1 11&== 21&%% 16&'1 12&=1 '&-% 6=&16 In2 /t# nt 7R/. Milion8 .&2. %.&.. .&2. .&6. .&'. .&1= .&-6 6&.. .&%1 1&2. .&.1 %&'.

Titl of th Pro: ct/ I#>l # nt d D8D 8or Ba# filter fan -31 8>Cnstallation of Solar li#htin# ,1..@W0 at 3olon*& D8D 8or Ba# filter fan 3=1 8>D8D 8or Ba# filter fan 2=1 8>D8D 8or Ba# filter fan 231 8>D8D for ondensate e6tra3tion !ump D8D for CD 8an 7otors !re;Heater fan S!/S installation& Sta#e redu3tion of boiler feed pump Cmpro"ement of !ower 8a3tor for ?B suppl* Swit3hin# off of !re;heater G// oolin# fan durin# S!/S runnin# !ressuri5ation and Dentilation s*stem for !*ro pro3ess 3ompressor house

En r!" /a2in! >ro: ct/ with in2 /t# nt %&1%$1'

El ctrical 1a2in!/ achi 2 d 7F;h8 %&'= %&'= 3&'3 3&%2 '&-2 3&%2 3&%2 %.-&3%&-. In2 /t# nt 7R/. Milion8 .&3. .&3. .&3. .&3. .&-. .&3. .&3. -&2. .&3.

Titl of th Pro: ct/ I#>l # nt d D8D 8or Ba# filter fan -=1 8>1 D8D 8or Ba# filter fan -=1 8>% D8D 8or Ba# filter fan -11 8>% D8D 8or Ba# filter fan 211 8>1 D8D 8or Ba# filter fan 231 8>1 D8D 8or Ba# filter fan -31 8>-+ D8D 8or Ba# filter fan -=1 8>1. Dariable 8reAuen3* dri"e for s3rew 3ompressor at power plant /epla3ement of Tube li#hts with L?D lamps

CII ENER+Y AUDIT$9AN %&1'

Total number of pro<e3t identified $ 22 >os&

!ro<e3t identified without in"estment $ %1 >os& !ro<e3t identified with in"estment +nnual sa"in#s from the !ro<e3t 1& %& 3& -& 2& 6& '& 1& $ 3- >os& $ /s& 22- Lakh

1o# of th Ma:or Pro: ct/ /edu3e the loss on i#nition ,LEC0 in fl*ash and bed ash of 1%&2 mw unit Cnstall multi;sta#e dra# "al"es for boiler feed pump re;3ir3ulation Cnstall e6pert optimisation s*stem for 1%&2 mw unit Eptimi5e the operatin# freAuen3* of #enerators Eptimise operation of kiln and p3 3oal firin# blowers Eptimi5e D/7 feed si5e b* redu3in# the 3rusher output si5e Cnstall automation s*stem for kiln /edu3e fines in the 3ement mill separator re<e3t durin# !! #rindin#

<n +oin! En r!" /a2in! >ro: ct/ %&1'$14 4 %&14$1D

El ctrical 1a2in!/ 7F;h8 3&-% 1'&6= %&21 1&1%&=' 3&%. 2&-1 1&33 1&-1 1&11 -=&%. In2 /t# nt 7R/. Million8 .&.. 1&'. .&13 .&.. .&.2 .&.. .&32 .&.. .&.6 .&.2 .&..

Titl of th Pro: ct/ Eptimise the operation of ?! Eptimise the operation of B8! 7ultista#e sta#e pressure redu3tion dra# "al"e Eptimise the operation of instrument air 3ompressor Cmpro"e the effi3ien3* of the ash 3on"e*in# ompressor 7inimise 3ompressed air leaka#e in ash 3on"e*in# area Cmpro"e the #rid !ower fa3tor Eptimi5e the Dolta#e of Distribution Transformer /epla3e 7etal Halide lamps with 7a#neti3 Cndu3tion Lamps /epla3e H!7D Lamps with 8L Lamps in the !a3kin# !lant Eptimise the Eperatin# 8reAuen3* of Generator

<n +oin! En r!" /a2in! >ro: ct/ %&1'$14 4 %&14$1D

El ctrical 1a2in!/ 7F;h8 6&'.&63 1.&3= =&'6 1&'3 .&-3 %&-= '&=3 -1&%. 12&'% -.&.1 In2 /t# nt 7R/. Million8 .&%. .&.% .&1. .&6. .&.. .&.1 .&.% .&.2 .&2. .&.. .&..

Titl of th Pro: ct/ /epla3e H!7D Lamps with 8L Lamps in !! /epla3e H!7D lamp with 7etal Halide Lamps in the !! Eptimi5e the 8l* +sh (nloadin# s*stem Eptimi5e the 3apa3it* of ement 7ill 9 !a3ker ompressor 7inimi5e ompressed +ir Leaka#e in the !lant /epla3e 3ompressed +ir with Blower Eptimi5e the operation of 3oolin# tower fans Eptimi5e ement mill 3oolin# water 3ir3uit Eptimise operation of oal firin# blowersF @iln 9 ! +"oid pressure drop a3ross silen3er in ooler 8ans Eptimi5e D/7 8eed si5e in /aw 7ill

<n +oin! En r!" /a2in! >ro: ct/ %&1'$14 4 %&14$1D

El ctrical 1a2in!/ 7F;h8
11&%6 %&'-&2' 111&'% 111&23 3%&-% -&'= 13-&'. 1&1' .&%2 1&6% -&.2

Titl of th Pro: ct/

/edu3e !ressure drop a3ross /aw mill fan outlet to ?S! inlet Eptimi5e su3tion in /aw 7eal Silo Top Ba# 8ilter Eptimi5e operation of Cdentified ba# filters Eptimise D*nami3 separator !erforman3e Eptimi5e Separator "ent "olume for ement 7ill Cmpro"e mill "entilation for 7 /edu3e pressure drop a3ross 7 "ent fan inlet damper Cmpro"e ement 7ill outlet material fineness Eptimi5e the operation of 3ement silo top air slide fans Eptimi5e the operation of 7 separator "ent Ba# filter +ir slide fan Eptimi5e ement mill silo aeration blowers Eptimi5e su3tion in 8l* +sh bin ,'2. 7T; >ew Bin0

In2 /t# nt 7R/. Million8

.&1. .&.. .&.. %2&.. .&.. .&.. .&.. 6&.. .&.. .&.. .&11 .&1.

PAT INITIATI3E1

Baseline GTG Tar#et to redu3e GTG

F '-6&1' @3al ) @# ?Aui"alent 3ement produ3t F -&11G

Tar#et Sp& ?ner#* 3onsumption F '1-&== @3al ) @# ?Aui"alent 3ement produ3t +3hie"ed in %.1%;13 F '1=&61 @3al ) @# ?Aui"alent 3ement produ3t

TEAM ;<R= IN ENC<N

16!! /tion /ch # in RDC; !i2 / o>>ort6nit" to #>lo" / for dir ct >artici>ation in n r!" con/ r2ation 4 >rod6cti2it" i#>ro2 # nt initiati2 /.

N o/ of /6! //tion/?Fai@ n/ i# >l # nt d

14&& 1%&& 1&&& H&& G&& 4&& %&& 1%I &

&H$&) &)$1& 1&$11 11$1%

1'%4

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%ID

'11

1%$1'

-%

ENER+Y M<NIT<RIN+ 4 REP<RTIN+ 1Y1TEM1

Plot-0 62.2 48 80 800 120 1300 48.4 43 =N<;LED+E MANA+ER 1<5T;ARE GCS CM RPMOVMOTORDETEMP 62.125 DEG C GCS CM RPMOVMOTORNDETEMP 47.922 DEG C GCS CM RP1CURRENT 48.302 AMPS GCS CM RP1LOAD 404.36 KW GCS CM RP2CURRENT 82.374 AMPS GCS CM RP2LOAD 838.53 KW GCS CM RPFIXEDMOTORDETEMP 48.273 DEG C GCS CM RPFIXEDMOTORNDETEMP 42.656 DEG C

62

Indi2id6al MCCM/ wi/ and / ction wi/ >ow r d tail/. 1>

61.8

d, load, c6rr nt and r6nnin! ho6r/ of all critical E6i># ntN/.

61.6

Co#>r //or/, wat r >6#>/ and -or w ll/ r6nnin! ho6r/. 1tart?/to> >ow r for all E6i># nt/ I#>ortant >ara# t r/ liF draft, t #> rat6r , f #onitor d and r cord d.
40 8.00 hours 7/26/2008 10:55:25 AM

61.4

61.2

d rat ar

61 44.5 30 100 50 400 47 7/26/2008 2:55:25 AM RP MOV MOTOR DE TEMP RP MOV MOTOR NDE TEMP Roller Press1 CURRENT Roller Press1 LOAD Roller Press2 CURRENT Roller Press2 LOAD RP FIXED MOTOR DE TEMP RP FIXED MOTOR NDE TEMP

<nlin #onitorin! of >ara# t r/ in DC1. HT #otor/ >ow r and t #> rat6r d tail/

43

ENER+Y M<NIT<RIN+ 4 REP<RTIN+ 1Y1TEM1

Dail" d 2iation anal"/i/. Dail" 3i-ration 4 A arin! T #> rat6r D 2iation R >ort PI /"/t # a2aila-l in all PC and 2 r" n!in Dail" R >ort on Utili@ation of 3ario6/ 56 l/.
P lot-0 100 1000 100

r can #onitor all >ara# t r/.

0.11236 861.38 79.931

80

60

G CS C OOLE RGR ATE 2LO AD -5.0070 KW G CS C OOLE RGR ATE 2SP E E D -124.12 R P M G CS C OOLE RU N DE R GRATE 2SE TP OINT 0.0000 m m W C

40

20

-20 -200 0 9/24/200 9 1:0 5:55 AM

hours AM 9/24/20093.34 2:43:05.022 COOLE RGRAT E2 LOAD C OOLE RGR ATE2 SP E E D UN DE R GR ATE 2 SE TP OIN T

9/24/2009 4:26:07 AM

44

ENER+Y M<NIT<RIN+ 4 REP<RTIN+ 1Y1TEM1 DAILY0 Dail" En r!" d 2iation r >ort ;EE=LY0 En r!" Con/ r2ation M Ca> x 9o-/?Pro: ct M 1 ction wi/ R 2i w M En r!" Ta/F 5orc M M<NTHLY0 Pow r Co#>ari/on with !ro6> 6nit/ Ar aFdown Anal"/i/ R >ort Monthl" P rfor#anc R 2i w M Monthl" Co##6nication M tin! tin! tin! tin! tin! tin!

45

I1< )&&1, 14&&1,1H&&1 4 %I&&1 CERTI5ICATI<N AUDIT <A1ER3ATI<N1 7A>ril$%&1'8

REPLICATI<N ARI1IN+ <UT <5 AE1T PRACTICE1 THR<U+H A11<CIATE1

A /t Practic / Cnstallation of >ew "ersion of +BB ontroller ,?!C ;30 for ?le3tro stati3 pre3ipitators Cnstallation of Delta star 3on"erters for belt 3on"e*ors Shell oolin# fan dri"es taken in D S for interlo3kin# Cnstallation of !;%. li#htin# ener#* sa"er in T!! han#in# of +luminum impeller b* 8/! ,8iber reinfor3ed !lasti3s0 impeller in @iln shell 3oolin# fans /etrofittin# ele3troni3 temperature 3ontrol de"i3es in old and manual window air 3onditioners for ener#* sa"in#s !ower fa3tor is maintained #reater than .&=1 Cnstallation of D8Ds for the oolin# water 3ir3ulation pumps to optimise the water flow to the 3ondenser for the TG set D8D for 3oolin# towers 9 ondensate e6tra3tion pump Boiler feed water pump sta#e redu3tion Eptimisation of runnin# of air 3ompressors usin# 7ana#ement S*stem ompressed +ir 1o6rc Group (nits Group (nits Group (nits CC onferen3e CC onferen3e Group (nits Group (nits Group (nits Group (nits Group (nits CC onferen3e

47

=N<;LED+E 1HARIN+

; ar alr ad" >art of C1I $ 1wit@ rland Partici>atin! in - nch#arFin! >roc // of ;hit ho>l #an 4 oth r/. P6-li/hin! - /t >ractic / in C # nt /6/taina-ilit" r >ort. 1harin! - /t /af t" 4 n2iron# ntal >ractic / =nowl d! 6> !radation at all l 2 l/ Partici>atin! in AEEM/ PAT 1ch # .

A;ARD1 4 ACC<LADE1 * %&1%$1'

Ta#ilnad6 Poll6tion control -oard $ +r Mo/t 6/ f6l >r / ntation Award -" CII +r nt ch En2iron# nt Award * +old cat !or" India C # nt 1 #inar * A /t Pa> r Award n Man6fact6rin! Exc ll nc Award '1/t All n Award

National Exc ll nc for En r!" Effici nt Unit Award -" CII

5ro/t 4 16lli2onM/ +r

Ta#il Nad6 1tat L 2 l 1af t" Award 71ch # II $ Low /t 5r E6 nc" rat 8

Lif /tand /till aft r 16n / t $ A total of 1.G -illion > o>l ha2 no acc // to l ctricit", H&J of th # in India

L t 6/ Con/ r2

l ctricit" to li!ht 6>

#illion/ of ho# / in India.