ACC LIMITED, GAGAL CEMENT WORKS

Format No.:
Last review date:
Rev. No.:
Page 1 of 19

ENERGY REVIEW

DEPT./AREA: _______

ENERGY REVIEW

SR.NO.

AREA

Prepared by

MACHINE
OR ZONE

ENERGY USAGE

SAVING
POTENTIAL

Approved By

TECHNOLOGICAL
FEASIBILITY

POSSIBILITY
FOR USAGE
OF
RENEWABLE
ENERGY

POTENTIAL
FOR WASTE
HEAT
RECOVERY

APPLICABLE
LEGAL
REQUIREMENT

Issued by

SIGNIFICANCE
NUMBER

STATUS OF
SIGNIFICANCE
YES

NO

CURRENT
CONTROLS

CONTROLS REQUIRED
REMARKS

ACC LIMITED, GAGAL CEMENT WORKS

Format No.:
Last review date:
Rev. No.:
Page 2 of 19

ENERGY REVIEW

DEPT./AREA: _______

ENERGY REVIEW

SR.NO.

AREA

Prepared by

MACHINE
OR ZONE

ENERGY USAGE

SAVING
POTENTIAL

Approved By

TECHNOLOGICAL
FEASIBILITY

POSSIBILITY
FOR USAGE
OF
RENEWABLE
ENERGY

POTENTIAL
FOR WASTE
HEAT
RECOVERY

APPLICABLE
LEGAL
REQUIREMENT

Issued by

SIGNIFICANCE
NUMBER

STATUS OF
SIGNIFICANCE
YES

NO

CURRENT
CONTROLS

CONTROLS REQUIRED
REMARKS

DEPT./AREA: Gagal Limestone Mines

ENERGY REVIEW

SR.N
O.

AREA

MACHINE OR ZONE

ENERGY USAGE

SAVING
POTENTIAL

TECHNOLOGICAL
FEASIBILITY

STATUS OF
POSSIBILITY
SIGNIFICANCE
POTENTIAL APPLICABLE
FOR USAGE
SIGNIFIC
FOR WASTE
LEGAL
OF
ANCE
HEAT
REQUIREME
RENEWABLE
NUMBER
RECOVERY
NT
YES
NO
ENERGY

CURRENT
CONTROLS

GAGAL LIMESTONE MINES

Nursary

Water pump -55 KW

Usage of electrical energy in water

pump operation

10

NA

17

Yes

Manual Operation
through DOL
Starter.

Nursary

Water pump -22 KW

Usage of electrical energy

NA

NO

Manual Operation
through DOL
Starter.

Hopper No -2

Water pump -30 KW

Usage of electrical energy

NA

NO

Manual Operation
through DOL
Starter.

Hopper No -2

Water pump -30 KW

Usage of electrical energy in

operation.

NO

Manual Operation
through DOL
Starter.

NO

Manual Operation
through DOL
Starter.

NO

Manual Operation
through DOL
Starter.

NO

Manual Operation
through DOL
Starter.

NO

Operation through
DC Compound
motor & Thyristor
drive Panel.

NO

Operation Through
DOL Starter &
control by PLC
system.

Mines Office

Water pump - 22 KW

Crusher Hopper

Water Pump - 15 KW

Crusher Hopper

Water Pump - 15 KW

Appron Feeder

90 KW

Usage of electrical energy in

operation.

Spillage Conveyor

3.7 KW

Approved By

NA

NA

NA

NA

Usage of electrical energy in

operation.
0

Prepared by

NA

Usage of electrical energy in

operation.
7

Usage of electrical energy in

operation.
0

Usage of electrical energy in

operation.
0

Issued by

NA

Issue date:

DEPT./AREA: Gagal Limestone Mines

ENERGY REVIEW

SR.N
O.

10

AREA

Impactor Crusher

MACHINE OR ZONE

1100 KW

ENERGY USAGE

SAVING
POTENTIAL

Usage of electrical energy in

operation.

20
10

11

12

Laminated Conveyor

Hammer Crusher

90 KW

600 KW

Usage of electrical energy in

operation.

Belt Conveyor- LSH 1

45 KW

10

Belt Conveyor- LSH 2.02

18.5 KW

Usage of electrical energy in

operation.
0

NA

15

Belt Conveyor- LSH 2.03

55 KW

Usage of electrical energy in

operation.

NA

16

Belt Conveyor- Shuttel Belt

9.5 KW

Usage of electrical energy in

operation.

NA

17

Belt Conveyor- LSH 3

45 KW

Usage of electrical energy in

operation.

NA

18

Belt Conveyor- LSH 4A

110 KW

Usage of electrical energy in

operation.

NA

19

Belt Conveyor- LSH 5 - Motor No-1

160 KW

Usage of electrical energy in

operation.

20

Belt Conveyor- LSH 5 - Motor No-2

110 KW

Usage of electrical energy in

operation.

Approved By

10

NA

NA

Issued by

Operation Through
vaccume Ckt.
Breaker(HT) &
control by PLC
system.
Operation through
DC Compound
motor & Thyristor
drive Panel.

NO

13

YES

Operation through
DOL Starter &
controlled by PLC
system.

NO

NO

NO

NO

NO

13

YES

NO

NA

14

Prepared by

CURRENT
CONTROLS

Operation Through
vaccume Ckt.
Breaker(HT) &
control by PLC
system.

NA

Usage of electrical energy in

operation.
10

NO

NA

Usage of electrical energy in

operation.
0

Yes

NA
7

13

TECHNOLOGICAL
FEASIBILITY

STATUS OF
POSSIBILITY
SIGNIFICANCE
POTENTIAL APPLICABLE
FOR USAGE
SIGNIFIC
FOR WASTE
LEGAL
OF
ANCE
HEAT
REQUIREME
RENEWABLE
NUMBER
RECOVERY
NT
YES
NO
ENERGY

Operation through
DOL Starter &
controlled by PLC
system.
Operation through
DOL Starter &
controlled by PLC
Operation through
system.
DOL Starter &
controlled by PLC
Operation through
system.
DOL Starter &
controlled by PLC
Operation through
system.
DOL Starter &
controlled by PLC
system.
Operation through
DOL Starter &
controlled by PLC
system.
Operation through
DOL Starter &
controlled by PLC
system.

Issue date:

DEPT./AREA: Gagal Limestone Mines

ENERGY REVIEW

SR.N
O.

21

AREA

Belt Conveyor- LSH 5 - Motor No-3

MACHINE OR ZONE

ENERGY USAGE

88.5 KW

Usage of electrical energy in

operation.

22

Belt Conveyor- LSH 2.04

75 KW

Usage of electrical energy in

operation.

23

Belt Conveyor- LSH 2.05

160 KW

Usage of electrical energy in

operation.

SAVING
POTENTIAL

NA

NA

3
24

Stacker- Boom Belt

75 KW

TECHNOLOGICAL
FEASIBILITY

STATUS OF
POSSIBILITY
SIGNIFICANCE
POTENTIAL APPLICABLE
FOR USAGE
SIGNIFIC
FOR WASTE
LEGAL
OF
ANCE
HEAT
REQUIREME
RENEWABLE
NUMBER
RECOVERY
NT
YES
NO
ENERGY

Stacker- Boom Hoist

5.5 KW

Usage of electrical energy in

operation.

NA

26

Stacker Travelling- Motor -1

5.5 KW

Usage of electrical energy in

operation.

NA

27

Stacker Travelling- Motor -2

5.5 KW

Usage of electrical energy in

operation.

NA

Usage of electrical energy in

operation.
Crusher- Dust Collector Fan

30

Crusher- Dust Collector Compressor

55 KW
37 KW

Usage of electrical energy in

operation.

NA

NA

Usage of electrical energy in

operation.

31
Hammer Crusher- Hydraulic Pump

15 kw

NO

NO

NO

NO

NO

NO

NO

NO

NO

NA

25

29

NO

NA

Usage of electrical energy in

operation.
3

NA

CURRENT
CONTROLS

Operation through
DOL Starter &
controlled by PLC
system.
Operation through
DOL Starter &
controlled by PLC
system.
Operation through
DOL Starter &
controlled by PLC
system.
Manual Operation
through control
panel.
Manual Operation
through control
panel.
Manual Operation
through control
panel.
Manual Operation
through control
panel.
Operation through
DOL Starter &
controlled by PLC
system.
Operation through
DOL Starter &
controlled by PLC
system.
Manual Operation
through control
panel.

GAGAL MINES HSD ASPECT

Prepared by

Approved By

Issued by

Issue date:

DEPT./AREA: Gagal Limestone Mines

ENERGY REVIEW
STATUS OF
POSSIBILITY
SIGNIFICANCE
POTENTIAL APPLICABLE
FOR USAGE
SIGNIFIC
FOR WASTE
LEGAL
OF
ANCE
HEAT
REQUIREME
RENEWABLE
NUMBER
RECOVERY
NT
YES
NO
ENERGY

SR.N
O.

AREA

MACHINE OR ZONE

ENERGY USAGE

SAVING
POTENTIAL

TECHNOLOGICAL
FEASIBILITY

Drilling

Drill Machines

Consumption of HSD

10

NA

17

Yes

Monitoring &
Controlling of
Operation & Maint.
Practices

Loading of Limestone

Shovels

Consumption of HSD

NA

17

Yes

Monitoring &
Controlling of
Operation & Maint.
Practices

Transporting of Limestone

Dumpers

Consumption of HSD

10

NA

17

Yes

Monitoring &
Controlling of
Operation & Maint.
Practices

Supporting Equipments

Dozer,LMV's

Consumption of HSD

10

NA

13

Yes

Monitoring &
Controlling of
Operation & Maint.
Practices

Prepared by

Approved By

Issued by

CURRENT
CONTROLS

Issue date:

DEPT./AREA: Gagal Limestone Mines

ENERGY REVIEW

SR.N
O.

AREA

Prepared by

Approved By

MACHINE OR ZONE

ENERGY USAGE

SAVING
POTENTIAL

TECHNOLOGICAL
FEASIBILITY

Issued by

STATUS OF
POSSIBILITY
SIGNIFICANCE
POTENTIAL APPLICABLE
FOR USAGE
SIGNIFIC
FOR WASTE
LEGAL
OF
ANCE
HEAT
REQUIREME
RENEWABLE
NUMBER
RECOVERY
NT
YES
NO
ENERGY

CURRENT
CONTROLS

Issue date:

DEPT./AREA: Gagal Limestone Mines

ENERGY REVIEW

SR.N
O.

AREA

Prepared by

Approved By

MACHINE OR ZONE

ENERGY USAGE

SAVING
POTENTIAL

TECHNOLOGICAL
FEASIBILITY

Issued by

STATUS OF
POSSIBILITY
SIGNIFICANCE
POTENTIAL APPLICABLE
FOR USAGE
SIGNIFIC
FOR WASTE
LEGAL
OF
ANCE
HEAT
REQUIREME
RENEWABLE
NUMBER
RECOVERY
NT
YES
NO
ENERGY

CURRENT
CONTROLS

Issue date:

DEPT./AREA: Gagal Limestone Mines

ENERGY REVIEW

SR.N
O.

AREA

Prepared by

Approved By

MACHINE OR ZONE

ENERGY USAGE

SAVING
POTENTIAL

TECHNOLOGICAL
FEASIBILITY

Issued by

STATUS OF
POSSIBILITY
SIGNIFICANCE
POTENTIAL APPLICABLE
FOR USAGE
SIGNIFIC
FOR WASTE
LEGAL
OF
ANCE
HEAT
REQUIREME
RENEWABLE
NUMBER
RECOVERY
NT
YES
NO
ENERGY

CURRENT
CONTROLS

Issue date:

10

CONTROLS REQUIRED

REMARKS

Replacement of 55 kw Motor
IMP 01(Completed)
with 18.5 KW Motor

Efficient operation

Efficient operation

Efficient operation

Efficient operation

Efficient operation

Efficient operation

Idle Running will be

minimized

Prepared by

Approved By

Issued by

Issue date:

11

CONTROLS REQUIRED

Idle Running will be

minimized

REMARKS

OCP

Idle Running will be

minimized

Motor Should be replaced by

IMP-3 in belt conveyor.
22 KW motor

Idle Running will be

minimized

Idle Running will be

minimized
Idle Running will be
minimized
Idle Running will be
minimized
Idle Running will be
minimized
Motor Should be replaced by
IMP-4 in belt conveyor.
110 KW motor
Idle Running will be
minimized

Prepared by

Approved By

Issued by

Issue date:

12

CONTROLS REQUIRED

REMARKS

Idle Running will be

minimized
Idle Running will be
minimized

Idle Running will be

minimized

Idle Running will be

minimized

Idle Running will be

minimized
Idle Running will be
minimized

can be operated as per

requirement only.

can be operated as per

requirement only.

Prepared by

Approved By

Issued by

Issue date:

13

CONTROLS REQUIRED

REMARKS

Monitoring & Controlling of

Operation & Maint.
Practices

OCP

Procurement of Small Shovel

PC-650

IMP

Monitoring & Controlling of

Operation & Maint.
Practices

OCP

Monitoring & Controlling of

Operation & Maint.
Practices

OCP

Prepared by

Approved By

Issued by

Issue date:

14

CONTROLS REQUIRED

Prepared by

Approved By

REMARKS

Issued by

Issue date:

15

CONTROLS REQUIRED

Prepared by

Approved By

REMARKS

Issued by

Issue date:

16

CONTROLS REQUIRED

Prepared by

Approved By

REMARKS

Issued by

Issue date:

17

SAVING POTENTIAL RATING (A)

TECHNOLOGICAL/ IMPLEMENTATION
FEASIBILITY RATING (B)

Less than 2000 Units/annum

Easy to implement well

established
technology/method, very
simple changes are
required

10

Less than 20,000

units/annum

Minor changes are

required (Revenue Budget)

Less than 2,00,000 Units/

annum

Major
interventions/changes are
required (CAPEX)

More than 2,00,000 Units

/annum

10

Technology not available

or not a proven technology

1 KW = 860 Kcal = 3600 KJ

1 Kcal = 4.187kj

Note
Give 1 mark bonus if the potential for waste heat recovery is there
Give 2 marks bonus if the selected option is renewable
options will not be significant in any case when, either A Or B is zero

Prepared by

Approved By

Issued by

Issue date:

36.5

438000

50

5475
273750

20000

100000