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					         ULTRATECH CEMENT LIMITED
                                                     ADITYA BIRLA GROUP - PROFILE
        (UNIT:-REDDIPALAYAM CEMENT
                  WORKS )                                                             BUSINESSES
             Welcome to CII                  GROUP              COMPANIES

                                                                                     ALUMINIUM
“11th National Award for Excellence in                  ABMCL
                                                        ADITYA BIRLA RETAIL          CARBON BLACK

      Energy Management- 2010”                          ADITYA BIRLA CHEMICALS
                                                        ADITYA BIRLA NUVO
                                                                                     CEMENT
                                                                                     CHEMICALS
                                                        BCCL                         COPPER
                                                        BIRLA CARBON                 FERTILIZER
                                                        BIRLA GLOBAL FINANCE         FINANCE

Team Members                                            ESSEL MINING & INDUSTRIES
                                                        GRASIM INDUSTRIES
                                                                                     GARMENTS
                                                                                     INSULATORS
                                                        HINDALCO INDUSTRIES          INSURANCE
Ashish Panpalia.                                        IDEA CELLULAR
                                                        INDAL ALUMINIUM INDUSTRIES
                                                                                     IT
                                                                                     RETAIL
                                                        INDO GULF FERTILIZERS &
M.P Singh.                                              CHEMICALS
                                                        PSI DATA SYSTEMS
                                                                                     STAPLE FIBRE
                                                                                     TELECOM
                                                                                     TEXTILE
                                                        ULTRATECH CEMENT
G.Suresh Kumar .                         1              LIMITED                      VISCOSE        2
                     ADITYA BIRLA GROUP                                                                   CEMENT BUSINESS AT A GLANCE
                         CEMENT BUSINESS
                                                                                                                                                •49     Million MT capacity
                                                                                                                                                •12     Integrated Units .
INTEGRATED UNITS                                                                                                                                •11     Split Grinding Units.
                                                                                                                        BhatindaDadri
                                                                                                                                  (G)           •5      Bulk terminals.
                                                                                                                                                •69     Ready-mix concrete plants.
                                                                                                                         Noida Gurgaon
                                                                                                                          Panipat Aligarh
                                                                                                                      Jodhpur
RAC   REC   ACW    APC     ADC   VCW    KCW            GCW                                                                  Shambhupura
W                  W       W                   RCW             HCW      NJFD                                    Kotputli
      W
                                                                                                                               Jawad
                                                                                                                                                             (G)
                                                                                                                                                       Durgapur
                                                                                                              Jaffrabad
                                                                                                                               (
                                                                                                                        MagdallaG)
                                                                   BIRLA WHITE                             Kovay                            Hirmi
                                                                                                           a                 Awarpur                Raipur
                                                                                                                                                         Jharsuguda
                                                                                                                                                                  (G)   RECW
GRINDING UNITS                                                                                                NaviMumbai B         (G)
                                                                                                                               Hotgi
                                                                                                                       (G)
                                                                                                                Ratnagiri                Hyderabad

                                                                                     White cement plant                  Malkhed
                                                                                                                   Ginigera         Tadipatri
                                                                                     Ready mix Concrete plants                 Bangalore
                                                                                                               MangaloreB       B          Chennai
NRC   ARC   NCMW   WBC                   DCW                 GEC
W     W            W       JCW
                                  BCW                ALC
                                                             W
                                                                        HOC          Ultratech Cement Plants                      (G)
                                                                                                                           Arakonam
                                               PCW   W                  W
                                                                                                                                          Reddipalayam
                                                                                     Ultratech Grinding Units (G)
                                                                          3      B   Ultratech Cement Terminals                                                                 4
             CEMENT MANUFACTURING PROCESS                                                                                        PLANT – SALIENT FEATURES

                                                                                  4 Stage                 •Reddipalayam cement works capable of using multiple fuels successfully
                                                                                  Preheate
                                                                                     r
                                                                                                          •Leader in waste fuel utilization in India
                                                                                          Coal Mill
                                                                 Raw Meal                                 •First Cement Plant in the World to get CDM
Mines                                                              Silo
                                                                                                          •Cross Belt Analyzer
                                                           Raw Mill                                       - Use of different limestone mix from four to five mines on daily basis
                                                Raw
              Crusher                          Material                                                   - Use of Marl (low grade limestone) up to 10 %
                                               Hopper
                                  Stacker &
                                  Reclaimer
                                                                                         Kiln             - No additives used other than Limestone & Marl for raw meal quality
                                                                                                          correction

                                 Cement Silo                           Clinker
                                                                                                          •No fatal accident since last Eight years
                                                                      stockpile                           •Ripper Dozer for environment friendly mining operation
                        Packer                    Cement
                                                   Mill
    Truck                                                                              Cooler             •Established schools one with CBSE & another with Matriculation (State
   Loading
             Dispatch                                                                                      board) syllabus



                                                                                                      5                                                                             6
                   PLANT – SALIENT FEATURES                                              PLANT – SALIENT FEATURES

  TECHNOLOGICAL FEATURES                                              ECO-FRIENDLY TECHNOLOGICAL FEATURES
State of the art technology adopted taking into consideration       • Designed to operate with 100% Petcoke.
Quality, Safety & Environment friendly aspects.                     • Installed ESP & pulse jet bag filters
Most of the Technology features introduced like:
                                                                    • Building Air conditioning Automation
• Robo lab.
                                                                      software
• Raw Meal Proportioning System.
• Laboratory Information And                                        • Designed structures, machines to
                                                                      minimize the noise effect always              RAW MILL
  Management system.
                                                                                                                      ESP
• Linkman – Plant Optimization                                      • Operated all equipments through DCS
  Software.                                                           (Distributed Control System) to eliminate
• Knowledge Manager For Process                                       the direct exposure of dust and noise to
  Studies.                                    ROBO LAB                the employees.
• PI Soft ware for on-line process                              7
                                                                    • Alternate/Hazardous       Fuel      Feeding              8

  information's.
         FINISHED PRODUCTS




OPC 43      OPC 53           PPC          PLANT
                                       PERFORMANCE


                                   9                 10
           TURN OVER (SALES) ( ` in Crores)                   CLINKER PRODUCTION (Lac MT)




900                                   621.34        11                                 10.4
      550.25           609.27                             10.1           10.32
                                                    10
500                                                  9
                                                     8
100                                                  7
                                                     6
      2007-08         2008-09        2009-10         5
                                                         2007-08        2008-09       2009-10



                                               11                                               12
     TOTAL CEMENT PRODUCTION (Lac MT)               TOTAL CEMENT DESPATCH (Lac MT)




      13.51        13.61        13.63         15                              13.72
14                                                  13.48        13.59
                                              14
13
                                              13
12                                            12
11                                            11
10                                            10
 9                                             9
 8                                             8
      2007-08     2008-09      2009-10             2007-08      2008-09      2009-10




                                         13                                            14
                     USAGE OF PET COKE (in place of conventional                                 USAGE OF FLY ASH IN PPC CEMENT
                                          fuel)
                                                   Due to non-availability of Petcoke
                                                          & Cost economics




                                                                                            28                  26.93        26.94
                90       79.6                                                                      26.55
% on CV Basis




                80                                                                          26
                70                        58.2
                60                                                 46.92




                                                                                        %
                50                                                                          24
                40
                30                                                                          22
                20
                10
                 0                                                                          20
                       2007-08           2008-09                  2009-10                         2007-08      2008-09      2009-10


                      Plant capable of utilizing 100 % Petcoke

                                                                                   15                                                 16
            % OF PPC CEMENT PRODUCTION                                               SPECIFIC FUEL CONSUMPTION


                                                                                                        Planned to reduce 20 kcal/kg
                                                                                                           of clinker by upgrading
                                                                                                         Existing Pre-heater from 4
    90                                                                                                  Stage to 5 Stage during Nov-
    80    73.98        74.2       77.19                                                                              2011
    70
%




    60
                                                                       785     784




                                                Kcal / Kg of clinker
    50
    40                                                                 780                     778
         2007-08     2008-09     2009-10                                                                              776
                                                                       775

                                                                       770
                                                                             2007-08          2008-09               2009-10

                                           17                                                                                          18
                                                    INTERNATIONAL BENCHMARKING
                                                         KWh/ton of Cement(PPC)
                                                           (Whitehopleman)
                      74                                   72.2
                      72




                                                                                                                                           BETTER
                      70   68.1                                          68.3
BENCHMARKING /        68
                      66
                                                                                      67.9         67.4


                                             62.0                                                                63.6         63.1
 GLOBAL BEST          64
                      62
                      60




                                                                          GS(05-06)



                                                                                       GS(06-07)



                                                                                                     GS(07-08)



                                                                                                                  GS(08-09)



                                                                                                                               GS(09-10)
                                                            GS (04-05)
                                             Indian Best
                           (Whitehopleman)



                                              (NCCBM)
                             World Best
                 19
                            INTERNATIONAL BENCHMARKING
                                  (Whitehopleman of
                        OVER ALL POWER KWh/ton ) Cement


80   78.7                                79.3
78




                                                                                                                         BETTER
                                                       74.1
76
74
72
                                                                    71.2         70.9                                              INNOVATIVE
70                     66.2                                                                    67.1
68
66
64
                                                                                                            66.6
                                                                                                                                    PROJECTS
62
60
                                                                                                                                  IMPLEMENTED
     (Whitehopleman)



                       (Whitehopleman)




                                                        GS(05-06)



                                                                     GS(06-07)



                                                                                   GS(07-08)



                                                                                                GS(08-09)



                                                                                                             GS(09-10)
                                          GS (04-05)
                         Indian Best
       World Best




                                                                                                                                                22
                         INNOVATIVE PROJECT-1                                                             WET FLY ASH DRYING
          INSTALLATION OF WET FLYASH DRYING SYSTEM
                                                                                                               SYSTEM
                                                                                         Rectification Done:-
Title:-           Installation of Wet Flyash drying system (WHR-Waste Heat
                                                                                                                    Feasibility study carried out and installed flyash
Recovery)
                                                                                         dryer                                  Capacity: 16 TPH
Problem Faced:- for effective Utilization of Cooler exhaust gas.
              • Cooler Exhaust gas was going outside as                  waste to
                                                                                         Investment:-               ` 7.5 Crores.
                atmosphere
              • Non availability of dry fly ash in the market.
              • Requirement of dry flyash for the manufacturing of PPC cement
                is 900 MT/day.                                                           Benefits & Savings :-   1. Total coal savings 6165 Tons/Annum
              • Total available dry fly ash is 800 MT/day from MTPS / NLC                                         2. Savings ` 38.3 Lakhs/Annum .
                                                                                                                      (Saving in Procurement of Dry flyash ` 400/MT)
                and 150 MT/day from market
                                                                                                                   3. Additional availability of dry fly ash 1.00 LAC
              • Abundant quantity of wet flyash is available at MTPS .                   MT/Annum.
              • Due to high moisture in wet fly ash, only 2% of the total fly ash                                    This has been taken as a CDM project under waste
                can be used in the system.                                               heat recovery
              • Shortfall of dry fly ash can be met by drying of wet fly ash.                                        (expected saving of 8000 - 10,000 CER’s / Annum).
                                                                                    23
                                                                                                                                                                         24
                 WET FLY ASH DRYING                                                                          WET FLY ASH DRYING
                      SYSTEM % PPC Production                                                                     SYSTEM      FLASH
                                                                                                                               DRIER
                                                                           73.98    74.15      77.2
                                              81              72.21
                                              72
                                         %



                                              63
                                              54   48.42
                                              45
                                                   2005-06    2006-07     2007-08   2008-09   2009-10

                                                                        Year

SCHEMATIC DIAGRAM                                     INCREASE IN PPC PRODUCTION

                          REDUCTION OF SPECIFIC POWER IN
                                 PPC PRODUCTION                                       Better
    Kwh Per Ton Of




                     26    25.17
                                      23.75
       Material




                     24                                       23.26
                     22
                     20
                          2007-08     2008-09                2009-10
                                                                                                        25                             26
                              INNOVATIVE PROJECT-2                                                                     INNOVATIVE PROJECT-2

 REDUCTION OF POWER CONSUMPTION IN RAW MILL CIRCUIT                                     REDUCTION OF POWER CONSUMPTION IN RAW MILL CIRCUIT
Innovative Project:- (A)                                                               Innovative Project:- (B)

Title:-                    Installation of SPRS (Slip Power Recovery System) in Raw    Title:-                    Modification of Raw mill inlet duct.
mill fan.                                                                              Problem Faced:-                    High pressure drop from Pre-heater Outlet to Raw Mill
                                                                                       Inlet                              Around 160 mmwg” and velocity in inlet duct was 26
Problem Faced:-                 Obsolescence of SPRS panel & High Power                m/sec.
consumption.                                                                           Rectification Done:-       Raw mill duct modified for reducing pressure and power.
Rectification Done:-       Installed the analogue system with Digital system.          Investment:-               `129 Lakhs.
Investment:-                ` 55 lakhs.                                                Benefits & Savings :-      Pressure drop reduced from 160 to 136 mmwg; Velocity
Benefits & Savings :-       Savings ` 5.73 Lacs/Annum.                                 reduced from                       26 m/sec to 18 m/sec there by reduced raw mill power
                                                                                       by 0.5 units                       per ton of raw meal


                                                                                                          RAW MILL DUCT
                                                                                                          MODIFICATION




                                                                                  27                                                                                        28
                                INNOVATIVE PROJECT-2                                                                       INNOVATIVE PROJECT-2

 REDUCTION OF POWER CONSUMPTION IN RAW MILL CIRCUIT                                         REDUCTION OF POWER CONSUMPTION IN RAW MILL CIRCUIT
Innovative Project:- (C)                                                                    Innovative Project:- (D)
Title:-                    Modification of GCT duct.                                        Title:-                    Replacement of Raw mill Fan.
Problem Faced:-                     High power consumption and high pressurization in       Problem Faced:-                    High power consumption
Preheater fan                       during Raw mill stoppage.                               Rectification Done:-       Low efficiency fan replaced by high efficiency.
Rectification Done:-       GCT outlet duct modified.                                        Investment:-               ` 56 Lakhs.
Investment:-               ` 56.5 Lakhs.                                                    Benefits & Savings :-      Fan efficiency increased from 76% to 84%.
Benefits & Savings :-      GCT inlet duct pressure reduced by 60 mmwc. Raw mill ESP                                    Power saving 0.12 unit/ton of material.
fan power                           reduced by 0.7 unit per ton of clinker. Preheater fan
outlet                              pressurization avoided during raw mill stoppage.




                     GCT DUCT
                   MODIFICATION




                                                                                       29                                                                                30
                              INNOVATIVE PROJECT-2                                            INNOVATIVE PROJECT-3

                       RESULT– REDUCTION IN SPECIFIC                    REDUCTION OF POWER CONSUMPTION IN KILN
                      POWER CONSUMPTION OF RAW MILL            Innovative Project:- (A)
                                                               Title:-                    Replacement of Cooler Fans.
                                                               Problem Faced:-                    High power consumption
                                                               Rectification Done:-       3 nos. of Low efficiency fans replaced by high
                 14                                            efficiency.
                      13.09                                    Investment:-               ` 32 Lakhs.
Kwh Per Ton Of




                                      12.45
                                                       11.7    Benefits & Savings :-      Fan efficiency increased & Power Saving 0.216
    Material




                 12                                            unit/ton of
                                                                                               clinker.
                 10
                      2007-08        2008-09         2009-10




                                                                                                                                           32
                                INNOVATIVE PROJECT-3                                                                 INNOVATIVE PROJECT-3

           REDUCTION OF POWER CONSUMPTION IN KILN                                                  REDUCTION OF POWER CONSUMPTION IN KILN
Innovative Project:- (B)                                                                 Innovative Project:- (C)
Title:-                    Replacement of Reciprocating compressors (2 nos)              Title:-                  Modification of Pre-heater twin cyclone Aerovane.
Problem Faced:-                   High power Consumption, high noise level and           Problem Faced:-                  High fuel Consumption.
water consumption.                                                                       Rectification Done:-     Aerovane height increased by 1.3 M and
Rectification Done:-       Replacement of Reciprocating compressors (2 nos) by                                    cyclone inlet reduced by 140 mm
Atlas Copco                        Make Screw compressors                                Investment:-             ` 25 Lakhs.
Investment:-               ` 53 Lakhs.                                                   Benefits & Savings :- Reduction in heat consumption by 4 Kcal/kg of clinker
Benefits & Savings :-      Power saving of 0.34units/ton of clinker , Noise level        increase in                      cyclone efficiency by 1 %
reduced from
                                95 to 88 db, No Water consumption for cooling
(previously 29.4 m3
                                / Hr.)




                                                                                                                                Inlet reduced by 140 mm   Aerovane increased by 1.3 M

                                                                                    33                                                                                                  34
                                         INNOVATIVE PROJECT-3                                             INNOVATIVE PROJECT-4
                               RESULT– REDUCTION IN SPECIFIC POWER            REDUCTION OF POWER CONSUMPTION IN CEMENT MILL
                                      CONSUMPTION OF KILN                 Innovative Project:- (A)
                                                                          Title:-                    Replacement of Reciprocating compressors (3 nos)
                                                                          Problem Faced:-                   High power Consumption, high noise level and
                                                                          water consumption.
                                                                          Rectification Done:-       Replacement of Reciprocating compressors (3 nos) by
Kwh Per Ton Of Material




                          32    30.9                                      Atlas Copco                        Make Screw compressors
                                                  29.9
                          30                                     29.03    Investment:-               ` 79 Lakhs.
                                                                          Benefits & Savings :-      Power saving of 0.3 unit / ton of cement, Noise level
                          28                                              reduced from
                          26                                                                              95 to 88   db, No Water consumption for cooling
                          24
                          22
                          20
                               2007-08          2008-09         2009-10



                                                                                                                                                             36
                             INNOVATIVE PROJECT-4                                                                                    INNOVATIVE PROJECT-4

    REDUCTION OF POWER CONSUMPTION IN CEMENT MILL                                                                        RESULT– REDUCTION IN SPECIFIC POWER
Innovative Project:- (B)                                                                                                 CONSUMPTION OF CEMENT MILL – 53 Grade
Title:-                  Mill optimization
Problem Faced:-                   High power Consumption, Low out put.
Rectification Done:-     RP Roller profile re-building at regular intervals
                         RP gap adjustment




                                                                                          Kwh Per Ton Of Material
                         Grinding media optimization
                                                                                                                    26      25.19
Investment:-             Nil
Benefits & Savings :- Output increased from 190 to 215 TPH and                                                                                23.7            23.5
                                                                                                                    24
                         reduced power consumption from 25 units to of 23.8 units.
                                                                                                                    22
                                                                                                                    20
                                                                                                                           2007-08          2008-09         20 09- 10




                                                                                     37
                                          INNOVATIVE PROJECT-4                                          INNOVATIVE PROJECT-5
                               RESULT– REDUCTION IN SPECIFIC POWER             REDUCTION OF POWER CONSUMPTION IN POWER PLANT
                                CONSUMPTION OF CEMENT MILL – PPC           Innovative Project:- (A)
                                                                           Title:-                  Installation of VFD for Power plant Cooling Tower fan.

                                                                           Problem Faced:-                 High power consumption in cooling fans.
Kwh Per Ton Of Material




                          26     25.17                                     Rectification Done:-    Installed VFD for cooling tower fan with interlock in
                                                                           Temperature.
                                                 23.75                     Investment:-            ` 0.4 Lakhs.
                          24                                      23.26
                                                                           Benefits & Savings :-   Savings ` 2.84 Lakhs/Annum.
                          22

                          20
                                2007-08         2008-09          2009-10




                                                                                                                                                             40
                            OVERALL POWER CONSUMPTION




                      80
                                                            ENVIRONMENTAL
Kwh/Ton Of Material




                            79.30
                      70
                      60
                                       67.1      66.56
                                                          PROJECTS / CARBON
                      50
                      40
                                                          EMISSION REDUCTION
                      30
                           2007-08   2008-09    2009-10




                                                                               42
                              ALTERNATE FUEL                                          INNOVATIVE METHOD FOR FEEDING ALTERNATE
                                                                                                    FUEL IN KILN .
WASTE FUEL – MECHANISED FEEDING SYSTEM:A mechanized
 waste fuel feeding system installed first time in India to reduce fossil fuel
 usage in Kiln

                                                                                                                   WOOD CHIPPING
                                                                                                                     MACHINE


                         WEIGH
                         FEEDER




                                                                                                                   PLASTIC CHIPPING
                                                                                                                       MACHINE


                                                   TRANSPORT SYSTEM
                                                                                 43                                            44
STORAGE FACILITY          FEEDING
                          SYSTEM
                 %      OF WASTE FUEL IN KILN ON CV BASIS                                                               QUANTITY OF WASTE FUEL IN KILN
                                                                                               SL
1. De – Oiled Rice bran (DORB)
                                                                 Due to non-                        #      Type of Fuel       UOM     2006-07    2007-08     2008-09     2009-10
2. De – Oiled cashew nut Shells
                                                               availability of
3. Saw Dust                                                   Alternate fuels &                 1               Tyre          MT       1,897      2,526       2391        3117
4. Bio – compost                                              cost economics.                           DORB (De oiled Rice
                             TNPCB                                                              2                             MT       7,939      17,392      10136       3097
5. Municipal Waste (RDF)                                                                                        Bran)
                              trial
6. Coir Waste / Dust                                                                            3        Cashewnut Shell      MT         0         264        5159        5235
7. Corn Waste                                                                                   4          Coconut Shell      MT         0        1,580        911          0
8. Ground nut shell
9. Palm seed Shell                                                                              5          Wooden Dust        MT         0          0         1993         370
10. Match stick waste     13                                                                    6           Oil Sludge        MT        226         0           44          0
                                                      10.89          11.26
11. Wood Strips           11      9.57
12. Shredded Tyres                                                                 7.93         7          Paint Sludge       MT        666       1,461       2010        2547
                           9
                        in %




13. Tyres Powder           7                5.3                                                 8         Groundnut husk      MT         0          0           14          0
14. Refinery Sludge        5
15. Paint Sludge           3
                                                                                                9            Charcoal         MT         0          0           0          64
16. Tyre Chips             1
                                                                                                MOU made Between M/S. UltraTech cement Limited (UTCL) & Municipal
                                 2005-06   2006-07   2007-08        2008-09       2009-10
                                                                                               Corporation of
                                                                                                TiruchirapallI (TMC) For“Disposal of Plastic waste from Municipal Solid Waste
                                                                                          45                                                                                       46
                                                                                               (MSW)
                             ALTERNATE FUEL                                                CO2 EMISSION / TON OF CEMENT
   RESULT &                                                                                                                             Better
  HIGHLIGHTS
•The First Cement Company in the World to get CDM Carbon                          0.8       0.74                               0.62
                                                                                                              0.72
                                                                                  0.7
Credit                                                                            0.6




                                                                          Tonne
     Apr 2005 to Mar 2006, CER 22,290 (Received on 3rd April 2007)
                                                                                  0.5
                                                                                  0.4
     April 2006 to Oct 2007, CER 28055 (Received on 6th Nov 2008)                 0.3
                                                                                  0.2
Obtained Negative fuel cost for use of Hazardous                                  0.1
                                                                                           2006-07      Year 2007-08         2008-09
waste like Paint sludge.

                                                                                   Reduction in CO2 emission by 16 %( From 2006-07 to
                                                                     47                                                                   48
                                                                                                        2008-09)
                                            SPECIFIC POWER CONSUMPTION (PPC)




 REDUCTION IN




                      Kwh /Ton Of Cement
                                           70    67.36
                                                            63.56      63.14

SPECIFIC POWER                             60
                                           50

 CONSUMPTION                               40
                                                2007-08    2008- 09   2009- 10




                 49                                                              50
                                                                        ENERGY SAVING PROJECTS
                        SL        Title of Energy Saving project implemented                       Year       of   Annual Electrical   Total      Investme
                        No.                                                                        Implementatio   Saving              Saving     nt
                                                                                                   n                                   s
                                                                                                                   Units        `         `            `
                                                                                                                   Million   Million   Million     Million
                                 Replacement of old driers by new version of driers in                 2007         0.017                           0.002


 ENERGY SAVING                1
                              .

                              2
                                    compressor house.

                                Compressor air optimization.                                           2007         0.272
                                                                                                                                 0.0
                                                                                                                                 54
                                                                                                                             0.8774
                                                                                                                                 91
                                                                                                                                           0.0
                                                                                                                                           54
                                                                                                                                       0.8774
                                                                                                                                           91       0.001

                              .


    PROJECTS
                                Raw mill and cement mill optimization.                                 2007         0.003    0.0096                   0
                              3                                                                                                            0.0
                              .                                                                                                             09
                         4.       Maintaining 120 deg centigrade in cement mill clinker weigh          2007         1.25      4.037     4.037        0
                                                                                                                                            6
                                      feeder .


  IMPLEMENTED            5.


                         6.
                                  Optimization of Lime stone reclaimer and belt conveyor running
                                      time

                                  Reducing operating pressure in fly ash compressor.
                                                                                                       2007


                                                                                                       2007
                                                                                                                    0.008


                                                                                                                    0.017
                                                                                                                             0.0258


                                                                                                                              0.054
                                                                                                                                           0.0
                                                                                                                                           25
                                                                                                                                            8
                                                                                                                                                     0


                                                                                                                                                      0
                                                                                                                                           0.0

LAST THREE YEARS         7.       Optimization of coal mill firing bag filters.                        2007         0.008    0.02584


                                                                                                                             0.02584
                                                                                                                                           54

                                                                                                                                            0.0
                                                                                                                                            25
                                                                                                                                                      0


                         8.       Optimization of silo top bag filter in Raw mill.                     2007         0.008              0.02584
                                                                                                                                            84       0


                                  Installation of VFD in 361 FN3 Fan .                                 2207         0.008    0.0258    0.0258       0.04
                              9
                              .
                                CCR AC AHU(Air handling unit) running timing stopped from              2007         0.008    0.02584   0.02584        0
                   51         1    7PM to 7AM.                                                                                                             52
                              0
                                           ENERGY SAVING PROJECTS                                                                                                                      ENERGY SAVING PROJECTS
SL    Ti2tle of Energy Saving project implemented                          Year       of   Annual                 Total      Investm   SL        Title of Energy Saving project implemented                 Year         of   Annual     Electrical   Total      Investment
No.                                                                        Implementatio   Electrical             Savings    ent       No.                                                                  Implementation    Saving                  Savings
                                                                           n               Saving
                                                                                                                                                                                                                               Units         `            `           `
                                                                                           Units           `          `          `                                                                                             Million    Million      Million    Million
                                                                                           Million      Million    Million   Million                                                                                            0.008    0.02584       0.02584
                                                                                                                                       23        Fitting of 45 Watt CFL bulb in place of 150 W HPSV               2007                                               0
11    Installation of control switch in packing plant                          2007         0.007    0.02261      0.02261      0.06                    fitting.                                                               0.000700   0.001737
                                                                                                                                       24        Installation of separate switch for coal stacker and             2007                                0.001737     0.0005
                                                                                                                                                       reclaimer in MCC room.

                                                                                           0.024     0.07752                           25        Interlocking provided for roller press P & V blower with         2007        0.004176   0.010440     0.010440     0.001
12    Common unloading system        for flyash                                2007                               0.07752       0
                                                                                                                                                      roller press motor.
13    Raw Mill main drive cooling fan interlocking.                            2007        0.048     0.15504      0.15504       0
                                                                                                                                       26        Local control switch provided for L21 BC7 tower                  2007        0.002942   0.009504     0.009504     0.001
14    Kiln oil pumps interlocking with temperature.                            2007        0.024     0.07752      0.07752       0                     lighting.
                                                                                                                                       27        Inter connection line made in between pyro & cement              2007          0.204     0.0561        0.0561   0.312300
15    Interlocking of sampler in cement mill.                                  2007          0.001 0.00323        0.00323       0                     mill air receivers.
                                                                                                                                       28        Two stage compressor (K51)converted into single                   2007         0.153      0.42          0.42       0.15
16    Optimization of bag filter purging with flyash bag filter fan            2007         0.003       0.0969     0.0969       0                   stage compressor.
17                                                                             2007        0.013     0.04199      0.04199       0
      Reviewing of HP fan running on cement mill silo top.                                                                             29        Seggreagation of lighting in long belt area in packing           2007        0.009075   0.027225     0.027225     0.005
                                                                                                                                                     plant.
18    Replacement of Kiln ESP RAL’S for false air leakage                      2007        0.007     0.02261      0.02261      0.02
                                                                                                                                       30        Power saving through interlock for LS reclaimer PCRD              2007       0.004140   0.010267     0.010267     0.002
19                                                                             2007        0.002     0.00646      0.00646       0                   motor during pile change.
      Optimization of Lime stone weigh feeder blaster operation       .
                                                                                                                                       31        Power saving in all cable cellars.                                2007       0.015715   0.050760     0.050760       0
20    Fixing of an exhaust fan in crusher venting line                         2007        0.004     0.01292      0.01292     0.001
                                                                                                                                       32        Commissioning of Screw compressor in pyro section.                2007         0.59      1.916         1.916      5.375
21    Placement of double stage compressor with single stage in packin g       2007         0.03        0.969      0.969        0
          plant.                                                                                                                       33        Bunker changed for optimizing coal reclaimer.                   2008           0.02      0.0942        0.0942       0
22    Optimization of coal mill ESP KV.                                        2007        0.204     0.65892      0.65892       0                P-20 energy saver installed in TPP.                             2008            0.02     0.0942        0.0942      0.25
                                                                                                                                53                                                                                                                                     54
                                                                                                                                             3
                                            ENERGY SAVING PROJECTS                                                                                                                       ENERGY SAVING PROJECTS
SL    Title of Energy Saving project implemented                                   Year       of   Annual Electrical    Total     Investm    SL    Title of Energy Saving project implemented                          Year       of   Annual Electrical   Total     Investm
No.                                                                                Implementatio   Saving               Saving    ent        No.                                                                       Implementatio   Saving              Saving    ent
                                                                                   n                                    s                                                                                              n                                   s
                                                                                                   Units        `          `          `                                                                                                Units        `         `          `
                                                                                                   Million   Million    Million   Million                                                                                              Million   Million   Million   Million

35    Optimization of coal mill bag filter fan.                                         2008        0.018    0.08478    0.08478      0       50.   Installation of high efficient impeller for packer bag filter.          2008                  2.6847    2.6847       0
                                                                                                              0.1413
                                                                                                                                                                                                                                           0.
36.   Otimization flow meter air slide fan 431 FN 1 & 2.                               2008          0.03               0.1413       0       51.   Preheater twin cyclone aerovanes modification.                          2008         1.040    4.8984    4.8984       2.5
                                                                                                                                                                                                                                           57
37.   School varanda lights taken in street light control.                             2008                             0.02355     0.015
                                                                                                       0.0       0.02                        52.   Aluminium impeller changed by FRP impeller for cooling fans.            2008        0.090      0.4293   0.4293     0.040
38.   Power saved by keeping cement mill 53 grade blaine 275 instead of                2008         1.105     5.181
                                                                                                                 355     5.181       0
                                                                                                                                             53.   CO2 purging system re-placed with N2 Purging system for fine coal       2008         11.67      5.5       5.5       6.9
39.       290.                                                                                                          0.17898
      Upgradation of clinker weigh feeder.                                              2008       0.038     0.17898               0.015              bin and bag filters in fine coal circuit
40.   Optimization of FK pump bag filter.                                              2008         0.03     0.1413      0.1413      0       54.                                                                                                            0.076
                                                                                                                                                   Optimization blower motor.                                              2008        0.0161     0.076                 0
                                                                                                                                             55.   Optimization of L91 FN1 Coal mill bag filter.                           2008         0.18      0.085     0.085       0
41.   Raw mill fan SPRS upgradation.                                                   2008         0.5       2.355      2.355      6.5
                                                                                                                                             56.   Optimization air slide fan 431 FN1 & 2.                                  2008        0.382     0.810    0.810            0
42.   Replacement of high efficient GCT pump                                           2008         0.5       2.355      2.355      0.5
                                                                                                                                             57.   Optimization of supply water for Cooling tower.                          2008                  0.077    0.077            0
43.   Installation of low head GCT pump.                                               2008         0.3       1.413      1.431      0.3
                                                                                                                                             58.
                                                                                                                                                                                                                                            0.             0.02826
44.                                                                                                                     4.05531                    Optimization of silo top bag filter by speed reduction.                  2008       0.006     0.02826                    0
      Installation of high efficiency cooler vent fan.                                   2008       0.861    4.05531                 4                                                                                                      1
                                                                                                                                             59.   Replacement of Kiln ESP RAL's for False air leakage                      2008       0.0076    0.03297   0.03297          0
45.   Installation of high efficiency Raw mill fan                                      2008       1.502                7.074        5.7                                                                                                    3
                                                                                                                                             60.   Optimization of Lime stone weigh feeder by feed deviation.               2008       0.002     0.0942    0.0942           0
46.
                                                                                                                  7.0
      3 numbers of high efficient cooler fans installed.                                2008        0.7        3.297    3.297        4.2     61                                                                                                            0.01884
                                                                                                                  74                               Installation of exhaust fan in crusher venting line.                     2008       0.004     0.01884                0.03
47.                                                                                     2008         3.2                15.072           5
      Installation of high efficiency Raw mill ESP Fan .                                                                                     62.   Replacement double stage compressor with single stage.                   2008       0.03       0.1413   0.1413       0.03
                                                                                                                 15.
48.                                                                                      2008       1.4          07
                                                                                                              6.594     6.594     12.975     63.   150W(HPSV) high pressure sodium vapors lamp replaced by 45 W             2008       0.008     0.03768   0.03768      0.8
      Reduction in Power consumption in Raw mill circuit.
                                                                                                                 2                                     CFL(Compact florescent lamp)
49.   Total four numbers of screw Compressor installed in place of reciprocating        2008        2.4      11.304     11.304       55
                                                                                                                                    4.8      64.                                                                                                           0.4293
                                                                                                                                                                                                                                                                        56
           compressor                                                                                                                              Optimization of bag filters in packing plant                             2008        0.09     0.4293                0.1
                                            ENERGY SAVING PROJECTS
SL    Title of Energy Saving project implemented                           Year       of   Annual Electrical    Total     Investm
No.                                                                        Implementatio   Saving               Saving    ent
                                                                           n                                    s



65.   Cooling fan of Kiln shell taken in DCS/MCC.                              2008
                                                                                           Units
                                                                                           Million
                                                                                                        `
                                                                                                     Million
                                                                                                      0.0942
                                                                                                                   `
                                                                                                                Million
                                                                                                                0.0942
                                                                                                                               `
                                                                                                                           Million
                                                                                                                           0.015
                                                                                                                                          PROJECTS
                                                                                                                                     IMPLEMENTED
                                                                                               0.
66.   461 FN4(Kiln Cooling shell fan) taken in DCS.                            2008         0.003               0.01413    0.010
                                                                                               00
                                                                                                          0.0
                                                                                               2
67.                                                                                                       141
                                                                                                     0.0552               0.0025
      Belt interlocking done in clay feeding area.                             2009                             0.0552
                                                                                               0.         3
68.   Belt interlocking done in gypsum feeding area.                           2009         0.015    0.05205    0.0520    0.0025
                                                                                               01
                                                                                               6                     5
69.


70.
      Use of energy efficient bearings.

      Interlocking of packing plant bag filters.
                                                                               2009        0.0016    0.005552


                                                                                                     0.283152
                                                                                                                0.0055
                                                                                                                     5
                                                                                                                     2
                                                                                                                          0.016
                                                                                                                                                         FROM 2007-2010
                                                                               2009        0.0816               0.2831    0.03
                                                                                                                     5
71.                                                                                                                  2
                                                                                                                0.90567
                                                                                                                                     Total No of Projects implemented :77
      Replacement of new version SPRS in Raw mill fan.                         2009                  0.90567               5.5
72.
                                                                                                0.
      Replacement of normal pumps by submersible pumps in Raw mill &           2009         0.04     0.1388     0.1388     0.04
73.        Coal mill.
                                                                                                2
                                                                                                                0.04511
                                                                                                                                     Total Units Saved in Million     : 30.47
      Interlocking RP cooling fans.                                            2009             6
                                                                                            0.013    0.04511              0.0015
74.
                                                                                                1
      Replacement of 150W HPSV by 45W CFL                                      2009
                                                                                                0.
                                                                                                     0.09022    0.09022   0.015
                                                                                                                                     Total Saved ` in Million        : 112.8
75.   Installation of VFD for Power plant cooling Tower fan .                  2009        0.0820    0.28454    0.28454    0.04
                                                                                                0
76.   Installation of Panel Air conditioner & Exhaust fan in Power Plant       2009             2
                                                                                            0.048
                                                                                                6
                                                                                                     0.16656    0.16656    0.016
                                                                                                                                     Total investment ` in Million   : 73.23
77.   Waste gas utilization for drying wet flyash (Waste heat recovery        2009         0.05045    0.175     0.175         7
          system).
                                                                                                                              57                                                58
                                                               TEAM WORK IN ENCON

                                     EMPLOYEE SUGGESTIONS RELATED TO ENERGY
                                                 CONSERVATION
                                  Name:-P.Jayaprakash                 Designation:-Engineer   Department:-Electrical.

INVOLVEMENT OF EMPLOYEES,         TITLE:-                Power optimization of colony street lights.

   TEAM WORK IN ENCON,            PROBLEM FACED:-
                                  according
                                                                  Timing of street lights are required to adjust frequently
                                                                                    to day light conditions by manual
                                  timers.
MONITORING & REPORTING AND        RECTIFICATION DONE:-   Manual timer replaced by Astronomical timers based on location
      IMPLEMENTATION              on                             (Latitude /Longitude) in place for Street light control.

                                  INVESTMENT:-           ` 13,640/.
       METHODOLOGY                BENEFITS & SAVINGS :- Power savings 30 minutes/day.
                                                                ` 12893.62/Annum.

                                  PAY BACK PERIOD :-                  1 Year.

                             59                                                                                         60
                              TEAM WORK IN ENCON                                                                          TEAM WORK IN ENCON

   EMPLOYEE SUGGESTIONS RELATED TO ENERGY                                                      EMPLOYEE SUGGESTIONS RELATED TO ENERGY
               CONSERVATION                                                                  TITLE:-       CONSERVATION Exhaust fan instead of
                                                                                                                 Installation of                                    Split A/Cs in MCC
 Name:-A.James .          Designation:-Fitter.      Department:-Mechanical work shop.        Name:-Kulanginathen
                                                                                             room of                          Designation:-Electrician.   Department:-TPP
TITLE:-                 Cement Mill Old Cooling Tower Replaced with new FRP (Fiber                                         DM (Demineralizing Treatment) pant to reduce power
                            Reinforced Plastics) type Cooling Tower.                         consumption
                                                                                             PROBLEM FACED:-         High Power Consumption.
PROBLEM FACED:-                  Cement mill Cooling Tower Contaminated with dust
due to 531BC6                                                                                BEFORE MODIFICATION:-            In DM Plant MCC room split A/C (2 Tons) was provided
                              Conveyor Belt      Spillage materials and     Efficiency       to
becomes Low.                                                                                                            maintain the room temperature to avoid failure of PLC.
                                                                                                                  Power consumption : 2 Kw X 24 Hrs X30 Days X 12 Months
RECTIFICATION DONE:-    Old cooling Tower replaced by new FRP (Fiber Reinforced                                                               = 17280 Kwh/Annum
Plastics) Type                                                                               AFTER MODIFICATION:-          Provided two exhaust fan to enhance air circulation. Now
                              Cooling tower.                                                 the
                                                                                                                        PLC room temperature is maintained.
INVESTMENT:-                 ` 3.0 Lakhs.                                                                               Power consumption : 0.4 Kw X 24 Hrs X 30 Days X 12
                                                                                             Months
BENEFITS & SAVINGS :- Reduction of 4 units/day and Savings ` 1.09unit/Annum .                                                                 = 3600 Kwh/Annum.
                                                                                              INVESTMENT:-        ` 4000/.
PAY BACK PERIOD :-            2.5 years.
                                                                                        61   BENEFITS & SAVINGS :-            Total units saving 13860 Per year and ` 41040/year.   62
                             TEAM WORK IN ENCON                                                                       TEAM WORK IN ENCON

  EMPLOYEE SUGGESTIONS RELATED TO ENERGY                                                        EMPLOYEE SUGGESTIONS RELATED TO ENERGY
Name:- C.krishnamurthy
                       CONSERVATION
                        Designation:-Asst. Manager. Department:-Electrical
                                                                                                            CONSERVATION
                                                                                             Name:-Guru Prasad .          Designation:-Asistant Mananager .   Department:-TPP.
Department                                                                                  TITLE:-                       Reduction of Auxiliary Power Consumption of TPP
                                                                                            cooling tower Fan 2.
TITLE:                        Power Saving through Local control Switch for 311
Conveyor belt in Limestone                                                                  PROBLEM FACED:-              High power consumption.
                          Crusher.                                                          BEFORE MODIFICATION: -      Cooling Tower Fan of 30 KW , 1500 RPM , normally in
                                                                                            continuous
PROBLEM FACED:-          High power consumption.                                                                     operation in DOL mode at Full speed at all loading conditions
                                                                                            of TPP.
RECTIFICATION DONE:-     Provided Local Control for that Area lighting. Whenever required
We can switch                                                                               AFTER MODIFICATION: -      Installed VFD in Cooling Tower Fan -2, and speed is being
                          ON the lighting .                                                 regulated with
                                                                                                                     respect to the loading of TPP
INVESTMENT :-            ` 6500/-
                                                                                            INVESTMENT:-             ` 32000/-
BENEFITS & SAVINGS :-    Reduction of 5110units/day and Savings ` 17731.7 / Annum.          BENEFITS & SAVINGS: -     Net Power savings   = 143865 Units / Annum .
                                                                                                                      Net Cost savings    = ` 5 Lacs / Annum .
PAY BACK PERIOD :-        4.3 months.                                                       PAY BACK PERIOD :-         1 months.

                                                                                     63                                                                                          64
                    ENERGY POLICY                                                               ENERGY MONITORING SYSTEMS
                                                            Plot-0
                                                              Ø       ENERGY MANAGER software
We at UltraTech Cement Limited (Reddipalayam                62.2 48   80 800 120 1300 48.4 43                                              GCS CM RPMOVMOTORDETEMP
                                                                                                                                           62.125
                                                                      ü     Individual MCC’s wise and section wise power details.DEG C
Cement Works ) are committed to evolving and                62                                                                             GCS CM RPMOVMOTORNDETEMP
                                                                                                                                           47.922
sustaining excellence in energy conservation to                       ü     Speed,load,current and running hours of all critical equipments.
                                                                                                                                   DEG C
                                                            61.8                                                                           GCS CM RP1CURRENT
reduce cost of production & improve environment.                                                                                           48.302

                                                                      ü     Compressors, water pumps and bore wells running hours.         AMPS
                                                                                                                                           GCS CM RP1LOAD
                                                            61.6
                                                                                                                                           404.36
We will work continuously to conserve energy and                                                                                           KW
                                                                      ü      Start/stop power for all equipments
achieve world benchmarks in terms of energy                 61.4
                                                                                                                                           GCS CM RP2CURRENT
                                                                                                                                           82.374

consumption in our process.                                           ü
                                                                                                                                           AMPS
                                                                            Other important parameters like draft,temperature, feed rate are
                                                                                                                                           GCS CM RP2LOAD
                                                            61.2                                                                           838.53
                                                                                                                                           KW
                                                                            also monitored and recorded.
Fostering a culture of participation and innovation         61     44.5 30 100 50 400 47   40
                                                                                                                                           GCS CM RPFIXEDMOTORDETEMP
                                                                                                                                           48.273

amongst employees for continual improvement in              7/26/2008 2:55:25 AM
                                                              RP   MOTOR DE TEMP
                                                                                                  8.00 hours
                                                              ØMOV Online monitoring of parameters in DCS.
                                                                                                                   7/26/2008 10:55:25 AM   DEG C
                                                                                                                                           GCS CM RPFIXEDMOTORNDETEMP

energy conservation.                                           RP MOV MOTOR NDE TEMP
                                                               Roller Press1 CURRENT
                                                                                                                                           42.656
                                                                                                                                           DEG C
                                                              Ø        HT motors power and temperature details
                                                               Roller Press1 LOAD
                                                               Roller Press2 CURRENT

                                                Unit           Roller Press2 LOAD
                                                               RP FIXED MOTOR DE TEMP

Head                                                   65      RP FIXED MOTOR NDE TEMP                                                                               66
         VARIOUS ENERGY MONITORING SOURCES USED                                                                                                                                                                   METHODOLOGY ADOPTED FOR ENERGY
                                                    Plot- 0


                                                    100 10 0 100
                                                            0
                                                                                                   0.1 1236
                                                                                                   861.38
                                                                                                   79.931                                                        S OOLER GR TE2LOA D
                                                                                                                                                               GC C        A
                                                                                                                                                                                                                           MONITORING
                                                                                                                                                               -5.0 070
                                                                                                                                                               KW
                                                                                                                                                                 S OOLER GR TE2SPEED
                                                                                                                                                               GC C        A
                                                    80                                                                                                         -124.12



•   Daily Energy Report deviation analysis.         60
                                                                                                                                                               RPM
                                                                                                                                                                 S OOLER UNDER ATE2SETPOINT
                                                                                                                                                               GC C
                                                                                                                                                               0.00 00
                                                                                                                                                               mmWC
                                                                                                                                                                              GR
                                                                                                                                                                                                     ü Energy management cell with clear cut responsibilities
                                                    40




•   Knowledge Manager.                              20
                                                                                                                                                                                                     ü Daily monitoring of Energy Deviation report.
                                                    0




•   Daily Vibration & Bearing Temperature Deviation.-20 -20 0 0
                                                              9
                                                    9/24 /20 0 1 :05 :55 A M                     9/24/2009 2:43:0hours A M
                                                                                                            3.34 5.0 22              9 /24 /200 9 4:26:07 AM
                                                                                                                                                                                                     ü Benchmarking National/International/group wise/Cluster units.
                                                                  A
                                                         COOLER GR TE 2 L OAD   COOLER GRATE 2 SPEED          U    GR
                                                                                                               NDER A TE2 SETPOINT




    Monitoring
                                                                                                                                                                                                     ü Regular study of equipments on deviation and their analysis.
•   PI system.
                                                                                                                                                                                                     ü Process evaluation & identification of energy conservation scope.
                                                Plot-0

                                                2000 2000 350 2000 500 300 200 9000
                                                                             0                                                                                              C MP
                                                                                                                                                                          G S C R 1LOAD
                                                                                                                                                                          -0.30538
                                                                                                                                                                          KW


•   Daily Monitoring of Utilization of Various Fuels.
                                                1500
                                                                                                                                                                            C MP
                                                                                                                                                                          G S C R 2LOAD
                                                                                                                                                                          1973.2
                                                                                                                                                                          KW
                                                                                                                                                                          G SKNM LO
                                                                                                                                                                           C
                                                                                                                                                                          1.3343
                                                                                                                                                                                M AD                 ü Feasibility study of suggestions and designing proposals for
                                                1000
                                                                                                                                                                          KW


•   RMP system for raw meal                     500
                                                                                                                                                                            C
                                                                                                                                                                          G SKNP F LO
                                                                                                                                                                          -7.8736
                                                                                                                                                                          KW
                                                                                                                                                                            C
                                                                                                                                                                                  H AN AD



                                                                                                                                                                          G SKNR E F LO
                                                                                                                                                                                  MSP AN AD
                                                                                                                                                                                                        sanctions.
                                                                                                                                                                          0.49301
                                                                                                                                                                          RMP
                                                                                                                                                                            C     OALE F L AD
                                                                                                                                                                          G SKMC SP AN O

                                                                                                                                                                                                     ü Taking corrective and preventive measures and ensuring
                                                0
                                                                                                                                                                          -0.2766
                                                                                                                                                                          KW
                                                                                                                                                                   C MM
                                                                                                                                                                 G SR M LOAD
                                                                        00
                                                -500 -500 0 -500 0 -50 -5 -1000                                                                                  2000.0
                                                   1/2 8 0:00
                                                5/2 00 5:4 AM                                                 10.00 minutes                  5/21/2008 5:50:00AM KW
                                                  R P
                                                    oller ress1 LO
                                                    oller ress2 LO
                                                  R P
                                                  KILNM L AD
                                                          MO
                                                                  AD
                                                                  AD
                                                                                                                                                                 G SKNT LO
                                                                                                                                                                   C
                                                                                                                                                                 -483.51
                                                                                                                                                                         PP AD
                                                                                                                                                                                                        implementation.
                                                                                                                                                                 KW
                                                    H AN AD
                                                  P F LO
                                                    M P AN AD
                                                  R ES F LO
                                                     O SP AN AD
                                                    C AL E F LO
                                                     MM
                                                    R M load
                                                     PP AD
                                                    T LO
                                                                                                                                                                                                67   ü Organizing internal and external Energy Audit survey.               68
                     METHODOLOGY ADOPTED FOR
                          SUSTAINABILITY
•   DAILY:
    ü Daily Energy deviation report
    ü Energy Task Force Meeting
    WEEKLY:
    ü Energy Conservation Meeting                         ISO 9001,
    ü Capex Jobs/Project Meeting
    ü Section wise Fortnightly Review Meeting
    ü Weekly Review
                                                     14001,18001& 27001
•   MONTHLY:
    ü Power Comparison with group units
                                                       CERTIFICATION
    ü Breakdown Analysis Report
    ü Master Action Plan Meeting
    ü Monthly Performance Meeting
                                                                          70
                                                69
                  AWARDS & ACCOLADES                                 AUDIT OBSERVATIONS (April-2010)

•ISO 9001    (QMS)       accreditation Certificate in 2001.
•ISO 14001   (EMS)       accreditation Certificate in 2001.
•OHSAS 18001 (OHSMS)       accreditation Certificate in 2003.
•ISO 27001   (ISO/IEC)     accreditation Certificate in
Feb.2010.
  ISO 9001     ISO 14001       OHSAS 18001        ISO 27001




                                                                71                                     72
AUDIT OBSERVATIONS (April-2010)        AUDIT OBSERVATIONS (April-2010)




                                  73                                     74
AUDIT OBSERVATIONS (April-2010)                                                ENVIRONMENTAL INITIATIVES




                                       No of Plants in Thousands
                                                                   80                                                       69
                                                                   70                                             60
                                                                   60                                   49
                                                                   50                         39
                                                                   40     27        30
                                                                   30
                                                                   20
                                                                   10
                                                                        2004-05   2005-06   2006-07   2007-08   2008-09   2009-10




                                  75
                                                                                                                                    76
                         ENVIRONMENTAL INITIATIVES                                                  ENVIRONMENTAL INITIATIVES
Ø Trial run taken for different types of hazardous waste in presence of CPCB
and TNPCB .
Ø Clinker loading chute and accessories for tippers during loading avoiding                                                CLINKER SILO
the heavy dust generation and spillage.
Ø Ripper Dozer is being used for Mines operation which is eco-friendly and
total avoidance of drilling and blasting.
Ø Alternate Fuel Storage Shed For Systematic Storage Of Different Fuels In
Closed Shed Eco-friendly.                                                                                            COAL STORAGE
                                                                                      LIME STONE STORAGE
Ø   SOX & NOX Analysers in Cement Pant and thermal power plant.                       YARD                           YARD

ØIncrease in GCT Height in order to reduce the dust emission in raw mill stack
by improving the efficiency of electro static precipitator.
Ø High Efficient auto tuning EPIC -2 controllers are installed in all ESP’s.
Ø Limestone transport vehicles are being covered with Tarpaulin and Emission
certificate.
Ø Green belt developed inside plant as well as Colony .                                                                                   78
                                                                                 77
Ø Noise protecting equipments like Ear plugs/Ear muffs, are used by personnel
              ENVIRONMENTAL INITIATIVES                           ENVIRONMENTAL INITIATIVES

                                               ü Ripper Dozer used for Mining.


COVERED
CONVEYOR
S




CONCRETE
ROAD IN THE
PLANT


                                          79
                                                                                              80
         ENVIRONMENTAL DAY CELEBRATION on 5TH
 Inauguration                    JUNE
                 Plantation – At Plant Prize Distribution




                                                                                   UTILISATION OF
Plantation - Employees   Plantation - School Children
                                                        Plantation - Family
                                                        members at Colony
                                                                                    RENEWABLE
                                                                                      ENERGY

                                                                              81                    82
               UTILISATION OF RENEWABLE ENERGY

Type of   Installed         2007-08               2008-09              2009-10
RES       Capacity
           in kW    Energy    Annual    Energy      Annual    Energy     Annual
                    Generate Savings    Generate    Savings   Generate   Savings

  Wind
                      d
           (5*225) (kWh)
            KW      2306750
                              (Lacs
                                 Rs)
                                69.2
                                          d
                                          (kWh)
                                        1738109
                                                    (Lacs
                                                       Rs)
                                                      76.6
                                                                d
                                                                (kWh)
                                                              2054163
                                                                         (Laces
                                                                            Rs)
                                                                           71.2
                                                                                     UTILISATION OF
  Solar     500 W
                      1650      0.30     10400        4.89     10400       3.66
                                                                                    WASTE MATERIALS
We are the first Cement Plant to register With        TEDA (Tamilnadu      Energy
Development Authority) for 100 KW Solar Energy for colony usages.
Expected Savings : 1.5 Lakhs units/Annum .
Savings           : ` 7.5 Lacs/Annum.
Investment      : ` 2 Crores .
                                                                                                      84
                   TPP FLY ASH GENERATION &                                                      DG SLUDGE GENERATION &
                          UTILISATION                                                                  UTILISATION
                                        Less generation of flyash in TPP
                                              due to use of Lignite
                                                                                     65.00   59.23
                                                                                     55.00                44.26
     10000.0                                                                                                          47.34




                                                                                KL
                                   8666.6
                                                8999.8                               45.00
      9000.0                                                                                                                      27.54
                                                              7550.6                 35.00
      8000.0
      7000.0                                                                         25.00
MT




      6000.0             5192.3                                                              2006-07    2007-08      2008-09     2009-10
      5000.0
               3620.1
      4000.0
      3000.0
               2005-06   2006-07   2007-08     2008-09       2009-10
                                                                                DG SLUDGE GENERATED IS USED AS AN ALTERNATE FUEL & FIRIED IN
                                                                                                      THE CALCINER.
           FLYASH GENERATED IN TPP IS COMPLETELY USED IN
                              PLANT                                        85                                                                  86
                                                                                                   REPLICATION ARISING OUT OF BEST
                                WASTE UTILISATION
                                                                                                   PRACTICES THROUGH ASSOCIATES
  FIRST RO PLANT REJECT                      SECOND RO PLANT REJECT WATER          1.   Installation of New version of ABB Controller (EPIC-3) for
         WATER PIT                                        PIT
                                                                                      Electro static precipitators.
                                                                                   2. Installation of Delta star converters for belt conveyors.
                                                                                   3. Additional Cooling fan drives taken in DCS for interlocking.
                                                                                   4. Installation of P-20 lighting energy saver in TPP (Thermal
                                                                                      power plant).
Effective Usage of Reject Water in Process                                         5. Changing of Aluminum impeller by FRP (Fiber reinforced
SECOND RO PLANT REJECT WATER PIT                                                      Plastics) impeller in Kiln shell cooling fans.
                                                                                   6. Retrofitting electronic temperature control devices in old and
                                                                                      manual window air conditioners for energy savings.
                                                                                   7. Power factor is maintained greater than 0.98.
                                                                                   8. Installation of VFDs for the Cooling water circulation pumps to
                                                      Utilising reject / waste
                                                                                      optimise the water flow to the condenser for the TG set .
                                                      water from power plant       9. VFD for cooling towers.
   Pump for conveying
                                                      with help of return valves   10. Optimisation of running of air compressors using Compressed
                                                      to cooler for cooling
    Reject water to the
                                                      purpose
                                                                                      Air Management System.                                          88
      Cement Plant
                  UNIT INITIATIVES TOWARDS CEMENT
                 SUSTAINABILITY & REDUCTION IN CO2                                                          SOCIAL ACTIVITIES
                               EMISSION                                                                     PROCESS ADOPTED
• We are a member of CSI (Cement Sustainability Initiative) reporting.
                                                                              • Identified 15 Villages from 4 Panchayats
• Marl usages in raw mix there by avoiding the use of pure limestone ,white
clay                                                                          • Focused on Education, Health, Welfare, Infrastructure development,
                                                                                Sustainable livelihood,
   & black cotton soil.
• Usages of Natural gypsum (low purity) , which reduces the clinker           • Building Partner ship with           Government,   Non-Governmental
                                                                                Organisation, Hospitals etc..
  consumption in cement.
                                                                              • Exploring Government Schemes
• Increasing the consumption of dry flyash up to 27 % in PPC Production.
• Use of Ripper dozer for mining operation ,there by eliminating drilling &   • Preparing planning & Budgeting activities
  blasting.                                                                   • Mobilization of Fund (Contributing with Government’s various Social
                                                                                welfare activities in terms of finance & infrastructure facility)
• Engaging DUPONT for improving safety standards in side Plant &
Colony.                                                                       • Implementing Projects & Activities
• Increased Blended cement production.                                        • Support on Disaster Management (Fire, Flood, Medical Emergency
• Use of Various high calorific value waste fuels in pyro processing.           etc..)
• Tamilnadu Government has selected our unit for consumption of Plastics
                                                                       89                                                                             90
in
              SOCIAL ACTIVITIES                                            SOCIAL ACTIVITIES
9th UltraTech Merit Awards Distribution                Eye Camp                    Compound wall at Village school




                                               Drinking water at Village Schools      Toilets at Village Schools




                                          91                                                                         92
AWARDS & ACCOLADES                                      AWARDS & ACCOLADES
                             ENERGY
                          •Global Cement Awards, Lowest Specific Energy consumption, clinker grinding –
                          2006.
                          •Lowest Specific Energy Consumption, raw meal grinding - 2006.
                          •National Energy Efficient Unit Award by CII (2004 & 2006,2007 & 2008)
                          •National Excellent Energy Efficient Unit Award by CII - 2009
                          •NCCBM Best Electrical Energy Performance Award 2008-09
                          •NCCBM Second Best Improvement in Thermal Energy Performance Award 2008-09




                     93         CII Energy Award 2009                                                     94
                                                                                NCCBM Award 2009
                             AWARDS & ACCOLADES                                                                  AWARDS & ACCOLADES

ENVIRONMEN                                                                           SAFETY
                                                                                    •State Level Safety Award from Tamil Nadu Government (1999,2000,2005 & 2006)
         T
•Greentech Environment Excellence Silver Award 2006 & 2009
•Global Cement Award Lowest specific CO2 emission - 2006                            •Safety Appreciation Award from NSC TamilNadu Chapter 2003
•Most Innovative Scheme for environmental impact abatement - 2006.                  •Greentech Safety Award - Bronze in 2006 , Silver in 2007 & Silver in 2010.
•FICCI Environment Sustainability of Business Award 2006 – 2007 .                   •Two First Prizes State Level Safety Award from TamilNadu Government
                                                                                     (2005 & 2006) n
                                                                                    •Global Cement Awards Lowest Injury Incidence Rate – First prize ($1000).(2006)
                                                                                                                                                                 Global Cement
                                                                                    •Golden Peacock Award GPOHSA 2009 & 2010 .
                                                                                                                                                                     Award




              FICCI AWARD                   Greentech Environment Award 2009          State Government
                                                                                                           Golden Peacock Award 2009 &          GreenTech Safety Award 2010.
                                                                               95                                                                                        96
                                                                                        Safety Award                   2010
                             AWARDS & ACCOLADES
 WCM(World Class Manufacturing)
•WCM Chairman’s Award for Manufacturing Excellence – Bronze Award in 2002        “Commitment unlocks the doors of
•WCM Chairman’s Award for Manufacturing Excellence – Silver Award in 2004
•WCM Chairman’s Award for manufacturing Excellence – Gold Award in 2009.
                                                                                 imagination, allows vision and gives us
•5’S Excellence Award by CII – 2005                                              the ‘right stuff’ to our dreams into
•Best Kaizen Award in Kaizen Mela Competitions – 2008
                                                                                 reality”.



                                                                                                              Thank
                                                                                                               You
                                                                            97                                         98
   WCM Silver                     Chairman’s Gold             WCM Gold
                                                          Award

				
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