Mangalam Cement

SR.NO

YEAR DESCRIPTION OF MEASURE SAVING PER YEAR

NET SAVING IN RUPEES PER

YEAR

1. 2012-13 REPLACEMENT OF EXHAUST FANS WITH POWERLESS VENTILATOR. 72727 UNITS 4,00,000

2. 2012-13 DM TRANSFER PUMP:-PUMP STOPPAGE AND USING PRINCIPLE OF GRAVITY

AND VACCUM FOR WATER TRANSFERING. 14000 UNITS 77000

3. 2012-13 POWER SAVING SCHEME IN CPP- BOILER FEED WATER PUMP OUTLET LINE

HEADER PRESSURE CONTROLLING BY BFP RPM WITH PID.

73440 UNITS 4,03,920

4. 2012-13 REDUCTION IN AUXILIARY BY OPTIMIZATION IN CPP-I CEP DISCHARGE

PRESSURE.

118404 UNITS 6,51,222

5. 2012-13 POWER SAVING SCHEME IN CPP- COMPRESSOR BY REDUCING RUNNING

HOURS OF COMPRESSOR.

371250 UNITS 20,41,875

6. 2012-13 REDUCTION IN AUXILIARY POWER BY STOPPING RAW WATER PUMP (5.5 KW.)

9974 UNITS 54,860

7. 2012-13 REDUCTION IN AUXILIARY BY OPTIMIZATION IN CPP-II CEP DISCHARGE

PRESSURE.

158400 UNITS 8,71,200

8. 2012-13 POWER SAVING SCHEME IN CPP TURBINE EXHAUST TEMPERATURE

CONTROLLING BY ACC FAN RPM WITH APPLYING PID AUTOMATION.

190444 UNITS 10,47,440

SR.NO YEAR DESCRIPTION OF MEASURE SAVING PER YEAR

NET SAVING IN RUPEES PER YEAR

09. 2013-14 CPP I & II:-REPLACEMENT OF AERODYNAMIC DESIGN FRP BLADE WITH

HUB (POWER SAVING 20 % AS PER COMMITMENT) (7 FANS-110 KW, 3 FANS-

15 KW).

1290000 UNITS 7095000

10. 2013-14 CPP-I:- UTILIZE TURBINE FIRST EXTRACTION STEAM FOR AUXILIARY

STEAM REQUIREMENT AT 20 kg/cm2 IN PLCE OF 86 kg/cm2

STEAM COST

REDUCTION FROM Rs

600 TO Rs 400 PER TON 792000

11. 2013-14

CPP-II:- UTILIZE TURBINE FIRST EXTRACTION STEAM FOR AUXILIARY

STEAM REQUIREMENT AT 20 kg/cm2 IN PLCE OF 86 kg/cm2

STEAM COST

REDUCTION FROM Rs

600 TO Rs 400 PER TON

792000

12. 2013-14 POWER SAVING SCHEME IN CPP1 BOILER FEED WATER OULET LINE

HEADER PRESSURE CONTROLLING BY BFP RPM WITH APPLYING PID

AUTOMATION.

467280 UNITS 25,70,040

13. 2013-14 COAL BELT CONVEYOR 5 NOS. BELT CONVEYOR BELT STOPPED

PERMANENTLY BY PROVIDING COAL CHUTE. 19454 UNITS 107000

14. 2013-14 POWER SAVING SCHEME IN CPP- INSTRUMENT COMPRESSOR BY

REDUCING RUNNING HOURS OF COMPRESSORS BY INSERTING ONE

MORE RECEIVER TANK & MODIFY MOTOR STOP TIME. BY DOING SO

MOTOR’S CONTACTOR LIFE ALSO INCREASE.

58080 UNITS 3,19,440

12.04%11.22%

9.59%8.98%

0.00%

2.00%

4.00%

6.00%

8.00%

10.00%

12.00%

14.00%

2010-11 2011-12 2012-13 2013-14

CPP AUX CONSUMPTION IN %

CPP AUX CONSUMPTION IN %

03 month Summary:-

Nov. -14 (from 14.11.14 to 30.11.14) saving w. r. t. RSEB= Rs. 26,03024

Dec.-14 (from 12.12.14 to 31.12.14) saving w. r. t. CPP= Rs. 32,55,164

CPP-Aux. Consumption=8.28%

CPP- Loading improvement =30%

CPP- Loading % achieved = 98.21%

Jan.-15 (up to 31.01.15) saving w. r. t. CPP= Rs. 82,92,122

CPP- Aux. Consumption=8.17%

CPP- Loading improvement =21.8%

CPP- Loading % achieved = 97.90%

Feb.-15 (up to 19.02.15) saving w. r. t. CPP= Rs. 49,72,419

CPP- Aux. Consumption=8.32%

CPP- Loading improvement =26.11%

CPP- Loading % achieved = 97.30%

98.21%

97.90%

97.30%

96.80%

97.00%

97.20%

97.40%

97.60%

97.80%

98.00%

98.20%

98.40%

Dec-14 Jan-15 Feb-15

PERCENTAGE AVERAGE CPP

LOADING

TILL 19th

95.8

114.2

170.8

169.7

116.3

148.4

0

20

40

60

80

100

120

140

160

180

2009-10 2010-11 2011-12 2012-13 2013-14 2014-15

WIND POWER FOR CAPTIVE USE IN

LACS KWH

LOW DUE TO CABLE

THEFT PROBLEM

(APR TO JAN)

6.20%

8.30%

11.50% 10.20%

7.60%

9.00%

0.00%

2.00%

4.00%

6.00%

8.00%

10.00%

12.00%

14.00%

2009-10 2010-11 2011-12 2012-13 2013-14 2014-15

PERCENTAGE GREEN POWER

(WIND POWER)

UESD

LOW DUE TO

CABLE THEFT

PROBLEM

(APR TO JAN)

0 0

100473

173375

123895129816

0

20000

40000

60000

80000

100000

120000

140000

160000

180000

200000

2009-10 2010-11 2011-12 2012-13 2013-14 2014-15

PETCOKE CONSUMPTION IN TON

PETCOKE CONSUMPTION IN TON

(APR TO JAN)

16.90%18.10%

12.50%

10.20%10.50% 9.60%

0.00%

2.00%

4.00%

6.00%

8.00%

10.00%

12.00%

14.00%

16.00%

18.00%

20.00%

2009-10 2010-11 2011-12 2012-13 2013-14 2014-15

PETCOKE CONSUMPTION IN % OF CLINKER PRODUCTION

PETCOKE CONSUMPTION

IN % OF CLINKER PRODUCTION

(APR TO JAN)

85 % PETCOKE &

15 % INDIAN

COAL USED

57% PETCOKE &

43 % INDIAN

COAL USED

100% INDIAN

COAL USED

100% INDIAN

COAL USED

100% PETCOKE

USED

100% PETCOKE

USED

0.8284

0.8201

0.8071

0.7950

0.8000

0.8050

0.8100

0.8150

0.8200

0.8250

0.8300

2012-13 2013-14 2014-15

Reduction in CO2 Emission due to Unit -I Upgradation (Kg/Kg Clinker)

Reduction in CO2 Emission due to unit -I upgradation (Kg/Kg Clinker)

(APR TO JAN)

15.35%

26.05%27.47%

31.06%

0.00%

5.00%

10.00%

15.00%

20.00%

25.00%

30.00%

35.00%

BASE YEAR 2007-10 2012-13 2013-14 2014-15( APR TO JAN)

FLY ASH CONSUMPTION IN %

0.56

0.55

0.51

0.48

0.49

0.50

0.51

0.52

0.53

0.54

0.55

0.56

0.57

2012-13 2013-14 2014-15

Reduction in CO2 Emission after using higher quantity of fly ash in PPC Cement Production(Kg/Kg Cement)

Reduction in CO2 Emission after

using higher

quantity of fly ash in PPC Cement

Production(Kg/Kg

Cement)

(APR TO JAN)

16.14%

17.01%

10.80% 10.22%

13.45%10.39%

6.95%

6.22%

0.00%

2.00%

4.00%

6.00%

8.00%

10.00%

12.00%

14.00%

16.00%

18.00%

HIGH GRADE LIME STONE

CONSUMPTION IN

PERCENTAGE

HIGH DUE

TO INDIAN

COAL USED

85.94

85.61

82.55

78.23

80.59

78.97

74

76

78

80

82

84

86

88

2009-10 2010-11 2011-12 2012-13 2013-14 2014-15

kwh/ton of cement

kwh/ton of cement

(APR TO JAN)

797.39 793

773

741

710720730740750760770780790800810

BASE YEAR 2007-10 2012-13 2013-14 2014-15 (APR TO DEC)

Kcal/ kg of clinker

Kcal/ kg of clinker

1) UNIT-1 UP GRADATION WITH 6 STAGE PREHEATER & PRECALCINER EFFICIENT

CROSS-BAR COOLER VRM & VCM FOR

CAPACITY UPGRADATION FROM 1700 TPD TO 3000 TPD

INSTALLATION OF VVVFD (MV DRIVE) ABB MAKE FOR 1250 KW HT MOTOR FOR VRPM AT UNIT-1 CEMENT MILL.

AFTER INSTALLATION OF VVVFD THE SPEED OF THE VRPM GOT REDUCED, HENCE INCREASED THE OUTPUT OF

THE VRPM AND BALL MILL AND REDUCED SPECIFIC ENERGY CONSUMPTION KW PER TONE OF CEMENT FROM

30.2 TO 26.72 KWH/TONNE OF CEMENT.

Cement production This year = 533236 MT

SEC of Cement Mill Last year =30.06 units (2012-13)

SEC of Cement Mill this year =27.95 units (Apr-14 To Jan-15)

Total units saved = (30.06-27.95) x 533236 = 2.11 x 533236 = 11,251,127.96

= 1.13 Million Units

Saving in Rs @5.5 = 1.13 x 5.5 = Rs 6.19 Million