OCL Bengal Cement Works(A Unit of OCL India Limited)

Dalmia Bharat Group Co.

Rich Heritage

Bengal Cement Works

The Group was established in 1939 and has a rich heritage of 75+ years of serving India

Dalmia advertisement on 15th August 1947

Re-published on 60th independence day by Times Of India

Cement

Sugar

Refractories

Power

9/2/2017 2

Bengal Cement Works

Pan India Footprint Of Dalmia CementFourth largest cement group in

India with 27 Million Tons of

installed cement capacity 186 MW

of captive power capacity

BCW1.35 MTPA

OBCW AT A GLANCE

Kapilas Cement Manufacturing Works 4

➢OCL Bengal cement Works (here-in-after referred to as OBCW), a Dalmia Bharat GroupCompany, is operating a Cement Grinding Unit having Installed capacity of 1.35 MTPA,now being upgraded to 1.75 MTPA situated at West Midnapur district in West Bengal .

➢Cement Plant commissioned on 27th March, 2014

➢A Solar PV Power Plant of 5.5 MW capacity commissioned on 30th March 2016

➢Certified for Integrated Management System of ISO 9001,14001 & 18001 ( Quality ,Environment & OHSAS ) .

➢Presently operating a FLS OK MILL (42.4) for both PSC & PPC in inter-grinding mode .

➢Predominantly manufacture PSC & PPC and catering to the entire pockets of West Begalwith 100% road despatches.

5

CERTIFICATIONS

Bengal Cement Works

5

Our Focus area IMS CERTIFIED UNIT

ISO 9001: 2008 ISO 14001: 2004 OSHAS 18001: 2007

9/2/20175

EXCELLENT ENERGY EFFICIENT UNIT AWARD IN 2016

CERTIFICATE OF MERIT FOR ENERGY EXCELLENCE FROM BEE IN 2016

CERTIFICATE OF TWO STAR RATING IN 2016

Process Flow Diagram

Bengal Cement Works

Truck Despatch

Bulker

Despatch

Wagon Tippler

Truck Tippler

Clinker Silo

Cement Silo

Raw material hopper

Stacker & reclaimer

CVRM

HAGCoal mill

Coal hopper

Bag House

Roto Packers

Clinker

Gypsum/slag

Coal Fly ash bulker

Fly ash Silo

9/2/2017 6

7Bengal Cement Works 9/2/20179

51.443.27

38.94 36

0

10

20

30

40

50

60

2014-15 2015-16 2016-17 2017-18

SPECIFIC ENERGY (KWH/T) FOR PSC

10%

17%

44.7

33.4430.01 28

0

10

20

30

40

50

2014-15 2015-16 2016-17 2017-18

SPECIFIC ENERGY (KWH/T) FOR PPC

BENCHMARK

10%

15%

Benchmark: Where We Are ..Where To Go…

BENCHMARK

27

85.581.5 78

59

20

40

60

80

2014-15 2015-16 2016-17 2017-18

Kcal/Kg for PSC

4037

28.6 26.5

0

10

20

30

40

50

2014-15 2015-16 2016-17 2017-18

KCal/Kg for PPC

28%

4%

28%

23%

Bengal Cement Works

Roadmap To Achieve Target SEC ( KWH/T)

50

.5

39

.5

36

.0

-6.9

-2.8

-0.7-0.2 -0.1 -0.3 -0.1 -1.2

-0.6 -0.8-0.3

-0.6

30

35

40

45

50

55

60

201

4-1

5

thro

ug

hp

ut

enh

ance

me

nt

by

ca

pa

city u

tilis

atio

n &

optim

izatio

n

cvrm

op

tim

iza

tion

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er

facto

r im

pro

ve

men

t

cvrm

ba

g h

ou

se

pu

rgin

g in

DP

mo

de

160

KW

com

pre

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pla

ce

me

nt

by 9

0 K

w

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izin

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om

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sse

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ipm

ent

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ization

201

5-1

6

cvrm

op

tim

isa

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ary

po

wer

redu

ctio

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aw

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al cir

cuit o

ptim

ization

cvrm

fa

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ien

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nh

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nt

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ill T

PH

en

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t

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g p

lan

t p

ow

er

red

uction

201

6-1

7-1

8 Q

1

SEC(KWH/T)

9Bengal Cement Works

ENCON Project with

investments

9/2/2017 16

10

ENCON Actions : without investment

Bengal Cement Works

SN ENCON actions with out investment YearAnnual

Million KWHSaving

Annual INRsaving

(Million)

1 Reduction of compressed air consumption in CVRM Bag house 2014-15 0.104 0.800

2 Reduction in running hour of Slag feeding group Bag filter fans 2014-15 0.050 0.370

3 Reduction of CVRM main drive SPC through Dam ring height adjustment from 192 to 150 mm 2015-16 2.000 15.400

4 Running of CVRM Bag house in DP mode 2015-16 0.144 1.110

5 Reduction of Packing plant SPC by replacing 160 KW compressor by 90 KW 2015-16 0.100 0.780

6 Reducing idle running of Material handling circuit drives through installation of belt starvation switches 2015-16 0.003 0.020

7 Reduction of WTP Cooling Tower fan power consumption through interlock with temperature sensor 2015-16 0.028 0.210

8 Reduction of Compressor power consumption by optimizing loading/unloading set point 2015-16 0.180 1.390

9 PLC interlock modification for process optimization ( Save 15 no of trippings) 2015-16 0.013 0.100

TOTAL 2.620 20.170

9/2/20179

SN ENCON actions with investment YearAnnual

Million KWHsaving

AnnualMINRSaving

1 Gear box radial bearing maintenance & CVRM optimization to run on minimum power mode 2016-17 0.46 3.93

2 CVRM ID fan cone gap correction from 33 mm to 12 mm 2016-17 0.052 0.44

3 Felt seal installation at CVRM dynamic separator seal gap 2016-17 0.03 0.26

4Nozzle ring area increment by removal of three nozzle blocks ( from 4.87m2 to 5.4 m2 )( reduction in nozzle ring velocity from 48 m/s to 40 m/s)

2016-17 0.1 0.92

5 Dam ring reduction by 6 mm( from 122 mm to 116 mm ) 2016-17 0.03 0.32

6Reduction of false air at mill reject chute flap & belt, mill inlet ducts , mill feed chute ,Separator outlet flage & Bag house chamber doors. ( from 18.4 % to 14 %)

2016-17 0.09 0.76

7 Coal mill grinding media regradation & pattern change ( from coarse to fine) 2016-17 0.09 0.79

8 Stop Auxiliary bag filter fan through tapping in main bag filter fan in each packer 2016-17 0.06 0.52

9Packer 1 & 2 bucket elevator group starting interlock modified to avoid group idle running during shift starting

2016-17 0.003 0.026

10Packer 1 & 2 belt bucket elevator & CVRM reject elevtor motor connection change from delta to star

2016-17 0.02 0.18

TOTAL 0.94 8.15

ENCON Actions : without investment

Bengal Cement Works

12Bengal Cement Works

ENCON Project with

investments

9/2/2017 212

13

ENCON Actions: with investment

Bengal Cement Works

SN ENCON actions with investment Year

AnnualMillion KWH

saving in year of installation

AnnualMINRSaving

Investment(MINR)

Payback period

1 Power factor improvement by installing 1500KVAR HT capacitor installation 2015-16 0.500 3.860 1.250 3 M

2Reducing power consumption of HAG fuel firing blower through VFD installation

2015-16 0.030 0.230 0.040 2 M

3 Reduction of Packing plant SPC by replacing 90 KW compressor by 45 KW 2016-17 0.195 1.500 0.900 6 M

4Reducing power consumption of packing plant bag filter Fan by VFD installation

2015-16 0.130 1.000 1.680 1.25 Y

5 Reducing power consumption of CVRM bag filter Fan by VFD installation 2016-17 0.026 0.200 0.050 3 M

6 Solar power generation unit 5.5 MW 2016-17 6.000 46.200 277.200 6 Y

7Installation of plant logistic automation system to improve operational efficiency of packing plant.

2015-16 0.200 1.550 2.500 1.6 Y

8Installation of VFD in 641 FN1 & 642FN1 ( 75*2 kw) Silo bin aeration blower 611BL2 ,packing plant compressor & 611FN1 Silo 1 bag filter fan.

2016-17 0.12 0.99 1.35 1.4 Y

9Installation of VVFD in reject bucket elevator bag filter fan , reject circuit bag filter fan & raw material feeding belts bag filter fan

2016-17 0.092 0.790.8

1 Y

TOTAL 7.3 56.32 285.77 1.25 Y

9/2/2017 10

SN ENCON actions with investment

Annual thermal saving (

MKCal/year)

AnnualMillion KWH

saving Status/Remarks

1Partial blocking of left most duct of CVRM hot air inlet

4052 -By uniform temp distribution heat saving is around 3KCal/Kg

2 Trimming of CVRM ID fan impeller - 0.58 Approx 80KW/Hr saving is estimated

3 CVRM ID Fan inlet duct area enlargement - 0.4 Approx 55 KW/Hr is estimated

4Reduction of system pressure of CVRM circuit by 25 mmwc through several maitenance activity

- 0.14 Around 25 KW/Hr is achieved

5 False air reduction from 14% to 10% - 0.20Reduction from 14% to 11.6% is achieved. By reducing upto 10% 15kw/hr saving is estimated

6Reduction of plant lighting power consumption by replacing HPSV light with LED base light - 0.13 In progress

7 9 no of VFD installation at various section - 0.12 In progress

TOTAL 4052 1.57

Bengal Cement Works

ENCON Actions: For 2017-18

15

ENCON Methodology: ENCON Approach

Bengal Cement Works

MANAGE MEASURE PROTECT

Unit Head

Energy cell

Energy cell head with cross functional team

Daily energy monitoring at

PD

Weekly energy monitoring by

energy cell

Monthly energy meeting

Scope identification

Action plan generation&

execution

Quantification , analysis &

record

9/2/201711

16

ENCON Methodology: Energy Levers

Bengal Cement Works

VRM POWER OPTIMIZATION

1. Dam ring

2. False air

3. Feed size control

4. Separator efficiency Power factor

& efficient silo management to avoid peak hour

usage

Fans & blowers efficient running

Compressor power minimization

Equipment idle run minimization

1. Stop interlocks

2. starvation stop

3. Shop stoppage power

Solar power

31%

5%

12%31%

11%10%

Effective use of Energy Levers in 2016-17

VRM optimization

Equipment idle running

Compressor powerminimizationFan & blower efficientrunningThermal energy saving

others

9/2/2017 12

17

ENCON Methodology: Power reports

Bengal Cement Works

Daily Energy report with real time data captureCCR operation screen with Total KWH & KWH/T display for main drives.

Column12500 kvA

Trafo for

Wagon Tippler

540kW Cement

Mill Separator

Fan for 561MD2

2500 kVA

Trafo Feeder

-1 for CCR

4150 kW

BagHouse Fan

561FN1

CCR Main

Incomer

2500 kVA

Tafo Feeder-

2 for CCR

6500kW Cement

Mill Main Drive

for 561MD1

Solar

Power

Feeder

400kW Coal

Mill Main Drive

for L41MD1

2500kVA Trafo

Feeder for

Packing Plant

Spare

Trafo

Feeder-1

Spare

Trafo

Feeder-2

400kW Belt

Conveyor Feeder

for 491BC3

MRSS

Outgoing

Feeder-1

MRSS

Outgoing

Feeder-2

18-08-2016 00:02 3139752 918607 8161475 25502312 98944160 5979773 56517248 2E+06 1552036 7368597 22 10 174219 99351864 0

18-08-2016 01:02 3139876 918637 8161882 25503988 98950672 5980121 56520604 2E+06 1552268 7368969 22 10 174219 99358432 0

18-08-2016 02:02 3140001 918670 8162287 25505650 98957104 5980504 56523928 2E+06 1552422 7369341 22 10 174219 99364912 0

18-08-2016 03:02 3140126 918703 8162695 25507300 98963344 5980817 56527292 2E+06 1552422 7369711 22 10 174219 99371208 0

18-08-2016 04:02 3140253 918736 8163105 25508956 98969656 5981199 56530656 2E+06 1552422 7370084 22 10 174219 99377576 0

18-08-2016 05:02 3140378 918769 8163514 25510632 98975904 5981554 56533972 2E+06 1552422 7370441 22 10 174219 99383864 0

18-08-2016 06:02 3140472 918802 8163903 25512324 98982016 5981820 56537324 2E+06 1552422 7370780 22 10 174219 99390024 0

18-08-2016 07:02 3140560 918835 8164277 25514018 98987872 5982181 56540648 2E+06 1552422 7371014 22 10 174219 99395928 0

18-08-2016 08:02 3140652 918867 8164649 25515704 98993328 5982517 56543872 2E+06 1552422 7371288 22 10 174219 99401424 0

18-08-2016 09:02 3140816 918899 8165090 25517392 98998520 5982794 56547104 2E+06 1552462 7371545 22 10 174219 99406664 0

18-08-2016 10:02 3140934 918930 8165547 25519004 99002424 5983055 56549888 2E+06 1552693 7371823 22 10 174219 99410592 0

18-08-2016 11:02 3141020 918961 8166006 25520676 99006216 5983394 56553036 2E+06 1552926 7372062 22 10 174219 99414416 0

18-08-2016 12:02 3141158 918992 8166460 25522364 99009136 5983739 56556208 2E+06 1553156 7372329 22 10 174219 99417360 0

18-08-2016 13:02 3141297 919023 8166825 25524048 99012592 5984151 56559360 2E+06 1553384 7372614 22 10 174219 99420848 0

18-08-2016 14:02 3141380 919053 8167190 25525728 99017112 5984543 56562532 2E+06 1553608 7372890 22 10 174219 99425400 0

18-08-2016 15:02 3141464 919084 8167555 25527404 99021352 5984936 56565752 2E+06 1553608 7373204 22 10 174219 99429672 0

18-08-2016 16:02 3141574 919115 8167920 25529074 99025680 5985349 56568952 2E+06 1553608 7373560 22 10 174219 99434032 0

18-08-2016 17:02 3141734 919146 8168284 25530684 99030672 5985712 56572040 2E+06 1553608 7373898 22 10 174219 99439064 0

18-08-2016 18:02 3141840 919149 8168360 25530032 99031208 5985971 56572040 2E+06 1553608 7374225 22 10 174219 99439608 0

18-08-2016 19:02 3141903 919149 8168433 25530032 99031800 5986170 56572040 2E+06 1553608 7374473 22 10 174219 99440200 0

18-08-2016 20:02 3142046 919149 8168513 25530032 99032496 5986281 56572040 2E+06 1553608 7374836 22 10 174219 99440912 0

18-08-2016 21:02 3142186 919149 8168601 25530032 99033232 5986389 56572040 2E+06 1553608 7375220 22 10 174219 99441640 0

18-08-2016 22:02 3142505 919149 8168682 25530032 99034240 5986549 56572040 2E+06 1553608 7375594 22 10 174295 99442664 0

18-08-2016 23:02 3142571 919149 8168761 25530032 99034904 5986698 56572040 2E+06 1553608 7375954 22 10 174295 99443328 0

19-08-2016 00:01 3142676 919149 8168903 25530032 99035616 5986794 56572040 2E+06 1553608 7376318 22 10 174295 99444048 0

Total Consumption 2924 542 7428 27720 91456 7021 54792 18624 1572 7721 0 0 76 92184 0

Dalmia Cements - Active Energy Report

9/2/201713

18

ENCON Methodology: Power reports

Bengal Cement Works

Date 06-08-2016

FTD MTD

TOTAL UNIT AVAILED AT OBCW FROM WBSEDCL kWh 169806.2 559274.3

SOLAR POWER CONSUMPTION kWh 14300.0 68379.0

TOTAL POWER CONSUMPTION AT BCW kWh 184106.2 627653.3

Distribution Loss % 0.8% 0.95%

Raw material handling with stacker(MCC 3)kWh 1982.0 12412.0

CLINKER SILO FEEDING(491BC3) kWh 2573.0 9312.0

Total Reclaimer and hopper feeding circuit(MCC 4)kWh 2137.0 7130.0

CVRM-IV

CVRM MAIN DRIVE kWh 107864.0 333048.0

BAG FILTER FAN kWh 40594.0 133354.0

CVRM CLASSIFIER kWh 1251.0 3430.0

CVRM Aux. as per FLS(MCC 5 INCLUDES HYDRAULIC,HAG)kWh 6172.0 22797.0

CVRM AUX(CEMENT TRANSPORT+CEMENT SILO BUCKET ELEVATOR)kWh 2376.0 11795.0

CVRM COMPRESSOR(70% TOTAL UNIT OF COMPRESSOR)kWh 2511.0 15100.0

LIGHTING kWh 3479.0 22113.0

MILL WATER SUPPLY MCC2 KWh 1424.0 6322.0

Total Power consumed for CVRM kWh 160768.0 519524.0

CVRM UNITS 167460.0 548378.0

Power consumed for PSC KWh 167460.0 503493.0

Power consumed for PPC KWh 0.0 44885.0

COAL MILL

COAL MILL MAINDRIVE kWh 3085.0 9298.0

PSC COAL GRINDING kWh 3085.0 9298.0

PPC COAL GRINDING kWh 0.0 0.0

COAL MILL AUX Incl FAN(MCC 6) kWh 1245.0 4388.0

PSC COAL MILL AUXILLARY kWh 1245.0 4388.0

PPC COAL MILL AUXILLARY kWh 0.0 0.0

Total Power consumed for COAL MILL 4330.0 13686.0

Packing plant

Packing Plant kWh 2660.0 14022.0

Packing Compressor kWh 2001.0 10014.0

Lighting kWh

Total Power consumed for PACKING HOUSE kWh 4661.0 24036.0

SERVICES

PROJECT WORK kWh 0.0 0.0

Lighting kWh 1199.0 7139.0

LIGHTING AND AUXILLARY UNITS and water supplykWh 1199.0 7139.0

Total Power consumption for SERVICES kWh 1199.0 7139.0

182553.0 621674.0

Specific Power Date 06-08-2016

FTD MTD

TOTAL POWER CONSUMED IN OBCW 182553.0 621674.0

CVRM RUN HRS - PSC hrs 22.5 64.5

CVRM RUN HRS - PPC hrs 0.0 5.8

CVRM - RUN Total hrs 22.5 70.3

PSC PRODN ton 4947.4 12926.6

PPC PRODN ton 0.0 1184.8

PRODN - TOTAL ton 4947.4 14111.4

COAL MILL RUN HRS PSC hrs 12.2 36.9

COAL MILL RUN HRS PPC hrs 0.0 0.0

COAL PRODN ton 47.9 157.4

Cement Despatch ton 2384.5 15621.4

Total Reclaimer and hopper feeding circuit(MCC 4)kwh/t 0.4 0.5

Material handling with stacker kwh/t 0.4 0.9

Clinker feeding kwh/t 0.5 0.7

CVRM MAIN DRIVE kwh/t 21.8 23.6

BAG FILTER FAN kwh/t 8.2 9.5

CVRM CLASSIFIER kwh/t 0.3 0.2

CVRM Aux. as per FLS kwh/t 1.2 1.6

CVRM AUX kwh/t 0.5 0.8

CVRM COMPRESSOR kwh/t 0.5 1.1

WATER SUPPLY and lighting kwh/t 0.2 0.5

Total Power consumed for CVRM (Grinding Power)kwh/t 32.5 36.8

Total Power consumed for PSC grinding of CVRM kwh/t 33.8

Total Power consumed for PPC grinding of CVRM kwh/t 0.0

Total Power consumed up to Grinding stagekwh/t 33.8 38.9

COAL MILL MAINDRIVE kwh/t 64.4 59.1

COAL MILL AUX Incl FAN kwh/t 26.0 27.9

Total Power consumed for COAL MILL kwh/t 90.4 87.0

Packing Plant kwh/t 1.1 0.9

Packing Compressor kwh/t 0.8 0.6

Total Power consumed for PACKING HOUSE kwh/t 2.0 1.5

SERVICES Lighting kwh/t 0.2 0.5

WORK SHOP kwh/t 2.0 1.5

Total Power consumption for SERVICES kwh/t 0.2 0.5

Power for cement grinding kwh/t 35.0 40.2

Packing power kwh/t 2.0 1.6

Plant lighting and auxillaries WITH WATER SUPPLYkwh/t 1.0 2.0

power on cement kwh/t 37.99 43.8

Specific Power

Daily powerreport format

9/2/201714

❖ Innovative Project (without investment):

1. CVRM dam ring height & internal air circulation optimization

2. Minimization of compressor power consumption

3. Power saving by minimization of idle running

❖ Innovative Project (with investment)

1. RFID system installation to increase packing plant through put

2. Power factor improvement by installing 1500KVAR HT capacitor

3. VFD installation at packing plant bag filter fans & HAG fuel firing blower0.9500.9600.9700.9800.9901.0001.010

Power Factor

Innovative Project executed & presented last year

Bengal Cement Works

Innovative Project (without investment): 1

Bengal Cement Works

✓ Scope: Due to in apropriate mixing length after HAG outlet duct & recirculation air duct joint, the inlet air through three ducts were having nonuniform heat distribution . The left most duct was carrying most of the heat content. This uniformity was leading non uniforming drying of material & higher specific heat requirement.

❖ Project : Baffle plate installation at Mill inlet duct to distribute uniform heat content to mill through all ducts

❖ Objective: To save thermal energy consumption by effective utilization of supplied heat inside mill

9/2/2017 20

✓Action taken :To resolve the non-uniform temperature distributionat CVRM inlet duct ,a modification with baffles platefixing ( 300 mm width) before the left most duct &between the left & middle duct is done on month ofNovember & it was further remodified to optimize inMar’17.

320 Deg C

133 Deg C

126 Deg C

Innovative Project (without investment): 1

Bengal Cement Works

❖ Projec: Baffle plate installation at Mill inlet duct to distribute uniform heat content to mill through all ducts

❖ Objective: To save thermal energy consumption by effective utilization of supplied heat inside mill

9/2/201721

Heat contribution by VRM inlet ducts ( Kcal)

Before modification After modification

10.09.2016 10.11.2016 04.04.2017 25.05.2017

Temp (

Deg C)

% of

total

heat

content

to mill

Temp

( Deg

C)

% of

total

heat

content

to mill

Temp (

Deg C)

% of

total

heat

content

to mill

Temp

( Deg

C)

% of total

heat

content to

mill

315 49.60% 258 43.80% 280.6 34.30% 287 33.90%

133 26.80% 138 31.50% 190.1 35.80% 190 40.10%

126 23.60% 118 24.70% 135.6 29.90% 140 25.90%

79.566.8

59.349

10.94 10.6111.6

9.1

0

2

4

6

8

10

12

14

0

20

40

60

80

100

FY'17 MARCH APRIL MAY

PSC heat cons(Kcal/Kg) vs Slag moisture%

Heat slag moisture %

Benefits :▪ Energy saved : 1100 T coal

▪ Energy saved : 7 Kcal/Kg cement

▪ Money saved: 5 Million INR

22

Innovative Project : 2

Bengal Cement Works

✓ scope :

▪ coal mill ( equipped with 1st generation staticseperator) was initially designed for :

Feed size of 80% retention at 8mm & ground

product of 15 % retention at 90 Micron sieve.

▪ Operational scenario was

Feed size of 40 % retention at 8 mm & ground

product required of 5% retention at 90 Micron

sieve.

▪ The supplier recommended media pattern wasnot efficient as it was too coarse for the feed &obtained TPH of coal mill was only 3.8 -4 TPHleading to SEC of around 0.7 KWH/T of cement.

❖ Project : coal mill productivity enhancement through grinding media optimization

❖ Objective : To save power consumption by coal mill runhour reduction

9/2/201721

✓ Action taken :

▪ Media pattern optimized to fine pattern

▪ 70 mm media was removed , 60 mm media

proportion reduced & 20 mm media is included.

0.0%

6.4%

12.2%12.7%

22.3%26.4%

20.0%

7.1%

14.2%15.0% 20.8% 20.8% 22%

0.0%

5.0%

10.0%

15.0%

20.0%

25.0%

30.0%

70 60 50 40 30 25 20

MEDIA PATTERN

Ball size ( mm)

9/2/2017 23Bengal Cement Works

0.60.5

0.50.6

0.70.8

0.70.65

0.4

0.0

0.2

0.4

0.6

0.8

1.0

Apr-16 May-16 Jun-16 Jul-16 Aug-16 Sep-16 Oct-16 Nov-16 Dec-16

Coal mill main drive KWH/T Cement

3.8 4.4 4.4

4.1 4.0 4.0 3.9 4.0

5.5

- .0

1.0

2.0

3.0

4.0

5.0

6.0

April'16 May'16 JUNE'16 JULY'16 AUG'16 SEP'16 OCT'16 Nov'16 Dec'16

Coal mill TPH

Benefits :▪ Energy saved : 92000 KWH in 2016-17

▪ Energy saved : 0.3 KWH/T

▪ Money saved: 0.79 Million INR

Innovative Project : 2

Innovative Project ( without investment ): 3

Bengal Cement Works

✓ Scope: Each packer is facilitated with two bag filters of 46000m3/hr & 23000 m3/hr. wheteher as per flow

measurement it was analysed that @ 17 m/s velocity , the circuit dedustiong volume requiremet is only 32000 m3/hr, canbe managed by running a single fan of 75 KW.

✓Action taken :

▪ An inhouse modified tapping is provided from the small bagfilter to larger one . the dedusting duct at designatedsources kept unaltered.

▪ The dedusting fan ( 37 KW, 23000M3/HR) is stopped. & through the suction of the remaining bigger fan ( 75 KW, 46000M3/HR) the whole dedusting purposed is successfully resolved.

▪ saving of around 15 Kw/Hr for two packer each i.e 30 KWH .

❖ Project : Elimination of Auxiliary bag filter fan through tapping in main bag filter fan in each packer

❖ Objective : To save the power consumption for two dedusting fan with successfull dedusting of the circuit

Benefits :▪ Energy saved : 60000 KWH in 2016-17

▪ Energy saved : 0.2 KWH/T

▪ Money saved: 0.52 Million INR

9/2/201724

Innovative Project (without investment): 3

Bengal Cement Works

❖ Project : Elimination of Auxiliary bag filter fan through tapping in main bag filter fan in each packer

❖ Objective : To save the power consumption for two dedusting fan with successfull dedusting of the circuit

9/2/2017 25

26Bengal Cement Works

Renewable

energy

9/2/2017 267

Own

consumption

Solar Module, Poly Crystalline Rating: 310 WattNos of module: 17760Total Output: 5.5 MWp

Inverter

Photovoltaic Inverter Rating: 648 KW/ 406 Volts

TransformerRating: 2500 MVA Volts: 11KV / 415 VoltsNos of Tx.: 2

HT BreakerRating: 800 AmpVolts: 12KVNos of Breaker: 2

Solar Panel

System Monitoring

Renewable Energy Usage :

Bengal Cement Works 27

5.5 MWp solar power plant is commissioned on April’16 to utilize non conventional renewable energy & reduction ofcarbon di oxide emission.

9/2/2017

1910991

11256009

0

2000000

4000000

6000000

8000000

10000000

12000000

14000000

KW

H

Solar Grid

15%

85%

11%

15%

0%

5%

10%

15%

20%

FY17 FY18

SOLAR POWER UTILISATION

28Bengal Cement Works

Water

consumption

reduction

9/2/201733

29

Reduction in process Water consumption :

Bengal Cement Works

0.17

0.08

0.07

0.00

0.02

0.04

0.06

0.08

0.10

0.12

0.14

0.16

0.18

2014-15 2015-16 2016-17

Water consumption KL/T

9/2/201734

Zero water spray for PSC

water spray for PPC is only 2 % of total feed.

30

Carbon

foot print

Bengal Cement Works 9/2/2017 30

31

Carbon Footprint Reduction

Bengal Cement Works

❖ Initiatives to reduce carbon footprint :

▪ Installation of 5.5 MWp solar power plant to utilize renewable energy

▪ Reduction of total KWH consumption through various initiatives.

▪ Reduction of thermal energy (Kcal/Kg) by process optimization

▪ Improving clinker factor by higher addition of slag/fly ash to cement.

▪ Reduction of internal vehicle fuel consumption by commissioningwagon tippler & use of battery driven vehicles.

▪ Reduction of Fuel oil consumption by improving reliability

0.40.29

0.25 0.220

0.00.10.20.30.4

CO2 emission (T/T of Cement)

0.2620.221

0.180 0.169

2014-15 2015-16 2016-17 2017-18

Scope 3: Indirect emissions from recieved clinker

0.067

0.0470.041 0.038

2014-15 2015-16 2016-17 2017-18

Scope 2: Indirect CO2 emission from purchased electricity

0.047

0.026 0.0250.020

2014-15 2015-16 2016-17 2017-18

Scope 1 : Direct CO2 emissions

9/2/201731

TARGET

50.14

63.15 63.16 64.06

0

20

40

60

80

2014-15 2015-16 2016-17 2017-18

Slag % in PSC

33.21

34.89 34.83 34.86

3232.5

3333.5

3434.5

3535.5

2014-15 2015-16 2016-17 2017-18

Fly ash % in PPC

32Bengal Cement Works

Going

green

9/2/201735

38%

15%7%

6%

31%

3% valuable trees withbig trunk

flower

fruits

medicinal

ornamental

PLANNED DEVELOPEMENT OF GREEN BELT

8701

11423

14378

3031

0

2000

4000

6000

8000

10000

12000

14000

16000

2014-15 2015-16 2016-17 2017-18(4M)

PLANTED SAPLINGS ( SURVIVED)

❖ Systematic green belt development initiative :▪ Total 37500 nos of survived saplings till FY 2017-18 . Survival

rate is around 85%.▪ 25% of total acquired area is developed as a green belt▪ 126 types of different species is planted through out the plant

area.▪ Quick growing forest tree plantation initiative along boundary

line having wood value & dust prevention potential.▪ Landscaping garden development at around 3 acre area for

beautification

Greenbelt Development Initiative

Green house for seedling development

❖ Systematic green belt development initiative :

▪ Organic farming vegetable cultivation through out 4500 Sq Ft area.▪ Canteen waste ,other agriculture & garden waste are used to prepare

vermin compost along with cow dung- received from distributed cows tonear by villagers. This eliminates the hazard of chemical fertiliser usage.Also ground water contamination is prevented.

▪ Development of green house round 300 Sq Mt for seedling development▪ Plantation of saplings around 2000 nos with medicine value

Greenbelt Development Initiative

35Bengal Cement Works 9/2/201738