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Location Max Temperature:47oC

Min Temperature:14oC

Annual Rainfall:600 -700 mm

1985 – M/s TEXMACO LTD Capacity – 1500TPD Cement Plant 1993 – Enhanced production capacity from -1500 TPD to 1800TPD 1995 – Management Change to ZUARI INDUSTRIES LIMITED 1998-99 – Plant capacity has enhanced to 5000 TPD (1.8MTPA- Clinker) 2000 – 50:50 Joint venture with Italcementi Group 2006 – Become 100 % share holder in ZCL. 2009 – Clinker production cap. increased to 1.8 to 2.0MTPA 2010 – New Clinker Line(2.3 MTPA)Commissioned.2016 - Management Changed to HEIDELBERG CEMENT

Plant history & Details

1985:TEXMACO LTD

1993:Enhanced Production

1500 to 1800TPD

1995:ManagementTook over by

ZCL

1998-99 :Enhanced

Clinker Prod1.6 to

1.8MTPA

2000:50:50 Joint

venture with

ItalcementiGroup

2006:Italcementi

become 100 % share holder in ZCL

2009:Enhanced

Clinker Product1.8 to

2.0 MTPA

2010 :New

Clinker Line(2.3 MTPA)

Commissioned

2016 :Management Took over by HEIDELBERG

CEMENT

Installed Capacity (Clinker) - 4.3 mMTPA

Installed Capacity (Cement) - 5.4 mMTPA

Wind Power Installed Capacity - 6 MW

Solar Power Installed Capacity - 550 Kwp

Product Range - OPC , PPC , PSC and MC

ZCL – Yerraguntla Plant

Arrested compressed air leakages

Installed VFD

Reduced Loading unloading set points

Separated packing plant silo aeration and installed 30 kw

compressor

Installed 55 Kw compressor and stopping bigger compressor

when equipment stop condition

Reduction of Compressor power consumption

Innovative project- 1

Pipe line modification for reducing pressure drop

Installed small receiver tanks for critical locations



Installed solenoid valves for auto

cut off the valve with equipment

running

Introducing SMS Alert system



Compressor speed increases sms will send to concerned and

solinoids intraduced is Known Concept, but applied for differently

and also it is beyond the scope of OEM and having high Replication

Potential in the sector

819 Kwh / day

19.39 Lakhs per Annum

6 Lakhs

4 months

100 % Replication is possible in All industries

Cemen

t silo

Modification

Innovative project-2

Direct feeding system to EEL-2 Vibrating screen by avoiding CB-2 :

Avoided Extra circuit running

by connecting directly to the

vibrating screen with

installation of one air slide

and diverting gate .

CB-2 Circuit is not required

when we are running one

product in one packer


Direct feeding system to EEL-2 Vibrating screen by avoiding CB-2 :

Packer is recently installed (2010 ) and modification in the packer

circuit is beyond the scope of OEM and having high Replication

Potential where ever EEL supplied same cicuit

80 Kw


6 Lakhs

2 months


Idler design for Increasing low bulk density Alternate fuel

Low bulk density alternate fuel like RDF is not flowing

through feeding hopper and belt is running with out material due to arch

forming and disturbing the pc outlet temperature ZCL designed a spike roller

for disturbing the material and leads to improved flowability

ZCL designed a spike roller for improving flow ability, it is beyond the scope of OEM and having high Replication Potential in the sector


Idler design for Increasing low bulk density Alternate fuel

1.43 Kcal / kg clink


1 Lakhs

1 months

Installed VFD

Installed floating valves for the storage tanks

Reduced Pump RPM

Further reducing Pump RPM with Ok mill or Kiln

running status

SMS Alert system

Daily monitoring and reporting power

consumption through mail

Reduction of Process Water Pumps Power Consumption

2462 Kwh / day

3278 Kwh / day

816 Kwh / day


ATOX-55 is the first mill in Asia order by Zuari cement ltd with design capacity 430 TPH

Mill Feed gain size : 120 mm

VRM- 2 ( ATOX – 55) Optimization with Reject B.E

Need for the projects

• To improve reliability of mill

• Higher power consumption

• Production enhance to

match

kiln production

Raw Mill-3 (ATOX-55) reject B.E

Reject B.E design (Original)Capacity : 225 TPH Grain size : 60 mmMill feed grain size : 120 mm

Reject B.E design (Modified)Capacity : 400 TPH Grain size : 150 mmMill feed grain size : 120 mm

OEM not accepted to change the B.E

Route cause• Under capacity reject B.E design• To control reject , fan speed keep higher side resulting fan power consumption is high to control rejects


Raw mill-3 (ATOX-55) Operating

Parameters Before B.E

Modification

Raw mill-3 (ATOX-55) Operating

Parameters After B.E

Modification


Advantages After Modification of Reject B.E

• After changing the B.E the mill stoppage during start up is reduced.

• With old B.E number of stoppages in 2013 was 168 .

• With Modified B.E number of stoppages in 2015 is zero .

• The mill fan speed reduced from 95 % to 92 % - Optimized .

Results achieved

• The Average mill production increased from 420 TPH to 437 TPH.

• Reliability of raw mill increased from 89 to 93 % .

•The specific power reduced by 1.2 kWh/ T of raw meal.

• Total Savings achieved in a year : 124.7 lakh /Year.


line-2 calciner fine coal transport blower speed reduced by 10 %.

PA fan VFD installed in line-2 kiln

Total Power saving : 800 kWh/day

line-1 calciner Fine coal transport blower speed reduced by 10 %.

Total Power saving : 600 kWh/day

Electrical Energy Saving projects

Energy Conservation Projects

Replaced entire Start up diesel with liquid Alternative fuel

Mixing Of Red mud in lime stone pile To Use High Sulfur

Pet coke

Need for the projects

Stared using high sulfur pet coke.

Facing problem of coating in smoke chamber & raiser ducts.

To neutralize the sulfur content in pet coke need red mud (rich in alkali)

Kiln not in stable operation .

Silica content in lime stone is higher

Challenges

Handling red mud with 25 % moisture

Mixed the red mud with lime stone & feed to additive hoppers (Two) having

capacity 400 MT each.

Hopper getting jam frequently and raw mix quality not matching with the pet

coke fuel.

Advantages of using Red mud in raw mix

* High sulfur pet coke consumption

* Low grade limestone utilization

* Kiln stable Operation with increase in

production.

* Reduced Raw mix and fuel cost.

* With mixing in lime stone pile , there is no

jamming in chutes/ Hopper.

* Quality of raw mix & clinker is consistence

Red mud spreading on stock pile


Pet coke

Results:Use of red mud in line-2 kiln is successful with enhanced kiln stable operations with high sulfur Pet Coke & consistent quality .

DescriptionKiln feed

Clinker

Production

Clinker

Production

TPH TPH TPD

Without red mud and 100 % pet coke 390 244 5844

With red mud and 100 % pet coke

with stable condition413 258 6194

Savings achieved :•With the optimized output we saved the specific power consumption by 0.65 kWh/ Tof clinker and Specific fuel 3 Kcal/Kg clinker.•By the use of red mud along with the fuel mix savings against increased clinkerproduction works 120 lakh /year• Saving due to reduction in energy consumption Rs : 123 lakh/year•Total saving per year Rs: 243 lakh/year


Pet coke

Brixmate Cement Quality Parameters

DESCRIPTION UnitTest

Results

Specification

IS:3466

PHYSICAL TESTS:

Residue on 45

Micron% 11.60 Max 15.0

Setting Time

- Initial Minutes 170 Min 90.0

- Final Minutes 310 Max 1440

Air Content % 7.40 Min 6.0

Water Retention % 74.00 Min 60.0

Compressive

Strength

7-Days MPa 12.00 Min 2.5

28-Days MPa 18.00 Min 5.0

Soundness -

Autoclave% 0.05 Max 1.0

Soundness - Le-

Chatliermm 1.25 Max 10.0

Advantages• Less shrinkages & cracks• Longer initial setting time• Greater Durability• Brick work with super finish• Lesser clinker consumption• Skilled man power not required for application

Results:• Carbon emission reduced to 50% compared to ordinary cements. • Eco friendly.

Manufacturing Brixmate Cement

Energy Saving Projects implemented during last 3

years with No Investments

Description of Energy Saving Projects implemented

Annual Electrical

Saving

Annual Thermal Saving

Total Annual Savings

Investment Payback

(Months)Million Units

Million Rs

Tones fuel

Million Rs

Million Rs

Million Rs

Reducing the line-2 water pump speed during kiln shut down

0.02 0.13 0.0 0.0 0.13 0.0 0.0

Replacement of diesel with pyrolysis oil

0.00 0.0 436 7.20 7.20 0.0 0.0

Reduction of surface in 43 grade cement

0.25 1.62 0.0 0.0 1.62 0.0 0.0

Coal Crusher bypass during fine (imported) coal unloading.

0.15 0.97 0.0 0.0 0.97 0.0 0.0

Increased OK mill PPC grinding 0.23 1.49 0.0 0.0 1.49 0.0 0.0

Maximizing unloading fly ash in bin instead of unloading in silo

0.06 0.39 0.0 0.0 0.39 0.0 0.0

Reduce the Damper loss in line-2 cooler vent fan

0.16 0.95 0.0 0.0 0.95 0.0 0.0




Annual Electrical

Saving



Investment Paybac

k (Month

s)Million Units

Million Rs

Tones fuel

Million Rs

Million Rs

Million Rs

Optimization of quarry water pumps 0.18 1.05 0.00 0.00 1.05 0.00 0.00

Optimized use of petcoke with Redmud & increase clinker Production

1.50 9.00 650 3.25 12.25 0.00 0.00

Optimisation of rawmill grinding media

0.27 1.62 0.00 0.00 1.62 0.00 0.00

Optimisation of CM-3 Grinding media 0.29 1.73 0.00 0.00 1.73 0.00 0.00

Optimisation of Idle running power by logic modification

0.40 2.41 0.00 0.00 2.41 0.00 0.00

Punch plate removal in Rawmill-3 0.69 4.16 0.00 0.00 4.16 0.00 0.00




Annual Electrical Saving



Investment

Payback

(Months)Million

UnitsMillion

RsTones fuel

Million Rs

Million Rs

Million Rs

Optimization of K line bag house fan

0.10 0.60 0.00 0.00 0.60 0.00 0

Optimize the loading of DG Transformer

0.00 0.02 0.00 0.00 0.02 0.00 0

Optimizing the fly ash unloading system

0.05 1.81 0.00 0.00 1.81 0.00 0

Optimising the Air volume in line-2 Rawmill

0.75 4.50 0.00 0.00 4.50 0.00 0

Reduction of damper loss in CM-1 Bag house fan

0.03 2.38 0.00 0.00 2.38 0.00 0

Total Saving without investment : 4.53 Cr


years with Investments





Investment

Payback

(Months)Million

UnitsMillion

RsTones fuel

Million Rs

Million Rs

Million Rs

Optimisation of Line-2 water pump by Instaltion of VFD

0.49 3.16 0 0 3.16 0.80 3.0

Damper and LRS losses reduced by installation of VFD for CM-2 sepax fan

0.32 2.06 0 0 2.06 1.60 9.3

Damper and LRS losses reduced by installation of VFD for CM-3 sepax fan

0.36 2.31 0 0 2.31 1.60 8.3

Optimized EEL packer Bag filter by Instaltion of VFD

0.16 1.03 0 0 1.03 0.45 5.3

Line-2 PA Fan optimized by Instaltion of VFD

0.16 1.03 0 0 1.03 0.95 11.1

Direct feeding of cement to EEL packer-2 vibrating screen bypassing CB-2 circuit

0.63 4.11 0 0 4.11 0.60 1.8

OK mill separator Felt seal arrangement

0.15 0.98 0 0 0.98 0.10 1.2




Annual Electrical

Saving



Investment

Payback (Month

s)Million Units

Million Rs

Tones fuel

Million Rs

Million Rs

Million Rs

Line-1 Calciner coal firing blower speed reduced by 10%

0.20 1.28 0.0 0.0 1.28 0.05 0.5

CM-2 Grinding media optimization 0.52 3.39 0.0 0.0 3.39 2.28 8.1

Cooler vent fan HT motor replaced with LT Motor and installed VFD

0.63 4.11 0.0 0.0 4.11 1.60 4.7

Installation of VFD for Line-1 Post Clinker Water Pupms

0.16 1.02 0.0 0.0 1.02 0.45 5.3

Replacement of 250w HPSV street lights with 60 W LED lights

0.05 0.31 0.0 0.0 0.31 0.53 20.0

Coal firing blower optimised with reducing blower speed by changing pully

0.20 1.31 0.0 0.0 1.31 0.05 0.5

Installation of high efficiency bag house fan in cement mill -2

0.03 0.21 0.0 0.0 0.21 0.80 46.7




Annual Electrical

Saving



Investment

Payback (Month

s)Million Units

Million Rs

Tones fuel

Million Rs

Million Rs

Million Rs

Installation of high efficiency bag house fan in cement mill -3

0.03 0.21 0.00 0.00 0.21 0.80 46.7

Installation of Solenoid Valve system In packing Plant for optimization of compressed air

0.30 1.94 0.00 0.00 1.94 0.60 3.7

Optimisation of line-2 Raw mill Circuit Air flow Volume After Reject B.E Installation

2.08 12.47 0.00 0.00 12.47 9.00 8.66

Reduction of Pressure drop Across Venturi in line-1 VRM

0.73 4.36 0.00 0.00 4.36 3.00 8.26

Optimization of Coal transport blowers in Line-2

0.36 2.18 0.00 0.00 2.18 0.05 0.28

Line-2 Pyro section Compressor Optimization

1.82 10.89 0.00 0.00 10.89 1.00 1.10

Line-2 cement mill section Compressor Optimization

1.49 8.91 0.00 0.00 8.91 1.00 1.35




Annual Electrical

Saving



Investment Payback

(Months)Million

UnitsMillion

RsTones fuel

Million Rs

Million Rs

Million Rs

Line-1 Pyro section Compressor Optimization

0.36 2.16 0.00 0.00 2.16 1.20 6.67

Optimization of line-1 pyro cooling water circuit

0.36 2.18 0.00 0.00 2.18 1.00 5.51

Optimization of line-1 cement cooling water circuit

0.33 1.98 0.00 0.00 1.98 1.00 6.06

Reduction of Pressure drop between bag house outlet to fan inlet in CM-4

0.33 1.98 0.00 0.00 1.98 0.15 0.91

Street lights optimization 0.06 0.37 0.00 0.00 0.37 0.49 15.69

Cement mill - 2 Bag house fan changed with High efficiency fan

0.07 0.44 0.00 0.00 0.44 3.00 82.64

Optimization of line-1 lighting voltage 0.01 0.07 0.00 0.00 0.07 0.20 34.3




Annual Electrical

Saving



Investment

Payback (Month

s)Million Units

Million Rs

Tones fuel

Million Rs

Million Rs

Million Rs

Reduction of damper losses in line-1 VCLM booster fan with installation of VFD

0.30 0.02 0.00 0.00 0.02 1.00 600

Reduction of line-1 pyro compressors pressure from 7.2 to 6 BAR

0.40 4.46 0.00 0.00 4.46 0.15 0.4

Reduction of pressure drop between Cm-4 bag house outlet to fan inlet

0.33 0.15 0.00 0.00 0.15 0.10 8

Reduction of pressure drop across venturi in line-1 VRM coal mill

0.40 1.98 0.00 0.00 1.98 0.10 0.61

Replacement of MV Lamps with metal halide lamps in workshop

0.02 2.97 0.00 0.00 2.97 0.20 0.81

Installation of energy efficient fluorescent lamps in line-1

0.06 0.37 0.00 0.00 0.37 0.49 15.58

Cement mill - 3 Bag house fan changed with High efficiency fan

0.07 0.44 0.00 0.00 0.44 3.00 82.6



S. No

Year of implementa

tion

No. of Energy Saving

Projects implemented

Annual Electrical Savings

Annual Thermal Savings


Investment Pay

back in MonthsMillion

UnitsMillion

RsTones fuel

Million Rs

Million Rs

Million Rs

1 2013-2014 13 2.5 19.76 0 0 19.76 5.24 3.2

2 2014-2015 19 11.5 69.3 650 3.3 72.5 20.9 3.5

3 2015-2016 22 5.1 33.04 436 7.20 40.2 13.3 4.0

Grand Total 19.2 122.1 1086 10.5 132.5 39.4 3.6

710

711

712

713

714

715

716

717

718

719

720

2013 -14 2014 -15 2015 -16

720

718

717

Specific Thermal Energy Consumption

3 Kcal / kg clink (0.4%)

Reduced

56.0

57.0

58.0

59.0

60.0

61.0

62.0

63.0

64.0

65.0

66.0

67.0

2013 -14 2014 -15 2015 -16

66.5

63.6

59.9

76.0

78.0

80.0

82.0

84.0

86.0

88.0

90.0

92.0

2013 -14 2014 -15 2015 -16

91.5

85.5

82.1

Specific Electrical Energy Consumption

10 % Reduced

10 % Reduced

Base Line Specific energy Consumption : 0.082385 Toe / Ton

Target For PAT Cycle-1 : 0.078583 Toe / Ton

Achieved Specific Energy Consumption : 0.0735429 Toe / Ton

Energy saving certificates : 11824

PAT CYCLE-1

Energy management cell formed with cross function team members. The coordinator for the Energy management cell is Energy Manager.We launched ‘’i.max for manufacturing excellence ‘’ program as plat form for key performance improvement Ideas generation from the all the employees and tracking the work process based on the priority. The daily review of energy monitoring by each section .Weekly review by plant head. Awards for the best idea & Energy savings implementedSMS alert system for stoppages to control the down time.

Strategy adapted to Reduce Energy Consumption

Head production

DGM-process

Maintenance head

GM-Mech

Quality headG.M -QC

Head E& I DGM-E&I

Team 2:

Kiln & Coal mill section head &

engineers

Team 3:

Crushers & raw mill section engineers

Team 5:

Cement grinding

incharge & engineers

Team 4:

Packing & dispatch section

engineers

Plant Head S.V.P-Works

Energy Manager

Head MinesGM-Mines

Team 1:

Mines section head &

engineers

Energy Management Committee

64.8%

35.2%

Idea contribution

Management Workers

Employees involvement & Suggestions status

0

50

100

150

200

Total Ideas New Ideas With outCapex

With smallCapex

With Capex Ideasimplementted

Ideas underProgress

172

8

6851 45 52

22

Energy ManagementCommittee includes OneEnergy Auditor & Two EnergyManagers :

Mr. Jignesh Kumar Duva –DGM (Production) - EA

Mr. P. Raghuram – DGM(Electrical & Instrumentation) -EM

Mr. G.SaiSunil Bharathbabu– Dy. Manager (Electrical) - EM

Strategy adapted to Reduce Energy Consumption

SL APPRISAL FACTORS

RATINGS (R)

REMARKS1-POINT 2-POINTS 3- POINTS 4-POINTS 5-POINTS

POINTS

AWARDE

D

01Equipment reliability

(Kilns)> 97% >97.5% >98% >98.5% >99% 5

02

SD Targets & Safety

Targets as per Group

Standards.

<92% 94% 96% 98% 100% 5

03 MTBF – Kilns ( Hours) <110 160 180 200 250 5

04Maintaining Power

Factor>0.97 >0.975 >0.98 >0.98.5 >0.99 5

05i.Max (Power)

KWH/T<84 <83 <81.5 <79.1 <78.2 5

06 Energy Saving Ideas 1 2 3 4 5 5

(PART -3 ASSESSMENT BY THE INITIATING OFFICER / IMMEDIATE SUPERIOR)

Energy Score Card

Displayed Energy Conservation & Wastage

consequences Awareness Posters at various locations in

the plant

Best Suggestion

Best Energy Conservation Team Best Energy Contribution Awards

Rcognisation Program for Encon Efforts

Best Suggestion Ideas Contribution

Operational Excellence Awards Energy Saving Measures

Rcognisation Program for Encon Efforts

Training Programs to Employees & Contract Workers

Energy conservation projects planned 2016-2018

Description of Energy Saving Projects Year




Investment

Payback

(Months)Million

UnitsMillion

RsTones fuel

Million Rs

Million Rs

Million Rs

Reduction of Pressure drop in C - line bag house out let to fan inlet duct

2016-17 0.37 2.2 0.0 0.0 2.2 1.2 6

Installation of mill scan for cement mill-2 2016-17 0.44 2.6 0.0 0.0 2.6 1.2 6

Installation of mill scan for cement mill-3 2016-17 0.44 2.6 0.0 0.0 2.6 1.2 6

Rawmix optimization after installation of crosbelt analyser

2016-17 0.00 0.0 458 1.83 1.8 18.0 118

Avoiding pnumatic conveying by Installation of new steel silo for export and slag cement.

2016-17 0.60 3.6 0.0 0.0 3.6 50.0 167

Installation of Fly ash feeding to mill discharge arrangement

2016-17 0.09 0.5 0.0 0.0 0.5 1.1 24

Replacement of 250w HPSV street lights with 60 W LED lights

2016-17 0.05 0.3 0.0 0.0 0.3 0.5 22

Energy conservation projects planned 2016-2018

Description of Energy Saving Projects Year




Investment

Payback

(Months)Million

UnitsMillion

RsTones fuel

Million Rs

Million Rs

Million Rs

Replacement of line-1 VCLM CA Fan HT motor with high efficiency motor along with VFD

2016-17 0.63 3.8 0.0 0.0 3.8 2.0 6

Installation of line-1 fine coal dosing system

2016-17 0.00 0.0 1832 7.30 7.3 30.0 49

Installation of Pyrojet burner for line-2 2016-17 0.00 0.0 916 3.65 3.7 15.0 49

Optimisation of RVRM-3 2016-17 2.35 14.1 0.0 0.0 14.1 2.0 2

Line-2 Calciner Coal firing points connecting to feed box

2016-17 0.00 0.0 664 2.65 2.6 0.3 1

Line-1 Calciner Coal firing points connecting to feed box

2016-17 0.00 0.0 180 0.72 0.7 0.3 5

Optimised EEL packer Bag filter by Installation of VFD

2016-17 0.16 1.0 0.0 0.0 1.0 0.5 6

Line-1 Old Pre heater Fan replacing with high efficiency fan.

2017-18 1.87 11.2 0.0 0.0 11.2 6.0 6

550 Kwp Solar Power Plant In The Plant Solar Street Lights In Colony Road &

Mines Operation

Utilization of Renewable Energy Resources

Utilization of Renewable Energy Resources

6 MW Wind Power Plant In Anathapur

Utilizing Bio mass as a Alternate fuel

Replacement of Electrical Energy with Renewable Energy

DescriptionInstalled Capacity

(kW)

2013-14 (million kWh)

% Share2014-15

(million kWh)%

Share2015-16

(million kWh)%

Share

Wind Energy 6000 0.00 0.00 3.08 1.19 14.81 6.68Solar Energy 550 0.50 0.18 0.70 0.27 0.75 0.34

Total 0.50 0.18 3.79 1.46 15.57 7.02

Utilization of Renewable energy ( % of Total Energy)

Replacement of Thermal Energy with Renewable Energy

DescriptionFuel Savings in

2013-14 (million kcal/year)

% Share

Fuel Savings in 2014-15 (million

kcal/year)

% Share

Fuel Savings in 2015-16 (million

kcal/year)

% Share

Biomass 65183.1 3.45 91323.5 4.80 83067.4 4.84

6. Awards

“Best Management Award” in 2016

Environment award “Greenco Gold rating Award” in 2016

6. Awards

Excellent Energy Efficient Plant in Cement Sector in INDIA (2015) by CII

Excellent Energy Efficient Plant in Cement Sector in INDIA (2016) by CII

Greenpro - Green product certification for Zuari Superlite AAC

Awards & Appreciation

……..aiming to conserve natural resources

54

When we heal the earth, we heal ourselves ~ David Orr

Great things are not done by impulse, but by a series of small things

brought together

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