East GU, Clinker debottlenecking,

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3 Acquisition of Tata Steel s Cement Business Acquisition of Raymond Ltd s Cement division 2001 Launch of Concreto Cement 2002 Mejia plant commissioned Sonadih Cement plant Line 2 added Acquisition of L&T s RMX business Cement business expansion in North East GU, Clinker debottlenecking, Further expansion projects Lafarge India Limited becomes part of Nirma Limited following divestment from LafargeHolcim 2016 Lafarge India Limited is rebranded Nuvoco Vistas Corp. Ltd. (continue s to sell products under the Lafarge Brand names 2017 Date 3

4 Cement Plants : 6 RMX Plants : 72 Aggregate Plants : 2

5 Mejia Cement Plant Cement Grinding 1.65 MT Date 5

6 PRODUCTS Duraguard Duraguard MF Infracem MODE DISPATCH 45 % despatch by rail 55% by road. RAW MATERIAL Clinker Received by rail from Sonadih cement Plant and Arasmeta Cement Plant Chemical gypsum Received by rail from various sources. Fly-ash Through Pipeline from DVC OUR HISTORY Mejia cement plant is the first green field project of our earlier company (Lafarge India Ltd.), it is a grinding unit with present capacity of 1.65 Million Tons per annum. AREA acres MANPOWER STRENGTH Permanent Employee Approx 56 Nos Contract manpower Approx 436 Nos

7 Inking of Agreement with DVC Start of Project Consent to enhance from 1.0MTPA to 1.5 MTPA obtained from WBPCB Awarded with CII Energy Efficient plant Certified with ISO : 2015 Awarded with CII SHE Excellence Award MOU with DVC Consent to establish for 1.0 MTPA obtained from WBPCB Commissioning of Project First Cement Dispatch by Road First Cement Dispatch by Rail Awarded with Golden Peacock for Health and Safety Consent to enhance from 1.5MTPA to 1.65 MTPA obtained from WBPCB Awarded with National FICCI CSR Special Jury Award (on Women Empowerment)

8 Stack kw kw Fresh air damper Separator fan kw Separator BH Mill vent fan kw rpm Mill vent BH Separator Cement Silo Fly ash Recirculation duct clinker Gypsum Reject SFM 62.0 Tph kw Cement mill Tph 9.23 Tph Temperature Pressure Air/Gas flow Sample 95 Deg C

9 Equipment Capacity Make Ball Mill 150 TPH KHD Mill Motor 2*2550 KW C.G. Packer 3*180 TPH Enexco Clinker Storage Ton KHD Cement Storage Ton KHD Gypsum Storage 2*4000 Ton KHD Wagon Tippler 20 Tips Per Hr Elecon

10 OVERALL PLANT SPC % over FY Plant Section FY FY FY Grinding SEC Fly Ash Bulker Handling Packing SEC Overall Mejia Plant SEC FY FY FY 17-18

11 Overall PPC Grinding SEC Section FY % over FY Mill Main Drive Separator & Bag house Fan FY FY Mill Auxiliary Mill Utility FY FY FY Overall PPC Grinding SEC

12 Overall Packing & Shipping SEC % over FY PLANT SECTION Packing Plant MCC Packing Plant Utility Overall Packing SEC FY FY FY FY FY FY 17-18

13 PLANT Plant-1 Plant-2 Plant-5 Plant-6 Plant-7 DCW- UTCL- Ambuja- NVCL- Durgapur Durgapur Sakrail Mejia Ball Mill Closed Circuit Rated Capacity TPH Operating Capacity Overall Plant TPH 143/ SEC/M T Second Best at National level as per CII Benchmark

14 2.b. National Benchmark (Cement Grinding SEC) Best at National level as per CII benchmark PLANT Plant-1 Plant-2 Plant-5 Plant-6 Plant-7 DCW- Durgapur UTCL- Durgapur Ambuja- Sakrail NVCL- Mejia Overall Grinding SEC/MT

15 2.b. National Benchmark (Packing & Shipping SEC) Top 3 at National level as per CII Benchmark PLANT Plant-1 Plant-2 Plant-5 Plant-6 Plant-7 DCW- Durgapur UTCL- Durgapur Ambuja- Sakrail NVCL- Mejia Overall Packing SEC/MT

16 Bench marking done with other plant in Group & National Level. Conducted Energy Audit through CII and got good action points for implementation Prioritized and formulated plant overall SEC target with Management Steering Committee. Objective set to optimize SEC, Stretched SEC target included in KPI of all concerned and taken as plant s one of the primary objective. Energy committee formulated and members are empowered to take decision on any operational points related to power optimization. Dynamic monthly SEC target set and monthly SEC tracking done by Management Steering Committee in cost meeting. Priority discussion on shop wise power consumption in Daily Operational meeting. Formulated special task force team for identification and rectification of compressed air leakages. Specific inspection done as per power mastery guideline.e.g: Major fan efficiency, separator efficiency, mill volume loading, compressor performance test, Particle size analysis by different samplings etc. Compressor run hour management supervised by shift in charge, tracking of compressor loading / unloading hour. Energy Management training conducted at Group Level for key personnel.

17 Sl Action Plan Energy Saving kwh/yr Savinsg in minr Investmen t minr SEC reduction 1. Installation of VFD in Aux. Bag filter Fan to avoid pressure loss across the damper 2. DP Mode operation of Vent bag house & optimizing compressed air consumption 235, , Addition of low rating Process Pump for Shutdown duration 4. Modification & de-rating of auxiliary circuit motors 10, Zero investment 50, Zero investment Optimization of Process water pump power by rerouting of water pipeline 23, Blade angle optimization & motor de-rating of Cooling tower fan 10, Zero investment 0.007

18 Total no. of Projects : 32 Total Energy savings : 44,43,675 kwh Project with : 11 Project with Zero : 21 Total Cost Savings : minr

19 Sl Action Plan Energy Saving kwh/yr Savinsg in minr minr SEC reduction 1. Modification of Wagon Tippler lighting system with DCS control 8, Zero Adding Flyash at Cement Mill outlet 545, Optimization and review of raw material transport circuit idle running during clinker and gypsum unloading 109, Zero Zero Optimization of Packing Plant Compressor operation as per Packer operation to reduce Packing power 24, Zero Optimizing of Compressor load to minimize the loading hours by tuning the load/unload settings as per actual requirement 64, Zero Installation of Process Optimizer LUCIE 436,

20 Sl Action Plan Energy Saving kwh/yr Savings in minr in minr SEC reduction 7. Modification of de-dusting line for Clinker Extraction conveyors with installation of shut-off gates & selective operation 35, Zero nd chamber media gradation done with High Chrome Grinding Media 237, Dose optimization Mill performance enhancer (Grinding Aid) resulting to higher Fly-ash addition & improvement in SPC 650, Zero Optimization of Bag Filter purging ON/OFF time in Finished grinding & Packing 12, Zero Optimizing of excess illumination in specific high mast tower area by switching of alternate fittings 8, Zero 0.006

21 Sl Action Plan Energy Saving kwh/yr Savings in minr Investmen t in minr SEC reduction 1. Optimization of Plant High Mast Tower lighting and achieved energy saving 77, Zero Replacement of conventional office lightings with LED lights Replacement of WT Main Bag Filter Fan Impeller with High efficiency impeller 59, , Modification in Air Slide Blower pipeline to stop Air Slide Fan 416FA25A 23, Zero Retrofitting of wagon tippler twins Fan to increase the efficiency 14, Optimizing FA Silo top Bag Filter Fan VFD with Auto control loop 13, Zero 0.009

22 Sl Action Plan Energy Saving kwh/yr Savings in minr Investmen t in minr SEC reduction 7. Installation of Frequency Drive for Wagon Tippler Bag Filter Fans 42, Connection of Air Slide 543AS02 with Cement Bin Aeration Blower 543AB01,02resulted stopping543fa02 Air Slide Fan 7, Zero Modification of MF Feeding Air Slide to MF Elevator by Connecting Air Slide Fan 512FA13 resulted stopping of 543FA01 fan 6, Zero Connection of VAC Elevator feeding blower 543FA04MT10 with Silo Extraction AS Blower resulted in stoppage of 512FA15A 14, Zero 0.009

23 Sl Action Plan Energy Saving kwh/yr Savings in minr in minr SEC reductio n 1. Optimization of cooling tower fan operation with temperature control 1, Zero Optimizing the pressure setting of Compressors in plant to reduce compressor running in load 42, Zero Replacement of existing process water pump with High Efficiency Pump for Cooling water circulation 95, Zero Replacement & Upgradation of obsolete package Air Conditioning system with Split Air Conditioner and occupancy sensors. Replacement of conventional Plant lightings, Street Lights and High Mast Area light fittings with LED lights 223, ,

24 Sl Action Plan Energy Saving kwh/yr Savinsg in minr minr SEC reduction 6. Improve Distribution Transformers Loading by using one transformer at a time 12, Zero De-rating of Air slide Fan motors 15, Installation of Automatic star-delta converter for under loaded motors De-rating of Motors in Packing Plant Loading Belt conveyor circuits 380, Zero Zero , Installation of Frequency Drive for Packing Plant Bag Filter Fans 475,

25 PROJECT 1 Title : Reduction in Cement Grinding SEC by Automatic Delta Star Motor Controller Implementation : As some Screw conveyors are running below 40% load but need high torque at starting. we develop a Current base Functional Block at Distributed Control System to for Change over from Delta to Star as per running load.

26 Implementation : Fixed Current Transformer & current transducer in the circuit to measure line current and communicate with DCS. Making panel with 2 nos contactor for star and delta and brought all the six terminals of the motor to panel and arranged proper way for star-delta operation and Logic developed as per requirement. Step-1- Motor always stars with Delta mode to reach the starting torque after a certain time limit it will start observing line current for star delta operation. Step-2-If Current Transformer( Sensing the line current) is below 50% of full load current then motor will run with star mode (energy saving mode) otherwise it will run with delta mode. Step-3-If it was running with Star mode after sensing line current and suddenly line current increased more than 40% of F.L current for any process deviation it will convert to delta mode even if any fault in current transformer, motor will operate in delta mode as per logic. (Default value set more than 50% of full load current).

27 Block developed in DCS (ABB library), ease to implement as & when requirement

28 Advantages : Innovative development of DELTA-STAR-DELTA Mono Block in ABB DCS System (STAR-DELAT Block does not exist in ABB DCS Library) Energy Saving (Reduction in KW and KWH). Improvement in power factor. Reduction in line current so it will minimize copper loss and reduces motor temperature and it leads to increase motor life. Cost benefits in our case: Saving for in-house development of the energy saver unit (2 nos) : 1.5 Lakhs Total expected Energy Saving : 23,996 Kwh/Year (Considering Mill running for 330 days) Total expected cost saving : 1.35 Lakhs/Year (Considering Power Cost 5.60 Rs./Unit)

29 PROJECT 2 Title : Energy saving by replacement of existing obsolete package AC system with individual Split AC units & optimizing the operations. Implementation : There are conditions that all the cabins & halls are not occupied continuously & all at a time during the General shift duty hours. Also as per our study the average occupancy of the rooms is for maximum 5 hrs a day & 24 days a month. But it is required to keep the package AC units continuously on for Servers Room, DCS Room, CCR Room & Lab Room continuously on 24x7 basis to maintain the equipment & system reliability. Thus there is huge Power consumption due to running of packages for cooling of few areas & even the other areas remain unoccupied.

30 Benefits : Individual AC units could be switched off when not required & when there is no occupancy in the rooms or cabins. AC temperature could be controlled individually as per comfort level. Gives Energy savings with low Energy consumption. Savings of 217,226 units/year. New generation AC units are less in maintenance & much more reliable.

31 PROJECT 3 Title : Temperature Control Start-Stop of Cooling Tower Fan. Implementation : It was observed that process water cooling tower Fan (11 kw motor) runs continuously 24x7 even through the process water temperature is very less & does not require further cooling. Avoided un-wanted running of cooling tower fan, by introducing a temperature control interlock to stop the fan with target temperature Set point. Thus saved the running power of cooling tower fan during entire 4 months of Winter season when ambient temperature is very low

32 Cooling Tower fan operation with temp control Temperature Controller Water Cooling Tower RTD Temp Controller

33 Cooling Tower Fan: It was observed that process water cooling tower Fan (11 kw motor) runs continuously 24x7 even through the process water temperature is very less & does not require further cooling. Avoided un-wanted running of cooling tower fan, by introducing a temperature control interlock to stop the fan with target temperature Set point. Thus saved the running power of cooling tower fan during entire 4 months of Winter season when ambient temperature is very low. Benefits: Total Energy Saving = 34,830 kwh Total Cost 5.60 Rs/Unit = 1.50 Lacs/Yr

34 In NUVOCO, management is committed to utilise renewable energy source, at first phase, Chittorgarh Unit, Rajasthan, 0.5MW Solar plant is under commissioning stage. In Mejia, Plant Roof-top 20 KW Solar stations installation project has been proposed for office lighting. Solar Panels at Chittorgarh Unit

35 YEAR SCOPE 1 EMISSIONS SCOPE 2 EMISSIONS TOTAL REDUCTION (KG) SCOPE 1 SCOPE 2 Reduction in Emission due to less consumption of clinker (higher CK ratio) Reduction in Emission due to Savings in kwh FY FY FY FY FY FY FY FY

36 Green Belt At Mejia Water Harvesting Pond Plantation Programme at Mejia Total plant area: Ha. Green belt developed inside plant: 6.83 Ha. Green belt developed at social forestry in community : 9.09 Ha. No of sapling planted inside plant : 3550 nos No of sapling planted in community : nos Plantation Near Workshop

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38 Nuvoco Vistas Corp. Ltd is committed for Green Supply Chain Management initiative. Mejia has already initiated the process to adopt Green purchasing practices in the plant to get benefits like To conservation of energy, water and other natural resources. To lowering of costs incurred towards waste management. To compliance with the environmental regulations. To improve brand image & reputation among customers as the organization is focusing towards greener product. To improve employee health due to lesser environmental impact. Further to development of green purchase/procurement Novoco is aiming at Reducing the usage of hazardous (toxic) products / chemicals in their manufacturing facilities & phasing out toxic chemicals use in a phase manner. The major purchasing like - capital goods, raw materials, maintenance consumables (electrical, mechanical, oils), building materials, & other consumables will be initiated with green procurement guidelines. As a initiative towards Green Supply Chain Management implementation at Mejia Cement Plant, is reflecting through its following actions..

39 Mejia is Certified as ISO : 2015 compliance cement manufacturing unit in Environmental Objective and Targets shows the commitment to achieve the Green Supply Chain Management.

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41 Energy awareness Programme among Shop floor People Monthly Energy committee Meting Productivity Capex Approved in Last two Finacial Year : Capex Budget Approved for FY Capex Budget Approved for FY = 16.5 minr = 10.5 minr

42 Systematic Monthly tracking Hourly Tracking Through EMS system Mill kwh VS TPH Mill Motor KW TPH

43 Thank You 8/29/