OCL Bengal Cement Works (A Unit of OCL India Limited) Dalmia Bharat Group Co.

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1 OCL (A Unit of OCL India Limited) Dalmia Bharat Group Co.

2 Rich Heritage The Group was established in 1939 and has a rich heritage of 75+ years of serving India Cement Dalmia advertisement on 15 th August 1947 Re-published on 60 th independence day by Times Of India Sugar Refractories Power 9/2/2017 2

3 Pan India Footprint Of Dalmia Cement Fourth largest cement group in India with 27 Million Tons of installed cement capacity 186 MW of captive power capacity BCW 1.35 MTPA

4 OBCW AT A GLANCE OCL Bengal cement Works (here-in-after referred to as OBCW), a Dalmia Bharat Group Company, 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 & ( 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 Begal with 100% road despatches. Kapilas Cement Manufacturing Works 4

5 5 Our Focus area CERTIFICATIONS IMS CERTIFIED UNIT ISO 9001: 2008 ISO 14001: 2004 OSHAS 18001: 2007 EXCELLENT ENERGY EFFICIENT UNIT AWARD IN 2016 CERTIFICATE OF MERIT FOR ENERGY EXCELLENCE FROM BEE IN 2016 CERTIFICATE OF TWO STAR RATING IN /2/

6 Process Flow Diagram Clinker Wagon Tippler Stacker & reclaimer Gypsum/slag Clinker Silo Fly ash Silo Truck Tippler Coal Raw material hopper Fly ash bulker Coal hopper Coal mill HAG CVRM Bag House Cement Silo Truck Despatch Roto Packers Bulker Despatch 9/2/2017 6

7 Benchmark: Where We Are..Where To Go SPECIFIC ENERGY (KWH/T) FOR PSC SPECIFIC ENERGY (KWH/T) FOR PPC % % BENCHMARK % % BENCHMARK Kcal/Kg for PSC % KCal/Kg for PPC 37 23% % 10 28% /2/

8 throughput enhancement by capacity utilisation & optimization cvrm optimization power factor improvement cvrm bag house purging in DP mode 160 KW compressor replacement by 90 Kw optimizing compressed air usage equipment idling minimization cvrm optimisation auxiliary power reduction by raw material circuit optimization cvrm fan efficiency enhancement & false air reduction coal mill TPH enhancement packing plant power reduction Q Roadmap To Achieve Target SEC ( KWH/T) 60 SEC(KWH/T)

9 ENCON Project with investments 9/2/

10 ENCON Actions : without investment SN ENCON actions with out investment Year Annual Million KWH Saving Annual INR saving (Million) 1 Reduction of compressed air consumption in CVRM Bag house Reduction in running hour of Slag feeding group Bag filter fans Reduction of CVRM main drive SPC through Dam ring height adjustment from 192 to 150 mm Running of CVRM Bag house in DP mode Reduction of Packing plant SPC by replacing 160 KW compressor by 90 KW Reducing idle running of Material handling circuit drives through installation of belt starvation switches Reduction of WTP Cooling Tower fan power consumption through interlock with temperature sensor Reduction of Compressor power consumption by optimizing loading/unloading set point PLC interlock modification for process optimization ( Save 15 no of trippings) TOTAL /2/

11 SN ENCON actions with investment Year Annual Million KWH saving 1 Gear box radial bearing maintenance & CVRM optimization to run on minimum power mode CVRM ID fan cone gap correction from 33 mm to 12 mm Felt seal installation at CVRM dynamic separator seal gap Nozzle 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) Annual MINR Saving Dam ring reduction by 6 mm( from 122 mm to 116 mm ) Reduction 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 %) Coal mill grinding media regradation & pattern change ( from coarse to fine) Stop Auxiliary bag filter fan through tapping in main bag filter fan in each packer Packer 1 & 2 bucket elevator group starting interlock modified to avoid group idle running during 9 shift starting Packer 1 & 2 belt bucket elevator & CVRM reject elevtor motor connection change from delta to 10 star ENCON Actions : without investment TOTAL

12 ENCON Project with investments 12 9/2/

13 ENCON Actions: with investment SN ENCON actions with investment Year Annual Million KWH saving in year of installation Annual MINR Saving Investment (MINR) Payback period 1 Power factor improvement by installing 1500KVAR HT capacitor installation M 2 Reducing power consumption of HAG fuel firing blower through VFD installation M 3 Reduction of Packing plant SPC by replacing 90 KW compressor by 45 KW M 4 Reducing power consumption of packing plant bag filter Fan by VFD installation Y 5 Reducing power consumption of CVRM bag filter Fan by VFD installation M 6 Solar power generation unit 5.5 MW Y Installation of plant logistic automation system to improve operational 7 efficiency of packing plant. Installation of VFD in 641 FN1 & 642FN1 ( 75*2 kw) Silo bin aeration blower 8 611BL2,packing plant compressor & 611FN1 Silo 1 bag filter fan. Installation of VVFD in reject bucket elevator bag filter fan, reject circuit bag 9 filter fan & raw material feeding belts bag filter fan Y Y TOTAL Y Y 9/2/

14 ENCON Actions: For SN 1 ENCON actions with investment Partial blocking of left most duct of CVRM hot air inlet Annual thermal saving ( MKCal/year) Annual Million KWH saving Status/Remarks By uniform temp distribution heat saving is around 3KCal/Kg 2 Trimming of CVRM ID fan impeller Approx 80KW/Hr saving is estimated 3 CVRM ID Fan inlet duct area enlargement Approx 55 KW/Hr is estimated 4 Reduction of system pressure of CVRM circuit by 25 mmwc through several maitenance activity 5 False air reduction from 14% to 10% Around 25 KW/Hr is achieved Reduction of plant lighting power consumption by replacing HPSV light with LED base light In progress Reduction from 14% to 11.6% is achieved. By reducing upto 10% 15kw/hr saving is estimated 7 9 no of VFD installation at various section In progress TOTAL

ENCON Methodology: ENCON Approach MANAGE MEASURE

identification Energy cell Weekly energy monitoring

Energy cell head with cross functional team Daily

15 ENCON Methodology: ENCON Approach MANAGE MEASURE PROTECT Unit Head Monthly energy meeting Scope identification Energy cell Weekly energy monitoring by energy cell Action plan generation& execution Energy cell head with cross functional team Daily energy monitoring at PD Quantification, analysis & record 9/2/

ENCON Methodology: Energy Levers Solar power Equipment idle run minimization 1. Stop interlocks 2. starvation stop 3. Shop stoppage power VRM POWER OPTIMIZATION 1. Dam ring 2. False air 3.

16 ENCON Methodology: Energy Levers Solar power Equipment idle run minimization 1. Stop interlocks 2. starvation stop 3. Shop stoppage power 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 11% 31% Effective use of Energy Levers in % 31% 12% 5% VRM optimization Equipment idle running Compressor power minimization Fan & blower efficient running Thermal energy saving others Compressor power minimization 16 9/2/

Report 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

17 ENCON Methodology: Power reports CCR operation screen with Total KWH & KWH/T display for main drives. Column1 Daily Energy report with real time data capture 2500 kva Trafo for Wagon Tippler 540kW Cement Mill Separator Fan for 561MD kva Trafo Feeder -1 for CCR Dalmia Cements - Active Energy Report 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 491BC : E : E : E : E : E : E : E : E : E : E : E : E : E : E : E : E : E : E : E : E : E : E : E : E : E Total Consumption MRSS Outgoing Feeder-1 MRSS Outgoing Feeder-2 9/2/

18 ENCON Methodology: Power reports Daily power report format Date Specific Power Date Specific Power FTD MTD FTD MTD TOTAL UNIT AVAILED AT OBCW FROM WBSEDCL kwh TOTAL POWER CONSUMED IN OBCW SOLAR POWER CONSUMPTION kwh CVRM RUN HRS - PSC hrs TOTAL POWER CONSUMPTION AT BCW kwh CVRM RUN HRS - PPC hrs Distribution Loss % 0.8% 0.95% CVRM - RUN Total hrs Raw material handling with stacker(mcc 3kWh PSC PRODN ton CLINKER SILO FEEDING(491BC3) kwh PPC PRODN ton Total Reclaimer and hopper feeding circkwh PRODN - TOTAL ton CVRM-IV COAL MILL RUN HRS PSC hrs CVRM MAIN DRIVE kwh COAL MILL RUN HRS PPC hrs BAG FILTER FAN kwh COAL PRODN ton CVRM CLASSIFIER kwh Cement Despatch ton CVRM Aux. as per FLS(MCC 5 INCLUDES HYDRkWh Total Reclaimer and hopper feeding circkwh/t CVRM AUX(CEMENT TRANSPORT+CEMENT SILO BUkWh Material handling with stacker kwh/t CVRM COMPRESSOR(70% TOTAL UNIT OF COMPREkWh Clinker feeding kwh/t LIGHTING kwh CVRM MAIN DRIVE kwh/t MILL WATER SUPPLY MCC2 KWh BAG FILTER FAN kwh/t Total Power consumed for CVRM kwh CVRM UNITS CVRM CLASSIFIER kwh/t Power consumed for PSC KWh CVRM Aux. as per FLS kwh/t Power consumed for PPC KWh CVRM AUX kwh/t COAL MILL CVRM COMPRESSOR kwh/t COAL MILL MAINDRIVE kwh WATER SUPPLY and lighting kwh/t PSC COAL GRINDING kwh Total Power consumed for CVRM (Grinding kwh/t PPC COAL GRINDING kwh Total Power consumed for PSC grinding ofkwh/t 33.8 COAL MILL AUX Incl FAN (MCC 6) kwh Total Power consumed for PPC grinding ofkwh/t 0.0 PSC COAL MILL AUXILLARY kwh Total Power consumed up to Grinding stagkwh/t PPC COAL MILL AUXILLARY kwh COAL MILL MAINDRIVE kwh/t Total Power consumed for COAL MILL COAL MILL AUX Incl FAN kwh/t Packing plant Total Power consumed for COAL MILL kwh/t Packing Plant kwh Packing Plant kwh/t Packing Compressor kwh Packing Compressor kwh/t Lighting kwh Total Power consumed for PACKING HOUSE kwh/t Total Power consumed for PACKING HOUSE kwh SERVICES Lighting kwh/t SERVICES WORK SHOP kwh/t PROJECT WORK kwh Total Power consumption for SERVICES kwh/t Lighting kwh Power for cement grinding kwh/t LIGHTING AND AUXILLARY UNITS and water skwh Packing power kwh/t Total Power consumption for SERVICES kwh Plant lighting and auxillaries WITH WATEkwh/t power on cement kwh/t /2/

Innovative Project executed & presented last year Innovative Project (without investment):

Minimization of compressor power consumption 3.

RFID system installation to increase packing plant through put 2.

19 Innovative Project executed & presented last year 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 blower Power Factor

Innovative Project (without investment): 1 Project : Baffle plate installation at Mill inlet duct to distribute uniform heat content to mill through all ducts Objective: To save thermal energy

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.

20 Innovative Project (without investment): 1 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 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. 320 Deg C 133 Deg C 126 Deg C Action taken : To resolve the non-uniform temperature distribution at CVRM inlet duct,a modification with baffles plate fixing ( 300 mm width) before the left most duct & between the left & middle duct is done on month of November & it was further remodified to optimize in Mar 17. 9/2/

21 Innovative Project (without investment): 1 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 Heat contribution by VRM inlet ducts ( Kcal) PSC heat cons(kcal/kg) vs Slag moisture% Temp ( Deg C) Before modification After modification % of Temp % of Temp ( % of Temp total ( Deg total Deg C) total ( Deg heat C) heat heat C) content content content to mill to mill to mill % of total heat content to mill % % % % % % % % % % % % FY'17 MARCH APRIL MAY Benefits : Heat slag moisture % Energy saved : 1100 T coal Energy saved : 7 Kcal/Kg cement Money saved: 5 Million INR 9/2/

Project Objective scope : coal mill ( equipped with 1st generation static seperator) was initially designed for : Feed size of 80% retention at 8mm & ground product of 15 % retention at 90 Micron

22 Project Objective scope : coal mill ( equipped with 1st generation static seperator) 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 was not efficient as it was too coarse for the feed & obtained TPH of coal mill was only TPH leading to SEC of around 0.7 KWH/T of cement. Innovative Project : 2 : coal mill productivity enhancement through grinding media optimization : To save power consumption by coal mill runhour reduction Action taken : Media pattern optimized to fine pattern 70 mm media was removed, 60 mm media. 30.0% 25.0% 20.0% 15.0% 10.0% 5.0% 0.0% proportion reduced & 7.1% 0.0% 6.4% MEDIA PATTERN 12.2% 20 mm media is included 14.2% 15.0% 20.8% 20.8% 22% 12.7% 22.3% 26.4% 20.0% Ball size ( mm) 9/2/

23 Innovative Project : 2 Coal mill TPH Coal mill main drive KWH/T Cement April'16 May'16 JUNE'16 JULY'16 AUG'16 SEP'16 OCT'16 Nov'16 Dec' Apr-16 May-16 Jun-16 Jul-16 Aug-16 Sep-16 Oct-16 Nov-16 Dec-16 Benefits : Energy saved : KWH in Energy saved : 0.3 KWH/T Money saved: 0.79 Million INR 9/2/

24 Project Objective Innovative Project ( without investment ): 3 : Elimination of Auxiliary bag filter fan through tapping in main bag filter fan in each packer : To save the power consumption for two dedusting fan with successfull dedusting of the circuit Scope: Each packer is facilitated with two bag filters of 46000m3/hr & m3/hr. wheteher as per flow measurement it was analysed 17 m/s velocity, the circuit dedustiong volume requiremet is only m3/hr, can be 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 designated sources kept unaltered. The dedusting fan ( 37 KW, 23000M3/HR) is stopped. & through the suction of the remaining bigger fan ( 75 KW, M3/HR) the whole dedusting purposed is successfully resolved. saving of around 15 Kw/Hr for two packer each i.e 30 KWH. Benefits : Energy saved : KWH in Energy saved : 0.2 KWH/T Money saved: 0.52 Million INR 9/2/

25 Project Objective Innovative Project (without investment): 3 : Elimination of Auxiliary bag filter fan through tapping in main bag filter fan in each packer : To save the power consumption for two dedusting fan with successfull dedusting of the circuit 9/2/

26 Renewable energy 26 9/2/

KWH Solar Panel Solar Module, Poly Crystalline Rating:

5 MWp Inverter Photovoltaic Inverter Rating: 648 KW/ 406

5 MWp solar power plant is commissioned on April 16 to

2 HT Breaker Rating: 2500 MVA Volts: 11KV / 415 Volts

: 2 Own consumption 14000000 12000000 10000000 8000000

27 KWH Solar Panel Solar Module, Poly Crystalline Rating: 310 Watt Nos of module: Total Output: 5.5 MWp Inverter Photovoltaic Inverter Rating: 648 KW/ 406 Volts System Monitoring Renewable Energy Usage : 5.5 MWp solar power plant is commissioned on April 16 to utilize non conventional renewable energy & reduction of carbon di oxide emission. Transformer Rating: 800 Amp Volts: 12KV Nos of Breaker: 2 HT Breaker Rating: 2500 MVA Volts: 11KV / 415 Volts Nos of Tx.: 2 Own consumption Bengal Cement 9/2/2017 Works 27 20% 15% 10% 5% 0% 0 85% 15% Solar SOLAR POWER UTILISATION 11% FY17 Grid 15% FY18

28 Water consumption reduction 9/2/

Reduction in process Water consumption : 0.18 0.17 Water consumption KL/T 0.16 0.14 0.12 0.10 0.08 0.08 0.07 0.06 0.

29 Reduction in process Water consumption : Water consumption KL/T Zero water spray for PSC water spray for PPC is only 2 % of total feed. 9/2/

30 Carbon foot print 9/2/

31 Initiatives to reduce carbon footprint : Carbon Footprint Reduction 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 commissioning wagon tippler & use of battery driven vehicles. Reduction of Fuel oil consumption by improving reliability Slag % in PSC Fly ash % in PPC CO2 emission (T/T of Cement) Scope 1 : Direct CO2 emissions TARGET Scope 3: Indirect emissions from recieved clinker Scope 2: Indirect CO2 emission from purchased electricity /2/

32 Going green 9/2/

16000 14000 12000 10000 8000 6000 4000 2000 0 8701 Greenbelt Development Initiative PLANTED SAPLINGS ( SURVIVED) 11423 14378 3031 2014-15 2015-16 2016-17 2017-18(4M) Systematic green belt development

33 Greenbelt Development Initiative PLANTED SAPLINGS ( SURVIVED) (4M) Systematic green belt development initiative : Total nos of survived saplings till FY 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 PLANNED DEVELOPEMENT OF GREEN BELT 31% 6% 7% 3% valuable trees with big trunk 15% 38% flower fruits medicinal ornamental

34 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 to near 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

35 9/2/

Dalmia Cement (Bharat) Limited, Kadapa. 18 th National Award for Excellence in Energy Management

Dalmia Cement (Bharat) Limited, Kadapa 18 th National Award for Excellence in Energy Management - 2017 Founded in 1935 by Shri Jaidayal Dalmia. The Group interests includes Cement, Sugar, Power and Refractory