Shree Cement Ltd.

Beawar, INDIA
National Award for Excellence in Energy Management 2009
Presented by Sanjay Singh

An Energy & Environment Conscious, Sustainable & Prosperous Organization

Presentation Sequence
Shree Cement Profile Cement Manufacturing Process Energy Performance Energy Saving Projects Innovative Projects: case studies Energy Management Practices in SCL Climate Security Recognitions

An Energy & Environment Conscious, Sustainable & Prosperous Organization

Shree Cement Profile

Among the Top Five Cement Groups in India. Operating at Beawar, Ras, Khushkhera, Suratgarh & Roorkee.

Largest Cement Player of North India. Entered into Merchant power business. One of the Highest Operating Profit Margins. Turnover- US$ 773 Million

An Energy & Environment Conscious, Sustainable & Prosperous Organization

Shree Cement Profile

Rising Trend in Cement capacity

An Energy & Environment Conscious, Sustainable & Prosperous Organization

Shree Cement Profile

Rising Trend in Power generation Shree Power Gen Capacity (MW)

An Energy & Environment Conscious, Sustainable & Prosperous Organization

Shree Cement Profile

Vision & Guiding Principles

Vision
To drive and sustain industry leadership of the company within a global context- by developing individual leadership competencies at every level, through a robust back bone of Trust, Support, Innovation and Reward.

Guiding Principles
Enforce good corporate governance practices Encourage integrity of conduct Ensure clarity and unambiguity in communication Remain accountable to all stakeholders Encourage socially responsible behavior
An Energy & Environment Conscious, Sustainable & Prosperous Organization

Shree Cement Profile

Management Systems
ISO-14001 Environmental Management System

OHSAS-18001 Occupational Health & Safety

SA- 8000 Social Accountability

ISO-9001 Quality Management

MANAGEMENT SYSTEMS

BS-EN 16001 Energy Management System

An Energy & Environment Conscious, Sustainable & Prosperous Organization

Shree Cement Profile

Marketing Strategy Convey social messages along with brand building such as Save Water, Blood donation, Swatantarta ke Rakshak etc.

Market Leader in Rajasthan, Delhi and Haryana

SHREE ULTRA

BANGUR CEMENT

ROCK STRONG

An Energy & Environment Conscious, Sustainable & Prosperous Organization

Shree Cement Profile

Global Partnership
First Indian Cement Company to join Cement Sustainability Initiative of WBCSD. Member of Cement Sector Task Force of APP-7, formed by Govts. of India, USA, China, Japan, Korea, Canada and Australia. Global Reporting Initiative to improve information sharing on Environment and Social issues. Endorsed the Global Roundtable Joint Statement on Climate Change to discuss issues for shaping public policy on climate change..
An Energy & Environment Conscious, Sustainable & Prosperous Organization

Shree Cement Profile

Achievements
Appointed Leader of Cement Sector Task Force for the 7th consecutive year by Bureau of Energy Efficiency, Ministry of Power, Government of India. Highest 4 star rating for 9th consecutive year by Whitehopleman U.K. One of the lowest Power & Fuel Consumption in the industry. Shree remains the benchmark for other companies in terms of overall energy efficiency. Recognized R&D Centre by Govt. of India
An Energy & Environment Conscious, Sustainable & Prosperous Organization

Shree Cement Profile

Pioneer Activities
Clinkerisation Unit (U-VII) of 1 MTPA commissioned in record time of 367 days . capacity

Company in the World to utilize 100% petcoke in its operations.

Plant in India to develop process for production of synthetic gypsum. Cement company of the World to receive 4.5 Lacs Certified Emission Reductions (CERs) on its Clean Development Mechanism project Optimal Utilisation of Clinker. Indian cement company to issue Corporate Sustainability Report according to GRI guidelines.

An Energy & Environment Conscious, Sustainable & Prosperous Organization

Cement Manufacturing Process

Raw mill silo Raw mill

Mines

Stacker

Raw mill hopper

Reclaimer

Preheater

Kiln

Clinker stock yard

Cement Mill hopper

Wagon & trucks

Packing

Cement silo

Roller press cum Cement mill 12

An Energy & Environment Conscious, Sustainable & Prosperous Organization

Energy Performance
Decreasing Trends & Targets
84

Annual Comparison of Power Consumption

2009-10 NCBM Avg. Benchmark

Annual comparison of Thermal Consumption

An Energy & Environment Conscious, Sustainable & Prosperous Organization

Energy Performance
Benchmarking
Power Consumption

120.00

100.00

The graph shows Shree power consumption is well below the average

80.00

kwh/t

60.00

40.00 Kiln 20.00

Total Raw Materials Grinding

Cement Grinding Packing 0.00 Average Shree Cement Best Aux

An Energy & Environment Conscious, Sustainable & Prosperous Organization

Energy Saving Projects

Implemented during 2007-08 & 08-09

An Energy & Environment Conscious, Sustainable & Prosperous Organization

Energy Saving Projects

Implemented during 2009-10
S N Title of Project Annual Electrical Savings Units Million
1. 2. 3. Installation of SPRS in Raw Mill Fan Installation of SPRS in (SKS) Fan 0.12 Implementation of Slip Power Recovery System in Raw mill ESP fan Installation of VFD in damper controlled Cooler fan (4Nos) Replacement of Cooler ESP fan HT Motor with LT motor and VFD Increase the stack Height of Cooler ESP Fan 0.43 0.72 2.59 2.4 2.5 0.48

Investments Rs. Million

Million Rs.
2.92 6.8

4. 5.

0.36 0.45

2.16 2.7

1.94 2.0

6.

0.12

0.72

0.2

An Energy & Environment Conscious, Sustainable & Prosperous Organization

Innovative Projects - Case Study - I

Installation of flame analysis system from Powitech for reduction of fuel consumption in Kiln
Before the installation of Powitech system = 741 kcal/kg.cl After the installation of Powitech system = 720 kcal/kg.cl

Annual Saving in Coal consumption = 2460 MT Annual saving in Rs = 19.7 million Cost involved in this project = 20 million Simple pay back = 12.17 months Reduction of CO2 Emission = 8019.6Ton / Annum
* As per clinker production for 2008-09

An Energy & Environment Conscious, Sustainable & Prosperous Organization

Innovative Projects - Case Study - II

Increase the stack Height of Cooler ESP Fan by 7.8 meters

Before the increase of stack height Fan Efficiency* measured before = 35.33%

After the increase of stack height Fan Efficiency measured after = 57.53%

Saving in Power Consumption of ESP fan = 16kWh

*Reduction of CO2 Emission = 108 Ton / Annum

* As per clinker production for 2008-09

An Energy & Environment Conscious, Sustainable & Prosperous Organization

Innovative Projects - Case Study - III Waste Heat Recovery at Six Stage Preheater A Milestone
Flue gases are released from preheater and Cooler. WHR installed for the recovery of the waste heat from exit gases.

Barriers: vLow heat content in gases that exit from 6 stage PH vHigh Dust Content vHigh cost of installation Solution: vSpecific design of boiler in view of high dust load and low enthalpy in waste gases vHammering system

8 MW WHR resulted in 349916 tons/ annum CO2 emission reductions An Energy & Environment Conscious, Sustainable & Prosperous Organization

Innovative Projects - Case Study III cont.

Kiln Feed

Pre Hea ter (PH ) Pre-heated Kiln feed Hot gas

Pre-heater Exit gases (300C) G C T

Coa l Mill

Kiln Feed PreHeater (PH) Preheat ed Kiln feed Kiln

Pre heater Exit gas (300C) GC T

Exit gases (150C)

Hot gas

Pre heater Exit gas (300C) PH Boil er Exit gas (150C)

Coal Mill

Raw mill and Vented out

HP, LP header & Flusher Fuel Kiln Hot Gas to Kiln Hot Gas to TAD Exit gases ESP Hot Gas to Kiln Clin ker
Clinker from Kiln

Turbine

Hot Gas to TAD ESP Vented out Air Quenched Cooler (AQC) Air Air AQC gas (400C)

Clinker from Kiln

Air Quenched Cooler (AQC)

Clin ker AQC Boiler

An Energy & Environment Conscious, Sustainable & Prosperous Organization

Energy Management Practices in SCL

Monitoring and Reporting System
SR.V P (Works)

Units Head

Managers (Process & Engg)

Chemical Engineer

Energy Monitoring CELL Headed by Energy Manager

Electrical Engineer Power Utilization

Engineer Utilities (Steam, Power & Water)

Energy Monitoring Measure Identification & Implementation

Energy Audit Benchmarking Contact Process Equipment Supplier

Investment & Return Analysis

Idea Generation Activities Small Group Activities

An Energy & Environment Conscious, Sustainable & Prosperous Organization

Energy Management Practices in SCL

Idea Generation Activities
Implementation of Suggestion Scheme Measures adopted in SCL Jo Soche Who Paave
Employees to think like leaders by providing them a platform

To communicate ideas To bring all the members into the mainstream To encourage active participation To tap into the latent potential of employees, reduce costs, increase productivity and ultimately, profits. Resulted in An Energy & Environment Conscious, Sustainable & Prosperous Organization

Commitment for Climate Security

Adoption of BS-EN 16001
Identification of Energy conservation areas in the plant. Prioritization of identified energy conservation areas. Finding out of technical feasibility including, market availability and cost benefit analysis. Renewable energy identification Benefits : Implementation of Energy Monitoring Plan and energy analysis thereby optimizing energy consumption. Benefits through cost reduction.
Development Environment Conscious, Sustainable & Prosperous Organization An Energy & Without Destruction

Commitment for Climate Security

Initiatives for Carbon Emission Reduction
S.N Title of project implemented Year of Implementation Total CO2 Reduction

Optimal utilization of clinker by using fly ash in cement

2001-02

293818
(Project completed in July-2010)

*Waste heat recovery from Preheater & Cooler for power generation

2008-09

51051

**Utilization of Biomass fuels for Pyro processing in Cement plant

2006-07

33232

*Project is under validation for CDM. **Registered at UNFCC

An Energy & Environment Conscious, Sustainable & Prosperous Organization

Commitment for Climate Security

CO2 Reduction as per CSI Protocol

When We PutEnvironment Conscious, Sustainable & Prosperous Organization An Energy & the Environment First, Development Will Last

Commitment for Climate Security

Optimal Utilization of Resources
Use of 100% Petcoke, a waste from Oil Refineries, thereby conserving Fossil Fuels.

Maximized use of slag, a waste from smelting plant, thereby conserving iron ore.

Developing new environment friendly alternative raw materials & conserving natural resources.
An Energy & Environment Conscious, Sustainable & Prosperous Organization

Commitment for Climate Security

Use of Alternatives

Alternatives
46 MW Green Power Plant
(WHR based)

Percentage
49.5 % of total power used 30 32 % replacement of clinker 100 % replacement of coal 2.4 % of Raw Material

Fly ash Petcoke Slag from Smelter

An Energy & Environment Conscious, Sustainable & Prosperous Organization

Commitment for Climate Security

Futuristic Approach to Mitigate CO2 Emissions

Cultivation of micro algae for 5% replacement of petcoke. Installation of 50 MW Solar Power Plant. LED and Solar power for lighting. Installation of Flue Gas Desulphurization Unit at Power Plant. Adoption of Powitech Process Optimization with Intelligent Technologies. Development of system design for use of pond fly ash.

An Our Earth - Our Future - Just Save It & Prosperous Organization Energy & Environment Conscious, Sustainable

Recognitions

First prize for Energy Conservation by Bureau of Energy Efficiency.

FICCI SEDF Corporate Social Responsibility Award.

CII Sustainability Award

Quality Excellence Award By NCCBM

Golden Peacock Award for Climate Security

Excellent Water Efficient Unit Awarded by CII

An Energy & Environment Conscious, Sustainable & Prosperous Organization

Recognitions

Energy Efficiency Award Awarded by CII

Green Business Award by Emergent Venture India & Financial Express

National Award for Excellence in Cost Management

Energy Conservation Award by Bureau of Energy Efficiency.

An Energy & Environment Conscious, Sustainable & Prosperous Organization

May our earth with all its beauty produce a harvest of PEACE and PROSPERITY

- Rigveda

Thank you

Visit us at: www.shreecementltd.com

An Energy & Environment Conscious, Sustainable & Prosperous Organization