Manufacturing Process Mining The cement manufacturing process starts from the mining of limestone, which is the main

raw material for making cement. Limestone is excavated from open cast mines after drilling and blasting and loaded on to dumpers which transport the material and unload into hoppers of the limestone crushers.

Crushing Stacking & Reclaiming of Limestone The LS Crushers crush the limestone to minus 80 mm size and discharge the material onto a belt conveyor which takes it to the stacker via the Bulk material analyser. The material is stacked in longitudinal stockpiles. Limestone is extracted transversely from the stockpiles by the reclaimers and conveyed to the Raw Mill hoppers for grinding of raw meal.

Crushing Stacking & Reclaiming of Coal The process of making cement clinker requires heat. Coal is used as the fuel for providing heat. Raw Coal received from the collieries is stored in a coal yard. Raw Coal is dropped on a belt conveyor from a hopper and is taken to and crushed in a crusher. Crushed coal discharged from the Coal Crusher is stored in a longitudinal stockpile from where it is reclaimed by a reclaimer and taken to the coal mill hoppers for grinding of fine coal.

Raw Meal Drying/Grinding & Homogenization Reclaimed limestone along with some laterite stored in their respective hoppers is fed to the Raw Mill for fine grinding. The hot gasses coming from the clinkerisation section are used in the raw mill for drying and transport of the ground raw meal to the Electrostatic Precipitator / Bag House, where it is collected and then stored and homogenised in the concrete silo. Raw Meal extracted from the silo (now called Kiln feed) is fed to the top of the Preheater for Pyroprocessing.

Clinkerisation Cement Clinker is made by pyroprocessing of Kiln feed in the preheater and the rotary kiln. Fine coal is fired as fuel to provide the necessary heat in the kiln and the Precalciner located at the bottom of the 5/6 stage preheater. Hot clinker discharged from the Kiln drops on the grate cooler and gets cooled. The cooler discharges the clinker onto the pan / bucket conveyor and it is transported to the clinker stockpiles / silos. The clinker is taken from the stockpile / silo to the ball mill hoppers for cement grinding.

Cement Grinding & Storage Clinker and Gypsum (for OPC) and also Pozzolana (for PPC) are extracted from their respective hoppers and fed to the Cement Mills. These Ball Mills grind the feed to a fine powder and the Mill discharge is fed to an elevator, which takes the material to a separator, which separates fine product and the coarse. The latter is sent to the mill inlet for regrinding and the fine product is stored in concrete silos.

Packing Cement extracted from silos is conveyed to the automatic electronic packers where it is packed in 50 Kgs. Polythene bags and dispatched in trucks.

Electrical Power For total power requirement of 90 MW (Jaypee Rewa Plant and Jaypee Bela Plant), we have CPP CPP CPP 1 2 3 25.0 25.0 37.0 MW MW MW

Four DG sets provide an emergency backup.

Technical Services

Owning a strong, durable and beautiful home is one of the innate desires of every human being. At Jaypee, the pioneers in the construction of mega Hydroelectric projects and other infrastructure projects, we fully understand that good cement and construction material alone will not ensure strong and lasting structures. Correct construction practices and quality control at the time of construction play an equally important role. Our understanding of the construction practices and related problems has prompted us to extend customized technical services specially tailored for the Individual Home Builders and large projects. We firmly believe that quality construction leads to satisfied customers.

The Jaypee Cement Technical Support Service offerings are: Technical Service Engineers Our Area Marketing Offices have a fully functional technical services department aptly supported by qualified Civil Engineers who visit and interact with the customers to asses their needs and accordingly advise them about the best construction practises so that the dream of a strong and durable home is realized. Some of the customer-centric initiatives taken up by the Technical Service Engineers are: Customized solutions to the problems of the individual home builder.

Training the masons and contractors so that they are aware about good construction practices. Train the channel partners (Dealers and Retailers) about the product and its correct usage. Interact routinely with the professionals (architects and engineers) and share information regarding latest developments in the product and industry.

The services of the Technical Service Engineers can be availed by all users of Jaypee Cement. For more details, please contact nearest Jaypee Cement Area Marketing Office or Jaypee Cement Authorized Dealers.

Nirman Mitr Services Mobile Concrete Testing Vans Looking at the importance of quality control tests at the time of construction, Jaypee Cement has introduced mobile testing vans under the brand name of Nirman Mitr. The vans are fully equipped to carry out strength and workability tests of concrete. The grading and quality of the aggregates used in concrete can also be tested. The services of Nirman Mitr are meant primarily for assisting

the customer in making good concrete for any application viz. footing, beams, columns, lintels, slabs etc. The services of Nirman Mitr can be availed by any prospective Individual Home Builder. The services of Nirman Mitr are free of cost, subject to the availability of the van and on a first come first serve basis. Currently, Nirman Mitr Vans are operating in the following locations:

1) Delhi 2) Dehradun 3) Allahabad 4) Lucknow

5) Kanpur 6) Patna 7) Gwalior 8) Indore

9) Faridabad 10) Karnal 11) Panchkula 12) Sonepat

Disclaimer: The Technical Service and Nirman Mitr Services are non-profit, free of cost services to provide information and guidance to the Jaypee Cement users on the correct application of cement and concrete. The services are meant for general guidance only and in no way replaces the services of professional consultants on projects. No legal liability can be accepted by Jaiprakash Associates Limited for its use.

Performance Jaypee Rewa Plant

Production Clinker Year Production (MTPA) 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2.317 2.173 2.561 2.918 3.106 3.131 Sp. Heat Total Cement Sp.Electrical Energy onsumption Conversion Production Consumption, (Net Basis) Factor (MTPA) kWh/t of Clk. Kcal/Kg of Clk. 2.579 768 70.4 0.803 2.413 748 71.9 0.786 2.562 704 67.5 0.769 2.819 708 66.4 0.770 3.207 698 66.3 0.759 3.253 698 65.5 0.759

2008-09 3.087 2009-10 3.204

3.043 3.218

691 688

64.9 62

0.762 .777

Jaypee Bela Plant Production Clinker Year Production (MTPA) 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 1.68 1.646 1.648 1.768 1.996 2.004 2.055 2.042

Sp. Heat Total Cement Sp.Electrical Energy Consumption (Net Conversion Production Consumption, Basis) Factor (MTPA) kWh/t of Clk. Kcal/Kg of Clk. 1.783 716 62.3 0.848 1.837 715 64.6 0.828 2.046 700 63.4 0.863 2.152 691 63.5 0.857 2.414 706 64.1 0.817 2.337 696 63.3 0.797 2.257 694 62.9 0.813 2.387 692 63.7 .801

Jaypee Ayodhya Grinding Operational, Tanda (U.P) Production Clinker Year Production (MTPA) 2005-06 2006-07 2007-08 2008-09 2009-10 -

Sp. Heat Total Cement Sp.Electrical Energy Consumption Conversion Production Consumption, (Net Basis) Factor (MTPA) kWh/t of CEMENT Kcal/Kg of Clk. 0.756 31.16 0.729 0.88 1.4824 0.91 1.4832 1.032 30.75 .686

Jaypee Cement Blending Unit, Sadva, Allahabad (U.P) Production Clinker Year Production (MTPA)

Sp. HeatSp.Electrical Total Cement Consumption Energy Conversion Production (Net Basis) Consumption, Factor (MTPA) Kcal/Kg of Clk. kWh/t of CEMENT

2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10

0.325 0.453 0.553 0.587 0.58 0.61 0.60 .719

5.84 4.93 4.46 4.34 4.39 4.25

0.662 0.687 0.680 0.689 0.685 .6835

Jaypee Cement Grinding Unit, Panipat (Haryana) Production Clinker Year Production (MTPA) 2008-09 2009-10 -

Sp. HeatSp.Electrical Total Cement Consumption Energy Production (Net Basis) Consumption, (MTPA) Kcal/Kg of Clk. kWh/t of Clk. 0.666 38.78 1.012 38.04

Conversion Factor 1.259 .7042

DALLA CEMENT FACTORY, Sonebhadra (UP)

Production Clinker Year Production (MTPA) 2008-09 0.351 2009-10 1.373

Sp. HeatSp.Electrical Total Cement Consumption Energy Production (Net Basis) Consumption, (MTPA) Kcal/Kg of Clk. kWh/t of Clk. 892 94.38 .146 804 86.79

Conversion Factor .7287

CHUNAR CEMENT FACTORY, Mirzapur (UP) Production Clinker Year Production (MTPA) 2007-08 -

Sp. HeatSp.Electrical Total Cement Consumption Energy Conversion Production (Net Basis) Consumption, Factor (MTPA) Kcal/Kg of Clk. kWh/t of CEMENT 0.039 45.80 0.747

2008-09 2009-10 -

0.612 1.702

42.30 43.91

0.729 .7129

Jaypee Gujarat Cement Plant, Sewagram Gujarat Production Clinker Year Production (MTPA) 2009-10 .43

Sp. HeatSp.Electrical Total Cement Consumption Energy Production (Net Basis) Consumption, (MTPA) Kcal/Kg of Clk. kWh/t of Clk. .27 788 74.59

Conversion Factor ..9628

Jaypee Wanakbori Cement Grinding Unit, Gujarat Production Clinker Year Production (MTPA) 2009-10 -

Sp. HeatSp.Electrical Total Cement Consumption Energy Conversion Production (Net Basis) Consumption, Factor (MTPA) Kcal/Kg of Clk. kWh/t of CEMENT .069 54.34 .7936

Jaypee Sidhi Cement Plant , Sidhi Production Clinker Year Production (MTPA) 2009-10 1.166

Sp. HeatSp.Electrical Total Cement Consumption Energy Production (Net Basis) Consumption, (MTPA) Kcal/Kg of Clk. kWh/t of Clk. .405 751.42 67.02

Conversion Factor .7800

Jaypee Roorkee Cement Grinding Unit , Roorkee Year Production Clinker Production (MTPA)

Total CementSp. Production (MTPA) Consumption (Net

HeatSp.Electrical Energy Basis) Consumption,

Conversion Factor

2008-09 2009-10 -

0.114

Kcal/Kg of Clk. -

kWh/t of CEMENT 57.07 .0.77

Jaypee Himachal Cement Plant , Baga Production Clinker Year Production (MTPA) 2009-10 .206

Sp. HeatSp.Electrical Total Cement Consumption Energy Production (Net Basis) Consumption, (MTPA) Kcal/Kg of Clk. kWh/t of Clk. 796.68 71.24

Conversion Factor -

Jaypee Himachal Cement Grinding & Blending Unit, Bagheri

Production Clinker Production Year (MTPA)

2009-10 -

Sp.Electrical Sp. Heat Total Cement Energy Consumption Conversion Production Consumption, (Net Basis) Factor (MTPA) kWh/t of Kcal/Kg of Clk. CEMENT .096 47.42 .82

Cement Brands Jaypee produces a wide variety of cements, which are specifically designed to cater to the customers requirements for different types of cements in each of its markets. All the brands, which the Company produces, are so evolved in their characteristics and properties that they will surpass BIS Standards. For each brand, the relevant BIS standards are mentioned in enclosed table along with a comparison with the BIS requirement.

The state-of-the-art cement plants operated by the Jaypee Group are equipped with the most modern technology from the globally leading technology providers. Extensive Instrumentation & fully automatic and computerized process control system, custom designed Quality Control software like QSO Expert and CADES in the Mines, Cross Belt Expert Analyser using the Prompt Gamma Neutron Activation Analysis - for the first time in India, X-Ray Fluorescence and X-Ray Diffraction analysers and optical microscope, enable production of cement of the highest quality consistently on a sustained basis. Jaypee Rewa Plant Quality control laboratory is accredited laboratory from National Accreditation Board for Calibration & Testing Laboratories, for chemical and mechanical Cement testing.

All brands are marketed in attractive HDPE bags, containing 50 Kgs of quality cement from Jaypee. Bags are identified with a conspicuous Jaypee Logo, which also over the years has come to be regarded as a Hallmark of quality.

Jaypee produces & markets both Portland Pozzolana Cement (PPC) & all grades of Ordinary Portland Cement (OPC). A brief introduction of each brand is enumerated as below:-

Particulars

Test Results Obtained Requirement IS: OPC-53 S

of

1 2 3 4 5 6 7 8 9 1 2 3

CHEMICAL PROPERTIES Lime Saturation Factor (LSF) 0.91 Alumina to that of Iron oxide Ratio % 1.31 (A/F) In soluble Residue (% by mass) 0.88 Magnesium oxide (% by mass) 3.18 Sulphuric Anhydride (% by mass) 1.86 Total Loss On Ignition (% by mass) 1.02 Tricalcium Aluminate (C3A) % 6.98 Tricalcium Silicate (C3S) % 49.49 Total Chloride ( % by mass) PHYSICAL PROPERTIES Fineness (M2/Kg) Setting Time (Minutes) Initial Final Expansion Le. Chatelier (mm) Auto clave (%) 0.013 407 145 195 1.00 0.18

0.80 To 1.02 0.66 Min. 2.00 Max. 5.00 Max. 5.00 Max. 4.00 Max. 10.00 Max. 45.00 Min. 0.10 Max.(For 0.05 Max.(For P.C.)* 370 Min. 60 Min. 600 Max. 5.00 Max. 0.8 Max.

N.C.)*

Compressive Strength (MPa) 3 Days 7 Days 28 Days

36.0 47.0 60.0

Not Specified 37.5 Min. Not Specified

Cement tested at temp.27 2C The above cement complies with IS: 12269 -1987 for 53 Grade Ordinary Portland cement. *N.C.(Normal Concrete Cement) *P.C.(Prestressed Concrete Cement) Despatched Week No : 11/2006 on 12/03/06

Jaypee OPC-53S Grade cement One of the very few cement manufacturers having the capability to manufacture this special grade of cement which due to its enhanced quality and performance parameters has been approved by the RDSO and is preferred by Indian Railways for manufacture of SLEEPERS. Jaypee OPC-53 S Grade is also used in heavily loaded or prestressed structures, which are subjected to high dynamic loads due to rapidly moving volumes, be it a train passing on the railway sleepers or a great volume of water moving at high speed to generate electricity in a Dam. The characteristics of OPC-53 S Grade cement with the prescribed BIS Standards IS: 12269 1987 can be seen in the table below.

Awards Cement Division of Jaiprakash Associates Limited with its Plants at Jaypee Rewa Plant (JRP), Jaypee Bela Plant (JBP), JAAGO & JCBU has been awarded the Integrated Management System comprising of ISO-9001:2000, ISO-14001:2004 & OHSAS-18001:1999 by the world renowned Bureau Veritas Certification. ISO-9001:2000 covers Quality Management System. ISO14001:2004 covers all Environmental Issues including conservation of Natural Resources and

Reduction of Emissions and Wastes. OHSAS-18001:1999 covers Operational Safety and reduces Risk to People, Plant & Machinery.

Environment

Plant Safety

Mines Safety

Energy Conservation