UltraTech Cement Limited: Unit - Rawan Cement …

1 CII 18th National Award for Excellence in Energy Management 2017. UltraTech Cement limited : unit - Rawan Cement Works Team Members: 1. Mr. Ram Prakash Nolkha 2. Mr. Pradeep Agrawal 3. Mr. Deepak Kumar Integrity Commitment Passion Seamlessness Speed Contents 1. Business and unit Overview 2. Cement Manufacturing Process & unit 's Milestones 3. Various Certifications and Energy Management System 4. Reduction in SEC, Innovation and Various Encon Projects 5. GHG Inventorization, Sustainability, Safety & CSR Activities 6. Best Practices (Green Supply Chain), Awards and Accolades Integrity Commitment Passion Seamlessness Speed Business Overview Integrated Units Largest Cement Player in India by an Even Larger Margin Grinding Units Baga Cement Works Bulk Terminals Bathinda Cement Works Bagheri Cement Works Roorkee Cement Works Sikandarabad Cement Works Panipat Cement Works Dadri Cement Works Jhajjar Cement Works Aligarh Cement Works Kotputli Cement Works Dalla Cement Works Tanda Cement Works Patna Cement Works Aditya Cement Sewagram Cement Works Vikram Cement Sidhi Cement Works West Bengal Cement Works Wanakbori Cement Bela Cement Works Works Hirmi Cement Works Dankuni Cement Works Gujarat Cement Works Magdalla Cement Works Jharsuguda Cement Works Awarpur Cement Jafrabad Cement Works Navi Mumbai Cement unit Works RWCW.

2 Nagpur Cement Works Pune Bulk Terminal unit Hotgi Cement Works Ratnagiri Cement Works Shankarapally Bulk Terminal Rajashree Cement Works Balaji Cement Works Andhra Pradesh Cement Works Ginigera Cement Number of Mangalore Bulk Works Units Symbol Terminal Arrakonam Cement Works Units BSBT- Dodballapur Integrated Plants 18. Reddipalayam Cement Works MILLION. Cochin Bulk Terminal 14 MILLION TPA Grinding Units 25. TPA (2017). (2004) Bulk Terminals 7. Integrity Commitment Passion Seamlessness Speed Looking Ahead Our Aspiration, Going Forward 25% Market Share Add 30 Million Tonne Capacity Double our revenues Triple the EBITDA. One in three homes built in India with UltraTech Cement No. 3 in the World Integrity Commitment Passion Seamlessness Speed UltraTech Rawan Cement Works At a Glance Plant Capacity RWCW is the largest RWCW Major Equipment Details RWCW. Clinker: MTPA unit of UltraTech Line 1 (1995) Line 2 (2013). Cement : MTPA Cement Ltd. in Eastern RAW MILL.

3 TPP Capacity: 55 MW Cluster of India WHRS: 15 MW Loesche VRM KHD Roller Press Brownfield 375 TPH 3 275 TPH. Project COAL MILL. MTPA Loesche VRM Pfeiffer VRM. Year 2013 40 TPH 90 TPH. KILN. Capacity Enhanced FLSmidth (SLC + ILC) KHD (4 Strings ILC). MTPA Year 2008 5600 TPD 10000 TPD. Cement MILL. Greenfield Project KHD RP + Ball Mill Polycom for Slag MTPA Year 1995 (PPC 305 TPH) Grinding (OPC 220 TPH) (PSC 220 TPH). Integrity Commitment Passion Seamlessness Speed unit 's Vision & Mission VISION. To be the Leader in Building Materials with focus on our Values & create a Sustainable future in the UltraTech Cement of Aditya Birla Group. MISSION. Leading with latest technologies for delivering the values to our customer's by following four focal areas: 1. Sustainability 2. Quality & Bosstomer Satisfaction 3. Employee Engagement & Team Empowerment 4. Cost Effectiveness & Innovation Integrity Commitment Passion Seamlessness Speed Cement Manufacturing Process Pre Clinkerization LS Grinding Mining Crushing Stacking & Reclaiming Clinkerisation Coal Grinding Clinker Post Clinkerization Grinding Additives Delivery Delivery Delivery Bulker Rack Truck Packing Integrity Commitment Passion Seamlessness Speed Our Final Products PPC PSC OPC 43 Grade Integrity Commitment Passion Seamlessness Speed unit 's Milestones & Achievements Rated as one of the best Cement plant in Safety with clear focus on Environment, Zero %.

4 Ground Water usage in Plant & Colony, Green Band in External BCE Audit Highest Conversion factor of Lowest Carbon Footprints/Specific CO2 Emissions among all UltraTech plants Manufacturing of Green Clinker & Successful Plant scale trial of Composite Cement (received license from BIS for manufacturing of Composite Cement ). First unit in UltraTech to achieve output of >12500 TPD Clinker from line-2 Kiln with 100% Petcoke, SEC of <50 kWh/MT of Clinker & 695 kCal/kg of Clinker 2nd Lowest Cost of Cement manufacturing in UltraTech for FY 2016-17 and presently we are at no. 1 in Q1 FY18 among all plants of UTCL. In-house manufacturing of Grinding Aid and lowest power consumption in PPC grinding among all UltraTech Cement Plants ( kWh/MT in July'2017). Integrity Commitment Passion Seamlessness Speed unit 's Best Practices Effective Safety Culture deployment in every action Cross functional SWOT Analysis every year in presence of Top management Structured Energy Management System for continual improvement Centralized Total Lubrication Management Use of Slag as Raw Material in Clinkerisation Green Clinker Shutdown Management System Well organized Inspection System (R1R2/S1S2) & Effective Preventive Maintenance Organized Hazardous Waste handling system Man less Operation of LS Stacker and Reclaimer in both lines Execution of Basic Condition Evaluation Use of PPF in place of HSD during light up of Kiln and TPP.

5 Effective Cross functional Why-Why Analysis of each breakdowns on fortnightly basis Integrity Commitment Passion Seamlessness Speed Certifications ISO 9001, 14001, OHSAS 18001 SA 8000 ISO 27001. Integrity Commitment Passion Seamlessness Speed Energy Management Policy Energy Policy implemented in 2009. Energy Policy states unit 's commitment towards continual energy performance improvement Energy policy is communicated at all levels Daily Review of Energy & PAT data BEST. Dedicated Energy Cell with fortnightly review Three layer Team Structure for stringent Monitoring Six Sigma Projects on Energy Conservation Real time power consumption data monitoring through online Energy Monitoring System Committed for continual improvement Integrity Commitment Passion Seamlessness Speed Energy Management Structure Restoring Basic Condition of Equipments COO & EP. Chairman Energy FH-Tech Technical Process/Energy Optimization Manager Champion Cell Energy Cell Functioning Focus Area Innovation Technological Up-gradation WT.

6 TPP Township Packing LSC RM Kiln CM Clinker AC, P&V Utilities Plant Loading Awareness / Campaign /. Knowledge Management Integrity Commitment Passion Seamlessness Speed Energy Monitoring, Reporting &. Implementation Methodology Online Energy Monitoring System Integrity Commitment Passion Seamlessness Speed Energy Monitoring, Reporting &. Implementation Methodology Energy Management Cell with clear cut responsibilities. Monitoring & Review Formats Daily monitoring of Energy Deviation report. Description Formats Daily Co-ordination Benchmarking with National/International/Group meeting on Power Units/Cluster units and action plan for improvement. and Performance Regular study of Equipments on deviation and their review analysis. Review of Daily Process Evaluation & Identification of Energy Conservation Power Report for any scope. deviation Energy Cell Meeting Feasibility study of suggestions and designing proposals for Points Compliance sanctions.

7 Review Promoting energy saving idea generation by shop floor Energy Audit teams and time bound implementation (Internal & External). Organizing Internal and External Energy Audit. Points Compliance Integrity Commitment Passion Seamlessness Speed Dedicated Energy Cell Cross Functional Action Team for Energy Conservation Mr. Lalit Nayak Electrical(SH) Mr. Ashok Ojha Electrical(SH) Energy Cell Meeting Mr. Amit Shekhar Mech. Cement Mr. Sudhanshu Barik Mech 1 LS Crusher Mr. Rishi Verma Instt. 5. Mill Mr. Rajesh Jaiswal Instt. All team presents Mr. Devendra Deshmukh Mines Operations Mr. Manish Mishra Process sectionwise Power Mr. Ashok Ojha Electrical(SH). Mr. Manish Paliwal Elect. Packing Mr. Sanjeev Mishra PP Operation and Performance Mr. Yogendra Verma Electrical(SH) 6. Plant Mr. Rajkumar Soni Mech Mr. Pushraj Mech. Mr. Rajesh Jaiswal Instt. Discussion over 2 Raw Mill Mr. Shashikant Tiwary Mech. Mr. Rangnath Electrical(SH) deviation (if any). Mr. Rishi Verma Instt.

8 Mr. Neeraj Singh Mech Mr. Sanjay Kateria Process 7 TPP. Mr. Lovkesh Kumar Instt. New Ideas on power Mr. Pawan Pothghan Operation Mr. Prakash Hardeniya Electrical(SH). Mr. Ravi Raw Electrical(SH). saving Mr. Karan raj Gupta Mech. 3 Coal Mill Mr. Animesh Sumen Mech. Mr. Dharmendra Mech Target date and 8 WHR Manikpuri Mr. kishor Nalge Instt. Mr. Abhishek Sen Instt. Responsibility Mr. Sanjeev Choubey Process Mr. Byomjit Dixit Electrical(SH). Mr. Rajesh Sharma Operation allocation Mr. Yogendra Verma Electrical(SH). Mr. Tiwari Mech Mr S P Yadav Utility (SH) Last meeting MOM. 4 Kiln Mr. Pramit Ujjain Mech 9 Utility Mr. Shyam Narayan Sahu Mech. Mr. Adityaram Instt. review Mr. Krishnakanth Singh Instt. Mr. Vikas Sahu Process Mr. Ankush Gwande Electrical Integrity Commitment Passion Seamlessness Speed Employee Involvement & Team Work Kaizen & Suggestions Schemes Kaizens/Suggestions Implemented Annual Improvement Projects 3000. Organization Knowledge 2112.

9 NOS. 2500 1821 1757. KIP Visits 2000. External & Internal Trainings on Energy 1500. 1000. Participation in Seminars 2014-15 2015-16 2016-17. Team competition Energy Conservation Week Monetary Savings in Rs. Lacs Awareness creating to all Colony residents 175 for Energy Conservation 155 135. Online Training need identification through 115. Poornata on Energy Conservation 95. 75. Reward & Recognition 2014-15 2015-16 2016-17. Integrity Commitment Passion Seamlessness Speed Employee Involvement & Team Work Annual SWOT Analysis Integrity Commitment Passion Seamlessness Speed Employee Involvement & Team Work Monthly Masscom Meeting Award Encon Project Good Work Done Award Monthly Masscom Meeting Best Encon Suggestion Award COO & EP Addressing Integrity Commitment Passion Seamlessness Speed unit 's Performance Integrity Commitment Passion Seamlessness Speed unit 's Performance GOOD. GOOD. Clinker Production (LMT) Cement Production (LMT). 2014-15 2015-16 2016-17 2014-15 2015-16 2016-17.

10 Production figures are combined for both Lines Integrity Commitment Passion Seamlessness Speed unit 's Performance Flyash Addition % Slag Addition %. GOOD. GOOD. 36 65. 60 34 55 32 50. 45. 30 40. 35. 28 30. % 25 %. 26 20. 2014-15 2015-16 2016-17 National 2014-15 2015-16 2016-17 National BM BM. In Q1: FY 2017-18 Flyash Addition is % In Q1: FY 2017-18 Slag Addition is %. Integrity Commitment Passion Seamlessness Speed Electrical Energy Performance Specific Power Consumption Specific Power Consumption GOOD. GOOD. KWh Per MT of Clinker (Both Lines) KWh Per MT of Clinker (Line-2). KWH/MT OF CLINKER. 70 KWH/MT OF CLINKER. 60 70. 60 50. 50. 40 40. 2014-15 2015-16 2016-17 National 30. BM (Top 3. Plants). 2014-15 2015-16 2016-17. National BM. In August'17: Achieved Output of >12500 TPD with 100%. In Q1 2017-18: Achieved kWh/MT of Clinker Petcoke with SPC of <50 Units/MT of Clinker National Benchmark Reference: CII Energy Benchmarking Manual 2015, Version Global Benchmarking: BEE presentation during interactive workshop on normalization factor in Ahmedabad Integrity Commitment Passion Seamlessness Speed Electrical Energy Performance PPC Specific Power Consumption Total Specific Power Consumption GOOD.