(*) Plant commissiones in March 07 of 18 MW. Power

The ever rising cost of energy inputs viz. coal and power have focused industry attention towards energy conservation. It is an effective way of reducing the manufacturing costs, green house emission and preservation of natural resources. Best practices adopted at Shree Cement are given below:

• Changing mindset through awareness.
• Ensuring cost effectiveness through continuous monitoring & energy audit.
• Evaluation of profits through energy management.
• Benchmarking and rating of energy efficiency parameters.
• Reducing obsolescence through technological sophistication.
• Continuous improvement through awareness training, team spirit, employees’ participation and communication.
• Better manpower management through best HRD practices.
• Fulfilling corporate responsibility to environment and society through implementation of Energy & Environment policy.
• To draw future plans for Energy Conservation.
• Increase utilization of waste products generated by other industries.

Pulverised coal is used as a fuel in the process of clinkerisation. In 2001-02 the company shifted from the use of imported coal as its principal feedstock to petcoke After installation of 36 MW power plant, ash generated is also being used as a fuel Quality of full (Coal/Pelestee) use in plant.


(a)used as a fuel in cemet plant are given below:

	2006.07	05.06
Quality(Lac MT)	4.01	2.61
Total cost(Rs in lac)	14495.37	8138.14
Average rate(R/M)	3610.35	3122.35

(b)Used in LP steam tunprise/Generators

Quality(Lac Mt)	0.07	0.03
Total rate(rs in lac)	300.48	111.70
Average rate(Rs/Mt)	4141.65	3475044

(c)Used in HP Turbine/Generators

Quality(Lac MT)	1.70	1.34
Tatal rate(Rs in lac)	6631.66	4167.61
Average rate(Rs/MT)	39900.76	3098.92

With a quest to excel in the field of production, energy and environment, Shree Cement has started putting up untiring efforts since beginning. Internal benchmarks were set. The energy saving potentials identified and proper plans formulated for modernisation of plant, effective monitoring, better operational controls, upgradation of process control and instrumentation, intelligent substitution like use of fly ash & petroleum coke, the byproducts of thermal power and refinery industry respectively. Besides, the management encouragement, participation of employees, Shree R&D center efforts and manpower training have also helped in achieving new heights in reducing energy consumption and use of alternate fuel which is considered to be a difficult task for cement industry.

Operational Measures

Shree Cement has been continuously striving to reduce energy consumption in cement manufacture at each stage. The increasing consciousness for energy conservation and steps taken towards effective monitoring, better operational control and process optimisation in addition to various modification/retrofitting of energy efficient equipments have contributed greatly in energy conservation and improved productivity. The management has set up an energy conservation cell, which has laid down the methodology of measurement of parameters. Logical approach and implementation of innovative ideas. To counter the emission level a full fledged environment improvement wing has also been established for monitoring stack emission, fugitive dust emission, noise level and other related parameters. Various other measures taken include -

• Prevention of idle running of equipment by providing interlocking arrangement and operating with a PLC system. Generation of daily report on idle running of equipment also in terms of monetary losses.
• Minimizing ingress of false air into the kiln, cooler, coal mill, cement mill and raw mill circuits.
• Raw mix optimization.
• Use of low ash coal.
• Ensuring operational availability of various equipment.
• Preventive maintenance approach.
• Efficient management information system for identifying various important parameters for efficient operation of the equipment and taking timely remedial measures.
• Setting targets for production and energy consumption in various sections of the plant.
• Involvement in benchmarking studies carried out by various national and international agencies, which is considered as one of the management tools to achieve excellence in all spheres.
• Regular monitoring and calibration of flow meters.
• Waste minimisation by installation of efficient dust collector equipments.
• Controlling lighting loads in plant and use of appropriate sized motors.
• Optimisation of grinding media

Various modification jobs carried out since last final yraes in the plant given below:

The Results continous thrust on impronving engry consumption level Rao brought down power & fuel consumption as under:

Although power consumption for the year indicate marginal increase during the year,the unit wise consumption has gone down for last year.

Energy Conservation Efforts At Shree Cement