CII NATIONAL AWARD FOR

EXCELLENCE IN ENERGY MANAGEMENT 2024

Presenting Team Members

❑ Avinendra Singh - Head Mechanical
❑ Anil Sachan Manager E&I

Confidential 1
 AN INTRODUCTION : MP BIRLA GROUP OF COMPANIES

Birla Corporation Limited is the flagship Company of the M.P. Birla Group. Incorporated as Birla Jute
Manufacturing Company Limited in 1919, it was Late Mr. Madhav Prasad Birla who gave shape to it. As
Chairman of the Company, he transformed it from a manufacturer of jute goods to a leading multi-
product corporation with widespread activities. Under the leadership of Mr. Rajendra S. Lodha, the
Company posted its best ever results in the years ended 31.3.2006, 31.3.2007 and 31.3.2008. The
Company continued to record impressive growth in 2008-09 and 2009-10.
Mr Harsh V Lodha is now Chairman of the Company.
The Company is primarily engaged in the manufacturing of cement as its core business activity. The
Company has acquired 100% shares of Reliance Cement Company Private Limited
(Reliance Cement). This acquisition provides Birla Corporation Limited with the ownership of high-
quality assets, taking its total capacity from 10 MTPA to 15.6 MTPA. after commissioning of Mukutban
plant capacity further increases to ~ 20 MTPA
Birla Corporation currently produces cement at eight locations through its 11 manufacturing units with
a combined capacity of almost 20 million tons per annum.

S.No. UNIT OPERATIONAL CAPACITY

1 RCCPL Pvt LTD – Maihar, IU 4.0 MTPA
2 RCCPL Pvt LTD- Mukutban IU 3.90MTPA

3 Satna Cement Works, IU 2.70 MTPA

4 Chanderia Cement Works, IU 4.20 MTPA
5 RCCPL Pvt LTD, Butibori, GU 0.50 MTPA
6 RCCPL Pvt LTD, Kundanganj, GU 2.21MTPA
7 Birla Corporation, Raebareli, GU 1.24 MTPA
Confidential 8 Birla Corporation, Durgapur, GU 2.05 MTPA 2
 VISION, MISSON & VALUES

VISION
To be admired
For our Performance,
Ethics and Culture

MISSION

To be the best- in- class

in every sector we operate

VALUES

• Integrity
• Professionalism
• Value Creation
• Social Commitment
Confidential 3
 GENESIS OF THE MAIHAR CEMENT PLANT
July
Ever Lowest MTD SHC-663.7
2024

June Ever Highest MTD CFA

2024 Consumption-20604 MT

March Highest Clinker Production- 3.7

2023 Million MT

Aug OPC53 Production started

2022
Feb Water Repellent (Rakshak
2021 Cement ) Production started
Sept
2019 Solar Commissioning

Aug
2019 WHR Commissioning

Aug
2016 IMS Certification

Aug Acquisition by Birla Corporation

2016 Pvt Ltd
May
2014 First Cement Dispatch
Confidential 4
 INTRODUCTION OF TECHNOLOGY/SPECIFICATION USED

LIMESTONE RAW MILL & PACKING

KILN & COOLER CEMENT
CRUSHING COAL MLL PLANT
MILLS

RAW MILL 1 & 2 KILN CEMENT MILL-1 & 2 ROTO PACKER

CRUSHER

• Make- • Make- • Make-ThyssenKrupp • TYPE-4 nos FLSmidth

• Make-Loesche VRM
ThyssenKrupp ThyssenKrupp Industries, • Capacity- 240 TPH rotating vertical semi
Industries india Industries, • Capacity- 10000 TPD PPC & 275 TPH automatic & 1 nos
Double shaft Germany, Roller • Ф6.2/5.8×88m (Upgarded OPC Beumar
press to 11500 TPD) • Capacity- 240 TPH
hammer impact
Crusher (POLYCOM)
PREHEATER WITH
• Capacity- 1600 TPH • Capacity- 375 PRECALCINER
(Upgrade to 400 Wall Putty &
STACKER WHRS &
TPH) & 400 TPH • DOPOL90 with PREPOL- Construction
Solar
MSC Chemical
• Make-NHI, China COAL MILL
• 6 stage, double string
• Capacity- 2000 TPH
• Make- FLSmidth ILC WHRS WALL PUTTY
RECLAIMER Private Limited/ COOLER • Make-Thermax • Capacity-1.5
ATOX 32.5
• Make- NHI, China India Pvt Limited Lac/Annum
• Capacity- 90 • Make- Polytrack cooler
• Capacity- 1000 TPH • Capacity- 12.25
TPH (For Coal) MW CONSTRUCTION
AFR CHEMICAL
• In-house 5 TPH SOLAR
pneumatic system • Capacity -45
• AFR system of 8 TPH • Capacity- 7.7 MW Lac/Annum
along with 20TPH • Proposal to
shredder further increase
to 3 MW

Confidential 5
 Specific Energy Consumption (Thermal & Electrical) FY22 To FY24
SPC increase in FY23
SHC (Kcal/kg Clinker) Clinkerization SPC (Kwh/MT Clinker) 1. Cooler fans upgradation
for clinker capacity
enhancement.
686 54.40
1% 2. Coal Mill SPC higher due
Reduction to low HGI coal as per
YOY 53.85 53.81 availability
678

671

2021-22 2022-23 2023-24

2021-22 2022-23 2023-24

SPECIFIC HEAT CONSUMPTION CLINKERIZATION SPC

Cement SPC (Kwh/T Cem)

❑ Plant has initiated various energy conservation 31.07
projects and by continuous improvement achieved 30.59
KPI target. 30.39

2021-22 2022-23 2023-24

CEMENT SPC
Confidential 6
 Specific Energy Consumption (Electrical) FY22 To FY24
OPC 53
KWH/MT PPC KWH/MT OPC production
increased
30.64
32.73 32.81

30.24

29.69 30.92

2021-22 2022-23 2023-24

2021-22 2022-23 2023-24

Overall Plant SPC (kwh/MT Cement )

68.20
68.11

67.00

2021-22 2022-23 2023-24

Overall Plant SPC

Confidential 7
 Competitors Benchmarking (Thermal & Electrical)
SHC (Kcal/Kg clinker) Clinkerization SPC (kWh/MT Clinker)
683
53.8
53.5
678
52.4
676.0
51

671.2

RCCPL, Maihar PLANT I PLANT II PLANT III RCCPL, Maihar PLANT I PLANT II PLANT III

SPECIFIC HEAT CONSUMPTION CLINKERISATION SPC

SEC Overall (kWh/MT Cement)

69.6
69
68.1

65.7

RCCPL, Maihar PLANT I PLANT II PLANT III

OVERALL PLANT SPC

Confidential 8
 Strategy framework for Project “SHIKHAR” to achieve Benchmark targets

How we are What Next How to achieve

1 2 3
Implementation of
Manufacturing Transformation “communities of practices”
Evaluation of existing by following objectives: and “copy with pride”
plant performance KPIs • Safety – Zero Harm. among all the units Vision
with respect to best • Implementation of CO2
achieved values. reduction initiatives . Ideas generations exercise
for reduction of cost, To be the best
• Improvement of reliability
of the equipment. efficiency and reliability manufacturing
Review the gap and • Reduction of clinker & through small group plants with respect
constraint from cement power activities (SGA) to safety, cost and
benchmarking KPI • Reduction of sp. Fuel efficiency.
parameters of other consumption. Evaluations of the best
cement plants • Higher usage of low cost ideas and implementation
CFA strategy.
• Higher usage of low cost
gypsum over imported gyp. Implementation of digital
Identify the potential to
• Improvement of TSR initiatives.
stretch upto maximum /
best targets and cost • Stores & spares inventory
reduction Skill development &
saving initiatives.
• Fixed cost Optimization. Training (Technical / Latest
developments)
Confidential 9
 Modus Operandi

Theideas of cost optimization and efficiency improvement

shall be inline with our company’s Mantra of 4 Vs (Vision,
Value, Velocity and Visibility)

Weekly review of the project status shall be done by

respective unit head.

Monthly review of the project status shall be done along with

monthly plant performance review meeting.

A sharing platform to be created in “One Drive” for regular

updates of all the workings and updates

Rewards & Recognition

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 UPCOMING PLANNED ENCON PROJECTS IN 2024-25

Annual Annual
INVESTMENT Electrical Thermal Target of
S. No PROJECTS
(Million INR) Saving Saving Completion
(Million KWH) (Million Kcal)

Completed
1 Installation of VFD’s in clinker transport bag filter fans 1.4 0.156 0

Modification work in Mill fan inlet box enlargement to decrease

2 pressure drop and Power reduction 2.275 0.195 0 Completed

Installation of Pendulum Flap valves at Cement mill reject

3 1.1 0.1296 0 Oct’24
hopper

Replacement of Fly ash Bulker unloading compressor with

4 6.1 0.864 0 Oct’24
lower pressure efficient compressor

5 VFD Installation in Pyro Compressor 1.8 0.144 0 Completed

Raw Mill duct CFD study and Modifications for pressure drop
6 1.5 0.183 0 Mar’25
reduction

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 ENERGY SAVING PROJECTS IMPLEMENTD IN LAST THREE YEARS

Impact on SEC/
Electrical Thermal Total
No of Major SHC (Electrical
Investment (INR Saving Saving Saving
Year Saving kWh /MT
Million) (Million (Million (INR
Projects cement or
KWH) Kcal) Million)
Kcal/Kg cement)

FY 2021-22 7 11.2 4.41 2862 33.3

SHC Reduced by 7.8 Kcal

FY 2022-23 8 39.05 0.6 30377 61.05 /kg clinker
SHC Reduced by 6.9 Kcal
FY 2023-24 15 151.3 2.67 26071 56.5 /kg clinker

Confidential 12
 ENERGY SAVING PROJECTS IMPLEMENTED: FY 2023-24

Annual
Annual Electrical
INVESTMENT Thermal
S. No PROJECTS Saving
(Million INR) Saving
(Million KWH)
(Million Kcal)
Reduction in Specific Heat Consumption from 678 to 671 kcal/kg Ck:

✓ Pre heater False air reduction from 6.5 to 5.5%

✓ PC temperature Optimization by 10 Deg C
1 4.25 0.24 13791
✓ PA fan optimization from 2370 to 2100 by 270 rpm reduction
✓ Raw Mill residue optimization from 4% to 3.6% on 212 micron
✓ Kiln and PH cyclone heat resistant paint application in bottom 2 cyclone
of both string
Kiln capacity upgradation from 10000 TPD to 11500 TPD
✓ PC veturi enlargement by 300 mm
2 145.8 0.1 2070
✓ TAD duct area enlargement by 5 %
✓ Kiln feeding system upgradation
WHRS Generation improvement by 0.4 Mw/hr
✓ Install Cooler curtain at Grate 2 start (LP boiler take up) after mid Tap
duct to increase WHR generation and AQC Id fan rpm optimization
3 (In-house) 1.43
✓ Chemical foam cleaning for proper heat exchange better flow of air
through fins for reducing ACC fan RPM
✓ Elimination of WHRS AQC Id fan inlet damper

Confidential 13
 ENERGY SAVING PROJECTS IMPLEMENTED: FY 2023-24

Annual
Annual Thermal
INVESTMENT Electrical
S. No PROJECTS Saving
(Million INR) Saving
(Million Kcal)
(Million KWH)
Cement Mills Operation optimization and TPH enhancement:

✓ Optimization of Mill fan with Mill feed at different rpm and feed level
✓ Dam ring optimization
4 ✓ Optimize compressed air Purging time in Bag House (In house) 8.43
✓ Mill Bag house DP optimization to avoid feed cuts
✓ Idle run of heater of cement mill bag house (excluding Rainy season)
✓ Dense phase Drier start stop incorporate with Compressor-04 nos (Post
clinkerisation)
Packing Plant SPC reduction of 0.6 kwh/T by-
✓ Installation of VFD in Bag filter fans
✓ Compressed air optimization by compressor loading and unloading pressure
5 0.15 0.202
✓ Optimize compressed air Purging time in Bag filters
✓ Separate airline for each packer to avoid line losses during packer stop
condition
Isolation valve at compressed air circuit to save power (12-13% compressed air)
6. (In house) 0.377
in un-utilised subsection in cement grinding

Compressed air Audit for compressor pressure optimization and leakages

7 1.5 0.09
arresting work of Cement and Packing section

Confidential 14
 ENERGY SAVING PROJECTS IMPLEMENTED: FY 2023-24

Annual
Annual Thermal
INVESTMENT Electrical
S. No PROJECTS Saving
(Million INR) Saving
(Million Kcal)
(Million KWH)

Raw Mill BH transport circuit (Chain conveyor) cyclic operation from continuous
8 (In house) 0.302
operation

Optimization of Utility power through Engineering control by-

9 Installation of Isolation valve in water circuit to avoid pressure loss during no 0.2 1.83
operation Flyash wagon operation in Cement Mills.
Reduction of Idle running of Coal mill auxilliary systems-

✓ Gearbox lubrication unit (System includes 3 nos. HP pump of 7.5kW each and
1 LP pump of 15kW
10. ✓ Roller lubrication (All Roller lubrication system pumps will stop after 20 mins (In house) 0.55
of mill stop)
✓ Hydraulic system (All Hydraulic system pumps will stop after 20 mins of mill
stop)

Confidential 15
 ENERGY SAVING PROJECTS IMPLEMENTED: FY 2022-23

INVESTMENT SAVINGS
Sl.No PROJECTS
(Lacs INR) (Lacs INR/annum)
Reduction in Specific Heat Consumption from 686.4 to 678.2 by:
✓ Curtain wall installed in cooler Grate 1 to improve recuperation
efficiency of cooler. 385 573.2
1 ✓ False Air reduction in Preheater from 8% to 6%
✓ Kiln operation, reliability and productivity improvement
✓ Cooler Upgradation (static grate fan and aeration elements )
(In house)
2 Reduced Pyro compressor loading and unloading pressure by 0.2 bar 11.88

(In house)
3 Reduction of Idle running of clinker transport group 2.20

(In house)
4 Reduction of Idle running of Gypsum transport group 3.19

(In house)
5. Reduction of Idle running of flyash transport group 1.15

Confidential 16
 ENERGY SAVING PROJECTS IMPLEMENTED: FY 2022-23

INVESTMENT SAVINGS
Sl.No PROJECTS
(Lacs INR) (Lacs INR/annum)

Logic made for reduction of idle run of cement mill transport group
and aux circuit.
561BC3 will only run when reject to be handled or will run in auto (In house)
6 7.32
mode for 5 min in 2hrs. hence save the power of belt conveyor and
supporting bag filter.

WHRS Power generation improvement and Reduction in Auxiliary

consumption through leakage identification in ACC system by
7 ultrasonic leakage detector instrument 4 11.25

VFD installed in Coal Mill Water spray pump L41WP2 1.5 0.26
8

Confidential 17
 ENERGY SAVING PROJECTS IMPLEMENTED: FY 2021-22

INVESTMENT SAVINGS
Sl.No PROJECTS
(Lacs INR) (Lacs INR/annum)

1 Reduction of false Air in PH circuit by 1% In house 68.5

Electrical energy saving through replacement of Cement Mill-1 mill fan

2 with new high efficiency fan. 38 15.96

Electrical energy saving through installation of VFD in cement mill

3 compressor 10 3.98

Electrical energy saving through installation of VFDs in packing plant bag

4 filter fans 641FN1, 642FN1, 643FN1, & 644FN1. 32 13.05

Electrical energy saving through installation of VFDs in bag filter fans

532FN1, 531FN1, 562FN2, & 561FN2 5.8
5 32

Enhancement of RM-1 & RM-2 capacity

6 0 167.6

Coal mill Productivity Enhancement by-

✓ GRR speed from 92% to 100%.

7 0 58.5
✓ Increasing dam ring height by 10 mm,
✓ grinding pressure increased from 150 bar to 159 bar and separator seal
gap adjustment
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 INNOVATIVE PROJECT

Project No 1- Kiln capacity upgradation from 11000 to 11500 TPD

Problem Statement:
• Potential of increase in Kiln production with bottleneck study
• To reduce the Cost of production

Modification:
• To maintain the velocity Profile in Kiln and Pre heater area at
Kiln 11500 TPD , detail study was Conducted along with OEM
• PC venture area was increased by width increase by 400 mm
to maintain velocity 22-24 m/s and avoid excess pressure drop
in the PH system
• TAD duct area also increased by 5 % to maintain same velocity
30-32 m/s

Benefits/Impact:
• Clinker Productivity increase from 11000 to 11500 TPD.
• Clinker Production increase.

Replicable Potential : Yes PC Venturi width

widening by 400
mm on each side

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 INNOVATIVE PROJECT

Project No 2- Heat resistance painting of bottom 4 cyclones

Problem Statement:
• High Radiation losses in Pre Heater system
• Increase in Sp. heat consumption
• High surface temperature of PH bottom cyclones

Modification:
• Paint reduce heat loss due to radiation via reflecting radiation away from the
surface. Due to low emittance value of the coating it absorbs less heat through
radiation. Ultimately, the surface temperature decreases thereby reducing
overall energy loss by radiation and convection thereby reducing heat
consumption of clinkerization process

• Surface temp reduced by 15-20 °C Heat resistance

paint
application
Benefits Achieved:

• SHC Saving- 2.6 Kcal/kg clinker Lacs

Replicable Potential : Yes

Confidential 20
 INNOVATIVE PROJECT

Project No 3- Raw Mill BH transport circuit cyclic operation from continuous operation

Problem Statement:
• Continuous operation of Bag house transport circuit.
• Idle equipment operation
• Increase Power consumption

Modification:

• Logic modified as chain conveyor 1&2 and 5 nos RAL of each chain
operation to be made cyclic with 10 min stop and run for next 10 min

Benefits Achieved:

• Power Saving- ₹ 7.5 Lacs/yr

• Power savings of ~14 kw/h
• Idle equipment operation reduced. 5 RAL of chain 1
stop and 5 RAL of
chain 2 ON

Replicable Potential : Yes

Chain conveyor-1 ON
and CV-2 STOP

Confidential 21
 6a. Utilisation of Renewable Energy sources (Onsite)

Onsite
Total
Generation Share % w.r.t to
Year Source-Solar Installed capacity (in MW) (million overall energy
kWh) consumption

FY 2021-22 Solar 7.7 13.82 4.89

7.7
FY 2022-23 Solar 14.29 4.67

7.7
FY 2023-24 Solar 13.67 4.44

Confidential 22
 GREEN AND CLEAN ENERGY : SOLAR AND WHRS GENERATION

Solar Generation (Lac Unit)

143

138
137

2021-22 2022-23 2023-24

WHRS Generation (Lac Unit)

716

677

636

2021-22 2022-23 2023-24

Confidential 23
 WASTE UTILIZATION AND MANAGEMENT
Shredder

New AFR System of 8 TPH along with 20 TPH shredder installed which will increase TSR rate upto 7 %

AFR Consumption (MT) AF TSR (%)

12642 1.74
1.47
8493
7188
0.78

2021-22 2022-23 2023-24 2021-22 2022-23 2023-24

AFR CONSUMPTION (MT) %TSR RATE

Confidential 24
 GREEN SUPPLY CHAIN MANAGEMENT

Cement Dispatch by Racks (Million

MT)

1.61
1.53

1.25

2021-22 2022-23 2023-24

• BTAP SYSTEM: Fly Ash procured through BTAP rake so as to reduce fly ash bulker freight cost.

• Procurement of coal from Sialgohari mines through trucks and the same trucks are being used for transporting of cement to near by markets so as
to lower freight cost and reduce overall cost of cement.

• Dispatching of cement through Rail mode instead of road ways to save costing as rail freight is comparatively very lower.

• Procurement of CFA through railway racks instead of trucks .

Confidential 25
 GHG INVENTORISATION

Total kgCO2 / Ton of Cement

707

697

688

2021-22 2022-23 2023-24

CO2 EMISSION FIGURES

Way Ahead:

• Internal target of Carbon Reduction <500 Kg

CO2 per Ton cement by 2030

• Dedicated Team is formed and preparing Road

map with action plans for the reduction of
Carbon footprints in the company

Confidential 26
 ENERGY MANAGEMENT SYSTEM

Analysis of Energy performance by Technical Head and Process

Head on daily basis

Review of Energy Performance in coordination meeting on Daily

Basis by Plant Head

Project SIKHAR, Copy Community of Practices and Copy with pride

(COP) meeting Chaired by Project leaders: Monthly

Fuel and AFR TSR Meeting by CMO on fortnightly basis

Energy and cost performance Review Meeting chaired by CMO :

Monthly

Confidential 27
 ENERGY MANAGEMENT COMMITTEE

Plant Head

Technical Head

HOD HOD HOD

Mechanical Production Electrical

Energy Coordinator
(Optimization)

Section Wise Team Leaders

• Prod Section Head- RM & RMH • Prod Section Head- Pyro • Prod Section Head- Cement Mill • WHR Mech engineer

• Mech Section Head- Crusher/ RM & RMH • Mech Section Head- Pyro • Mech Section Head- Cement Mill • WHR E& I engineer

• E & I Section Head- Crusher/ RM & RMH • E & I Section Head- Pyro • E & I Section Head- Cement Mill • Packing Plant E& I engineer
• Utility & WTP Mech Engineer
• Lighting and project E& I engineer
Confidential 28
 IMPLEMENTATION OF INTEGRATED MANAGEMENT SYSTEM

ISO 9001:2015
Certificate Issue Date- 01 Sept 2021
Expiry Date- 31 Aug 2024

ISO 14001:2015
Certificate Issue Date- 01 Sept 2021
Expiry Date- 31 Aug 2024

ISO 45001:2018
Certificate Issue Date- 01 Sept 2021
Expiry Date- 31 Aug 2024

Certificate No.- IND21.2063/IM/U

Confidential 29
 AWARENESS TRAINING and Reward & Reorganization PROGRAM
❑ Awareness sessions and Reward & Recognition to workmen for their commendable work

Confidential 30
 AWARDS & ACCOLADES

1. Awarded by CII (Confederation of Indian Industry) as Energy Efficient unit in 24th National Award for Excellence in Energy Management 2023,
Mr Ashok Kumar (Deputy Director General of Bureau of Energy Efficiency) and Mr R Dinesh (Chairman CII) accredited the prestigious award.

2. RCCPL Maihar won “Gold” Award in cement category for sustainable energy performance and Best energy efficient unit by SEEM national
energy management India on Sep’23 at New delhi.
Confidential 31
 AWARDS & ACCOLADES
1

“Significant Achievement in Environment Management and Significant Achievement in Corporate

Excellence” for CII-ITC Sustainability Awards

Confidential 32
 AWARDS & ACCOLADES
1 2

3 1. Award for energy efficiency unit in 23rd CII National Award for excellence in
energy management in Aug 2022 at New Delhi.

2. Silver Award in cement category for sustainable energy performance and best
energy efficient unit by SEEM national energy management India on Sep’22

3. Award for energy excellence in integrated cement for 2019-22 during 17th
NCB international conference at New Delhi

Confidential 33
 Thank You !!

Confidential 34