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Integrity Commitment Passion Seamlessness Speed

ULTRATECH CEMENT LIMITED

Andhra Pradesh Cement Works, Tadipatri

Water Excellence

We Preserve We ConserveWe Prevent

Confederation of Indian Industry GreenCo Certified Company


Unit Vision & Mission

Vision 2020

To be a Model Cement Plant by 2020 with a clear focus on Safety, Environment,

Quality, Cost, Productivity, Delivery, Employee & Societal Satisfaction.

Mission 2020To deliver superior value to our customers, shareholders, employees and society at

large with Systems & Team based, Safe & Environment friendly work culture through

Innovation, Skill up-gradation, Conservation and Technological up-gradation

adhering to Aditya Birla Group Values.


Water Policy

Reducing water

consumption with the use

of latest technologies

in process and

procurement

Water Policy states the units commitment towards

Maximum utilization of

recycled water.

Maximum recharging of ground water

Maintaining water quality

as per standards for

processes and domestic

demands

Spread awareness

among employees and nearby

communities for effective utilization of

water

Compliance of all

applicable legislation related to water use.


Water Roadmap

Water Line From Generation Source Distribution line


ZLD for CPP, STPs for Plant, Mines and ColonyCompliance and public disclosure

Process Effluent Management

• Cement Plant does not generate any liquid

waste.

• The waste water generated from TPP is

treated in ETP and used in dust suppression.

• ZERO WATER DISCHARGE is maintained

throughout the plant, mines and colony.

Domestic Waste water generated

from Colony treated in Sewage

Water Treatment Plant and the

water is used for greenbelt

development.

Sewage Management Water Cess returns of Cement Plant

Public display system at various entrance gates and theatre to create

awareness


Water Consumption in APCW total (M3)

992066965294

937870

874508

800000

850000

900000

950000

1000000

1050000

2014-15 2015-16 2016-17 2017-18Wat

er C

on

sum

pti

on

(M3)

Year

Water consumption (M3)

697.75

517.63443.14

692.77

442.43

876.5

0

200

400

600

800

1000

2012 2013 2014 2015 2016 2017

Rainfall in mm

0.260.23

0.29 0.27

0

0.1

0.2

0.3

0.4

2016-17 2017-18

M3

/To

n

Specific Water Consumption

Grand Total To Clinker

Grand Total To Cement

Area-wise Specific water consumption

Area FY 2016-17 FY 2017-18

Plant (m3/ton of cement)0.136 m3/ton

0.094 m3/ton

Thermal Power Plant (m3/MW power generation)

0.247 m3/MW 0.236 m3/MW

Mines (m3/ton of limestone) 0.0147 m3/ton 0.0096 m3/ton

0.1360.094

0.247 0.236

0.0147 0.00960

0.1

0.2

0.3

2016-17 2017-18

Area-wise Specific Water Consumption

Plant (m3/ton of cement) Thermal Power Plant (m3/MW power generation) Mines (m3/ton of limestone)


% of recycled water used in the process & other utilities

S. No. Water Usage Unit

FY 2017-18

TOTAL April May June July Aug Sep Oct Nov Dec Jan Feb Mar

1 Total water withdrawal m3 85937 68032 58480 78545 73785 61736 66241 68986 69202 69809 72368 99847 872968

2 Total water recycled or reused m3 16856 13368 15942 16944 12848 8258 17632 18234 20738 19354 13160 18422 123184

3Recycled / Reused water as apercentage of total waterwithdrawal

% 19.614 19.65 27.261 21.57217.413 13.376 26.618 26.431 29.96727.724 18.185 18.45 14.11

872968

12318414.11

0

150000

300000

450000

600000

750000

900000

1050000

m3 m3 %

Total water withdrawal Total water recycled or reused Recycled / Reused water as a percentage of totalwater withdrawal


% of fresh water used in cement manufacturing & CPP

S. No. Water Usage UnitFY 2017-18

TOTAL April May June July Aug Sep Oct Nov Dec Jan Feb Mar

1 Total water withdrawal m3 85937 68032 58480 78545 73785 61736 66241 68986 69202 69809 72368 99847 872968

2 Total water recycled or reused m3 16856 13368 15942 16944 12848 8258 17632 18234 20738 19354 13160 18422 123184

3Recycled / Reused water as apercentage of total waterwithdrawal

% 19.614 19.65 27.261 21.572 17.413 13.376 26.618 26.431 29.967 27.724 18.185 18.45 14.11094107

4Fresh water as a percentage oftotal water withdrawal

% 80.38 80.35 72.74 78.43 82.58 86.62 73.38 73.57 70.03 72.28 81.81 81.55 85.89

872968

123184

14.11% 85.89%0

150000

300000

450000

600000

750000

900000

1050000

Total water withdrawal Total water recycled or reused Recycled / Reused water as a percentage oftotal water withdrawal

Fresh water as a percentage of total waterwithdrawal

M3


Water harvested quantity/Water positive initiatives

Implementation of RWH Structures

Check Dam

Mines Pit

RWH Structure

Infiltration Wells

Pond development works at Real-fab workshop

Mines Pit Check-dam

Infiltration Wells Pond Development


Site detailsArea in Sq m

(A)Runoff coefficient

(B)Rain fall in mm

(C)

PotentialA*B*C

(X)

Actual rain water harvested (M3)

(Y )

Mines 8445818 0.5 600 2533745 1075000

Township 566562 0.5 600 169968 91553

Plant 1092655 0.5 600 327796 91553


Rainwater Harvesting potential captured for different areas

2008 2012 2015 2018

Andhra Pradesh Cement Works - Mines

Capacity: 3.00 Lac M3 Capacity: 12.00 Lac M3 Capacity: 14.00 Lac M3Capacity: 7.00 Lac M3


Water harvested quantity/ Water positive initiatives

Check Dam

Previous Capacity - 56005 M3

Removed –(2015) - 13885 M3

Removed – (2016) – 21449 M3

Present Capacity : 91339 M3

Mines PitStorage CapacityMines Pit 1 - 12.50 L. M3

Mines Pit 2 - 1.50 L. M3

Existing Water QuantityMines Pit 1 - 10.50 L. M3

Mines Pit 2 - 0.25 L. M3

RWH Structure

Storage Capacity - 13900 M3

Catchment Area - 20 AcersLocation - Near Bore well Captured during - 10000 M3 rainy season

Infiltration Wells Nos. – 10

Interconnected Wells

Pond development works at Realfabworkshop

Capacity – 3000M3



Sr. no Description Taken in FY15-16 Status

1 Bore wells recharging pits 10 Completed

2 Lake type bore wells recharging (50X50m) 1 Completed

3 Gallery system (silt prevention) at check dams 2 Completed

4 Ponds in open area 2 Completed

5 Check dam capacity enhanced by desilting of the bed 21,449 m3 Completed

Rainwater harvesting completed

❑ Enhanced the storage capacity of the check dam water quantity from

56,005m3 to 91339m3.

❑ Due to the above initiative, surrounding bore wells (>22 no's) yield was

improved to good extent in and out of the fence. (Approx. 3.3 L. m3 water

storage increased)

❑ Piezometer reading of the bore well are checked up and found improvement

in the ground water table by the recharging pits and check dam.

❑ Capacity of pond / desilting / bund formation done outside boundary to

approx. 8.46 L m3


Water Consumption Reduction Initiatives

SectionConsumption

2016-17Action Plan Period

Expected Water Consumption

Responsibility Status

Raw Mills 604 m3/Day

Water consumption reductionachieved by process optimizationdone in the raw mill water spraysystem and using waste Coca-Colainstead of water in the raw mill waterspray system.

Short Term 368 m3/DayMr Sharad

TripathiCompleted

Coal Mills 195 m3/DayCoal mill operation optimised with airflow due to which 4 m3/day reduced.

Short Term 191 m3/Day Mr Sridhar Completed

Cement Mills

60 m3/Day

Optimization of clinker extractionsystem in auto operation to maintainuniform clinker temperature forreducing water consumption ingrinding operation.

Short Term 50 m3/DayMr Narendra Singh Thakur

Completed

109 m3/DayOptimisation of recirculating air flowto mill to reduce water spray.

Short Term 91 m3/DayMr Narendra Singh Thakur

Completed


Water Consumption Reduction Initiatives

Sr. No Focus Area of Water Management Responsibility Target DateExpected savings in

Lac. m3/annum

1Roof top rain water harvesting system in colony commonareas (2 Guest houses & School etc.,)

Kiran Kumar Completed Achieved : 0.015

2 Mines pit water pump leakages arresting Amar Mishra Completed Achieved : 0.001

3RO - Water line replaced with corroded GI pipe line to PVC,due to which flushing to be done every time to removethe corrosive particles in the pipe.

Kiran Kumar Completed Achieved : 0.022

4 Feasibility of use of less water consumption grass / lawn Kiran Kumar Completed

5Feasibility of use of shower arrangement for horticulturewatering purpose rather than direct hose feeding

Kiran Kumar Completed

6 Expired soft drink liquids to spray instead of water P B Singh Completed Achieved : 0.066

7Optimization of water distribution in Township and workercolony

Kiran Kumar Completed


Water Consumption Reduction Initiatives – Long Term

Sr. No Focus Area for Water Management Responsibility Target DateExpected savings in

Lac m3/annum

1 Modification of Line-2 cooler from Pyro step cooler to modified cooler (IKN)Function Head

(Technical)2018-19 1.0

2 Study & optimization of water consumption in VRMs P B Singh Completed

3 Slit removal from Bugga check dam RBB/ADK Completed

4 Explore the possibility of developing water pond near Gate No-8 RBB/ADK Completed Achieved : 0.03

5 Optimisation water consumption in horticulture Kiran Kumar Completed Achieved : 0.024

6 Roof top water harvesting of coal yard shed Kiran Kumar 30.11.2018 work under progress

7 Expansion of mines Phase-1 sump up to 1.0 Lac m3 RBB Completed Achieved : 1.0

8 Phase - II sump expansion @ 0.51 Lac m3 RBB Completed Achieved : 0.51

9 Check dam I & II expansion @ proposed from 69900 m3 to 85000 m3 RBB/ADK Completed Achieved : 0.15

10 Trench developed to divert surface water to water pond near real-fab workshop RBB/ADK Completed Achieved : 0.15

11 Drilling of infiltration bore wells at check dam I @ depth 10 m RBB/ADK CompletedTo increase rain waterutilisation-Intangible

12Diversion of rain water from surface roads into mines sump by formation of drains /trenches

RBB/ADK Completed Achieved : 0.05


Fresh water consumption reduction initiatives 2017-18 - Plant

Sr. No. Initiative Benefits

1Rerouting of underground water pipe lines to identify the water leakages immediately

Identify leakage and reduce losses.

2Reducing of re-circulation of water quantity to avoid the evaporation losses

Reduction in consumption of water

3Installation of flow meters in long & underground pipe lines

Easy identification of leakages to avoid the wastage of water.

4Water pipe line laid for operation of cement mills and raw mills from STP

STP water can be used for plant operation and fresh water can be reduced.

5Covered the cooling with GI sheets to avoid the algae formation and to avoid the water evaporation

Reduce evaporation losses and algae formation

6Collection of township drain water to STP to be increasedand same to be used for gardening

Fresh water consumption will be reduced

Water positive initiatives


Fresh water consumption reduction initiatives 2017-18 - TPP


1MGF and SSF backwash was done , when the differential pressure is more than0.35 Kg/cm2.

4000 m3 /annum

2By observing the clarity of Back wash water, Filter Back washing timereduced

650 m3 /annum Saving in filter wash water

3 Recycling of sludge pit water in to ETP PIT. 1460 m3/annum

4 Reuse of Boiler blow down water directly in to cooling tower. 12800 m3/annum

5CEP Bypass line connected to cooling tower, during shut down drained water shallbe utilized in cooling water.

2 Boilers X 4 Times X 150 M3 =1200 m3 of d. m. water or 2040 m3 of Raw water

6Drawing of Fresh water avoided by effective Utilization of Final waste water fordust Suppression in Coal yard, Ash handling system, Bed ash cooling, Wagontippler dust Suppression, horticulture purpose, ACC and Fire hydrant purpose.

14600 m3/annum

7Ensuring the function of float valves in the township & plant premises as perschedule to avoid overflow of water.

Reduction in overflow losses(200m3/annum)

8Cooling water COC maintained 8 to 9 against 5 to 6 cycles to avoid Blow downwater wastage

Reduction in blow down water consumption ( 7300 m3/annum)



Fresh water consumption reduction initiatives 2017-18 - TPP


9 Continuous blow down of boiler ensured against intermittent boiler blow down 20 X 365 = 7240 m3/annum

10 Connection of SWAS sample water directly into the cooling tower basin. 36 m3 X 365 = 13140 m3/annum

11Installation of auto-side stream filter in Phase-2 cooling tower to minimize the coolingwater wastage.

8200 m3 /annum

12Installation of strong acid cation and strong base anion to increase the output and tominimize the wastage water.

6100 m3 /annum

13 Final waste water pump discharge connected to fire hydrant line to save fresh waterReduction in fresh water consumption(600 m3/annum)

14

As per original design the Boiler b/d line from Boiler drum is connected to CBD Vesseland outlet is connected to IBD Vessel. Since the temperature is 1000 C, a quenchingwater lining is connected to the IBD Vessel to bring down water temperature from1000 C to approx..450 C .To get rid of the huge water quenching (approximately 320 m3)CBD vessel outlet line connected to cooling water basin directly.

400 x 365x.35 = 94900 m3 /annum

By the Above Best Practices, We achieved : 17.23 Lac m3/AnnumFrom all the above initiatives: we have achieved : 20.88 Lac m3/Annum



Effluent & STP quality

Effluent Treatment Plant & Sewage Treatment Plant Water Balance

Cooling Tower Blowdown (40 KLD)

Boiler Blowdown (30 KLD)

Waste Water Plant Blowdown (110 KLD)

ETP

100 KLD To WTP

80 KLD To Green Belt Development & Dust Suppression

Colony Sewage(405 KLD)

Plant Sewage(50 KLD)

TPP Sewage (25 KLD)

STP

10 KLD losses due to evaporation

460 KLD To Green Belt Development & Dust Suppression

10 KLD Evaporation During Sludge Drying Beds



Financial Year Treated Water Output from STP (m3/day) Water Utilisation horticulture (m3/day)

2013-14 276 276

2014-15 324 324

2015-16 351 351

2016-17 256 256

2017-18 261 261

STP water is using in Horticulture and provision was made for making water spray in Raw mill and Cement mills VRMs.

Sr. No Parameters UNIT Apr-17 May-17 Jun-17 Jul-17 Aug-17 Sep-17 Oct-17 Nov-17 Dec-17 Jan-18 Feb-18 Mar-18 Average Limits

1 pH - 7.72 7.17 7.21 7.48 7.08 7.43 7.9 7.18 7.64 7 7.21 7.37 7.37 5.5 – 9.0

2Total dissolved solids @180ºC

mg/L 1825 860 610 2100 904 1758 1016 1214 1876 1662 1520 1706 1528.44 Max 2100

3Total suspended solids@105ºC

mg/L 4 2 <4 48 4 4 4 10 4 <1.0 3 7 10.50 Max 200

4Biochemical Oxygen demand (3 days at 27°C)

mg/L <2 <2 <2 12.5 2 6.4 <4 9 13 5 6 20.2 9.26 Max 100

5 Chemical Oxygen Demand mg/L 4 <4 60 13 12 24 16 39.5 35 17 20 56.2 25.86 Max 250

6 Oil & Grease mg/L <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 Max 10

EFFLUENT TREATMENT PLANT ANALYSIS REPORTS



SEWAGE TREATMENT PLANT QUALITY (17-18)

Sr.No

ParametersUNIT

Apr-17

May-17

Jun-17

Jul-17

Aug-17

Sep-17

Oct-17

Nov-17

Dec-17

Jan-18

Feb-18

Mar-18

Average

Limits as per APPCB

1 pH - 7.79 6.91 7.21 6.96 7.16 7.31 7.6 7.29 7.58 6.91 7.67 7.02 7.28 5.5 – 9.0

2Total dissolved solids @180ºC

mg/L

830 882 610 656112

0840 724

1012

724 642 600 786785.5

0< 2100

3Total suspended solids@105ºC

mg/L

28 13 <4 1 9 5 3 4 11 17 31 18 12.73 < 200

4

Biochemical Oxygen demand (3 days at 27”C)

mg/L

6 6 <2 60 5 28 26 12 18 12 20 12 18.64 < 100

5Chemical Oxygen Demand

mg/L

48 24 60 128 18 52 51 47.4 43 32 72 36.1 50.96 < 250

6 Oil & Greasemg/

L<1.0 <1 <1.0 <1.0 <1.0 <1.0 <1.0 <1 <1.0 <1.0 <1.0 <1.0 <1.0 < 10


Amount of water given to communities for drinking, domestic use & irrigation

Augmentation of Groundwater Beyond the fence

The following Data have been included

❖ Rain water harvesting Pits

❖ Check Dam construction

❖ Check dam desilting work

❖ Desilting work

❖ Breached Pond Construction

❖ Water Tank Renovation

❖ Excavation of Sajjaladennai River

Water Given to Communities

Initiative Name of the village Capacity (M3) No of beneficiaries

Rain Water Harvesting Venkatampalli - 886

Check Dam Construction Ayyavaripalli 26,910 1565

Check Dam Desilting Bhogasamudram 13455 554

Breached Pond flow diversion / extension Venkatampalli 720000 2122

Water Tank Renovation Ayyavaripalli 54700 2451

Rain Water Harvesting Bhogasamudram - 3043

Excavation work for rain water Sajjaladennai - 3590

Total No. of Beneficiaries 14211

Amount of Water given to Communities for domestic Purpose 815086 M3


1. Rain water harvesting pit and water flow at Venkatampalli

Amount of water given to communities for drinking, domestic use & irrigation

2. Check Dam Construction at Ayyavaripalli

3. Check Dam Desilting Work at Bhogasamudram

4. Breached Pond flow diversion / extension at Venkatampalli

5. Water Tank Renovation at Ayyavaripalli

6. Rain water harvesting pit at Bhogasamudram panchayat

7. Water tankers are provided fornearby villages during summer


Replicability of the idea implemented within the sector/outside the sector

Water Positive Initiative – ICRISAT Project

Purpose : To improve water table in nearby villages to eliminate the water scarcity.

Scope : Nearby villages and surrounding factory premises.

What is ICRISAT: ICRISAT works closely with a variety of companies and foundations to help achieve their CSR objectives. This ranges from rural development and women empowerment to becoming water and carbon neutral.

Incoming years, due to water scarcity in nearby villages and plant premises during summer season. The appropriate and desired level of water table need to be maintained.

For this purpose, ICRISAT will do the study on the water accumulation and catchment areas in nearby villages and plant surrounding. The project will be implemented based on the study to improve the water table.

Status : Procurement request sent to corporate.

Study Cost : Rs. 05 Lakhs Project Cost : Rs. 07 Crores


Recognition and Awards

Received 9th National Award for Excellence in Water Management at Jaipur and Received National Water Management Award – 2005 & 2012


Best Practices Implemented

Sr. No. Description Of Best Activity Benefits

1 Using of EVOLOC in mines pits To reduce the water evaporation losses by 35 %

2Installed fresh air damper at Cooler ESP inlet to reduce water consumption in cooler

Water saving by 16 m3/hr

3Circulation of complete water balance sheet to colony, plant & TPP to monitor & control same circulated to all concern departments.

To review and take control measures to avoid more water consumption

4 Installation of flow meter in all most at required locations Leakage and loss can be identified and water supply

5Water pipe line laid for operation of cement mills and raw mills from STP

STP water can be used for plant operation and fresh water can be reduced.

6Water line filters pressure difference more than 0.5 bar immediate cleaning should be done

To avoid the plant stoppages

7 Bore wells piezo meter readings taking once in a month To monitor the ground water level



Sr. No. Description Of Best Activity Benefits

8

Installation of Strong acid cation and strong base anion to increase the output and to minimize the wastage water. (50m3/reg. x 122 nos = 6100 m3/annum)

6100 m3/annum

9MGF and SSF backwash was done, when the differential pressure is more than 0.35 Kg/cm2 4000 m3 /annum

10Installation of Auto side stream filter in phase 2 cooling tower to minimize the cooling water blow down wastage

8200 m3/annum

11Continuous blow down of boiler ensured against intermittent boiler blow down

20 X 365 = 7240 m3/annum



Using of EVOLOC in Mines Pits.

Resulted 35% saving in Water Evaporation in Mines pits; (March 12, 2015 to April 18, 2015 # Saving 19796 M3 )

DateWater Level in

Evaloc PAN(mm)

Water Level in Normal Water PAN

(mm)

Difference(mm)

Sump AreaSq. Mtr

WaterEvaparationwith Evaloc(Cubic Mtr)

Normal Water Evaporation(Cubic Mtr)

Water Saving(Cubic Mtr)

12.03.2015 155 155 0 126900 0 0 0

13.03.2015 151 145 6 126900 507.6 1269 761.4

14.03.2015 143 130 13 126900 1015.2 1903.5 888.3

17.03.2015 120 98 22 126900 2918.7 4060.8 1142.1

17.03.2015 160 160 0 126900 0 0 0

18.03.2015 155 147 8 126900 634.5 1649.7 1015.2

19.03.2015 141 119 22 126900 1776.6 3553.2 1776.6

23.03.2015 115 82 33 126900 3299.4 4695.3 1395.9

24.03.2015 104 70 34 126900 1395.9 1522.8 126.9

25.03.2015 160 160 0 126900 0 0 0

26.03.2015 154 145 9 126900 761.4 1903.5 1142.1

27.03.2015 150 132 18 126900 507.6 1649.7 1142.1

02.04.2015 70 10 60 126900 10152 15481.8 5329.8

02.04.2015 160 160 0 126900 0 0 0

04.04.2015 146 132 14 126900 1776.6 3553.2 1776.6

10.04.2015 75 60 15 126900 9009.9 9136.8 126.9

11.04.2015 70 45 25 126900 634.5 1903.5 1269

14.04.2015 60 30 30 126900 1269 1903.5 634.5

15.04.2015 160 160 0 126900 0 0 0

16.04.2015 155 150 5 126900 634.5 1269 634.5

18.04.2015 145 135 10 126900 1269 1903.5 634.5

Total 37562.4 57358.8 19796.4



Sr. No.

Best Practice Pictures

1 Installation of Auto side stream filter in phase 2 cooling tower to minimize the cooling water blow down wastage

2 Installation of Strong acid cation and strong base anion to increase the output and to minimize the wastage water. (50 m3 /reg. x 122 nos. = 6100 m3 /annum)

Sr. No.


3 Effluent Treatment Plant (ETP) and FinalEffluent Handling & Disposal - DM Plantregeneration waste water is neutralized inthe neutralization pit and thentransferred to Effluent Pit. Other effluentssuch as MGF backwash, UF rejectbackwash, RO reject, cooling tower blowdown and side stream filter backwash arerouted to Effluent Pit and mixed up withneutralized DM plant waste water. Thefinal mixed up effluent is further treatedin the Effluent Treatment plant ofcapacity 24 m3/hr.

4 Major Drawing of 21362 m3 avoided -Drawing of Fresh water avoided byeffective Utilization of Final waste waterfor dust Suppression in Coal yard, Ashhandling system, Bed ash cooling, Wagontippler dust Suppression, horticulturepurpose, ACC bottom filling Pond andFire hydrant purpose.



Sr. No. Best Practice Pictures

6 Water sprinkle and Drip Irrigation.

Sr. No. Best Practice Pictures

7 Recycling of sludge pitwater in ETP PIT throughpump placement and linemodification. Savings of1460 M3/annum.

8 CBD vessel outlet lineconnected to coolingwater basin directly.Savings of 94900M3/day

Sr. No.


9 Final waste water pumpdischarge connected toFire hydrant line to savefresh water.(Reductionin fresh waterconsumption

10 Overflow of drinkingand domestic wateravoided byproviding Float valves



The school staff and students along with theresidents of the UTCL went on a “Save WaterCampaign” on 22nd April 2016 all around thecolony by elevating placards, banners andproclaimed slogans on the issue.

Unit Head addressing the campaign team

Water conservation awareness Programme atnear by village Thummalapenta School

Awareness created by displaying the boards in thetownship


Process Initiatives

Sr. No Initiative Savings Pictures

1Installed fresh air damper at Cooler ESP inlet

to reduce water consumption in cooler

16 m3/hr. 2

Raw mix optimised for improvement of Clinker

nodulation which in turn reduced water

consumption in preheater to remove coating

build ups

3

In Raw mill, feed material discharge chute

modified to rectangle shape instead of arch

shape. Due to improper material distribution

of material between rollers, high water

consumed for stable bed formation in mill

18 to 14 m3/hr.

Before After


Process Initiatives


4 Water nozzle modification in cement mills 0.36 m3/hr

5

Instead of wasting UT pump return water, a

hose arranged to utilise this return water to

main line - Line-1 Pre heater 1st floor UT

pump return water saving

4 - 5 m3/hr


Process Initiatives


6

To reduce water consumption in cement ball

mills, inlet damper of mill kept 100% open

for Controlling of mill outlet Temperature

1.5 m3/hr

7

In Raw mill, water consumption reduced by

replacing fresh water with expired FMCG

liquid material (BBD – Best Before the Date)

for stable bed formation in mill.

0.46 m3/hr

Before After


"It is the small things that make for perfection and perfection is not a small thing."

- Shri. Aditya Vikram Birla

Our journey of improvement continues……….

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