Recommendations

Among the major recommendations are:

• Setting up an apex body to give thrust to various energy conservation programs
• Creation of energy consumption data bank to help formulate energy conservation policies and strategies.
• Development of energy consumption norms from industry, which are specific to individual unique characteristic of plants.
• Evolving of energy information exchange system among various functionaries.
• Introduction of training programs/ refresher courses, setting up of in plant kiln and mill simulators and well conceived HRD program.

• Sponsoring of special R&D projects on energy conservation sulted to Indian conditions.
• Development of engineering capabilities vertical roller mills, roller presses, liner metallurgy, micro processor based control systems, waste fuel handling technologies etc.

• Effecting fuel substitution through use of Natural gas and waste fuels like waste rubber / tyres, municipal wastes etc. upto 25% substitution of fuel may be possible through use of waste fuels.
• Switching over to LSHS (low sulphur heavy stock) based captive power plants in place of DG sets.
• Leaving the balance wet process plants to market forces.
• Among the plant specific measures proposed are:

• Setting up of energy conservation cell
• Conducting energy audit study.
• Setting up of house keeping and operational control standards
• Deter house keeping and controls through proper loading of motors, stopping idle running, PF and Load factor improvement, preventive maintenance and condition monitoring of equipments use of captive power for kiln running and prevention of false air etc.

• Optimization through raw mix optimization, primary air control, ball mill optimization, material fineness control and use of grinding aids, mineralizers, slurry thinners and clinker quality
• Manufacture of blended cements like OPC and PSC.

• Technology upgradation improved mill internals and diaphragms, closed circuit grinding with high efficiency separators, kiln replacements, computerized process controls, increased preheater stages, use of low pressure drop cyclones etc.
  Use of energy saving devices like variable frequency drives, slip power recovery systems, fluid couplings, soft starts, high efficiency fans, flat belts, helical gears etc. the pay back periods are generally less than 2 years for these devices.
  Use of high pressure roller presses for clinker grinding and vertical roller mills for RM grinding for new projects are substantial expansions.

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