Fuel:

• Due to frequent variations in the quality of coal, inadequate supplies and transportation bottlenecks go for substitute fuels like, lignite, rice-husk, petroleum coke etc.
• Use alternate fuels such as natural gas and pet coke.
• Use industrial and agricultural combustible wastes as supplementary fuel.

Power Supply:

• For uninterrupted power supply have your own captive power plant.

Operational Measures:

• Use improved insulating bricks/blocks in kiln and preheaters.
• Rationalise compressed air utilization.
• Use energy efficient equipment
  • High efficiency fans
  • Improved Ball Mill internals
• Carry out Heat and gas balance
• Recover waste heat of preheater and use for cogeneration of power.
• Increase utilization of waste products generated by other industries(substitution like use of fly ash and petroleum coke, the by products of thermal power and refinery industry respectively)
• Install fly ash handling & feeding system.
• Reduce energy consumption in manufacturing at each stage & monitor energy performance of the plant.
• Prevent idle running of equipment by providing interlooking arrangement and operating with PLC system. Generate daily report on idle running of equipment, also in terms of monetary losses.
• Eliminate ingress of false air into the kiln, cooler, coal mill, cement mill and raw mill circuits by plugging leaks.
• Optimise raw mix
• Use low ash coal
• Adopt preventive maintenance approach
• Repair steam leaks
• Reinforce heat insulation
• Establish efficient management information system for identifying various important parameters for efficient operation of the equipment and taking timely remedial measures.
• Regularly monitor and calibrate flow meters.
• Minimise waste by installing efficient dust collector equipment.
• Modify the equipment to recover heat from the preheater and cooler in the process of cement making and effective use of industrial waste.
• Use exhaust gas from kiln to dry raw material and coal etc.
• Carry out energy audits.
• Before improving a process, activities of good housekeeping and equipment improvement should be applied to promote energy conservation.
• Avoid extra fine grinding of product to prevent wastage of power since it does not enhance long term strength.

• Reduce compressed air pressure from 8 Kg/Cm2 to 7.0 Kg/Cm2 where ever possible to conserve energy, when required pressure at usage point is 6.0 Kg/Cm2
• Stop use of compressed air for floor cleaning.
• Check for compressed air leakage and arrest it.
• Switch off one compressor if requirement can be met by balance operating compressors.

DG Sets Operation and Maintenance

• Improve SFC of the DG sets
• DG sets flue gas temperature is more than 4500C install waste heat recovery boilers on DG sets to generate additional power & pre heat fuel oil
• Improve specific electricity generation by loading in excess of 60% and upto 80%

• Replace underloaded / overloaded motors with proper size motors. Replace the motors with energy efficiency motors.
• Prevent idle operation of the motors

• If possible switch off one transformer running under loaded in parallel. Maintain all transformers at a loading of 70 to 80 % of rated capacity to minimize loss component (no load losses).
• Try to have separate transformer for lighting where voltage can be kept low.

• Improve power factor by regular checking of current of all the capacitors and their timely replacement.
• Install Automatic power factor correction device to have power factor of 0.99 to 1.00

• Replace 40W Tube light by slim 28W Tube light and electromagnetic choke with electronic choke.
• Replace 400 Watt Mercury Vapour lamps with 250 Watt sodium vapour lamps or 250 W metal hallide lamps.
• Replace 250 Watt Mercury Vapour lamps with 150 Watt sodium vapour lamps or 150 W metal hallide lamps.
• Provide more transparent sheet instead of asbestos sheets to use natural light.
• Install energy saver for reducing the lighting load.
• Prevent unnecessary lighting of the electric lamps.
• Rationalize lighting in identified areas i.e remove excess lighting in identified areas. Also relocate lighting, if necessary.