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1. Our Uniqueness ONLY CEMENT PLANT IN THE WORLD MANUFACTURING 16 VARIETIES OF CEMENT. OPERATING WITH 8 MANAGEMENT SYSTEMS. First in India to produce High Strength Special Cement for Airstrips & Railway Sleepers , since 1976. First in India to produce Oil Well Cement ( as per API Spec.) , s ince 1985 Kudangulam Nuclear Power Plant Cement Supply . New Product DIG (Dalmia Infra Green) Patent obtained. Used for development of our Chennai & Cochin Airports. Our Dalmiapuram AFR TSR % in FY20-21 is 18.5 % ( Max Monthly 26% ) . Indian Avg., is @ 4%.

2. System Installed in Pre-processing unit Equipment Make & Model Design Pre-processing storage shed - 2100 m2 [ L : 50 m * W: 42 m ] Chain conveyor RUD India 40 TPH Imported shredder SIDSA [ XLC 4500 ] 25 TPH Indigenous shredder Alfa- therm 15 TPH Screen ECOSTAR Hexact 7000 25 TPH Belt conveyor-1 KEE 40 TPH Belt conveyor-2 KEE 30 TPH Belt conveyor-3 KEE 30 TPH Belt conveyor-4 KEE 30 TPH Belt conveyor-5 KEE 30 TPH 1.Storage Shed 3. Eco star screen 2.Imported shredder machine 4. < 80mm size collected in tipper

3. CHAIN CONVEYOR BC 1 BC 5 BC 4 BC 3 MAGNETIC SEPERATOR ECOSTAR SCREEN IMPORTED SHREDDER TO YARD BC 2 ALFA- therm SHREDDER FEED BELT CONVEYOR Pre-processing circuit-Flow sheet

4. System Installed in Co-processing unit Equipment Make & Model Design Co-processing storage shed 1000 m2 [ L :50 m * W:20 m ] Extractor cum weigh feeder ATS 25 TPH Belt conveyors-1 Masyc 20 TPH Belt conveyors-2 Masyc 20 TPH Belt conveyors-3 Masyc 20 TPH Belt conveyors-4 Masyc 20 TPH Apron conveyor Sanghavi 20 TPH Double flap ATS 25 TPH Shredder-1 Idea Holding 15 TPH Shredder-2 Idea Holding 15 TPH 1.Storage Shed 2.ATS extractor 3.Transportation conveyor 4.ATS double flap

5. EXCAVATOR BC 1 To Yard ATS EXTRACTOR BC 2 BC 3 BC 4 Apron Conveyor Weigh Feeder Double Flap MANUAL DIVERTOR TO PC OLD Weigh Feeder Co-processing circuit -Flow sheet

6. Challenges: ATS extractor design capacity is 25 TPH but we were unable to increase above 19 TPH due to usage of low bulk density material [< 0.1 T/M3] Action Taken: Calibrator portion height increased by 200 mm As per design, gap between extractor to Calibrator was 250 mm. After modification, gap increased up to 450 mm. Results: 24 TPH - actual flow rate achieved by keeping the calibrator position @ 350mm Changes made after installation in ATS Extractor

7. Challenges: ATS weigh feeder calibration issue – Provision not available to take out the material for conducting drop test Action Taken: In-house designed, manual diverter with chute arrangement made to take out the material from system Results: Once in a month - drop test is being carried-out. Changes made after installation in Transportation system

8. Challenges: Transportation belt conveyor capacity constraint [20 TPH] Action Taken: Belt conveyor BC-2, 3 & 4 – Head pulley diameter increased from 400 mm to 600 mm [ linear speed increased from 1 m/s to 1.5 m/s] Results: System capacity enhanced and operated up to 24 TPH Changes made after installation in Tranportation conveyor

9. Challenges: Material is flying and continuous spillage across the full length of Green fuel transport circuit. Action Taken: Skirting [500 mm height] provided on both sides of transportation conveyor across the length [ 310 M ] Old ESP sheets used as deck plate throughout the transportation belt conveyor to avoid material accumulation Results: Material spillage & accumulation eliminated Changes made after installation in Tranportation conveyor

10. Challenges: Feed pipe jamming issue due to castable / Refractory failure - usage of high silica RDF material. Action Taken: Existing bend portion replaced with - Wear & temperature resistant Arco plate without refractories. Results: Jamming issue eliminated. Changes made after installation in Feed pipe

11. Challenges: Imported shredder machine output less while using low bulk density material i.e.,Multi layer plastics, Footwear waste. Action Taken: Online shredder machines, shredo make relocated outside of Co-processing shed & Alfa- therm make kept near to imported shredder Shredder machines installed along with feeding conveyor (VFD drive), permanent magnet arrangement & discharge conveyor. Results: Consuming the entire availability of low bulk density material Changes made after installation shredder machine

12. Challenges: M/s SIDSA shredder blade worn out is high in short period of operation, reducing the life of blades and output of shredder Action Taken: Arco plate welded over the shredder blade instead of hard facing Results: Wear rate is less than 3 to 5mm against the earlier worn-out of 10 to 15mm (within 10 days period) Changes made after installation in Imported shredder

13. Cutting Mill Bomb calorimeter Make & Model : IKA C2000 basic GCV determination of green fuel After GCV testing , bomb will be washed and residue is extracted for chloride and Sulphur testing. Make & Model : In-smart system shredding equipment for Green fuel sampl ing Input size of Green fuel to the cutting machine is < 100mm and moisture content <15% Output size of Green fuel is <20mm Moisture above 15% is being dried then it will be feed to cutting mill Green fuel Testing Equipments Installed

14. Auto Titrator Electrode is provided for testing of Moisture in liquid & solid Green fuel and both should be soluble in Methanol Chloride, CaO, MgO and Fe2O3 will be estimated by respective electrodes with EDTA back titration. Muffle Furnace is used to estimate the Ash content and Volatile matter of liquid , semi liquid and solid green fuel at controlled temparature. Muffle Furnace Green fuel Testing Equipments Installed

15. HOT AIR OVEN Oven is used test the Inherent and surface moisture of liquid and solid AFR VISCOMETER D etermination of viscosity of liquid AFR Measure viscosity at constant room temperature. It is used to test Specific gravity of the Liquid AFR HYDRO METER Green fuel Testing Equipments Installed

16. SAMPLING & TESTING OF GREEN FUELS: Minimum 3 Kg of representative s ample is collected from truck /Unloading/Stacking point. Sample preparation : Size of the sample is reduced to <20 mm by cutting mill. Sample quantity is reduced to 500g by coning & quartering From the above Sample, take the 100gms (A) in a steel tray and keep it in hot air oven at temp. 108±2° C. Record the readings until get the concurrant reading. Cool and Weigh (B) . Calculation as below : % Oven dry Moisture(X) = (A-B) x 100 100 The above oven dried sample is pulverized in cutting mill to pass through 10mm sieve completely and mixed thoroughly Procedure followed for Sampling and analysis

17. ASH: weigh 0.5 g -1.0 gram of sample in pre weighed crucible and keep it in muffle furnace at 850 +/-50 degree. After 45 min, Crucible to be taken out from furnace then it is to be cooled and weighed Again crucible to be kept on furnace for 15 min. This is to be continued to get the concurrent reading & error should be <0.1% Ash % = Initial weight-final weight*100/weight of sample GCV: Take approximately 1 gram material and perform the GCV test in isothermal Bomb calorimeter. O2 pressure should be maintained 25-30 kg/cm2. CHLORIDE: After G CV determination, wash the bomb and collect the washings in 250 ml beaker. To the above solution add 2ml of K2CrO4 indicator Titrate against 0.1 N AgNO3 till colour changes from yellow to brick red % Chloride = Burette reading X N of AgN O 3 X 35.45 X 100 Weight of Sample X 1000 Procedure followed for Sampling and analysis

18. Description FY’19-20 [YTD] Line-1 TSR% 4.4 Line-2 TSR% 11.3 Savings through Green fuel ( Rs.Cr ) 7.81 Savings through GM ( Rs.Cr ) 1.84 Overall Savings ( Rs.Cr ) 9.65 Green fuel Journey

19. Description FY’20-21 [YTD] Line-1 TSR% 8.5 Line-2 TSR% 18.5 Savings through Green fuel ( Rs.Cr ) 16.05 Savings through GM ( Rs.Cr ) 0.74 Overall Savings ( Rs.Cr ) 16.79 Green fuel Journey

20. Description FY’21-22 [YTD] Line-1 TSR% 10.7 Line-2 TSR% 19 Savings through Green fuel ( Rs.Cr ) 15.8 Savings through GM ( Rs.Cr ) 0.42 Overall Savings ( Rs.Cr ) 16.26 Green fuel Journey

21. Green fuel Journey

22. Road map for achieving 35% TSR – Material Availabilty Fuel type Cost Generation wet Moisture Generation Dry Landed cost [Wet Basis] Freight cost [Wet Basis] Net Revenue MT/Month % MT/Month Rs /MT Rs /MT Lakhs/month Solid Negative cost 15091 27 11033 -491 15 -72 Zero cost 3875 40 2334 Positive cost 12500 34 8257 426 141 71 Liquid Negative cost 640 51 312 -2000 -13 Zero cost 75 20 60 Positive cost Overall [Solid + Liquid] 32181 32 21996 -104 62 -14 Considering only ( - ve cost) 15731 28 11345 -552 15 -85

23. Consumption plan & Savings for 35% TSR Line-2 Green fuel consumption plan for 35% TSR S.No Description Units Footwear waste  Plastic  waste (paper mill) MLP Plastics RDF Oil soaked cotton Resin waste Rubber elastic Paint sludge Grinding sludge Rubber foam High ash solid Solid waste Liquid Total / AVG A Clinker Production MT/Day 4500 4500 4500 4500 4500 4500 4500 4500 4500 4500 4500 4500 4500 4500 B Kiln Operation Days 29 29 29 29 29 29 29 29 29 29 29 29 29 29 C AFR Consumption on Wet Basis MT/month 63 2265 1000 9250 5 30 21 300 10 209 1615 640 15408 D Moisture % 3 55 10 30 16 10 60 25 20 10 18 20 60 32 E AFR Consumption on Dry Basis MT/month 61 1019 900 6475 4 27 5 225 8 188 1292 256 8717 F AFR Calorific Value - NCV Kcal/Kg 5050 5450 5817 3100 3500 4100 6100 3500 2250 5100 3150 4100 1850 4459 G % of AFR on TSR % 0.3 5.0 4.7 18.1 0.0 0.1 0.0 0.7 0.0 0.9 0.0 4.8 0.4 35.0 H AFR Consumption on Wet Basis MT/day 2 78 34 319 1 0.7 10 7 56 22 531 I AFR Consumption on Dry Basis MT/day 2 35 31 223 1 8 6 45 9 361 J Ash content in receipt % 7 7 6 34 14 7 4 20 45 7 35 30 2 26 K Pet coke/coal cost Rs/Mkcal 2050 2050 2050 2050 2050 2050 2050 2050 2050 2050 2050 2050 2050 2050 L AFR cost Rs/Mkcal -267 322 22 218 49 -630 -229 -250 -1031 -284 137 -413 -2432 59 M Savings Rs.Lacs 7 96 106 368 3 1 18 1 22 130 21 774 N Revenue through Negative cost Rs.Lacs -2 -1 -5 -16 -1 -6 -6 -32 -13 -82

24. Calculation for preparation of Green Fuels Recipe DPM -Line 2   SHC 850 Kcal/ kg Kiln R.Hrs 24   Clinker 4500 TPD   Clinker 188 TPH   Raw Meal to clinker 1.52 Ratio   Sl No Name Wet qnty TPD TPH Cl, % H2O, % Ash, % C.V TSR (%) Individual Cl, gms/t clk 1 Raw Meal Chlorine   285 0.050         760 2 Footwear waste  2 0.1 0.9 3 7 5050 0.28% 4 3 Plastic  waste  (paper mill) 78 3.3 0.75 55 7 5450 5.01% 130 4 MLP Plastics 34 1.4 0.95 10 6 5817 4.72% 73 5 RDF 319 13.3 0.73 30 34 3100 18.10% 517 6 Oil soaked cotton 0.0 0.9 16 14 3500 0.01% 7 Resin waste 1 0.0 1.12 10 7 4100 0.10% 3 8 Rubber elastic 1 0.0 0.6 60 4 6100 0.05% 1 9 Paint sludge 10 0.4 1.8 25 20 3500 0.71% 41 10 Grinding sludge 0.0 0.8 20 45 2250 0.02% 1 11 Rubber foam 7 0.3 0.8 10 7 5100 0.86% 13 12 High ash solid 0.0 1.2 18 35 3150 0.00% 13 Solid waste 56 2.3 2 20 30 4100 4.78% 248 14 Liquid 22 0.9 6 60 2 1850 0.43% 294 Green Fuel MIX Total/Average 531 21 1.2 32 27.0 4459 35% 1325 Total Chlorine input (Green Fuels + Raw Meal) 2085 Chloride Input to the sysytem for 35% TSR

25. Modifications planned for achieving 35% TSR Pre-calciner height increase for increasing retention time from 3.5 s to 7.8 s. Installation of chlorine By-pass system. Pre-heater fan to 8,40,000 m3/Hr and RABH fan upgradation to 12,67,000 m3/Hr [No margin in existing fan] Additional module & RABH upgradation to 11,15,000 m3/Hr. Existing duct diameter increase from Down comer to Bag house outlet.

26. Ash Content High Ash content in Green fuel Clinker strength reduction due to Clinker LSF and C3S fluctuation High ash content will affect the mines life High ash content leading to higher wear in shredder blades We need GF proper blending / pile formation Calorific Value Calorific value variation in Green fuel PC temperature fluctuation while feeding high CV material like Footwear, MLP & Rubber elastic waste along with low CV RDF. Temperature fluctuation leading to increase in F.Cao We need GF proper blending with High CV material Moisture Content High Moisture in Green fuel - High moisture content will result in flame cooling, higher gas volume and CO formation - We need drying system or need to have penalties for higher Moisture. Challenges in Quality, Productivity , KPI’s of clinker & quality of cement

27. Chloride Content High Chloride content in Green fuel Increase in Hot meal and clinker chlorine - Coating Build-up formation in kiln & Inlet riser - Chloride input to the system leading t o excess recirculation in pyro system . - High chloride circulation incorporates with clinker dynamics like C3S ,C2S and C3A. - Which in turn impact on cement hydraulic properties like Strength and setting time. - Chlorine bypass system will solve both the issues of circulation of chloride as well as reaction in kiln . Challenges in Quality, Productivity , KPI’s of clinker & quality of cement Foreign material Foreign material contamination - Segregation & Disposal of Contaminations like stone, glass bottles, ferrous / Non-ferrous material is too difficult - Segregation at source & proper installation of equipment's like magnetic detector

28. Heavy Metals Heavy Metal content in Green fuel - Heavy metals and minor elements present in Green Fuel is affecting the formation of C3S in Kiln and affecting quality of clinker - When the feeding of Spent wash, Grinding /paint sludge, observed that complete disturbance of kiln with high CO formation and free lime, chloride in clinker Alkali Content High Alkali content in Green fuel - Excess alkali input from Green fuels having adverse effect on alkali Sulphur ratio . - High amount of Na and K leads to formation of Orthorhombic instead of cubic C3A . - C3A cubic modification responsible for higher early strength compare with C3A orthorhombic modification. - The ratio of C3ACcubic)/C3A( ortho ) influences the water demand for the cement. - C3A( ortho ) demands more water . Challenges in Quality, Productivity , KPI’s of clinker & quality of cement

29. Tom Lewis Curve – For Line-2 [Oct’21]

30. Green fuel Preparation and handling cost Material Consumption quantity on wet (MT/Month) Consumption quantity on dry (MT/Month) Moisture % NCV (Kcal/Kg) TSR % Landed cost on Dry basis (Rs/MT) * Handling cost on Dry basis (Rs/MT) Diesel cost on Dry basis (Rs/MT) Total cost on dry ( Rs / MKcal ) Paper mill 2556 1150 55 5450 6.4 222 589 380 219 RDF 4557 3190 30 3100 10.1 -143 379 244 155 Multi layer plastic 100 90 10 5817 0.5 -456 294 190 5 cotton waste 83 70 16 3500 0.2 315 204 148 FRP/ Resin 22 20 10 4860 0.1 294 190 100 SCF 111 100 10 5817 0.6 300 294 190 135 Grinding sludge 8 6 20 2250 0.0 -6383 331 214 -2595 Rubber elastic 10 10 2 6100 0.1 -2041 270 174 -262 Total 7447 4636 38 3813 18.0 -58 426 275 163 *Payment to contractor based on lump sum basis

31. Scope for further reduction of handling cost Shredder material transportation from Co-processing to Pre-processing through Belt conveyors instead of Tippers. (Investment cost for 250 M long belt conveyor is 6 Cr) Grab crane arrangement @ pre-processing unit to avoid pay loader operation. (Investment cost for Grab crane 60 L)

32. Best Practices FIFO rules is being followed. Camera provided in critical point i.e., Storage shed,weighfeeder & Pre-calciner feeding point (8 Locations across the circuit). Spark arrestor is mandatory for all vehicle which is entering into Alternate fuel area. Truck tarpaulin removal station with fall back arrestor & safety harness. Wheel choke usage for AFR trucks @ parking and during un-loading. Special type nose mask / Hand gloves provided for Green fuel handling manpower. Fire fighting equipments - smoke / beam detector, water monitor & overhead fire hydrant lines with sprinkler arrangements in both Pre-processing & Co-processing circuit. ATS extractor hopper load and Green fuel feed rate LED display provided in site. Payment to contractor is converted from time rate to tonnage basis

33. Achievements Highest ever AFR consumption in YTD basis in FY’21-18.5% Highest month average TSR – 26.6 % [Jun’21 MTD] Highest day average TSR – 32 % [ Achieved more than 30 % for 12 days] Savings through Green fuel, 2 Cr per month – Since Dec’20. Green fuel feeding system designed capacity is 20 TPH . Through innovative ideas we achieved 24 TPH Team DPM Won the CII Waste Management Award as Best Case studies – [There were several applicants, out of which 53 Participants got shortlisted for Presentation from which,  27 Participants were selected as Best ones]. In Line-1, Month average TSR achieved above 10 % - Since Feb’21 [ with In-house system ]  

34. Support required from Management Additional shed – for separate storage of receipt material as well as for making pile formation Chlorine By-pass system - Chloride input from green fuel leading t he excess recirculation in pyro system . PC height increase – To avoid CO formation Replication of Line-2 Green fuel handling system for Line-1 Equipment available only for finger print analysis of Goods Receipts Following equipment's are not available to test complete analysis of Green Fuel, -ICP, AAS, CHNS, Flash point analyzer, Gas chromatography, TGA [Presently analysis is being carried-out once in 3 months @ third party lab] Impact of minor elements in pyro process is affecting the quality and productivity of clinker

35. Thank You !!