1. DSCL ENERGY SERVICES COMPANY LTD 2 nd Floor, Kanchenjunga, 18 Barakhambha Road, New Delhi 110001 Tel. 0091 11 23316801 Fax 0091 11 23319062 Draft Presentation 23-09-05 Energy Cost Reduction Study at

2. Contents Accepted Energy cost reduction measures for implementation Status Way forward Accepted measures but to be decided after trial Energy cost reduction measures on ‘Hold’ Way forward

3. Summary of savings Most Likely Savings Possible Savings Investment (Rs. Lacs) Pay bac k kW Kg /hr CM/ day Rs. Lacs kW Kg /hr CM/ day Rs. Lacs Most Likely Possi ble Mon ths I Measures of Less than 6 months Payback Sub Total 2076910108222871012135413-4 II Measures of Greater than 6 months payback Sub Total 135267661151352886612558607-8 TOTAL342336762233573757624693100 III Accepted Project but to be decided after trials Sub Total ---15--- 222 IV Project on hold Sub Total 2044-513044-5840418 Total3623807628936241977319135129 Long Term Projects Total---418---43470080022 Grand Total 3623807670736241977753835929

4. Measures of Less than 6 months Payback List of Energy Saving Measures Most Likely Savings Possible Savings Investment (Rs. Lacs) Payb ack kW Kg /hr CM/ day Rs. Lacs kW Kg /hr CM/ day Rs. Lacs Most Likely Poss ible Mont hs 1. Installation of higher Efficient bigger BFW Pump 93--31.593--31.5552 2. Utilization of Steam instead of using Electrical Heaters in Power House for F.O. pre-heating ---22--- 10 5 3. Installation of screen to avoid re- crushing of fines before crusher and to reduce unburnts. 5.243-10.75.261-14.8556 4. DG Cooling Tower Pump Efficiency Improvement 14--4.814--4.8225 5. High Efficiency Low Head Pump for DM Water supply 11.4--3.8511.4--3.85226 6. Chemtech Cooling Tower pump Efficiency Improvement 11--3.2811--3.281.5 5 7. Floorwise segregation of cooling water 48--16.363--256126 8. Return water from top 3 segments of Fermenters directly to CT instead of sump 24--8 --8223 Accepted Energy Conservation Measures:

5. Measures of Less than 6 months Payback List of Energy Saving Measures Most Likely Savings Possible Savings Investment (Rs. Lacs) Payb ack kW Kg /hr CM/ day Rs. Lacs kW Kg /hr CM/ day Rs. Lacs Most Likely Poss ible Mont hs 9. Chiller condensate recovery --101.1--101.1Nil Imme diate 10. Arresting steam Leakages -26-6.6-26-6.6112 SUB- TOTAL 2076910108222871012135413-4 Accepted Energy Conservation Measures:

6. Measures of Greater than 6 months Payback List of Energy Saving Measures Most Likely Savings Possible Savings Investment (Rs. Lacs) Payb ack kW Kg /hr CM/ day Rs. Lacs kW Kg /hr CM/ day Rs. Lacs Most Likely Poss ible Mont hs 1. Efficiency improvement of 03 area CT pumps 15--518--6337 2. Segregation of HP and LP Lines for Raw Water supply from sump 9--39--34416 3. Bigger high efficient raw Water supply pumps to RO Plant 14.7--4.517.7--6348 4. Installation of smaller low head RO pump for starch preparation 4--1.58--2.7239 5. Low head pump for soft water tank 7.5--2.58.5--3238 6. Main CT Fans - Power Consumption Optimization 19--5.319--5.33.5 8 7. DG and Chemtech CT Fans - Power consumption Optimization 4--1.354-- 1.4 12 8. Chilled water distribution system 14--4.7514--4.75338 9. Flash steam recovery from the flash tank in the Dextrose Plant + saving of RO Water -2056.25-2056.255510 Accepted Energy Conservation Measures:

7. Measures of Greater than 6 months Payback List of Energy Saving Measures Most Likely Savings Possible Savings Investment (Rs. Lacs) Payb ack kW Kg /hr CM/ day Rs. Lacs kW Kg /hr CM/ day Rs. Lacs Most Likely Poss ible Mont hs 10. Condensate Recovery of Mycelium Broth PHE -22.4378.2-22.4378.2669 11. Cooling Water return from seal pot and de-composition vessel directly to Fermenter sump 9.73--3.289.73--3.28227 12. Usage of RO Rejects for the Backwashing of MGF, ACF, Sidestream Filter and Plant Cleaning ---2.5--- 5524 13. Line condensate Recovery -18242.6-18242.6229 14. Lighting Energy conservation 2.55--0.862.55--0.861.2 17 15. WHRB Steam Utilization 36207-6336207-6915 3 SUB-TOTAL135267661151352886612558607-8 Accepted Energy Conservation Measures:

8. On HOLD List of Energy Saving Measures Most Likely Savings Possible Savings Investment (Rs. Lacs) Payb ack kW Kg /hr CM/ day Rs. Lacs kW Kg /hr CM/ day Rs. Lacs Most Likely Poss ible Mont hs 1. ETP Final Discharge Pumps: Gravity flow or Installation of high efficiency pump 20--330--10.3224-8 2. Condensate & Flash Heat Recovery during sterilization of PF and IF ---17.3--- 15.4 11 3. Crystallizer and Evaporators condensate Utilization in the De- aerator instead of using in Ion- Exchange columns -44-11-44-11889 4. Usage of Raw Water instead of Soft water in the Dextrose Plant CT ---0.41--- Nil Imme diate 5. Usage of Raw Water instead of Soft water in the 03 Area CT ---1.02--- Nil Imme diate 6. Wheeling of Power to Grid ---18--- 15 10 SUB-TOTAL2044-513044-5840418 Projects on hold

9. To be decided after trials List of Energy Saving Measures Most Likely Savings Possible Savings Investment (Rs. Lacs) Payb ack kW Kg /hr CM/ day Rs. Lacs kW Kg /hr CM/ day Rs. Lacs Most Likely Poss ible Mont hs 1. Zero BOD stream to be taken directly to Clarifier ---15.47--- 227 Projects to be decided after trials

10. Long Term Projects List of Energy Saving Measures Most Likely Savings Possible Savings Investment (Rs. Lacs) Payb ack kW Kg /hr CM/ day Rs. Lacs kW Kg /hr CM/ day Rs. Lacs Most Likely Poss ible Mont hs 1. Co-Generation Opportunities: Option 1: Running of CFB at 28 TPH Load and install a Back pressure STG and Utilization of 7.5 kg/cm2 steam for the Jet cooker + Installation of suitable Electrical Compressor ---418--- 700 20 Option 2: Running of CFB at 32 TPH and install a Extraction cum condensing Turbine and fulfill 10kg/cm2 requirement thro' PRDS + Installation of suitable Electrical compressor ---434--- 800 22 Long term projects – Cogeneration option

11. Project-1: Installation of high efficient high capacity Boiler Feed Water Pump for CFB OBSERVATION Combined efficiency of 2 BFW pumps: 33% OPPORTUNITY Replacing these 2 pumps with a single high capacity high efficient pump. BENEFITS Power savings – 93 KW Annual savings – Rs. 31.5 lacs Investment – Rs. 5 Lacs (Including motor) Payback: : 2 months ISSUES: Hydraulic testing of the boilers SOLUTION Use the existing pumps during the hydraulic tests

12. Project-1: Installation of high efficient high capacity Boiler Feed Water Pump for CFB STATUS Agreed, Pump specifications frozen and Enquiry floated SPECIFICATIONS PROCESS OWNER New pump Design specs Flow (cum/hr)Head (m)Motor (KW) 45570110

13. CFB-BFWP: Existing System Design Flow (cum/hr)Head (m)Power (KW) 27.964090 Power:86.7 KW Design Eff: 55% Actual eff:33% Power:87.1 KW Design Eff: 55% Actual eff:33% Two pumps with a total capacity of 55.8 Cum/hr is operated. Design Efficiency of each pump: 55% Combined system efficiency:33% Opportunity for shifting to a single high capacity high efficient pump Total flow: 33.8 cum/hr Discharge pressure: 56 kg/cm2 Suction pressure: 1.1 kg/cm2

14. CFB-BFWP: Installation of efficient, bigger Pump New pump Design specs Flow (cum/hr)Head (m)Motor (KW) 45570110 Total flow: 33.8 cum/hr Discharge pressure: 56 kg/cm2 Suction pressure: 1.1 kg/cm2 Total flow: 33.8 cum/hr Discharge pressure: 56 kg/cm2 Suction pressure: 1.1 kg/cm2 New bigger sized pump Power:80 KW Design Eff: 70% The combined efficiency of both the pumps is 33%s Replacing these 2 pumps with a single high capacity high efficient pump. For hydraulic testing the old pump can be used. Power savings – 93 KW Annual savings – Rs. 31.5 lacs Investment – Rs. 5 Lacs (Including motor) Payback: : 2 months

15. Project-2: Usage of Steam heaters instead of Electrical Heaters in power house for FO preheating OBSERVATION 184 kW electrical heaters are used for FO pre-heating at the power house OPPORTUNITY Electrical heaters may be replaced with steam heaters BENEFITS Savings in energy cost: 22 Lac Rs. Per annum Investment: Rs 10 Lacs (Investment to be revalidated taking into account automation sensors and other controls) Payback:5 monthsISSUES: Investment to be revalidated

16. STATUS Agreed and already in touch with vendors for freezing the investment PROCESS OWNER DSCL ES Role Would revalidate the investment required and the cost benefit analysis Project-2: Usage of Steam heaters instead of Electrical Heaters in power house for FO preheating

17. Usage of Steam instead of Electrical Heaters in power house In the HFO Separator 72 kW Heaters (one standby) are used presently for heating of F.O. Booster Heaters are also of 72 kW(one standby) rating each. One Electrical Lube Oil Heater of 40 kW is also in operation.

18. Total Steam Requirement: 4.5 to 4.8 TPD Saving Possible: 22 Lac Rs. Per annum Investment: Rs 10 Lacs (Investment to be revalidated taking into account automation sensors and other controls) Payback:5 months Total Steam Requirement: 4.5 to 4.8 TPD Saving Possible: 22 Lac Rs. Per annum Investment: Rs 10 Lacs (Investment to be revalidated taking into account automation sensors and other controls) Payback:5 months Usage of Steam instead of Electrical Heaters in power house Actual consumption:45.2 KW A.C:30.1 KW Lube oil heater: A.C: 20.1 KW

19. Project-3: Installation of screen before crusher to reduce unburnts OBSERVATION 30 to 50% of coal fed into the crusher is –6 mm size and fines. More than 50% of coal fed into the boiler is less than –2 mm. Average unburnts in ash is 15% OPPORTUNITY Reduction of fines in coal by installing a screen before the crusher and reduction of unburnts in ash BENEFITS Coal savings – 43 kg/hr to 61 Kg/Hr Annual savings – Rs. 10.2 to 14.3 lacs Savings due to crusher load reduction: 5.2 KW Annual savings:0.48 Lacs Total savings: Rs. 10.7 to 14.8 Lacs Investment – Rs. 5 Lacs Payback: 5.6 month

20. ISSUES:NilSTATUS Agreed and already quotation for the screen has been obtained PROCESS OWNER Project-3: Installation of screen before crusher to reduce unburnts

21. Installation of screen before crusher to reduce unburnts 10*10 cm 8*8 mm Requirement: (-)6 mm to +2mm As per samples taken on 19 th & 20 th 25.9% 25.4% 53.3% 37.2% 44.1% 32% Rejects 5.1% 33.4% 5 mm sieve

22. Installation of screen before crusher to reduce unburnts 10*10 cm 8*8 mm Unburnts increase because of fines. Provision of screens at the Inlet to hammer mills. As per samples taken on 14 h & 20 th 43.03% 22.48% 63.2% Rejects 0.85% 2 mm sieve Requirement: (-)6 mm to +2mm

23. Installation of screen before crusher to reduce unburnts Proposed scheme 6*6 mm screen Possibility of maintaining the fines from 5 to 10% in imported coal

24. Installation of screen before crusher to reduce unburnts Sample size: 1.5 kg Average fines (-2mm) in raw coal : 18.8% Average fines (-2mm) to coal bunker: 60% - 2 mm sieve coal increases from 18.8 units to 60 units Avg unburnts in ash: 15.47% 25% of the total fines generated at crusher Limit fines Generation at crusher by installation of screen at inlet to the crusher. This Will help reduce the unburnts in ash and reduce power consumption at the crusher Maintaining unburnts from 5 to 8% Coal savings – 43 kg/hr to 61 Kg/Hr Annual savings – Rs. 10.2 to 14.3 lacs Savings due to crusher load reduction: 5.2 KW Annual savings:0.48 Lacs Total savings: Rs. 10.7 to 14.8 Lacs Investment – Rs. 5 Lacs Payback: 5.6 month 25% of the total fines generated at crusher Limit fines Generation at crusher by installation of screen at inlet to the crusher. This Will help reduce the unburnts in ash and reduce power consumption at the crusher Maintaining unburnts from 5 to 8% Coal savings – 43 kg/hr to 61 Kg/Hr Annual savings – Rs. 10.2 to 14.3 lacs Savings due to crusher load reduction: 5.2 KW Annual savings:0.48 Lacs Total savings: Rs. 10.7 to 14.8 Lacs Investment – Rs. 5 Lacs Payback: 5.6 month Unburnt % variation