Cement, Energy and Environment

Challenges Faced with work details Innova ons are not easy as they require a lot of dedica on, hard work, team spirit and right direc on, however every innova on has to go through challenges. To lower down the consump on of energy in illumina on firstly the tradi onal lights were replaced with CFL lamps but when LED lights which were found with be er illumina on, cost effec ve and many such features already described above lead to this innova on for the plant. (i) Retrofi ng of FTL 36 Wa with 18W LED rod - One challenge was to replace the 36W Fluorescent tubes with around same wa age LED lights but they were found to be very costly, however a er measuring the Lux level of 18W LED it was obvious that they can be the one to one replacement of 36W lights and also found to be cost effec ve but it creates so much amount of E- wastage so we decided to use the exis ng light fixtures and remove the FTL rod, copper choke & starter and retrofit this with 18Wa LED retrofit rod without using external services.. Further we stopped to purchase the new spares of FTL type material and use that removed as a spare for our colony area. Work Details (i) We have retrofi ed approx. 400 nos FTL lights with 302 No. LED lights with annual saving of Rs. 4.5 Lac/Annum & Payback period was 2.5 months which results in approx. saving of 59000 Kwh/Year. (ii) Retrofi ng of 2*2 roof mounted type surface panel fi ngs having FTL 4*14 Wa with 4*8W LED rod - Another challenge was minimisa on of maintenance cost because these type of fi ngs are installed in our offices, CCR and all I/O & VFD rooms in which we faced the problem of high failure rate of electronic chokes as well as lamps so to overcome this problem a er much research and discussion with vendor, we arranged tailor made LED rod of 8W in place of 14 Wa to retrofit the exis ng fi ngs in same fixture by removing the FTL lamps & electronic high frequency choke and to reduce the E-waste genera on and found no sacrifice in Lux level then it was decided to replace the 4*14W FTL lamps with 4*8W LED rods. We have retrofi ed approx. 275 no of fi ngs which had 1100no 14W FTL lamps with 1100 No. 8Wa LED lights with annual saving of Rs. 2.8 Lac/Annum & Payback period was 9.5 months which results in approx. saving of 24090 Kwh. (iii) Retrofi ng of well glass 2*18 Wa CFL fi ngs with 18W LED retrofit Kit- Replacement of all conven onal lights Retrofi ng of 2X2 Panel having 4*14W FTL lamps with 4*8W LED 91