Bestway Cement Limited Chakwal

Projects For Environment Improvement

Date: 01-November-2017
Sr # Project Description Project Cost Analyzed / observed results

1-Reduction of 1,185,101 MWh Load in from National grid until today since 2010.
1 Waste Heat Recovery Plant 2580 MPKR
2-Reduction of Ton 782,166 CO2 Emission

AQC Boilers( L-I & L-II) 1-Avg steam generation capacity of AQC boiler (L-I & L-II) increased up to 21 TPH from 17.5 TPH
Generator and Super Heater thus increasing WHRPP power generation by 1.1 MW/hr
2 102 MPKR
Parts Replacement to increase 2- Reduction of power load on National Grid by 26.4 MWH per day.
Heat Transfer efficiency 3- Reduction of 17.4 Tons per day CO2 emission

Up gradation of cooler EP Line

3 #1 130 MPKR 1- Dust emission reduced up to 19 mg/Nm3 as per international standards.

1- Imported material received and erection contract being finalized, comissioning will be done in
4 Upgradation of Cooler EP Line 130 MPKR Planned KSD of May/June -18.
#2 2- Expected results are reduction in dust emission upto 19.0 mg/Nm3 as per Internation
standards.

1- Power saving of 0.59 MW Per Hour

Raw Mill # 1 4000 KW motor
5 replacement with 3400 KW 26.24 MPKR 2-Reduction of Power Load on National Grid by 14.16 MWh per day
3- Reduction of 9.34 Tons per day CO2 emission

Cement Mill #04

Up-Gradation by C-Hope.

Phase I - Installation of air slide

1. Power saving of 0.15 MW per Hours
from Cyclone to discharge
6 31.6 MPKR 2- Reduction of power load on National Grid by 3.6 MWH per day.
bucket elevator.
3- Reduction of 2.3 Ton per day CO2 Emission
Phase II- Modification in
Cyclones, system fan and V
separator.

Cement Mill #02 1. Power saving of 0.15 MW per Hours

7 Up-Gradation (Installation of 1.8 MPKR 2- Reduction of power load on National Grid by 3.6 MWH per day.
Air Slide and Rotary Sluice) 3- Reduction of 2.3 Ton per day CO2 Emission

Cement Mill #03 1. Power saving of 0.15 MW per Hours

8 Up-Gradation (Installation of 1.8 MPKR 2- Reduction of power load on National Grid by 3.6 MWH per day.
Air Slide and Rotary Sluice) 3- Reduction of 2.3 Ton per day CO2 Emission

Cement Mill #01 1. Power saving of 0.15 MW per Hours

9 Up-Gradation (Installation of 1.8 MPKR 2- Reduction of power load on National Grid by 3.6 MWH per day.
Air Slide and Rotary Sluice) 3- Reduction of 2.3 Ton per day CO2 Emission

Packer up gradation / 1-Reduction in dust emissions & Cement wastage

10 replacement for 03 packer with 140 MPKR
Ventometic Packers due to decreased bags burstage

1- Reduction in %age Load variation from ± 30 % up to ± 5 %.

L-I & L-II Pre-Hopper Bin
2- Consistent coal flow during Coal Mill ON & OFF hence reducing the coal consumption and
11 Installation at Coal Dozing 48 MPKR
temperature variation in the PC temperatures.
System (04 Pfisters)
3- Reduction of 6.5 Tons per day CO2 emission

1- Kiln Production increased by 10 TPD.

Modification of Kiln Inlet (Both 2- Fuel conservation as Kiln downtime reduced to Zero from 01 no per month for Kiln Inlet
12 Lines) 10.2 MPKR Cleaning & Boulder formation.

13 ABC Cooler Inlet Modification 36.8 MPKR 1- Reduction in Heat consumption upto 7.5 Kcal/kg clinker (Under comissioning)
by M/s FLS at L-II 2- Reduction of 19.5 Tons per day CO2 Emission
 Sr # Project Description Project Cost Analyzed / observed results

02 Water Filtration Plant at Water filtration plant installed at Hostels and Canteen for Availability of Clean & Healthy
14 2.15 MPKR
Hostels & canteen drinking water for Plant Employees as well as Contractors

Sewerage Water Treatment

15 3.5 MPKR Utilization of treated sewerage water for in house Plantation
Plant

Maintenance Cost Of Dust Controlling Equipments

CRUSHER TO RAW MILL FEED AREA FILTER BAGS REPLACEMENT
Sr# Date Asset Code Job Description Cost (PKR)

Q9ALC 1- 960 Bags , 38 Cages , 2 jacks & 3 SOVS replaced.

1 12-May-17 355,000
Bag filter of Limestone Crusher 3- 10 Disc plates repaired

V2ALC
2 8-Jun-17 1- 128 Bags, 02 Jacks and 12 meter sealing doors replaced. 44,800
Bag filter of clay crusher
2-2 Disc plates repaired.

A2ALC 1- 160 Bags , 15 Cages replaced.

3 8-Jun-17 63,500
Bag filter of feeding silo top 2- 02 Disc & 02 SOVS repaired

B41ALC 1- 32 Bags replaced & 96 Bags cleaned

4 25-Sep-17 11,200
Bag Filter of Raw Mill top 3- 02 Disc Plates, 01 SOV, 01 Jack and 01 Air pipe repaired

2M1ALC 1- 32 Bags replaced & 32 Bags cleaned

5 15-Sep-17 11,200
Bag Filter of Mill no 2 to silo

COAL MILL BAG REPLACEMENT L- I

Sr# Date Asset Code Job Description Cost (PKR)
1- 1792 Bags replaced
K28ALC 2- 30 cages replaced
1 9-Mar-17 2,703,000
Main Bag filter of Coal Mill 3- 04 Disc Plates, 02 SOV, 01 Jack and 01 Air pipe repaired
4- Proper sealing of door done

K27 ALC
2 28-Aug-17 Coal Mill small Bag filter Boiler 1- 49 Bags replaced 17,150
Side

COAL MILL BAG REPLACEMENT L- II

1- 2304 Bags replaced
1 26-Dec-16 K28ALC 2- 130 cages replaced 3,521,000
Main Bag filter of Coal Mill 3- 04 Disc Plates, 02 SOV, 01 Jack and 01 Air pipe repaired
4- Proper sealing of door done

K28ALC 1- 600 bags replaced

2 26-Oct-17 230,000
Main Bag filter of Coal Mill 2- 40 cages replaced

KILIN COOLER AREA FILTER BAGS REPLACEMENT (L-1 & L-II)

Sr# Date Asset Code Job Description Cost (PKR)

B11ALC 1- 128 Bags replaced

12-May-17 Bag Filter of CF Silo Bucket 2- 01 Jack and 01 Air pipe repaired 44,800
1 Elevator L-I 4- Proper sealing of door done

F45ALC 1-192 Bags replaced

2 16-Jun-17 Bag Filter of CF silo Inside L-I 2- 02 Sovs and 01 Air pipe repaired 67,200
3- Proper sealing of door done

H70ALC 1-160 Bags replaced

3 30-May-17 Bag Filter of Clinker Silo Bulk 2- 02 Sovs, 02 Disc Plates, 5 house pipe and 01 Air pipe repaired 56,000
Loading L-I 3- Bag filter dropping chute area maintenance done

1-160 Bags replaced

B1ALC
4 18-Feb-17 Bag filter at CF silo Top L-II 2- 04 Disc Plates repaired 56,000
Sr # Project Description Project Cost Analyzed / observed results

H70ALC 1-160 Bags replaced

5 23-Jun-17 Bag Filter of Clinker Silo Bulk 2- 02 Sovs, 02 Disc Plates, 5 house pipe and 01 Air pipe repaired 56,000
Loading L-II 3- Bag filter dropping chute area maintenance done

RAW MILL ESP MAINTENANCE L-I

Sr# Date Asset Code Job Description Cost (PKR)
Two faulty chamber rectified. EP inspection and maintenance of
1 Jan-17 E20S
Rapping/hammeing and chrona gaps conducted. 22,555

Missing hammers were installed and adjusted (Missing crona wires

2 Feb-17 E20S
were removed). Gap of plates were adjusted for steps.

Four Missing hammers were installed . Three Missing crona wires were
3 Mar-17 E20S removed and two dead chamber activated. Three Gap of plates were 1,164,574
adjusted and fixed by strips. Elevator gear box replaced.

4 Apr-17 E20S During Kiln stopage Two damaged and the two Missing hammers were
removed and four new installed. Two chrona wires were removed. Gap
of two plates were adjusted and fixed by the strips.
5 May-17 E20S Two crona wire were removed. 6 Gaps of plates adjusted.
06 dust collecting plates base bolts replaced. 09 targets of dust
6 Jun-17 E20S collecting plates replaced. 05 broken crona wires removed. 03 rapping 3,958
camp studs adjusted.

01 plate gap adjusted. . 01 insulator replaced. EP internal walkways

7 Jul-17 E20S cleaning conducted. 14,440

RAW MILL ESP MAINTENANCE L-II

1 Jan-17 E20S Hammers and chrona gaps adjustment was conducted. 29,652

Five faulty and three missing hammer were replaced with new one.
2 Feb-17 E20S
Seven Plate gaps were adjusted and fixed with strips.

3 Apr-17 E20S Three damaged and two missing hammers were removed and installed 21,456
back the new hammers. Two chrona wires were removed. Gap of three
cathodic plates were adjusted by strips.Temperature of the kiln EP
controlled between 98 to 102 C during operation

4 May-17 E20S All hammers clamps are tightened. Inspection of rapping & hammering
motors was done. Three faulty crona wires removed.
Inspection of rapping & hammering motors was done. 02 targets
5 Jun-17 E20S
replaced. 03 collecting plates base bolts replaced.
01 plate gap adjusted. 03 rapping camp studs adjusted. 01 insulator
6 Jul-17 E20S replaced. EP internal walkways cleaning conducted. 172,177

COOLER ESP MAINTENANCE L-I

Sr# Date Asset Code Job Description Cost (PKR)
Chrona wire gap adjustment, collecting plate rectification and
1 Jan-17 G52AC
Moisture entring point control was done.

Five Missing hammers were installed and four damaged chrona wire
removed. Two faulty chamber were rectified. Gap for four plates were
2 Mar-17 G52AC adjusted by using strips. Proper sealing of chutes and EP door was 171,634
done. Hard Facing conducted and Drag chain conveyor was installed at
discharge of EP (Removing screw conveyor).

Two dead chambers were activated by removing damaged chrona

Apr-17 G52AC wires. Three Hammers and three cathodic plates were rectified by
3 adjusting gaps.
4 June-17 till July-17 G52AC Old EP was replaced with New EP by M/s ELEX 130 million
COOLER ESP MAINTENANCE L-I
1 Jan-17 G52AC Chrona wire gap adjusted and collecting plate rectified
Five Missing hammers were installed . Two Missing crona wires were
2 Feb-17 G52AC removed and one dead chamber activated. Four Gap of plates were
adjusted and fixed by strips.
 Sr # Project Description Project Cost Analyzed / observed results
On 13.03.17 two faulty chambers were rectified by removing the
damage crona wires.
3 Mar-17 G52AC 98,511
Sealing of chutes done and poor effeciency chambers were retrofied.
Maintenance of Screw conveyor conducted.

Seven damaged and three missing hammers were rectified with new
hammers. Three damaged/hanged crona wires were removed. Two
faulty chambers rectified due to chrona wire hanging. Gap of five
4 Apr-17 G52AC
plates were adjusted by using strips. Proper sealing of chutes were
done. and Drag chain conveyor was installed at discharge of EP
(Removing screw conveyor).

Jun-17 G52AC 03 dust collecting plates targets replaced while 06 cracked joint points
5 of targets repaired.
6 Jul-17 G52AC 03 plates base bolts tightened. 05 crona wires target bolts replaced. 2,367
Maintenance of Screw conveyors.
CEMENT MILL # 1 Main BAG REPLACEMENT
Sr# Date Asset Code Job Description Cost (PKR)
1-100 Bags replaced & 63 Bags cleaned.
1M7ALC 2- 27 cages replaced.
1 Mar-17 249,806
Main Bag filter of cement Mill 2- Sealing of top doors done
4- Maintenance of Technical Gallery Done

CEMENT MILL # 2 Main BAG REPLACEMENT

Sr# Date Asset Code Job Description Cost (PKR)
2M7ALC 1-216 Bags replaced & 39 Bags cleaned.
1 20-Mar-17 Main Bag Filter of cement Mill # 2- Sealing of top doors done 453,600
2 3- Maintenance of Technical Gallery Done

CEMENT MILL # 3 Main BAG REPLACEMENT

1-90 Bags replaced & 63 Bags cleaned.
1M7ALC
2- 15 cages replaced.
1 30-Jun-17 Main Bag filter of cement Mill # 200,430
2- Sealing of top doors done
3
4- Maintenance of Technical Gallery Done

CEMENT MILL # 4 Main BAG REPLACEMENT

1-112 Bags replaced & 63 Bags cleaned.
1M7ALC
2- 23 cages replaced.
1 30-Jul-17 Main Bag filter of cement Mill # 2- Sealing of top doors done 252,726
4
4- Maintenance of Technical Gallery Done

L-I Dooms, Cement Mill Feeding Area & silo top Bag Filters

G1M
1 13-Mar-17 1-384 Bags replaced 134,400
Bag Filter of Clinker Doom Top

2 7-Jan-17 H12ALC 1-160 Bags cleaned and 5 Disc plates maintenance done 56,000
Bag filter of Belt No # 2

H10ALC 1-12 Bags replaced, 148 Bags cleaned and 5 Disc plates maintenance
3 8-Jan-17 4,200
Bag filter of Belt No # 3 done

4 9-Jan-17 H8ALC 1-08 Bags replaced, 152 Bags cleaned, 5 Disc plates maintenance and 2,800
Bag filter of Belt No # 2 sealing work done

H6ALC 1-74 Bags replaced, 86 Bags cleaned, 5 Disc plates maintenance and
5 7-Feb-17 25,900
Bag filter of Belt No # 4 sealing work done
 Sr # Project Description Project Cost Analyzed / observed results

6 10-Jan-17 H4ALC 1-160 Bags cleaned, 5 Disc plates maintenance and sealing work done 56,000
Bag filter of Belt No # 6

7 4-Dec-16 H2ALC 1-160 Bags cleaned & 03 SOVS repaired 56,000

Bag filter of Belt No # 1

X2ALC 1-192 Bags replaced, 10 cages replaced 160 Bags cleaned & 03 SOVS
8 1-Jul-17 67,200
Bag filter of Gypsum Crusher repaired

L3ALC
9 1-Jul-17 1-128 Bags replaced, 10 cages replaced 160 Bags cleaned & 03 SOVS 44,800
Bag filter of feeding Gypsum Silo repaired
Top

L1ALC
10 1-Jul-17 Bag filter of feeding clinker silo 1-192 Bags replaced, 32 cages replaced & 03 disc repaired 67,200
top

L5ALC
11 1-Oct-17 Bag filter of feeding clinker silo 1-128 Bags replaced 44,800
top

1M47ALC
12 25-Apr-17 1-96 Bags replaced & connecting duct maintenance done 33,600
Bag filter of Cement Silo Top - 1

1M47ALC
13 25-Apr-17 1-160 Bags replaced, 01 jack maintenance done 56,000
Bag filter of Cement Silo Top - 2

1M47ALC
14 14-Apr-17 1-96 Bags replaced, 01 disc plate repaired and sealing done 33,600
Bag filter of Cement Silo Top - 3

L-II Dooms, Cement Mill Feeding Area & silo top Bag Filters
H64ALC 1-180 Bags replaced, 12 Bags cleaned, 10 cages replaced, 01 new disc
1 26-Apr-17 68,000
Bag Filter of H61 Belt DE top installed & 03 Disc plates maintenance done
H12ALC
2 9-Jan-17 Bag Filter of Belt No # 5 from 1-160 Bags cleaned & 03 Disc plates maintenance done 56,000
CCR
H10ALC 1-20 Bags replaced , 140 Bags cleaned & 03 Disc plates maintenance
3 12-Jan-17 7,000
Bag filter of Belt No # 3 done
H8ALC 1-141 Bags replaced , 19 Bags cleaned,11 cages replaced & 03 Disc
4 18-Jan-17 Bag filter of Belt No # 2 plates maintenance done 49,350

H6ALC 1-141 Bags replaced , 19 Bags cleaned,10 cages replaced & 03 Disc
5 16-Feb-17 49,350
Bag filter of Belt No # 4 plates maintenance done
H4ALC
6 18-Feb-17 1-160 Bags replaced 56,000
Bag filter of Belt No # 6

7 3-Jan-17 H2ALC 1-96 Bags replaced & 64 Bags cleaned 33,600

Bag filter of Belt No # 6
L3ALC
8 3-Jan-17 1-128 Bags replaced 44,800
Bag filter ofGypsum silo top
L1ALC
9 30-Jun-17 1-192 Bags replaced, 48 cages replaced 67,200
Bag filter of clinker silo top
 Sr # Project Description Project Cost Analyzed / observed results
L5ALC
10 20-May-17 1-128 Bags replaced 44,800
Bag filter of Gypsum silo top
1M47ALC
11 4-Sep-17 1-96 Bags replaced (All Bags Replaced) 33,600
Bag filter of Cement Silo # 1

12 23-Apr-17 1M49ALC 1-160 Bags replaced (All Bags replaced) 56,000

Bag filter of Cement Silo # 2
1M49ALC
13 4-Sep-17 1-96 Bags replaced (All Bags Replaced) 33,600
Bag filter of Cement Silo # 3
2M47ALC
14 4-Sep-17 1-96 Bags replaced (All Bags Replaced) 33,600
Bag filter of Cement Silo # 4
PACKING PLANT BAG FILTERS MAINTENANCE L-I & L-II
Sr# Date Asset Code Job Description Cost (PKR)
N41ALC
1 13-Feb-17 1-128 Bags replaced (All Bags Replaced) 44,800
Bag filter of Cement Silo # 4
N43ALC
2 25-Feb-17 1-128 Bags replaced (All Bags Replaced) 44,800
Bag filter of Cement Silo # 4

N47ALC
3 16-Mar-17 1-128 Bags replaced (All Bags Replaced) 44,800
Bag filter between silo 3 & 4
PIp64ALC
4 16-Jan-17 1-06 Bags replaced 2,100
Bag filter of main bin # 1

P2p64ALC
5 18-Jan-17 1-08 Bags replaced, 120 Bags cleaned 2,800
Bag filter of main bin # 2

P1P12ALC
6 19-Jan-17 1-64 Bags replaced, 256 Bags cleaned 22,400
Bag filter of Packer # 1
p1p15Alc
7 29-Jan-17 1-96 Bags replaced, 224 Bags cleaned 33,600
Bag filter of Packer # 2
p1p18Alc
8 28-Jan-17 1- 320 Bags cleaned 112,000
Bag filter of Packer # 3
P2P12ALC
9 26-Jan-17 1- 96 Bags cleaned, 224 Bags cleaned 33,600
Bag filter of Packer # 4
P2P15ALC
10 26-Jan-17 1- 310 Bags cleaned 108,500
Bag filter of Packer # 5

11 17-Jan-17 P2P18ALC 1- 180 Bags cleaned 63,000

Bag filter of Packer # 6

P2P12ALC
12 17-Mar-17 1-320 Bags replaced (All Bags replaced) 112,000
Bag filter of Packer # 7

P2P15ALC
13 17-Apr-17 1-320 Bags replaced (All Bags replaced) 112,000
Bag filter of Packer # 8

14 27-Apr-17 P2P18ALC 1-320 Bags replaced (All Bags replaced) 112,000

Bag filter of Packer # 9

15 27-Apr-17 P2P12ALC 1-320 Bags replaced (All Bags replaced) 112,000

Bag filter of Packer # 10

P2P12ALC
16 15-May-17 1-320 Bags replaced (All Bags replaced) 112,000
Bag filter of Packer # 11

17 15-May-17 P2P18ALC 1-320 Bags replaced (All Bags replaced) 112,000

Bag filter of Packer # 12

TOTAL COST(PKR) 13,507,204

 4118400 37765000
331200 42331000
172800 48585000
76800 51440000
54000 702020000
54000 84870000
4,807,200 97680000
87610000
4607130 32800000
200,070 1185101000
1185101