EARN PROGRAM /

Sr. EARN
Saving OBJECTIVE
No. PILLAR
TARGET

S.NO

Reduce power consumption by 1480\ units/day by

1
ENERGY

Provided air booster in CMM to

doing the following activites Sr No -1,2,3,4

1 reduce Compressure setting 2
by 6.0 Kg to 5.0 Kg

S.NO
1480units/day 1
on 22 LPDC
on-50 ton/D of Reduce energy consumption
ENERGY

by installing IFC controller for 2

2 dis.( 98
units/ton Air Line to redude fluctation of
saving on net line . 3
dispach)
4

Reduction of energy S.NO

consumption in LPDC holding 1
furnace by Reducing heater
ENERGY

capacity by 80 Kw to 36 Kw, 2
3
and as well as lining pattern
from glass wool lining to
Hiseal Board in 04 LPDC 3
machine .

EARN PROGRAM /
S.NO
1
Providing shut off valve in All
ENERGY

C/S machine to prevent air

4 Energy
leakages during machine ideal 2
condation .

S.NO
1
Reduce furnace oil
ENERGY

F.O consumption by modifiction 2

5 consumption is done in furnace lining , by 80 Ltrs/ton
85 ltrs/ton reducing cell temperature of
furnace. 3

Reductioion in polloution leval S.NO

Prevention
Polloution

by reducing flash in casting 1

Polloution
7 due to that we have lost metal 2
prevention
17.5 Ton/Month remelting that
FO requiremt is 1700 lts .
3
 EARN PROGRAM /
S.NO
Prevention
Polloution
Improve lux level inside plant 1
Polloution
8 by providing transperent sheet
prevention
inside factory .
2
LEGAL COMPLIANCE

S.NO
1
All Legal REGULAR MONITORING OF 2
9 requirements ALL APPLICABLE LEGAL 3
identified. REQUIREMENTS 4
5
6
7

12.5
2.4
 EARN PROGRAM / PROJECTS FOR YEAR 2011-12
TIME BOUND PROGRAM

RESPONSIBILI
ACTIVITY TY June July August September October
Procurement of air booster for suitable rating . Mr. Ashwani

Installation of booster pump on CMM and trial . Mr. Ashwani

Monitoring of energy consumption Mr. Ashwani

after booster installation .
RESPONSIBILI
ACTIVITY TY June July August September October
Monitoiring of fluctuation on present leval and cons- Mr. Ashwani
mption .
Procurement of suitable rating controller and air Mr. Ashwani
reciver tank & material of pipe line .
Pipe line modification work as per new layout of IFC Mr. Ashwani

Trial of IFC at different different setting for plant re - Mr. Ashwani

quirement .
RESPONSIBILI
ACTIVITY TY June July August September October
Procurement of lining material for 04 LPDC Mr. Ashwani
holdingfurnace as per the heater rating .
Reliing of LPDC holding furnace as per new lining Mr. Ashwani
pattern .
Monitoring of consumption after replacement of coil Mr. Ashwani
rating & relining of holding furnace .

EARN PROGRAM / PROJECTS FOR YEAR 2011-12

RESPONSIBILI
ACTIVITY TY June July August September October
Procurement of Sht off valve of suitable rating . Mr. Anu Kumar

Installation of valve on all machine . Mr. R.K Singh

Trail of machine after valve installation . Mr. Anu Kumar

RESPONSIBILI
ACTIVITY TY June July August September October
Material procurement for new lining Mr. Pramod

Fabrication work as per new design . Mr. RK Singh

Relining of furnace as per new pattern . Mr. Pramod

Trial of furnace after installation and oil consumpt- Mr. Pramod

ion afetr modification .
RESPONSIBILI
ACTIVITY
TY June July August September October
Standrized pressure setting for all LPDC M/c . Mr. Anu Kumar
Identification of all problemtic dies . Mr. Vinod

Correction work as per problem identified . Mr. Vinod

 EARN PROGRAM / PROJECTS FOR YEAR 2011-12
RESPONSIBILI
ACTIVITY TY June July August September October
Material procurement . Mr. Rajeev

Fabricaton and sheet fixing work as per layout . Mr. Rajeev

RESPONSIBILI
ACTIVITY TY June July August September October
Review of all legal requirements Mr.Arvind
Do gap analysis Mr.Arvind
Updating in related chapters Mr.Arvind
Document control compliance Mr.Arvind
Training for regular update Mr.Arvind
Training of Legal register Mr.Arvind
Audits of legal register Mr.Arvind
2011-12
PROGRAM
Calculation
TIMINGS
October November December January February March April May
160

TIMINGS
October November December January February March April May
360

TIMINGS
October November December January February March April May
800

2011-12
TIMINGS
October November December January February March April May 160

TIMINGS
October November December January February March April May

TIMINGS
October November December January February March April May
2011-12
TIMINGS
October November December January February March April May

TIMINGS
October November December January February March April May
112500
 2009-2010 2010-20
EARN PILLER HEAD EARN Program Program Program Carry Investme saving EARN Program
Taken Completed Forword nt (Lac) (Lac) Taken
Energy Management 5 4 1 4.49 5.68 7
Water Management 4 4 0.37 3.9 3
waste Management 5 4 2 5.5 4.8 7
Prevention of Poloution 3 3 6 0 6

Total 17 15 3 16.36 14.38 23

 2010-2011 2011-2012
EARN Program Program
Program Program Carry Investme saving Investme saving
Program Complete Carry
Completed Forword nt (Lac) (Lac) nt (Lac) (Lac)
Taken d Forword
4 24.2 27.36 5 5 1 14 34.56
2 1 1.37 2.31 1 1 1 4.8 4.5
6 7.4 7.7 1 1 3.4 36.75
5 8.7 12 2 2 5.5 0

17 1 41.67 49.37 9 9 27.7 75.81

 2012-2013
EARN Program Program
Investme saving
Program Complete Carry
nt (Lac) (Lac)
Taken d Forword
5 4 1 12.86 39.96
0 0 0 0 0
0 0 1 0 0
1 1 1 15 12

6 5 3 27.86 51.96
 ENERGY MANAGEMENT -EARN PROGRAME (Indicator - Specific
YEAR current
Target Actual
Base line data Present level Producti
value Achived
on level

224
2008-
627364 551213 657063 551213 TON/MO
2009
NTH

300
2009-
690220 559287 466749 559287 TON/MO
2010
NTH

300
2010-
559287 450000 450000 450000 TON/MO
2011
NTH

500
2011-
720000 720000 44400 675600 TON/MO
2012
NTH
-EARN PROGRAME (Indicator - Specific KWH Consumption)
Energy
investme Amount
saving
Projects under taken nt In saving in
KWH/An
(lacs) (Lacs)
um
TO REDUCE POWER CONSUMPTION BY CHANGING 2 No's
SILICARB FURNACE TO CRUCIBLE TYPE FURNAC
TO REDUCE POWER CONSUMPTION BY PROVIDING ON OFF TIMMER
FOR SHOP FLOOR LIGHTING
TO REDUCE POWER CONSUMPTION BY PROVIDING TEMPERATURE
CONTROLLER IN COOLING TOWER RC FAN MOTOR
4.49 105850 5.68
POWER CONSUMPTION TO BE REDUCED BY PROVIDING
CAPACITOR BANK FOR IMPROVEMENT OF POWER FACTOR
FROM .96 TO UNITY.
PROVIDED THYRISTOR DRIVE FOR H/T FURNACE
K
TO REDUCE POWER CONSUMPTION BY CHANGING 2 No's SILICARB
FURNACE TO CRUCIBLE TYPE FURNAC 900000
TO REDUCE POWER CONSUMPTION BY PROVIDING PROPER 800000
INSULATION ON TOP OF FURNACE COVER 700000
O REDUCE POWER CONSUMPTION BY REDUCING THE MOTOR 600000
CAPACITY FROM 15 HP TO 7.5 OF COLLING TOWER PUMP
500000
POWER CONSUMPTION REDUCE PROVIDING CENTRILIZED POWER 24.2 805190 60.38 400000
PACK SYSTEM FOR ALL 7 GDC MACHINE 300000
Reduce energy consumption in C/S machine by providing heat 200000
resistance plate and heater position to be changed 100000
Improve main header of compressor discharge 0
Power saving by doing automation in fume exhaust system 09
20 -2
0
REPLACED ALL METAL HELID STREET LAMPS BY ENERGY EFFECENT
0 8- 0 9
20 20
LIGHTS .
REDUCE POWER CONSUMPTION BY MODIFYLING HYDRAULIC
POWER PACK MAIN LINE AND IN PUMP IN BOTH LPDC LINE
REDUCTION OF ENERGY CONSUMPTION IN LPDC HOLDING
FURNACE BY CHANGING LINING PATTERN . 14 460800 34.56
REDUCE FURANCE OIL CONSUMPTION BY PROVIDING LADDAL
PREHEATING SYSTEM IN MELTING SECTION .

REDUCTION IN FO OIL BY DOINING RELINING PATTERN MODIFIED .

Provided air booster in CMM to reduce Compressure setting by 6.0 Kg to 5.0

Kg
Reduce energy consumption by installing IFC controller for Air Line to
redude fluctation of line .
Reduction of energy consumption in LPDC holding furnace by Reducing
heater capacity by 80 Kw to 36 Kw, and as well as lining pattern from glass 12.86 532800 39.96
wool lining to Hiseal Board in 04 LPDC machine .
Providing shut off valve in All C/S machine to prevent air leakages during
machine ideal condation .
Reduce furnace oil consumption by modifiction done in furnace lining , by
reducing cell temperature of furnace.
 KWH Saving/Annum
900000
800000
700000
600000
500000
400000
KWH Saving/Annum
300000
200000
100000
0
09 10 11 12
20 20 20 20
0 8- 0 9- 1 0- 1 1-
20 20 20 20
Year 2008-2009 2009-2010 2010-2011 2011-2012

KWH Savi 105850 805190 460800 532800

 WATER MANAGEMENT -EARN PROGRAME (Indicator - Specific KL
YEAR current
Base line dataPresent levelTarget valueActual Achived Producti
on level

224
2008-
1392KL 950 KL 750 KL 950 KL TON/MO
2009
NTH

300
2009-
950 KL 950 KL 900 KL 923 KL TON/MO
2010
NTH

300
2010-
950 KL 950 KL 900 KL 860 KL TON/MO
2011
NTH
ARN PROGRAME (Indicator - Specific KL Consumption)
Investme Water Amount
Projects under taken nt In saving saving in
(lacs) KL/Anum Rupees
Re-cycling of quenching water
Push button on each tap
Canteen waste water to used for land escaping 0.37 5304 KL 3.9
Use of STP water for gardening,shop floor cleaning

Water prevention by doing cleaning of rain harvesting pit

and improve working of STP plant.

Water saving by doing automation in all over head tank

1.37 600 KL 2.31

Use of STP water for urinals.

WATER PREVENTION DOINING BY CLEANING RAIN
HARVESTING PITS .
STP TREATMENT CAPACITY TO BE INCREASE BY 18KL TO 1.6 670 KL 3
30 KL /DAY
USE STP WATER FOR COMPONENT CLEANING
 WASTE MANAGEMENT -EARN PROGRAME (Indicator - Kg Redu

YEAR current
Base line data Present level Target value Actual Achived Producti
on level

224
2008-
240 TON 210 TON 200 TON 210 TON TON/MO
2009
NTH

300
2009-
235 TON 212 TON 200 TON 212 TON TON/MO
2010
NTH

300
2009-
220 220 175 182 TON/MO
2010
NTH
PROGRAME (Indicator - Kg Reduction)
Waste
Investme Reductio Amount
Projects under taken nt In n in saving in
(lacs) (Tons/An Rupees
num)
Re-use of un-burnt sand
Nozzle change at defined frequency to
avoid sand waste 4.5 240 4.8
Repleaeced CI stalk by ceramic stalk
Reuse of alum. Chips/ Flashes
Re-use of un-burnt sand
Nozzle change at defined frequency to
avoid sand waste
Rectification in die gap
Automation in c/s m/c for shooting
provided ms plate to collect unburnt
sand 7.4 216.48 7.7
Provided a frame to reduce wastage of
ceramic blanket in LPDC furnace

Reduction of consumption of CI stalk by

doing proper maintenance and
preheating at standerd temp. range
Re-use of un-burnt sand by crushing in
sand mullar machine

Water cooling provided in sand nozzel .

3.4 540 36.75
Modification done in sand hopper of
core shooter machine .
Modification done in core die as per requi
 PREVENTION OF POLLUTION-EARN PROGRAMS
YEAR (Indicator-Source Reduction/Efficent process/opmial utilization of Resource/Reduction in
waste Generation/Improved Effecency)
Program Description Improvements Environmental gains
Provision of canopy for D.G. Reduction in sound level Reduction in db level
Provision of exhaust chimney To reduce so2 level from air Air Polloutin
Overhauling of hyd. Power pack Reduction in db level Noise polloution
2008-2009
Arresting air leakages Reduction in db level Noise polloution
Die maintenance to avoid extra
Reduction in db level Noise polloution
filing and fettling
Add aditive in furnace oil to reduce
corban containts from exhaust fume
Reduction of FO consumption Reduction of SO2 gases
Melting Furnace in auto mode after reach
desired temp.
Reduction of FO consumption Reduction of SO2 gases

Provided a frame to reduce wastege of Reduction in ambient Reduction in ambient

heat losses from die preheater burners temperature temperature
2009-2010
Provided ceremaic blanket to reduce heat Reduction in ambient Reduction in ambient
loss from LPDC furnace temperature temperature
Replaced manual sand decoring gun by
Sand decoring m/c Reduction in db level Noise polloution

Modification done in suction line of

Hydroulic power pack to reduce noise Reduction in db level Noise polloution

Reduce polloutio level inside

production by installig 40 natural air
Reduction of fume gases level
ventilators and use transperent sheet
inside factory premise . Air Polloutin
to improve natural lightig inside the
factory .

Improve lux level inside plant by

2010-2011 providing transperent sheet inside Lux level improved Improvement
factory .

Remove Two nos of power pack from

LPDC line and noise level on plate Reduction in db level Noise polloution
form reduces from 90 db to 82 db .
 Status on EARN Project Implementation
Energy Con
Nos of 2500
Correspon Total
EARN Energy 2000
ding Energy Investme Energy
Year Program Saving
Productio Consume nt (Lacs) Cons./Tons
Implemen (KWh) 1500
n (Tons) d (KWh)
ted
1000
2009-2010 2665.64 5886857 4 4.49 105850 2208.4216173 500
2010-2011 3711.23 7068039 4 24.2 810144.6 1904.5003947
0
2011-2012 5216.82 8035988 5 24 1351261 1540.3997071
2012-2013 5216.82 8035988 4 12.86 0 1540.3997071 10 11 12
20 20 20
0 9- 1 0- 1 1- 1
20 20 20 20

Water Con
4.50
Nos of 4.00
Correspo Total
EARN Water 3.50
nding Water Investme Water
Year Program Saving
Producti Consume nt (Lacs) Cons./Tons 3.00
Impleme (KL)
on (Tons) d (KL) 2.50
nted 2.00
1.50
2009-2010 2665.64 11400 4 0.37 5304 4.28 1.00
0.50
2010-2011 3711.23 11076 2 1.37 600 2.98 0.00
2011-2012 5216.82 10320 1 4.8 670 1.98
10 11 12
2012-2013 5216.82 10320 0 0 670 1.98 20 20 20
0 9- 1 0- 1 1-
20 20 20
 Energy Cons./Tons

Energy
Cons./Tons

10 11 12 13
20 20 20 20
0 9- 1 0- 1 1- 1 2-
20 20 20

Water Cons./Tons

Water
Cons./Tons

10 11 12 13
20 20 20 20
0 9- 1 0- 1 1- 1 2-
20 20 20
Supplier Name: Alicon Castalloy

PILLAR HEAD

ENERGY MANAGEMENT (in Kwh)

WATER MANAGEMENT ( in KLD)

WASTE MANAGEMENT

PREVENTION OF POLLUTION
 MIS
FY: 2009 -2010
Investment
Brief Description of each Earn programs
(Rs Lacs)
1-TO REDUCE POWER CONSUMPTION BY CHANGING 2 No's SILICARB
FURNACE TO CRUCIBLE TYPE FURNAC .
2-TO REDUCE POWER CONSUMPTION BY PROVIDING ON OFF TIMMER FOR
SHOP FLOOR LIGHTING . 3-TO
REDUCE POWER CONSUMPTION BY PROVIDING TEMPERATURE
CONTROLLER IN COOLING TOWER RC FAN MOTOR . 4- 4.9
POWER CONSUMPTION TO BE REDUCED BY PROVIDING CAPACITOR BANK
FOR IMPROVEMENT OF POWER FACTOR FROM .96 TO UNITY. 5-
PROVIDED THYRISTOR DRIVE FOR H/T FURNACE

1- RECYCLING OF H/T QUENCHING TANK WATER .

2- PROVIDED PUSH TYPE TAP IN ALL WATER TAPS . 3-
CANTEEN WASTE WATER USED FOR LAND ESCAPING . 4- 0.37
USE STP WATER FOR GARDANING AND FLOOR CLEANING PURPOSE .

1- REUSE OF UNBURNT SANDIN C/S MACHINE . 2-

NOZEL FREQUENCY TO BE DEFINE TO PREVENT SAND WASTAGE IN C/S
MACHINE . 3-
REPLACED ALL CI STALK BY CERAMIC STALK . 4- RE 4.5
USE CHIPS AND METAL SPILAGE .

1- PROVIDED CANOPY FOR DG SETS . 2-

PROVIDED WET SCRUBER FOR MELTING FURNACE. 3-
OVERHAWLING OF ALL POWER PACK MOTORS . 4-
START DOING DIE MAINTENACE AT DEFINE FREQUENCY TO REDUCE EXTRA 6
FLASH .
Corresponding
Savings

5.68

3.9

4.8

0
Supplier Name: Alicon Castalloy

PILLAR HEAD

ENERGY MANAGEMENT (in Kwh)

WATER MANAGEMENT ( in KLD)

WASTE MANAGEMENT

PREVENTION OF POLLUTION
 MIS
FY: 2010 -2011
Investment
Brief Description of each Earn programs
(Rs Lacs)
1- TO REDUCE POWER CONSUMPTION BY CHANGING 2 No's SILICARB
FURNACE TO CRUCIBLE TYPE FURNAC .
2- TO REDUCE POWER CONSUMPTION BY PROVIDING PROPER INSULATION
ON TOP OF FURNACE COVER . 3. REDUCE
POWER CONSUMPTION BY REDUCING THE MOTOR CAPACITY FROM 15 HP
TO 7.5 OF COLLING TOWER PUMP . 4- POWER
CONSUMPTION REDUCE PROVIDING CENTRILIZED POWER PACK SYSTEM
FOR ALL 7 GDC MACHINE . 5 - Reduce
24.2
energy consumption in C/S machine by providing heat resistance
plate and heater position to be changed . 6 - Improve main
header of compressor discharge . 7- Power saving by
doing automation in fume exhaust system

1- WATER PREVENTION DOING BY CLEANING OF RAINHARVESTING AND

IMPROVING STP CAPACITY . 2-
PROVIDED WATER LEVAL SENSORS IN ALL OVER HEAD TAKS . 3- 1.37
STP WATER USED FOR URINALS .

1- REUSE OF UNBURNT SANDIN C/S MACHINE . 2-

NOZEL FREQUENCY TO BE DEFINE TO PREVENT SAND WASTAGE IN C/S
MACHINE . 3-
RECTIFICATION OF DIE GAP IN C/S DIES . 4-
PROVIDED COLLECTION PLATE IN C/S MACHINE FOR COLLECTING UNBURNT
SAND . 5-
PROVIDED AMS FRME TO REDUCE WASTAGE OF CERAMIC WOOL IN ALL 7.4
LPDC FURNACE . 6-
AUTOMATION DONE IN CORE SHOOTER M/C FOR SHOOTING . 7-
TO REDUCE CONSUMPTION OF CI STALK PREHEATED AND PROPER
MAINTENANCE STARTED .

1- START ADDING ADITIVE IN FO TO REDUCE CONSUPTION AND SULFER

DISCHARGE . 2-
MELTING FURNACE BURNER DONE IN AUTO MODE TO REDUCE FO
CONSUMPTION . 3-
PROVIDED A MS FRAME IN ALL LPDC TO PREVENT WASTAGE OF FLAME
DURING DIE HEATING . 4-
PROVIDED CERAMIC BLANKET IN ALL LPDC HOLDING FURNACE TO PREVENT 8.7
HEAT LOSSES . 5-
REPLACED MANUAL SAND DECORING BY SAND DECORING GUN . 6-
MODIFICATION DONE IN SUCTION LINE OF ALL LPDC POWER PACK TO
REDUCE DB LEVAL IN PLANT .
 Corresponding
Savings (Rs Lacs)

60.38

2.31

7.7

12
Supplier Name: Alicon Castalloy

PILLAR HEAD

ENERGY MANAGEMENT (in Kwh)

WATER MANAGEMENT ( in KLD)

WASTE MANAGEMENT

PREVENTION OF POLLUTION
 MIS
FY: 2011 -2012
Investment
Brief Description of each Earn programs
(Rs Lacs)
1- REPLACED ALL METAL HELID STREET LAMPS BY ENERGY EFFECENT LIGHT
2- REDUCE POWER CONSUMPTION BY MODIFYLING HYDRAULIC POWER
PACK MAIN LINE AND IN PUMP IN BOTH LPDC LINE .
3.REDUCTION OF ENERGY CONSUMPTION IN LPDC HOLDING FURNACE BY
CHANGING LINING PATTERN . 4-
REDUCE FURANCE OIL CONSUMPTION BY PROVIDING LADDAL PREHEATING 14
SYSTEM IN MELTING SECTION . 5 -REDUCTION
IN FO OIL BY DOINING RELINING PATTERN MODIFIED .

1- WATER PREVENTION DOING BY CLEANING OF RAINHARVESTING AND

IMPROVING STP CAPACITY . 2-
STP TREATMENT CAPACITY TO BE INCREASE BY 18KL TO 30 KL /DAY . 3- 1.6
STP WATER USED FOR CASTING QUENCHING .

1- REUSE OF UNBURNT SANDIN C/S MACHINE BY CRUSHING IN SAND

MULLER MACHINE. 2-
WATER COOLING ARRANGEMENT RPOVIDED IN C/S MACHINE TO REDUCE
SAND SPILAGE IN MACHINE. 3- 3.4
MODIFICATION DONE IN SAND HOPPER TO REDUCE SAND SPILAGE . 4-
MODIFICATION DONE IN DIE AS PER CAVITY REQUIREMENT .

1- PROVIDED TURBO VENTILATORS IN MAIN PRODUCTION HALL TO REDUCE

FUME GAS LEVAL INSIDE PLANT . 2-
PROVIDED TRANSPERENT SHEET INSIDE PLANT TO IMPROVE DAY LIGHT
INSIDE THE FACTORY . 3- 5.5
REMOVED TWO NOS OF HYDRAULIC POWER PACK FROM LPDC LINE TO
REDUCED SOUND LEVAL INSIDE THE FACTORY .
 Corresponding
Savings (Rs Lacs)

34.56

36.75

0
Supplier Name: ALICON CAST ALLOY
Phase: 4
Legal Compliance Management
ASSESMENT OF LEGAL STATUS - PREVIOUS YEARS
Complianc
e Mgmt.
Licence/Consent Reqmts 2009 2010 2011 Valid Upto Plan Remarks
- -
Factory Current Licence Ref HP
9919
Manpower
Licenced Production

Corrosponding Production

Water Act 1974 Consent

No. Domestic effluent Permissible

Industrial Effluernt Permissible

Effluent Analysis- Done/not
done
Stacks monitoring-Done/ Not
done
Air Act 1981 Consent No.
Ambient air
monitoring-Done/Not done
Total water consumed in the
Water Cess Act1977 & plant
Water Cess Rules 1978 Submission of water cess to
SPCB

Hazardous waste records Form-3

Hazardous Waste Submission of annual returns
Authorisation No. Form-4
Submission of Env. Statement
Form-5

Display Board For

Hazardous Wate at Factory The Supreme Court
Gate Orders( Board Size 6' X4')

Licence to Petroleum Class-A(KL)

Storage
Class-B(KL)
1- 750 KVA
DGNOC/Licence
2- 1000 KVA

Tube well/Bore Well Nos. of Bore Well

Registration
Status of bore well Registration

Any Directives received

from SPCB in the past &
Compilance thereunder