Reduction of Auxiliary Power Consumption for a Cement Plant in Rajasthan

Customer Background and Thermax Partnership: At one of the leading cement manufacturer’s unit at Rajasthan, Thermax is providing Operation and Maintenance (O&M) services for its captive power plant of capacity 21 MW and WHR power plant of capacity 13 MW since 2008. The plant has an 89 TPH AFBC (Atmospheric Fluidised Bed Combustion) boiler and 5 WHR (Waste Heat Recovery) boilers of 72 TPH combined (both boilers are made by Thermax).  

Project Background: Auxiliary power consumption is one of the key performance indicators for a power plant. As a part of the customer’s ‘energy efficiency’ drive, the Thermax team took a target of reducing the auxiliary power consumption to enhance the net power generation. 

Approach: Thermax team conducted a detailed analysis of the equipment data using advanced proprietary tools. They also organised workshops to drill down on the key parameters driving higher auxiliary power consumption.

Specific teams were formed to study:  

  1. Power consumption pattern equipment-wise and area wise 
  2. All possible ideas for improvement

Solution: Thermax team presented a comprehensive plan to the customer for reducing auxiliary power consumption for captive and WHR power plants. The plan included actions with and without capital investments. Over the span of the last two years, various opex initiatives such as ‘auto control logics for flow optimisation’ and capex initiatives such as ‘VFD installation’ were implemented. The customer also agreed for capex investment after being apprised by the Thermax team about the long term savings and lifecycle cost reduction. 


  • For the captive power plant72.4 lakhs of unit cost saved through capex and 18.8 lakhs unit cost saved through opex 
  • For WHR unit 8.7 lakhs of unit cost saved through capex and 1.9 lakhs unit cost saved through opex
  • The total auxiliary power consumption was reduced by 1% for captive power plant and 2.2% for WHR unit 
  • Carbon footprints reduced by 1,200 tCO2e/year for captive unit and 1,300 tCO2e/year for WHR unit



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