Vesuvius India Limited presented on their sustainability initiatives at an expo in 2016. They discussed approaches to sustainability through cost reduction and differentiation. Key initiatives included skull reduction, enhancing tundish life, and high-speed casting. Future focus areas were to continue initiatives and replicate successes across sites. Vesuvius is committed to safety, environment, energy conservation and values like creativity, reliability, cooperation and integrity. Sustainability initiatives included waste management, emissions reduction, and community support. Health and safety programs included audits and safety improvements. Benchmarks and results from specific sites were provided.

1. Sustainability Expo 2016
17th June 2016
Partnering for a sustainable future
Vendor - Vesuvius India Limited
1

2. 2
Sustainability Initiatives
Approach to Sustainability :
Vesuvius Mission , Vision and sustainability initiatives .
Reduce operating cost through value addition.
Differentiation through mechanization.
Key initiatives and results/benefits derived
Major initiative company wide
Examples -Skull reduction, enhancement of tundish life, high speed casting – LD#3.
Reduction in specific consumption, differentiation through mechanization , Commissioning
Cases explained:
Examples of initiatives across Vesuvius
TSL specific 3 examples of energy saving initiatives and health and safety.
Focus Areas for the future (FY 17-20) in the area of Sustainability
To continue the initiatives and add on with more engagement .
To replicate the establish break through initiatives at site level .

3. 3
Vesuvius Commitments
Vesuvius Mission & Vision:
Vesuvius remains committed to protecting employees by reducing and eliminating workplace
hazards. Our aim is to identify, eliminate, reduce and control all workplace risks.
Committing to:
• Safety
• Environment
• Energy conservation
Vesuvius Values:
• Creativity: Innovation in everything
• Reliability: Know-How - Quality - Consistency
• Cooperation: Team work - Partnership
• Embracing diversity: Respecting the différence
• Integrity: Trustworthiness - Honesty - Transparency
Sustainable Initiatives:
• Environnent Management: One of the best environmental friendly organizations in area
of Waste Management. Systematic efforts have also been made towards “Go Green”
which are as follows:
Tree Plantation Program at CL

4. 4
Vesuvius Sustainability Initiatives
• Introduction of LED lamp for area lightning resulting in decrease in electricity consumption
approx. 110,000 KWH/Year.
• Upgradation of air conditioning system to decrease electricity consumption approx. 75,000
KWH/Year.
• Heat recuperation facility introduced in Kiln to reduce in LPG consumption by 15% (equivalent to
45MT of LPG)
• Improved finished good packing reducing utilization of wood & hydrocarbon products. (Wood
saving- 43 CUM, Hydrocarbon- 2.7MT).
• Engaged ourselves in plantation of about 150 saplings within our premises as an act towards
replenishment of natural resources & ensure overall socio economic development.
• Corporate Social Responsibility: Vesuvius India has always encouraged a strong
sense of social awareness and spirit of giving back to the community at large. Few such
initiatives are as follows:
•Provide financial support to needy children of two local, dilapidated primary schools:
one near Kolkata Plant and one near Vizag Plant.
•Organize Blood Donation Camps on regular intervals.
•Welfare programs for Contractual employees: Scholarship Program at East I

5. 5
Vesuvius Sustainability Initiatives
• Employee/Labour Practices:
• Living The Value Awards- Aims at emphasizing the core Group Values (Creativity, Integrity,
Reliability, Co-operation and Embracing Diversity) and giving visibility to individual or team
behaviours that successfully support and demonstrate these values in their everyday business
activities.
• Excellence Award – STARZ: Shop floor employees are involved in process improvement by
rewarding them for generating ideas/suggestions in terms of Safety, Quality, Cost and Delivery and
take initiative to implement those at shop floor.
• Best Technicians Award: To reward and motivate the collective efforts of the individual / group
(contractual technicians at sites) for the commendable performance in basic disciplines such as
Attendance, Safety improvement, Opportunity generation and implementation of any improvement
opportunity which will benefit Customer and the Company.
• Magic Square: Magic square is a process through which we can assess the competencies or skill
sets of an operator and its finally helps in performance evaluation and career progression.
• Health & Safety: More than 30% of employees involved every month in Safety Audits.
More than 4 Safety Improvement Opportunities/
person implemented in 2015.
Reduction of Energy consumption and GHG emissions: Target
is to reduce energy consumption per ton sold by 10% every 3 years.

6. 6
Sustainability in our approach in TSL cases explained
Ideas 1 Sustainability initiatives Indication
Benchmarking of
tundish refs LD3
• Environment
Management
Reduction of usage of Refractory
Less usage of CO2
• Health and Safety Minimising human exposure to hot
tundish and steel
• Employee Labour
Practices
Scholarship for workmen and
hospitalisation benefits
Ideas 2 Sustainability initiatives Indication
Trough refs
practices HBF
• Health and Safety Minimising human exposure to hot
trough and reducing the manual job
Ideas 3 Sustainability initiatives Indication
KPO ref
commissioning
• Health and Safety Safe installation as per SWI and
trouble free commissioning

7. 7
Bench marking tundish refractory in LD#3 TSCR
I. Improvements targeted
Yield enhancement through YES tundish.
SEN that can cast @ 4.2 Mt/Min
Continuous steel temp monitoring in tundish.
Homogenization of steel & reduction of NMI.
Sustainable R&D and reduction in use
CFD & Water modelling of LD#3 tundish as well as SEN
Integrating temperature monitoring with stopper (Accurod).
Introducing tundish gas diffuser to float NMIs
II. Description of initiatives
III. Results achieved
Current design YES tundish with TGD
Two tundish converted to YES design –3.5 Mt skull saved/seq. (Saving potential – 3800 Mt/Yr).
4 pieces newly modelled SEN tried. Throughput established upto 4.0 Mt/min from 3.8 Mt level.
Accurod converted in one caster & helping operation for sequence planning. No additional provision
required in tundish. TGD – Still under evaluation – Awaiting bulk trial.

8. 8
Bench marking trough refractory practice at H BF
I. Improvements targeted
Minimizing human exposure to hot trough.
Reducing the specific consumption.
Strengthening the back up of trough.
Other improvements (Ramp, Burner, Faster
discharge, PCPF spout)
Vesuwreck trimming Vs. manual breaking.
Reducing waste by controlled grinding
New design of back up approved. Installation planned in Jul-Aug.
II. Description of initiatives
III. Results achieved & work going on
Vesuwreck Grinding Process
Manpower reduced by 4 nos.
Specific consumption figures improving. Can target 0.48 level with improved back up.
Better preheating & ramp modification have improved the trough life by 5000 Mt.
With proposed cross section trough life of 125 K can be targeted.
Currently working on faster discharge technique & PCPF spout to improve efficiency.
Old heating Co Jet heating Existing CS Proposed CS

9. 9
KPO – Successfully Commissioned Refractory systems
I. SMS – Tundish
State of art technology SEM2085 DS tube
changer system commissioned successfully.
Dry Vibrating Mass installed & commissioned
successfully in 70 ton tundish.
Plan to optimize tundish refractory &
understand flow simulation in tundish to
deliver desired quality.
Safe commissioning of refractory systems
Installed & Commissioned trough successfully.
To introduce mechanized breaking & pump
casting to ensure safe operational practice.
To set industry best sp. consumption to
contribute on operating cost.
II. BF – Trough
III. Granshot - Tundish
Largest Granshot plant in India successfully installed
& commissioned with Vesuvius refractory.
Highest 10 heats (573 mins) casting done in single
tundish on 26.04.2016.
Continuous improvement of tundish life by
upgrading refractory performance.
SEM 2100 DS DUMAG

10. 10
Way forward through small ideas
Segments Where we stand Progress so far
Environmental
Management
Improved preheating systems to
reduce CO usage
Trial burner working at
HBF effectively
Feeding system for mold flux to
reduce waste
System for LD2 is coming
in July
CSR Improving contractual workmen kid
welfare and future awareness
Apart from scholarships ,
Carrier seminars arranged
Heath &
Safety
Turbo S launched globally,
Improving awareness
Training imparted to all
levels with AV cases
Human rights SA 8000 audit done for site level Complying to norms
Ethical business
practices
Every employee has gone through
ABC training
No gift policy from last 4
years. Awareness high
Sustainable
Ideas Site
Single contractual partner with vision to
implement our ideas ,single vendor for
transportation of our goods
Various relationships
programs continue