Wadi Cement Works 29- 31st Aug 2018
Best Practices in Energy Efficiency & Energy Optimization
Presented at :-19th National Award for
Excellence in Energy Management 2018Presented by: Vikas Kumar
Lokesh Rao
1
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
Plant Overview – Wadi Cement Works
Agenda
2
Renewable Energy sources, utilization of waste for replacing the conventional energy
Energy Efficiency & Benchmarking with Global best SEC
Innovative Projects – Case Studies in EE
Involvement of Employees, Team work in ENCON, Monitoring & Reporting, Implementation
Energy Saving Projects
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
ACC Wadi Geographic Location
KARNATAKA
STATE
Plant Site
Clinkering : 5.83 MTPA, Cement - 6.03 MTPA Power - 125 MW
Wadi-1
Wadi-2
3
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
Genesis of the plant...............Wadi Cement Works
1978 1983 1995 2001 2006 2010 2014
1968
1968: Wadi I set up with installed capacity of 0.4 MTPA
Kiln 1 & 2 1978: MFC Installation
1983: Ist 1.0 MTPA
IndigenousPlant in India &
25 MW CPP installed
1995: CPP expanded to 50 MW
Wadi-2 Commissioning
2.0 MTPA
2006 With in house
modification at Wadi II total capacity of Wadi- 4.2 MTPA
WD 2Expansion
clinkering & CPP(50 MW)
Total capacity 6 million Tons &
125 MW CPP
CommissioningAFR platform
(16 TPH)
India’s Ist 1.0MTA Plant
2018-19
Expansionof AFR platform
(20% TSR)
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
Plant layout_Wadi-2
L&T make impact bar crusher Crusher 1 – 1000 TPHCrusher2 – 1200 TPH
Raw Mill-1 (Atox 50)Capacity – 450 TPHRaw Mill-2 (Pfeiffer 5600 B)Capacity – 560 TPH
Raw Meal Silo1 Nos. CF SiloCapacity – 21000 T
Complex SLC & ILC Combination of
6 stage PH
ILC Height –182 mSLC Height - 120 m
Kiln : Size – 6 m Dia X 96 m Length,BDP – 12500 TPD, Make –FLS, Inclination – 4%, RPM – 5 max. ,Drive – Twin Drive
RM1 RM2
Coal Mill-1 (Atox KM25)
Capacity – 50 TPH
Coal Mill-2 (Loeshe LM43.4 D)
Capacity – 93 TPH
Cr1 Cr2
SLC
ILC
K4
KM1 KM2
CM (Ball Mill) – 2 Nos.Capacity – 220 TPHx 2Make - FLS
VRPM – 2 Nos.Q –230 TPHMake- AMCL
Clinker SiloQ. – 1.15 LT
Cement SiloCap.- 10000t Tx 3
Packer- 4 Nos.Cap. -180 TPHX 4Double discharge
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
Reduction in SEC Performance in last 3 - Years
In Year 2016, both SEC & STEC have been increased from previous years due to;
✓ Low PRI of Kiln; 83.79% in Y’16 from 93% in Y’15 after 100% pet coke firing.
✓ Increased AFR consumption from 4.17 % - TSR in Y 2015 to 6.23 % -TSR in Y 2016.
✓ Low PRI of Kiln due to TA Duct failure in Dec 2016 (PRI-50%) and Jan 2017 (PRI-48%)
660.0
670.0
680.0
690.0
700.0
710.0
720.0
730.0
Y'15 Y'16 Y'17 Y'18 GAP Top 10 NationalBest
697.6
709.7
722 719.6
702
686
17.6
STEC K Cal/ Kg Clinker
0.00
10.00
20.00
30.00
40.00
50.00
60.00
Y'15 Y'16 Y'17 Y'18 GAP Top 10 NationalBest
56.6158.23 56.92 56.37
4.57
51.843.9
Clinkering SEC KWh/T cli.
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
SEC of Cement Grinding in year 2018 has been increased from previous years due to;
✓ Change in product portfolio
✓More Concrete C+ production instead of PPC;
✓ Less throughput & High grinding SEC during concrete + production
✓ High clinker temperature leads to poor availability of VRPM – Pregrinder.
Reduction in SEC Performance in last 3 - Years
0.00
10.00
20.00
30.00
40.00
Y'15 Y'16 Y'17 Y'18 GAP Top 10 NationalBest
34.26 34.95 34.9235.12
4.62
30.5 28.8
Grinding Energy KWh/T Cem.
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
Y'15 Y'16 Y'17 Y'18 GAP Top 10 NationalBest
74.55 77.2273.93 72.58
1.39
71.1963.13
Total Energy KWh/T Cem
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
SEEC - Comparison with Global Best SEC
1.6 2.1 1.98 1.83 0.7
16.97 18.3 16.64 16.4711.1
38.69
49.0741.84
48.86
23.9
20.5
21.85
20.3919.15
17.05
34.26
34.95
34.9235.12
27.07
4.92
5.38
4.933.9
0
20
40
60
80
100
120
140
2015 2016 2017 2018 Global Best
General Consumption
Cement Grinding
Clinker Production
Solid Fuel Preparation
Raw Meal Preparation
Raw Material Preparation
72.5877.22
73.93
63.91
8.67
74.55
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt. 9
Road map to achieve benchmark/global best SEEC
Sr. No.
Title of Project Saving
1 Expansion of Alternative Fuels project TSR increase from 12 to 20%
2 Replacement of Beumer pan conveyor with Aumund 1.7 KWh/T Cem
3 PIT navigation system - Intelligent optimization software for Cement Kiln
1 KWh/T Cem10 K Cal/Kg Clic.
4 Replacement of DC drive of Kiln String Fan with MV Drive0.4 KWh/T Cem
5 Replacement of DC drive of old Baghouse Fan with MV Drive0.57 KWh/T Cem
6 Replacement of DC drive of old Cooler ESP Fan with MV Drive0.2 KWh/T cem
7 Replacement of Cross bar cooler with IKN Cooler 1.5 KWh/T Cem10 K Cal/Kg Clic.
8 Installation of double flap damper below Coal mill #2 BH discharge
0.1 KWh/T cem
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt. 10
Road map to achieve benchmark/global best SEEC
Sr. No.
Title of Project Saving
9 Tapping heat from Cooler & Kiln exhaust gases by installing waste heat recovery system
13.2 MW Potential
10 Replacement of Cement Mill & Raw Mill separator DC drive with LV drive
0.17 KWh/T Cem
11 Replacement of Coal Crusher & Lime stone crusher Apron feeder DC drive with LV drive 0.11 KWh/T Cem
12 Replacement of calciner string fan impeller with lower sized impeller in order to improve operating efficiency
0.14 KWh/T Cem4 Kcal/Kg Cli.
13 Replacement of existing three way separator with V separator0.7 KWh/T Cem
14 Maximization of fly ash absorption from current level of 33.5% to 35%
0.8 KWh/T cem
Total 7.39 KWh/T Cem
24 K Cal/Kg Clic.
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt. 11
Energy Saving projects implemented in FY 2017-18
Sr. No.
Title of Project
Annual SavingElectrical(KWh) Thermal (Mio. K
Cal)
Total Annual Saving (Mio. INR)
Investment made (Mio. INR)
1 Improvement in RM#2 PRI from 560 to 570 TPH by1) Arresting false air from 25 % to 13 %2) Modification in Mill feed chute3) Maintaining crusher output size 90% passing 75 mm
561250 2.81 0
2 Interlocking of crusher hopper level sensor with apron feeder RPM to reduce idle running & reliability of lamella plate
99000 0.495 0.05
3 Old stacker travel drive converted from Rdol to VFD 79200 0.396 0.05
4 Replacement of soft starter with VFD in old high grade & shale reclaimer 217661 1.1 0.2
5 Reduction in rake (coal & Gypsum) unloading time from 9.6 hrs to 7 hrs 449000 2.25 0
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt. 12
Energy Saving projects implemented in FY 2017-18
Sr. No.
Title of Project
Annual Saving
Electrical(KWh)
Thermal (Mio. K Cal)
Total Annual Saving (Mio. INR)
Investment made (Mio. INR)
6 Cooling tower Hot water pumping system modification & replaced 75 KW motor with 45 KW motor. 144000 0.7 0.05
7 Replacement of Conventional lights with LED lights 171915 0.86 2
8 Reduction in clinker cooler Temperature by 1) replacement of cooler fan FA 4 & 5 with motor 2) Replacement of impeller of Cooler fan FA 6 & FA 7 3) Replacement of Cooler 3rd compartment plates
11467.94 (T) 13.76 8.2
9 Reduction in avoidable electrical energy loss in GRR by replacing GRR with SPRS in RM#1 fan (3400 KW & 6.6 KV)
1222000 6.11 7.5
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt. 13
Energy Saving projects implemented in FY 2017-18
Sr. No.
Title of Project
Annual SavingElectrical(KWh) Thermal (Mio. K
Cal)
Total Annual Saving (Mio. INR)
Investment made (Mio. INR)
10 Replaced ILC tertiary air duct damper to enable operation at oxidizing kiln conditions to reduce CO and improve clinker quality (C3S)
1100000 5.5 6
11 Improvement in NAI of both VRPM to ensure 100% Cement Mill running with Pre-grounded material by carrying out following jobs 1) Replacement of separator rotor & stator 2) Replacement of impeller of Sepax fan3) installation of chillers unit for gearbox
oil cooling
2245000 11.23 5.6
12 Reduction in primary air in firing burner from 9.9 % to 6.7% by replacing the existing fan with high pressure& low volume blower.
13696 (T) 15.89 20
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt. 14
Energy Saving projects implemented in FY 2016-17
Sr. No.
Title of Project
Annual Saving
Electrical(KWh)
Thermal (Mio. K Cal)
Total Annual Saving
(Mio. INR)
Investment
made (Mio. INR)
1Reduction in false air ingress in Coal Mill#1 from > 35% to < 15% 60000 0.27 0
2Reduction in false air ingress in Coal Mill#2 from 35% to TARGET < 15%
90000 0.41 0
3
Reduction in false air ingress in Raw Mill#1 (mill inlet to fan outlet) from ≈ 17% to Target < 10%
207740 0.94 0
4Improved thermal substitution rate (TSR) from 5.69% to 6.32%
7648 13.33 0
5Improvement of Throughput from 52 TPH to 60 TPH in coal mill # 2 during PetcokeGrinding
176538 0.8 0
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt. 15
Energy Saving projects implemented in FY 2016-17
Sr. No.
Title of Project
Annual SavingElectrical(KW
h) Thermal (Mio. K Cal)
Total Annual Saving
(Mio. INR)
Investment
made (Mio. INR)
6Replacement of new cooler ESP duct to reduce false air ingression 360000 1.8
1
7
To maintain L/S crusher output size, R 75mm in the range of 5-10% in order to improve throughput and SEEC in Raw Mill VRM
339270 1.54 0
8
Skew correction in old high grade reclaimer by installing LVDT in place of skew pot
72000 0.36 0.05
9
Optimisation of CM#1 & CM#2 throughput by 95 % and 90% respectively in case of PPC grinding by:a) Increasing mill ventilation rateb) grinding media optimisation andc) 100% petcoke fired Clinker quality
optimisation.
935193 4.68 1
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt. 16
Energy Saving projects implemented in FY 2015-16
Sr. No.
Title of Project
Annual Saving
Electrical(KWh)
Thermal (Mio. K Cal)
Total Annual Saving
(Mio. INR)
Investment
made (Mio. INR)
1
Reduction in SEEC in Raw Mill -1 by1) Improving Raw Mill#1 Fan efficiency
from 70% to 78% by maintaining optimum axial and radial cone overlap.2) Reducing False Air from 30% to 12%
across the mill circuit.3) Increasing PRI by optimizing mill feed size.(earlier R75 ~ 25 to 30% and present R 75~ 5 to 10%).4) Strengthening of daily walk by
inspection, Preventive Maintenance and CBM activities; resulting improve in MTBF
1647652 7.12 0.5
2
Reduction in clinker cooler discharge temp by 20 deg C (By Raw mix design modification)
12792 15.65 0
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt. 17
Energy Saving projects implemented in FY 2015-16
Sr. No.
Title of Project
Annual SavingElectrical(KW
h) Thermal (Mio. K Cal)
Total Annual Saving
(Mio. INR)
Investment
made (Mio. INR)
3
Improvement in TSR to 5.69% by enhancing usages of AFR at kiln (PCPF facility - Pre- and Co-processing facility
commissioned on Dec 2014)
12752.84 156 700
4
Reduction in SEEC of Raw Mill -2 by1) Improving Raw Mill#2 Fan efficiency
from 79% to 83% by maintaining optimum axial and radial cone overlap. 2) Reducing False Air from 25% to 11% across the mill circuit.3) Strengthening of daily walk by inspection, Preventive Maintenance and CBM activities; resulting improve in MTBF 4)Installing SPRS in place of GRR for Raw Mill#2 System Fan
4099980 17.71 9.35
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt. 18
Energy Saving projects implemented in FY 2015-16
Sr. No.
Title of Project
Annual SavingElectrical(KWh
) Thermal (Mio. K Cal)
Total Annual Saving
(Mio. INR)
Investment
made (Mio. INR)
5 “War on Waste” To Improve the housekeeping and Reduce the waste generation i.e. Reduction in spillages, compressed air & water leakage, Lubricants etc.
198000 (E)
1200 (T)2.32 0
6 Improved in throughput & reduction of idle running hour of mines LS crushers by 2-shift operation of mining activities instead of 3 - shift operation.
115500 0.5 0
7 Cooler static inlet modification to ABC
5816 6.96 35
7.1 Improving the cooler recuperation efficiency from 65% to 69 % .
7.2 Reduction in cooler vent gas temperature from 302 oC to 298 oC
7.3 Reduction in clinker exit temperature from 220 oC to 170 oC
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
INNOVATIVE PROJECT -1 Page 1 of 4
Plant : WD` Title of the measure :
Reduction in primary air in firing burner from 9.6 % to 6.7% by modification of jet air nozzle
Category A Known concept with Unique Application
Description of the energy conservation measure:
The Wadi2 Kiln operates with KHD pyrojet burner commissioned in Oct 2017. The jet air nozzles diameter was reduced from 27 mm to 17mm. There are total 16 holes for jet air. The area is reduced from 9156 mm2 to 3632 mm2
Problem Faced:
✓ Higher Primary Air intake
✓No any significant reduction in NOx emission
✓ Higher Fuel consumption
✓ Poor Nodulisation of clinker
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
Problem Analysis and action taken Page 2 of 4
Problem Action taken
1. Higher PA consumption & Low Burner momentum
1.Replaced FLS duplex burner to KHD pyro jet burner2. Jet air nozzle dia. reduction from 27 mm to 22 mm3. Replacement of PA fan with Blower
2. Formation of coating in raiser duct.
1.Started using high alkali content material in raw meal corrective to maintain A/S in clinker.2.Installation of Cardox socket in kiln raiser duct to dislodge the coating.3.Cyclone / Raiser duct air blaster sequence changed to auto mode.
3. Flushing of clinker in pan conveyor tunnel due to fine clinker.
1. Increased alumina ratio for better nodulization.2. Cooler operation mode changed from random to
shuttle.3. PC discharge chute modification
4. Higher NOxEmission
1. Reduction in PA Air2. Jet air nozzle dia. reduction from 27 mm to 22 mm
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
Picture/ sketch before modification Picture/ sketch after modification
PRODUCTIVITY IMPROVEMENT POTENTIAL Page 3 of 4
22 mm Dia.
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
TANGIBLE IMPACT OF THE PROJECT Page 4 of 4
Result & Benefit
•The jet air blower operating speed is reduced from 1260 rpm to 860 rpm
•NOx reduction from 905 mg/Nm3 & 1027 mg/Nm3 to 730 mg/Nm3 & 887 mg/Nm3 respectively. (reduction by 175 mg/Nm3 and 140 mg/Nm3)
•The reduction in primary air from 9.6% to 6.7% - Savings of 4.1 Kcal/Kg Clinker
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
INNOVATIVE PROJECT -2 Page 1 of 5
Plant : WD Title of the measure : Improvement in RM#2
PRI from 560 to 570 TPH by internal modification in Raw Mill #2 (Pfeiffer 5600 B)
Category B New concept (risks taken/self driven / beyond OEM)
Description of the energy conservation measure:Problem Faced:❖Mill body vibration high 16 to 18 mm/sec & air Separator was running in the range of vibration levels 20-22 mm/sec. There was no any oil cooling arrangement for the hydraulic system. This causes following problems–•Mill buffer seal & Pull rod failure frequently •Buffer & it’s side liner got damage .•Cracking of mill surrounding Platform•Damage of hydraulic Cylinder top bush & seal•Not Able to increase the Feed more then 560 tph
Identification of problem and root Cause Analysis✓ Continuous studies by OEM Since 2010 but no solution was provided✓To reduce the oil temperature we have installed separate oil cooling arrangement✓ Carried out brainstorming session & also taken ideas from sister Works i.e. ChandaWorks
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
Picture/ sketch before modification Picture/ sketch after modification
Electrical Energy Conservation Case Study Page 2 of 5
Before dam ring increase Material empty After dam ring increase material height
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
Picture/ sketch before modification Picture/ sketch after modification
Innovative Project 2 Page 3 of 5
Oil Tank
Pump
Filter 10 µ
Valve Block
Hydraulic
Cylinder 3 Nos
Pump
Oil Tank
Pump
Hydraulic Cylinder
3 Nos
Valve Block
Filter 20 µ
Filter 20 µ
Heat Exchanger
Pump
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
Electrical Energy Conservation Case Study Page 4 of 5
Execution & Implementation Dam ring height & feed chute height has been increased & mill body vibration & separator vibration reduced drastically
Result & Benefit
✓ Decreased mill internal recirculation of materialresulted in lower mill DP caused increase in feed by15-20 TPH.
✓MILL vibration Reduced from 20- 22 mm/sec to<7 to 8 mm/sec
✓Silo feed bucket elevator load increase around 15to 20 Amps
✓Mill power consumption comes down around 1.33Unit/ton of cl.
✓Buffer seal & Liner plate life has been increased
✓Cracking of Mill surrounding platform eliminated
✓Hydraulic Cylinder top bush life increased
✓Reduction in frequent mill breakdown due to sealdamage & pump failure
✓Reduction in oil temperature resulting in reductionin seal damage, solenoid malfunctioning & oilconsumption.
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
Monetary and Non Monetary benefits Page 5 of 5
Parameter UoM OEM design
Before modification
After Modification
Output Tph 560 560 575-585
Product fineness Residue-90µ
% 25 27 27
Product fineness Residue-212µ
% 3 6 6
Mill Body Vibration mm/sec 20-25 <7
Separator vibration mm/sec 22-28 <8
SEEC MD KWh/T Mat 9.3 8.9 8.1
SEEC Fan KWh/T Mat 10.24 8.3 7.4
Total SEEC KWh/T Mat 19.4 18.9 17.8
Total reduction of around 1 KWh/T mat has been achieved
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
INNOVATIVE PROJECT -3 Page 1 of 3
Plant : WD Title of the measure : Reduction in Clinker
temperature by replacing 4 Nos. Cooler fan & 1 compartment cooler platesCategory A Known concept
with Unique Application
Description of the energy conservation measure:
The clinker cooler recuperation zone has 4 fans (4,5,6,7) for first moving compartments .These fans are replaced with higher pressure ratings. Design pressure of fan 4&5 is changed from 88 mbar to 120 mbar whereas of fan 6&7 is changed from 88 mbar to 112 mbar. The cooler plates (350) of compartment 2 were also replaced during the shutdown.
Problem Faced:
✓ Higher Clinker Exit temperature
✓ Higher Thermal Energy Consumption✓ Restriction in Fan Flow
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
TANGIBLE IMPACT OF THE PROJECT Page 3 of 3
•The grate speed is reduced from 14-16 ST/min to 10-12 ST/min. There is improvement in clinker bed height and clinker cooling. •The ESP inlet temperature on finer clinker side is around 320 deg C and on coarser side is around 240 deg C. •The measured clinker temperature was in the range of 145 -155 deg C. This reduction in clinker temperature from earlier 175-180 deg C corresponds to reduction in cooler losses by ~ 4.0 kcal/kg Clic.
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
Renewable Energy sources & Compliance of RPO
30
Solar Delineators @ all curve ant intersection
Solar Powered Zebra crossing with flasher & buzzer
Solar Street Lights installed at Plant & various location
Particulars Units Y'2013-14 Y'2015-16 Y'2016-17 2017-18 Total
REC's Liability (Solar & Non-Solar) Nos. 20782 23010 27017 41517 112326
REC's Purchased (Solar & Non- solar) Nos. 20615 23083 25286 26000 94984
Purchase of solar power MWh 0 0 1700 15517 17217
Short / Excess Purchased (Solar & Non-Solar)
Nos. -167 73 -31 0 0
To promote Renewable Energy we have consumed 19106 MWh of
solar power at Wadi Cluster during Y2017-18.
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
Utilisation of waste for replacing the conventional energy
Pre-processing: Capacity- 200 M3/Hr
Co-processing: Capacity- 150M3/Hr
Consists of Metso M&J 4000 S
hook shredder, REMA belt
conveyors, Steinert Magnetic
Separator & Eco-star screen.
Suitable for material with bulk
density= 0.1 to 0.6 t/m3
Suitable for material having
moisture range= 0 to 70 %
Facility to handle both HZ & NHz
Waste
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
AFR Performance
Plan to increase TSR % from 12% to 20% by the year 2020 by adding another Pre-processing line of having investment of Rs. 70 Cores – In progress
Utilisation of waste for replacing the conventional energy
0.02
4.09
6.43
9.69
11.39
10
71
70 1
55
16
2
23
94
66
16
79
30
2994242340
62530
40521
0
50000
100000
150000
200000
250000
300000
Y'14 Y'15 Y'16 Y'17 Y'18
0.00
2.00
4.00
6.00
8.00
10.00
12.00
TSR (%) TSR (m Kcal) TSR (MT)
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
GHG Inventorisation
33
Scope -1 : Emissions from Kiln fuel, CPP fuel, Own vehicle fuel consumption, Calcination, fuel for drying if any
Scope -2 : Emissions from Grid electricity consumptionSpecific GHG (KG CO2/T cem) increased in the year 2015 due to higher clinker production
✓Various Energy Efficiency measures taken for reduction of SEEC & STEC, resulting reduced GHG Emission
✓ Increased in TSR from 6.43% in 2016 to 9.69% in 2017
✓ CPP SHR has been reduced from 3448 Kcal/kWh in Y 2014-15 to 3363 Kcal/kWh in Year 2017-18
✓ CPP, APC has been reduced from 13.3 % to 12.8% due to various energy efficiency measures taken like VVFDs in BFW, ACWP, CEP, SA fan in STGs .
✓ Way forward - Potential to be tapped for additional reduction in GHG Emission by WHRS – 13.2 MW & Improve TSR up to 20%
0
200
400
600
800
1000
1200
1400
1600
1800
2015 2016 2017 2018
1651
1394 13961354
992939 916 904
Sp. Net CO2 (Kg CO2/T Cem) Sp. Net CO2 (Kg CO2/T Clic.)
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
Green Procurement & Green mission Policy
1. Optimization of natural resources
2. Installation waste heat recovery
system to produce green energy
3. Sustainable reduction in Plant
Energy consumption
4. Reduction in plant water
consumption
5. Cement manufacturing with Zero
harm to Environment
6. Our slogan “Manufacturing of
Green Cement”
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
Projects implemented in Green mission Policy
1. Dispatch of Bulk Cement to bulk terminal at Mumbai via rail transportation (16% of total dispatch- 359730.8 MT)
2. Major portion of Cement Bag dispatch through rail to reduce GHG emission (53% rail & 47% road)
3. Major portion of Clinker dispatch through rail to reduce GHG emission (82% rail & 18% road)
4. Finalizing the order of electrical equipments based on efficiency & BEE star rating.
5. 100 % own fly ash transportation through pumping. Bulker movement has been eliminated.
6. Zero waste discharge from the boundary of the plant.
7. Major portion of fly ash transportation through rail transportation.
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
Involvement of Employees, Team work in ENCON, ….
✓To achieve our objective of manufacturing of Green Cement we have formed various cross functional team to improve the performance by enhancing energy Efficiency & minimum harm to environment✓Identifying the gap in performance and develop Roadmap for bridging the GAP✓Monitoring progress in weekly review meeting along with functional manager chaired by unit head for improving operational excellence
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
Involvement of Employees, Team work ….
37
Project methodology1. Problem Identification 2. Observation3. Analysis 4. Action 5. Check (Saving
validation by Plant FICO
6. Standardization7. Conclusion
Basic problem solving tools1. Check Sheet2. Stratification/ Classification3. Pareto Diagram4. Cause & Effect Diagram
4a. Brain Storming4b. Cause & Effect Analysis4c.Cause Analysis Table4d. Why-Why Analysis
5. Histogram6. Scatter Plot & Correlation7. Graphs & Control Charts
S.No Section Wadi
1) Quarry/Mines 42) Production 53) Electrical Energy 104) Quality 55) Maintenance 56) CPP 107) Geocycle 68) Packing Plant 39) Plant logistics/GIGO 4
Total Projects 52
Project of Year 2017
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
Online monitoring of electrical energy – EMS
Hourly Tracking of section wise SEC through auto generated SMS
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
3
9
Energy Management System & Energy Policy
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
PAT Cycle Performance
Baseline SEC Target SEC Assessment year Normalized SEC
0.0922
0.0874
0.0829
GtG
SEC (
toe/t
on o
f eq.
Cem
)
Nos. of ECerts: (+) 23426 Nos.
ACC Limited, Wadi Cement Works 19h National Award for Energy Excellence in Energy Mgmt.
Major Investment for Energy Conservation
# Project Description AmountRs. Cr.
Current Status
1 Replacement of SF Bar Cooler fans 0.82 Implemented
2 Bed Ash Coolers for AFBC & CFBC Boilers 6, 7 at CPP 4.1 Implemented
3 New PYROJET Burner 1.5 Implemented
4 CPP – Zero Liquid discharge project 8.25 Implemented
5 Online condenser cleaning system 0.82 Implemented
6 Replacement of GRR with SPRS in RM#1 fan. 0.93 Implemented
7 Up gradation of CM inlet fly ash feeding system 0.70 In progress
8 To increase TSR % from 10% to 20% in Y’2020 by adding another Pre-processing line.
70 In progress
9 Air cooled condenser for TG4 & TG5 50 In progress
10 Replacement of PH ILC string fans with high Efficiency fan 2 In progress
11 Replacement of 3-way separator to standard separator 5 In progress
12 Up gradation of DCS Operating 3 In progress
13 Replacement of Condenser Tubes TG5 1.5 In progress
14 PIT navigation system - Intelligent optimization software for Cement Kiln
2.5 In progress
Total 151.08 cr. (10% of turnover)
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
ENVIRONMENT POLICY
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ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
SD 2030 action Plan for Water :-“Target for Water Y 2020 – 32% reduction in specific fresh water withdrawal vs 2015”
Key Initiatives
▪ Conservation of Rain water at mines pitsof capacity 40 Lakh m3 used to run theplant.
▪ “RO” Plant for drinking water at plant &colony
▪ Monitoring of water consumption on dailybasis.
▪ Zero water discharge from plant.
▪ 100% utilization of CPP cooling towerand DM plant blow down water, Boilerblow down, RO discharge, Sand filterback wash water etc. “ZLD concept”.
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Initiative - Water ManagementLits/
t cem
Specific Water consumption
0
100
200
300
400
500
600
2014 2015 2016 2017 Target
2020
524
405
337 318276
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt. 44
Environmental ProjectsE
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Pro
ject
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s ▪ Continuous Emission monitoring system for ILC & SLC string has beeninstalled for online monitoring of flue gases and reporting to SPCB/CPCB.▪ Online ambient Air Quality monitoring Station has been installed formonitoring the quality of ambient air.▪ ROC-F9 & L-8 Drill Machine with dust collector is used at mines for reducing the fugitive emission during drilling.▪ Nonel technology is being used for ground vibration monitoring analysis and redesigning of Blasting pattern.▪ Eco- friendly Electric Shovel is being used for dumper loading inside the mines. ▪CPP ZLD project has been commissioned to reduce water consumption▪ESP transformers has been replaced from single phase to 3 phase to improve ESP performance▪ TSR (Thermal substitution rate) has been increased up to 12% by commissioning Pre & Co-processing platform (PCPF). ▪New water tanker with spray nozzles has been procured at mines to reduce fugitive emission
ACC Limited, Wadi Cement Works 19h National Award for Energy Excellence in Energy Mgmt.
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
Mr. Piyuesh Goyal, Hon’ble Minister of State (Independent Charge) forMines, Power, Coal & New Renewable Energy GOI awarded the trophy toDr. S B Singh, Cluster Head South, ACC Limited
FIMI – Health & Safety Award
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Wadi Cement works bagged the FIMI – Health & Safety Award Y15-16
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
National Award for Excellence in Energy Management by CII
National Award as “Energy Efficient Unit” by CII in year 2018, 2017 & 2016
ACC Limited, Wadi Cement Works 19h National Award for Energy Excellence in Energy Mgmt.
Awards & Accolades
Green Manufacturing Excellence Gold Award - 2012
National Award for Excellence in Energy Management- 2011
India Manufacturing Excellence Gold Award - 2012
Green Manufacturing Excellence Award- 2014
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
▪ National Award for outstanding performance in promoting rural and agriculturaldevelopment – by ASSOCHAM
▪ Indira Priyadarshini Vrikshamitra Award - by The Ministry of Environment andForests for "extraordinary work" carried out in the area of afforestation
▪ FICCI Award - for innovative measures for control of pollution, waste management& conservation of mineral resources in mines and plant
▪ Subh Karan Sarawagi Environment Award - by The Federation of Indian MineralIndustries for environment protection measures
▪ Drona Trophy - By Indian Bureau Of Mines for extra ordinary efforts in protectionof Environment and mineral conservation in the large mechanized mines sector
▪ Indo German Greentech Environment Excellence Award
▪ Golden Peacock Environment Management Special Award - for outstandingefforts in Environment Management in the large manufacturing sector
▪ Indira Gandhi Memorial National Award - for excellent performance inprevention of pollution and ecological development
Awards And Accolades
ACC Limited, Wadi Cement Works 19th National Award for Energy Excellence in Energy Mgmt.
Thank You
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