National Award for “Excellence in Energy Management … Award... · § Cement Manufacturing...

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Chennai

1st & 2nd September 2010

ACC Wadi-II Plant

11th National Award for “Excellence in Energy Management – 2010”

Welcome to

World’s Largest Clinker Production

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11th National Award for “Excellence in Energy Management – 2010”ACC Wadi

01.09.2010

Contents

§ Company Details

§ Cement Manufacturing Process

§ Energy Conservation & Consumption per unit of Product

§ Comparison with Global norms/benchmark data

§ Innovative & Environmental Projects

§ Involvement of Employees, Team work in Encon, Monitoring & Reporting formats and implementation methodologies

§ Renewable Energy sources, Utilization of waste for replacing the conventional energy & Water Management

§ Implementation on Energy front amongst associates (Vendors / Suppliers, contractors etc)

§ Certifications

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Company DetailsCompany Name : ACC Limited., Wadi Cement Works

Wadi-II Plant

Address : ACC Limited, Wadi Cement Works

WADI (P.O) – 585225,

Gulbarga District, Karnataka State

Phone: 08472 - 202406

Fax : 08476 – 202190

Type of Industry : Cement

Type of Process : Dry Process

Production Capacity of the plant :

Product : Portland Pozzolona Cement

Capacity : 33.5 Lakh tons cement per annum

Energy Cost as a % of manufacturing cost : 47.14 %

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Contents

§ Company Details








§ Certifications

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6.1 Cement Manufacturing Process Mass Flow ( Pre- Post Expansion)

Coal Mill50 t/h

Stock Coal20000 t

Preheater SLC5500 TPD

Rotary kiln Dia 6.0m x96m,5500+7000

Vertical roller mill 560 t/h

SF Cross Bar coolerCap: 13000 tpd

Crusher1000 t/h

Cement ball mill withPregrinders 6&7225 t/h (PPC)

Raw Material Extraction

Conv.belts1000 t/h

Clinker siloCap: 115000T

Silo -1 Cap:11000T

Silo - 2 Cap:11000T

Silo - 3Cap: 11000T

CF silo21000 t

Fly AshCap: 2300 t

GypsumCap: 20000 t

Crusher1200 t/h

Conv.belts1300 t/h

Shale storageCap: 2x9000 t Shale

Vertical roller mill 425 t/h

Preheater ILC7000 TPD

=12500 TPD

Coal Mill90 t/h

Stock Coal30000 t

Clinker silo

Cap: 60000T

Raw materialIron ore, Bauxite & Laterite Cap:20000

Fly AshCap: 4000 t

Post Expansion

ExistingCap: 2x40000 t Limestone

For bulk transport

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Energy Policy

Our Mission is :

To be amongst the lowest energy consumers in the cement industry

We have to accomplish our mission by:

§ Benchmarking our performance against comparable technology & capacity

§ Promoting & encouraging Energy Saving & conservation of natural resources.

§ Creating awareness among all people concerned within the organization through workshops, seminars, external training and Annual Zonal Energy Award Competition.

§ Carrying out regular internal & external audits to identify areas for improvement.

§ Adopting cleaner and energy efficient technologies in all areas.

§ Reducing specific energy consumption by atleast 2.5% every year

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Contents

§ Company Details








§ Certifications

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Energy Consumption of Wadi II Plant:

Energy Conservation & Consumption per unit of Product

§ Specific energy consumption includes the power consumption of all auxiliaries including transformer losses, colony power, plant and colony lighting, plant and colony water pumps, ETP etc..

§Process power for year 2009 is 69.97 Units/T as against 71.43 Units/T in 2008

§ From the year 2007 onwards, the thermal Energy consumption is calculated on as fired basis (initially it was on as received basis).

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Information Provided as per prescribed Form -A of the annual report

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Energy Consumption per unit of Product:


Information Provided as per prescribed Form -A of the annual report

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§ Company Details








§ Certifications

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Comparison with Global norms/benchmark data

Comparison of specific energy consumption - Region

Given below is the comparison with other Energy Efficient units in India. However Vasavdatta Cements, Sedam is our nearest competitor within the region

Source: CII - Manual on Best Practices in Cement Industry

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Comparison of specific energy consumption – With National and International Benchmarks

Source: CII - GBC Green Cementech Conference 2010, Hyderabad

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Road map to achieve benchmark

At ACC Wadi Cement Works we are committed to achieve and surpass world class standards in Specific Energy consumption. For this we follow the three pronged strategy as under:

§ Implementing the concept of Energy Efficiency at the proposal and design stage itself

§ Identifying the opportunities through internal and external sources like conducting Energy audits, brain storming sessions and training programmes.

§ Increasing awareness among all the stakeholders and by motivating them

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Road map to achieve benchmark

§ Energy Efficiency at it’s best in the design stage itself…4 After Hookup, the existing Kiln will be the World’s single

largest kiln of 13000 TPD4 Tallest pre-heater of 175 mt. height with in line calciner to

enhance the thermal energy efficiency of the plant4 World’s largest and highly efficient SF 6X8 cross bar cooler, to

further improve the thermal energy efficiency.4 Tallest bag house chimney of 180 mt. height to reduce the fan

power consumption by utilizing the natural draft.4 Total 6 nos.of MV drives for kiln main drive(1350KW X 2),

preheater fans(1350KW X 2),Bag house fan(1750KW), and Coal Mill Fan(2000KW)

4 Total 15 nos.of 12 pulse VVFDs (total 6400KW) for Cooler fans, cooler ESP fan, PA fan etc.. and 7 nos.of 6 pulse VVFDs (total 1150KW) for other applications like separators and belt conveyors etc..

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Contents

§ Company Details








§ Certifications

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Innovative & Environmental Projects

Synopsis:Increasing the fly ash absorption is a very attractive option for the cement plants, in view of the reduction in co2 emissions on one hand and the reduction in manufacturing cost on the other. But maintaining the quality norms of cement , at increased fly ash absorption levels is a challenging task.

Approach & Methodology:4 After internal discussions, we decided to increase the C3S content of clinker

by adjusting required CaO & flux. We have increased C3S from 53% to + 55% by adjusting Flux.

4 Laboratory Trials with different sources of gypsum & additives was conducted to get the desired quality of cement

4 Plant scale trials conducted with different additives & gypsum to establish the quality of cement

4 Optimizing the residue levels in the cement & maintaining on the consistent basis.

Innovative Projects:

§ Project 1 - Increasing Flyash absorption in PPC:

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Results & cost benefit analysis:

Year avg. FA increased from 26.80 to 30.34%

Maximum monthly average Fly ash achieved: 34.2%

Maximum day average Fly ash achieved : 34.8%

At 30.34% overall savings in cash cost : Rs 74 / MT

Savings accrued for the YR 2009 : Rs. 2075 Lakhs

Impact on energy consumption:

Reduction in Total Energy Kwh/Ton of Cement

Reduction due to increase in clinker factor =2.35 Kwh/ton of Cement Increase in Grinding Energy = 1.12 Kwh/Ton of Cement

Overall Reduction in Total Energy Kwh/Ton of Cement = 1.23Kwh/Ton of Cement

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Synopsis:

Shovels and Dumpers are the major energy consuming equipment in the Mines. They consume huge quantity of Diesel oil and in turn release Co2 and other noxious gases into the atmosphere.

Electric shovel offers the benefits of reliability in operation with lower carbon footprint compared to their diesel – powered counter parts.

Results & cost benefit analysis:

1400 TPH Electric Shovel was commissioned in the month of June 2009.

Investment = 14 Crores

Specific Power consumption of Electric Shovel = 0.25Kwh/Ton of material

§ Project 2 - Commissioning of Electric shovel at Mines:

Innovative Projects:

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Operating cost of Electric Shovel = Rs.2.20/- per Ton of material

Operating cost of EX 1200 Diesel Shovel = Rs.6.60/- per Ton of material

Annual operating cost saving = Rs. 2.25 Crores

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4 Cement industry has the unique opportunity of reducing CO2 through product modification i.e. with the Production of Blended Cement. Wadi-II Plant produces PPC only and thus contributes to significant reduction of CO2. The validation of the project under CDM is under progress.

4 Monthly Co2 emissions are quantified at the Plant level and the same is sent to our Central Energy & Environment Conservation Cell. From there, the entire group Co2 emissions are reported to Holcim, which are in turn published to World Business Council for Sustainable Development (WBCSD).

Environmental Projects:

§ Project Linked with Carbon Emission Reduction initiative

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Summary of Co2 Emission:

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Environmental Projects:

List of Energy Conservation Projects implemented

List of Energy Conservation Projects implemented

during 2007

during 2007--08, 200808, 2008--09 & 2009

09 & 2009--1010

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Energy Conservation Projects implemented during 2007

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Energy Conservation Projects Porposed for 2010

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Energy Conservation Projects Porposed for 2010

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Environmental Initiatives proposed for 2010

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Contents

§ Company Details








§ Certifications

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Involvement of Employees, Team work in Encon, Monitoring & Reporting formats and implementation methodologies

§ M/S.ACC Ltd., Wadi Cement Works is committed for conservation of energy. The Energy Management is the critical focus of the top management. The result is evident from the remarkable improvement in terms of specific power consumption. It has reduced from 78 kWh/ton of cement in 2004 to 72.06 kWh/ton of cement for the period 2009.

§ At the Corporate level we have an Environment and Energy Conservation Cell, directly representing to the Managing Director. They review the energy consumption parameters of all our units regularly.

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§ At the plant level we have the Energy Apex committee and Energy First committees for various departments. There are total seven Energy first committees that belong to various departments and consist of the frontline workforce in each department. They are formed with the clear mandate of

4 Better management of available power4 Pinpoint the wastages4 Identify energy efficient measures 4 Increase awareness among all

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§ The Energy Apex committee works under the leadership of Director (Plant), and Head –Operations with all department heads as members. This committee meets once in a fortnight to review the plant energy consumption during that period, status of various on going energy conservation measures and the suggestions received from Energy first committees. Energy Manager acts as a coordinator between these two, and looks after formulation of proposals and their implementation. The energy consumption parameters are reviewed in daily production meetings, and the reasons for variance if any, and the actions to be taken are discussed

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Organization Structure for Energy Conservation activities at Wadi-II:

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Energy Conservation Projects of Wadi-II which involve Employees & Team work with different implementation methodologies:

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Brown paper exercises for energy conservation

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Brown paper exercises for energy conservation

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§ % breakup of time currently spent (average basis) of senior executives in various functions are as follows:

a) Technology Implementation - 15 %

b) Manufacturing excellence - 15 %

c) Materials Management - 20 %

d) Marketing Coordination activities - 15 %

e) Analyzing Competitors Profile - 10 %

f) Quality Management - 10 %

i) Energy Conversation Measures - 15 %

Total - 100%

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§ Frequency of review of energy consumption and energy conservation projects are Daily / Weekly / Monthly.

§ The energy consumptions in the plant is monitored daily and reviewed at regular intervals. At the beginning of every financial year targets are fixed for both electrical and thermal energy consumptions. The same parameters are closely monitored by the Energy Manager and concerned Section In charge as follows:

4 Monitoring of specific power consumption for major units4 Monitoring of energy MCC wise

Monitoring & Reporting:

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§ The daily Power Consumption parameters are reviewed in the daily production meetings, and the performance is reviewed in the fortnightly Energy First and Apex committee meetings.

§ The energy consumption parameters are also closely monitored by the corporate office. The Environment and Energy Conservation Cell (EECC) in the Technical Support Services (TSS) office at Thane reviews the energy consumption parameters of all our units regularly. They also set the targets to be met and provide support in attaining them

Monitoring & Reporting:

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§ Format of Daily Specific Power Report:Monitoring & Reporting Formats:

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Monitoring & Reporting:§ Format of Fortnightly & Monthly General Management Report:

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Contents

§ Company Details








§ Certifications

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Renewable Energy sources, Utilization of waste for replacing the conventional energy & Water Management

§ The percent share of renewable energy capacity to total captive power capacity of ACC is 6% at present, and the target is to increase this share to 15% by 2013.ACC has two wind forms located at Rajasthan and Tamil Nadu, which have generated 40 million units of wind power is during 2009.

§ As a part of the CSR activity Wadi Cement Works has donated 37 nos.of TATA Solar lamps, worth Rs.5 Lakhs to the neighboring villages, during 2009 – 10.

Renewable Energy Sources:

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§ As a part of expansion, AFR feeding system is being installed at our plant, which will be in operation from October 2010.This system is designed by FL Smidth, with a capacity of 2 to 20TPH, based on the type of material. This will enable us to replace approximately 55 % of the fuel fired in ILC by RDF (Refuse Derived Fuel).

§ At present AFR usage is being carried out at our Wadi I plant. AFR testing lab is also commissioned during the Year 2009 which will cater to the needs of both Wadi I and Wadi II plants.

Utilization of Waste as Fuel:

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Commissioning of AFR testing laboratory in 2009 :

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§ Rain Water Harvesting and Water Management

4 Conservation of Rain water (Water storage in mining area equivalent to 185 days consumption)

4 24 Lakh cu.m water in mines sump4 Construction of Barrage at Kagina River4 Reverse Osmosis Plant4 Reduction in water consumption 4 Zero water discharge from plant

Water Management:

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§ Afforestation and Green belts :

4 Clad with thick band of luxuriant plantations, Wadi Mines poses the most modern and one of the biggest Limestone mines of Asia in terms of production. The mines has done systematic plantation on dumps when dump had attained their full heights The slopes are well laid with green grassy lawn to protect the soil erosion

4 The long tree plantation along the mining lease boundary and on edges of ultimate pit limits garlands the mines and motivates for environment propagation at mines

4 Overall 2.05lakh trees have been planted in the plant and neighboring areas. Approximately 10 Ha of green belt has already been developed on the dumps. The trees like Neem, Eucalyptus, Gulmohar, Subabool, Sisso, and Cassacimia have been commonly planted

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§ Afforestation and Green belts at Mines :

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§ Company Details








§ Certifications

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Implementation on Energy front amongst associates (Vendors / Suppliers, contractors etc)

§ The rail movement of goods is more environment friendly compared to road. At ACC rail transport in large –rake loaded quantities is preferred and bulk cement distribution is promoted. ACC dispatches 51% of its cement by rail, compared to the industry average of 37%.

§ At Wadi Cement Works, 85% of the cement dispatches are carried out by rail. Apart from this rail transport system for fly ash handling is near completion. At present the fly ash is transported from Raichur Thermal Power station through bulkers by road. After completion of this system, the movement of fly ash by road will be reduced to 50%.

Material Transportation (Inbound & Outbound) by Rail:

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§ As a policy, all our vendors are requested to include only energy efficient motor for their equipment (fans, compressors etc).

Vendors Policy :

§ In a short span of time, ACC has accomplished four instances of environmentally-friendly GREEN BUILDINGS.4 Our corporate head quarters “Cement House”, which is a

70 year old corporate building in Mumbai, has received the Gold shield from IGBC in LEED New construction & Major renovation category.

4 A 45 year old residential apartment in Thane (La residency) is redesigned and converted as a state of the art residential facility. This building incorporates the unique and energy efficient Geo-thermal air conditioning system. This is a pre-constructed platinum rated LEED project.

Environmentally-friendly GREEN BUILDINGS:

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4 ACC Greens Village, residential colony at the new ACC plant near Bellary, is under execution. This project promotes solar energy, rain water harvesting and natural air cooling. A climate responsive strategy for the colony has been designed based on climate analysis, factoring sun path, wind Details and water cycles.

4 New CCR building of Chanda cement works, is also planned as an energy efficient green building.

Environmentally-friendly GREEN BUILDINGS:

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Contents

§ Company Details








§ Certifications

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Certifications

ISO 9001:2000 ISO 18001:2000

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Certifications

ISO 14001:2004IMC RAMKRISHNA BAJAJ NATIONAL QUALITY AWARD 2007

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Certifications

National Energy Management Award 2008

National Award for Excellence in Water Management 2009

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Certifications

Institution of Engineers (India) Safety innovation Award 2009

FIMI – Abheraj Baldota Environment Award 2009

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