Satendra Singh ACC Ltd, Kymore Cement Works 15 June, … · Satendra Singh ACC Ltd, Kymore Cement...

For a Zero Waste Future

© 2014 Holcim Technology Ltd

Satendra SinghACC Ltd, Kymore Cement Works

© 2014

15th June, 2016


Overview of Madhya Pradesh

2

ACC Kymore Cement Works

Ramky Hazard Waste Management

Hoswin Incinerator

Rajratan Technique & Technology

Ultratech Cement

Jaypee Cement

Reliance Cement

Other Cement Players

• ACC Kymore cement Works holds 2% of Hz waste market (Pharma, Automobile, Manufacturing/Engineering, Refinery, Chemical, Textile & Beverages & other NHz wastes, like FMCG, Laminates GeneratingUnits, etc.


About Company

ACC Limited is a pioneer inextending co-processingservices in the country toprovide a safe andenvironmentally friendlymethod for the managementof wastes to the industry andsociety. These services areprovided under the brandname of Geocycle , which istheglobal waste managementbrand of Lafarge-Holcim, thepromoter of ACC Limited.Lafarge - Holcim is one of theworld leaders in cementmanufacturing and has anexperience of more than 30years in waste co-processing.

3


GreenCO - Journey

Green Journey of Kymore Cement Works has brought several laurels in the form of prestigious Awards like:

• GreenCo Award (Gold Category)-2014,

• Earth Care Award for Reduction of Green House Gases Emission in Large Enterprises Category–2014,

• CII 14th National Best Energy Management Award–2013,

• CII Environmental Best Practices Award–2013,

• Eco-Corporate Yes Bank Award for Natural Capital-2013,

• CII Environment Best Practices Award-2011,

• National Energy Conservation Award-2010 (First Prize) from BEE, Ministry of Power, Govt. of India, etc.

4


Site Overview of Geocycle Ky


Preprocessing & Coprocessing

6

Preprocessing Line – Flow sheet

Co-processing Line – Flow sheet

Walking Floor With CBC

Weighfeeder

Long BeltMetal detector

RAL with Shut gate

Sacrificial Belt

© 2014 Holcim Technology Ltd 7

Details of Facility

• Shredding Line – 200 m3/Hr (90000 TPA) from M/s Metso, Denmark consists of M&J4000 S hook shredder, REMA belt conv.,Steinert Magnetic Separator & Eco-starScreen

• Storage & Processing Shed 100m x 40mwith 5.5 m high concrete walls.

• Geomembrane sheet is provided in floorof facility and firewater retention basinalong with separate leachate collectionsystem to avoid the contact of spillagematerial with soil and water

Moving Machines• Liebherr Hydraulic Arm Handler• Liebherr Wheel Loader• Terex mini skid Loader• Jungheinrich Fork-Lift• Genie Scissor Lift

Fire Fighting• Fire fighting with 1200 m3 water storage and 3 pumps of 410 cu.m/hr with 1 Jockey pump• 597 ESFR Sprinkler, 5 Hose real & 8 Hydrant post

• Walking Floor with Chain belt conveyor M/s Westeria cap. 160 m3

• Weighfeeder cap.24 TPH• Long belt conveyor 171 m in length• Sacrificial belt , Rotary air lock

( 100 m3/Hr) m/s BMH with ATS Safety shut off gate


Pics of Facility


Walking Floor

Shredding Line Pit 1 Pit 2

WFPower

Metso cont. Hyd room

Pump House

Colour code

Description Qty at Site

DCP type Extinguisher

13

CO2 Type Extinguisher

11

Water Type Extinguisher

1

Foam TypeExtinguisher

2

Spill control Kit

2

Safety Eye Washer and Body shower

2

First Aid Box 3

Emergency Exit

2 in PCPF

PCPF Load CenterGround

Floor

1stFloor

Emergency Facility Available at Pre Processing Facility

Outbound Area

Inbo

und

Are

a

Emergency Exit 1

Emergency Exit 2

Fire D

oor

Assembly Area


Salient Features of facility

Induction

• Pre-processing is carried out in an enclosed and sealed area

• Geo membrane and complete leachate control systems in place on work floor.

• Emphasis on OH&S – PPE, Fire fighting system, FPE & CSM

• Modern facility with state of the art handling and processing equipment

• No effluent or by product is generated

• Zero discharge and non-polluting

• Compliance with national rules and guidelines for Hazardous waste

• Respects waste management hierarchy

• Waste to product


Fire fighting Facility - Pump house with Water tank and fire water retention basin


Pics of load Centre


Fully Equipped LAB

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Sample storage room Lab – Equipment

Lab equipment room Lab – Equipment



More area of contact for proper hold

Additional tightening arrangement

Hemi spherical back support with chain & zipper/Strap

tying arrangement is finalized



Emergency Eye wash & Safety Shower provision at Lab



RAMP

Providing of Ramp for wheel chair of handicapped is developed in Administration and lab building



Fire fighting line (Deluge valve) Housekeeping



First Aid training to all staff members



First Aid Box available at site



Locking arrangement for Fire fighting pump main val ve



Wheel choke provided for Truck



Power distribution drawing provided at MCC



Frequently training on emergency handling to all Se curity staff



Isolation procedure, Electrical earthing rod with rescue rod & First aid procedure display a t site



Instruction & Signage provided


Kiln2 Biomass Feeding System

26


Kiln2 Biomass Feeding System


Achievement of Year’15

• Ever Highest TSR 4.77% Cumulative(Highest in ACC)

• Ever Highest GAV 25.21 CroreCumulative (Highest in ACC)

• Co-processed Quantity 61943 MThigher than 2014 (45826 MT in 2014)

• Highest TSR in the month of Dec10.64 % (K1 & K2) and 21.41% in K1

• Highest TSR of the day 30.16 % in K1 (12th Dec'15)

• Successfully completion of Dream Run(Total 1860 MT with TSR 27.51% weekcumulative) in the K1


Kymore Plant

Clinker Production Capacity (TPD) K1- 4500, K2- 4500

Installed Pre & C0-processing Capacity (TPH) K1-15, K2-15

Executive Summary: AFRTSR – TEE [%]

•GAV & TSR of 2017, 2018 & 2019 is tentative

154178

226 237 252

337

436

507539

0

100

200

300

400

500

600

2011 2012 2013 2014 2015 2016 2017 2018 2019

GAV(INR mio)

GAV(INR mio)

0.91

3.71 4.03

2.85

4.77

8.75

11.49

13.3914.24

0.891.37

1.93 1.87

3.52

4.775.75

6.85

8.03

0.00

2.00

4.00

6.00

8.00

10.00

12.00

14.00

16.00

2011 2012 2013 2014 2015 2016 2017 2018 2019

TSR TEE


• Investment made : 66.30 Cr

• Annual savings achieved : 25.20 Cr

• Payback : 5 Years

• We save 60394 Tons of tradition fuel and raw material in year 2015

Cost of Project

31

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Satendra Singh ACC Ltd, Kymore Cement Works 15 June, … · Satendra Singh ACC Ltd, Kymore Cement...

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