17th National Award for “Excellence in Energy Management ... … · 9 Replacement of GRR by MVVFD...
Transcript of 17th National Award for “Excellence in Energy Management ... … · 9 Replacement of GRR by MVVFD...
17th National Award for “Excellence in Energy Management – 2018
Presented By : Mr. B Baral
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ACC Limited
Genesis of the plant....
1989 1995 1997 2005 2007 2007 2014
1923
1923 Plant Established
Total Capacity0.09 MTPA
Wet Process
1995: Inception of Dry process
(Kiln 1) – Total Capacity1.0 MTPA
1997: Inception of Dry process
(Kiln 2) – Total Capacity2.2 MTPA
2005 –Installation
of Over Land Conveyor(Length –
11.5 Kms)
2007 –
Installation
of New
25 MW CPP
2007 –Installation of
New Ball Mill –Total Grinding Capacity
– 2.5 MTPA (Old inefficient
ball millswere stopped)
2014 –
Successful
commissioning
of Geocycle
PCPF Project
Standing
with
pride in
2017
(after 94
years)
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ACC Limited
Process Flow…
2 Raw Mills RM1 –333 TPH RM2 –337 TPH
2 Kilns -K-1 (ILC) –4820 TPD-K-2 (SLC) –4980 TPD
3 Cement mills (Ball Mill) with 1PG -2.35MTPA Capacity)
Packing House- 4 Packers with capacity of 180+180+150+240 TPH)
Quarry -- MHG Mines (2.9 MTPA) - BMG Mines (1.2 MTPA)- JamuwaniMines (0.2 MTPA)
Quarry Raw Mills Kilns Cement Mills Packing House
BDP figures are shown here.
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ACC Limited
Sp. Energy Consumption in Last 3 Years
730.57734.58 734.80 733.87
700.00
710.00
720.00
730.00
740.00
750.00
760.00
2015 2016 2017 2018 YTD
JUNE
KCal/ Kg of Clinker
79.31
85.2082.80
78.96
70.0072.0074.0076.0078.0080.0082.0084.0086.00
2015 2016 2017 YTD Jun2018
Year wise kWh/t Cement
Higher SEEC in 2016 due to Low Production
4.6% reduction
75.29
79.7478.63
76.87
72.00
74.00
76.00
78.00
80.00
82.00
2015 2016 2017 YTD Jun
2018
Year wise kWh/t of Clinker
Higher SEEC in 2016 due to Low Production 2.2%
reduction
31.47
34.333.72
31.51
30
32
34
36
2015 2016 2017 YTD Jun 2018
Year Wise kWh/t of Cement Grinding
Higher SEEC in 2016 due to Low Production
6.5% reduction
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ACC Limited
National & Global Benchmark
79.31
65.0457.04
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
Best Achive Figure National Best International Best
SEEC (kWh/t Cement)
22% Gap
724
678
651
600
620
640
660
680
700
720
740
Best Achive Figure National Best International Best
STEC (Kcal/kg of Clinker)
Higher Electrical Energy due to
❖ Ball Mills in place of VRM
❖ Old & Scattered Colony
❖ Higher SEEC in PH fans due
to higher Pressure drop
across preheater
❖ 11 KM Long Belt Conveyor
for LS Conveying from Mines
Higher Thermal Energy due to
❖ Lower recuperation
efficiency of old design cooler
(Grate Cooler) as compared
to Latest cross bar cooler .
❖ Higher TSR %
6.4% Gap
Note: National Benchmark Source : Energy Benchmarking for Cement Industry - May 2015, Version-2 by CII and NCCBM Awards 2015
International Benchmark Source : N. A. Madlool et al./ Renewable and sustainable Energy reviews 15 (2011) 2042 -2060
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ACC Limited
Sr
No.Description
Investment
Rs Lacs
Saving in
Kcal/kg
Clinker
1New high efficiency cooler is required with loading <45
TPD/m2.2000 10
2 Installation of tube dust conveyor for line-2 cooler. 70 1.5
3 TA diameter need to enlarge for Whole 66 m length for K-2 150 2.5
4Modification of existing hood with sufficient
volume to enable to obtain hot air velocity will be < 5m/s.200 2
5K-1 Preheater top Cyclone modification to get high
efficiency (efficiency > 96%)150 2
6
To reduce the thermal energy consumption by replacing
Single flap damper with double flap damper in lower most
cyclone in both Kilns10 0.4
7 Alumina painting in Pre-heater Cyclone
25.80 Cr.18.4
kcal/kg cli.
Road Map to Achieve Benchmark/Global Best
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ACC Limited
Sr
No.Description
Investment
Rs Lacs
Saving in
kWh/ T of
Cement
1 Replacement of GRR by MV VVFD for Bag house fan of K-1 100 0.43
2 Replacement of Pre heater fan GRR by MVVVF for kiln-2 120 0.17
3Replacement of GRR by MV VVF Drives for both E Mill-1& E
Mill-2 Fan100 0.18
4 Elimination of Booster fan by rerouting the duct K-2 320 0.27
5
Reduction of Bag House DP by addition of two nos. of extra module
in both Bag House or additional bag filter capacity 1.6 Lacs m3/hr
along with existing Bag house
400 0.43
6Replacement of low efficient Cooler ESP Fan Kiln-1 by energy
efficient fan rotor 50 0.11
7Revamp of EMS Systems with Upgraded Server, with connectivity to
mines, colony, OLC 50 0.10
8Replacement of two nos. Compressors(capacity 1200cfm,2kg/cm2)
for Fly ash unloading by Energy efficient compressors50 0.23
Road Map to Achieve Benchmark/Global Best
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ACC Limited
Sr
No.Description
Investment
Rs Lacs
Saving in kWh/
T of Cement
9 Replacement of GRR by MVVFD for Raw Mill-2 Sapex Fan 100 0.16
10 Replacement of GRR by MVVFD for Atox Mill Fan 60 0.10
11
Replacement of old reciprocating compressor used for coal
conveying from mill o/l to fine coal bin by turbo blower in E
Mills by turbo blower
40 0.08
12 Reduce pressure drop in preheater down comer duct – Kiln 1 Nil 0.08
13Reduce pressure drop in Line 2 Kiln – 3rd stage cyclone in Kiln
stringNil 0.04
14Reduce pressure drop across the duct from bag house outlet to
fan inlet –Kiln 2Nil 0.09
15 Reduce pressure drop across the circuit in Raw mills Nil 0.07
16Reduce pressure drop in down comer duct of Kiln Line 2 , Kiln
stringNil 0.05
17 Installation of RAL in feeding system of both the Raw Mills 20 0.21
13.05 Cr.2.38 kWh/t
Cement
Road Map to Achieve Benchmark/Global Best
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ACC Limited
Encon Projects (Last 3 years summary)
UnitNo
Investment
Low
Investment
Medium
InvestmentTotal
No of project
implemented# 36 11 6 53
Electrical
Energy Saving
Million
kWh19.26 4 3.38 26.64
Thermal
Energy saving
Million
kcal 195.93 372.94 21313.28 21882.15
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ACC Limited
Energy Saving Project implemented in FY 2015-16
Sl
No.Project Description
Annual
Elect. Energy
( kWh)
Annual
Saving
(Million
Rs.)
Invest.
(Million
Rs.)
1New Preheater fan for Line-2 for TSR %
improvement153437.49 0.21 10
2MV VVFD repair/ replacement for Bag house
fan line-22511000 13.61 0
3Reduction in Bag house-1 Fan Power by GRR
operation in place of damper control578000 2.66 0
4"Reduction in Clinkering Compressor Power
by Leakage arresting "77550 0.36 0
5Reduction in Specific Electrical energy by
increasing in Atox Mill Production1186000 6.69 0
6Reduction in power Consumption of Flash
Dryer Fan RM-11167000 6.58 0
7
Installation of new screen for tertiry crusher
feeding system /Improvement in TC Screen
availability
1155579 6.52 39.5
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ACC Limited
Energy Saving Project implemented in FY 2015-16
Sl
no.Project Description
Annual
Elect.
Energy (
kWh)
Annual
Saving
(Million
Rs.)
Invest.
(Million
Rs.)
8
Regrading of grinding media , Grinding Pattern
optimization in all the cement mills & other
improvement (Sapex fan Replacement of CM-9,
CM-8 Main motor replacement
1920000 10.41 0
9Avoid Pressure drop across PH fan inlet damper BY
New GRR installation229192.8 1.32 1.8
10Pneumatic gate provided for Atox mill reject coal to
ingress false air in the mill24518 0.14 0.1
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ACC Limited
Energy Saving Project implemented in FY 2015-16
Sl.
NoTitle of Project
Annual Thermal
Saving
Annual Thermal
Cost Saving (Rs
million)
Investment
Made (Rs
million)MCal
11Full feed operation of PCPF
Project for line-114867 ton/year 253 620
12Biomass feeding system for
line-26446.2 ton/year 9.01 40
13
T A Duct partial replacement for
improvement of thermal energy
consumption for line-2
45.94 ton/year 0 0
14
T.A Duct damper installation for
improvement of thermal energy
consumption for line-1.
372.94 ton/year 0.52 0
15Both kiln inlet Analyzer
reliability improved.149.99 ton/year 0 0
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ACC Limited
Energy Saving Project implemented in FY 2016-17
Sl
No.Project Description
Annual
Elect.
Energy (
kWh)
Annual
Saving
(Million
Rs.)
Invest.
(Million
Rs.)
1 De-Coal Crusher Modification by replacing hammer 198000 0.99 0
2Energy saving by optimization of Energy in CA unit
in CPP64240 0.32 0
3Installation of VFD for Kiln-1 Main Drive Cooling
Blower Motor.23040 0.12 0
4"High torque motor in CM-1&CM-9 has been
installed for clinker Rotary Feeder594000 2.97 0
5 False air leackage points Identification & plugging 356400 1.78 0
6 Restrict the grinding frequency from OPC & PPC. 475200 2.38 0
7
Interconnecting of Bag Filter Suction pipe for Both
the Fly ash silo top Bag filetr & stoppage of Bag filter
fan for Old Fly ash Silo
237600 1.19 0
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ACC Limited
Energy Saving Project implemented in FY 2016-17
Sl
no.Project Description
Annual
Elect.
Energy (
kWh)
Annual
Saving
(Million
Rs.)
Invest.
(Million
Rs.)
8Clinker Quality analysis and action at raw mix /Coal
for reduction of hard grove clinker grindability1188000 5.94 0
9De-water Pump operation Optimization done in
MGH360000 1.8 0
10Synchronization of both the mining operations
improve to more TPH of OLC514800 2.57 0
11Improvement in LS size by maintaining the mines LS
input size , moisture to TC crusher,1029600 5.15 0
12"False air points was arrested in Both the Raw Mill
Circuit "792000 3.96 0
13 False air points was arrested in Both the Emills 594000 2.97 0
14False air points was arrested in Both the Preheater
Circuit792000 3.96 0
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ACC Limited
Energy Saving Project implemented in FY 2016-17
Sl
no.Project Description
Annual
Elect.
Energy (
kWh)
Annual
Saving
(Million
Rs.)
Invest.
(Million
Rs.)
15 Cooer air flow has been optimised 633600 3.17 0
16Replacement of Low efficiency Pre heater fan by new
fan and GRR by MVVVF for kiln-11124640 5.62 10
17VRM table liner replacement & Replacement of VRM
Bucket elevator chain by New chain1188000 5.94 4
18 Grinding media regarding for CM-1 second chamber 475200 2.38 2
19
Power saving in Clinker loading area BC-04 Belt by
interlocking bag filter fan with belt and avoid manual
intervention
18000 0.108 0
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ACC Limited
Energy Saving Project implemented in FY 2017-18
Sl
No.Project Description
Annual
Elect.
Energy (
kWh)
Annual
Saving
(Million
Rs.)
Invest.
(Million
Rs.)
1Installation of 2 nos. 10kW(p) solar PV system at
admin & SMTI building29500 0.177 2
2Reduce the running of shell cooling fans by interlock
with shell scanner50333 0.302 0
3Avoid idle running of packer 1 bag filter fan by
interlock fan running with blower operation275000 1.65 2
4Avoid idle running of air slide fans in dry fly ash silo
area5667 0.034 0
5Minimize air infiltration / reduce false air across atox
mill circuit83167 0.499 0.05
6Minimize air infiltration / reduce false air across e
mill-2 circuit74833 0.449 0
7Minimize air infiltration / reduce false air across e
mill-1 circuit55500 0.333 0
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ACC Limited
Energy Saving Project implemented in FY 2017-18
Sl
No.Project Description
Annual
Elect.
Energy (
kWh)
Annual
Saving
(Million
Rs.)
Invest.
(Million
Rs.)
8Reduce False Air In Kiln 1 Pre-Heater Down comer
Duct365833 2.195 0
9 Reduce Damper Loss In Pre-Heater Fan 944667 5.668 10
10 Avoid operation of KY471FAA VVFD at 50 Hz 10667 0.064 0
11Replace existing HPSV and HPMV lamps with LED
inside plant8667 0.052 0.5
12 Optimize lighting voltage in the plant to 210 V 33333 0.2 0
13Optimize Voltage of Identified Distribution
Transformers79833 0.479 0
14 Improve vacuum in turbine – TG 5 735833 4.415 2.5
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ACC Limited
Energy Saving Project implemented in FY 2017-18
Sl
No.Project Description
Annual
Elect.
Energy (
kWh)
Annual
Saving
(Million
Rs.)
Invest.
(Million
Rs.)
15 Optimize the operation of ACW pump-TG5 7333 0.044 0.648
16Optimize the operation of condensate extraction pump
-TG 421000 0.126 0
17 Optimize the operating pressure of BFP in TG-4 & 5 1260000 7.56 0
18 Arrest Air infiltration in BLR – 2 & 3 924000 5.544 0.02
19 Reduce the generating pressure of select compressors 1050000 6.3 0
For a zero-waste future
© 2016 Geocycle
Kymore PCPF Performance
2016-07-20
Innovative Project-1 TSR improvement
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ACC Limited
2
Preprocessing Line
• Shredding Line – 200 m3/Hr from
M/s Metso, Denmark consists of M&J
4000 S hook shredder, REMA belt conv.,
Steinert Magnetic Separator & Eco-star
Screen
• Storage & Processing Shed 100m x 40m
with 5.5 m high concrete walls.
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 and
Jockey pump
• 597 ESFR Sprinkler, 5 Hose real,
8 Hydrant post
Innovative Project-1 TSR improvement
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ACC Limited
2
Co-processing Line
• 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
Innovative Project-1 TSR improvement
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ACC Limited
Action & result:
▪ Gap in between rotor & top plate of rotascale dosing system adjusted up to 0.2 mm from 0.4 mm & that of bottom plate <0.1 mm & calibration done as on opportunity.
▪ Preheater fan speed control replaced from GRR to VFD for maintaining calciner outlet CO with fan speed.
% CO PH outlet before start of project CO ppm PH outlet CO during final assessment
Action implemented :AF dosing optimization by reducing variation of calciner outlet temperature fluctuations
Innovative Project-1 TSR improvement
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ACC Limited
Action implemented : Optimization of coal firing with calcineroutlet temp loop
•Relocation of calciner outlet temperature
thermocouple for better temperature monitoring &
action. It avoided frequent coating build up &
difference in temp.
Initial calciner outlet temp. point
Innovative Project-1 TSR improvement
Temp. point relocated
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ACC Limited
▪ Availability of Kiln inlet gas analyzer was issue due to very fast retraction of Kiln inlet gas analyzer because of analyzer tip heating
For increasing Kiln inlet
analyzer reliability first
action was taken by putting
coolant (Volvo super cool)
in ratio of 1:10 with cooling
water for analyzer tip.
Second step was analyzer
tip radiator descaling by
sulphonic descalant .As a
result cooling efficiency of
Analyzer tip is increased &
analyzer is able to sustain
Kiln inlet area on an
average from 2 minute to 5
minutes.
1 to 2 minute retention of probe in Kiln
Improved 5 minute retention of probe inside Kiln inlet
Innovative Project-1 TSR improvement
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ACC Limited
High CO fluctuations were observed particularly when AF feed rate is low
around 2 t/h (Designed capacity 24 t/h) or there is change in AF set point
.There is avalanche falling of heterogeneous AF mix from weigh feeder to
long belt conveyor. Also if material falling from working floor to chain
conveyor is stacking up, it may overload the chain conveyor.
To resolve the issue & maintain consistent material bed, level sensor limit of
chain conveyor manual input is provided in DCS for CCR operator to adjust
according to feed rateLevel sensor limit provided
Innovative Project-1 TSR improvement
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ACC Limited
Action implemented: Minimizing AF dosing fluctuations of calciner
% feed rate of weigh feeder(Cap 24 t/h)
Level low (mm)
Level High (mm)
0-10 75 125
11-20 100 200
21-30 125 225
31-40 150 250
41-50 200 350
51-100 350 450
Level sensor
installed
Level sensor installed – make Prosonic S
Level Indicator
Innovative Project-1 TSR improvement
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ACC Limited
Action implemented: Minimizing AF dosing fluctuations of calciner
High CO fluctuations dosing earlier After level sensor setting changes improved AFR dosing
Innovative Project-1 TSR improvement
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ACC Limited
Action implemented: Minimizing AF dosing fluctuations of calciner
Jamming at long belt discharge chute
To minimize jamming downtime of long belt discharge level sensor is
installed at long belt discharge. Because of early indication of hopper
jamming: long belt overloading & jamming is avoided.
Level sensor installed at long belt discharge level.
Innovative Project-1 TSR improvement
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ACC Limited
2
AF co-processed in Cement Kiln
Innovative Project-1 TSR improvement
30
ACC Limited
Natural Resources conservation
• ACC Kymore save 124910 MT of Traditional Fuel from 2015
• TSR % increased from 4.76 % to 8.8 %
Innovative Project-1 TSR improvement
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ACC Limited
Disposal of Narcotic materials into Kiln
Innovative Project-1 TSR improvement
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ACC Limited
▪ TSR % improved from 4.76 to 8.8
▪ GAV achieved in 2017 is 11.37 Cr
▪ Adherence of HWM 2016 and state of art facility
▪ CAPEX invested for odour control system and LIMS in 2018
▪ IMS Certified facility
▪ Leaves no residue that needs to be landfilled
▪ Reduces greenhouse gas emissions
▪ Preserves non-renewable fossil fuels and natural resources
Summary
Innovative Project-1 TSR improvement
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ACC Limited
Pre-blending of fly ash from different sources
Cement Having more than 10 source for fly ash, to maintain consistence quality of fly ash before feeding, this system give good result to maintain cement quality as well as CF% reduction.accordingly.
Final Product
Cap.1000 MT Cap.4000 MT
To cement mills
To cement mills
No. Fly ash Sources : 12LOI % Range : 0.8 – 8.0%Color variation – 50-85%Delivered Cost : 465-1150/MTReceipt qty. (MT) : 700-2500SOP : Displayed
CPP Bulker
OutsiderBulker
Innovative Project-2 Clinker factor
Improvement
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ACC Limited 34
Consistent dosing of flyash in mill
• Standby Coriolis dosing system taken in line for CM9 having more than
720 hrs MTBF(Rotascale & coriolis for CM-9)
Innovative Project-2 Clinker factor
Improvement
35
ACC Limited 35
PMR implementation of flyash feeding equipment.(In house correction
of SFMs, Rotasale)
Worn out SFM plateIn house Corrected
SFM
Innovative Project-2 Clinker factor
Improvement
36
ACC Limited 36
• %SO3 variation in material fed from crusher hopper due to
improper mix prepared : Clear demarcation of material in
gypsum yard for separate stock of ACC0012 & mineral
gypsum . Receipt tracking
• Outsourcing of limestone crushing activity with clear agreement
with third party for supply schedule & planned maintenance of
crusher. Day to day product size/Chemical composition of major
component.
Crusher
hopper
Minimizing %SO3 variation
Innovative Project-2 Clinker factor
Improvement
37
ACC Limited 37
• Sufficient prefed stock of
150 ton ACC0012 & 320
tons mix prepared before
feeding.1 hour/shift Pay
loader engaged for mixing
under supervision of
officer.
•Codification of ACC0012 in SAP for smooth tracking of intake of
material with help from HSSA.(zmm_0054)
•0.1% reduction in %SO3 (from 2.3% in 2017 to 2.2% in 2018 YTD on
average basis keeping setting time same
Innovative Project-2 Clinker factor
Improvement
Minimizing %SO3 variation
38
ACC Limited 38
CM 9 clinker Hopper feed chute Deflector plate fixed to feed hopper at center
BEFORE AFTERDeflector plate
installed
Innovative Project-2 Clinker factor
Improvement
39
ACC Limited 39
Performance status
63.5463.88
62.42
60.56
58
59
60
61
62
63
64
65
2015 2016 2017 2018 YTD
Clinker factor
in cement %
Innovative Project-2 Clinker factor
Improvement
40
ACC Limited
0.50.49 0.49 0.49
0.43 0.43
0.35
0.4
0.45
0.5
0.55
2013 2014 2015 2016 2017 2018(till
July)
Diesel Consumption(L/TMH)
One example of Making Impossible ->PossibleReduction in Specific Diesel Consumption from 0.50 to 0.43 on Ltr/TMH
Dumper on New Road
Old Route New Route
Innovative Project-3 Diesel
consumption reduction
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ACC Limited
Lead Reduction of Main Haul Road
1. Ideation for How to reduce lead with safety
2. Planning for route defining
3. Removal of all scraps and store house from Block-2 area
4. Ripping of Block -2 dolomite and backfilling it on the defined route
5. Extraction of limestone and removal of OB from the route path
6. Backfilling in the defined area.
7. Making Proper gradient with Dozer
8. Laying of Hume pipe . So that the route is stable during monsoon
9. Widening of Road near culvert area
10. Compacting haul Road with Dozer and Dumper Operation and Coping with Shale and hard Material.
Innovative Project-3 Diesel
consumption reduction
Success StoryMining Operations optimized to work in 2 shifts instead of 3 shifts
Changing the mindset of
people from comfort to
stretched zone
Discussion / Brain Storming with Unionrepresentatives, HEOs, Maintenance, Crusher &support staff.
1 Shift - Maintenance (OLC & Crushers)2 Shift - Operations
• United acceptance of challenge• Counseling operators and mechanicsand giving confidence.• Cascading targets• We Can & We Will
• Safety: Elimination of Night operations ofmachines• To iterate plan & establish sequence ofworkings so as to get ample time for bothOperation & Maintenance.•Reduction in Idle Hours during operation andmonitoring efficiencies & payload by using OBIS• Good coordination in production and minessite in-charge with single objective.• Improved Morale of workmen•Improved Life of HEMM
Improved Quality of Life
Improved Working conditionReduction in Mining Cost Rs/T (excluding royalty & Tax) from Rs/T 129.9 (2016 ) & 111.9 (2017)
& Presently we are operating at Rs/T 104.1 (Till July2018 )
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ACC Limited
Renewal Energy
0
1
2
3
4
5
6
7
2013-14 2014-15 2015-16 2016-17 2017-18
4.7
6.0 6.0
6.5
7.0
0.80 1.00 1.001.25
1.50
Renewal Energy
Target Non-solar %Target Solar%
44
ACC Limited
Utilization of Waste Material as Fuel.
0
20000
40000
60000
80000
100000
120000
140000
160000
2015 2016 2017 2018
101633
143142
157961.83
72152.62
4.75% 6.69% 7.35% 6.80%
M Kcal from AFR
TSR%
45
ACC Limited
List of Industrial Waste Co-Processed by ACC
✓ HUL Waste
✓ Plastic Waste
✓ Spent Carbon
✓ ETP Sludge & ETP
Bio Sludge
✓ Paint Sludge
✓ Nivea Waste
✓ CIL Waste
✓ Acid Tar Sludge
✓ Mattel Toys
✓ Plant & Colony
Waste
✓ Laminated Waste
✓ SRF Waste
✓ Trade Rejects
✓ Scrap Tyres
✓ Chemical Sludge
✓ Phosphate Sludge
✓ Footwear Scrap
✓ Green Mash with
Resin
✓ Godrej Waste
✓ ITC Waste
✓ SEP Sludge
✓ N Butanol Salt
✓ Spent Wash
✓ Liquid wastes
Trade rejects
Process waste
F
M
C
G
ETP Sludge, WTP Sludge, Spent Carbon
Food
Pro
ducts
Auto
mobile
Chem
i
cal
Narmada Chematur Petrochemicals
46
ACC Limited
Sr
No.Name of the Environment Project
Year of
ImplementationCorrective & preventive actions
1Installation of Roof Top Solar system at
Admin Building and SMTI.
2017 Installed 2 nos. 10 kVA Roof Top
Solar system
2
OPC production reduction in product portfolio
for CO2 emission reduction /t cement produced
2018 Increased PPC & ACC gold grinding
in production plan.
3
Reduction of energy consumption in Pre-
heater fan line-1 by installing MVVF Drive by
replacing GRR
2016 Purchasing & erection of 1 no.
MVVF Drive with control panel & 1
lot control and power cable.
4
Backhauling process i.e utilization of inward
raw material trucks for cement outbound
2017 Giving priority for unloading if
same vehicle for outbound
movement.
5
To improve aesthetic beauty and rehabilitation
of land by plantation and fencing to cover the
plantation.
2015 To plant sapling in the back filled
area and around the mines boundary.
6 Reduction of oil leakage and soil pollution by
replacing old Transformer (huge oil leakage)
with new 2MVA 6.6/440V transformer.
2015 Purchasing & installation of new
2MVA 6.6kV/440V
GHG Inventorisation.
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ACC Limited
Environmental Projects
Sr No. Name of the Environment ProjectYear of
Implementationcorrective & preventive actions
7Online continuous emission monitoring at
CM-9
2015 Installed CEMS in CM-9
8Online continuous emission monitoring at
Boiler-1 , Boiler-2 & Boiler-3 in CPP
2015Installed CEMS in Boiler-1 , Boiler-2 &
Boiler-3
9
To reduce thermal losses through
plenum chamber of Boiler No.1,2,&3
2015 Arresting of heat losses through plenum
air box by application of insulating
material in Boiler No. 1,2&3
10To reduce noise and dust emission while
drilling
2014 To deploy new drilling machine ROC L6
to increase efficiency and reduce dust
emission and noise levels at BMG
11To control resource (fuel) depletion by
introducing efficient hauling equipment
2014 To control resource (fuel) depletion by
introducing efficient hauling equipment at
MHG
12
Reduction of energy consumption in
Plant area to replace 70W MH light
fitting by 48W LED light.
2015 Purchasing & Installation of 200 nos.
LED light in 2nd phase
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ACC Limited
Environmental Projects linking with Carbon
Emission Reduction
971 976 973 967
800 800
0
200
400
600
800
1000
1200
Actual 2015 Actual 2016 Actual 2017 2018 YTD June Target 2018 Target 2019
Gross CO2 Emissions (kg CO2/t clinker)
1199 1211 1229 1238
800 800
0
200
400
600
800
1000
1200
1400
Actual 2015 Actual 2016 Actual 2017 2018 YTD June Target 2018 Target 2019
Net CO2 emissions(kg CO2/t cement)
49
ACC Limited
Environmental Projects with carbon Emission Reduction
11.5 Km long
overland Belt
Conveyor was
installed in 2007 to
eliminate the
vehicle movement
& carbon emission.
Massive plantation
in & around plant &
mining area to
reduce the CO2
50
ACC Limited
SNCR project under commissioning phase
51
ACC Limited
1.All Purchase orders & RFQ being send electronically.
2. All RFQ value >5 lacs are directly send through eBRAVO solution,
offer collection and comparative statement are prepared directly at eBravo
Solution.
3. Convert Bulkers from 10wheelers to 18 wheelers to 22 wheelers
4. Explore of nearest dry flyash source at Jaithari, Which is L1 source for
Kymore works
5. FY 2017 GPS installed for all Inbound and outbound vehicles (Cement &
Flyash truck)
6. Initiative for merging of multiple PR in single PO.
Green Supply Chain.
52
ACC Limited
Enchasing Cement Backhauling opportunity
Before After
1. Communication of
Raw material
sourcing vis-à-vis
cement dispatch
requirements
Logistics needed to contact Procurement department or vise versa from time to time for incoming raw material and locations
Information already known regarding raw material sourcing
2. Kind of vehicle to
be used
Fly ash mostly used to come in bulkers/closed containers
Now vehicles which are compatible with cement-bag loading are in use
3. Negotiation –
Elements for
Flyash
Backhauling not mandatory
1. Cement backhauling is mandatory condition
2. Vendor development for those who are willing
4. Information Flow VerbalProduction>Procurement>Logistics>Vendors
53
ACC Limited
Best Practices: Implemented in Green Supply Chain
54
ACC Limited
Involvement of Employees, Team Work in Encon
0102030405060
3121
4551
28
1421 18
39
MS
SFA
Total SGAs
Total Nos. of Person Involved
MS-132
SFA-135
Total Nos. of project implemented-267
55
ACC Limited
Brainstorming session: Energy Reduction
56
ACC Limited
Awareness Campaign: Energy Dream Run-’17
57
ACC Limited
GreenCo Site Assessment & Training
58
ACC Limited
ISO 50001-11: Re-certification Audit in Jul’18
59
ACC Limited
ISO 50001-11: Internal Auditor Training Jun’18
60
ACC Limited
Energy Monitoring System
61
ACC Limited
Daily Reporting Section Wise Format
62
ACC Limited
Daily Reporting Equipment Wise Format
63
ACC Limited
ISO 50001-2011 & CII GreenCo Gold
64
ACC Limited
% Investment for Energy Conservation Projects
The Financial Resource Allocation for energy conservation projects is conducted on monthly basis, where a committee of DGM Capex and Director Plant in the chair, review the activities carried out in the month, gives directions to the Energy Conservation cell for focused attention. Certain identified schemes where sizeable investment is required, the same are discussed at length and accordingly Director Plant sanctions the funds. Wherever the Financial commitments are substantial, the same are referred to Corporate Office for necessary sanctions under Capital Schemes
The total financial allocation for Energy efficiency projects is around 26.40% of our total fund allocation.
Energy Savings projects (in Lacs) 6,948.20
SUB TOTAL (in Lacs) 26323.20
26.40%
65
ACC Limited
CII GreenCO Award ( Gold) -2017
66
ACC Limited
GreenCO Gold Rating Awarded by CII-2014
67
ACC Limited
CII National Award for Energy Efficiency 2017
68
ACC Limited
CII National Award for Energy Efficiency 2016
69
ACC Limited
CII GreenCo Best Practice Award 2016
70
ACC Limited
Earth Care Award for Reduction of Green House Gases
Emission (Large Enterprises Category) - 2014
71
ACC Limited
CII 14th Environmental Best Practices Awards 2013
72
ACC Limited
National Awards : At a Glance
73
ACC Limited