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

2

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)

3

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.

4

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

5

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

6

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

7

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


8

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


9

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

10

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

11

ACC Limited


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

12

ACC Limited


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

13

ACC Limited


Sl


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

14

ACC Limited


Sl


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

15

ACC Limited


Sl


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

16

ACC Limited


Sl


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

17

ACC Limited


Sl


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

18

ACC Limited


Sl


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

20

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


21

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


22

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


23

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


Temp. point relocated

24

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


25

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


26

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


27

ACC Limited


High CO fluctuations dosing earlier After level sensor setting changes improved AFR dosing


28

ACC Limited


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.


29

ACC Limited

2

AF co-processed in Cement Kiln


30

ACC Limited

Natural Resources conservation

• ACC Kymore save 124910 MT of Traditional Fuel from 2015

• TSR % increased from 4.76 % to 8.8 %


31

ACC Limited

Disposal of Narcotic materials into Kiln


32

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


33

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

34

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)


Improvement

35

ACC Limited 35

PMR implementation of flyash feeding equipment.(In house correction

of SFMs, Rotasale)

Worn out SFM plateIn house Corrected

SFM


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


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


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


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 %


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

41

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 )

43

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

http://img.tradeindia.com/images/l/0/logo_12934.gif

http://www.contrib.andrew.cmu.edu/~jwilder/pepsi.jpg

http://images.google.co.in/imgres?imgurl=http://www.indiacatalog.com/images/logos/local/th_tata_cummins.jpg&imgrefurl=http://www.indiacatalog.com/search_results/design.html&usg=__5Cf-zRprq2JWFpPutfIAS6ST1MI=&h=95&w=95&sz=4&hl=en&start=20&tbnid=mFHvi2OOga2U-M:&tbnh=80&tbnw=80&prev=/images?q=Logo+of+Tata+Cummins&gbv=2&hl=en&sa=G

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.

47

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

48

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

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ACC Limited

SNCR project under commissioning phase

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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.

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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

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ACC Limited

Best Practices: Implemented in Green Supply Chain

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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

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ACC Limited

Brainstorming session: Energy Reduction

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Awareness Campaign: Energy Dream Run-’17

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GreenCo Site Assessment & Training

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ACC Limited

ISO 50001-11: Re-certification Audit in Jul’18

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ISO 50001-11: Internal Auditor Training Jun’18

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Energy Monitoring System

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Daily Reporting Section Wise Format

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Daily Reporting Equipment Wise Format

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ISO 50001-2011 & CII GreenCo Gold

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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%

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ACC Limited

CII GreenCO Award ( Gold) -2017

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ACC Limited

GreenCO Gold Rating Awarded by CII-2014

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ACC Limited

CII National Award for Energy Efficiency 2017

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ACC Limited

CII National Award for Energy Efficiency 2016

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ACC Limited

CII GreenCo Best Practice Award 2016

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ACC Limited

Earth Care Award for Reduction of Green House Gases

Emission (Large Enterprises Category) - 2014

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ACC Limited

CII 14th Environmental Best Practices Awards 2013

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ACC Limited

National Awards : At a Glance

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17th national award for “excellence in energy management ... … · 9 replacement of grr by mvvfd...

Documents