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ACC Limited Jamul Cement Works “National Award for Excellence in Energy Management 2017-18” Presented By: Sanjay Sharma – Chief Manager (E&I) Swapan Roy – Manager (Process)

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Page 1: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

ACC Limited

Jamul Cement Works

“National Award for Excellence in Energy Management 2017-18”

Presented By:Sanjay Sharma – Chief Manager (E&I)Swapan Roy – Manager (Process)

Page 2: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

2

ACC Limited

Contents:

Company Profile and Process

Specific energy consumption ƒ

Benchmarking

Project Implemented & Road Map for future ENCONƒ ƒ

Innovative projects

Best Practices Implemented on Energy front

Utilisation of renewable energy source

Utilisation of waste material as alternate fuel

GHG Inventorisation

Grean Supply chain

Team work, Employee Involvement & Monitoring

Implementation of ISO 50001

Page 3: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

3

ACC Limited

Plant location and salient features

Few facts

▪ Distance from nearest airport, Raipur ~60Km by road.

▪Jamul Cement Works established in 1965 & Renovated in 2015-16

▪ Plant clinkering capacity of 2.8 MTPA

▪ Plant grinding capacity of 2.8 MTPA

▪ Power from own CPP of 25 MW

▪ Power demand from CSEB of 30 MVA

▪ Limestone supplied from 3 mines, namely

➢ Jamul [3 km]

➢ Pathariya [24 km]

➢ Nandini Kundini [22 km]

Page 4: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

4

ACC Limited

Process Flow diagram – Jamul Plant

Raw material extraction & preparation

Raw meal preparation

ClinkerizationCement Grinding

Jamul Mines

Pathariya Mines

Nndini KundiniMines

L/S pile- Mixed Grade

Capacity : 35,000t X 2

L/S pile- High grade

Capacity : 5,000t X 2

L/S – Double impact crusher

Capacity : 1500 tph

Roller Press

Capacity : 350 tph X 2

Blending silo

Capacity : 16,500 Tons

Kiln

Dia: 5.6 m X 82 m

Capacity : 9,000 TPD

6 stage, 2 string PH

In line calciner

Clinker silo

Capacity : 75,000 Tons

Hot air to RP

Hot air to Coal Mill

Cement VRM

Capacity : 175 TPH

OPC

6000 T

Slag

5000 T

Storage silo

16 X 1000 T

3 X 3000 T

Cement EDM

Capacity : 6 X 30TPH

Coal VRM

Capacity : 90 TPH

Page 5: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

5

ACC Limited

Plant achievement highlights ....

First plant in ACC Limited to be accredited for ISO 50001 (Energy Management System) in 2012

Reduction of 18.8 unit (21%) in specific Electrical Energy from 2015-16.

Significant improvement in reduction of thermal energy consumption by 115 MJ/t clinker (14%) from 2015 – 16

First plant in LH group to maximize (up to 69%) slag absorption in PSC cement

First Plant in LH group producing PPC with uses of 100% wet Fly ash[ Pond ash]

First plant in Chhattisgarh State to use renewable energy(Solar power) from third party

Page 6: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

6

ACC Limited

Energy Conservation Team Structure

Abhay Singh

Swapan Roy

Amit Mishra

Sanjay Sharma

Core

Team

Team Members Circle area

Energy

Circles

Raw Material extraction

Raw Material crushing

Raw Mills

Homogenizing plant

Kilns

Coal Mills

Coal Handling plant

Cement Grinding

EOT Cranes

Packaging

CPP Boiler

CPP Turbine

Auxiliaries

S K Sharma

Ganesh Rathore

Rahul Jha

Kumund Sinha

Teekam Chandrakar

B.Kaushik

Sanjay Tiwari

Swapan Roy

Rajendra singh

Anil Sharma

Rajesh Pathania

Tulendra choudhary

Chandan Upadhay

1

2

3

4

5

6

7

8

9

10

11

12

13

Champions

G.Kewat

Kuldeep sharma

Page 7: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

7

ACC Limited

Where we are………. overall KWh/Ton of Cement

21%

2015-16 2017-18

89.3 70.4

Impact(INR, Cr)

20.3

11.5%

Page 8: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

8

ACC Limited

STEC – kCal/Kg of Clinker

14%

2015-16 2017-18

823.2 708.5

Impact(INR, Cr)

29.39

7%

Page 9: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

9

ACC Limited

Energy reduction trend

Page 10: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

10

ACC Limited

Achievement in PAT Target

936.0

890.0

802.0

754.0

550.0

500.0

550.0

600.0

650.0

700.0

750.0

800.0

850.0

900.0

950.0

1000.0

Baseline Target for PAT- I Achieved in PAT-I Target for PAT- II Achieved up to 17-18

Kcal/

Kg

Cem

en

t

41%

27%

1. BEE has issued 11295 REC of Rs.11.29 Crore to Jamul Cement Works for achieved the PAT cycle-I target.

2. Reduction of 38 & 27 % from target of PAT Cycle – 1 &2 respectively.

Page 11: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

11

ACC Limited

Summary : ENCON Efforts

Energy Conservation Projects ( Summary for last 3 years) ‰No investment

▪ No of project implemented : 18

▪ Saving Kwh/T of Cement : 7.7

▪ Saving in INR, Crore : 8.32

‰Medium Investment

▪ No of project implemented : 16

▪ Saving Kwh/T of Cement : 11.0

▪ Saving in INR, Crore : 11.97

Page 12: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

12

ACC Limited

Benchmarking with Competitors

Aspirating for 2018-19 : SEEC - 68 KWh/ Ton cement & STEC - 675 Kcal/ Kg clinker

SEEC STEC

82

73

77

79

72

70.4

92

97

127

76

126

0 50 100 150

Plant 1

Plant 2

Plant 3

Plant 4

Plant 5

Jamul

Plant 6

Plant 7

Plant 8

Plant 9

Plant 10

Plant 1 Plant 2 Plant 3 Plant 4 Plant 5 Jamul

Plant 6 Plant 7 Plant 8 Plant 9 Plant 10

725

724

760

735

734

682

708.5

733

814

830

822

718

0 200 400 600 800 1000 1200

Plant 1

Plant 2

Plant 3

Plant 4

Plant 5

Plant 6

Jamul

Plant 7

Plant 8

Plant 9

Plant 10

Plant 11

Kcal/Kg

Page 13: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

13

ACC Limited

Major Technology driven project Implemented for Energy Conservation

Replacement of reciprocating compressors with screw compressor.

Installation of capacitor bank to improve power factor

Installation of MV/ VFD Drive

Increase the PRI of Ball mills by grinding media optimization, liner replacing and process optimization.

Reduction in idle running of the equipments by providing the interlocks in DCS.

Page 14: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

14

ACC Limited

ENCON PROJECTS IMPLEMENTED IN 2017-18

Sl. No. Title of Project Year Annual

Electrical

Saving

(kWh)

Annual

Electrical

Cost

Saving

(Rs

million)

Annual

Thermal

Saving

(Million

Kcal)

Annual

Thermal

Saving

(Rs

million)

Total

Annual

Savings

(Rs

million)

Investme

nt Made

(Rs

million)

Payback

(Months)

1Upgradation of Colony Power distribution system

from 3.3kv to 11 kv2017-18 30000 0.19 0.19 0.54 34.89

2 Upgradation of Cement Mill main drive LRS 2017-18 120000 0.74 0.74 0.45 7.27

3 Elevator Drive station for close circuit 2017-18 30000 0.19 0.19 0.07 4.52

4 Repl of Girth Gear and Pinion for CM 1 2017-18 30000 0.19 0.19 0.32 20.68

5Optimize operational efficiencies in RP & kiln and

cement grinding section2017-18 7500000 46.43 46.43 0.00 0.00

6Thermal energy reduction by optimization of raw mix

2017-18 0.00 8,000 16.72 16.72 0.00 0.00

7Limestone crusher TPH to be increased from 916 to

10502017-18 147000 0.91 0.91 0 0.00

Page 15: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

15

ACC Limited

ENCON PROJECTS IMPLEMENTED IN 2017-18

Sl. No. Title of Project Year Annual

Electrical

Saving

(kWh)

Annual

Electrical

Cost

Saving

(Rs

million)

Annual

Thermal

Saving

(Million

Kcal)

Annual

Thermal

Saving

(Rs

million)

Total

Annual

Savings

(Rs

million)

Investme

nt Made

(Rs

million)

Payback

(Months)

8Improvement of raw mill tph through process

optimization from 318 to 325 2017-18 162000 1.00 1.00 0 0.00

9Optimization of new coal VRM tph from 54 tph to 60

tph2017-18 84000 0.52 0.52 0 0.00

10 CM 5 O/L diaphragm modification 2017-18 54000 0.33 0.33 4.5 161.55

11Ball mill No. 1,2 & 3 Inlet bearing sump capacity

modification from 30L to 250 L2017-18 180000 1.11 1.11 0.9 9.69

12Optimizationof compressed air in Clinkerisation &

Ball mills area.2017-18 135000 0.84 0.84 0 0.00

13Replacement of HPMV with 90/150W LED lamp 150

Nos. street light.2017-18 82125 0.51 0.51 1.2 28.33

Page 16: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

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ACC Limited

ENCON PROJECTS IMPLEMENTED IN 2016-17

Sl. No. Title of Project Annual

Electrical

Saving

(kWh)

Annual

Electrical

Cost

Saving

(Rs

million)

Annual

Thermal

Saving

(Million

Kcal)

Annual

Thermal

Saving (Rs

million)

Total

Annual

Savings

(Rs

million)

Investme

nt Made

(Rs

million)

Payback

(Months)

1

Carry out the maintenance and reduced

the pressure drop across compressor inlet

filters

115000 0.54 0.54 0.00 0.0

2

Reduced leakage and interconnect coal

mill and cement mill compressor to avoid

unloading

9000 0.04 0.04 0.10 28.4

3

Reduced generation pressure and use

cement mill 7 & 8 fluxo compressor only

for conveying purpose

120000 0.56 0.56 0.10 2.1

4Minimised the compressed air leakages in

the plant158000 0.74 0.74 0.10 1.6

5

Installed servo control voltage

transformers for lighting and maintain

lighting voltage at 210 V

22000 0.10 0.10 0.18 20.9

Page 17: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

17

ACC Limited

ENCON PROJECTS IMPLEMENTED IN 2016-17

Sl. No. Title of Project Annual

Electrical

Saving

(kWh)

Annual

Electrical

Cost

Saving

(Rs

million)

Annual

Thermal

Saving

(Million

Kcal)

Annual

Thermal

Saving (Rs

million)

Total

Annual

Savings

(Rs

million)

Investme

nt Made

(Rs

million)

Payback

(Months)

6

Improved mills ventilation for cement mill

1 to 6 and avoid over grinding 150000 0.71 0.71 0.00 0.0

7

Increased specific surface area of second

chamber in all cement mills by using

smaller size grinding media

1350000 6.35 6.35 0.00 0.0

8

Changed the pulley size and reduce

pressure drop across ca fan inlet damper –

coal mill 5

35000 0.16 0.16 0.01 0.7

9Replaced V-belt with cogged flat belt in

identified equipment104000 0.49 0.49 0.10 2.5

10

Adoptated new energy efficient

technology to meet out the our future PAT

target.

1530000 7.19 69499.00 57.96 65.15 18000.00 120.0

Page 18: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

18

ACC Limited

ENCON PROJECTS IMPLEMENTED IN 2015-16

Sl. No. Title of Project Annual

Electrical

Saving

(kWh)

Annual

Electrical

Cost

Saving

(Rs

million)

Annual

Thermal

Saving

(Million

Kcal)

Annual

Thermal

Saving

(Rs

million)

Total

Annual

Savings

(Rs

million)

Investment

Made (Rs

million)

Payback

(Months)

1Regrading & grinding media optimization

in mills168,000 0.81 0.81 1.00 14.9

2

Optimization of compressor running /

Enhanced the efficiency of compressor /

Leakages of compressed air.

140,000 0.67 0.67 0.00 0.0

3 Reduction in Idle running of equipments . 140,000 0.67 0.67 0.00 0.0

5 Controlling fine coal residue and moisture 0.28 0.25 0.25 0.02 1.0

6 Reducing false air ingress in the system 0.14 0.12 0.12

7Improve burning in kiln by arresting

infiltration air in the system0.26 0.25 0.25

Page 19: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

19

ACC Limited

Road MAP for Future ENCON

Sl. No. Title of Project Year Annual

Electrical

Saving

(kWh)

Annual

Electrical

Cost

Saving

(Rs

million)

Annual

Thermal

Saving

(Million

Kcal)

Annual

Thermal

Saving

(Rs

million)

Total

Annual

Savings

(Rs

million)

Investme

nt Made

(Rs

million)

Payback

(Months)

1 Upgradation of Slag Dryer Bag filter 2018-19 90000 0.56 0.56 0.6 12.92

2 Automation of packing plant 2018-19 180000 1.11 1.11 0.4 4.31

3Optimize operational efficiencies in RP & kiln and

cement grinding section2018-19 7500000 46.43 46.43 0.00 0.00

4Thermal energy reduction by optimization of raw mix

2018-19 0.00 8,000 8.36 8.36 0.00 0.00

5Limestone crusher TPH to be increased from 1050 to

11502018-19 105000 0.65 0.65 0.00 0.00

6Improvement of raw mill tph through process

optimization from 325 to 330 2018-19 288000 1.78 1.78 0.00 0.00

7 Slag reclaimer TPH improvement 2018-19 96000 0.59 0.59 8.00 161.55

8Optimization of new coal VRM tph from 60 tph to 70

tph2018-19 144000 0.89 0.89 0.00 0.00

9Cooler Fans flow optimization from 2.2 Nm3/kg to

1.8 2018-19 264000 1.63 1.63 0 0.00

10 PH FAN flow Optimiztion 2018-19 165000 1.02 1.02 0 0.00

11 Slag dryer BF inlet duct modifiation 2018-19 57600 0.36 0.36 0.6 20.19

12Modification of Cement VRM and Ball mill reject

handling circuit2018-19 297000 1.84 1.84 21.0 137.07

Page 20: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

20

ACC Limited

Road MAP for Future ENCON

Sl. No. Title of Project Year Annual

Electrical

Saving

(kWh)

Annual

Electrical

Cost

Saving

(Rs

million)

Annual

Thermal

Saving

(Million

Kcal)

Annual

Thermal

Saving

(Rs

million)

Total

Annual

Savings

(Rs

million)

Investme

nt Made

(Rs

million)

Payback

(Months)

13Ball mill No. 1,2 & 3 outlet bearing sump capacity

modification from 30L to 250 L.2018-19 90000 0.56 0.56 2.5 53.85

14 CM 4 &6 O/L diaphragm modification 2018-19 96000 0.59 0.59 9.0 181.74

15 To start producing of PPC cement 2018-19 2.51 2.51 7.5 35.86

16Removing of supporting roller of CM VRM to reduce

mill DP as well as power2018-19 81000 0.50 0.50 0.1 2.39

17

Replacement of hood with entire bricks for slag

dryer 1&2 2018-19 48000 0.30 0.30 3.5 141.36

18 Installation of APFC panel with passive filter in MRSS

to improve the power factor from 0.92 to 0.99

2018-19 40.00 40.00 50.0 15.00

19Replacement of HPMV with 90/150W LED lamp –

3Noshigh mast & 200 Nos. street light.2018-19 109500 0.68 0.68 3.0 53.11

20Optimization of water pump running as per study

conducted.2018-19 87600 0.54 0.54 2.0 44.26

21Reduction in idle running of the equipments of

material handling circuit.2018-19 162000 1.00 1.00 0.0 0.00

Page 21: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

21

ACC Limited

Removal of cement VRM supporting rollers

1)We have analyzed that support rollers are not contributing to bed stabilization , improve mill PRI and reduction of mill Vib.

2) Support rollers creating high mill DP3) We are facing difficulty for maint. Inside the mill

Initiatives Taken

Result

Innovation No. 1 Reduction in SEEC in VRM

177.81 170.65 175.24

211.89237.11

40.4839.03

48.92

41.52

37.61

33.18

30

35

40

45

50

0

50

100

150

200

250

1 2 3 4 5 6 7 8 9TPH KWH

1.PRI improved by 10%2.Reduction in power by 4~5 kwh/T cement3.Easy maint. 4.Replicate to others sister unit.5.Reduction in high mill vib and DP.

Page 22: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

22

ACC Limited

PPC Production with 100% utilization of wet fly ash (Pond ash) without any capex.

1.VRM Idleness, on account of silo full, an average of 200Hrs/month .2.Variable cost of PPC vs PSC is cheaper due to higher price of slag3.Many plants uses wet FA max 7~10 % to produce PPC but our plant using 34% ( dry basis).

Initiatives Taken

WF upgradated Liner provided Rewards Recognition

Result

Innovation No. 2Reduction in SEEC in VRM

▪Reduced by 0.5 Kwh/t cement.

▪ Improve the reliability.

▪ Saved Rs 42 Crores

Business

1

▪The idea can be replicated in other (wherever applicable) units across the business.

Group

2

▪Ease of maintenance and operation.

People

3

Page 23: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

23

ACC Limited

Cement silo interconnection & Metal removal from slag

1) Mill unstable for separate grinding compare to co grinding2) Blending stopped due to silo extraction issue3) Nos of silo less compare to Product fortfolio4)Frequent feed cut in VRM due to metal in slag

Initiatives Taken

Result

Innovation No. 3Reduction in SEEC in VRM

1.Sales volume increased2.Reduction in power by 1.5 kwh/T cement3.Easy maint. 4.Replicate to others sister unit.5.Mill stoppage due to sudden vib reduced drastically

Page 24: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

24

ACC Limited

1. Fan inlet manual damper settings by draft measurement at suction points.

2. Fan I/L motorized damper opening restrictions by logic changing from DCS

3. Process B/F false air study and leakage arresting.4. Stopping of circuit B/F in material handling circuits[ raw slag, wet Flyash]

and making soft button in DCS for depending on type of material handling.

5. Monitoring of BFs fan power in TIS for tracking

Initiatives Taken

Result

Best Practices ….Followed Reduction in SEEC through B/F Optimization

Reduction of 180 kWh [0.5 kWh/T of cement]

Page 25: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

25

ACC Limited

1. Following strict discipline of minimum limestone pile quantity from ~ 15Kt to 30kt which resulted in less variation in LS quality

2. Strict control in limestone pile quality in every 15% level3. Maintaining optimum clinker composition- Raw mix optimization4. Burner optimization with microscopy5. Clinker cooler performance improvement by minimizing losses-

optimizing cooler air flow.

Initiatives Taken

Result

Microscopic evaluation Cooler fans SEEC Cooler fan flow optimization

Reduction in STEC in Clinkering

Saved 20MJ/Tclk

Page 26: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

26

ACC Limited

1. Optimisation of dam ring from 415 to 350 mm at various stages and grinding pressure optimisation

2. Optimisation of water addition with modification and positioning of water lancer

3. Bed stability with addition of slag while clinker grinding and clinker addition while slag grinding

4. Central feed chute height optimisation5. Interlock provided on Rota scale rpm,bin level & regular cleaning to

avoid fluctuation 6. Usage of activated gypsum (35% of total gypsum) without additives

maintaining IQN.

Initiatives Taken

Result

Reduction in Clinker Factor

1. 1st Plant in India & LH group achieving highest slag( 69±0.5%) absorption in PSC, [CF: 24.8]

2. Cement quality improved without affecting mill throughput.3. Annual Savings achieved around 39.3 Crores

Page 27: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

27

ACC Limited

▪ Installation of DALOG for avoiding of torque ▪ Fuel split ratio optimization depending on Kiln feed LSF▪ Separate Water spray nozzle installed on table for bed formation for

pet coke▪ Online mill fan “PROMEOCON” flow meter calibrated for better mill

control.▪ Modification of mill central chute for better distribution of feed on

table.▪ PID tuning with Process+ Automation▪ EMD test for critical HT motors by third Party▪ Electronic Display (LED) board provided at prominent locations▪ Unique initiative taken by Jamul as Energy officer tour (EOT ) done by

assigned officers / Sr. NMS staff as per roaster. Attractive scheme of credit points and gifts

Other Best Practices ….

Page 28: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

28

ACC Limited

Utilisation of renewable energy source

Type of RES Installed

Capacity

Energy Generated

(MWh)

Annual Savings

(INR, Crores)

Solar photovoltaic– PPA 1.75 MW 3000 1.15

Solar

Photovoltaic

(Installation Under

progress)

5.5 MW & 30 MW 9900 & 54000

3.96 & 21.6

Page 29: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

29

ACC Limited

Sr. No Type of Waste Fuel usedQuantity of waste fuel used

(Tons)

2017-18

Waste fuel as % of total fuel

1 Dolachar 24456

12.34%2 Flue dust 2269

3 Pyrolytic oil46

Utilization of Waste Material as Alternate Fuel

TSR future plan

Details of AFR used in 2017-18

No AFR in 2017 considered for AFR feeding system preparation

Page 30: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

30

ACC Limited

CO2 Emission Reduction Trend

20%

Reduction in CO2 generation by 12% from last FY

Page 31: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

32

ACC Limited

Project Implemented under Green Supply chain

Sr. No. Project TitleInvestment

in LakhsImplemented in

1 Renovation of four chamber Slag Dryer Bag filter 59.2 2015

2

Installation of Wet fog system at different transfer and

loading points, Water sprinkling system, Bobcat, Two no. of

hand driven sweeping machine 321.8 2016

3 Self Propelled Road Sweeping Machine 40 2016

4 Up gradation of Environment Lab 27.97 2016

5 Three stage Sewage Treatment Plant 113.89 2014

6 Continuous Ambient Air Quality Monitoring Station 26 2017

7 Dust Emission monitoring system for Stacks 8.74 2016

8Up gradation of Bag filters of Cement Mill , Raw Mill, Coal

Mill Etc. 93.43 2014

9 Stack and Ambient Air Monitoring system 8.76 2016

10More than 30% Water Reduction under the special drive

5 2015

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ACC Limited

Project Implemented under Green Supply Chain

11

Every employ has been provided with “Carbometer Card” to

have in his pocket every time which will remind him about

his carbon footprint all the time. 2014

12 Bio Gas plant has been installed 3 2014

13Solar Cooker was distributed in the colony for the

promotion of Save Fuel 3.5 2014

14 7 KWh of Solar Power system was installed 8 2014

15ECO LAB was established and inaugurated for the training

and promotion of sustainable development 7 2014

16 Installation of new ID fan in Secondary Crusher Bag filter

has increased the dust collection capacity 8.5 2015

17 Promote the Solid waste management initiatives. 0 2015

18 Conversion of ESP with Hybrid ESP 500 2017

19 Installation of SOX and NOX analyser for ESP 47.6 2017

20 Installation of ETP analyser 18.15 2017

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ACC Limited

We care…for our environment

Dust emission from Raw mill/VRM stack -15mg/Nm3

Dust emission from kiln ESP stack - 18 to 20 mg/Nm3

Water fogging at crusher LS dump hopper

Water spraying at LS stacker belt

Timer based water sprinkling system at weigh bridge area

Road swiping machine

Continues Ambient air Monitoring System (CAAQMS) for PM10, PM2.5, SO2 & NOX

Continuous Emission Monitoring System (CEMS) Installed at Kiln

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ACC Limited

Team Work in Encon…

Ideations Energy circle formation Idea Implementation

▪ 2 ideation sessions wereconducted on “Electrical energy”involving 48 NMS and MS staff

▪ >80 ideas were generated

▪ Total 18 energy circles formedcovering 78 persons

▪ Working in small groups inrespective circles

▪ Total 10 ideas implemented

▪ 18 units reduction frombaseline

Monitoring & Tracking Training & Coaching

▪ TIS implemented

▪ KPI’s monitored through TIS & PDboards in every dept

▪ Awareness sessions conducted. People were made conscious about the energy

▪ Driven by people power

Step – 1.

Implementation

Step – 2

Sustainability

Reviews

▪ Weekly review started fromMay – 2015

▪ Total 10 reviews conducted

▪ Daily feedback to departments

Rewards EOT

▪Recognition for good work

▪ Celebrating quick wins

▪ Daily One Energy Officer

▪ Energy Observation tour of 4 hrs

▪ Sharing of observations in MIS meeting

Date Name of Energy Officer

02-Feb-18 D.Jena

03-Feb-18 Salim Sabry

04-Feb-18 V.K. Chhibber

05-Feb-18 Chandan Upadhayay

06-Feb-18 G.K. Agarwal

07-Feb-18 Aditya kumar (Elect)

08-Feb-18 D.datta

09-Feb-18 Pushkar Chandrakar

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ACC Limited

Tracking of KPI’s- Single tool with multiple information

1. Daily tracking of all major KPI’s with TIS2. Monitoring of sectional power with individual equipment consumption

Review of daily performance

Analysis of problems

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ACC Limited

ISO 50001:2011 Certification…

Step – 3

Accreditation

In continue with our journey for energy efficiency improvement JamulCement Works is the first plant in ACC to accredited with ISO 50001:2011(Energy Management System) which helps us to achieve our aspiration withcomprehensive and structured approach.

Page 37: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

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ACC Limited

Energy reduction through Water conservation

▪ Reduction in Cooling Tower Blow Down by

increasing the COC

▪ Stopping overflow from the GCT water tank by

providing control loops through flow control

valves.

▪ Change of mind set of topping up the waste

water tank with raw water for emergency

▪ Arresting of water pipe line leakages through

out the plant – 389 points attended

▪ Flow control valves installed in all the overhead

tanks

▪ Unique initiative of reducing the capacity of

flush tanks

▪ Stickers pasted near the water taps to reduce

leakages etc.

▪Zero water discharge

Provers

We are water positive

-27%

1859

1399

4958

Water Cons 15-16

CPP Plant

120

Domestic

3596

Water Cons-17-18

Pla

nt

Do

mes

tic

CP

P

27% reduction in water consumption

Aspiration

of <3000

M3/Day

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ACC Limited

ECO Lab has been developed to provide training regarding sustainable development

Glimpses of ECO LAB

Page 39: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

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ACC Limited

Some acknowledge of our efforts

Green manufacturing excellence award in leader category - Frost & Sullivan

Indian manufacturing excellence award - Economics times.

Gold Award by Energy activation across regional networks (EARN) for best ideas & best pillars – Holcim

“Excellent Energy Efficient Unit” Award in 2012-13

Page 40: ACC Limited Jamul Cement Works · 2018-09-13 · 3 ACC Limited Plant location and salient features Few facts Distance from nearest airport, Raipur ~60Km by road. Jamul Cement Works

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ACC Limited

Some acknowledge of our efforts

Three National awards (For Electrical,Thermal & Overall reduction in PSC cement manufacturing) – NCCBM

Two Nos State level awards for “Energy Conservation and Innovation in Energy conservation” – CREDA

“ Energy Efficient Unit” Award in 2013-14 – CII

Excellent Energy Efficient Unit” Award in 2016-17 – CII

“ Received First Runner Up Trophy in Large scale category in Eastern Region for Excellence in Energy Conservation 2017-18

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ACC Limited

For you an Idea could be a scrap but remember for me your one idea can make a difference