17th National Award for “Excellence in Energy Management...
66
17th National Award for “Excellence in Energy Management – 2017 Presented By : Mr. B Baral & Mr. Ravi Kumar
Transcript of 17th National Award for “Excellence in Energy Management...
17th National Award for “Excellence in Energy Management – 2017
Presented By : Mr. B Baral
&
Mr. Ravi Kumar
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
Encon Projects (Last 3 years summary)
UnitNo
Investment
Low
Investment
Medium
InvestmentTotal
No of project
implemented# 34 11 9 54
Electrical
Energy Saving
Million
kWh17.88 2.94 17.28 38.10
Thermal
Energy saving
Million
kcal 568.92 24084.84 28548.53 53202.29
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ACC Limited
Last 3 years Thermal Encon Projects
Sr
No.
Project Description Thermal
Energy
(Mkcal)
Saving
(Million
Rs.)
Invest.
(Million
Rs.)
1 Full feed operation of PCPF Project for line-1 14867.12 253.0 620.00
2 Biomass feeding system for line-2 6446.16 9.01 40.00
3T A Duct partial replacement for improvement of
thermal energy consumption for line-245.94 0.06 0.00
4T.A Duct damper installation for improvement of
thermal energy consumption for line-1.372.94 0.52 5.70
5 Both kiln inlet Analyzer reliability improved. 149.99 0.21 0.00
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ACC Limited
Last 3 years Thermal Encon Projects
Sr
No.
Project Description Thermal
Energy
(Mkcal)
Saving
(Million
Rs.)
Invest.
(Million
Rs.)
6Kiln feed SFM to coriolis feeding system
replacement Line-2738.7 8.07 4.5
7CFG to RFT conversion in Compartment
modification, fan replacement for Kiln-18362.6 8.1 1.6
8CFG to RFT conversion in Compartment
modification, fan replacement for Kiln-28362.6 8.1 4.0
9Coriolis system installation in Calciner firing for
coal fluctuation reduction Line-2.1456.5 1.4 11.0
10Kiln inlet ,Calciner outlet gas analyzer
installation.1456.5 1.4 1.2
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ACC Limited
Last 3 years Thermal Encon Project...cont.
Sr
No.
Project Description Thermal
Energy
(Mkcal)
Saving
(Million
Rs.)
Invest.
(Million
Rs.)
11 Kiln-1 Pyrojet burner installation. 2913.0 2.8 14.8
12Kiln feed SFM to Coriolis feeding system
replacement Line-11456.5 1.4 4.5
13Use of thermo graphy for Preheater radiation
loss reduction728.2 0.7 Nil
14Applied of leakage arresting material loctite in
Preheater728.2 0.7 Nil
15Replacement of K2 Burner with high
momentum Burner2865.753 2.54 12.95
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ACC Limited
Last 3 years Thermal Encon Projects..cont.
Sr
No.
Project Description Thermal
Energy
(Mkcal)
Saving
(Million
Rs.)
Invest.
(Million
Rs.)
16
Optimization of the DDF firing blower By
reducing the coal conveying air from 4300m3/hr
to 3900 M3/hr) in Kiln-13335 3.168 1.0
17Cooler horse shoe modification in Kiln-1 &
Kiln-2 as per Lafargeholcim norm1450 1.525
Nil
18 Both Cooler operation in auto mode 737.7 0.80 Nil
19 Kiln inlet trough modification in K-1 142.4 1.34 Nil
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ACC Limited
Last 3 years Electrical Encon Projects
Sl no. Project Description
Elect. Energy
(Million
kWh)
Saving
(Million
Rs.)
Invest.
(Million
Rs.)
1Replacement of Low efficiency Pre heater fan by
new fan and GRR by MVVVF for kiln-11.12 5.62 10.00
2De-Coal Crusher Modification by replacing
hammer0.20 0.99 0.00
3Energy saving by optimization of Energy in CA unit
in CPP0.06 0.32 0.00
4Installation of VFD for Kiln-1 Main Drive Cooling
Blower Motor.0.02 0.12 0.00
6VRM table liner replacement & Replacement of
VRM Bucket elevator chain by New chain1.19 5.94 4.00
7Grinding media regrading for CM-1 second
chamber 0.48 2.38 2.00
8High torque motor in CM-1&CM-9 has been
installed for clinker Rotary Feeder0.59 2.97 0.00
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ACC Limited
Last 3 years Electrical Encon Projects
Sl
no.Project Description
Elect. Energy
(Million
kWh)
Saving
(Million
Rs.)
Invest.
(Million
Rs.)
9 Restrict the grinding frequency from OPC & PPC. 0.48 2.38 0.00
10
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
0.24 1.19 0.00
11Clinker Quality analysis and action at raw mix /Coal
for reduction of hardgrove clinker grindability1.19 5.94 0.00
12 Dewatering Pump operation Optimisation done 0.36 1.80 0.00
13Synchronization of both the mining opertions
improve to more TPH of OLC0.51 2.57 0.00
14Improvement in LS size by maintaining the mines LS
input size , moisture to TC crusher,1.03 5.15 0.00
15False air points was arrested in Both the Preheater
Circuit0.79 3.96 0.00
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ACC Limited
Last 3 years Electrical Encon Projects...cont.
Sl
no.Project Description
Elect. Energy
(Million
kWh)
Saving
(Million
Rs.)
Invest.
(Million
Rs.)
16 MV VVFD repair/ replacement for Bag house fan line-2 2.51 13.61 0.00
17Reduction in Bag house-1 Fan Power by GRR operation
inplace of damper control0.58 2.66 0.00
18Reduction in Clinkering Compressor Power by Leakage
arresting0.08 0.36 0.00
19Reduction in Specific Electrical energy by increasing in
Atox Mill Production 1.19 6.69 0.00
20Reduction in power Consumption of Flash Dryer Fan
RM-1 1.17 6.58 0.00
21Installation of new screen for tertiry crusher feeding
sysytem /Improvement in TC Screen availability 1.16 6.52 39.50
22
Regreding of grinding media , Grinding Pattern
optimization in all the cement mills & other
improvement (Sapex fan Replacement of CM-9, CM-8
Main motor replcaement)
1.92 10.41 0.00
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ACC Limited
Last 3 years Electrical Encon Projects...cont.
Sl
no.Project Description
Elect.
Energy
(Million
kWh)
Saving
(Million
Rs.)
Invest.
(Million
Rs.)
23
Fan efficiency improvement by installation of
new fan with suitable capacity (Kiln-1 Preheater
Fan)
1.40 7.13 10.00
24Reduction in E Mill-1 Fan Power by reducing
GRR steps inplace of Damper control0.16 0.79 0.00
25 Installation of VVFD for Bag Filter Fan 0.11 0.57 0.90
26 Auto Control Common Header pressure of BFPs 0.16 0.80 0.00
27 Installation of VVFD for BFPs 6 Nos. 1.60 8.14 20.00
28 Optimisation of Centralised AC System 0.03 0.13 0.00
29 Packer-3 Belt modification for energy saving 0.02 0.12 0.00
30Reduction of Electrical Energy Consumption
during Shutdown0.63 3.19 0.00
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ACC Limited
Last 3 years Electrical Encon Projects...cont.
Sl
no.Project Description
Elect. Energy
(Million kWh)
Saving
(Million
Rs.)
Invest.
(Million
Rs.)
31 Voltage Optimization for Transformer 0.95 4.83 0.00
33
Electrical Energy saving due to E Mill and Atox
Mill Production increase after installation of coal
Mil inertization project
13.37 0.00 170.00
34Reduction in Bag house-1 Fan Power by GRR
operation inplace of damper control0.58 2.94 0.00
35Reduction in Clinkering Compressor Power by
Leakage arresting0.08 0.39 0.00
36Reduction in Specific Electrical energy by
increasing in Atox Mill Production 1.19 6.04 0.00
37Reduction in power Consumption of Flash Dryer
Fan RM-1 1.17 5.94 0.00
38
Installation of new screen for tertiry crusher
feeding sysytem /Improvement in TC Screen
availability
1.16 5.88 25.00
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ACC Limited
Reduction in Specific Energy Consumption
76.4175.29
*79.74
77.04
72.00
74.00
76.00
78.00
80.00
82.00
2014 2015 2016 2017 YTD JUN
Year wise kWh/t of ClinkerHigher SEEC due to
Low Production
80.9979.31
*85.20
82.61
70.0072.0074.0076.0078.0080.0082.0084.0086.00
2014 2015 2016 2017 YTD
JUN
Year wise kWh/t Cement Higher SEEC due to Low Production
33.08
31.47
*34.3 34.3
30.00
32.00
34.00
36.00
2014 2015 2016 2017 YTD JUN
Year Wise kWh/t of Cement Grinding
Higher SEEC due to Low Production
729.10 730.57734.58 735.14
700.00
710.00
720.00
730.00
740.00
750.00
760.00
2014 2015 2016 2017 YTD
JUNE
KJ/ Kg of Clinker Increase due to higher TSR%
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ACC Limited
Energy Benchmarking
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 Kilns
10 0.4
7 Alumina painting in Pre-heater Cyclone
25.80 Cr.18.4
kcal/kg cli.
Road Map to Achieve Benchmark/Global Best
17
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
Innovative Project-1
Observation:
It has been observed that the Cooler ESP fan line-1 ID fan Drawing more
power…. Compare to cooler ESP fan line-2. ESP Dust spillage from various
point for ESP inlet Cone observe. During shut down we have found that
there is erosion in casing & missing Guide vanes . As a result extra air
ingress in ESP & disturbing gas distribution and damaging colleting
electrodes etc.
Reduction of Specific Electrical Energy Consumption by
Modification of Guide Vanes & Damage casing in Cooler
ESP line -1 inlet Cone.
In
no
vate
to
Excel
20
ACC Limited
Problem & Root Cause Analysis In
no
vate
to
Excel
Problem Defination
▪Cooler ESP ID draw more power.
▪ Dust spillage from ESP inlet Cone.
▪ Increase stack emission.
▪ Collecting Electrode bend and displacement in 1st Field in particular portion.
Root Cause Analysis : Observation During Kiln Shut down
▪Missing & Wear out existing Guide vanes.
▪Wear out ESP inlet cone casing as flue gas directly hit the casing due to missing of
Guide Vane.
▪ In absence of guide vane Gas Distribution has been disturbed, hence it damage
collecting electrodes in a particular part and reducing ESP efficiency. Increasing
Dust emission.
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ACC Limited
Problem and Root cause analysisIn
no
vate
to
Excel
Guide
vane
position
Casing
Hole
Dust spillage from ESP
Casing
22
ACC Limited
What we have doneIn
no
vate
to
Excel
•Modification of Guide vanes in position based on CFD
analysis.
• Patch work done in ESP Casing
ESP INLET CONE LAYOUT WITH modified GUIDE VANES
Fixing of Guide Vanes
23
ACC Limited
Identification of High velocity Zone Through CFDIn
no
vate
to
Excel
Before After
24
ACC Limited
Cooler ESP Fan Energy Conservation ProfileIn
no
vate
to
Excel
After Before
25
ACC Limited
SEEC performance trendIn
no
vate
to
Excel
0.00
0.50
1.00
1.50
2.00
2.50
SEEC Cooler ESP Fan K1 MTD
Before Project Implementation
NOV-2016
0.00
0.10
0.20
0.30
0.40
0.50
0.60
SEEC Cooler ESP Fan K1 MTDFEB-2017
After Project Implementation
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ACC Limited
Backup calculation of Savings / Improvement In
no
vate
to
Excel Before Project implementation
Average TPD KW SEEC
4534.75 230 1.22
After Project implementation
Average TPD KW SEEC
4721.15 156 0.40
Annual Savings
Electrical Energy Savings in KW 74
Annul Savings in SEEC 0.4
Annual Energy Savings in KWH 5,83,462.18
Annual Monetary Savings INR @ Rs 5.0/unit 29,17,310.88
Annual Electrical energy Saving in KWH : 5.83L Unit.
Annual Monetary Savings INR @ Rs 5.0/unit : Rs. 29.17 Lacs
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ACC Limited
Environment Improvement by installation of Guide Vanes to
prevent frequent failure of Filter Bag causes High Emission
Innovative Project-2In
no
vate
to
Excel
• kiln-2 Bag house commissioned in the year 2012.
• Bag house was designed with an inlet operating condition of 850,000 m3/hr at 150 °C and -50 mm WG for a dust load of 60
g/m3 at inlet and 30 mg/Nm3 at outlet.
• Bag types used are woven fibre glass with PTFE lamination.
• Initially the Bag house operation was good after one year wear problems in the bag filters started.
• In practice, gas flow is uneven in inlet, resulting in high gas velocity in some modules. This may lead to wear in bags and thus overall higher dust emissions than expected.
•Damages have been observed in all the modules with major impact in module Nos. 4A, 5A, 4B, 6B and 6A particularly.
Problems definition :
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ACC Limited
Problem Definition & Root Cause Analysis
In
no
vate
to
Excel
• The CFD team analyzed the process data and
equipment dimensions, created a 3D geometry of the
Bag house, its inlet & outlet duct to prepare computer
model of flow distribution inside Bag house.
• Several modifications are tried and the most
optimum modification has been inferred.
• Modifications include the insertion of new guide
vanes in the inlet duct, inlet plenum and common
inlet duct.
CFD study Out Come :
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ACC Limited
Problem Definition & Root Cause Analysis
In
no
vate
to
Excel
30
ACC Limited
Problem Definition & Root Cause Analysis
In
no
vate
to
Excel
31
ACC Limited
Site Implementation: Fixing of Guide Vanes
In
no
vate
to
Excel
Site Implementation based on CFD study :
32
ACC Limited
Impacts & BenefitsIn
no
vate
to
Excel
• Homogenized flow distribution inside the Bag
house inlet duct, which will lead to better gas
distribution to various bag modules.
• Reduction of velocity inside initial modules, lead
to reduction in damage of bags.
• Reduction in dust emissions.
The stack Emission come down to the level of 50 – 70
mg/Nm3, before shut down it was around250-
300 mg/Nm3 at normal operating condition for Bag
house stack.
33
ACC Limited
Impacts & BenefitsIn
no
vate
to
Excel
Investment : INR 10 Lacs
Savings in Filter Bags : INR 55 Lacs
Materials Consumed
Year Wise materials consumtion details Year wise cost incurred in INR Lacs
2014 2015 2016
2017 ( actual 200 nos. till July & estimated 550 nos. for remaining period)
2014 2015 20162017 ( Actul till Jul-17 & estimated till Dec-17)
Saving w.r.t 2016 on A/C of Bag
Cages0 0 1460 0 0 0 69.27 0
54.95
Filter Bags
3550 945 2120 750 126.27 32.94 76.39 21.44
Total 3550 945 3580 750 126.27 32.94 145.66 21.44
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ACC Limited
In
no
vate
to
Excel
Innovative Project-3
The objective of the project is to Lead Reduction by making a shorter distance Haul Road at Block I,
Connecting Block III to Block I
ACTIONS TAKEN
1. Backfilling is planned in worked out pit of Block I for Hauling Limestone to BMG Crusher
2. Design of optimized Layout of new haul road.
3. Comparison of Results between them.
RESULTS
1. Average lead reduction to be achieved 0.7 kms
2. Safe running hours of Dumpers
3. Reduction in Diesel consumption Rs 0.88Lak
Total saving 19.5 Lakhs / Year
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ACC Limited
In
no
vate
to
Excel
Innovative Project-4
Changing the mindset
of people from
comfort to highly
stretched zone
Discussion / Brain Storming with Unionrepresentatives, HEOs, Maintenance,Crusher & support staff.
1 Shift - Maintenance (HEMM & Crushers)2 Shift - Operations
Mining Operations optimized to work in 2 shifts instead of 3 shifts in both the Mines
1
2
• United acceptance of challenge• Counseling operators and mechanicsand giving confidence.• Cascading targets• We Can & We Will
• Safety: Elimination of Night operationsof machines• To iterate plan & establish sequence ofworkings so as to get ample time forboth Operation & Maintenance.•Reduction in Idle Hours duringoperation• Hot seat changeover of operations•Good coordination in production andmines site in-charge with singleobjective• Improved Morale of workmen
Improved Quality of Life
3
Improved Working conditionReduction in overall Mining Cost by 3.80 Rs/T
(excluding royalty)
36
ACC Limited
Environmental Projects conti....
Sr
No.Name of the Environment Project
Year of
ImplementationCorrective & preventive actions
1Installation of Roof Top Solar system at
Admin Building and SMTI.
2016 Installed 2 nos. 10 kVA Roof Top
Solar system
2
Online continuous emission monitoring at CM-
1, CM-8, VRM, Coal Mill kiln -1 & 2, Cooler
ESP kiln -1 & 2
2016-2017 Installed CEMS in 8 nos. Stacks at
plant
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
To improve the mine discharge water qualities
by construction of check dams.
2015 To construct 03 Nos. of check dams
in the mine discharge water drain in
Kalehra Village.
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
37
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
38
ACC Limited
Environmental Projects linking with Carbon
Emission Reduction
1199 1211
1045
800 800 800
0
200
400
600
800
1000
1200
1400
Actual 2015 Actual 2016 2017 YTD Target 2017 Target 2018 Target 2019
Net CO2 emissions(kg CO2/t cement)
39
ACC Limited
Environmental Projects linking with Carbon
Emission Reduction
62.7 63.5 63.962.8
76.475.3
79.7
76.8
33.131.5
34.3 34.5
81.079.3
85.282.7
3047.6
3054.0
3072.0
3074.3
3030.0
3040.0
3050.0
3060.0
3070.0
3080.0
3090.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
90.0
2014 2015 2016 2017 (TILL MAY)
Clinker Factor Production %
Electrical Energy
Consumption in Clinkering
Kwh/t Clk
Electrical Energy
Consumption in Grinding
Kwh/t CemGrd
Electrical Energy
Consumption Cement Kwh/t
Cem
Specific Thermal Energy
Consumption MJ/T Clinker
40
ACC Limited
Environmental Projects linking with Carbon
Emission Reduction
81.879.8 78.9
87.0
9.1 8.9 9.1 9.1
3268.0
3288.0
3300.7 3300.0
3200.0
3220.0
3240.0
3260.0
3280.0
3300.0
3320.0
3340.0
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
90.0
100.0
2014 2015 2016 2017 (TILL MAY)
PLF %
Aux.
Consumption
%
Heat Rate
kCal/kWh
41
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
42
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
43
ACC Limited
Brainstorming session: Energy Reduction
44
ACC Limited
Awareness Campaign: Energy Dream Run-’17
45
ACC Limited
GreenCo Site Assessment & Training
46
ACC Limited
ISO 50001-11: 2nd Surveillance Audit
47
ACC Limited
Energy Monitoring System
48
ACC Limited
Daily Reporting Section Wise Format
49
ACC Limited
Daily Reporting Equipment Wise Format
50
ACC Limited
ISO 50001-2011 & CII GreenCo Gold
51
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%
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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%
CAPITAL SCHEMES_May_2014 (1).xlsx
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ACC Limited
Utilization of waste
for replacing the conventional energy
0
20000
40000
60000
80000
100000
120000
140000
160000
180000
200000
2013 2014 2015 2016 2017 till
Jun
85221
60289
101633
143142
195563
4.03% 2.85%
4.75%
6.69%
9.14%
M kcal from AFRTSR %
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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
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ACC Limited
GreenCo Best Practices in Waste Management- 2016
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ACC Limited
Best Practices – 1: Implemented in Green Supply Chain DIESEL CONS,. LOCO 2015
D/CON. Loco 1 Loco 2 Loco 3 Loco 4
JAN 0 3254 3764 6208
Feb 0 2540 2870 5397
Mar 0 3702 3214 7706
Apr 0 3597 3103 7603
May 0 3713 2494 6813
Jun 0 4583 4382 8272
Jul 0 3500 3920 7998
Aug 320 5480 3100 6000
Sep 0 3200 3250 2750
Oct 0 3150 3832 3850
Nov 0 3341 3790 1720
Dec 0 3729 3402 3700
TOTAL 320 43789 41121 68017
DIESEL CONS,. LOCO 2016
D/CON. Loco 1 Loco 2 Loco 3 Loco 4
JAN 0 3350 2131 6346
Feb 0 2363 2650 4367
Mar 0 3434 4548 4350
Apr 0 2970 2512 4060
May 0 3280 3650 6100
Jun 0 5250 4000 6650
Jul 0 4270 3750 7050
Aug 0 3750 2850 6300
Sep 0 3600 2800 4650
Oct 0 3590 2000 5100
Nov 0 4050 2200 5550
Dec 0 3150 1450 5550
TOTAL 0 43057 34541 66073
Total Diesel Consumption in
2015 is 153247 LitreTotal Diesel Consumption in
2016 is 143671 Litre
1.Decrease in ideal time of loco(Earlier loco was kept on running due to starting issue, the problem
was solved by replacing the old ignition system with new and advanced circuit)
Reason for Diesel Saving
Total Diesel Saving 9576 Litre and
Cost benefit is 612864 INR
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ACC Limited
Best Practices–2: Implemented in Green Supply Chain
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ACC Limited
Best Practices–3: Implemented in Green Supply Chain
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ACC Limited
Best Practices–4: Implemented in Green Supply Chain
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ACC Limited
Kymore Mining Lease is Awarded as 5 star Mines by Ministry of Mines
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ACC Limited
CII National Award for Energy Efficiency 2016
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ACC Limited
Earth Care Award for Reduction of Green House Gases
Emission (Large Enterprises Category) - 2014
63
ACC Limited
CII 14th National Award for Energy Efficiency-2013
64
ACC Limited
CII 14th Environmental Best Practices Awards 2013
65
ACC Limited
National Awards : At a Glance
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ACC Limited
