best practices adopted by acc limited

EECC ACC Limited 2/19/2015

Best Practices adopted by ACC on Energy Efficiency improvement

Author : K.N Rao

Director EECC

ACC Ltd

Date : 26th February 2015

2

ACC Limited EECC EECC 2/19/2015

Indian Cement Industry

India is the second largest Cement producer after China

Approximate production of 251 Million Tonnes per annum.

Cement industry comprises of 183 large cement plants (97% Installed capacity) and more than 360 mini cement plants.

More than 97% of the plants have adopted Energy Efficient dry manufacturing technology

Indian cement plants are comparable with the best in the world.

The industry’s average energy consumption is estimated to be about 725 kcal/kg clinker thermal energy and 85 kWh/t cement electrical energy.

The best thermal and electrical energy consumption presently achieved by the Indian cement industry is about 684 kcal/kg clinker and 65.5 kWh/t cement

Comparable to the best reported figures of 651 kcal/kg clinker and 57 kWh/t cement in a developed country like Japan.

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ACC Limited EECC 2/19/2015

A Pan India Footprint

Nationwide footprint

17 cement plants with a capacity of 30 million tonnes/annum

~9000 employees

21 sales units, 54 area offices

194 warehouses, ~ 10,000 dealers

> 50 RMX plants

Region (North)

Region (East)

Region (South)

GAGAL

TIKARIA

LAKHERI

KYMORE

CHANDA

KUDITHINI

WADI

THONDEBHAVI

MADUKKARAI

BARGARH JAMUL

CHAIBASA

SINDRI

DCW

VIZAG

Region (West)

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ACC – Sp. Energy consumption & Carbon footprint

Total Reduction in

MTOE in

2011 -2014 ~ 8%

compared to baseline

MTOE Report - PAN ACC PLANT Baseline

SEC

kCal/kg

Target

SEC PAT

Cylce-1

Kcal/kg

cement

GtG SEC of

YTD-14-15

* (kCal/kg)

GAGAL-I 787.7 752.94 752.91

GAGAL-II 795.54 760.09 748.26

LAKHERI 970.87 918.07 820.83

KYMORE 850.08 809.60 774.74

TIKARIA 138.73 133.04 149.98

CHAIBASA 794.32 760.86 748.36

BARGARH 881.29 840.10 730.50

JAMUL 936.48 890.25 871.31

CHANDA 897.56 852.43 652.77

WADI 921.95 874.33 833.99

MADUKKARAI 1241.4 1180.98 1179.37

CO2

Down by 33 per cent in

twenty years

Reduced from 550 to

538 Kg/T of cement

from 2011 to 2013

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Typical Levers

2/19/2015

ACC Limited

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Communication

Capability

building

Knowledge & data

management

Core Services

Boot Camp

Centre Of Excellence

Plant Visit Deep Dive & data analysis Find out Encon scope Prepare Road Map Achieve Asp. target

Energy Module Energy Hand book Case study Best Practices HEAT map

Training Model Plant Sharing B.P Benchmarking Dream run Award & Recognition

Newsletter Community meet Conf call WAR room performance dialogue

Model Plant tour Experiential learning Live measurement & calc Sharing best practices Soft Skill training

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Gainful utilisation of Slag, a

waste industrial byproduct

Fly ash, waste from thermal

power plants, to make

superior Blended cements

Portland Slag Cement

Portland Pozzolana Cement

Part replacement of clinker

which is made from

limestone; leading to

• Mineral conservation

• Emissions reduction

• Waste management

• Lower cost, higher volume

• Superior cement

Clinker Factor – Improve Clinker Quality

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Clinker Factor – Improve Clinker Quality

• Optimize raw mix to enhance

clinker quality for better

absorption of pozzolonic

material

• Process & equipment

management (Dozing rate of

additive / enhancers , Use of

Rotascale & other equipment

for precise feeding)

• Optimize PSD, Blaine,

air/internal spray

• Benchmark / Compare key

parameters across plants:

(Clinker %, CaO clinker,

R45%)

• Use of Additives

Some of ACC plants have attained clinker substitution rate (slag as

well as PPC) as per norms specified by BIS

2011 2012 2013

% Recycled Material

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ACC Limited EECC EECC 2/19/2015

Faster Stronger Durable, High Strength PPC, A Performing Cement in Concrete with its performance Competitive to OPC 53 in Market

Faster , Stronger durable, High Strength PSC, Tailor

made Cement for Coastal Markets

Foundation to Roof Cement : Faster , Stronger durable, High Strength PSC

Productisation- Special Products

Premium Brands developed which have faster setting and high early

strengths of OPC and durability of Blended Cements with much Lower

clinker Factor and launched in different Markets

ACC Gold is the only one of its kind , specially formulated fly ash based Blended cement with higher strength, increased durability and water repellent properties

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Productisation- Special Concrete

Value Added Solutions (VAS) of as

many as 19 products for different

specific customer requirements

ACC set up India’s first commercial ready mixed concrete business in 1993

Supercrete (Highapplications, all tailored to meet Performance concrete -M100)

UTWT 24 / Speedcrete

Ready to use mortar

Bucketcrete (Bucket concrete)

Permecrete( Pervious concrete)

Lightcrete (Light weight concrete)

Thermocrete (Heat/Sound Insulation concrete)

Jetsetcrete ( High Early strength concrete)

HiDensecrete (High density concrete)

Easecrete (Self compacting concrete)

Colourcrete (Colour concrete)

Coolcrete (Temperature controlled concrete)

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WHR – Power Generation

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• Holcim’s Global Geocycle Philosophy and Policy

• Hazardous & non-hazardous Industrial wastes

• Municipal Solid wastes

• Agro waste & Bio-mass

• Energy plantations

• Service to industry & society

• Stakeholder engagement

• Community livelihood opportunities

• Thermal substitution

• Strengthening AFR activity and future plans

AFR – Use of waste material

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ACC provides sustainable waste management solutions through co-processing in cement kilns under Holcim’s Geocycle India banner.

Complete solutions for Industrial Wastes, Agricultural waste, Bio-mass, Municipal Solid Waste

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Typical wastes we manage

ETP /Paint sludge Solvents Carbon fines Oil filter fluffs Sorted municipal solid

waste Plastics Packaging materials Rubber wastes /tyre

chips Textile waste Mill scale Blast furnace dust Expired FMCG waste

Waste Paper Solid Waste

Waste Paint Rice Husk

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Leadership in managing Hazardous & non-hazardous Industrial, municipal and agro wastes

Our own and sponsored energy plantations Service to industry & society; Advocacy Regular Stakeholder engagement Community livelihood opportunities Achieved Thermal substitution rate of 5 per cent 3 Pre-processing platforms being set up Future plans to strengthen AFR activity


Hot commissioning 2014

Kymore

Wadi

Madukkarai

Kymore Wadi

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AFR - Energy Plantations

• Use of waste lands

• Jatropha & Caster

• Opportunities for creating livelihoods in local communities

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Energy Intensity

2008 2009 2010 2011 2012 2013 YTD

THERMAL ENERGY

2008 2009 2010 2011 2012 2013 YTD

ELECTRICAL ENERGY

Spe

cifi

c En

erg

y C

on

sum

pti

on

(k

Cal

/kg)

ACC SEC Target

Target SEC

Achieved SEC

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Specific Energy Consumption Trend

0.0

20.0

40.0

60.0

80.0

100.0

650

670

690

710

730

750

770

790

2012 2013 2014

Ele

crri

cal E

ne

rgy

The

rmal

En

erg

y

Gagal-1

Thermal Energy (kCal/kg of clinker) GtG SEC (kCal/kg cement)

Electrical Energy (kWh/T of cement)

0.0

20.0

40.0

60.0

80.0

100.0

650

670

690

710

730

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770

790

2012 2013 2014

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rgy

The

rmal

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y

Gagal-2



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2012 2013 2014

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rmal

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erg

y

Kymore

Thermal Energy (kCal/kg of clinker)

GtG SEC (kCal/kg cement)


0.0

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100.0

650

700

750

800

2012 2013 2014

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crri

cal E

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rgy

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erg

y

Lakheri

Thermal Energy (kCal/kg of clinker)

GtG SEC (kCal/kg cement)


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0.0

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100.0

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700

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850

2012 2013 2014

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crri

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rmal

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Chaibasa



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Bargarh



0.0

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840

2012 2013 2014

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Jamul



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0.0

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Chanda



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900

950

2012 2013 2014

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Wadi

Thermal Energy (kCal/kg of clinker) - WD-1 GtG SEC (kCal/kg cement)

Electrical Energy (kWh/T of cement) - WD-2 Electrical Energy (kWh/T of cement) - WD-1

Thermal Energy (kCal/kg of clinker) - WD-2

0.0

20.0

40.0

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900

1000

1100

1200

2012 2013 2014

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Madukkarai



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Energy Intensity - Thermal

• Increase number of Stages of

Preheater

• Optimization of raw mix and fuel mix

• CFD study for duct / cyclones &

modifications

• Modification of burners

• Heat recuperation loss – improve

clinker cooler efficiency with latest

technology

• Periodic Thermal imaging study to

identify and reduce radiation losses

• Replacement of PD Blower with Turbo

Blower

• Smart Automation like Kiln Master

• Explore increase of stages in

Preheater

• Continuously monitor and control

Oxygen level.

Seven Stage Preheater at Lakheri

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Energy Intensity - Electrical

• Real time monitoring of process parameters

and specific energy to optimize operation

• 3rd generation high efficiency separator to

replace old one

• Mechanical conveying to replace pneumatic

conveying

• Fan study – Resize fans – Replace impeller/fan

• Rationalize compressed air requirement and

pressure

• Use of VFDs in place of Damper / GRR control

• Use CFD study to reduce pressure drop across

ducts and cyclones

• De-bottlenecking projects to increase

productivity of entire system • Install Pre grinder to support ball mill grinding

and optimize ball mill as per PSD analysis

• Smart Automation like Mill Master

• Reduce false air entry in VRM circuit, ball mill

inlet & preheater

Thondebhavi – Electrical SEC

Target 2011-12 2012-13 2013-14

Specific Electrical Energy (KW/T

23 %

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Energy Intensity - Sourcing

• Use of Petcoke to replace

conventional fossil fuel

• Optimize energy sourcing – Mix

of coal from various sources to

optimise on GCV Vs cost

• Demand management- Optimize

TOD uses

• Maximum linkage coal realization

2011 2012 2013

% o

f Pet

coke

Year

% Pet Coke Consumption

• Use of Renewable energy – Wind Energy from 19 MW capacity Wind farms at Tamilnadu, Rajasthan and Maharashtra

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Logistics – Move Less

Safety Zero harm – onsite

and offsite

Cost to serve

Time to serve

Best in class OET and ODT

Service Quality

Clean bag to end customer

Aspirations

▪ People

▪ Vehicle

▪ Process

Safety excellence

▪ Network optimization

▪ Hub and Spoke

▪ Swaps

Strategic excellence

▪ Move efficiently

▪ Handle less

▪ Move less

▪ Contract efficiently

▪ Service quality

Operational excellence

▪ RFID, GPS ▪ MLP ▪ Truck scheduler ▪ ePassport ▪ Parking yards ▪ Distribution centers

Asset utilization

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Green Buildings

• Cement House – ACC’s

Headquarters (1939/2009)

•La Residency – Hostel for

Academy participants (1966/2010)

• Chanda CCR – Central Control

Room Building (2011)

What we achieved – Going beyond Energy Conservation !

Green Buildings seen as simple examples of Sustainable Construction.

LEED

GOLD

LEED

PLATINUM

LEED

PLATINUM

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• Propagating Concrete as superior road building material. Seminars for State Governments

• Technical training on Concrete Roads for road building contractors and supervisors.

• Promotion of blended cements at technical seminars and articles in journals.

• Promoting good construction practices.

• Promoting Holcim Foundation for Sustainable Construction, Holcim Global Awards contest. 4th Global

Holcim Awards now open.

Green Building - Sustainable Construction

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Green Building – Sustainable Construction

Courtesy : Danish Rashid

Making affordable green construction materials and practices

available in semi urban/rural India

Stimulating rural demand for cement as well

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