greenco best practices · contract with goa government ... frp waste from suzlon mangalore ......

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Trusted Technology – Solid Strength

Green House Gases Emission Mitigation

Greenco Best Practices

Trusted Technology - Solid Strength

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Green House Gases Emission Mitigation


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INVENTRIZATION MANAGEMENT CELL – 35 Numbers

Head(PQC & R&D)

Energy Managers 08 Numbers

50001 Energy Auditors

08 Numbers

Process & QC06 Numbers

Electrical 03 Number

Power Plant05 Numbers

Mines 03 Numbers

DGM (Process)


VASAVADATTA CEMENT GHG INVENTORY

yearEmission intensity kg CO2 /

MT Clinker

Emission Intensity kg CO2 /MT Cement

ActualNormalised for Max PPC

47 % with Base Year

2009-10 902 921 867

2010-11 934 855 802

2011-12 921 752 752

2012-13 921 752 733

2013-14 882 744 704

2014-15 891 746 702

2015-16 846 721 687

2015-16 values yet to Establish.

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Top Management Commitments

� Reduce GHG emissions from existing facilities by 2-3 % bynext Two year.

� Reduce Vendor /Customer GHG emissions by 5 %

� Use alternative or renewable sources of energy to cater 10 % ofenergy needs

� Focus on energy efficiency with equal emphasis on clean energy knowing the limitations of energy efficiency.

� To project energy efficiency: renewable energy mix of 10:90 to reach the goal of reduction of GHG intensity and figures.


Action Plan For Achieving The Targets in Reducing GHG

KIL, Cement Division Unit – VC has implemented no. of projects to reduce GHG intensity reduction. Projects from following categories are implemented.

1. Specific Thermal energy reduction

2. Specific Electrical energy reduction

3. Clinker factor improvement

4. % TSR increase

5. Heat rate/PLF improvement

6. Supply chain optimization


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CARBON BLACK FEEDING ARRAGEMENT

HOPPER

RAL(VFD)

Pneumatic conveying line to

Hopper

Hopper to Mill feeding system

Pneumatic

line



BENZO FURON STORAGE AND FEEDING ARRANGEMENT

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Instillation of AFR Feeding system in Unit-4 Preheater to consume more Alternative

fuels .

Action Plan to Consume AF in Unit -4

Total TSR Achievement of 10 % Total TSR Achievement of 10 %


30.00

32.02

32.50

33.00

34.00

28.00

29.00

30.00

31.00

32.00

33.00

34.00

2012-13 2013-14 2014-15 2015-16 2016-17

Fly Ash Injection in PPC Grinding

4.5 Kg CO2/MT

of Cement

reduction

4.5 Kg CO2/MT

of Cement

reduction

1.5 Kg CO2/MT

of Cement

reduction

1.5 Kg CO2/MT

of Cement

reduction

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Instillation of Roto Scale for Fly Ash feeding

Fly Ash Feeding Roto

Scale Started on 25th Dec

2015 at Unit-4 Cement

Mill

Fly Ash Feeding Roto

Scale Started in Unit-3

In Jan 2016.

Fly Ash Feeding Roto Scale

Platform and Separate Surge

Bin Ready at Unit-1 & 2

Cement Mill Started on 22nd

Jan 2016

Carbon Management with respect to AFR

� Hot Disc Instillation

� Use of Black Carbon , Municipal Waste , Plastic Waste

� Contract with Goa Government

� Involvement of VC in Making Goa Plastic Free State

� TXR –Facility for Rack Fitness Checking


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Hot Disc


Various Types of Waste used in Hot Disc


Type Of AFR Source

Shredded Tyre Chips Imported

Tyre & Tyre Waste Imported

Goa MSW Goa

Plastic Waste From Sunrays Compost Bangalore

FRP Waste From Suzlon Mangalore

Polyfiber Gujarat

Plastic Waste From Moogambigai Mangalore

Agriculture Waste Local

Coconut Coir Waste Mangalore

Shredded Toot Stalks Mangalore

Shredded Cotton Stalks

In-house generated Dumper Tyre Waste In House Garage

Plastic Waste From Paper Mill Dandali

MSW from HIL Bangalore

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Total Alternate Fuel Co-processed in Vasavadatta Cement Sedam All

Figures in (MT)

3017

13601

2166422388

0

5000

10000

15000

20000

25000

2012-13 2013-14 2014-15 205-16



�Disposal of plastic waste causing a big Problem for Goa Govt. and we were in

need

�Goa PCB & Municipal corporation visited VC site for solution. They Witnessed

HDR installed for scientific AF Co- processing.

�VC conducted trial of plastic waste with support & guidance of Indian Centre for

Plastics in the Environment(ICPE) & KSPCB. Trial run demonstrated that there was

no negative influences on stack emissions & kiln product quality.

�Goa Govt. joined hands with VC for Co-processing of plastic waste& MOU signed.

�Goa PCB & monitoring cum working committee, established material recovery

facility /Balling station as joint venture

�Dry Waste is send to VC for Co-Processing.

�Goa PCB issued appreciation letter for this joint effort for safe disposal of plastic

New-Project ( 2014-15): Usage of Goa Municipal waste In HDRDisposal of plastic waste & other Non- Recyclable waste from Goa To VC

Appreciation

Letter

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Training Class for Goa Municipal and PCB Authority



� Sunrays Bengaluru an authorized concerned for handling Non hazardous

Industrial wastes.

�They take various type of wastes form industries, segregate them into

biodegradable & non Biodegradable wastes

�In the process of waste disposal non bio degradable plastic are segregated &

Baled.

�These baled plastic are supplying to VC for Co processing to convert waste to

energy.

�Sunrays Bengaluru issued appreciation letter for this joint effort for safe disposal

of plastic

Appreciation

Letter

New-Project ( 2014-15): Usage Sunrays Compost Plastic waste In HDRDisposal of plastic waste & other Non- Recyclable waste from Bengaluru To VC

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Total Plastic waste co-processed from Goa Municipal Co. in Vasavadatta Cement Sedam.

All Figures in (MT)

638

2287

1849

0

500

1000

1500

2000

2500

2013-14 2014-15 2015-16



� Vasavadatta Cement has spent around Rs 100 Lakhs for

providing TXR facilities at VC yard.

� For TXR facility following infrastructure has been provided.

� We have provided concrete pathway for a length of 800m and

2m width on either side of R&D line-2.

� Wagons checking facility like Air compressor system, Rake

Testing Rig (RTR), Welding transformer, welding tapping points

at every 30 m interval along the examination line, Lister truck

2T capacity for movement and tools & tackles.

� Lighting arrangements have been provided at every 10mtr

interval on either side of the track for working in night shifts.

� For maintenance of wagons a service room is provided for TXR

staff.

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TXR checking point

CONCRETE PATHWAY


TXR checking point facilities

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TXR checking point inaugurated by Divisional Railway Manager, Secunderabad


� On an average 27 rakes in a month are being checked at TXR point at

VC railway siding.

� The invalid rakes which used to travel 300 kms (To & Fro) for checking

at Hyderabad is totally avoided.

� Around 900 liters of diesel per rake is saved (@ 3lit/Rake/Km)

Benefits of TXR Facility

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Way Foreword for reduction in GHG

Steps taken and Motivation



List of other Project in direction of Reducing GHG Emission

1. Reduction in Diesel Consumption in Vehicle use and in Light Up : Scope -3

2. Increase in Bulk Loading : Scope-1

3. Use of Hi-Silica Bauxite which is available in near by source : Scope -3

4. Use of More Chemical Gypsum than Imported Gypsum :Scope -3

5. Transportation of fly ash by Rail : Scope -2

6. Gypsum by rail or by truck Based on Reverse cement transportation: Scope-3

7. One way dispatch which will reduce one way emission of Dispatch vehicle.: Scope -2

8. Celebration of No-Vehicle day celebration :Scope -3

9. Emission Monitoring of Vehicle every quarter at our Garage Department with

External Agency : Scope -3

10. More And More Plantation . etc : Scope -3

11. Education to Transporters for optimum use of Vehicle : Scope-3

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Organising capacity building programmes to relevant employees once in a year to involve them in GHG emission activities

1. Motivate all employees to save Fuel consumption by conducting NO VEHICLE day on

every 1st of month

2. Internal Training Classes and External Faculty Training classes are conducted to

educate our employees

3. Every month Bench marking / Plant Performance and KPI review meeting is done

chaired by HMO to monitor all key points of consumptions.

4. Truck Turn Around Time / Two way loading system is motivated to reduce diesel

consumption of Road Transport

5. External Training are attended on regular basis to up grade our knowledge and

same is distributed to all employees by conducting Internal Classes.

6. Attended all Conference of Energy/Greenco/Environment / PAT/GHG / Quality

conducted by various Organization at national and International Level.


External Training for our Employees

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Our Employees involvement in Educating on GHG matter : At CemSemConference

Q-3 (2015-16) Inventrization Calculation


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As per the practices, ‘NoVehicle Day’ is organized onfirst day of every month.Employees will not bring theirvehicle to the plant on thisday.Safety Pledge was taken by allthe employees, near missincidences / safety suggestionsgiven were awarded foremployees, contract labourer’s,etc.Our Head ManufacturingOperations, Dr. Chander KumarJain, addressed the gathering.Employees, Contract Labourersand HOD’s were participated inthe event.

No Vehicle Day to communicate to the lowest level of Employee

101 Lts of Diesel Saved per

day hence 404 lts per

month and 4848 Lts of

diesel per year , which

reduces Kg of CO2 per ltr.

101 Lts of Diesel Saved per

day hence 404 lts per

month and 4848 Lts of

diesel per year , which

reduces Kg of CO2 per ltr.

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World Environment Day – HMO Addressing School Children's about Importance of GHG


ENERGY SAVER RATH AT COLONY MAIN GATE


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ENERGY SAVER RATH AT MATRUCHAYA COLLEGE


Utilisation of Rain Harvested water in %


67.00

35.00

43.00

96.00

2011-12 2012-13

2013-14 2014-15

Electricity Bill at our Water source

i.e Kagina was in terms of Lacks

For the year 2015-16 it Is almost Nil

Completely stopped River Kagina water pumping power consumption

90 Kw per hour with 20 Hours running for 238 days Avoided leading to reduction of CO2 Emission

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Rain water collecting in Mines Area Through Proper Channel


PLANTATIONREDUCTION OF 3200 TONS CO2 /ANNUM

Year Colony Factory Mines Total Survival %

Total 199922 166522 143526 509970 56%

The details of tree plantation in factory, colony and mines area(Numbers)

LOCATION AREA (HA)

Factory 41.5Colony 23.0Mines 20.5Total 85.0


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AFFORESTATION IN THE PLANT


Tree Plantation at Near by

Villages & in Plant

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NDTV Energy ChallengeAward was presented by Abhay Deol Cine Actor in presence of

Mr N K Ranganath, Managing Director – Grundfos Pumps India, Mr S Raghupathy, Executive

Director, CII-Godrej GBC, Dr Prem Jain, Chairman – IGBC – CII

VASAVADATTA CEMENT SEDAM

No of proposed Not Initiated In progress

71 KW 293527.9651

Rs. 94809532.71


16TH NATIONAL AWARD FOR EXCELLENT IN ENERGY MANAGEMENT IN CEMENT SECTOR 2015 AWARD RECEIVING PHOTO.

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15TH NATIONAL AWARD FOR EXCELLENT IN ENERGY MANAGEMENT 2014 AWARD RECEIVING PHOTO.


Manufacturing Excellence Award

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“Best Environment Practices Award -2013”

Conducted by M/s CII on 27th / 28th Nov 13 Our HOT DISC Project for Co-Processing

Waste is considered as “Most Innovative Project”

greenco best practices · contract with goa government ... frp waste from suzlon mangalore ......

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