plant name: acc limited, thondebhavi cement...

© LafargeHolcim Ltd 2015

Plant Name: ACC Limited, Thondebhavi Cement Works

Quality Circle Forum of India,

Hyderabad Chapter

Category : Energy Excellence

© 2015 Company

Company Profile

2

Set up as a Green Field Project in Lush

Green Village of Thondebhavi

Installed Capacity – 2 Million MT (OPC/PPC)

Grinding System with VRM (Make : Loesche)

Capacity – 250 TPH (PPC)

ISO 14001: 2015 and ISO 50001:2011 Certified

1

2

3

4 42%

53%

6%

OPC PPC C+

Product Portfolio

Lowest SEEC across ACC/ACL5

© 2015 Company 3

Plant Process Layout - TCW

Clinker silo

100000 t

Cement silos

2x 10000t1x1000t

PPC OPC

Fly ash storage silo

1X3500 t

Fly ash

feeding silo

1X 500 t

Fly Ash Bulker Unloading

Wagon Tippler

Clinker Hopper

(500T)

Gypsum Hopper (300T)

Gypsum Gantry

15000t

Reclaimer

(120TPH)

Gypsum Crusher

(150TPH)

Mill Bag House & Fan

(3300KW fan motor)

Vertical Roller Mill – LM 56.3+3 (250 TPH PPC)

Installed Motor capacity 5400 KW

WF

Mill Building

RMHBuilding

Gypsum Cr

Building

Packing Plant

Truck Loading &

Bulk Loading

© 2015 Company

ISO 50001:2011 Certified, Energy Policy

4

© 2015 Company

1. Specific Electrical Energy Consumption

5.3%

SEEC (kWh/t Cement)

27.42 26.2 25.16 23

3.443.01 2.65

2

2016-17 2017-18 YTD Sept'18 Aspiration

Auxiliaries

Mill Section

30.86 29.2227.81

25.0

4.8%

© 2015 Company

2. Internal Benchmark

53.15

52.30

48.47

47.58

46.10

42.61

41.22

40.07

39.67

38.70

37.05

36.26

34.28

32.49

32.03

31.03

27.81

0.00 10.00 20.00 30.00 40.00 50.00 60.00

Plant 1

Plant 2

Plant 3

Plant 4

Plant 5

Plant 6

Plant 7

Plant 8

Plant 9

Plant 10

Plant 11

Plant 12

Plant 13

Plant 14

Plant 15

Plant 16

THONDEBHAVI

SEEC (kWh/t Cem) – YTD 2018

61.45

53.49

50.38

48.84

47.70

45.54

42.36

41.16

39.20

38.83

38.83

36.70

35.72

34.96

33.72

32.22

29.91

0.00 20.00 40.00 60.00 80.00

Plant 1

Plant 2

Plant 3

Plant 4

Plant 5

Plant 6

Plant 7

Plant 8

Plant 9

Plant 10

Plant 11

Plant 12

Plant 13

Plant 14

Plant 15

Plant 16

THONDEBHAVI

SEEC (kWh/t Cem) - 2017

Lowest Specific Electrical Energy Consumption across ACC/ACL

© 2015 Company

2a Road Map to achieve National Benchmark

S

No

Projects Energy

savings

(kWh/t of

cement)

Timeline

1 Usage of Grinding additive 1.0 Sept’18

2 Removal of Venturi at Bag house fan

inlet duct to reduce pressure drop0.3 Dec’18

3 Installation of high efficient screw

compressor for Flyash unloading to improve unloading rate

0.3 Dec’18

4 Re orientation of Armour ring angle

from 25 Deg to 15 Deg 0.35 Dec’18

5 Replacement of Mill feed rotary feeder 0.20 Sept’18

6 Strengthening of Flyash pumping

system for improving pumping rate @ 120 TPH

0.25 Sept’18

7 Installation of 7.5 KW compressor for

instrument air at Big Flyash Silo 0.20 Oct’18

8 Grit cone segment replacement and

feed chute repair job0.20 Dec’18

Total 2.80

27.8

25

1

0.3

0.3

0.35

0.2

0.25

0.2

0.2

YTD July'18

Grinding additive

Venturi removal

High Eff. Screw Compressor

Armour angle to 15Deg

Mill Rotary feeder replacement

Flyash pumping @ 120 TPH

Instrument compressor at FA Silo

Grit cone replacement

Mission

© 2015 Company

Energy saving projects implemented in FY 2017-18

8

No Title of ProjectAnnual

Electrical Saving (kWh)

Annual

Electrical Cost Saving (Rs million)

Total Annual

Savings (Rs million)

Investment Made

(Rs million)

Payback

(Months)

1

Installation of mesh at mill

inlet ducts to avoid material

accumulation and pressure

drop

332900 1.9 1.9 0 0

2

Modified Water Spray

Nozzles with compressed air

for uniform distribution of

water

166460 0.99 0.99 0 0

3

Build up of Support ring

Height from 40mm to 65 mm

and Width from 35 mm to

55mm.

277437 1.66 1.66 0 0

4

Removal of stump cone and

extension of grit cone chute

by 400mm to reduce main

drive load

166460 0.99 0.99 0 0

© 2015 Company

Energy saving projects implemented in FY 2017-18

9

No Title of Project

Annual

Electrical Saving (kWh)

Annual

Electrical Cost Saving (Rs million)

Total Annual

Savings (Rs million)

Investment Made

(Rs million)

Payback

(Months)

5

Optimisation of counter and

Working pressure for smooth

operation of mill

332900 1.99 1.99 0 0

6Optimisation of compressed air

by arresting leakages110900 0.65 0.65 0 0

7Installation of LED lights in place

of HPSV lights204000 1.2 1.2 0.5 5

8

Installation of 3rd flyash

unloading line to improve flyash

unloading rate

296000 1.77 1.77 0.2 0

9

Improvement in Mill MTBF from

180 hrs to 250 hrs by inhouse

designed SMART app.

145200 0.87 0.87 0.2 3

10Reduction of average Rake

unloading time from 7 hrs to 5 hrs304920 1.8 1.8 0 0

Total 2337177 13.82 13.82 0.9 8

© 2015 Company

Innovative Projects Implemented

10

• Removal of stump cone and extension of grit cone chute and maintained 600mm

height from table.

• Build up of Support ring Height from 40mm to 65 mm and Width from 35 mm to 55mm.

• Modified Water Spray Nozzles with compressed air for uniform distribution of

water

• Optimisation of counter and working pressure for smooth operation of mill

• Installation of mesh at mill inlet ducts to avoid material accumulation and pressure drop

• Increase in BA pressure from 40 to 45 bar and reduce PA pressure from 10 to 8

bar

• Installation of Flyash unloading line No.3 using existing compressor

© 2015 Company 11

1. Table Support Ring Build up from 40 X 35 mm to 65 X 55 mm

65mm

55 mm

Action taken:

▪ Build up of Support ring Height from 40mm to 65 mm and Width from 35 mm to 55mm.

▪ Distance between Roller tyre back face and support ring reduced from 30mm to 15mm when

rollers rest on buffer

Benefits realised:

• Consistent bed height above 65 mm as against previous level of 50mm, resulted in increase

grinding efficiency.

• Increase in throughput of mill from 280 TPH to 295 TPH in PPC.

• Savings ~ 0.25 kWh/t Cem

Implemented Innovations

© 2015 Company

12


2. Removal of Stump cone from table

AfterBefore

Action taken:

▪ Removal of stump cone and extension of grit cone chute by 400 mm.

▪ Distance from Table to reject chute reduced from 700mm to 600mm for

uniform distribution of material

Benefits realised:• Reduction in Main drive load Savings - ~ 0.15 kWh/t)

• Uniform distribution of material across grinding path. Better mill stability

Grit Cone Chute

Stump Cone

© 2015 Company

13


3. Installation of nozzle @ 60 deg and Armour ring @ 25deg

Nozzle ring Angle :60 Deg

Nozzle ring Angle :80 Deg

Armour Ring : 25 Deg

Action taken:

▪ Reinstallation of Louver ring with the angle of 60 deg and

armour ring angle to 25 deg

▪ Maintaining louver ring area of 3.97 m2 by blocking 2 louvers

behind each roller (Total 12 Nos)

Benefits realised:

• Reduction of mill fan power consumption by ~270 KW

• Impact ~ 1.0 kWh/t Cem

Armour Ring : 10 Deg

© 2015 Company

14

4. Modification of Table Water Spray Nozzles

Before

Water Spray Nozzle with single pipe at height of 100mm from Dam ring

Modified Water Spray Nozzles with compressed air for uniform distribution of water▪ Height above Dam ring – 50 mm

▪ Distance from Inner Dam ring – 100 mm▪ Distance from Roller – 50 mm▪ Angle towards Roller – 35 Deg

*Better distribution of water resulted in uniform bed there by reduction in vibrations to the level of 5 mm/s from previous 6 to 7mm/s.*Water requirement reduced from 4.5M3/hr to 3 M3/hr

After


© 2015 Company


15

5. Installation of mesh in inlet duct to reduce pressure drop by 4 mbar at mill inlet

Action taken:

▪ To Reduce pressure drop at inlet duct due to material accumulation, mesh of 2” size

installed at inlet ducts to avoid accumulation

Benefits realised:

• Reduction of material accumulation at inlet duct, resulting in reduction of mill inlet draft

from -50 mm WC to -20 mm WC

• Reduction of Bag house power consumption by 0.3 kWh/t Cem

© 2015 Company


16

6. Installation of Fly-ash Unloading line No 3 in 500 MT Silo

• Improvement in unloading rate from 50 TPH to 80 TPH.

• Minimizing pumping and Unloading of Fly-ash from Big Silo, reduction in SEEC

• Minimizing stoppage of mill on account of Fly-ash silo level.

• Utilization of Mill operation person dedicatedly for Mill

Line No 3

Line No 1 Line No 2

Before After

• Improvement in unloading rate from 50 TPH to 80 TPH.

• Minimizing pumping and Unloading of Fly-ash from Big Silo, reduction in SEEC

• Minimizing stoppage of mill on account of Fly-ash silo level.

• Utilization of Mill operation person dedicatedly for Mill

© 2015 Company


17

7. Optimisation of mill by operating counter pressure from 23 Bar to below 18 Bar

Action taken:

▪ Operating the mill counter pressure below 18 bar.

▪ Reduction of piston accumulator N2 pressure from 10 bar to

8 bar and increased bladder accumulator pressure from 40 bar

to 45 bar.

▪ Working pressure Min set point fixed at 65 bar.

▪ Counter Pressure Min set point fixed at 12 bar.

▪ Maintaining Net Grinding pressure at 50 bar

Benefits realised:

• Reduction in mill vibrations from 7 mm/s to 5 mm/s

• Reduction in mill reject load from 30 to 34 amps from 24 to

27 amps.

• Reduction in main drive power and Baghouse power

© 2015 Company 18

▪ Installation of compressor of 7.5 KW for Flyash unloading during Mill Stoppage, Eliminating running of 110 KW compressor

Provision of Lighting ON/OFF through DCS in timer mode


© 2015 Company

Implemented Innovations - SMART App

19

➢ To strengthen the quality of

WBI (walk by inspection) and

develop full proof system to

eliminate the human errors.

➢ To improve the health of

equipment by immediate

reporting and action executed.

➢ To minimize time for actual

WBI and report generation.

© 2015 Company

Implemented Innovations – SMART App

QR CODE ON

EQUIPMENTINPUT BY WBI

INSPECTORDATABASE

SERVER

Equip scan

SMS ALERT E-Mail ALERT

WAN

WAN

TIMELY

EXECUTION

© 2015 Company 21

Entering the Observations with photographs, readings along with Risk level in the app


© 2015 Company 22

➢ Reports will be generated automatically at mentioned time slot and will be sent to concerned

team.

➢ If high priority alarms persists, notification will be triggered to concerned person as message/mail.


© 2015 Company

Green Power Sourcing – Renewable Energy

23

93%71%

36% 35%

7%

24%

21% 20%

5%

43% 45%

2016 2017 YTD Sept'18 2018

Solar Purchase BESCOM I Ex

▪ Solar power in used extensively for cement manufacturing at Thondebhavi

▪ To use about 15 MW of solar power to meet over half of annual power requirement -

~23 MU of solar power

▪ Switching to solar power will reduce CO2 emissions by 19,000 tonnes every

year – Eqv. to 22.5 trees every year or a saving of 45 million litres of water

© 2015 Company

TEAM and Review Mechanism

24

SourabhModi

Swaroop G

(Process)AK Tripathy

(E&I)

Saravanan

(Mech)

Vikram,Arvind

KarthikLakshmi

Velu, Chandru

Naveen, Paramesh, Rajasekhar

Deepak, Anil, Mumtaj, Ganga, Rajesh

Murthy Vikram, Guruchaan

Team Leader

Team Members

(MS)

Patrollers,

SFAs

Business

Partners

TEAM

▪ Formation of Cross functional team including contract workmen

▪ Continuous monitoring of Specific Electrical Energy Consumption (SEEC) through EMS

▪ Hourly reporting of SEEC through Whatsapp

▪ Weekly performance review with Director Plant and deriving and implementation of action plan

Weekly Performance review along with steering

committee chaired by Director Plant

Mr. H.S Rathore

Director PlantACC

Thondebhavi

© 2015 Company


Discussion with operation team to optimise mill further

▪ Identification and

Rectification of leakages

through Walk by

inspections and shared

in Whatsapp.

▪ Immediate action by

shift engineer to rectify.

Rewarding the best performers in the

shift operation

© 2015 Company


Innovation Lab

▪ Developed an Innovation Lab set up in Plant

▪ Brainstorming and Ideation sessions conducted on regularly

▪ Motivational and Positive Environment for Ideation session

▪ Implementation of Innovate Ideas and Reward Program in Place

© 2015 Company

Awards & Accolades

27

▪Innovative Project Award – National Energy Management Award – 2013

▪ Energy Efficient Unit – National Energy Management Award – 2013

▪Energy Efficient Unit – National Energy Management Award – 2016

© 2015 Company

Awards & Accolades

28

▪ CII ITC Sustainability Awards - 2014

▪ National Energy Conservation Award – BEE – 2012

▪ Golden Peacock National Quality Award – Winner - 2014

© 2015 Company

Awards & Accolades

29

Awards for Lowest Ever Specific Power

consumption across ACC

Award for Consistent

Performing Plant for the

period of 3 years in SEEC

© 2015 Company

Plantation

30

2000 Nos saplings ( 400 Nos Fruits Saplings) Plantation inside plant and

near by communities

Plantation at Community

SchoolPlantation at Railway StationPlantation in Plant

© 2015 Company

Bio Diversity

We facilitated Bio diversity at our Plant premises to encourage Birds by

providing Welcome Rest Shelter, Bird feeders and Drinking Water

plant name: acc limited, thondebhavi cement...

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