ACC LIMITED CHANDA CEMENT WORKS CHANDRAPUR, MAHARASHTRA. Capacity: Clinkering 2.31 MTPA Cement 3.8 MTPA 40MW CPP

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1 ACC LIMITED CHANDA CEMENT WORKS CHANDRAPUR, MAHARASHTRA Capacity: Clinkering 2.31 MTPA Cement 3.8 MTPA 40MW CPP Excellence in Energy Management

2 GREEN BULIDING CERTIFICATION "LEED - Platinum award from Indian Green Building Council for CCR building under NC (New Construction) category. This is the 1st Industrial building in Indian Cement Industry that got the Green Building award. 2

3 Moment of Pride for Chanda Lowest in Thermal Energy consumption in Holcim globally & in India 2 nd Best Plant in Electrical Energy in Holcim (South Asia) Certified Model plant in India for Sp. Electrical Energy among Holcim South East Asia Golden Peacock Environment Management Award

4 SR. NO Name of the Awards Year Authority 1 AWARDS Golden Peacock Environment Management Award 2017 Golden Peacock 2 Excellent Energy Efficient Unit 2016 CII 3 Excellent Energy Efficient Unit 2015 CII Capability Centre Green Campus Learning Award Green Manufacturing Excellence Award Challengers Category ET Indian Manufacturing Excellence Award Gold certificate Green Manufacturing Excellence Award Silver Category Indian Manufacturing Excellence Award Silver Category 2013 Mc Kinsey LEED Platinum Award 2011 Economic Times Group and Frost & Sullivan. Economic Times Group and Frost & Sullivan. Economic Times Group and Frost & Sullivan. Economic Times Group and Frost & Sullivan. Indian Green Building Council 4

5 Quarry to Lorry New plant commissioned in 2010 Quarry Crusher Raw Mill CF Silo Kiln Clinker Silo Sindola Mines-17 km from plant Govari Mines-25 km from plant Cement Mill VRM Limestone crusher 1200 TPH impact crusher. L&T make. Cement Mill 1 VRM 560 TPH Pfeiffer make. 1.5% residue on 212 micron Cement Silo 1 X tons CF silo Blending efficiency 10:1 1 dry process kiln 6 stage double string preheater with ILC 7000 TPD FLS make 5.5 M dia and 86 M long Packing House Dispatch Tons Clinker 260TPH LOESCHE 2 Mills X 75 TPH each 1 Mill (VRM ) X 260 TPH (PPC) Loesche 5 Cement silo of 2400 Tons each 2 Silos of Tons each Total Capacity = Tons 6 Electronic packer 3 X 120 TPH EEL Make 3 X 240 TPH each EEL Make 9 wagon loading machines of 120 TPH each.

6 Product Portfolio Product Portfolio OPC Con+ PPC OPC Con+ PPC 6

7 ENERGY REDUCTION Thermal Energy Kiln EE Clinkering (kwh/t clinker) YTD'17 Bench Mark EE Grinding (kwh/t cement) YTD'17 Bench Mark EE Total (kwh/t cement) YTD' YTD'17 Bench Mark ONE OF THE LOWEST IN INDIAN CEMENT INDUSTRY 7

8 Energy Conservation Projects (Last 3 years summary) No investment No of project implemented : 165 Electrical Energy Saving : 23.5 Million kwh Thermal Energy Saving : 85.3 Million Kcal Low Investment No of project implemented : 43 Electrical Energy Saving : 36 Million kwh Medium Investment No of project implemented : 27 Electrical Energy Saving : 39 Million kwh Total no of Projects Implemented ( Last three years) : 235 Electrical Energy Saving : 98.5 Million Kwh Thermal Energy Saving : 85.3 Million Kcal 8

9 Brain Storming Sessions Ideas Summary Stage1 in Jan 2014 Stage2 in Mar 2015 Stage3 in Jan 2016 Stage4 in Feb 2017 Total Total Ideas Total Ideas Prioritized High Impact, low & medium ease of Implementation Completed In Progress

10 Innovative Project Project Title: cm-3 output improvement and power reduction This report is solely for the internal use. No part of it may be circulated, quoted, or reproduced for distribution outside the company organization without prior written approval from ACC Limited. This material was used during an oral presentation; it is not a complete record of the discussion.

11 Innovative Project SEEC Reduction CM-3 Team Information: Cross Functional From Right to Left : Mr.Sambaiah T, Mr.Satish Singh, Mr.Avasa Mishra (Mentor), Mr.Srinivas (Project Leader), Mr.Prajith, Mr.Jogi ACC 11

12 Step 1:- (a) Problem Definition 1.1) Brief description of Problem Specific Electrical Energy Consumption of CM Kwh/T.Cem in PPC, leading to High Cost of Cement Grinding on the basis of Jan- Dec 2016 Data. Estimated Saving (Mandatory): Tangible Benefit Rs Lakhs (for 12months) Present Level: Target: Specific power consumption Kwh/T PPC.Cement based on (Jan- Dec 2016) 30Kwh/T. cement in PPC 12 ACC

13 No.of mill stoppages Cumm% of stops (1.2) History of Problem No.of stops cumm(%) Interpretation: 20% of stoppage reasons leading to 80% of total stoppages Mill tripping due to reject Belt Overload Silo Feed Elevator trip due to Boot Level/Bag House Differential Pressure problem Mill stoppage due clinker w/f belt failure Mill diverter Problem 13 ACC

14 Analysis Step : 3.1 Brain Storming Brain Storming Session conducted for cross functional team for Reduction of Specific Electrical Energy in CM-3. All the participants are divided into groups and discussed all the points group wise on ACC 14

15 Analysis Step : 3.1 Brain Storming Brain Storming Session : Participants are noting down the brain storming points on the flip chart ACC 15

16 Analysis Step : 3.1 Brain Storming Points ACC 1. Mill reject Belt 531BC2 dust spillage and mill stoppage during mill re empty out 2. Silo Elevator trip due to Boot Level Bag House Purging Cycle 3. Clinker Silo Extraction DBC KW transducers provided for ideal power saving 4. Clinker extraction gates optimization for better clinker granulometry 5. Clinker hopper discharge chute modification 6. Standby equipments should be in ready condition for avoiding mill stoppage 7. Clinker Belt weigh Feeder replacement with Apron feeder 8. VFD to be installed in mill bag house fan 9. CM-3 Gypsum reversible belt replaced with Chute 10. Compressor air optimization with separating CM-3 and Packing hous 11. Mill Nozzle Ring Velocity is high 12. Mill scatter ring width is 40mm 13. CFD Study for CM-3 Bag House Fan 14. Mill outlet duct Castable frequent failure 15. Clinker Weigh feeder calibration 16. Variation in Fly ash fitness 17. High false air across the mill system 18. Gypsum size variation 19. Variation of mill dp due to outlet pressure point jam 20. Mill Reject belt overload 21. Operator Training on Hydraulics 22. Mill Water Spray Pipe Line Modification 16

17 Analysis Step : 3.2 Cause & Effect Diagram MACHINE MAN/OPERATOR TRAINING CONCENTRATIO N ATTITUDE Compressor air optimization Clinker w/f belt failure BE KW Fluctuations BE Boot Level Clinker Extraction DBC KW transducer SKILL HEALTH MOTIVATION Mill Reject Belt BC1& BC2 Overload Mill Internal Water Spray inside the mill Improvement in CM-3 Output In PPC & OPC Mill Outlet duct castable failure Mill scatter ring width Clinker Extraction DBC Gates OTHER MATERIAL OPERATIONAL METHODS

18 WHY - WHY Analysis 3.3 Identify the root causes: S.No Valid Probable Cause WHY WHY WHY WHY 1 Silo Feed Elevator Load Fluctuations Bag House Differential pressure high Bag House Purging Cycle sequence One Cycle is operated with high load and another with low load Uneven Bucket elevator load during each cycle 2 Mill Output decrease Clinker Hopper get empty No material coming from DBC Frequent Jamming of Clinker Extraction Gates No KW Transducer to Clinker Extraction DBC 3 Operation of maximum Silo Extraction Gates Clinker granulometry disturbance in the mill Mill Vibrations 4 Clinker w/f belt Clinker w/f Belt failure Foreign material stuck up 5 Mill Reject Belt Overload Reject belt get overload High reject from mill during mill startup Mill reject material going directly on the reject belt 6 Mill Nozzle Ring Velocity High Nozzle area blockage Velocity across nozzle increases 7 Mill scatter ring Width Scatter ring width is low ACC Gases escapes from nozzle ring Gap between nozzle ring and mill table 18

19 Step 4:- Action step S.No Valid Probable Cause Last Why-Why Analysis point (Root Cause) Action Plan Target Date Responsible Person Status 1 Silo Feed Elevator KW Fluctuations Uneven Bucket elevator load during each cycle Optimization of Bughouse Purging Cycle Srinivas/Velu Completed 2 No KW Transducer to Silo Extraction DBC No KW Transducer to Clinker Extraction DBC Installation of KW Transducers Prajith Clinker DPC Completed Power Transducer 3 Operation of maximum Silo Extraction gates 4 Clinker w/f Belt failure 5 6 Mil Reject Belt Overload Mill Nozzle Ring Velocity High 7 Mill Scatter ring width ACC Mill Vibrations Foreign Material stuck up in the chute Mill reject material going directly on the reject belt Velocity across nozzle increases Gap between nozzle ring and mill table Optimized silo extraction gates Chute modification done Mill reject discharge given to reject elevator Nozzle ring velocity optimization Increase of scatter ring width from 70 to 110mm srinivas Completed Srinivas/Pathak Completed SEAL GAP KAGE WITH RUBBER Mill reject diversion Srinivas Completed srinivas Completed Mill scatter ring Srinivas/Satish Completed 19

20 Improvement jobs done- CM-3 Main bag house purging Optimization Before Purging Cycle Before Trial Cycle 1 : 2,6,9,12 BE Load:62.1 Cycle 2 : 1,3,4,6,11 BE Load:77 Cycle 3 : 2,3,5,8,13 BE Load:90.4 Cycle 4 :7,9,10,14 BE Load:75.0 Cycle 5 :1,3,4,6,11 BE Load: 74 Cycle 6 : 2,3,5,8,13 BE Load: 85.5 Cycle 7 : 7,9,10,14 BE Load:85.0 After Purging Cycle After Trial Cycle 1 : 2,3,6,9,12 BE Load:83.1 Cycle 2 : 1,3,4,6,11 BE Load:80.6 Cycle 3 : 2,,5,8,13 BE Load:80.0 Cycle 4 :7,9,10,14 BE Load:81.3 Cycle 5 :1,3,4,6,11 BE Load: 80.6 Cycle 6 : 2,,5,8,13 BE Load: 80.0 Cycle 7 : 7,9,10,14 BE Load:

21 Passing [%] Passing [%] Silo extraction gates optimization Fine, dusty Normal clinker, some dust Coarse, no dust Before Project Fine, dusty Normal clinker, some dust After Project 70 Very coarse, no dust 70 Coarse, no dust DPC-2 Operation of Single Gate 13 Sep 2016 DPC-2 Operation of Single Gate 13 Sep Very coarse, no dust Clinker grain size [mm] Clinker grain size [mm] 21 ACC

22 Clinker Hopper Discharge Chute Modification Clinker W/F Front view Clinker W/F Back view Problems Faced 1. Frequent failure of Clinker w/f belt due to plates stuck up and hot clinker 2. Material spillages due to Belt sway Benefits after chute modification 1. No mill stoppages due to Clinker w/f belt damage 2. No material spillages 3. Belt life increased from 1month to 6 months 22

23 Action Step : Mill Reject Belt Overload Before Project After Project Inference : Mill reject directly given to reject Bucket Elevator to avoid reject belt overload during reject bin empty out ACC 23

24 Action Step : Scatter ring optimization Before Project After Project Scatter ring width 70mm Wide Scatter ring width110mm Wide Inference : Scatter ring provided at gap between mill table and nozzle ring not to pass hot gases out of nozzles it causes disturbances in nozzle velocity ACC

25 5. Check Step : CM-3 PPC 38.0 Before Project After Project May/16 Jun/16 Jul/16 Aug/16 Sep/16 Oct/16 Nov/16 Dec/16 Jan/17 Feb/17 Mar/17 Apr/17 May/17 Jun/ May/16 Jun/16 Jul/16 Aug/16 Sep/16 Oct/16 Dec/16 Jan/17 Feb/17 Mar/17 Apr/17 May/17 Jun/17 TPH Kwh/Ton Inference : Higher the Mill TPH Lower the Specific Electrical Energy Consumption and Vice Versa. Higher the Specific Electrical Energy Consumption (Kwh/Ton) will lead to higher cement grinding cost 25 ACC

26 Innovative Project Project Title: Modification in hydraulic pump with provision of oil conditioning filter in Raw Mill VRM hydraulic system This report is solely for the internal use. No part of it may be circulated, quoted, or reproduced for distribution outside the company organization without prior written approval from ACC Limited. This material was used during an oral presentation; it is not a complete record of the discussion.

27 Problem Problem Definition Frequent failure of hydraulic main pump Frequent oil contamination Hydraulic valve malfunction Hydraulic power pack Radial piston pump 27

28 Process followed Cross function team was formed to analyze the problem RCFA was done using Solve technique Major root causes from RCFA: 1. Negative suction 2. Contamination Solutions identified: 1. Positive suction arrangement 2. Offline filer arrangement 28

29 Detailed problem analysis Pump failure was from starvation due to negative suction There was no arrangement for return line filter and this led to oil contamination and subsequent valve malfunction Negative suction pump Return line Hydraulic power pack Hyd. system return line without filter 29

30 Implementations Following actions were implemented in the hydraulic system: 1. Pump location was changed from top of the tank to ground level to provide positive suction 2. Offline filter with oil cooler was provided in the tank Offline filter Positive suction arrangement provided Cooler Offline filter 30

31 Cost benefits analysis Total implementation cost :1.5 Lakh (approx.) Spares: Oil 1.4 Lakh, filter,ferrule fittings and hoses Manpower:1 technician and 1 helper for 8 hrs Realized benefits Production loss on account of downtime: 1 shift x 2 times/year=2 shifts=16 hrs/ year Potential savings from production loss=16 hrs x3.5 Lakh/hr=56 Lakh per year (realization from per ton of Clinker@INR 1000) Savings in maintenance Cost: 1000 Liter oil for two times in a year=2 Lakh(@ INR 200/Liter oil) Cost of hydraulic pump: =1.8 Lakh X2=3.6 Lakh Total savings= Lakh =61.6 Lakh per year 31

32 Overall Results Life of hydraulic pump &its components increased with positive suction arrangement Hydraulic system problems minimized Oil replacement interval increased Reduced downtime of the raw mill VRM 32

33 We have many more ideas in pipe line to sustain and improve performance to achieve aspiration value Section (kwh/t clk) Equipment Lever Actions Time line RML LS crusher OLBC PRI EE Crusher TPH should be improved from 1000 to 1200 TPH after completion of road construction Utilizing full capacity of OLBC by strengthening structure Aug 17 June Rawmill EE Replacement of worn out separator static blades to improve separator efficiency Sep Rawmill EE Optimization of dam ring height Sept 17 RMP 0.40 Mill Fan EE Installation of MV VFD for Raw mill Fan in place of GRR July Mill Fan False air Reduction in False air by another 2% Sep RM MD PRI Further improvement in PRI from 102 to 105 % Dec 17 ACC Limited 33

34 We have many more ideas in pipe line to sustain and improve performance to achieve aspiration value Section (kwh/t clk) Equipment Lever Actions Time line Kiln Coal Mill Kiln Improving the coal mill PRI by replacing PRI Sep 17 the liners of table & rollers TEI Cooler horse shoe modification to reduce clinker temperature Dec EE Replacement Coal Mill bags to improve of coal the draft mill main and compressor bag filter air utilization 0.19 Pre heater EE Further reduction in False air Dec 17 Dec 17 Section (kwh/t of Cem) 0.10 Mill MTBF Installation of Magnetic separator on CM-3 reject belt Dec 17 Cement mill Mill Fan Mill EE EE Installation of MV VFD for new CM VRM bag house fan Installation of Magnetic separator on Gypsum Feeding Belt Dec 17 Sep Mill EE Modification of water spray nozzle of CM3 to avoid frequent jamming and wear of nozzle Sept 17 ACC Limited 34

35 Several activities were conducted to make this happen Formation of 7 Energy circle for driving and sustaining the improvement Energy Circles Dedicated Energy observation tour to spot anomalies such as false air, idle running Several Idea generation session and implementation of ideas and best practices Plant Tours Benchmarking exercise with the best performing plants (completed Maratha benchmarking exercise) Daily equipment wise electrical energy analysis Forums

36 Role of Management Systems in Improving Energy Efficiency Implementation of ISO-9001 has helped to remain vigilant to avoid any lapses on quality parameters and commit ourselves to supply quality products to customer on time ISO with its focused approach on environmental protection has led to take proactive steps in combating pollution with long term vision of sustainable development which in turn has fuelled initiatives for finding ways for optimum energy consumption Implementation of Energy Management System ISO-50001:2011 has made a coherent contribution among various wings of energy saving activities: Consistency in running of cement plant has improved Plant Load Factor of Power Plant Increased PRI(5.5% improvement) and MTBF(from 47 to 280 hrs) has led to lower energy consumption per ton of cement production Created renewed and focused awareness on energy conservation and led to many initiatives in energy savings 36

37 Renewable Energy and Utilization of waste Renewable Energy: Extensive usage of solar lighting inside plant and colony Solar panel of 15.0 kw capacity installed on CCR roof top and used for electricity requirement of the complete CCR building. Waste Utilization: Usage of STP treated water for gardening purpose In house recycling and reuse of waste lubricants for non critical equipments Usage of fly ash generated from CPP 37

38 TREE-PLANTATION & SAPLING DISTRIBUTION ACC Limited 2000 Trees planted near by villages & plant

39 Tree Plantation and Distribution Statistics Name of the Industry ACC Limited, Chanda Cement Works ACC Limited, Sindola Limestone Mines ACC Limited, Govari Limestone Mines Total Factory area (In Hectares) ( In case of local body total area) Total Nos. of tree planted from up to Total Nos. of trees survived so far(as per Mar 31) Target of tree plantation in the year Plantation-3000 Nos Distribution to Villages Under CSR-7000 Nos Avenue plantation / Road side plantation to be carried out in Plantation-4000 Nos - Plantation-6000 Nos - No. of Trees Planted as on 24/07/2017 Plantation-2200 Nos Distributed to Villagers under CSR-7000 Nos Plantation-3857 Nos Plantation-3980 Nos ACC Limited

40 Solid Waste Management Waste identification Segregation & Collection Recycling or disposal as per waste characteristics. Dedicated scrap yard COLOUR CODED DUSTBINS ARE PLACED AT PROMINENT PLANT LOCATION FOR COLLECTION & SEGREGATION OF WASTE. ACC Limited

41 WAY FORWARD. Sr.No ENVIRONMENT EXCELLENCE PROJECTS UNDER IMPLEMENTATION PROJECT COST (Crore INR) 1. Water intensity reduction project Conversion of 15 MW CPP ESP to Hybrid filters Plantation in Plant, colony & mines for the year Installation of 3Nos. CAAQMS at Gowari Mines

42 GHG : THE 2020 PLAN. Building for Tomorrow LH GROUP TARGET India specific target 1)Reduce net specific CO 2 emission per ton of cementations products by 33% (vs. 1990) 1) Specific net CO2 Emission <516 KG/T of Cementitious materials 2)Thermal Substitution Rate - 12% 1)Recover more than 60Mt of waste derived resources The target is not cascaded to regions for the time being 1)Reduce freshwater withdrawal per ton of cement by 20% vs Reduction of freshwater vs )32% reduction in specific freshwater withdrawal (l/t cem) 2)32% reduction in specific water consumption (l/t cem) 1)Zero fatalities 2)LTI FR < )Reduce TIFR by 50% Vs )To have minimum of 30% of each gender at all management levels 5)Disease rate < 0.1 1)Zero fatalities 2)LTI FR < )Reduce TIFR by 30% Vs 2015 Chanda Targets In House Beyond our Fences 1) Specific net CO2 Emission < KG/T of Cementitious materials 2)Specific Heat consumption <2870 MJ/T of Clinker 3) Clinker factor <76.4% 1)Will distribute 100,000 Saplings to surrounding villages 1) 0.58 million Tons of fly ash to be consumed 2) 0.10 million Tons of synthetic Gypsum to be consumed 1) Will make Chanda Zero Plastic Zone. 1)33 % reduction in specific Fresh water withdrawal (l/t cem) vs [%] 2) 35 % reduction in specific fresh water consumption (l/t cem) vs [%] 3)Implementation of WASH Pledge 4)Baseline assessment of biodiversity condition of all active quarries will be established 5) Development of Biodiversity Management plan for all active quarries 1)Will provide more water to local communities and nature than we withdraw from fresh water sources in water scarce area 1) Zero fatalities 2)LTI FR < ) Reduce TIFR by 30% Vs )Seat belts for company & contractor vehicles= 100% 5)Defensive drivers training for employees and contractors - 50% 6)Employees health assessment (risk based) - 100% of employees 7) Industrial hygiene sampling Annually 8)Crystalline silica testing for quarry & plant Annually 9) To have minimum of 15% of each gender at all management levels 10) Make all villages in our area free of open defecation 1) Will develop initiative to impact people

43 INCREASE ABSORPTION OF FLYASH & REDUCE CARBON EMISSION Fly ash absorption percentage Apr/16 May/16 Jun/16 Jul/16 Aug/16 Sep/16 Oct/16 Nov/16 Dec/16 Jan/17 Feb/17 Mar/17 % FA absorption Concrete + % FA absorption - PPC YTD-17 Aspiration YTD-17 Aspiration 43

44 Rain Water Harvesting Rain water harvesting system is adopted. Ponds are developed at Plant and abandoned pits in mines are used. In the expansion project water pipeline has been laid down along OLBC from mines to meet the additional requirements of water at cement plant if required. 44

45 Rain Water Harvesting Recharging of Ground Water through construction of 2 ponds of size35mx25m and 22mx70m having recharging capacity of 8 million Ltrs & 19 million Ltrs respectively. 45

46 We are adopting best practices in safety and processes to sustain our model plant aspirations CO Level Digital Display has been displayed at Coal Mill Circuit Power Distribution box is fixed at each department for power supply Stands have been fabricated inhouse for fixing & providing 24 V hand lamps. ACC Limited Solar power based traffic light blinkers have been fixed Pad Locks with photo & labels are used during isolation.

47 We are adopting best practices in safety and processes to sustain our model plant aspirations All the Load Centers by replacing the conventional Rubber Insulation mats with INSULKOTE - Z1311 having a resistivity of 33KV/ mm. Load Centers provided with PHOTOGLOW 915 PAINT to guide the way towards EMERGENCY EXIT during BLACKOUT Pull Chord switches have been provided with LED lamp to display the healthiness of the switch Cables trays are being painted with color codes for easy identification ACC Limited Cable Entry sealed by CEMENT MORTAR 473 having a temperature resistivity is 1450 C for 4 hrs Chanda Cement Works Proximity device has been fixed on Tail-end drum guards of conveyors for safety of person

48 Thank You Thank You