Best Practices adopted by ACC on Energy Efficiency improvement. Author : K.N Rao Director EECC ACC Ltd Date : 26th February 2015

Transcription

1 Best Practices adopted by ACC on Energy Efficiency improvement Author : K.N Rao Director EECC ACC Ltd Date : 26th February 2015 ACC Limited EECC 2/19/2015

2 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. 2 ACC Limited EECC 2/19/2015

3 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 GAGAL TIKARIA LAKHERI DCW SINDRI KYMORE CHAIBASA JAMUL BARGARH CHANDA VIZAG WADI THONDEBHAVI KUDITHINI MADUKKARAI Region (North) Region (East) Region (South) Region (West) 3

4 ACC Sp. Energy consumption & Carbon footprint PLANT MTOE Report - PAN ACC Baseline SEC kcal/kg Target SEC PAT Cylce-1 Kcal/kg cement GAGAL-I GAGAL-II LAKHERI KYMORE TIKARIA CHAIBASA BARGARH JAMUL CHANDA WADI MADUKKARAI GtG SEC of YTD * (kcal/kg) Total Reduction in MTOE in ~ 8% compared to baseline CO 2 Down by 33 per cent in twenty years Reduced from 550 to 538 Kg/T of cement from 2011 to

5 Typical Levers 5

6 Model Plant tour Experiential learning Live measurement & calc Sharing best practices Soft Skill training Boot Camp Communi cation Centre Of Excellence Newsletter Community meet Conf call WAR room performance dialogue Capabilit y building Training Model Plant Sharing B.P Benchmarking Dream run Award & Recognition Plant Visit Deep Dive & data analysis Find out Encon scope Prepare Road Map Achieve Asp. target Core Services Knowledg e & data managem ent Energy Module Energy Hand book Case study Best Practices HEAT map ACC Limited 6

7 Clinker Factor Improve Clinker Quality 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 7

8 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 % Recycled Material Some of ACC plants have attained clinker substitution rate (slag as well as PPC) as per norms specified by BIS 8

9 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 Faster Stronger Durable, High Strength PPC, A Performing Cement in Concrete with its performance Competitive to OPC 53 in Market Foundation to Roof Cement : Faster, Stronger durable, High Strength PSC Faster, Stronger durable, High Strength PSC, Tailor made Cement for Coastal 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 9 ACC Limited EECC 2/19/2015

10 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) 10

11 WHR Power Generation 11

12 AFR Use of waste material 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 12

13 AFR Use of waste material 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 13

14 AFR Use of waste material 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 Waste Paint Solid Waste Rice Husk 15

15 AFR Use of waste material 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 Kymore 3 Pre-processing platforms being set up Wadi Future plans to strengthen AFR activity Hot commissioning 2014 Madukkarai Kymore Wadi 17

16 AFR - Energy Plantations Use of waste lands Jatropha & Caster Opportunities for creating livelihoods in local communities 18

17 Specific Energy Consumption (kcal/kg) Energy Intensity THERMAL ENERGY ELECTRICAL ENERGY YTD YTD Target SEC Achieved SEC ACC SEC Target 19

18 Thermal Energy Elecrrical Energy Thermal Energy Elecrrical Energy Thermal Energy Elecrrical Energy Thermal Energy Elecrrical Energy Specific Energy Consumption Trend Gagal-1 Gagal Thermal Energy (kcal/kg of clinker) GtG SEC (kcal/kg cement) Thermal Energy (kcal/kg of clinker) GtG SEC (kcal/kg cement) Electrical Energy (kwh/t of cement) Electrical Energy (kwh/t of cement) Kymore Lakheri Thermal Energy (kcal/kg of clinker) Thermal Energy (kcal/kg of clinker) GtG SEC (kcal/kg cement) GtG SEC (kcal/kg cement) Electrical Energy (kwh/t of cement) Electrical Energy (kwh/t of cement) 20

19 Thermal Energy Elecrrical Energy Thermal Energy Elecrrical Energy Thermal Energy Elecrrical Energy Specific Energy Consumption Trend Chaibasa Bargarh Thermal Energy (kcal/kg of clinker) Electrical Energy (kwh/t of cement) GtG SEC (kcal/kg cement) Jamul Thermal Energy (kcal/kg of clinker) Electrical Energy (kwh/t of cement) GtG SEC (kcal/kg cement) Thermal Energy (kcal/kg of clinker) GtG SEC (kcal/kg cement) Electrical Energy (kwh/t of cement) 21

20 Thermal Energy Elecrrical Energy Thermal Energy Elecrrical Energy Thermal Energy Elecrrical Energy Specific Energy Consumption Trend 850 Chanda Madukkarai Thermal Energy (kcal/kg of clinker) GtG SEC (kcal/kg cement) Electrical Energy (kwh/t of cement) Wadi Thermal Energy (kcal/kg of clinker) GtG SEC (kcal/kg cement) Electrical Energy (kwh/t of cement) Thermal Energy (kcal/kg of clinker) - WD-1 Electrical Energy (kwh/t of cement) - WD-2 Thermal Energy (kcal/kg of clinker) - WD-2 GtG SEC (kcal/kg cement) Electrical Energy (kwh/t of cement) - WD-1 22

21 Energy Intensity - Thermal Increase number of Stages of Preheater Seven Stage Preheater at Lakheri 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. 23

22 Energy Intensity - Electrical Real time monitoring of process parameters and specific energy to optimize operation 3 rd 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 Specific Electrical Energy (KW/T 23 % Target

23 % of Petcoke 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 Use of Renewable energy Wind Energy from 19 MW capacity Wind farms at Tamilnadu, Rajasthan and Maharashtra % Pet Coke Consumption Year 25

24 Logistics Move Less Safety Zero harm onsite and offsite Cost to serve Aspirations Time to serve Best in class OET and ODT Service Quality Clean bag to end customer People Vehicle Process Safety excellence Operational excellence Move efficiently Handle less Move less Contract efficiently Service quality Asset utilization RFID, GPS MLP Truck scheduler epassport Parking yards Distribution centers Strategic excellence Network optimization Hub and Spoke Swaps 26

25 Green Buildings Cement House ACC s Headquarters (1939/2009) LEED GOLD La Residency Hostel for Academy participants (1966/2010) Chanda CCR Central Control Room Building (2011) LEED PLATINUM LEED PLATINUM What we achieved Going beyond Energy Conservation! Green Buildings seen as simple examples of Sustainable Construction. 27

26 Green Building - Sustainable Construction 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. 4 th Global Holcim Awards now open. 28

27 Green Building Sustainable Construction Making affordable green construction materials and practices available in semi urban/rural India Stimulating rural demand for cement as well Courtesy : Danish Rashid 29

28 30