ACC Limited

Bargarh Cement Works

“National Award for Excellence in Energy Management 2019-20”

2

ACC Limited

Milestones of IDCOL Cement Limited

Year Description

1963� Foundation stone laid by Industrial Development Corporation Of Orissa Ltd

(IDCOL), Govt. of Orissa on 19th Dec’1963

1967� Plant started on 10th May 1967 with 2 wet process kiln each of 600 TPD

(0.37 MTPA) & Grinding capacity 0.3 MTPA

1982 –1985

(1st Phase)

� First phase of expansion with capital of 1.6 Million INR to increase volume.� Installation of Cement Mill No 3.� Grinding capacity enhanced to 0.565 MTPA.

1991 –1995(2nd

Phase)

� Second Phase of expansion by commissioning of one new dry process kiln with capacity 1800 TPD of five stage SP with in line Pre calciner.

� Cement Grinding capacity enhanced to 1 MTPA by installation of 2 HPGRs andmixing plant.

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ACC Limited

Takeover by ACC in Dec 2003

Year Description

Dec., 2003

� Acquisition of plant by ACC Limited in Dec 2003. Cost of share purchased – 176.41 Cr. (23 Cr. equity shares @ Rs 7.67 per share)

Reasons for Disinvestment of the erstwhile IDCOL Cement Limited : -� Sick unit, Too much Bureaucratic & Political interference , Excess manpower, high

overtime, Poor Industrial culture , Poor Technical capabilities of the employees to run the plant efficiently.

� Labor unions were very strong supported by local politicians resulted in poor performance of the plant.

2005-2006(3rd Phase)

� Investment of INR 86 Cr. to increase the kiln capacity from 1800 TPD to 2600 TPD.� Conversion of Raw mill to 3 fan system, Replacement of Kiln ESP with Bag House &

Cooler ESP upgradatation by addition of 2 fields

2007 -2010

(4th Phase)

Increased the clinker capacity to 0.9 MTPA and cement production capacity from 1.02 MTPA to 2.144 MTPA by following up gradations with a huge Investment by ACC:-

� Addition of one more stage to PH with new down comer duct and fan.� Installation of Slag VRM (145 TPH).� Close circuiting of existing cement mills.� Installation of new limestone crusher at mines (650 TPH).� Installation of Mixing plant.� Cement Silo (10,000 tonnes)� Packing plant.� CPP (2X15 MW)� Wagon tippler.� Stacker reclaimer system for coal and slag handling.

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ACC Limited

Bargarh - Location

Approved Capacity after Plant Expansion : Clinkering : 0.9 MTPA, Cement – 2.14 MTPA, CPP - 30 MW

Western Odisha –Nearest Airport Jharsuguda 100 KM, Raipur 220 Km

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ACC Limited

Mines Overview

Mines Lease Area 448.392 ha

Mines Reserve 11.89 MT

Life of Mine 10 Years

Stripping Ratio 4

Dungri Limestone Quarry (DLQ) is located at 43 KM from the plant. Lime stone is being transported through Meter Gauge railway line by wagons. Limestone reserve available at DLQ as on 01.04.2014 is 11.89 Mio Tons.

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ACC Limited

Plant - Equipment Details

Quarry Transportation Raw Mill Raw meal Silo Kiln

Cement Silos Coal Mill

• Dungri Mines located 53 KM from Plant

• Limestone reserves 12.4 Million Ton

• Expected life 10-12 yrs• Impact crusher 650

TPH (Make L&T, 2009)

• Transportation of Limestone by Wagons through meter gauge railway line.

• LOCO – 1200 HP (2NOs), 635 HP (3 Nos)

• Vertical Roller MillCapacity 230 TPH( Make: Loesche, 1995)

• Feed through open circular stock pile (Cap: 30000 MT)

• 2 Nos CF Silo• Capacity :

5000 MT each

• Six Stage Preheater with Inline Calciner

• Kiln BDP 2860 TPD• Old Folax cooler

(Fuller KCP – 1995)• Clinker storage silo

(Cap : 60000 MT)

• 5 Packers (3 in old Packing plant and 2 in New Packing Plant)

• Capacity : Packers 1 & 2 – 150 TPH, Packer 3 – 100 TPH, Packers 4 &5 –240 TPH

• 5 Silos with manual extraction system

• Silo 1 to 4 - 3000 MT(Year – 1967)

• Silo No 5 – 2500 MT (Year – 1987)

• Silo 6 – 10000 MT (2009)

• Total – 24500 MT

• Vertical Roller mill for Slag grinding(Pfeiffer – 2009)

• Capacity 145 TPH• Mixing plant Cap

300 TPH for PSC and F2R

• CM#3 (90 TPH), with HPGR2 as pre-grinder(Fuller KCP 1995)

• CM# 4 (55 TPH) with HPGR1 as pregrinder

• Vertical Roller Mill Capacity (Loesche 1995)

• 25 TPH (Normal coal)

• 12.5 TPH• (Petcoke)

CPP

Coal & Slag Stock Piles

• Capacity – 2 X 15 MW

• CFBC Boilers – 2 Nos

• Make : Cethar VesselsYear : 2009

• Coal: 20000 MT

• Slag: 30000 MT

Cement millsSlag VRMPacking Plant

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ACC Limited

Energy Conservation Team Structure

Narendra Bhardwaj

Pankaj Vidyarthi

Parmanand Rai

D Bhadra

Core

Team

Team MembersTeam Members Circle areaCircle area

Energy Circles

Raw Material extraction

Raw Material crushing

Raw Mills

Kilns

Coal Mills

Cement Grinding

Packaging

CPP Boiler

CPP Turbine

Auxiliaries

S Kundu

S Sen

Sunil Samal

JN Majhi

Tamal

N B Jagati

Tapan Mohanty

Balraju

Aklesh

Lokesh Verma

1

2

3

4

5

6

7

8

9

10

ChampionsChampions

M Jadhav

S Mishra

Team Leader : Director Plant

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ACC Limited

Plant achievement highlights ....

� ACC Bargarh is Certified for ISO 50001 -Energy Management System, ISO

14001- Environment Management System and ISO 9001- Quality

Management System

� Significant improvement in Reduction of 18 unit/t of cement in Electrical

Energy from 2017-18.

� Thermal Energy Reduction by 60 kCal/kg of clinker

� Reduction of Clinker Factor by 3.63 % (From 46.8% to 43.2)

� First Plant in LH group producing 100% Composite Cement and saves

natural resources, utilize more fly ash from power plant .

� ACC Bargarh Cement Works Won CII Green CO Gold Award in 2019

� ACC Bargarh Cement Works won CII Energy Award as Energy Efficient Unit

in 2014, 2019

� ACC Bargarh Cement Works received awards for Sustainable Waste

Management from International Society of Waste Management in 2019

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ACC Limited

ACC’s Green Products - Cement

ACC GOLDFly ash based Cement with water repellent properties

Migration from OPC , PPC, PSC to Composite Cement,

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ACC Limited

Carbon Foot print of ACC’s Green Cement Products

Sl.No Name of the Product Kg CO2/T of Cement*

1 ACC Suraksha Power 612.73

2 ACC Concrete+ Xtra Strong 595.69

3 ACC Gold Water Shield 512.25

4 ACC F2R >> Superfast 417.23

5 ACC HPC Long life 280.00

� ACC is in the process of publishing its externallyassured Environment Product Declaration (EPD) forall its Cement products shortly

� ACC is the first cement company in India obtainedGreen Product certification for all its CementProducts

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ACC Limited

Where we are………. overall KWh/Ton of Cement

18.2

kWh/t

Major improvement done through Process Fan replacement,

VFD appliationCooler replacement PRI improvement

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ACC Limited

Energy reduction trend

92.4 89.0 87.0

51.847.8 46.5

46.8744.4

43.2

50.0

70.0

90.0

110.0

130.0

150.0

170.0

190.0

210.0

2017-18 2018-19 2019-20

Year

%Clinker factor Grinding power Kwh/T Cem Clinkering power, Kwh/T Clk

Reduction in Clinker Factor Saved

30,000 T CO2 emission/yr

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ACC Limited

STEC – kCal/Kg of Clinker

60 kCal/ kg

of Clinker

After Installation of New Cooler and with other process improvement Thermal energy

reduced by 60 kCal/kg of clinker

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ACC Limited

Achievement in PAT Target

Reduction of 14.8 % from baseline of PAT Cycle

881

752 751

650

700

750

800

850

900

Baseline PAT Cycle-1 PAT Cycle-2

kCal/kg of

Cement

Reduction of

130 kCal/kg of Cement

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ACC Limited

Summary Of Energy Savings Project in Last 3 Years

Year Major Energy Saving Project

(Nos)

Total Savings (Million INR)

Total Investment (Million INR)

2017-18 12 18.9 7.5

2018-19 20 107.5 40

2019-20 10 80 125

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ACC Limited

Major Technology driven project Implemented for Energy

Conservation

� Replacement of Clinker cooler with New modified Cooler

� Thermal Energy Savings

� Replacement of Preheater fan with New efficient fan

� Replacement of Baghouse fan with New efficient fan

� Replacement of Cooler ESP fan with New efficient fan

� Replacement of Cement Mill HPGR fan with New efficient

fan

� Modification of Cone Gap and install GRR in CM-3

Separator fan

� Installation of VVFD in 5 nos Bagfliter fan

� Improve heat Transfer by implement CFD implementation

at PH Cyclone

50 kCal/kg clk

0.7 kwh/t clk

3.5 kwh/t clk

7.5 kwh/t Clin

1.5 kwh/t cem

15 MJ/t clk

0.7 kwh/t clk

0.5 kwh/t cem

1.5 kwh/t clk

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ACC Limited

ACTION PLAN FOR ENCON

� Installation of MV VFD in Preheater Fan, Raw Mill Fan

� Installation of 10 nos LV VFD in Cement mill & Packing house area

� Increase AFR usage in Kiln with the tie up with Municipality and other waste agencies

� Replacement of inefficient Compressor of 160 kW with efficient Compressor 132 kW

� Replacement of inefficient motor with energy efficient motor

� Power factor Improvement -- Main load centre at LC 4 and in CM-3 Circuit

� Replacement of In efficient Pump with New Efficient Pump at Water treatment plant

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ACC Limited

Ideas

/Initiatives

Taken

Innovative Project : 1Dedusting Modification at Packing House

� High Power Consumption� Damper Loss� High usage of Compressed air

Issues/

Challenges

� At Packing Plant packer no 4 and Packer no 5 was connected with four nos dedusting bag filter for Elevator, Air slide, Hopper and different belt transfer points venting.

� All the venting points and bag filter flow and pressure has been measured and compared with required and design volume . After the measurements , we have made main duct modification and connect with one bag filter of each packer.

� Two nos bag filter of 37 kW each has been stopped

665 BF-2

665 BF-2

664 BF-2

664 BF-1

Energy saved 55 kW

Less Use of Compressed air

Reduce carbon foot print

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ACC Limited

� To Substitute HSD consumption during Kiln Light up by an alternate

low cost fuel

� Calorific value of Pyrolitic Oil is 10000 kcal/kg

� Calorific value of diesel Oil is 9500 kcal/kg

� Cost of Diesel is 80 rs/ltr

� Cost of Pyrolitic Oil is 35 Rs /ltr

� In three Light up of Kiln ,Plant has been used 23 kl Pyrolitic

After

Result

Innovation No. 2

Utilization of Low Cost fuel for Kiln Light up

Before • Diesel Was used for Kiln Light up

� Replacement of 23 kl of diesel with Pyrolitic oil gives the benefit of Rs. 9.2 lakhs

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ACC Limited

Innovation -3 Improvement of Power factor by Relocating Capacitor Bank

� Power factor at main distribution Load Centre was 0.82� I2R Loss was high� Energy Loss

Initiatives

Taken

Result

Issues/

Challenge

s

� Power factor study has been conducted in the entire circuit and Measurement has been taken at all major Load centres and calculated the required KVAR to improvement Power Factor.

� it has been observed that there was excess 3MVAR capacitor bank at 132/11KV substation. The same has been relocated at LC-4 main incomer and installed 3MVAR Capacitor Bank at LC-4 main

� Power factor Improved from 0.82 to 0.92� KVA demand reduced at TG

Improvement Made

without any investment

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ACC Limited

Best Practices

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ACC Limited

Equipment wise Energy Monitoring

Equipment wise Energy Monitoring (Upto Clinker)

CLINKERING ONDATE ONDATE ONDATE TARGET

CRUSHER SECTION kWh PROD SEEC SEEC

DLQ 6,070.34 3000 2.02 2.5

STACKER RECLAIMER 886.50 3000 0.30 0.3

TOTAL 6,956.84 3000 2.32 2.8

RAWMILL

RAWMILL MD 23181 2700 8.59 8.5

RAWMILL FAN 15009 2700 5.56 6

MCC3 4854.1 2700 1.80 1.5

Total 43931 2700 16.3 16.00

COALMILL

COALMILL MD 3,477 245 14.19 14.00

COALMILL FAN 5,999 245 24.49 22.00

Aux-2 1,551 245 6.33 6.00

Total 11026.9 245 45.01 42

KILN

KILN MD 5,014 2300 2.18 2

PH FAN 37,624 2300 16.36 14.5

BH FAN 15,510 2300 6.74 6.2

COOLER EX FAN 4,671 2300 2.03 1.5

COOLER 12,926 2300 5.62 5.8

Aux-1 2,931 2300 1.27 1.1

MCC4 ESP 2,584 2300 1.12 1.2

Aux-2 11,330 2300 4.93 5.5

KILN Total 92,591 2300 40.26 37.8

CLINKERING WITHOUT NP 1,54,505 2300 74.53 73.36

Non Process 12756 2300 5.55 5.80

CLINKERING WITH NP 1,67,261 2300 80.08 79.16

Equipment wise Energy Monitoring (Grinding)

GRINDING POWER ONDATE ONDATE ONDATE TARGET

SLAG VRM kWh PROD SEEC SEEC

SLAGVRM MD 35,438 1500 23.63 30

BF FAN 18,400 1500 12.27 12.5

Aux-1 6,900 1500 4.60 6

Aux-2 3,200 1500 2.13 1.8

Total 73,937.50 1500 49.29 50.30

CM3 kWh PROD SEEC TARGET

MD1 23,786 3,200 7.43 8.00

MD2 25,507 3,200 7.97 8.00

RP1 2,012 3,200 0.63 2.50

RP2 5,867 3,200 1.83 2.50

SEPEX FAN 12,356 3,200 3.86 4.00

SEPERATOR FAN 9,075 3,200 2.84 3.00

Aux-1 17,406 3,200 5.44 5.00

Total CM-3 1,01,008 3200 31.57 33.00

MIXING 4,500.00 4700 0.96 0.90

Non Process 5240 4700 1.11 1.20

TOTAL GRINDING 1,84,686 4700 39.29 41.65

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ACC Limited

Road map to best in class performance

Grinding

RML(kWh/t mat)

RMP(kWh/t CLi)

Kiln(kWh/t CLi)

Grinding

Bargarh (YTD – 2019-20) Road Map to achieve target 2020-21

26

2.4

9.8

0.8

13

Total

Aux

Vent Fan

Seperator

Raw Mill Main …

23.8

2.0

9

0.8

12

Total

Aux

Vent Fan

Seperator

Raw Mill Main …

51

15.5

2.5

7.5

7.2

15.10

2.2

Total

Aux & Fuel pre

ID FAN

Cooler fans

Bag House Fan

Preheater Fan

Main Drive

38.3

12.5

1.2

5.0

5.8

12

1.8

Total

Aux & Fuel pre

ID FAN

Cooler fans

Bag House Fan

Preheater Fan

Main Drive

3.8

1.6

2.2

Total

Aux

Sec Crusher MD

Pri Crusher MD

51.4 40

2.6

1.0

1.5

Total

Aux

Sec Crusher MD

Pri Crusher MD

Grinding

NP 7.8 NP 7Total Upto Clinker Total Upto

Clinker88 75

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ACC Limited

Raw Material Management

� We are using 30% medium grade Lime stone

� Utilisation of Red Mud waste from Aluminium Industry

� 100 % utilization of our own CPP generated Flyash and Bed Ash

� Utilisation of Fly Ash (increased from 20% to 28%) from Other Industry

� Utilisation of Slag from steel industry

� Plastic Waste Utilization from Industry and Municipality

� We are in process to take entire plastic waste from 5 major Municipality in Odisha and already made agreement

� Expired Product from HUL and Other Industry

� ETP Sludge from Industry

� Spent Carbon from Industry

ACC

Bargarh is Committed to work towards

Clean and Green Environment

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ACC Limited

� Improve output of Raw Mill VRM by increasing velocity of Nozzle ring

� Close Monitoring and Maintain Raw Mix quality to reduce jamming tendency and improve kiln operation

� Replacement of Major Process Fans, -PH fan, Baghouse Fan, Cement Mill fan

� Utilization of existing GRR & VFD from low energy savings equipments /areas to High energy savings equipments /areas

� Optimisation of Preheater inlet O2 by reducing jamming condition with proper raw mix and addition of Soda Ash and reduced fan RPM from 860 to 832 RPM . Savings achieved 52 kW and improve thermal energy (6 Deg C reduced at PH outlet )

� Running of Lower rated air compressor for Kiln & Raw mill Section ,power reduced by 30 kW

� Reduced pressure drop at PH Cyclone by implementation of CFD

� Clinker cooler performance improvement by minimizing losses- optimizing cooler air flow.

� Raw Mill section; all the interlock timing optimized with RM Maid Drive

� Usage of activated gypsum (35% to 50% of total gypsum) without additives maintaining IQN.

� Cement Mill Separator fan Cone Gap adjusted and Fan flow optimised, reduced 90 kW

� Bed stability with addition of slag while clinker grinding and clinker addition while slag grinding

� Central feed chute height optimisation

� Interlock timing optimised in cement mill section group drive

� Bag filter DP & Flow optimised with VFD and damper setting

Best Practices ….Followed

Reduction in Energy Consumption

Initiatives

Taken

Power consumption optimised By 1.3 kWh/t cem with Bagfilter

operational Optimisation,Flow , Purging Pr setting,

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ACC Limited

� Energy Monitoring System and Energy Dash Board Displayed in CCR

� Replaced old conventional lights with LED Lights

� Replaced old Air condition system with 4 star & 5 star AC

� Installed Day Light sensor and Auto timer for lighting circuit

� Reduce Voltage at Colony transformer and lighting transformer from 235 to 210 V

� Installing Energy Efficient Fan for Process application

� High performance Roller Press for Cement Mill

� Energy Efficient Pump installed

� Energy efficient Air Compressor is being used ,

� Solar Hot Water System at Guest House

� Solar Light at Mines

Other Best Practices ….

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ACC Limited

Green Co rating – GHG Emissions

0

100

200

300

400

500

600525

505505

410396

390

ACC

BCW

2017-18 2018-19 2019-20

CO2 emission, kg CO2/T Cement

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ACC Limited

Renewable Energy

� ACC Bargarh is purchasing Renewable Energy Certificate about INR 12 Million per year as per RPO

� ACC Bargarh is also initiated to install Solar Power Plant in Consultation with Odisha Renewable Development Agency

� We are using Solar Heater, Solar Street Light

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ACC Limited

Utilization of Waste as Alternate Fuel

AFR Feeding System:

� Hopper, Screw conveyor, Belt conveyor and Pneumatic Feeding system for feeding biomass (rice husk) into the calciner.

� AFR Feeding system: Starter kit solution for feeding Hazardous & other Wastes into the system

� Small belt conveyor to unload material into the bucket of hoist system

� Weigh feeder for gravimetric feeding and slide gate for proper sealing to avoid back fire from calciner.

AFR Storage Shed:

� Well designed and maintained AFR storage shed with 50 T capacity with Concrete flooring with impervious bentonite clay membrane sheet to avoid percolation and soil pollution.

� Solid, Semi Solid Feeding System is available.

� AFR Laboratory:

� Hazardous waste sample evaluation: State of the Art laboratory is

available.

Type of Waste Fuel Used

Quantity of (Tons) 2019-20

Waste fuel as % of total fuel

Rice Husk 3387

3.50%

AFR;CIL WASTE 14.9

Plastic waste 48.06

Spent Carbon 89.24

Flue dust 514

ETP sludge Non

Hazardous 62.5

ETP sludge Haz 82

AF-Non Haz-BOILER

ASH-COCA COLA 15.46

Pyrolytic Oil 23.34

AFR;HUL WASTE 99.06

Trade Reject 21.56

WTP Sludge 25.1

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ACC Limited

We are Water Positive

1. Reduction of cooling water blow down waterby maintaining the water qualityparameters

2. Cooling tower basin cleaning

3. Reduction in dump loss

4. Media & activated Carbone replaced inmulti grade filters and carbon filter in thepre treatment plant

5. Replaced passing water & steam valves

6. Alarm provided at cooling tower forebay toavoid over flow

7. Facilitated operation of water pre-treatmentplant from CPP CCR for close monitoring

8. Installation of Zero Liquid Discharge plantis under [progress, will complete by Dec19

9. Installation of sulfuric acid auto dosingsystem for cooling tower water treatmentto maintain the water quality parameter –

10.Recirculation of GCT discharge water in the system

11.Recirculation of comp cooling water in the system

12.Installation of water level sensor in water tank at raw mill, GCT and cooler area to avoid water over flow and wastage of water

13. Rain water Harvesting through 2nos reservoir and through Roof Top

14.We Have ETP & STP

Online Monitoring system

H2SO4 Auto dosing system

Rain Water harvesting t reservoir and through Top Roof Recharge Structure

395

267220

Sp water, m3 /T of Cement

2017-18 2018-19 2019-20

3.6

3.28 3.2

CPP : Sp water, m3 / MWH

2017-18 2018-19 2019-20

91

5535

Sp domestic water, m3 /T of Cement

2017-18 2018-19 2019-20

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ACC Limited

We care…for our environment

Dust emission from Raw

mill/VRM stack – 10 to

13mg/Nm3

Dust emission from kiln ESP

stack -22 to 38 mg/Nm3

Water sprinkling for her LS

stock pile.

SNCR project Installed for

De-Nox system for Kiln

operation

Plant concrete road after

road swiping water

sprinkling by movable

vehicle.

Road swiping machine for inter

plant concert road swiping

CEMS (Continues Ambient

air Monitoring System)

(CAAQMS) for PM10,

PM2.5, SO2 & NOX

Continuous Emission

Monitoring System (CEMS)

Installed at Kiln

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ACC Limited

5U1 BF1

3B FB1

1. Installation of state of art pulse jet bag filters at kiln, Coalmill, Slag VRM, Cement mill and packing plant and highefficient ESP at Cooler and CPP

2. Installation of online emission monitoring system CEMS atKiln, Cooler, CPP and Slag VRM and online data transmissionto CPCB and SPCB site.

3. Installation of online Ambient Air Quality Monitoring systemat 3 locations.

4. Installation of SNCR system to reduce and control NOx

emission

5. Replacement of existing damage collecting electrodes atcooler ESP to improve the collection efficiency and maintainthe stack emission below the norms.

6. Retrofit the TR Controllers and Replacement of existingRapper panel with new generation Rapper to improve theESP efficiency and to maintain the stack emission below thenorms

7. AFR System in Kiln operation for different type of wastefeeding.

We care…for our environment

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ACC Limited

5U1 BF1

3B FB1

8. Installation of wet fog type dust suppression system at MGWagon Tripler, MG Lime stone stacker , BG WagonTripler, Mines Crusher hopper for control of fugitive dustemission.

9. Installation of water sprinkler system at approach road nearcement mill 3 and packing plant area and installation of waterGun at Raw material area to control the fugitive dust emissionduring vehicle movement

10. Concreting of Roads in front of Packing plant Truck loadingarea and operation of road sweeping machine to control thefugitive dust emission.

11. De –dusting system improvement at cement mill, kiln area bymodification of venting line , venting chute, dampers etc. (361 BF1 discharge chute , Slag HPGR dischargechute, venting modification at Kiln feed bin , Cement Mill 3HPGR, Mixing plant, Cooler drag chain, Packing plant etc)

12. De-dusting System installed at Clinker silo tunnelbelts for Clinker extraction.

We care…for our environment

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ACC Limited

Dust suppression system – Road sweeping M/c & Water sprinkler system at different places

Concreting of road of truck parking

Concreting of truck parking area

Best Practice – control of dust emission

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ACC Limited

Awareness & Training – Energy& Environment Conservation

36

ACC Limited

Thank You