Best Practices adopted by ACC on Energy Efficiency improvement · 2 ACC Limited EECC 2/19/2015 Indian Cement Industry India is the second largest Cement producer after China Approximate
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EECC ACC Limited 2/19/2015
Best Practices adopted by ACC on Energy Efficiency improvement
Author : K.N Rao
Director EECC
ACC Ltd
Date : 26th February 2015
2
ACC Limited EECC EECC 2/19/2015
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.
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ACC Limited EECC 2/19/2015
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
Region (North)
Region (East)
Region (South)
GAGAL
TIKARIA
LAKHERI
KYMORE
CHANDA
KUDITHINI
WADI
THONDEBHAVI
MADUKKARAI
BARGARH JAMUL
CHAIBASA
SINDRI
DCW
VIZAG
Region (West)
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ACC Limited EECC 2/19/2015
ACC – Sp. Energy consumption & Carbon footprint
Total Reduction in
MTOE in
2011 -2014 ~ 8%
compared to baseline
MTOE Report - PAN ACC PLANT Baseline
SEC
kCal/kg
Target
SEC PAT
Cylce-1
Kcal/kg
cement
GtG SEC of
YTD-14-15
* (kCal/kg)
GAGAL-I 787.7 752.94 752.91
GAGAL-II 795.54 760.09 748.26
LAKHERI 970.87 918.07 820.83
KYMORE 850.08 809.60 774.74
TIKARIA 138.73 133.04 149.98
CHAIBASA 794.32 760.86 748.36
BARGARH 881.29 840.10 730.50
JAMUL 936.48 890.25 871.31
CHANDA 897.56 852.43 652.77
WADI 921.95 874.33 833.99
MADUKKARAI 1241.4 1180.98 1179.37
CO2
Down by 33 per cent in
twenty years
Reduced from 550 to
538 Kg/T of cement
from 2011 to 2013
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ACC Limited EECC 2/19/2015
Typical Levers
2/19/2015
ACC Limited
6
Communication
Capability
building
Knowledge & data
management
Core Services
Boot Camp
Centre Of Excellence
Plant Visit Deep Dive & data analysis Find out Encon scope Prepare Road Map Achieve Asp. target
Energy Module Energy Hand book Case study Best Practices HEAT map
Training Model Plant Sharing B.P Benchmarking Dream run Award & Recognition
Newsletter Community meet Conf call WAR room performance dialogue
Model Plant tour Experiential learning Live measurement & calc Sharing best practices Soft Skill training
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ACC Limited EECC 2/19/2015
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
Clinker Factor – Improve Clinker Quality
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ACC Limited EECC 2/19/2015
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
Some of ACC plants have attained clinker substitution rate (slag as
well as PPC) as per norms specified by BIS
2011 2012 2013
% Recycled Material
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ACC Limited EECC EECC 2/19/2015
Faster Stronger Durable, High Strength PPC, A Performing Cement in Concrete with its performance Competitive to OPC 53 in Market
Faster , Stronger durable, High Strength PSC, Tailor
made Cement for Coastal Markets
Foundation to Roof Cement : Faster , Stronger durable, High Strength PSC
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
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
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ACC Limited EECC 2/19/2015
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)
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ACC Limited EECC 2/19/2015
WHR – Power Generation
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ACC Limited EECC 2/19/2015
• 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
AFR – Use of waste material
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ACC Limited EECC 2/19/2015
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
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ACC Limited EECC 2/19/2015
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 Solid Waste
Waste Paint Rice Husk
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ACC Limited EECC 2/19/2015
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 3 Pre-processing platforms being set up Future plans to strengthen AFR activity
AFR – Use of waste material
Hot commissioning 2014
Kymore
Wadi
Madukkarai
Kymore Wadi
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ACC Limited EECC 2/19/2015
AFR - Energy Plantations
• Use of waste lands
• Jatropha & Caster
• Opportunities for creating livelihoods in local communities
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ACC Limited EECC 2/19/2015
Energy Intensity
2008 2009 2010 2011 2012 2013 YTD
THERMAL ENERGY
2008 2009 2010 2011 2012 2013 YTD
ELECTRICAL ENERGY
Spe
cifi
c En
erg
y C
on
sum
pti
on
(k
Cal
/kg)
ACC SEC Target
Target SEC
Achieved SEC
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ACC Limited EECC 2/19/2015
Specific Energy Consumption Trend
0.0
20.0
40.0
60.0
80.0
100.0
650
670
690
710
730
750
770
790
2012 2013 2014
Ele
crri
cal E
ne
rgy
The
rmal
En
erg
y
Gagal-1
Thermal Energy (kCal/kg of clinker) GtG SEC (kCal/kg cement)
Electrical Energy (kWh/T of cement)
0.0
20.0
40.0
60.0
80.0
100.0
650
670
690
710
730
750
770
790
2012 2013 2014
Ele
crri
cal E
ne
rgy
The
rmal
En
erg
y
Gagal-2
Thermal Energy (kCal/kg of clinker) GtG SEC (kCal/kg cement)
Electrical Energy (kWh/T of cement)
0.0
20.0
40.0
60.0
80.0
100.0
650
700
750
800
2012 2013 2014
Ele
crri
cal E
ne
rgy
The
rmal
En
erg
y
Kymore
Thermal Energy (kCal/kg of clinker)
GtG SEC (kCal/kg cement)
Electrical Energy (kWh/T of cement)
0.0
20.0
40.0
60.0
80.0
100.0
650
700
750
800
2012 2013 2014
Ele
crri
cal E
ne
rgy
The
rmal
En
erg
y
Lakheri
Thermal Energy (kCal/kg of clinker)
GtG SEC (kCal/kg cement)
Electrical Energy (kWh/T of cement)
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ACC Limited EECC 2/19/2015
Specific Energy Consumption Trend
0.0
20.0
40.0
60.0
80.0
100.0
650
700
750
800
850
2012 2013 2014
Ele
crri
cal E
ne
rgy
The
rmal
En
erg
y
Chaibasa
Thermal Energy (kCal/kg of clinker) GtG SEC (kCal/kg cement)
Electrical Energy (kWh/T of cement)
0.0
20.0
40.0
60.0
80.0
100.0
120.0
650
700
750
800
850
2012 2013 2014
Ele
crri
cal E
ne
rgy
The
rmal
En
erg
y
Bargarh
Thermal Energy (kCal/kg of clinker) GtG SEC (kCal/kg cement)
Electrical Energy (kWh/T of cement)
0.0
20.0
40.0
60.0
80.0
100.0
700
720
740
760
780
800
820
840
2012 2013 2014
Ele
crri
cal E
ne
rgy
The
rmal
En
erg
y
Jamul
Thermal Energy (kCal/kg of clinker) GtG SEC (kCal/kg cement)
Electrical Energy (kWh/T of cement)
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ACC Limited EECC 2/19/2015
Specific Energy Consumption Trend
0.0
20.0
40.0
60.0
80.0
100.0
650
700
750
800
850
2012 2013 2014
Ele
crri
cal E
ne
rgy
The
rmal
En
erg
y
Chanda
Thermal Energy (kCal/kg of clinker) GtG SEC (kCal/kg cement)
Electrical Energy (kWh/T of cement)
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
650
700
750
800
850
900
950
2012 2013 2014
Ele
crri
cal E
ne
rgy
The
rmal
En
erg
y
Wadi
Thermal Energy (kCal/kg of clinker) - WD-1 GtG SEC (kCal/kg cement)
Electrical Energy (kWh/T of cement) - WD-2 Electrical Energy (kWh/T of cement) - WD-1
Thermal Energy (kCal/kg of clinker) - WD-2
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
800
900
1000
1100
1200
2012 2013 2014
Ele
crri
cal E
ne
rgy
The
rmal
En
erg
y
Madukkarai
Thermal Energy (kCal/kg of clinker) GtG SEC (kCal/kg cement)
Electrical Energy (kWh/T of cement)
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ACC Limited EECC 2/19/2015
Energy Intensity - Thermal
• Increase number of Stages of
Preheater
• 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.
Seven Stage Preheater at Lakheri
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ACC Limited EECC 2/19/2015
Energy Intensity - Electrical
• Real time monitoring of process parameters
and specific energy to optimize operation
• 3rd 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
Target 2011-12 2012-13 2013-14
Specific Electrical Energy (KW/T
23 %
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ACC Limited EECC 2/19/2015
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
2011 2012 2013
% o
f Pet
coke
Year
% Pet Coke Consumption
• Use of Renewable energy – Wind Energy from 19 MW capacity Wind farms at Tamilnadu, Rajasthan and Maharashtra
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ACC Limited EECC 2/19/2015
Logistics – Move Less
Safety Zero harm – onsite
and offsite
Cost to serve
Time to serve
Best in class OET and ODT
Service Quality
Clean bag to end customer
Aspirations
▪ People
▪ Vehicle
▪ Process
Safety excellence
▪ Network optimization
▪ Hub and Spoke
▪ Swaps
Strategic excellence
▪ Move efficiently
▪ Handle less
▪ Move less
▪ Contract efficiently
▪ Service quality
Operational excellence
▪ RFID, GPS ▪ MLP ▪ Truck scheduler ▪ ePassport ▪ Parking yards ▪ Distribution centers
Asset utilization
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ACC Limited EECC 2/19/2015
Green Buildings
• Cement House – ACC’s
Headquarters (1939/2009)
•La Residency – Hostel for
Academy participants (1966/2010)
• Chanda CCR – Central Control
Room Building (2011)
What we achieved – Going beyond Energy Conservation !
Green Buildings seen as simple examples of Sustainable Construction.
LEED
GOLD
LEED
PLATINUM
LEED
PLATINUM
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ACC Limited EECC 2/19/2015
• 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. 4th Global
Holcim Awards now open.
Green Building - Sustainable Construction
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ACC Limited EECC 2/19/2015
Green Building – Sustainable Construction
Courtesy : Danish Rashid
Making affordable green construction materials and practices
available in semi urban/rural India
Stimulating rural demand for cement as well
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ACC Limited EECC 2/19/2015
www.acclimited.com
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