For a Zero Waste Future
© 2014 Holcim Technology Ltd
Satendra SinghACC Ltd, Kymore Cement Works
© 2014
15th June, 2016
© 2014 Holcim Technology Ltd
Overview of Madhya Pradesh
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ACC Kymore Cement Works
Ramky Hazard Waste Management
Hoswin Incinerator
Rajratan Technique & Technology
Ultratech Cement
Jaypee Cement
Reliance Cement
Other Cement Players
• ACC Kymore cement Works holds 2% of Hz waste market (Pharma, Automobile, Manufacturing/Engineering, Refinery, Chemical, Textile & Beverages & other NHz wastes, like FMCG, Laminates GeneratingUnits, etc.
© 2014 Holcim Technology Ltd
About Company
ACC Limited is a pioneer inextending co-processingservices in the country toprovide a safe andenvironmentally friendlymethod for the managementof wastes to the industry andsociety. These services areprovided under the brandname of Geocycle , which istheglobal waste managementbrand of Lafarge-Holcim, thepromoter of ACC Limited.Lafarge - Holcim is one of theworld leaders in cementmanufacturing and has anexperience of more than 30years in waste co-processing.
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© 2014 Holcim Technology Ltd
GreenCO - Journey
Green Journey of Kymore Cement Works has brought several laurels in the form of prestigious Awards like:
• GreenCo Award (Gold Category)-2014,
• Earth Care Award for Reduction of Green House Gases Emission in Large Enterprises Category–2014,
• CII 14th National Best Energy Management Award–2013,
• CII Environmental Best Practices Award–2013,
• Eco-Corporate Yes Bank Award for Natural Capital-2013,
• CII Environment Best Practices Award-2011,
• National Energy Conservation Award-2010 (First Prize) from BEE, Ministry of Power, Govt. of India, etc.
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© 2014 Holcim Technology Ltd
Site Overview of Geocycle Ky
© 2014 Holcim Technology Ltd
Preprocessing & Coprocessing
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Preprocessing Line – Flow sheet
Co-processing Line – Flow sheet
Walking Floor With CBC
Weighfeeder
Long BeltMetal detector
RAL with Shut gate
Sacrificial Belt
© 2014 Holcim Technology Ltd 7
Details of Facility
• Shredding Line – 200 m3/Hr (90000 TPA) from M/s Metso, Denmark consists of M&J4000 S hook shredder, REMA belt conv.,Steinert Magnetic Separator & Eco-starScreen
• Storage & Processing Shed 100m x 40mwith 5.5 m high concrete walls.
• Geomembrane sheet is provided in floorof facility and firewater retention basinalong with separate leachate collectionsystem to avoid the contact of spillagematerial with soil and water
Moving Machines• Liebherr Hydraulic Arm Handler• Liebherr Wheel Loader• Terex mini skid Loader• Jungheinrich Fork-Lift• Genie Scissor Lift
Fire Fighting• Fire fighting with 1200 m3 water storage and 3 pumps of 410 cu.m/hr with 1 Jockey pump• 597 ESFR Sprinkler, 5 Hose real & 8 Hydrant post
• Walking Floor with Chain belt conveyor M/s Westeria cap. 160 m3
• Weighfeeder cap.24 TPH• Long belt conveyor 171 m in length• Sacrificial belt , Rotary air lock
( 100 m3/Hr) m/s BMH with ATS Safety shut off gate
© 2014 Holcim Technology Ltd
Pics of Facility
© 2014 Holcim Technology Ltd
Walking Floor
Shredding Line Pit 1 Pit 2
WFPower
Metso cont. Hyd room
Pump House
Colour code
Description Qty at Site
DCP type Extinguisher
13
CO2 Type Extinguisher
11
Water Type Extinguisher
1
Foam TypeExtinguisher
2
Spill control Kit
2
Safety Eye Washer and Body shower
2
First Aid Box 3
Emergency Exit
2 in PCPF
PCPF Load CenterGround
Floor
1stFloor
Emergency Facility Available at Pre Processing Facility
Outbound Area
Inbo
und
Are
a
Emergency Exit 1
Emergency Exit 2
Fire D
oor
Assembly Area
© 2014 Holcim Technology Ltd
Salient Features of facility
Induction
• Pre-processing is carried out in an enclosed and sealed area
• Geo membrane and complete leachate control systems in place on work floor.
• Emphasis on OH&S – PPE, Fire fighting system, FPE & CSM
• Modern facility with state of the art handling and processing equipment
• No effluent or by product is generated
• Zero discharge and non-polluting
• Compliance with national rules and guidelines for Hazardous waste
• Respects waste management hierarchy
• Waste to product
© 2014 Holcim Technology Ltd
Fire fighting Facility - Pump house with Water tank and fire water retention basin
© 2014 Holcim Technology Ltd
Pics of load Centre
© 2014 Holcim Technology Ltd
Fully Equipped LAB
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Sample storage room Lab – Equipment
Lab equipment room Lab – Equipment
For a Zero Waste Future
© 2014 Holcim Technology Ltd
More area of contact for proper hold
Additional tightening arrangement
Hemi spherical back support with chain & zipper/Strap
tying arrangement is finalized
For a Zero Waste Future
© 2014 Holcim Technology Ltd
Emergency Eye wash & Safety Shower provision at Lab
For a Zero Waste Future
© 2014 Holcim Technology Ltd
RAMP
Providing of Ramp for wheel chair of handicapped is developed in Administration and lab building
For a Zero Waste Future
© 2014 Holcim Technology Ltd
Fire fighting line (Deluge valve) Housekeeping
For a Zero Waste Future
© 2014 Holcim Technology Ltd
First Aid training to all staff members
For a Zero Waste Future
© 2014 Holcim Technology Ltd
First Aid Box available at site
For a Zero Waste Future
© 2014 Holcim Technology Ltd
Locking arrangement for Fire fighting pump main val ve
For a Zero Waste Future
© 2014 Holcim Technology Ltd
Wheel choke provided for Truck
For a Zero Waste Future
© 2014 Holcim Technology Ltd
Power distribution drawing provided at MCC
For a Zero Waste Future
© 2014 Holcim Technology Ltd
Frequently training on emergency handling to all Se curity staff
For a Zero Waste Future
© 2014 Holcim Technology Ltd
Isolation procedure, Electrical earthing rod with rescue rod & First aid procedure display a t site
For a Zero Waste Future
© 2014 Holcim Technology Ltd
Instruction & Signage provided
© 2014 Holcim Technology Ltd
Kiln2 Biomass Feeding System
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© 2014 Holcim Technology Ltd
Kiln2 Biomass Feeding System
© 2014 Holcim Technology Ltd 28
Achievement of Year’15
• Ever Highest TSR 4.77% Cumulative(Highest in ACC)
• Ever Highest GAV 25.21 CroreCumulative (Highest in ACC)
• Co-processed Quantity 61943 MThigher than 2014 (45826 MT in 2014)
• Highest TSR in the month of Dec10.64 % (K1 & K2) and 21.41% in K1
• Highest TSR of the day 30.16 % in K1 (12th Dec'15)
• Successfully completion of Dream Run(Total 1860 MT with TSR 27.51% weekcumulative) in the K1
© 2014 Holcim Technology Ltd 29
Kymore Plant
Clinker Production Capacity (TPD) K1- 4500, K2- 4500
Installed Pre & C0-processing Capacity (TPH) K1-15, K2-15
Executive Summary: AFRTSR – TEE [%]
•GAV & TSR of 2017, 2018 & 2019 is tentative
154178
226 237 252
337
436
507539
0
100
200
300
400
500
600
2011 2012 2013 2014 2015 2016 2017 2018 2019
GAV(INR mio)
GAV(INR mio)
0.91
3.71 4.03
2.85
4.77
8.75
11.49
13.3914.24
0.891.37
1.93 1.87
3.52
4.775.75
6.85
8.03
0.00
2.00
4.00
6.00
8.00
10.00
12.00
14.00
16.00
2011 2012 2013 2014 2015 2016 2017 2018 2019
TSR TEE
© 2014 Holcim Technology Ltd 30
• Investment made : 66.30 Cr
• Annual savings achieved : 25.20 Cr
• Payback : 5 Years
• We save 60394 Tons of tradition fuel and raw material in year 2015
Cost of Project
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