ACC Wadi

th
11 National Award for Excellence in

Energy Management 2010
Welcome to
Worlds Largest
Clinker Production
Line
Chennai
st nd
1 & 2 September 2010
ACC Wadi-II Plant
Contents
Company Details
Cement Manufacturing Process
Energy Conservation & Consumption per unit of Product
Comparison with Global norms/benchmark data
Innovative & Environmental Projects
Involvement of Employees, Team work in Encon, Monitoring
& Reporting formats and implementation methodologies
Renewable Energy sources, Utilization of waste for replacing
the conventional energy & Water Management
Implementation on Energy front amongst associates
(Vendors / Suppliers, contractors etc)
Certifications
ACC 2
11th National Award for Excellence in Energy Management 2010 01.09.2010
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1
Company Details
Company Name : ACC Limited., Wadi Cement Works
Wadi-II Plant
Address : ACC Limited, Wadi Cement Works
WADI (P.O) 585225,
Gulbarga District, Karnataka State
Phone: 08472 - 202406
Fax : 08476 202190
Type of Industry : Cement
Type of Process : Dry Process

Production Capacity of the plant :
Product : Portland Pozzolona Cement

Capacity : 33.5 Lakh tons cement per annum
Energy Cost as a % of : 47.14 %
manufacturing cost
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Contents
Company Details
Certifications
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6.1 Cement Manufacturing Process Mass Flow ( Pre- Post
Expansion)
Raw Material Gypsum Cement ball mill with
Cap: 20000 t Pregrinders 6&7
Extraction Silo -1
225 t/h (PPC)
Cap:11000T
Fly Ash Fly Ash
Cap: 2300 t Cap: 4000 t Clinker silo Clinker silo
Crusher Crusher Cap: 115000T For bulk transport Silo - 2
1000 t/h 1200 t/h Stock Coal Stock Coal Cap: 60000T
Cap:11000T
20000 t 30000 t SF Cross Bar cooler
Cap: 13000 tpd Silo - 3

Conv. Conv.
Coal Mill Coal Mill Cap: 11000T
belts belts
50 t/h 90 t/h Rotary kiln Dia 6.0m
1000 t/h 1300 t/h
x96m,5500+7000
Raw material =12500 TPD
Iron ore, Bauxite &

Laterite Cap:20000 Preheater SLC Preheater ILC
5500 TPD 7000 TPD
Shale storage Vertical roller
Cap: 2x9000 t Shale mill 425 t/h CF silo Existing
Cap: 2x40000 t Limestone Vertical roller 21000 t
Post Expansion
mill 560 t/h
5
ACC 01.09.2010
11th National Award for Excellence in Energy Management 2010
Wadi
Energy Policy
Our Mission is :
To be amongst the lowest energy consumers in the cement
industry
We have to accomplish our mission by:
Benchmarking our performance against comparable technology &
capacity
Promoting & encouraging Energy Saving & conservation of
natural resources.
Creating awareness among all people concerned within the
organization through workshops, seminars, external training and
Annual Zonal Energy Award Competition.
Carrying out regular internal & external audits to identify areas
for improvement.
Adopting cleaner and energy efficient technologies in all areas.
Reducing specific energy consumption by atleast 2.5% every year
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Contents
Company Details
Certifications
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Energy Conservation & Consumption per unit of

Product
Energy Consumption of Wadi II Plant:
Specific energy consumption includes the power consumption of all

auxiliaries including transformer losses, colony power, plant and colony
lighting, plant and colony water pumps, ETP etc..
Process power for year 2009 is 69.97 Units/T as against 71.43 Units/T in 2008
From the year 2007 onwards, the thermal Energy consumption is calculated
on as fired basis (initially it was on as received basis). 8
ACC 11th National Award for Excellence in Energy Management 2010 01.09.2010
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Product
ACC Information Provided as per prescribed Form -A of the annual report9

Wadi

Product
Energy Consumption per unit of Product:
Information Provided as per prescribed Form -A of the annual report

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Contents
Company Details
Certifications
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Comparison of specific energy consumption - Region
Given below is the comparison with other Energy Efficient

units in India. However Vasavdatta Cements, Sedam is our
nearest competitor within the region
Source: CII - Manual on Best Practices in Cement Industry

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Comparison of specific energy consumption

With National and International Benchmarks
Source: CII - GBC Green Cementech Conference 2010, Hyderabad

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Road map to achieve benchmark

At ACC Wadi Cement Works we are committed to achieve and
surpass world class standards in Specific Energy consumption. For
this we follow the three pronged strategy as under:
Implementing the concept of Energy Efficiency at the proposal and design stage itself
Identifying the opportunities through internal and external sources like conducting Energy
audits, brain storming sessions and training programmes.
Increasing awareness among all the stakeholders and by motivating them
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Road map to achieve benchmark

Energy Efficiency at its best in the design stage
itself
4 After Hookup, the existing Kiln will be the Worlds single
largest kiln of 13000 TPD
4 Tallest pre-heater of 175 mt. height with in line calciner
to enhance the thermal energy efficiency of the plant
4 Worlds largest and highly efficient SF 6X8 cross bar cooler, to
further improve the thermal energy efficiency.
4 Tallest bag house chimney of 180 mt. height to reduce the
fan power consumption by utilizing the natural draft.
4 Total 6 nos.of MV drives for kiln main drive(1350KW X 2),
preheater fans(1350KW X 2),Bag house fan(1750KW), and
Coal Mill Fan(2000KW)
4 Total 15 nos.of 12 pulse VVFDs (total 6400KW) for Cooler fans,
cooler ESP fan, PA fan etc.. and 7 nos.of 6 pulse VVFDs (total
1150KW) for other applications like separators and belt
conveyors etc..
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Contents
Company Details
Certifications
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Innovative Projects:
Project 1 - Increasing Flyash absorption in PPC:
Synopsis:
Increasing the fly ash absorption is a very attractive option for the cement
plants, in view of the reduction in co2 emissions on one hand and the
reduction in manufacturing cost on the other. But maintaining the quality
norms of cement , at increased fly ash absorption levels is a challenging task.
Approach & Methodology:

4 After internal discussions, we decided to increase the C3S content of
clinker by adjusting required CaO & flux. We have increased C3S from 53%
to + 55% by adjusting Flux.
4 Laboratory Trials with different sources of gypsum & additives was
conducted to get the desired quality of cement
4 Plant scale trials conducted with different additives & gypsum to
establish the quality of cement
4 Optimizing the residue levels in the cement & maintaining on the
consistent basis.
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Results & cost benefit analysis:
Year avg. FA increased from 26.80 to 30.34%
Maximum monthly average Fly ash achieved: 34.2%

Maximum day average Fly ash achieved : 34.8%
At 30.34% overall savings in cash cost : Rs 74 / MT
Savings accrued for the YR 2009 : Rs. 2075 Lakhs
Impact on energy consumption:
Reduction in Total Energy Kwh/Ton of Cement
Reduction due to increase in clinker factor =2.35 Kwh/ton of Cement

Increase in Grinding Energy = 1.12 Kwh/Ton of Cement
Overall Reduction in Total Energy Kwh/Ton of Cement = 1.23Kwh/Ton of Cement
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Innovative Projects:
Project 2 - Commissioning of Electric shovel at Mines :
Synopsis:
Shovels and Dumpers are the major energy consuming equipment in the Mines.
They consume huge quantity of Diesel oil and in turn release Co2 and other
noxious gases into the atmosphere.
Electric shovel offers the benefits of reliability in operation with lower
carbon footprint compared to their diesel powered counter parts.
Results & cost benefit analysis:
1400 TPH Electric Shovel was commissioned in the month of June 2009.
Investment = 14 Crores
Specific Power consumption of Electric Shovel = 0.25Kwh/Ton of material
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Operating cost of Electric Shovel = Rs.2.20/- per Ton of material

Operating cost of EX 1200 Diesel Shovel = Rs.6.60/- per Ton of material
Annual operating cost saving = Rs. 2.25 Crores
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Environmental Projects:
Project Linked with Carbon Emission Reduction initiative
4 Cement industry has the unique opportunity of reducing

CO2 through product modification i.e. with the
Production of Blended Cement. Wadi-II Plant produces
PPC only and thus contributes to significant reduction of
CO2. The validation of the project under CDM is under
progress.
4 Monthly Co2 emissions are quantified at the Plant level

and the same is sent to our Central Energy &
Environment Conservation Cell. From there, the entire
group Co2 emissions are reported to Holcim, which are
in turn published to World Business Council for
Sustainable Development (WBCSD).
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Summary of Co2 Emission:
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Environmental Projects:
implemented
-
10
Projects2009
Conservation 09 & -
08, 2008
-
of Energy 2007
List during
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Energy Conservation Projects implemented during 2007
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Energy Conservation Projects Porposed for 2010
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Energy Conservation Projects Porposed for 2010
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Environmental Initiatives proposed for 2010
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Contents
Company Details
Certifications
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Involvement of Employees, Team work in Encon, Monitoring &
Reporting formats and implementation methodologies
M/S.ACC Ltd., Wadi Cement Works is committed for

conservation of energy. The Energy Management is the
critical focus of the top management. The result is
evident from the remarkable improvement in terms of
specific power consumption. It has reduced from 78
kWh/ton of cement in 2004 to 72.06 kWh/ton of cement
for the period 2009.
At the Corporate level we have an Environment and
Energy Conservation Cell, directly representing to the
Managing Director. They review the energy
consumption parameters of all our units regularly.
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At the plant level we have the Energy Apex committee

and Energy First committees for various departments.
There are total seven Energy first committees that
belong to various departments and consist of the
frontline workforce in each department. They are formed
with the clear mandate of
4 Better management of available power
4 Pinpoint the wastages
4 Identify energy efficient measures
4 Increase awareness among all
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The Energy Apex committee works under the leadership of

Director (Plant), and Head Operations with all department
heads as members. This committee meets once in a
fortnight to review the plant energy consumption during
that period, status of various on going energy conservation
measures and the suggestions received from Energy first
committees. Energy Manager acts as a coordinator between
these two, and looks after formulation of proposals and
their implementation. The energy consumption parameters
are reviewed in daily production meetings, and the reasons
for variance if any, and the actions to be taken are
discussed
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Organization Structure for Energy

Conservation activities at Wadi-II:
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Energy Conservation Projects of Wadi-II which involve Employees &
Team work with different implementation methodologies:
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Brown paper exercises for energy conservation
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Brown paper exercises for energy conservation
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% breakup of time currently spent (average basis) of

senior executives in various functions are as follows:
a) Technology Implementation - 15 %
b) Manufacturing excellence - 15 %
c) Materials Management - 20 %
d) Marketing Coordination activities - 15 %
e) Analyzing Competitors Profile - 10 %
f) Quality Management - 10 %
i) Energy Conversation Measures - 15 %
Total - 100%
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Monitoring & Reporting:
Frequency of review of energy consumption and energy

conservation projects are Daily / Weekly / Monthly.
The energy consumptions in the plant is monitored daily

and reviewed at regular intervals. At the beginning of
every financial year targets are fixed for both electrical and
thermal energy consumptions. The same parameters are
closely monitored by the Energy Manager and concerned
Section In charge as follows:
4 Monitoring of specific power consumption for major units
4 Monitoring of energy MCC wise
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The daily Power Consumption parameters are reviewed in

the daily production meetings, and the performance is
reviewed in the fortnightly Energy First and Apex
committee meetings.
The energy consumption parameters are also closely
monitored by the corporate office. The Environment and
Energy Conservation Cell (EECC) in the Technical Support
Services (TSS) office at Thane reviews the energy
consumption parameters of all our units regularly. They
also set the targets to be met and provide support in
attaining them
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Monitoring & Reporting Formats:
Format of Daily Specific Power Report:
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Format of Fortnightly & Monthly General Management Report:
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Contents
Company Details
Certifications
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Renewable Energy Sources:
The percent share of renewable energy capacity to total

captive power capacity of ACC is 6% at present, and the
target is to increase this share to 15% by 2013.ACC has
two wind forms located at Rajasthan and Tamil Nadu,
which have generated 40 million units of wind power is
during 2009.
As a part of the CSR activity Wadi Cement Works has
donated 37 nos.of TATA Solar lamps, worth Rs.5 Lakhs to
the neighboring villages, during 2009 10.
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Utilization of Waste as Fuel:

As a part of expansion, AFR feeding system is
being installed at our plant, which will be in
operation from October 2010.This system is
designed by FL Smidth, with a capacity of 2 to
20TPH, based on the type of material. This will
enable us to replace approximately 55 % of the
fuel fired in ILC by RDF (Refuse Derived Fuel).
At present AFR usage is being carried out at our
Wadi I plant. AFR testing lab is also commissioned
during the Year 2009 which will cater to the needs
of both Wadi I and Wadi II plants.
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Commissioning of AFR testing laboratory in 2009 :
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Water Management:
Rain Water Harvesting and Water Management
4 Conservation of Rain water (Water storage in mining
area equivalent to 185 days consumption)
4 24 Lakh cu.m water in mines sump
4 Construction of Barrage at Kagina River
4 Reverse Osmosis Plant
4 Reduction in water consumption
4 Zero water discharge from plant
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Afforestation and Green belts :
4 Clad with thick band of luxuriant plantations, Wadi Mines

poses the most modern and one of the biggest
Limestone mines of Asia in terms of production. The
mines has done systematic plantation on dumps when
dump had attained their full heights The slopes are well
laid with green grassy lawn to protect the soil erosion
4 The long tree plantation along the mining lease
boundary and on edges of ultimate pit limits garlands
the mines and motivates for environment propagation
at mines
4 Overall 2.05lakh trees have been planted in the plant
and neighboring areas. Approximately 10 Ha of green
belt has already been developed on the dumps. The
trees like Neem, Eucalyptus, Gulmohar, Subabool, Sisso,
and Cassacimia have been commonly planted
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Afforestation and Green belts at Mines :
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Contents
Company Details
Certifications
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Implementation on Energy front amongst associates (Vendors

/ Suppliers, contractors etc)
Material Transportation (Inbound & Outbound) by Rail:

The rail movement of goods is more environment friendly
compared to road. At ACC rail transport in large rake
loaded quantities is preferred and bulk cement distribution
is promoted. ACC dispatches 51% of its cement by rail,
compared to the industry average of 37%.
At Wadi Cement Works, 85% of the cement dispatches are
carried out by rail. Apart from this rail transport system for
fly ash handling is near completion. At present the fly ash
is transported from Raichur Thermal Power station through
bulkers by road. After completion of this system, the
movement of fly ash by road will be reduced to 50%.
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Vendors Policy :
As a policy, all our vendors are requested to include only
energy efficient motor for their equipment (fans,
compressors etc).
Environmentally-friendly GREEN BUILDINGS:
In a short span of time, ACC has accomplished four
instances of environmentally-friendly GREEN BUILDINGS.
4 Our corporate head quarters Cement House, which is a
70 year old corporate building in Mumbai, has received
the Gold shield from IGBC in LEED New construction &
Major renovation category.
4 A 45 year old residential apartment in Thane (La
residency) is redesigned and converted as a state of the
art residential facility. This building incorporates the
unique and energy efficient Geo-thermal air conditioning
system. This is a pre-constructed platinum rated LEED
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Environmentally-friendly GREEN BUILDINGS:
4 ACC Greens Village, residential colony at the new ACC

plant near Bellary, is under execution. This project
promotes solar energy, rain water harvesting and natural
air cooling. A climate responsive strategy for the colony
has been designed based on climate analysis, factoring
sun path, wind Details and water cycles.
4 New CCR building of Chanda cement works, is also

planned as an energy efficient green building.
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Contents
Company Details
Certifications
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Certifications
ACC ISO 9001:2000 ISO 18001:2000 60
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Certifications
IMC RAMKRISHNA BAJAJ NATIONAL ISO 14001:2004

QUALITY AWARD 2007 61
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Certifications
National Award for Excellence in National Energy

Water Management 2009 Management Award 2008
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Certifications
Institution of Engineers (India) FIMI Abheraj Baldota

Safety innovation Award 2009 Environment Award 2009
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th

11 National Award for Excellence in

11th National Award for Excellence in Energy Management 2010 01.09.2010

Type of Process : Dry Process

Product : Portland Pozzolona Cement

11th National Award for Excellence in Energy Management 2010 01.09.2010

11th National Award for Excellence in Energy Management 2010 01.09.2010

Cap: 13000 tpd Silo - 3

Iron ore, Bauxite &

11th National Award for Excellence in Energy Management 2010 01.09.2010

11th National Award for Excellence in Energy Management 2010 01.09.2010

Energy Conservation & Consumption per unit of

Specific energy consumption includes the power consumption of all

ACC Information Provided as per prescribed Form -A of the annual report9

Energy Conservation & Consumption per unit of

Information Provided as per prescribed Form -A of the annual report

11th National Award for Excellence in Energy Management 2010 01.09.2010

11th National Award for Excellence in Energy Management 2010 01.09.2010

Comparison with Global norms/benchmark data

Comparison of specific energy consumption - Region

Given below is the comparison with other Energy Efficient

Source: CII - Manual on Best Practices in Cement Industry

11th National Award for Excellence in Energy Management 2010 01.09.2010

Comparison of specific energy consumption

Source: CII - GBC Green Cementech Conference 2010, Hyderabad

11th National Award for Excellence in Energy Management 2010 01.09.2010

Comparison with Global norms/benchmark data

Road map to achieve benchmark

audits, brain storming sessions and training programmes.

Increasing awareness among all the stakeholders and by motivating them

Road map to achieve benchmark

11th National Award for Excellence in Energy Management 2010 01.09.2010

Approach & Methodology:

11th National Award for Excellence in Energy Management 2010 01.09.2010

Innovative & Environmental Projects

Year avg. FA increased from 26.80 to 30.34%

Maximum monthly average Fly ash achieved: 34.2%

At 30.34% overall savings in cash cost : Rs 74 / MT

Savings accrued for the YR 2009 : Rs. 2075 Lakhs

Impact on energy consumption:

Reduction in Total Energy Kwh/Ton of Cement

Reduction due to increase in clinker factor =2.35 Kwh/ton of Cement

Overall Reduction in Total Energy Kwh/Ton of Cement = 1.23Kwh/Ton of Cement

11th National Award for Excellence in Energy Management 2010 01.09.2010

Innovative & Environmental Projects

Results & cost benefit analysis:

Specific Power consumption of Electric Shovel = 0.25Kwh/Ton of material

Operating cost of Electric Shovel = Rs.2.20/- per Ton of material

Annual operating cost saving = Rs. 2.25 Crores

Innovative & Environmental Projects

4 Cement industry has the unique opportunity of reducing

4 Monthly Co2 emissions are quantified at the Plant level

11th National Award for Excellence in Energy Management 2010 01.09.2010

Summary of Co2 Emission:

11th National Award for Excellence in Energy Management 2010 01.09.2010

Innovative & Environmental Projects

11th National Award for Excellence in Energy Management 2010 01.09.2010

Energy Conservation Projects implemented during 2007

Innovative & Environmental Projects

11th National Award for Excellence in Energy Management 2010 01.09.2010

11th National Award for Excellence in Energy Management 2010 01.09.2010

Innovative & Environmental Projects

11th National Award for Excellence in Energy Management 2010 01.09.2010

Innovative & Environmental Projects