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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
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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
manufacturing cost
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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 4
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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
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11th National Award for Excellence in Energy Management 2010
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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
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 7
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From the year 2007 onwards, the thermal Energy consumption is calculated
on as fired basis (initially it was on as received basis). 8
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Energy Conservation & Consumption per unit of
Product
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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 11
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Comparison with Global norms/benchmark data
Wadi
Identifying the opportunities through internal and external sources like conducting Energy
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Comparison with Global norms/benchmark data
Wadi
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
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Innovative & Environmental Projects
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.
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Innovative & Environmental Projects
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11th National Award for Excellence in Energy Management 2010 01.09.2010
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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.
1400 TPH Electric Shovel was commissioned in the month of June 2009.
Investment = 14 Crores
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Innovative & Environmental Projects
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Innovative & Environmental Projects
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Environmental Projects:
implemented
-
10
Projects2009
Conservation 09 & -
08, 2008
-
of Energy 2007
List during
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Innovative & Environmental Projects
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Innovative & Environmental Projects
Energy Conservation Projects implemented during 2009
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Innovative & Environmental Projects
Energy Conservation Projects Porposed for 2010
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Innovative & Environmental Projects
Environmental Initiatives proposed for 2010
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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 32
11th National Award for Excellence in Energy Management 2010 01.09.2010
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Involvement of Employees, Team work in Encon, Monitoring &
Reporting formats and implementation methodologies
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11th National Award for Excellence in Energy Management 2010 01.09.2010
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Involvement of Employees, Team work in Encon, Monitoring &
Reporting formats and implementation methodologies
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Involvement of Employees, Team work in Encon, Monitoring &
Reporting formats and implementation methodologies
Energy Conservation Projects of Wadi-II which involve Employees &
Team work with different implementation methodologies:
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Involvement of Employees, Team work in Encon, Monitoring &
Reporting formats and implementation methodologies
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Brown paper exercises for energy conservation
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11th National Award for Excellence in Energy Management 2010 01.09.2010
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Involvement of Employees, Team work in Encon, Monitoring &
Reporting formats and implementation methodologies
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Involvement of Employees, Team work in Encon, Monitoring &
Reporting formats and implementation methodologies
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Involvement of Employees, Team work in Encon, Monitoring &
Reporting formats and implementation methodologies
Monitoring & Reporting:
Format of Fortnightly & Monthly General Management Report:
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11th National Award for Excellence in Energy Management 2010 01.09.2010
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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 48
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Renewable Energy sources, Utilization of waste for replacing
the conventional energy & Water Management
ACC 49
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Renewable Energy sources, Utilization of waste for replacing
the conventional energy & Water Management
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ACC 11th National Award for Excellence in Energy Management 2010 01.09.2010
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ACC 11th National Award for Excellence in Energy Management 2010 01.09.2010
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Renewable Energy sources, Utilization of waste for replacing
the conventional energy & Water Management
Wadi
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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 55
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Implementation on Energy front amongst associates (Vendors
/ Suppliers, contractors etc)
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
project. 57
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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 59
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Certifications
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Certifications
ACC 11th National Award for Excellence in Energy Management 2010 01.09.2010
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Certifications
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Certifications
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