Best Practices Towards Environmental Excellenceqcfihyderabad.com/cementconclave2018/wp-content/uploads/... · 2018-10-24 · ILC Height –182 m SLC Height - 120 m Kiln : Size –6

Wadi Cement Works 15th Oct. 2018

Best Practices Towards Environmental Excellence

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ACC Limited, Wadi Cement Works

ACC Wadi Geographic Location

KARNATAKA

STATE

Plant Site

Clinkering : 5.83 MTPA, Cement - 6.03 MTPA Power - 125 MW

Wadi-1

Wadi-2

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Genesis of the plant...............Wadi Cement Works

1978 1983 1995 2001 2006 2010 2014

1968

1968: Wadi I set up with installed capacity of 0.4 MTPA

Kiln 1 & 2 1978: MFC Installation

1983: Ist 1.0 MTPA Indigenous

Plant in India & 25 MW

CPP installed

1995: CPP expanded to 50 MW

Wadi-2 Commissioning

2.0 MTPA

2006 With in house

modification at Wadi II total capacity of Wadi- 4.2 MTPA

WD 2Expansion

clinkering & CPP(50 MW)

Total capacity 6 million Tons &

125 MW CPP

CommissioningAFR platform

(16 TPH)

India’s Ist 1.0MTA Plant

2018-19

Expansionof AFR platform

(20% TSR)

ACC Wadi 2 - Video edited.wmv


Plant layout_Wadi-2

L&T make impact bar crusher Crusher 1 – 1000 TPHCrusher2 – 1200 TPH

Raw Mill-1 (Atox 50)Capacity – 450 TPHRaw Mill-2 (Pfeiffer 5600 B)Capacity – 560 TPH

Raw Meal Silo1 Nos. CF SiloCapacity – 21000 T

Complex SLC & ILC Combination of

6 stage PH

ILC Height –182 mSLC Height - 120 m

Kiln : Size – 6 m Dia X 96 m Length,BDP – 12500 TPD, Make –FLS, Inclination – 4%, RPM – 5 max. ,Drive – Twin Drive

RM1 RM2

Coal Mill-1 (Atox KM25)

Capacity – 50 TPH

Coal Mill-2 (Loeshe LM43.4 D)

Capacity – 93 TPH

Cr1 Cr2

SLC

ILC

K4

KM1 KM2

CM (Ball Mill)– 2 Nos.Capacity – 220 TPHx 2Make - FLS

VRPM – 2 Nos.Q –230 TPHMake- AMCL

Clinker SiloQ. – 1.15 LT

Cement SiloCap.- 10000t Tx 3

Packer- 4 Nos.Cap. -180 TPHX 4Double discharge

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ACC Limited 23.10.2018

Emergency Preparedness

Emergency Handling Services available at Main Gate round the clock with

facility of Fire Engine with Fire fighters & Ambulance


Organization Chart for Energy & Environment Dept.


ENVIRONMENT POLICY

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IMS & Alternate fuel (AFR) Policy....


Green Procurement & Green mission Policy

1. Optimization of natural resources

2. Installation waste heat recovery system to produce green energy

3. Sustainable reduction in Plant Energy consumption

4. Reduction in plant water consumption

5. Cement manufacturing with Zero harm to Environment

6. Our slogan “Manufacturing of Green Cement”


Projects implemented in Green mission Policy

1. Dispatch of Bulk Cement to bulk terminal at Mumbai via rail transportation (16% of total dispatch- 359730.8 MT)

2. Major portion of Cement Bag dispatch through rail to reduce GHG emission (53% rail & 47% road)

3. Major portion of Clinker dispatch through rail to reduce GHG emission (82% rail & 18% road)

4. Finalizing the order of electrical equipments based on efficiency & BEE star rating.

5. 100 % own fly ash transportation through pumping. Bulker movement has been eliminated.

6. Zero waste discharge from the boundary of the plant.

7. Major portion of fly ash transportation through rail transportation.


IS/ISO 14001:2015 Certification

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ACC – SD 2030 Plan

2020

2030

Water & Nature

We will

•Reduce net specific CO2 emissions by 40% per tonne of cement (vs. 1990)

We will

•Reduce specific freshwater

withdrawal in cement operations by 30%

•Show a positive change for biodiversity•Implement WASH pledge at all

our sites

We will

•Have zero fatalities

•Reduce LTI FR <0.20•Reduce TIFR by 50%

•Benefit 3.25 million people from our social programs•Assess 100% high risk active

suppliers+ Top sub-suppliers with high risk identified & assessed

Note:. Baseline year is 2015 unless stated otherwise

WASH Pledge: Water, Sanitation and Hygiene Implementation at the Workplace, LTIFR: Lost Time Injury Frequency Rate, TIFR: Tot al Injury Frequency Rate

We will

•Reduce specific freshwater

withdrawal in cement operations by 19%

•Complete BIRS baseline assessments at all quarries•Have BMP for all quarries

We will

•Have zero onsite fatalities

•Reduce LTI FR < 0.50•Reduce TIFR by 30%

•Benefit >1 Mio people from our social programs•Assess 80% high risk active

suppliers

Climate CircularEconomy

People & Communities

We will

•Use 9.6 million tonnes of waste-

derived resources per year

We will

•Reduce net specific

CO2 emissions by 34% per tonne of cement (vs. 1990)

We will

• Use 10.7 million tonnes of waste-

derived resources per year

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23.10.2018

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ACC Limited

Spot Measurement Details

Measurement of Kiln stack gases is carried out every year by third party in direct & compound mode which includes measurement of (O2,CO,CO2,NOX,VOC,PM,Sox,HCl,HF,NH3,Benzene,Formaldehyde,Dioxin & Furan, Mercury & heavy Metals)

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Environment permits

Sr. No. Authorization Name Validity

1 Consent to Operate for WD#1 30th June 2021

2 Consent to Operate for WD#2 30th June 2021

3 Consent to Operate for CPP 30th June 2021

4 Consent to Operate for Mines 30th June 2021

5 Bio-Medical Waste Authorization Life time

6 Hazardous Waste Authorization 30th June 2021

7 Permission to use Pet coke as a fuel in cement Kiln

8 Kagina Water Withdrawal Permission 1st Feb 2019


GHG Inventorisation

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Scope -1 : Emissions from Kiln fuel, CPP fuel, Own vehicle fuel consumption, Calcination, fuel for drying if any

Scope -2 : Emissions from Grid electricity consumptionSpecific GHG (KG CO2/T cem) increased in the year 2015 due to higher clinker production

✓Various Energy Efficiency

measures taken for reduction of SEEC & STEC, resulting reduced

GHG Emission

✓ Increased in TSR from 6.43% in 2016 to 9.69% in 2017

✓ CPP SHR has been reduced from 3448 Kcal/kWh in Y 2014-15 to

3363 Kcal/kWh in Year 2017-18

✓ CPP, APC has been reduced from 13.3 % to 12.8% due to various

energy efficiency measures taken like VVFDs in BFW, ACWP, CEP, SA

fan in STGs .

✓ Way forward - Potential to be tapped for additional reduction in

GHG Emission by WHRS – 13.2 MW & Improve TSR up to 20%

0

200

400

600

800

1000

1200

1400

1600

1800

2015 2016 2017 2018

1651

1394 13961354

992939 916 904

Sp. Net CO2 (Kg CO2/T Cem) Sp. Net CO2 (Kg CO2/T Clic.)

ACC Limited, Wadi Cement Works 16

Environment Protection InitiativesE

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s ▪ Continuous Emission monitoring system for ILC & SLC string has beeninstalled for online monitoring of flue gases and reporting to SPCB/CPCB.▪ Online ambient Air Quality monitoring Station has been installed formonitoring the quality of ambient air.▪ ROC-F9 & L-8 Drill Machine with dust collector is used at mines for reducing the fugitive emission during drilling.▪ Nonel technology is being used for ground vibration monitoring analysis and redesigning of Blasting pattern.▪ Eco- friendly Electric Shovel is being used for dumper loading inside the mines. ▪CPP ZLD project has been commissioned to reduce water consumption▪ESP transformers has been replaced from single phase to 3 phase to improve ESP performance▪ TSR (Thermal substitution rate) has been increased up to 12% by commissioning Pre & Co-processing platform (PCPF). ▪New water tanker with spray nozzles has been procured at mines to reduce fugitive emission- Rs. 1.7 Cr.


Environment Protection InitiativesE

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s ▪ Primary measures has been implemented to reduce Nox Emission fromkiln stack e.g. Fuel mix optimization, Replacement of existing burner withlow NOx burner etc.▪De-Nox system is installed to further reduce the Nox emission from Kilnstacks▪Hydraulic Rock breaker is used to avoid the secondary blasting.▪Plant is having close circuit equipment cooling systems to minimize thewater consumption.▪Heavy metals & Gases monitoring has been carried out by third partyonce in a year.▪Monthly monitoring of Ambient air quality, stacks and water analysis bythird party.▪Reporting of CO2 emission on monthly basis to LH.▪There are 2 Reverse air bag house,2 cooler ESPs, 2 coal mill bag house,4Cement Mill bag house and 90 other process & auxiliary bag filtersinstalled to eliminate fugitive emission from all the transfer points.


Initiative - Water Management

Action Areas

Water Conservation

Key Initiatives

▪Conservation of Rain water (Water storage in mining area equivalent to 185 days consumption)

▪ 48 lakh cu.m water in mines sump

▪Construction of Barrage at Kagina River▪Reverse Osmosis Plant

▪Reduction in water consumption ▪Zero water discharge from plant

▪Adopting new technology of air cooled condensers

& Zero Liquid Discharge etc

WaterManagement


Water conservation at Kagina River


Water Meters

River intake Mines Sump old line Mines Sump New line

Coal Mill -2 Raw Mill -2 Clinker cooler


PCPF Facility for co-processing of waste

Pre-Processing

Co-Processing

▪ ACC Wadi invested Rs. 65 Cr to build this state-of-art modern facility as solution for waste disposal.

▪ Different type of waste are co-processed in this facility to save Environment and Help to promote “Clean

India Project”

▪ Different kind of bio-waste/industrial waste are being used as fuel to save natural resources (Coal).

▪ By using alternate source of energy, environmental benefits of lower CO2 emission.


Effort toward sustainability(AFR Utilization)

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27.5

28

28.5

29

29.5

30

30.5

31

31.5

32

32.5

33

2016

2017

H1-2018

29.38

32.18 32.53

Fly ash % PPC

0

2

4

6

8

10

12

2016 2017 H1-2018

6.43

9.69

11.39

Thermal substitution Rate %


Effort toward sustainability….(Raw material optimization: long term planning software – QSO)

Taken Block Forced Block Wasted Block Passive Block

Planning 2018-2022


Effort toward sustainability….(Raw material optimization:short term planning software – QM)

Description0 High Grade

Limestone

Shale

Qty (LT) 58.00 11.18

SiO2 11.34 23.64

Al2O3 2.14 5.24

Fe2O3 0.77 2.11

CaO 46.96 36.88

MgO 0.61 0.99

LS 135.00 50.00

Quarry Planning - 2018

Planning Blocks in Yellow with Black

dots. Quarry faces as on date are in white Lines

2018

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23.10.2018

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ACC Limited

Power Plant –

Stack 3, CEMS

Room

Power Plant –

Stack 3, Probe

set

Installation of CEMS in all three stacks of CPP and Kilns

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23.10.2018

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ACC Limited

Installation of opacity meter across the plant…


New Online AAQ Monitoring system

De-NOx system to reduce NOx Emission-

Project Cost 48.8 Mio. INR

Air Compressor Control JB Piping Layout

Control Switch Indicators Ammonia Tank & structure Power supply feeder

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STACK EMISSION REPORT

2

9

13.87

11.79

18.46 19.13

12.48

28.38 27.98

18.74 18.9920.65

19.6220.46 20.07

18.89 19.48

0.00

5.00

10.00

15.00

20.00

25.00

30.00

CPCB Emission Norms: <30 mg/NNm3

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AAQ monitoring results

Near STPKagina Guest house

River pump ingalgi Wadi TownRawoor village

PM 2.5PM 10 SO2 NO2

Parameter Limit

PM10 100 µg/m3

PM 2.5 60 µg/m3

SO2 80 µg/m3

NO2 80 µg/m3


Green curtainsaroundthe PCPF truck park & Coal Wagon movementarea

to control vehicular emissions.


Construction of CC roads in and around the Plant.


New Road Development (CHP and Raw Material area)


Wadi-2 Truck parking yard concerting job: In Progress


State of art latest technology water spraying system


“Lechler Water Mist Beam” machine


Installation of water spaying system on belt conveyors


Telescopic chute facility for bulk cement loading


Transfer point dust collectors


Belt curtain in lime stone crusher hopper


Water spray system and belt curtain arrangement to control dust emission


Mechanized housekeeping


Raw material covered shed


Coal covered shed


Covered belt conveyors


Green belt development along the road


Green belt development along the road


Green belt development at main gate


Tree Plantation/ Green Belt development


Dense Afforestation Curtails Dust & Noise Pollution


Afforestation Developed on Backfill area


Green belt development in plant across the road…


Environment Day Celebration...


Go Green Initiatives

Promoting Envirofit smokeless chulla

Distribution of Plantation and Kitchen Garden Seeds


Tree Plantation at nearby community

Mega Community Plantation in local villages



Mr. Piyuesh Goyal, Hon’ble Minister of State (Independent Charge) forMines, Power, Coal & New Renewable Energy GOI awarded the trophy toDr. S B Singh, Cluster Head South, ACC Limited

FIMI – Health & Safety Award

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Wadi Cement works bagged the FIMI – Health & Safety Award Y15-16


19th National Award for Excellence in Energy Management by CII

National Award as “Excellent Energy Efficient Unit” by CII in year 2018


National Award for Excellence in Energy Management by CII

National Award as “Energy Efficient Unit” by CII in year 2017, 2016 & 2015


Awards & Accolades

Green Manufacturing Excellence Gold Award - 2012

National Award for Excellence in Energy Management- 2011

India Manufacturing Excellence Gold Award - 2012

Green Manufacturing Excellence Award- 2014


▪ National Award for outstanding performance in promoting rural and agriculturaldevelopment – by ASSOCHAM

▪ Indira Priyadarshini Vrikshamitra Award - by The Ministry of Environment andForests for "extraordinary work" carried out in the area of afforestation

▪ FICCI Award - for innovative measures for control of pollution, waste management& conservation of mineral resources in mines and plant

▪ Subh Karan Sarawagi Environment Award - by The Federation of Indian MineralIndustries for environment protection measures

▪ Drona Trophy - By Indian Bureau Of Mines for extra ordinary efforts in protectionof Environment and mineral conservation in the large mechanized mines sector

▪ Indo German Greentech Environment Excellence Award

▪ Golden Peacock Environment Management Special Award - for outstandingefforts in Environment Management in the large manufacturing sector

▪ Indira Gandhi Memorial National Award - for excellent performance inprevention of pollution and ecological development

Awards And Accolades


Thank You

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Documents

Best Practices Towards Environmental Excellenceqcfihyderabad.com/cementconclave2018/wp-content/uploads/... · 2018-10-24 · ILC Height –182 m SLC Height - 120 m Kiln : Size –6