Acc LTD Laheri Cement Works

National Award for Excellence in Energy Management 2012 by CII Sohrabji Godrej Green Business Centre
ACC Lakheri Cement Works
ACC Ltd - Lakheri Distt Bundi (Rajasthan)

Lakheri, Bundi, Rajasthan

Strength Performance Passion 22nd 23rd Aug 2012
Agenda
Company Profile and Plant History Process & Business Growth Energy Conservation Activities Reduction on Specific energy figures Global Bench Mark Specific energy Innovative projects Environmental projects Involvement of Employees Team work in ENCON Monitoring, Reporting and implementation methodologies Renewable Energy Sources, Utilization of waste
2 ACC Lakheri Cement Works Strength Performance Passion 22nd 23rd Aug 2012
Company Profile

Name of plant Year of establishment I up-gradation, 1997 II up-gradation, 2007 Present capacity Process No of Kilns
: : : : : : :
Lakheri Cement Works 1905 Wet to Dry process 0.48 MTPA addn 1 PH with calciner string 1.5 MTPA Dry One (1) PPC and OPC 25 MW
Types of cement produced : Captive Power Plant (CPP) :
Major suppliers of plant & machinery: Alstom, Pfeiffer, Siemens, ABB, SKF, FLSmidth, BHEL, ELGI, Elecon, MICO, GE, etc.
Plant History

Plant History
1905 : Foundation of Lakheri started with four cylindrical, pillbox-shaped vertical Kilns to produce hydraulic lime 1917 : Installation of Indias first cement plant at barren foot hills of Arawali mountain installed capacity of 0.32 mtpa using wet process of manufacturing from 3 nos. of kilns. 1997 : Modernization and Expansion by replacing wet process kilns with a single dry process kiln of capacity 1200 TPD and raising its cement manufacturing capacity to 0.60 MTPA. 2000 : By adopting Kaizens as a way of life, Total productive maintenance (TPM) philosophy, employees innovations and dedications, The plant could achieve production to a level of 0.7 mtpa from the same establishment. 2007 : The capacity of the plant is raised by more than two folds to a level of 1.5 mtpa by adding second string of pre-heater with calciner to the existing kiln with replacement of grate cooler and addition of new close circuit cement grinding system. 2007 : Installation of 25 MW capacity Thermal power plant. The manufacturing process is supported by an economical and reliable captive thermal power source. 2009 : Conceived Shikhar Project, In plant R & D with TSS support in Kiln Calciner String Pre heater and cooler modification. Usage of AFR. Transformation of Lakheri. 2011 : No 1 performer in all ACC plants. Winner of National Level energy conservation award, Green Tech Environment Excellence award and Golden Peacock Environment Management award. IMEA Award, Green Manufacturing Excellence Award.
Process Flow
Raw material extraction Raw meal preparation Clinker production Raw material preparation
Shipping station
Cement grinding
Shipping station
Business Growth
1600000 1400000 1200000
Second Up gradation
1000000 800000 600000 400000 200000 0
1600 TPD to 3200 TPD First Up gradation Wet to dry
1995-96
1998-99
2002-03
2005
2007
2008
2011
Clinker
Total Cement
PPC
6
Strength Performance
Passion
22nd 23rd Aug 2012
Energy Policy
Energy Policy
We, at Lakheri Cement works are committed to formulate and implement Total Energy Management System and in the process continuously strive to improve the energy performance in all its activities through Reduction in energy consumption by continuously improving the manufacturing process, without impairing productivity. Minimizing the waste and utilize the same for value addition. To adopt energy efficient technologies and optimize utilization of fuels and other resources. To increase the use of renewable sources of fuel and energy and optimization of raw material by the use of alternative material. Creating awareness among employees through various forums, upgrade their skills to conserve energy and natural resources, to achieve above goals. Date: 01.07.2009 Place: Lakheri (Director Plant) Lakheri Cement Works
Energy Conservation Activities

Energy Conservation Cell at
corporate level which act as facilitator

Energy Communities like
Electrical ,Thermal, Clinker factor, MTBF are formed at to enhance energy efficiency of all ACC plants.
An Energy Performance Cell
( Lakhelavya) is formed at plant level with Energy Manager as coordinator and participation of various HODs for implementation of identified projects

Brainstorming for energy conservation conducted every year. Small group and Energy Circle teams are formed comprising of workmen and middle management staff which work towards focused improvements for enhancing the productivity and energy conservation. The meeting for Energy consumption and analysis is carried out on daily basis Variance of energy consumption review weakly dash board meeting for each module An unique initiative of Energy Observation Tour ( EOT) on daily basis by staff employees to observe and stop any energy wastages in the plant. Implementation of ISO : 50001 ( Energy Management System)

Online power consumption is monitored on daily basis and the analysis
of the deviations is discussed in the daily production meeting which is headed by DGM (Prod) and weekly chaired by Sr GM/ Director Plant.
Internal and external training programme conducted for staff as well as
shop floor level.

Internal
and External energy Cholamandalam and Techport.
audits
by
TERI,
CII,
Orchid,
The specific power consumption for all the sections vis-a-vis their
respective targets and the deviations are analyzed and corrective actions are implemented.
Energy awareness prorgramme like poster, painting, quiz, slogan,
nukkad conducted at nearby school and plant level.

Employees are awarded for best innovative projects at plant level, R.O
level and H.O level

Best Kaizen and best suggestion from SHIKHAR suggestion box
scheme are awarded every month.

Energy Conservation Cell

Chairperson - Director Plant Sr GM ( Plant Operation)
C O R E
C O M M
GM Mining
Chief Mgr E&I
Energy Manager
GM Engg.
DGM Production
Chief Mgr Finance
I T T E E
Chairperson- Sr Sr GM
GM Mining Chief Mgr E&I DGM Production GM Engineering
O P E R A T
Energy Manager
I O N A L
HOD Mines
HOD CR
HOD VRM
HOD Kiln
HOD Cement Mill
HOD Packing
HOD E&I
HOD W/S
T E A M
Energy Conservation Cell

Chairperson Respective HOD S H O P F L O O R AE E&I Shift I/C W/S Shift I/C Mines Shift I/C Crusher Shift I/C VRM Shift I/C Kiln Shift I/C CM Shift I/C PP T E A M
Energy Reporting Format
Energy Reporting Format
Energy Review Format
Daily Production meeting format Energy Review Format
Weekly Dash Board Review Format
Awareness Creation on Energy Conservation
Group Discussion of Energy Circles
Nukkad by plant Employee on ENCON
Daily Energy Talk during dash board

Training program for employees

Strength Performance Passion
18
22nd 23rd Aug 2012
Specific Energy Consumption

Specific Electrical Energy (Unit/ Ton Cement)
95 90 85 80 75 70 2008 2009 2010 2011 2012 YTD Target 2012
93.81 91.19 84.59 82.27 79.9 79
Specific Energy Consumption
Specific Thermal Energy ( Kcal/ Kg Clinker) 723
725 720 715 710 705 700
721 717 713 709 709
2008
2009
2010
2011 2012 YTD Target 2012
Specific Energy Reduction
Sp energy Section w ise, RMP
2.00 1.50 kWh/ ton 1.00 Mat. 0.50 0.00 2008 2009 2010 2011 2012 YTD 1.80 1.78 1.46 1.30 1.18
Sp energy Section w ise,RML
21.00 18.00 15.00 kWh/ ton 12.00 Mat. 9.00 6.00 3.00 0.00
18.92
17.25
15.31
14.27
14.02
2008
2009
2010
2011
2012 YTD
Sp energy Section wise, Clinkering

38.00 36.00 kWh/ ton 34.00 Mat. 32.00 30.00 2008 2009 2010 2011 2012 YTD 36.61 37.32 37.26 36.04 34.00
Sp energy Section w ise, Grinding 40.00 38.00 kWh/ ton 36.00 Mat. 34.00 32.00 30.00 2008 2009 2010 2011 2012 YTD 38.72 37.83 37.93 37.15 36.77
National & International Benchmark Weekly Dash Board Review Format

79.9 80 60 67 65
Comparison of Specific Electrical Energy
kWh/ ton 40 Cement

20 0 National Bench Mark International Bench Mark Lakheri Cement
800
667
709 660
Comparison of Specific Thermal Energy
700 600 500 300 200 100 0
kcal/ kg 400 Clinker
National Bench Mark
International Bench Mark
Lakheri Cement
Ref: Report of the Working Group on Cement Industry for XIIth 5 year Plan 2012-2017 - Department of
Indian Policy & Promotion, Ministry of Commerce & Industry. December 2011 ACC Lakheri Cement Works Strength Performance Passion 25 22nd 23rd Aug 2012
PAT Obligation ( Gate to Gate )
1200 K cal/K g of C em ent 1000 800 600 400 200 0 2008 2009 2010 2011 2012 YTD Base line Target in data 2014-15 936.85 938.23 970 854.54 834.93 793.3 940
Green Energy
7.5 MW Captive Wind Plant at Jodhpur
Wind Power Generation, Mwh
14000.00 12000.00 10000.00 8000.00 6000.00 4000.00 2000.00 0.00 2008 2009 2010 2011 2012 YTD
Excellence in Energy Management

Energy Conservation Projects ( Summary for last 3 years)
No investment
No of project implemented Equivalent Kwh Total Energy Saving

Medium Investment
: 17 : 4.15 Million Kwh : 3569 Million Kcal : 32 : 27.077 Million Kwh : 23286 Million Kcal : 25452 Ts Co2 (Grid Emission factor 0.94 Tco2/MWh)
28
No of project implemented Equivalent Kwh Total Energy Saving Net CO2 reduction
Passion
22nd 23rd Aug 2012
Energy Conservation Projects in year 2009

Title of the Projects Implemented Annual Saving ( Rs Million) Investment Rs. Million
Modification in new P.H. lower(C-7) cyclone inlet ,top cyclone(C-1) inlet & dip tube height and Cooler IKN Horse shoe modification) Replacement of low efficiency pumps with a single high efficiency pump Installation of VFD for DC Fan in VRM, Packer 4, Primary Crusher Install Multi step capacity controller on selected compressors to optimize operating pressure Installation VFD drive for cooler fan no3, fan no -04
ACC Lakheri Cement Works Strength Performance
6.0
3.0
0.39 0.84 2.03 0.95

Passion
0.788 1.05 1.44 0.7

29 22nd 23rd Aug 2012

Operate 132 kW compressor and stop 160 kW compressor top reduce operating load/unload power Reduce operating pressure range for compressors (N0.332CP04,332CP03,442 CP 01) Rectify unloading system to reduce unload power for 160 kW screw compressor no.332 CP O4 Modify piping and operate coal conveying compressors at low pressure Dilution Air Fan operation, optimization in compound mode (New VRM running)
0.25
nil
0.32
nil
0.63 0.32 0.56

Passion
nil 0.03 NIL

30 22nd 23rd Aug 2012

CFL for colony residence lighting (1500 nos) Mill out put and Sp power optimization through (1) Process optimization (increasing grinding press) (2) size of mill feed L/S (3) Usage of Marvel slurry 4) Mill fan inlet damper removal Idle running of dust separation group to be avoided by interlocking with wobbler group Energy Saving by reducing damper setting of Clinker silo bag filter fan Drive no.521FN01 Installation of GRR in E-mill Fan
0.40
0.135
8.56
nil
0.14 0.24 1.58
nil nil 0.6

31
Passion
22nd 23rd Aug 2012

Area increased by Removing inlet silencer of cooler fan ( High pressure drop in cooler fan3,5 & 8)* Saving=0.25unit/mmWg*3 PID control of cooler fan operation Reduction of cement-06 mill power by Optimization of output by chemical dosing Power saving by using 556CP01/CP02 air to old cement mill by providing separate CM06 GGLS compressor and stopping one old cement mill compressor. TOTAL
0.22 0.92 2.59
nominal nil nominal
0.81
nominal
27.75
7.74
32
Passion
22nd 23rd Aug 2012
Major Energy Conservation Projects in year 2010

Title of the Projects Implemented Annual Saving (Rs. Million) Investment (Rs. Million)
Modification in Fan inlet box in order to minimize the velocity difference between duct and fan I/L Replacement of VRM1 main motor (1200 KW) with 1000 KW motor (Spare motor) Installation of VFD drive for cooler fan no3 Installation of VFD drive for cooler fan no 04
0.42
0.03
0.67
Nil
1.346 1.098
0.65 0.7

Installation of VFD drive for cooler fan no -06 Installation of VFD for PD Blower of new high momentum burner Installation of GRR for E-mill vent fan E-mill fan casing modification as per new impeller
1.098 0.336 0.623 2.079
0.8 0.75 0.5 0.65

Installation of VFD for cement mill separator fan Installation of High capacity PD blower in place of two PD blowers Installation of chemical mixing pump to increase the output of CM6 to 160 TPH from 154, hence reduce sp. power consumption Modify piping for low pressure compressor to reduce pressure drop and operate compressors at lower pressure
0.123 0.673
0.18 Nil
6.57
0.5
0.33
0.2
35
Passion
22nd 23rd Aug 2012

Modification of cyclone for improvement of collection efficiency and thermal efficiency Replacing kiln inlet seal with the iteca seal to improve thermal as well as electrical efficiency Installation of high momentum burner
72.0
3.0
2.0
1.5
2.64
6.0
Total
92.00
Strength Performance Passion
14.668
36 22nd 23rd Aug 2012

Replacement of E.E. Impeller for cooler Fan No. 4 Replacement of E.E. Impeller for cooler Fan No. 10 Connection of 930 KVAR capacitors with VRM-2 Main Drive Attending false air in graces in TA duct.
0.560 0.120 0.30
0.2 0.2 Nil
3.12
1.2

Attending to cooler old panel, plate gaps, side casting gap and under grates. Replacing the Conventional chokes with Electronic Chokes for 30 No's Tube light Fittings. Reduce pressure drop in down comer duct Preheater 1000W halogen replaced with 400W MH
1.81
1.0
0.08 1.19 0.41
0.07 1.0 0.10

Installation of VFD for PD blower no.351PD03 optimization of compressed air system Attending false air in graces in TA duct. Regarding of grinding media in second chamber of close circuit cement mill
1.01 1.05 3.12
0.5 Nil 1.2
5.17
4.5

Attended Calciner tertiary air bend - for flap control open , false air (3%) Pressure Loss 30-40 mmwg In colony ordinary 100/60w bulb replaced with CFL Improvement in efficiency of VRM2
0.06
0.05
1.34 1.45
0.05 4.0
Total
20.79
14.07
Implemented Projects 2012

Energy saving project :
Installation of 18 kw screw compressor in place of 35 kw compressor for old coal mill bag house and fuel transportation.
Cost benefit analysis:

Cost of new compressor = Nil
( used spare in Kiln section)
Saving in Power =12 kwh Run hrs. Per day = hrs. 20 Annual savings in Kwh = 79200 Annual cost savings = 3.56 Lakhs (@ unit cost of Rs.4.50/-) Simple Pay back period = Immediate

Stoppage of old cement mill compressor during OPC Grinding by interconnecting with CM6 compressor no 556 CP01/02

Cost for interconnection = Nil Saving in Power =20 kwh Run hrs. Per day = hrs. 24 Annual savings in Kwh = 72000 Annual cost savings = 3.24Lakhs (@ unit cost of Rs.4.50/-) Simple Pay back period = Immediate

Removing the dampers of cooler fan no 3,4,5 and 8 having VFDs to avoid loss of power through dampers.

Cost for removing dampers = Nil Saving in Power = 6.8 kwh Run hrs. Per day = hrs. 24 Annual savings in Kwh = 53960 Annual cost savings = 2.42 Lakhs (@ unit cost of Rs.4.50/-) Simple Pay back period = Immediate.

Installation of Energy Efficient Impeller for cooler fan no 4 ,6,9 and 10.

Cost of replacement of impellers = 6.0 Lakhs Saving in Power =13 kwh Run hrs. Per day = hrs. 24 Annual savings in Kwh = 1.03 Annual cost savings =4.63 Lakhs (@ unit cost of Rs.4.50/-) Simple Pay back period = 15 months

Installation of power factor improving capacitors in CPP and LC # 3. Improvement in PF from 0.92 to 0.95

Cost for installation of APFC = 10 Lakhs Saving in Power =15 kwh Run hrs. Per day = hrs. 24 Annual savings in Kwh = 118800 Annual cost savings = 5.34 Lakhs (@ unit cost of Rs.4.50/-) Simple Pay back period = 6 months

Modify piping and to run compressor at lower operating pressure for coal transportation compressor.
Before
After

Cost for Modifying pipe line = Nil Saving in Power =5 kwh Run hrs. Per day = 6 Annual savings in Kwh = 59400 kwh Annual cost savings = 2.67 Lakhs (@ unit cost of Rs.4.50/-) Simple Pay back period = Immediate ACC Lakheri Cement Works Strength Performance Passion
46 22nd 23rd Aug 2012
Road map to achieve bench mark..

Description
Electrical energy
Investment Rs Lakh 75.0
Unit/ ton cmt 1.25
Medium Voltage Drives (HT VFD) for Calciner Fan - 1200 KW Retrofit impeller of high efficiency (78-80% at operating parameters) in VRM -1 Fan for Power saving Medium Voltage Drives (HT VFD) for Coal Mill Vent Fan - 650 KW Installation of Capacitor Banks to improve the Power factor and hence operating efficiency of TG TOTAL
20.0 50.0 15.0 160
1.48 1.40 0.35 4.48

47 22nd 23rd Aug 2012
Passion

Description
Electrical energy
Investment Rs Lakh
Unit/ ton cmt
Installation VFD with high efficiency impeller Retrofitting in Cooler fan no 471 FN06, 471FN07, 471FN09 Installation of VFD for Compressors Installation Heavy duty pressure regulating valve for all bag filters.
20.0 15.0
0.4 0.15
5.0 Compressed air management system TOTAL 235

ACC Lakheri Cement Works Strength Performance Passion
0.15 0.10 0.8 5.28

48 22nd 23rd Aug 2012
35.0 75.0

Description
Thermal energy
Investment Rs Lakh
Kcal/ kg clk
Modification of remaining Cyclone for improvement of collection efficiency and thermal efficiency Utilisation of waste heat from Preheater & cooler exhaust Installing rotoscale for Calciner coal feeding system
25 3000
8 (1.5 MW)
150 TOTAL 3175
2 10
Innovative Projects - 1 Project Title: Optimization of cooler efficiency
Synopsis:
We have observed that clinker cooler and ESP exit temperature is in higher side 170-180 C and 280-300 C respectively. This is resulting a direct impact on thermal efficiency and cost of production. After so many ideation sessions following has been done for improving the cooler efficiency.
Innovative Projects - 1
Modification in Cooler IKN Blocking of two rows of IKN out of eight rows. Sp. aeration distribution changed 02 rows for Fan No 01 and 04 rows for fan No 02, as against earlier 03 in Fan 01 and 05 in Fan 02. Reduced inlet width of IKN from more than 1200 mm to 1050 mm. Last 5 rows of cooler grate plate pattern changed from one moving one stationary to two moving one stationary . Horse shoe & sealing of gaps Changed in pattern of IKN horse shoe, less width of fines side and more width of coarse side (E mill), in original design it was just reverse
Innovative Projects -1
Inter compartment sealing
Reduction of cooler IKN area
Increasing the number of Static rows in Cooler last compartment
Benefits:
By this cooler modification there is a substantial reduction in clinker temperature to 150-160 C from 170-180 C and ESP exit temperature decreased to 250-260 C from 280-300 C. Saving: Finally it is impacted reduction in sp thermal energy by 8 MJ/ton Clinker. Annual saving Rs17.6 Lac. Other Benefits: Conservation of natural resources by reducing coal consumption and helps to mitigate CO2 emission
Project Title: Increasing use of Alternative fuels Synopsis:

Co-Processing refers to the use as alternative fuels and raw materials (AFR) or disposal of waste materials in industrial processes to recover energy and material from them. Due to the high temperature (> 1200 degree C) and long residence time in cement kiln all types of wastes can be effectively disposed without any harmful emissions. Co-processing leaves no residue as the incombustible, inorganic content of the waste materials are incorporated in the clinker matrix. Therefore, after the waste is co-processed, it becomes a part of the product and no liability lies with the waste generators, whatsoever. Respecting the waste management hierarchy Co-processing of waste is done only when the options of Reduce, Reuse and Recycling have been addressed. Thus, Co processing ranks higher on the waste disposal hierarchy and eliminates the need for landfills and incineration. 53
ACC Lakheri Cement Works Strength Performance Passion 22nd 23rd Aug 2012
Approach and Methodology:

After internal discussion & study of site, it was decided to make feeding arrangement for Alternative fuels at kiln inlet. After finalizing the drawings, Procurement of steel, double flap damper & shut off slide gate had been done. During plant major shut down, The AFR feeding system has been installed. Trials of the various Alternative fuels like Mustard Husk, Saw dust, Soya Husk, Tire Chips etc. has been taken
Results: After various trials, it has been found that there is no

adverse effect on emissions or kiln operation due to co processing of AFR materials into Kiln. Cost benefits: It has been evaluated that Basis: Co processing of 100 T of Alternative Fuels Quantity of AF Cost of AF (Biomass) CV of AF TSR Savings Other Benefit : Conservation of Natural Resources. Reduction in CO2 emission
ACC Lakheri Cement Works Strength Performance Passion 56 22nd 23rd Aug 2012
= 100 T = 2000 Rs/T = 3000 Kcal/Kg = 0.33% = 800 Rs/T
Project Title : Reduce specific thermal energy consumption by

mixing of High VM biomass with low VM pet-coke.
Key Issues: High cost of conventional fuel Separate arrangement required for AFR feeding in kiln/calciner Problem of AF handling Inadequate availability of AF Pet coke contains low VM - Difficult to burn Need fine grinding Has to maintain excess Oxygen for proper burning High ash of other fossil fuels
At Lakheri 100% Petcoke is being used in kiln firing. As petcock contains low VM hence some excess amount of oxygen required for proper combustion. This excess air leads to reduce thermal efficiency of the kin system. Increasing cost of Petcock and conventional coal is also a factor for considering Alternative Fuel (AF). But again the feeding of alternative fuel in kiln requires lot of arrangement and modification to be done. Due to improper availability of AF this capital expenditure looks some time unviable Looking above Lakheri plant after many ideation sessions and brain storming came with a unique solution to feed Saw dust in the Kiln by blending with Petcock itself.
The methodology used is Use of saw dust To increase VM of firing fuel Lab scale trial of grinding of pet coke with saw dust Check availability of saw dust in near by villages Plant scale trial Optimum storage of biomass Optimization of burning operation After many trials this feeding methodology found very successful this has resulted reduction in preheater temperatures from 285 c to 274 c and there is considerable amount of power saving due to less air require for kiln/calciner. The Saw dust is being grind with petcock in the Ball Mill
Analysis of Petcoke Proximate Analysis Sample Details Pet coke % Moisture (As recd.) 5.2 9.1 % VM 0.6 % Ash CV cal/gm (GOD) 8390
%S
5.4
Analysis of Saw Dust Proximate Analysis Sample Details % % Moisture VM (As recd.) 17.3 64.9 CV cal/gm (GOD) %S
% Ash
%Fixed C
Saw Dust
0.5
17.3
Passion
4440
0.1
60 22nd 23rd Aug 2012
Results :
Reduction in %O2 at kiln inlet by 0.4% (2.4 to 2.0%) Reduction in %O2 at PH outlet 0.6% (4.4 to 3.8%) Increase in AFR TSR from 0.65% to 1.8% , fuel replacement cost w.r.t Indian grade fuel = 800 Rs/ts (5.0 Lac) Reduction in sp thermal energy consumption from 2998 to 2965 , equivalent to 7.9 Kcal i.e. 94.6 Rs Lac by considering only 50% = 47.3 L Total Benefit = Rs 52.3 L
Specific Thermal Energy ( Kcal/ Kg Clinker) 723
725 720 715 710 705 700
721 717 713 709 709
2008 2009 2010 2011 2012 YTD Target 2012

61
Passion
22nd 23rd Aug 2012
Environmental Projects
RABH
RABH
Air condenser Aircooled Cooling Tower
ESP
Sewage Water Treatment

62 Strength Performance Passion 22nd 23rd Aug 2012
Dust Suppression System
Continuous Emission Monitoring System
Continuous weather monitoring system
Environment monitoring Van
Jatropha Plantation
7.5 MW Wind Power
Alternative fuels & Raw Materials

Alternative Raw materials Marble Slurry
Marble Slurry Bio mass
Lime Sludge Coagulation Sludge Alternative Fuels Biomass - Mustard Husk,

Saw Dust, Rice Husk, tree pruning etc.
AFR feeding
Shredded Tires
Expired Products
Jatropha Plantation
Shredded Tires Industrial Solid Waste Expired Products ETP Sludge

66
Passion
22nd 23rd Aug 2012
Thank You

Acc LTD Laheri Cement Works

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National Award for Excellence in Energy Management 2012 by CII Sohrabji Godrej Green Business Centre

ACC Lakheri Cement Works

ACC Ltd - Lakheri Distt Bundi (Rajasthan)

Lakheri, Bundi, Rajasthan

Types of cement produced : Captive Power Plant (CPP) :

1000000 800000 600000 400000 200000 0

1600 TPD to 3200 TPD First Up gradation Wet to dry

ACC Lakheri Cement Works

22nd 23rd Aug 2012

Energy Conservation Activities

corporate level which act as facilitator

Energy Conservation Activities

Energy Conservation Activities

shop floor level.

and External energy Cholamandalam and Techport.

nukkad conducted at nearby school and plant level.

level and H.O level

scheme are awarded every month.

Energy Conservation Cell

Chief Mgr E&I

Chief Mgr Finance

HOD Cement Mill

Energy Conservation Cell

Energy Reporting Format

Energy Reporting Format

Energy Review Format

Daily Production meeting format Energy Review Format

Weekly Dash Board Review Format

Awareness Creation on Energy Conservation

Group Discussion of Energy Circles

Nukkad by plant Employee on ENCON

Daily Energy Talk during dash board

Training program for employees

22nd 23rd Aug 2012

Specific Energy Consumption

93.81 91.19 84.59 82.27 79.9 79

Specific Energy Consumption

Specific Thermal Energy ( Kcal/ Kg Clinker) 723

725 720 715 710 705 700

721 717 713 709 709

2011 2012 YTD Target 2012

Specific Energy Reduction

Sp energy Section w ise, RMP

Specific Energy Reduction

Sp energy Section w ise,RML

Specific Energy Reduction

Sp energy Section wise, Clinkering

Specific Energy Reduction

National & International Benchmark Weekly Dash Board Review Format

Comparison of Specific Electrical Energy

kWh/ ton 40 Cement

Comparison of Specific Thermal Energy

700 600 500 300 200 100 0

kcal/ kg 400 Clinker

National Bench Mark

International Bench Mark

PAT Obligation ( Gate to Gate )

Excellence in Energy Management

No of project implemented Equivalent Kwh Total Energy Saving

ACC Lakheri Cement Works

22nd 23rd Aug 2012

Energy Conservation Projects in year 2009