ACC Limited Bargarh Works

“National Award for Excellence in Energy Management 2018-19”

Milestones of IDCOL Cement Limited

Year Description

❖ Foundation stone laid by Industrial Development Corporation Of 1963 Orissa Ltd (IDCOL), Govt. of Orissa on 19th Dec’1963

❖ Plant started on 10th May 1967 with 2 wet process kiln each of 600 TPD 1967 (0.37 MTPA) & Grinding capacity 0.3 MTPA

1982 – ❖ First phase of expansion with capital of 1.6 Million INR to increase volume. 1985 ❖ Installation of No 3. (1st Phase) ❖ Grinding capacity enhanced to 0.565 MTPA.

1991 – ❖ Second Phase of expansion by commissioning of one new dry process kiln with 1995 capacity 1800 TPD of five stage SP with in line Pre calciner. (2nd ❖ Cement Grinding capacity enhanced to 1 MTPA by installation of 2 HPGRs and Phase) mixing plant.

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1 Takeover by ACC in Dec 2003

Year Description ❖ Acquisition of plant by ACC Limited in Dec 2003. Cost of share purchased – 176.41 Cr. (23 Cr. equity shares @ Rs 7.67 per share) Reasons for Disinvestment of the erstwhile IDCOL Cement Limited : - Dec., 2003 ❖ Sick unit, Too much Bureaucratic & Political interference , Excess manpower, high overtime, Poor Industrial culture , Poor Technical capabilities of the employees to run the plant efficiently. ❖ Labor unions were very strong supported by local politicians resulted in poor performance of the plant.

❖ Investment of INR 86 Cr. to increase the kiln capacity from 1800 TPD to 2600 TPD. 2005-2006 ❖ Conversion of Raw mill to 3 fan system, Replacement of Kiln ESP with Bag House & (3rd Phase) Cooler ESP upgradatation by addition of 2 fields

Investment of INR 572 Cr. to increase the clinker capacity to 0.9 MTPA and cement production capacity from 1.02 MTPA to 2.144 MTPA by following up gradations:- ❖ Addition of one more stage to PH with new down comer duct and fan. ❖ Installation of Slag VRM (145 TPH). 2007 - ❖ Close circuiting of existing cement mills. 2010 ❖ Installation of new crusher at mines (650 TPH). th (4 Phase) ❖ Installation of Mixing plant. ❖ Cement Silo (10,000 tonnes) ❖ Packing plant. ❖ CPP (2X15 MW) ❖ Wagon tippler. ❖ Stacker reclaimer system for coal and slag handling. 3 ACC Limited

Bargarh - Location

Western Odisha – Nearest Airport Jharsuguda 100 KM, Raipur 220 Km

Approved Capacity after Plant Expansion : Clinkering : 0.9 MTPA, Cement – 2.14 MTPA, CPP - 30 MW 4 ACC Limited

2 Mines Overview Dungri Limestone Quarry (DLQ) is located at 43 KM from the plant. Lime stone is being transported through Meter Gauge railway line by wagons. Limestone reserve available at DLQ as on 01.04.2014 is 11.89 Mio Tons.

Mines Lease Area 448.392 ha Mines Reserve 11.89 MT Life of Mine 10 Years Stripping Ratio 4 5 ACC Limited

Plant - Equipment Details

Coal & Slag Quarry Transportation Raw Mill Raw meal Silo Kiln Stock Piles

• Six Stage • Dungri Mines located • 2 Nos CF Silo • Coal: 20000 • Transportation of • Vertical Roller Mill Preheater with 53 KM from Plant MT Limestone by Capacity 230 TPH • Capacity : Inline Calciner • Limestone reserves Wagons through ( Make: Loesche, 5000 MT each • Kiln BDP 2860 TPD • Slag: 30000 12.4 Million Ton meter gauge 1995) • Old Folax cooler MT • Expected life 10-12 yrs • Feed through open (Fuller KCP – 1995) • Impact crusher 650 railway line. circular stock pile • Clinker storage silo TPH (Make L&T, 2009) • LOCO – 1200 HP (2NOs), 635 HP (3 (Cap: 30000 MT) (Cap : 60000 MT) Nos) CPP Packing Plant Cement Silos Slag VRM Cement mills Coal Mill

• 5 Packers (3 in old • 5 Silos with manual • CM#3 (90 TPH), • Vertical Roller • Capacity – 2 X 15 extraction system • Vertical Roller Packing plant and 2 in mill for Slag with HPGR2 as pre- MW • Silo 1 to 4 - 3000 MT Mill Capacity New Packing Plant) grinding grinder • CFBC Boilers – 2 (Year – 1967) (Loesche 1995) • Capacity : (Pfeiffer – 2009) (Fuller KCP 1995) Nos • Silo No 5 – 2500 MT • 25 TPH (Normal Packers 1 & 2 – 150 • Capacity 145 TPH • CM# 4 (55 TPH) with • Make : Cethar Vessels (Year – 1987) coal) • Mixing plant Cap TPH, Packer 3 – 100 • Silo 6 – 10000 MT HPGR1 as pregrinder• 12.5 TPH Year : 2009 300 TPH for PSC TPH, Packers 4 &5 – (2009) • (Petcoke) 240 TPH • Total – 24500 MT and F2R 6 ACC Limited

3 Energy Conservation Team Structure

Team Leader : Director Plant Energy Champion : Head Operation Team Members Circle area Champions

Narendra Bhardwaj 1 Raw Material extraction S Kundu

2 Raw Material crushing S Sen Parmanand Rai 3 Raw Mills Sunil Samal

4 Kilns JN Majhi D Bhadra 5 Coal Mills Tamal Core Energy Team Circles 6 Cement Grinding N B Jagati Pankaj Vidyarthi 7 Packaging Tapan Mohanty

8 CPP Boiler Balraju S Mishra 9 CPP Turbine Aklesh

10 Auxiliaries Lokesh Verma M Jadhav 7 ACC Limited

Plant achievement highlights ....

Sl.No Major Energy❑ savingsSignificant improvementprojects in Reduction of 21Savings unit/t of cementUnit (19.1%) in Increase Cement Mill 3 Output from 90 to 134 TPH by process optimisation adding 1 Electrical Energy from 2016-17. 4.5 (kWh/t cem) separate feeding system, roller replacement

Reduction of Slag VRM❑ MainFirst Drive Plant Power within LH residue group optimisation producing of Product 100% mix Composite Green Cement and 2 (Fly ash & Slag) with the addition of Separate feeding system and optimise Hydraulic 5.5 (kWh/t cem) system and Residue optimisationSuccessfully established Green cement in the market with better quality.

Installation of VFDs & GRR installation at different equipment 3 ❑ Reduction of Clinker Factor by 4.27 % (From 48.6%3.5 to 44.4%)(kWh/t cem)

Reduction of Clinker factor by 4.5% by increase of fly ash and activated 4 2.5 (kWh/t cem) additives with separate❑ flyWe ash saved feeding Natural system Resources By Utilization of Portable screen through Optimization of Bag filter Mechanicalfan, Air Compressor separation , Pumps and operation we have recovered 76000 High Grade 5 limestone, for waste soil Mix dump. 1.8 (kWh/t cem) Reduction of utility Power by optimization of Colony & Lighting TR Voltage, 6 2.2 (kWh/t cem) drinking water pump ❑operACC, office Bargarh & Street lightCement etc Works Won CII Green CO Gold Award in 2019

Reduction in idle running of the equipments by providing the interlocks in 7 1 (kWh/t cem) DCS. ❑ ACC Bargarh is Certified for ISO 50001 -Energy Management System, ISO

Installation of New Energy14001 Efficient- Environment Burner in Kiln Management System and ISO 9001- Quality 8 Management System 60 MJ/t Clinker Improve heat Transfer by implement CFD implementation at Cyclone 1 A ,1 B, 9 15 MJ/t Clinker and 3 ❑ ACC Bargarh Cement Works won CII Energy Award as Energy Efficient Unit Optimization of Grate speedin 2015 with under grate pressure in PID loop and 10 Optimize cooler air flow distribution 10 MJ/t Clinker

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4 Summary Of Energy Savings Project in Last 3 Years

Major Energy Total Total Savings Year Saving Project Investment (Million INR) (Nos) (Million INR)

2016-17 13 44 39

2017-18 12 18.9 7.5

2018-19 20 107.5 40

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Summary : ENCON Efforts

No. Of Projects 25,000 T CO2 No Investment Reduction Energy Conservation Projects ( Summary for Medium Investment last 3 years) 34% ‰ No investment 66% ▪ No of project implemented : 15 ▪ Saving Kwh/T of Cement : 10 44 Energy Savings▪ Saving in INR, Crore : 6.48 ‰ Medium Investment Savings inprojects CR implemented ▪ No of project implemented : 29 No Investment ▪ Saving Kwh/T of Cement : 11.6

▪ Saving in INR, Crore : 8.0 42% Medium Investment 58%

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5 Where we are………. overall KWh/Ton of Cement

Impact of 15 CR

21 kWh/t

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Energy reduction trend

Reduction in Clinker Factor Saved 230.0 %Clinker factor Grinding power Kwh/T Cem Clinkering power, Kwh/T Clk 40,000 T CO2 emission/yr 210.0

190.0 48.67 170.0 46.87 44.4 150.0

130.0 61.4 51.8 110.0 47.8

90.0

70.0 94.9 92.4 86.0

50.0 2016-17 2017-18 2018-19 Year

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6 Achievement in PAT Target

900 881 Reduction of

850 130 kCal/kg of Cement

800 /kg of

752 751 kCal Cement 750

700

650 Baseline PAT Cycle-1 PAT Cycle-2

Reduction of 14.8 % from baseline of PAT Cycle

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STEC – kCal/Kg of Clinker

Concerned Area ,We are in process to Major up gradation / replacement of Cooler in October 2019

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7 ACTION PLAN FOR ENCON

❑ Major Up gradation and partial Replacement of Cooler in major shutdown to Improve Clinker productivity , Reliability, Electrical and Thermal energy. Investment : INR 150 Million ❑ ReplacementTarget of In efficient Energy Fan with Savings High efficiency fan for PH fan. Raw Mill Fan, Cement Mill Fan 100 MJ/t clinker ❑ Increase AFR usage in Kiln with the tie up with Municipality and other waste 8agencies kWh/t clinker 4.5 kWh/t cem ❑ Installation of LV VFD in Ground Clinker Silo Bagfilter fan, Gr Slag Silo Bag filter Fan, CF Silo Bagfilter fan and applications

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Innovative Project : 1 Beneficiation of Clay Mixed Limestone Mines Life Increasedwith Portable Power screen ▪ Limited Reserve of Lime stone Issues/ ▪ Clay Mixed Limestone was not usable due to the following reasons ▪ Difficulties to maintain Crushed Limestone quality (LSF) Challenges ▪ Jamming in VRMby & Klin, 15 Cyclone Months ▪ Also its affect on the burnability during clinkerization ▪ Impact overall Kiln Production and Power consumption Ideas ▪ To utiliseNatural very good quality Resources high grade lime stone recovered , we need to Segregate of Clay /Initiatives ▪ We initiated to Install Mobile Screen in line with all permits and requirement and Taken 1 Lakhfinally installed MT Mobile (High Screen toGrade recover limestone LS from ) anotherclay mixed stone 6 lakhs MT is under process

Jamming & Clogging issues resolved Result • Mineral Conservation by utilization Clay mixed limestone • Increase Mine Life • Less Stripping Ratio • Reduction of RME Cash Cost, Total savings RS 12 million. 16 ACC Limited

8 Innovation No. 2 Reduction in SEEC in VRM

1) High Power Consumption Issues/ 2) Residue was not maintained goes on higher side 8 @ 90 Micron ChallengesCO2 Emission3) High Vibration 1) Lot of Trail Taken to improve PRI & Utilize Slag VRM output 2) We have made feeding system from Fly ash Silo to VRM to Mix up Reduction 1900Fly ash and T/yr Slag together in SlagWe VRM areto improve Grinding reside & PRI Slag Initiatives 3) Slag VRM Roller Pressure Optimized Taken 4) Residue maintained at 2 to& 3 Flyashat 90 Micron together in VRM to 5) Stabilization of mill Vibration improve output and quality

Sp power Reduction 6.5 kWh/ t product

1) Sp. Power reduction Result 2) Reduction in high mill vib and DP 3) PRI improved 17 ACC Limited

Innovation -3 Product Changeover from PPC /OPC/PSC to 100% Composite 1st Plant in IndiaCement producing (Green Product )

Bargarh Cement Works has changed the product (PSC/PPC/OPC ) in 100%to Composite Composite Cement (100%) cement successfully with the below product mix

Earlier Product Current Raw Material Mix(PSC/PPC/OPC Product ) composite Reduce Environment pollution Clinker (%) 48.67 43.4

Slag (%) 44.5 25 Fly ash converted to Product Gypsum & 3.98 4.6 Additives ( %) Flyash (%) 2.85 Less Use27 of Clinker Savings of Natural Resources

More Use of Fly Ash from Own CPP and Other Power plant

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9 Innovation No. 4 Reduce of Fuel Consumption and emission of Fly Ash Bulker

CO2 Reduction 253 T/yr

Fly ash Bulker unloading was done at Fly ash silo, where the vehicle has to travel 2 km from truck Issues/ parking yard to fly ash silo (plant inside), and the waiting time of vehicle was high. As well as Vehicle Challenges movement inside the plant also createTotal hazards Diesel & extra Saved fuel consumption and importantly create pollution. 1.0 Lakhs Ltr/yr We have made an arrangement of fly ash bulker to be empty at Truck parking yard itself, with the help of Initiatives Compressed air line (extended from plant to Truck parking yard), and calculated air pressure and venting Taken pressure to transport Fly ash from bulker to Silo directly and stopped vehicle movement inside plant, improve Road safety, pollution as well as decreased the waiting time of fly ash bulker

Sp fuel consumption (Fly Ash Bulker) 2.5 Litrs/ per km Total KM 4 kM Fuel Req 10 Lts/ Vehicle Result No of Vehicle 30 nos/day 300 lts /day Total Diesel Reqd. 9000 lts/month Total Cost of Diesel 6,03,000 Rs/ month 72,36,000 Rs/ Year 19 ACC Limited

Best Practices

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10 Equipment wise Energy Monitoring

Equipment wise Energy Monitoring (Upto Clinker) Equipment wise Energy Monitoring (Grinding) CLINKERING ONDATE ONDATE ONDATE TARGET CRUSHER SECTION kWh PROD SEEC SEEC GRINDING POWER ONDATE ONDATE ONDATE TARGET DLQ 6,070.34 3000 2.02 2.5 SLAG VRM kWh PROD SEEC SEEC STACKER RECLAIMER 886.50 3000 0.30 0.3 SLAGVRM MD 35,438 1500 23.63 30 TOTAL 6,956.84 3000 2.32 2.8 RAWMILL BF FAN 18,400 1500 12.27 12.5 RAWMILL MD 23181 2700 8.59 8.5 Aux-1 6,900 1500 4.60 6 RAWMILL FAN 15009 2700 5.56 6 MCC3 4854.1 2700 1.80 1.5 Aux-2 3,200 1500 2.13 1.8 Total 43931 2700 16.3 16.00 Total 73,937.50 1500 49.29 50.30 COALMILL COALMILL MD 3,477 245 14.19 14.00 CM3 kWh PROD SEEC TARGET COALMILL FAN 5,999 245 24.49 22.00 MD1 23,786 3,200 7.43 8.00 Aux-2 1,551 245 6.33 6.00 MD2 25,507 3,200 7.97 8.00 Total 11026.9 245 45.01 42 KILN RP1 2,012 3,200 0.63 2.50 KILN MD 5,014 2300 2.18 2 RP2 5,867 3,200 1.83 2.50 PH FAN 37,624 2300 16.36 14.5 BH FAN 15,510 2300 6.74 6.2 SEPEX FAN 12,356 3,200 3.86 4.00 COOLER EX FAN 4,671 2300 2.03 1.5 SEPERATOR FAN 9,075 3,200 2.84 3.00 COOLER 12,926 2300 5.62 5.8 Aux-1 17,406 3,200 5.44 5.00 Aux-1 2,931 2300 1.27 1.1 MCC4 ESP 2,584 2300 1.12 1.2 Total CM-3 1,01,008 3200 31.57 33.00 Aux-2 11,330 2300 4.93 5.5 MIXING 4,500.00 4700 0.96 0.90 KILN Total 92,591 2300 40.26 37.8 CLINKERING WITHOUT NP 1,54,505 2300 74.53 73.36 Non Process 5240 4700 1.11 1.20 Non Process 12756 2300 5.55 5.80 TOTAL GRINDING 1,84,686 4700 39.29 41.65 CLINKERING WITH NP 1,67,261 2300 80.08 79.16 21 ACC Limited

Road map to best in class performance

Bargarh (YTD – 2018-19) Road Map to achieve target 2019-20

Pri Crusher MD 2.2 Pri Crusher MD 1.5 RML Sec Crusher MD Sec Crusher MD (kWh/ Aux 1.6 Aux 1.0 t mat) 3.8 Total Total 2.6

Raw Mill Main Drive 12.92 Raw Mill Main… 12 RMP Seperator 0.8 Seperator 0.8 (kWh/t Vent Fan Vent Fan 9.2 CLi) 9.8 Aux 2.4 Aux 2.0 Total 25.6 Total 24.2

Main Drive 2.2 Main Drive 1.8 Preheater Fan 15.10 Preheater Fan 14.5 Kiln Bag House Fan 7.2 Bag House Fan 6.2 (kWh/t Cooler fans 7.5 Cooler fans 6.5 CLi) ID FAN 2.5 ID FAN 2.1 Aux & Fuel pre 15.5 Aux & Fuel pre 13.5 Total 51 Total 44.5 Total Upto NP 7.8 NP 7 Clinker 88 Total Upto 79 Clinker Grinding Grinding 51.4 40 Grinding 22 ACC Limited

11 Best Practices ….Followed at Mines to improve Energy Consumption and increase Mines Life

▪ Using Quarry Master Scheduling for optimizing the use of Medium Grade Limestone.

▪ Increase Mines life by Blending of 30 to 35 % Medium grade limestone with High Grade Limestone. 10% Reduction in ▪ LSF requirement reduced from 120 to 102 by using Quarry Master Scheduling low ash content fuel. Diesel Consumption

▪ Minimise Diesel Consumption -Single engine operation during Empty wagon movement from Plant to Mines. Clay Mixed Limestone ▪ Utilise Clay Mix High Grade Limestone by using Mobile Screen

▪ Consumption of Soil/Clay Mixed Limestone after Beneficiation

▪ Using Solar Street Light at Mines Solar Street Light 23 ACC Limited

Raw Material Management

▪ We are using 30% medium grade Lime stone ▪ Utilisation of Red Mud waste from Aluminium Industry ▪ 100 % utilization of our own CPP generated Flyash and Bed Ash ACC ▪ Utilisation of Fly Ash (increased from 20% to 28%) from Other Industry Bargarh is Committed to work towards ▪ Utilisation of SlagClean from steel and industry Green Environment ▪ Plastic Waste Utilization from Industry and Municipality ▪ We are in process to take entire plastic waste from 5 major Municipality in Odisha and already made agreement ▪ Expired Product from HUL and Other Industry ▪ ETP Sludge from Industry ▪ Spent Carbon from Industry

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12 Best Practices ….Followed Reduction in specific power for Clinker section

▪ Improve output of Raw Mill VRM by increasing velocity of Nozzle ring

▪ Close Monitoring and Maintain Raw Mix quality to reduce jamming tendency and improve kiln operation

▪ Kiln PC firing pipe line dia reduced and install VFD to improve blower power & thermal energy

▪ Utilization of existing GRR & VFD from low energy savings equipments /areas to High energy savings equipments /areas Initiatives ▪ Optimisation of Preheater inlet O2 by reducing jamming condition with proper Taken raw mix and addition of Soda Ash and reduced fan RPM from 860 to 832 RPM . Savings achieved 52 kW and improve thermal energy (6 Deg C reduced at PH outlet )

▪ Running of Lower rated air compressor for Kiln & Raw mill Section ,power reduced by 30 kW

▪ PID Loop Optimisation for cooler fan flow control.

▪ Reduced pressure drop at PH Cyclone by implementation of CFD

▪ Clinker cooler performance improvement by minimizing losses- optimizing cooler air flow.

▪ Raw Mill section; all the interlock timing optimized with RM Maid Drive 25 ACC Limited ▪

Reduction in Grinding Power & Clinker Factor

1. Diverting Semi finished HPGR product to mill outlet to optimise mill PRI 2. Increasing CM-3 output by increase Grinding pressure from 1600 to 1900 PSI 3. Slag VRM Roller Pressure Reduced from 35 Bar to 15 bar and maintain residue at the desired Initiatives level. Taken 4. Increasing fly ash absorption by process optimisation 5. Usage of activated gypsum (35% to 50% of total gypsum) without additives maintaining IQN. 6. Cement Mill Separator fan Cone Gap adjusted and Fan flow optimised, reduced 90 kW 7. Bed stability with addition of slag while clinker grinding and clinker addition while slag grinding 8. Central feed chute height optimisation 9. Interlock timing optimised in cement mill section group drive 10. Bag filter DP & Flow optimised with VFD and damper setting 11. Compressed air pressure optimised and reduced at different points including Bag filters. 1. 1st Plant in India & LH group produced 100% Composite Cement successfully Result 2. Power reduction about 15 kWh/t cem and absorbed load reduced 800 kW 3. Cement quality improved without affecting mill throughput. 4. Clinker Factor reduced by 4 %

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13 Reduction in SEEC through B/F Optimization

1. Optimise VFD setting as per draft Measurement and velocity of Suction Power consumption optimised points of Bag filter fans and reduce Frequency of VFD drives attached to Initiatives the bag filters. as per system requirement Taken 2. Fan inlet manual damper settings by draftwithout measurement any investment at suction points. 3. Reduce and optimise bag filter Purging Pressure from 5.2 to 4.7 kg/cm2 4. Fan I/L motorized damper opening restrictions by logic changing from DCS 5. Stopping of Raw Material handling bag filters, at material handling circuits[ raw slag, wet Fly ash] and making soft button in DCS during monsoon , and type of material handling.

Result Reduction of 120 kWh [1.3 kWh/T of cement]

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Other Best Practices ….

▪ Energy Monitoring System and Energy Dash Board Displayed in CCR

▪ Replaced old conventional lights with LED Lights

▪ Replaced old Air condition system with 4 star & 5 star AC

▪ Installed Day Light sensor and Auto timer for lighting circuit

▪ Reduce Voltage at Colony transformer and lighting transformer from 235 to 210 V

▪ Installing Energy Efficient Fan for Process application

▪ High performance Roller Press for Cement Mill

▪ Energy Efficient Pump installed

▪ Energy efficient Air Compressor is being used ,

▪ Solar Hot Water System at Guest House

▪ Solar Light at Mines

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14 Carbon Foot print of ACC’s Green Cement Products

Sl.No Name of the Product Kg CO2/T of Cement* 1 ACC Suraksha Power 612.73 2 ACC Concrete+ Xtra Strong 595.69 3 ACC Gold Water Shield 512.25 4 ACC F2R >> Superfast 417.23 5 ACC HPC Long life 280.00

❑ ACC is the first cement company in India obtained Green Product certification for all its Cement Products

❑ ACC is in the process of publishing its externally assured Environment Product Declaration (EPD) for all its Cement products shortly 29 ACC Limited

ACC’s Green Products - Cement

ACC

GOLDFly ash based Cement with water repellent properties

Migration from OPC to PPC, PSC, Composite Cement, Masonry Cement to LC3 Cement

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15 Carbon Foot print of ACC’s Green Concrete Products

Kg CO /m3 ACC is in the process of publishing Sl.No Name of the Product 2 of Concrete its externally assured Environment Product Declaration (EPD) for all its 1 ACC Adhaar 208 Concrete products 2 ACC Suraksha 134 Name of Kg CO /m3 of Sl.No 2 3 ACC Neev 160 the Product Concrete 4 1 M10 111 ACC Flowcrete 238 2 5 ACC Imprintcrete 238 M20 156 3 6 ACC Ready to use mortar 136 M25 178 4 7 ACC Bucket Crete 131 M30 208 5 8 ACC Ecocrete 100 M35 245 6 9 ACC Permecrete 260 M40 267 10 ACC Jet setcrete – High early 7 216 M45 282 strength concrete 8 M50 305 11 ACC Feather Crete - Light 186 9 weight concrete M60 312 12 ACC Coolcret - Temperature 10 267 M70 327 controlled concretee 31 11 ACCM80 Limited 334 13 ACC Thermocrete 149

Green Co rating – GHG Emissions

CO2 emission, kg CO2/T Cement

547 525 600 505 457 500 410 396 400 ACC 300 BCW

200

100

0 2016-17 2017-18 2018-19

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16 Renewable Energy

▪ ACC Bargarh is purchasing Renewable Energy Certificate about INR 12 Million per year as per RPO

▪ ACC Bargarh is also initiated to install Solar Power Plant in Consultation with Odisha Renewable Development Agency

▪ We are using Solar Heater, Solar Street Light

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Utilization of Waste as Alternate Fuel

AFR Feeding System: Quantity of Waste fuel as ▪ Hopper, Screw conveyor, Belt conveyor and Type of Waste waste fuel % of total fuel Pneumatic Feeding system for feeding biomass (rice Fuel Used used (Tons) - husk) into the calciner. 2018-19 ▪ AFR Feeding system: Starter kit solutionInvestment for feeding forRice Husk 2601 Hazardous & other Wastes into the system AFR;CIL WASTE 3.06 ✓ Small belt conveyor to unload material into the bucket of hoist system Plastic waste 21.82 ✓ Weigh feeder for gravimetric feeding and slide gate for proper sealing to Spent Carbon 63.52 avoid back fire fromCO calciner.-Processing INR 50 Million HUL (Industry AFR Storage Shed: 287.02 4.7% expired product) ▪ Well designedOn and maintained date AFR storage TSR shed with is 50 T6.5% capacity with @40%ETP sludge GAV30 Concrete flooring with impervious bentonite clay membrane sheet to avoid AFR;HUL WASTE 130.05 percolation and soil pollution. ▪Solid, Semi Solid Feeding System is available. Trade Reject 20.48

▪ AFR Laboratory: ▪ Hazardous waste sample evaluation: State of the Art laboratory is available.

GAV (%) 33.30 %

8.33% 8.20%

YTD 2017 YTD 2018 YTD 2019 34 ACC Limited

17 We care…for our environment

Dust emission from Raw Road swiping machine for inter mill/VRM stack – 10 to plant concert road swiping 13mg/Nm3

Plant concrete road after Dust emission from kiln ESP road swiping water stack -22 to 38 mg/Nm3 sprinkling by movable vehicle.

Water sprinkling for her LS SNCR project Installed for stock pile. De-Nox system for Kiln operation

CEMS (Continues Ambient Continuous Emission air Monitoring System) Monitoring System (CEMS) (CAAQMS) for PM10, Installed at Kiln PM2.5, SO2 & NOX

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We care…for our environment

1. Installation of state of art pulse jet bag filters at kiln, Coal mill, Slag VRM, Cement mill and 5packing plant and high efficient ESP at Cooler and CPP U 2. Installation of online emission monitoring system CEMS at Kiln, Cooler, CPP and Slag VRM and1online data transmission to CPCB and SPCB site. BF 3. Installation of online Ambient Air Quality Monitoring system at 3 locations. 1

4. Installation of SNCR system to reduce and control NOx emission

5. Replacement of existing damage collecting electrodes at cooler ESP to improve the collection efficiency and maintain the stack emission below the norms. 3

6. Retrofit the TR Controllers and ReplacementBof existing Rapper panel with new generation Rapper to improve the ESP efficiency and to maintain the stack emissionFbelow the norms B 7. AFR System in Kiln operation for different type1 of waste feeding. 36 ACC Limited

18 We care…for our environment

8. Installation of wet fog type dust5suppression system at MG Wagon Tripler, MG Lime stone stacker , BG Wagon Tripler, Mines Crusher hopper for control Uof fugitive dust emission. 9. Installation of water sprinkler system1 at approach road near cement mill 3 and packing plant area and installation of water Gun at Raw material area to control the fugitive dust emission during vehicle movement BF

10. Concreting of Roads in front of 1Packing plant Truck loading area and operation of road sweeping machine to control the fugitive dust emission.

11. De –dusting system improvement at cement mill, kiln area by modification of venting line , venting chute, dampers etc. ( 361 BF1 discharge chute , Slag HPGR discharge chute, venting modification at Kiln feed bin , Cement Mill 3 HPGR, Mixing plant, Cooler drag chain, Packing plant etc)3

12. De-dusting System installed at Clinker Bsilo tunnel belts for Clinker extraction. F B 1 37 ACC Limited

We are Water Positive

CPP : Sp water, m3 / MWH 1. Reduction of cooling water blow down water 3.6 by maintaining the water quality parameters 2. Cooling tower basin cleaning 3.28 3.12 3. Reduction in dump loss 4. Media & activated Carbone replaced in multi grade filters and carbon filter in the pre treatment plant 2016-17 2017-18 2018-19 Online Monitoring system 5. Replaced passing water & steam valves

Sp water, m3 /T of Cement 6. Alarm provided at cooling tower forebay to 395 avoid over flow 7. Facilitated operation of water pre-treatment 267 220 plant from CPP CCR for close monitoring 8. Installation of Zero Liquid Discharge plant H2SO4 Auto dosing system is under [progress, will complete by Dec19

9. Installation of sulfuric acid auto dosing system for cooling tower water treatment to maintain the water quality parameter – 2016-17 2017-18 2018-19 10.Recirculation of GCT discharge water in the system Sp domestic water, m3 /T of Cement 91 11.Recirculation of comp cooling water in the

66 system 55 Rain Water harvesting t reservoir and through Top Roof Recharge 12.Installation of water level sensor in water Structure tank at raw mill, GCT and cooler area to avoid water over flow and wastage of water 13. Rain water Harvesting through 2nos 2016-17 2017-18 2018-19 reservoir and through Roof Top

14.We Have ETP & STP 38 ACC Limited

19 Awareness & Training – Energy& Environment Conservation

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Best Practice – control of dust emission

Thank You Concreting of road of truck Concreting of truck parking area parking

Dust suppression system – Road sweeping M/c & Water sprinkler system at different40 places ACC Limited

20 Back up Slides

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