Chanda Cement works

Presented by – Naresh Macherla (Head Production)

Content:

● About us
● Sp. Energy Consumption in last 3 Years
● Benchmarking for Cement Manufacturing Excellence
● Energy Saving Projects implemented in Last 3 Years
● Innovative Projects Detail
● Utilization of Renewable Energy Sources
● Waste Utilization and Management
● GHG Emission Reduction and Action Plan
● EMS System and Learnings from Others
● Our Net Zero Commitment
● Moment of Glory
 Presence of Adani Cement Across India

Gagal
#
90 MTPA 62.0% Darla / Suli
Cement Capacity Clinker Factor Ropar Nalagarh Asian Nalagarh
Rajpura
Bhatind Roorkee
a
Dadri
18 10 Rabriyawas
Ametha
Kymore
Integrated Units Captive Ships
Marwar Tikaria
Mundwa Chaibasa
86% 86+ Lakheri
Sangh
Farakka
Sindri
Share of Blended Cement Ready-Mix Concrete plants i Navalakhi Sankrail
Ambujanagar Damodhar
Dahej Bargarh
Muldwarka
10.6% 6 Panvel
Surat
Bhatapara
Thermal Substitution Rate Bulk Cement Terminals BCCI Jamul
Chanda Maratha cement works Wadi Integrated Plants
# Grinding Units
1,00,000+ 23 Vizag
Bulk Terminal
Blending unit
Channel partners across India Grinding Units
Kudithini Ambuja
# 1. Order placed for capacity expansion of 14 MTPA Cement incl. 8 MTPA Clinker Bhatapara & Maratha), under
implementation.
Thondebhavi ACC
2..Including Tuticorin Grinding Unit & Penna cement.
Mangalore
Sanghi
Madukkarai Dahej
Cochin
Tuticorin
Plant Location details

Maharashtra

Chanda

▪ Located in Ghugus Tehsil, Chandrapur district. ▪ Chanda has two Limestone mines, both located in
▪ Chandrapur - 27 km / Nagpur – 165 km. Yuvatmal district.
▪ Chanda plant got commissioned in 1970. ▪ Sindola Mines -17 km from the plant
▪ Plant upgraded in 2010 to 2.318 mtpa Clinker & ▪ Govari Mines -25 km from the plant
3.80 mtpa cement. ▪ Captive power plant located in the factory.
• Turbines - 1 X 15 MW and 1 X 25 MW

Chanda is the first cement plant set-up in the Maharashtra state.

“Quarry to Lorry” – Plant major equipment
Clinkering Capacity : 2.31 mtpa
Cement Capacity : 3.80 mtpa
Quarry Crusher Raw Mill RM Silo Kiln Clinker Silos
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• Sindola (23 mio ton, • 1 X 18,000 tons CF • 1 Dry process Kiln 6 stage
• Limestone Crusher
0.6 mtpa CtO, • 1 VRM - 560 TPH Silo, FLS Make double string PH with ILC • Defunct Silo of 1 lakh
1200 TPH impact
Stripping Ratio 1:1) Pfeiffer make • Blending efficiency • 7,000 TPD FLS make ton capacity
crusher, L&T make
• Govari (26 mio ton, • 4.0% residue on 10:1 • 5.5 m dia. X 86 m long • New Clinker Silo of
• OLBC – 8.5 km from
2.89 mtpa CtO, 212 micron • Cooler: FLS 5X6 crossbar 1,00,000 MT storage
Sindola to Plant
Stripping Ratio 1:2) upgraded with ABC inlet capacity

Coal Mill Cement Mill Cement Silos Packing house Dispatch

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• Existing: 2 Mills X 75 TPH each, • Existing: 5 X2400 MT each • Existing: 3 X 120 TPH each • Existing: 4 wagon and 6
• 75 TPH VRM FLS ACC Babcock with VRPM • New: 2 X 12000 MT each EEL Make, Single discharge truck loading machines
make • 1 VRM X 260 TPH (PPC), Loesch • Total Capacity = 36,000 MT • New: 3 X 240 TPH each EEL • New: 12 wagon and 5
• 3 rollers make Make, double discharge truck loading machines
Specific Thermal Energy Consumption in last 3 years

780 30

760 25.5 25
767

740 17.5 20

14.3
739
720 15

703
730
700 10
5.8

680 5

660 0
FY22 FY23 FY24 Target FY25

STEC - Clinkering (Kcal/kg clinker) TSR%

Despite of increasing TSR% we are continuously decreasing STEC consumption

SEEC Consumption in last 3 years (Upto Clinker)

62.5 30

62.04 62.00 25.5 25

62
61.59 20
17.5
61.5
15
60.92 14.3
61
10

60.5
5.8 5

60 0
FY22 FY23 FY24 Target FY25

SEEC - Clinkering (kWh/t clinker) TSR %

Despite of increasing TSR% we are slightly decreasing SEEC consumption

SEEC Consumption in last 3 years (Grinding & Overall )

SEEC - Cement Grinding (kWh/t SEEC - Overall (kWh/t cem)

cem) 80
34.5
75 77.9
34 34.25
76.1
33.5 34.12 70
71.4
33 33.3 65

32.5 70.0
60
32 32.4

55
31.5

31 50
FY 22 FY 23 FY24 Target FY25 FY22 FY23 FY24 Target FY25
Information on Competitors, National and Global Benchmark
as per CII Benchmarking Details

Energy Benchmarking
Total SEEC STEC
Parameters
(kWh/T cem) (kCal/kg Clk)
ACC Cements (Unit : CD) 71.36 739
Competitor 1 69.30 735
Competitor 2 71.40 746
Competitor 3 71.65 758
National Benchmark 56.15 676
Target for 2024-25 70.00 730
Target for 2030 60.00 700
Energy Saving Projects Implemented in last 3 Years

Thermal Total Impact on SEC/SHC

Electrical
No. of Energy Investment Savings Saving (Electrical kWh/MT
Year Saving
Saving Projects (INR Million) (Million (INR cement or Kcal/kg
(Million kWh)
Kcal) Million) cement)

FY 2021-22 9 3.0 6.84 3,600 37 2.53/1.2

FY 2022-23 7 26.7 1.87 4,485 48.7 0.88/1.7

FY 2023-24 9 102.7 1.98 31,061 69.34 0.57/8.9

 List of Encon Projects implemented in FY 2021-22

Annual Total
Annual Annual Annual
Thermal Annual Investment
Sr Electrical Electrical Thermal Payback
Title of Project Saving Savings Made
No. Saving Cost Saving Saving (Rs (Months)
(Million (Rs (Rs Million)
(kWh) (Rs Million) Million)
Kcal) Million)

1 Optimization of Raw mill DP through HLC 26,40,000 10.56 0 0 10.56 0 0

Replacement of T12 lamps with LED

2 96,360 0.4 0 0 0.4 2.4 72
lamps
Reduction of dam ring height to improve
3 13,20,000 5.28 0 0 5.28 0 0
mill output
Change in delivery setting pressure of
4 3,37,833 1.35 0 0 1.35 0 0
compressors
Optimization of kiln, PC firing through Kiln
5 - 0 3600 9.72 9.72 0 0
Master HLC
Reduction of Raw mill fan power by
6 13,20,000 5.28 0 0 5.28 0 0
increasing GRR loading

7 Removal of Cement mill 3 fan damper 4,62,000 1.8 0 0 1.8 0.15 1

Reduction of fan power by arresting false

8 4,75,200 1.9 0 0 1.9 0 0
air across coal mill circuit

Removal of dampers of separator vent fan

9 1,91,400 0.77 0 0 0.77 0 0
- Cement mill 1 & 2
 List of Encon Projects implemented in FY 2022-23
Annual Annual Annual Total Investm
Annual
Electrical Thermal Thermal Annual ent
Sr Electrical Payback
Title of Project Cost Saving Saving Savings Made
No. Saving (Months)
Saving (Rs (Million (Rs (Rs (Rs
(kWh)
Million) Kcal) Million) Million) Million)
Installation of downcomer duct water
1 5,45,530 2.7 0 0 2.7 10.5 46
spray system

Rerouting of compressor air lines to

2 6,27,904 3.76 0 0 3.76 0.3 0.2
reduce power consumption

Replacement of duoflex burner with

3 - 0 1559 13.25 13.25 15 13.5
pyrojet burner

4 Removal of RABH fan inlet damper 2,67,191 1.6 0 0 1.6 0 0

Replacement of Kiln seal Inlet and Kiln

5 - 0 2090 17.77 17.77 0.4 0.27
Outlet lamella Seal

Installation of Martin make air blasters

6 - 0 836 7 7 0.5 0.86
in cooler inlet to improve efficiency

Improvement of separator seal with felt

7 4,36,909 2.62 0 0 2.62 0 0
in cement mill 3
 List of Encon Projects implemented in FY 2023-24
Annual Annual Annual Total
Annual Investmen
Electrical Thermal Thermal Annual
Sr Electrical t Made Payback
Title of Project Cost Saving Saving Savings
No. Saving (Rs (Months)
Saving (Rs (Million (Rs (Rs
(kWh) Million)
Million) Kcal) Million) Million)
1 Installation of ABC inlet in Kiln Cooler - 0 20849 40.8 40.8 100 29.4

2 Removal of damper from cooler ESP fan 3,50,000 1.99 0 0 1.99 0.2 1.21

Removal of coal mill bag house fan

3 3,00,000 1.71 0 0 1.71 0.2 1.4
damper
Reduction of false air across Raw mill
4 7,02,000 4.02 0 0 4.02 0.1 0.3
circuit to < 15%
Application of heat resistance paint on
5 - 0 3312 5.63 5.63 0.8 1.71
kiln shell
Installation of bolted type spikes for
6 - 0 2400 4.08 4.08 0.2 0.59
stripping wheel in AFR feeding

PID loop for AFR weigh feeder Vs Chain

7 - 0 2400 4.08 4.08 0.2 0.59
conveyor to reduce fluctuations
Usage of THERMACT PC additive to
8 - 0 2100 3.57 3.57 1 3.36
improve burnability of Coal
Improvement of Raw mill output to > 550
9 6,30,000 3.46 0 0 3.46 0 0
TPH
List of Encon Projects planned in FY 2024-25
Annual Electrica Annual Therm Investment Ma
Annual Energy Payback (Mo
Sr No. Title of Project l Saving (Million al Saving de
Saving (ToE) nths)
kWh) (Million Kcal) (Rs in Million)

Optimization of Raw mill Hydraulic

1 pressure to improve mill output to 560 0.546 - 46.95 0.1 2
TPH
2 Installation of HLC in Raw mill 1.12 - 93.4 3 24
Reduction of Raw mill cyclone DP
3 0.4 - 34.3 2 12
through CFD

4 Installation of HLC in Kiln 1 7500 835.58 3 26

5 Installation of new Kiln Inlet analyzer - 3000 300 5 15

Installation of shredder to reduce AFR
6 - 7500 749.5 400 48
size
7 reduction of coal crusher output size 0.4 - 34.3 - -
Installation of VFD in unloading
8 0.4 - 34.3 1 5.5
compressor
Cement mill 3 Baghouse fan impeller
9 0.6 - 51.6 10 4
replacement
List of Encon Projects planned in FY 2024-25
Annual Electric Annual Therm Investment Ma
Annual Energ Payback (Mo
Sr No. Title of Project al Saving (Milli al Saving de
y Saving (ToE) nths)
on kWh) (Million Kcal) (Rs in Million)

10 Installation of mechanical conveying system

in place of pneumatic system for
3 - 154.7 40 29
transferring cement to old silos from new
cement mill
11 Installation of High efficient low pressure
compressor for Flyash unloading in old mills 0.4 - 34.3 3.5 19

12 Installation of 3 S Roller in CM3

3.77 - 324.5 270 24
13 Replacement of AFR double flap damper 0 3 0.377 0.5 2
14 Installation of additional Raw coal hopper
to maintain coal ash as per Raw mix 0 4500 449.7 10 12.5
 Innovative project -1: Installed PCPF block for burner
▪ Frequent failure of Burner castable (3 months) due to high wear rate at the tip area.
▪ Installed PCPF block for burner for the first time in AAA to improve burner reliability
▪ PCPF block up 1.8 m length from burner tip during Feb’24 Shutdown PCPF block area
observed intact after 1.5 month of operation.

Before After
Can be replicated in all the Cement plants
Innovative project -2: Usage of Coal Catalyst
Actions implemented – Feeding coal catalyst in kiln and PC in the ratio of 1 KG for 10 MT coal

Can be replicated in all the Cement and power plants

Innovative project -3: Installation of cooler ABC inlet
Before
Heat Balance
Heat Input Heat Loss
Heat energy enter into the Kcal/Kg
Kcal/Kg clink 383 109
cooler Heat through cooler vent clink
Kcal/Kg
Kcal/Kg clink 16 32
Sensible heat of cooling air Heat through clinker out clink
Sensible heat of cooling Radiation losses fro Kcal/Kg
Kcal/Kg clink 1.02 6
water cooler clink
Kcal/Kg
29
Evaporation of water clink
Total 400 167

Cooler efficiency % 57

After
Heat Balance
Heat Input Heat Loss
Heat energy enter into the Kcal/Kg
Kcal/Kg clink 383 109
cooler Heat through cooler vent clink
Kcal/Kg
Kcal/Kg clink 17 23
Sensible heat of cooling air Heat through clinker out clink
Sensible heat of cooling Radiation losses fro Kcal/Kg
Kcal/Kg clink 0.89 6
water cooler clink
Kcal/Kg
23
Evaporation of water clink
Total 401 155

Cooler efficiency % 67
Can be replicated in plants which are suffering with frequent Snowman
formation
Energy Saving projects initiated at Chanda Cement Works
1. Installation of Water spray system in downcomer duct
Inconsistency in Kiln Operation eliminated by installation of Water spray system

PH false
air
reduced
from 12%
to 6%

• Down comer duct water spray @ 10m3/hr in each string, to reduce PH O/L temperature to the level of 230 oC
• Consistent AFR consumption and Kiln feed during Raw mill and Coal mill stoppages as gas temperature is
maintained.
• Better control of Preheater fan and RABH Inlet Temperatures to avoid tripping of Calciner firing resulting in kiln
disturbances.
2. Synchronization of Walking floor with CBC to avoid fluctuation in AFR Feed & to
control high CO in the system

• PID loop Optimization – Chain conveyor Speed Vs Weigh Feeder TPH

• Optimization of Walkie Floor forward stroke (26 Sec) divided into three intervals with delay time of
7 sec to optimize fluctuations.

AFR Feed Fluctuations Walkie Floor Stroke Optimization

BEFORE AFTER
3. To control high CO in the system Mixing of Biomass with RDF

Mixing of AFR – RDF:Biomass

Actions taken:
•Separate Loadall for
mixing of RDF & Biomass
• Mix prepared separately

Advantages:
• Enhanced flow ability of
material
• Reduction of Jamming issues,
Thus eliminating CO high
issue.
• Reduction of variations in Cl in
AFR feed
• Minimised moisture
 0
1000
1200

400
600
800

200
01.12.2023 00:00

Before
03.12.2023 23:00
05.12.2023 04:00
06.12.2023 11:00
07.12.2023 16:00
08.12.2023 22:00
10.12.2023 05:00
11.12.2023 10:00
12.12.2023 15:00
13.12.2023 20:00
15.12.2023 02:00
16.12.2023 07:00
17.12.2023 14:00
19.12.2023 00:00

Before
20.12.2023 06:00
21.12.2023 22:00
23.12.2023 05:00
24.12.2023 14:00
25.12.2023 19:00
After
28.12.2023 01:00
29.12.2023 06:00
01.01.2024 00:00
02.01.2024 07:00
AFR circuit Striping wheel spikes repaired

04.01.2024 20:00
07.01.2024 11:00
22.01.2024 22:00
Std dev of CO variation- 58

24.01.2024 05:00
25.01.2024 12:00
26.01.2024 19:00
03.02.2024 05:00
04.02.2024 13:00
08.03.2024 18:00
10.03.2024 13:00
12.03.2024 10:00
13.03.2024 15:00
14.03.2024 21:00
16.03.2024 02:00
17.03.2024 08:00
Actions implemented – To control High variation of CO in system

18.03.2024 14:00
21.03.2024 23:00
23.03.2024 05:00
24.03.2024 15:00
27.03.2024 03:00
After

29.03.2024 15:00
30.03.2024 20:00
01.04.2024 01:00
02.04.2024 06:00
03.04.2024 11:00
discharge to make uniform bed of the AF material.

Std dev of CO variation- 16

16 after repairing stripping wheel after walking floor
Standard deviation of CO peaks reduced from 58 to
4. To control high CO in the system Stripping wheel spikes repaired

Series20
 5. Kiln Shell painting

Reduction of Kiln Shell Radiation

• To reduce Shell radiation Heat resistance paint applied on Kiln (ARREST MASTER 3001 L)
• Achieved savings of ~ 2.76 Kcals/Kg clinker

Kiln Shell Radiation Before Painting Kiln Shell Radiation after Painting
Ambient temperature 35 oC Ambient temperature 35 oC
Clinker production 315 tph Clinker production 315 tph

Heat Heat Heat Heat

transfer transfer transfer transfer
Distance Kiln dia. Kiln lengthTotal C.S.A vg. Temp., Radiation Distance Kiln dia. Kiln lengthTotal C.S.A vg. Temp., Radiation
cofficient cofficient cofficient cofficient
(Radiation) (Convection) (Radiation) (Convection)

mtr mtr mtr m2 o

C Kcal/kg cli. mtr mtr mtr m2 o
C Kcal/kg cli.
20-25 5.5 5 86.3938 349 22.8380 6.1781 2.1448 20-25 5.5 5 86.3938 310 19.7610 6.3059 1.6886
25-30 5.5 5 86.3938 368 24.4594 6.1137 2.3962 25-30 5.5 5 86.3938 326 21.0008 6.2537 1.8690
30-35 5.5 5 86.3938 386 26.1214 6.0503 2.6616 30-35 5.5 5 86.3938 355 23.3720 6.1567 2.2268
35-40 5.5 5 86.3938 372 24.8519 6.0985 2.4582 35-40 5.5 5 86.3938 361 23.8715 6.1368 2.3042
40-45 5.5 5 86.3938 363 24.0168 6.1311 2.3268 40-45 5.5 5 86.3938 355 23.3826 6.1562 2.2284
45-50 5.5 5 86.3938 364 24.1164 6.1271 2.3424 45-50 5.5 5 86.3938 345 22.5473 6.1899 2.1005
50-55 5.5 5 86.3938 299 18.9176 6.3416 1.5684 50-55 5.5 5 86.3938 284 17.8704 6.3858 1.4222
55-60 5.5 5 86.3938 302 19.1369 6.3323 1.5994 55-60 5.5 5 86.3938 289 18.2368 6.3704 1.4730
60-65 5.5 5 86.3938 308 19.6505 6.3106 1.6727 60-65 5.5 5 86.3938 295 18.6356 6.3535 1.5287
65-70 5.5 5 86.3938 302 19.1859 6.3302 1.6064 65-70 5.5 5 86.3938 285 17.9520 6.3823 1.4335
70-75 5.5 5 86.3938 288 18.1526 6.3739 1.4613 70-75 5.5 5 86.3938 277 17.4038 6.4052 1.3581
75-80 5.5 5 86.3938 273 17.1510 6.4156 1.3237 75-80 5.5 5 86.3938 265 16.5608 6.4395 1.2440
80-86 5.5 6 103.6726 245 15.2971 6.4878 1.2924 80-86 5.5 6 103.6726 237 14.8120 6.5046 1.2170
24.85 Kcal/kg cli. 22.09 Kcal/kg cli.

Saving in STEC 2.76 kCal/kgclk

6. Reduction of Limestone feed size

Actions implemented - Limestone feed size reduced in stacking pile.

BEFORE AFTER

•Feed size has wide variations, stones up to 250 x 150 x 100 mm •After reduce feed size below 65 mm and mill feed increased .
were observed in the Limestone pile. •Lime stone feed size maintain below 65 mm.

Limestone pile wise Sieve analysis Limestone 65 mm sieve size reduced 5.89 %
 7. Raw mill hydraulic pressure increased from 180 to 185 Bar

TPH Hyd Operating Pr.

Optimisation of Grinding Pressure : 556 562 560
533
▪ Mill was operating 180 bar @ 532 tph.
▪ Leakages in Hydraulic cylinders arrested.
▪ Hydraulic cylinder No 2 replaced. 180 185 188 190

▪ Trial taken by increasing Grinding pressure step by step from 180 to 185 and
then upto 190 bar. 180 185 188 190
Trial time process parameters by hourly basis
 8. Installation of rod gate in raw mill inlet duct

Actions implemented -
Modification of mill inlet hot air duct
▪Installation of air blasters
▪Installation of rod gate inside hot air duct
BEFORE AFTER
Waste Utilization & Management

• AFR material stored in a covered shed with proper ventilation

• AFR shredder project (~Rs 41 Cr.) is ongoing, expected to complete by March 2025, after which we
can reach the TSR value up-to 25.5%.

Waste as fuel Quantity (MT) GCV (kCal/Kg) TSR (%)

FY22 39,537 2485 5.8
FY23 96,375 2364 14.3
FY24 RDF/ Biomass 1,48,985 2058 17.5
Target FY25 2,15,370 2232 25.5

Saving of natural resources

Coal Saving due to AFR usage : 71591 MT
Waste Utilization & Management

Waste as percentage
Waste as Raw material Quantity (MT) Replaced material
of raw material
FY22 16853 0.5
FY23 Red mud 19293 Iron Ore 0.7
FY24 21396 0.7
FY22 0 0
FY23 Wet Slag 9980 Bauxite 0.35
FY24 6167 0.2
FY23 Limestone Sludge 1034 0.04

Saving of natural resources

Coal Saving due to AFR usage : 71591 MT
IMS Certificates

Our plant is IMS certified for Environment, Energy and Quality.

Reduction in GHG
800 732 730 734
700 657 Chanda has taken CO2 emission intensity
600
500 reduction measures such as
400
300 ▪ Clinker factor reduction
166 163 161 157
200
▪ Improving Thermal Substitution Rate (TSR)
100
0 ▪ Installing Waste Heat Recovery System
2020-21 2021-22 2022-23 2023-24 (WHRS)
Scope 1 Scope 3
▪ Reducing Thermal & Electrical Energy
intensities
107963
CO2 reduction : tCO2 97378 ▪ Increasing renewable energy consumption
▪ Adoption of new technologies
35981
12956 9272

2019 2020 2021 2022 2023

Traditional Fuel Replaced

64677 MT
SD 2030
Technology Adoption
Technology Remarks
Cooler hot air recirculation, for increasing waste heat Commissioned WHRS with Cooler gases, PH
recovery (WHR) power generation. commissioning in progress

IoT – Industry 4.0 Implemented WBI app, BoG, TIS, HLC under digital
transformation drive

Chlorine bypass system for increasing alternative fuel Study completed. Under progress
usage.
Electric vehicles for raw materials/ products Trial done with electric vehicle for cement loading
transportation
 Moments of Glory

➢ Platinum award in 1st Half Yearly Udaaan Championship for increasing TSR from 9.3 to 20%.

➢ 3rd National Sustainability Awards on Cement and RMC by QCFI for Excellence in AFR .

➢ IconSWM-CE award for “Highest TSR & Best Volumes of AFR” at the 13TH International Conference on Sustainable

Waste Management and Circular Economy for the year 2023.

➢ IBM Awards : Chanda received 2nd Prize for Environmental Monitoring, Publicity and Propaganda and 3rd Prize for

Reclamation BIS has honored “Outstanding performance in Quality” to ACC Chanda for achieving zero failures in

Cement Quality in the last two years.

➢ Chanda Cement Works received Best performer award in AFR excellence category in 1st International Cement

conclave organised by QCFI Madurai and Ahmedabad Chapter.

1st Half Yearly Udaaan Championship
3rd National Sustainability Awards on Cement and RMC by QCFI (Excellence in AFR, ACC
Chanda Cement Works)
(IconSWM-CE award)

Chanda Plant awarded for “Highest TSR & Best Volumes of AFR” at the 13TH International
Conference on Sustainable Waste Management and Circular Economy for the year 2023.
IBM Awards for Chanda Cement

Chanda Cement Works received 2nd Prize for Environmental Monitoring, Publicity and
Propaganda and 3rd Prize for Reclamation.
Reward from BIS to Chanda Cement Works

BIS has honored “Outstanding performance in Quality” to ACC Chanda for achieving zero failures in
Cement Quality in the last two years.
 Thankyou

1) 1st Plant in Adani group for highest AFR consumption more than 600 TPD (With
Co- Processing facility)
2) First plant to achieve 21% TSR in Adani group.
THANK YOU