ACC Chanda Cement Works - A Profile

ACC pioneered the Cement Industry in Maharashtra by setting up the State ’s first
cement plant, the Chanda Cement Works, in 1969. The Works is located in the
Vidarbha region of Maharashtra near Chandrapur at a distance of 150 kms to the
south of Nagpur. It has two production lines whose initial total capacity of 0.4 million.
tonnes was progressively raised by introducing precalciner technology (in 1980) and
by other improvements (in 1987) to 0.62 million tonnes per annum. In the year 2000,
by introducing a six-stage preheater and a new calciner, modernization and expansion
of this plant has been successfully carried out with in house engineering skills. This
has helped to increase the cement production capacity to 1.0 million tonnes per
year with a reduction in the total dust load to the atmosphere.

In spite of the proximity of the Works to coal mines and consequent lower cost of coal,
the variable cost of production is high. The workers therefore opted for and installed
Captive power plant as one of its major steps.

Before the installation of Power plant, electricity requirement of ACC Chanda Cement
Works was 18 MVA, which was met by drawing electricity from Maharashtra State.
Electricity Board (MSEB) through contract demand of 18 MVA.

The existing plant of ACC Chanda Cement Works is located about 20 km from
Chandrapur in W-SW direction. The town of Ghugus is located 2 km north of the
plant. The Wardha River is located 0.75 km to the south of the plant.
The confluence point of the Nirguda and Wardha rivers is also at a distance of 0.75 km from the
plant.

ACC Chanda Cement Works is located at 79 7' N longitude and 19 55' E latitude. o
The mean sea level of the plant site is 214.3 meters. Geologically, this area comprises
of sedimentary rocks of the Vindhyan range approximately 1600 million years old.
The topography of the area is fairly flat with no hills or valleys in the immediate vicinity.
of the plant site. The climate of the region is characterised by summer, winter and
monsoon. The summer season lasts from March to June and is characterised by
extremely hot and dry climate, the mean of maximum temperature (in May) being
around 45 C.o Winter season lasts from November to February. The mean minimum
o
temperature is about 11 C in December. The south-westerly monsoon usually sets in
the third week of June and lasts till September. The major part of rainfall occurs in
the months of July and August. The months of December and January represent a
short mild apology of a winter season. The predominant wind direction and wind
speed changes from season to season. During the monsoon season predominant wind
directions are from SW and during winter season from NE and during summer season
Wind flows from all directions but predominantly from the SW to NW quadrant.

ACC Chanda Cement Works (CCW) has been established in 164.08 hectares of land.
which, plant occupies about 43.15 hectares In remaining hectares of the area colony,
railway line, approach road, play grounds, green belts & other facilities of colony are
situated. A housing colony with all necessary infrastructure having greater hygienic
an atmosphere and showing high aesthetic value is existing. Facilities such as
dispensary, high school, market, community centre-cum-club, two guest houses
bank, public telephone booth, post office, stadium/playground, bus stand and all
Other necessary facilities are already available.

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The limestone mining area of Chanda Cement Works is located about 9 km to the SW.
direction. Total lease area of Sindola Mine is 840.83 Hectares. Crushers are installed
in this mine for limestone crushing. Another Gowari Mine has 772.74 Hectares of land
on lease just 2 km from Sindola mine with a left turn just from the vicinity of the
plant. Another major river is Painganga which confluences with the Wardha River
near village Wadha about 4.3 km from ACC Chanda Cement Works towards SE
direction. In addition, there is a local river i.e. Nirguda River which meets Wardha
River adjacent to the existing plant at about 0.75 km towards south direction.

kwh/Tn. CLINKER

77.4 Kcal / kg. CEMENT

610

77.2
600

77
590

76.8 580

570
76.6

560

76.4
550

76.2 540

530
76 2004-05 2005-06 2006-07
2004-05 2005-06 2006-07 YEAR
YEAR

ENERGY CONSERVATION COMMITMENT, POLICY & SET UP

Keeping in view of continuous depletion of natural resources, CCW is putting effort in.
continual basis to conserve energy with sustainable developments so as to contribute
in a better way for the future requirements of the nation.

The Energy management activities are done on a daily basis. The power consumption of
Each department is communicated to the Head of departments well before the daily meeting.
so as to communicate the same to down the line for actions to be taken. The energy
management policy yet to be committed.
The Energy Management Cell is:
Chairman: Plant Head
GM (Tech.), MGR (Production), MGR (Maint.), All HOD (Production & E & I)
and Energy Manager (Coordinator)

The functions involved are: Energy monitoring & analysis, auditing & review of
proposals, implementation and evaluation of implemented proposals. After proper
estimation of the proposals, the details are put in the budget for sanction along with
payback period. The energy consumption target for different departments are set and
reviewed periodically for any chances to improve further.

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 Energy Conservation Cell

PLANT HEAD

GM (TECH.) MGR (Production) MGR

(Maintenance)

HEAD OF (E&I) ENERGY ALL PRODUCTION

MANAGER HODs

DETAILS OF CONSCIOUS EFFORTS AND MEASURES ON PROCESS CHANGE.

Reduction in water consumption:
After modernization the kiln exit gas temperature has reduced from 396 deg.C to 300
deg.C. Hence cooling water requirement at the gas conditioning tower for cooling exit
gases has reduced.
For conserving water we have implemented various schemes. Water consumption has
not increased even after enhancing our production capacity from 600,000
MT/year to 10.00 Lakhs MT/year. The entire cooling water is being re-
circulated.
Reduction in coal consumption:
Heat energy requirement in kilns has been reduced from 890 Kcal/Kg clinker to 730
Kcal/kg clinker. Hence coal consumption has reduced from 25.5% to 21.4%.

Reduction in raw material consumption & conservation of natural minerals:

We have successfully modified our raw mix design for using fly ash as a substitute for
Bauxite. This modification has resulted in completely eliminating use of Bauxite.
conserving about 24000 MT/year of the valuable mineral.
Innovation & Facility provided for reuse of waste products:
A huge quantity of fly ash is generated from the thermal power plants in our country.
which is a waste material and a lot of amount is spent for handling and disposing the
same. Large land area is wasted by way of land filling the disposed fly ash. ACC
through in-house Research & consultancy studied the suitability of fly ash and
developed best quality blended cement branded as SURAKSHA after carrying out
various laboratory tests at our Research Centre Laboratory.

ACC Chanda is the first plant in the State of Maharashtra to manufacture Portland.
Pozzolana Cement (PPC) using fly ash by investing a huge amount for fly ash extraction
system at the Chandrapur Super Thermal Power Station (CSTPS) Chandrapur and
transportation of fly ash to cement plant through specially made bulkers to avoid any
fugitive emission during transport.
A fly ash handling system has also been constructed at the cement plant to enable
storing and feeding of fly ash to cement mills.

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We have also purchased 10 bulkers for the transportation of fly ash from CSTPS and
Nagpur Khaperkeda Thermal Power Station which is about 215 Kms away thereby
aiding them in removing the dust nuisance at the Power Stations and utilizing the
national waste for production purposes.

Similarly, ACC Chanda Works is utilizing waste products such as coal fines and
iron/mill scale from steel industry and Phospho Gypsum from fertilizer plants.

Steps for reuse/recycle of waste:

A new fly ash storage silo is being constructed for the re-use of fly ash generated at our
Captive Power Plant and being used for cement manufacturing resulting in
conservation of natural resources i.e. Bauxite.
DETAILS REGARDING EFFLUENT TREATMENT PLANT AIR & WATER POLLUTION
Control Systems
Domestic effluent:
A new Sewage treatment plant has been installed outside the plant with a treatment
capacity of 450 m3/day and all the domestic effluent from the residential colony is
diverted to this plant for treatment. The treated water is used for fruit garden and
plantation along the road to nearby Ghugus village, also along the road to
Chandrapur. The Capital expenditure on STP Plant is
Rs 4 million.

Domestic effluent from the various buildings/sheds within the factory and Power plant
area is conveyed through separate drains to septic tanks from there it is disposed in
soil through soak pits.
INDUSTRIAL EFFLUENT:
a) Cement Plant:
Industrial water consumption is mainly for the cooling of kiln exhaust gas discharged.
through Pre heater at 330oC to gas conditioning tower before they are vented out
through ESP below 150oC and for the cooling of machinery such as Compressors,
Blowers, mill Bearings etc. Major quantity of total water is required in gas conditioning.
tower which ultimately gets evaporated out.

The water in use for cooling of machinery is re-circulated. Re-circulation tank and
pumps are provided with a cooling tower to re-utilize the entire quantity of cooling
water in circulation for cooling of machineries and for plantation and gardening
purposes.
There is no generation of industrial effluent and water is not discharged outside the
plant.
b) Captive power plant:
Effluent Treatment Details:
Industrial effluent generation of the co-generation power plant is non-hazardous and
Physico-chemical treatment of effluent is sufficient to meet the MPCB norms.
The effluent from various sources is discussed below:
Steam Generator Blow-down:
The salient characteristics of the blow-down water from the point of view of pollution
the pH and temperature of water since suspended solids are negligible. The pH is
in the range of 8.5 to 9.5 and the temperature of blow-down water is around 100 oC.

The steam generator blow-down is cooled down in the blow-down tank and the overflow is
taken to holding tank. The quantity of blow-down water is approximately 60.0 m3/day.
Steam generator blow down water is used for gardening, green belt development and
water sprinkling of roads in power plant itself.

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Effluent from Cooling Tower Blow-down:
Cooling tower blow-down is clear water, which meets MPCB norms without treatment.
Total quantity of cooling tower blow-down is 180.0 KL/day and the same is pumped to
gas conditioning tower of the cement plant.
Effluent from Ash Handling System:
The bed ash from the steam generators is conveyed by pneumatic conveying system to
the bed ash silo. Similarly the fly ash is conveyed to fly ash silo by pneumatic system.

Separate ash coolers are provided for cooling bed ash with air. The hot gas is recycled.
into the system. Therefore cooling tower blow-down effluent is not used for quenching
the bed ash. Hence no effluent generation from Ash handling system.
Effluent from Water Treatment Plant:
The effluent from the generation of the cationic resin units in the water treatment
plant is generally acidic in nature and that from the anionic resin units is alkaline in
nature. The wastewater from the water treatment plant is neutralised in a neutralising
pit. The neutralised effluent has suspended solids less than 100 ppm and pH is in the
range of 7.5 to 8.0. The neutralised effluent is discharged to the ETP
collection/holding tank.

Similarly, drains from the filtration plant and softening plant are discharged into the ETP.
collection/holding tank. Total quantity of effluent generation from this source will be
96.0 KL/day.

Hence total quantity of effluent generation is 336.0 KL/day. Neutralization and

Primary treatment units are provided. Treated effluent meets the MPCB norms.
collection & holding tank the treated water is pumped to gas conditioning tower in
cement plant for cooling the kiln exhaust gases.
Fugitive Emissions:
In the raw mill section, the fugitive emission points are the various transfer points of
the conveying belts. These emissions are arrested effectively with the help of three
dust collectors. In addition to this, two dust collectors are also provided to arrest the
dust emissions due to the blending and storage silo venting.

At the cement mill section, a total of 8 dust collectors are in operation for controlling the dust.
emission from all the transfer points of material conveying equipments. Two dust
Collectors are provided to arrest the dust generated due to the venting of cement.
storage silos.

In the coal handling section, the fugitive emissions from the coal crusher and the
Transfer points of the conveying belts are arrested with the aid of four dust collectors.
of bag filter type.

At the ropeway unloading station, coal gantry and coal handling section, the fugitive
emission is controlled with the help of water spraying arrangements.
In the Captive Power Plant, 6 dust collectors are provided for the coal belt conveyor.
transfer points.

The fugitive emissions from the packing house is controlled by four dust
collectors of bag filter type.

Besides this, we have also installed dust collectors for DPC clinker discharge at the gantry.
for arresting the fugitive emissions.
Solid and Hazardous Wastes.

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There is no generation of hazardous waste. However, the biomedical waste generated
used bandages, cotton, etc. are incinerated from the factory and Mines dispensary.
by dumping it into (burning) running kilns. One person is trained in handling and
disposing this waste.

All the dust collected from ESPs and bag filters are taken back into the process.
process as these are the part of product.

The lubrication oils used for various machineries are replaced after a certain period.
This used oil is collected and stored in earmarked area before sale. This oil is
disposed off to vendors at Nagpur and Chandrapur who are authorized by the CPCB.
As this oil comes under category no. 10 of Hazardous Waste (M&H) rules, 1989, all
Necessary precautions for collection, storage and disposal are taken. The
the generation of used oil has reduced from 4.5 KL per year to 3.0 KL per year during last
2 years.
Details of efforts taken by the company towards
environment preservation
Plantation undertaken in and around the industry locations/ sites
Tree plantation has been a continuous activity at our Chanda works. In this regard we
have planted 198,700 trees so far, out of which 145,000 are surviving. During the
Current year our target is to plant 10,000 trees in the factory area and 5,000 trees in
Mines area.

Our budget for tree plantation for the current year for plants and mines is Rs. 6.00 Lakhs.
Out of 164.39 hectares of land in total, we have covered 25 hectares of land with
plantation and gardening.

Inside the plant plantation program and gardening for improving the greenery is a
Continuous practice at our Works. Plantation is being carried out in colony areas and
along the road leading to the nearby village of Ghughus and also along the road leading to
Chandrapur.

We have prepared a fruit garden outside the plant, near STPlant and the treated water.
from STP Plant is used for this fruit garden, which is flourishing well. The names of
fruit and plantation for greenery which are planted inside as well as outside the
factory is furnished as below.
The plants planted are Shewan, Sheshu, Sheesham, Neelgiri, Cashia, Karanj, Neem.
Rantree, Gulmohar, Ashoka, Palas, Hiwar Dhaora, Khair etc.

Planting trees is a main activity in all our public functions such as Independence.
Day, Republic Day, May Day, World Environment Day, Energy Conservation Day, etc.
involving the employees and their families.

Besides this we have also planted 10,268 Jatropha trees in the year 2005 at the
leased areas of the factory and this year also we have planted a further 100,000 units of
Jatropha trees.
Improvement in house-keeping to make it environment-friendly.
We have purchased manually operated Road Sweepers for cleaning of the roads in the
plant.
For controlling fugitive emissions due to vehicular movement, an automatic water sprinkler.
A system has been provided on all the roads inside the plant which runs on auto mode.
as per the frequency fixed through DCS panels in Central Control Room.

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The initiation of TPM activities in our plant has made a notable contribution to improvement in
productivity, safety and working environment. Improvements in safety and working
environment largely contributed through the projects undertaken by employees under
Quality Circle and Small Group Activity has also helped in good housekeeping.

Environment-friendly inputs like Fly ash from our own and nearby CTPS, coal fines &
iron/mill scale from steel industry, and phospho gypsum from fertilizer and chemical
Plants are being used for the manufacture of cement.

ACC Chanda cement works has put up a fly ash extraction collection and
transportation and feeding system with a capital investment of RS.7.00 Crores

In place of open trucks, Bulkers are used for the transportation of fly ash in order
to avoid dust emission while transportation from Thermal power station Chandrapur
and Khaper Kheda, Nagpur and from NTPC, Ramagundam, (A.P)
Development & production of eco-friendly products:
Eco-friendly Portland Pozzolana cement is manufactured by using fly ash from
Thermal power plants.

Acoustic horns, which are the latest technological development in the international
Market, are under consideration for use for cleaning of bags inside the dust collectors
to improve the collection efficiency.

Chanda Cement Works has outlined its safety policy and made it clear to everyone.
employees of the plant. Safety audits are conducted every year by an outside agency
like National Safety Council of India and Loss Prevention Association of India.

We are complying with all the norms of Water and Air Acts. Hence no penalties & no
Legal actions initiated against Chanda Cement Works by the Pollution Control Board.
All the pollution control equipment is tuned to operate with efficiency, therefore
Emission of Suspended Particulate Matter (SPM), SO2, and NO2 are always controlled.
to be less than the MPCB norms. No waste material is dumped outside the plant. Bio
medical waste is burned in our kilns.

Environmental & safety management system available for:

On-site hazards:
At Chanda cement works, the on-site safety hazards are coal catching fire in the open.
yards and in fine coal hopper, fire hazard in coal mill dust filters.

For extinguishing fire in fine coal hopper of possible fire, we have provided auto CO2
purging system.

For coal mill dust collector safety we have replaced the polyester fabric bags needle felt.
with Co-Polymer-Antistatic bags apart from providing CO2 purging system.

Whenever there is a fire in the fine coal hopper or coal dust collector, the CO2 purging.
The system will come into action and reduce the presence of oxygen to ZERO in the fine coal.
hoppers or dust collector bags compartment, whichever the case may be, thereby
starving the fire.

The mill will automatically trip due to the detector sensing the higher temperature and
sending signal to control panel for the purging of CO2. in case
of the fire in the coal heaps is extinguished by operating the water sprinkler or by
ring main hydrant system provided covering the whole plant area.

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II. Off-site hazards:
As such, offsite hazards are minimal but the fly ash generated at Chandrapur
Thermal power station and Nagpur, Khaper Kheda is carried in bulker trucks by road.
without polluting the atmosphere and pumped into fly ash silos in the plant, thereby
reducing both the thermal power plants fly ash handling problem as well as their
environmental problem.
We are in regular contact with local fire brigade authorities and local government authorities.
to meet any likely off site hazards.

The trucks which are transporting coal and other raw materials are properly covered
with tarpaulin to prevent pollution problem enroute.
Facilities for treatment/disposal of:
1. Effluents:
Inside the plant, the effluents are discharged to individual soak pits. Domestic
Effluents from our colony are treated in the sewage treatment plant and the treated water
is used for gardening and plantation purposes in the colony and roadside plantation.
Emissions
Stack emissions are monitored continuously by a competent agency and our
Environmental Engineers and the emissions are within limits (i.e.), within MPCB
norms.
3. Waste:
No solid waste is generated in the plant.
No hazardous waste generated in the plant.

The waste oil generated/removed from machinery such as compressors, mill bearings
etc is collected in drums and sold to market vendors approved by the Pollution
Control Board.

New fly ash silo initiated by Chanda cement works for collecting the fly ash to
Avoid fly ash rising due to wind when unloaded into the material gantry. For
New PTFE bags for dust collectors are adopted (in place of conventional type
needle felt polyester bags) which are very high in cost but more effective in controlling
the dust emission
Implicit in the statement that no creature is superior to another and
Human beings should not have absolute power over nature.