I recently had the opportunity to visit the ACC plant in Amethi, now under the ownership of the Adani Group. It was a wonderful experience, enriched with frugal innovations, wide-ranging discussions, and profound learning. Here are the highlights of my visit:
1. Plant History and Acquisition
The ACC plant was established in 1997 in Amethi and has been recently acquired by the Adani Group, marking a new era for the facility.
2. Production Capacity
The plant boasts an impressive production capacity of 12,000 MT of cement daily, making it a significant player in the industry.
3. Sustainable Practices
- The plant uses a mixture of 60% clinker, 35% fly ash, and 5% gypsum in its cement production.
- The consumption of over one million tonnes of fly ash annually is a remarkable example of reuse and recycling, preventing vast amounts of waste from being released into the atmosphere.
4. Workforce
The plant employs around 100 company employees and 800 local contractual employees, contributing to the local economy and providing job opportunities.
5. Tackling Environmental Challenges
The plant faces high PM (particulate matter) emissions due to the nature of the industry. I suggested several practical solutions, including:
- Using green nets across loading areas.
- Plastic coverings for unused fly ash.
- Installing air curtains at inlets and outlets.
- Deploying mist sprayers around the campus.
- Implementing PM-resistant horticulture and plantation.
- Proposing a small pond with algae that can adsorb PM.
6. Power Requirements and Renewable Energy
The plant requires 25 MW of power, sourced as follows:
- 6–7 MW from solar energy (via energy exchange).
- 6–7 MW from the grid (normal purchase).
- 12–13 MW from an in-house coal-fired plant.
We discussed a comprehensive plan to transition entirely to solar energy by leveraging Adani and government convergence, including solar roofing along nearby canal systems.
7. Production Lines
- The plant has two production lines, with the latest being a Chinese line. This is a recent phenomenon where China has gained expertise in building entire production lines, reducing costs by 40–45%.
- We discussed the potential for Indian SMEs to collaborate and provide comprehensive line systems.
8. Railway Logistics
- The plant has existing railway lines for raw material inflow.
- We planned for the doubling of these lines to reduce dependency on truck-based logistics, aiming for a complete switch to rail transportation.
9. CSR Initiatives
- ACC–Adani Group is actively involved in CSR initiatives with the district administration.
- Recent efforts include the introduction of an AI-based X-ray screener and support for nearby SHGs in the cold-pressed oil mill business.
My visit to the ACC plant at Amethi was an experience, showcasing the blend of innovation, sustainability, and social responsibility.
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