ACC Limited has announce that operations of its new project at Wadi II Plant in Karnataka have stabilized and commercial production is declared as commenced from May 1, 2011. The Wadi cement plant of ACC Limited, in India’s southern state of Karnataka, now enjoys the distinction of being the world’s largest cement plant. The company recently completed this challenging integrated cement project in Karnataka comprising an expanded clinkering line of 12,500 TPD at Wadi together with two satellite cement grinding plants manufacturing Portland Slag cement and flyash based Portland Pozzolana Cement. ACC faced numerous challenges to complete the project without disrupting operations of the existing plant. As the world’s largest kiln line, the commissioning of ACC Wadi marks it, as being among the most notable achievements of engineering excellence in the global cement industry.
ACC first set up a cement plant at Wadi in 1968. Then in 1978 the plant introduced the use of the energy efficient pre-calcinator technology from Mitsubishi for the first time in India. It made news again in 1982 when it inducted India’s first one million tonnes per annum kiln. A new plant was established in 2001 close to the old one. It came to be called New Wadi Plant. Comprising of one cement kiln with a capacity of about 5500 tonnes per day or 2 million tonnes per annum, it was again the largest kiln in India.
All operations at Wadi are now mammoth in scale and setting new trends and benchmarks – the largest limestone mining operations, the largest captive power plant in the industry, largest in inward and outbound logistics and the largest in bulk cement operations. The project reinforces ACC’s commitment to environment conservation in more ways than one. The plant incorporates sophisticated environment management systems and equipment that are designed to maintain very high levels of emission control. The two satellite grinding units manufacture environment-friendly blended cements using hazardous industrial waste by-products such as fly ash from thermal power plants and slag from steel plants. In addition Wadi promotes the use of alternate fuels through the co-processing of wastes.
According to Kuldip Kaura, CEO & Managing Director, “This has been a major milestone not only for ACC but also for the entire cement industry to see the successful commissioning and stabilization of clinker production from the World’s largest kiln at Wadi. ACC thanks everyone involved with the project for their continuous efforts and hard work which has made this possible.”