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AIA’s products demonstrate exceptional operational
efficiency, meticulously tailored to
meet the specific demands of each casting application. Our
High Chrome and Sintercast
technologies are renowned for their advanced quality and
superior throughput, maintained
through precise metal composition ratios. This efficiency
directly translates into
significant power savings during operation, reducing coal
consumption and leading to
substantial carbon savings. Ultimately, this contributes
significantly to lowering
CO2 emissions, making a meaningful impact on
greenhouse gas reductions for
our customers.
For example, in the context of cement grinding, we observed
substantial savings in alloys
and a reduced carbon footprint by transitioning grinding
elements from conventional alloy
grades to VEGA Specific Grade. An analysis highlighted the
anticipated reduction in
greenhouse gases achieved through improved performance in
grinding mills and tube mills.
In the period from April 2023 to March 2024, the castings
supplied by AIA Engineering
Limited (via Vega Industries) for Vertical Mills and Tube
Mills demonstrated promising
results. By utilizing Ceramic-based Grinding elements
(Sintercast) for Vertical Roller
Mills (VRM) and optimizing the alloy combinations in
grinding media and latest
liners/grate plates, an estimated 46.12 tonnes of
CO2 equivalent greenhouse
gas emissions were avoided per tonne of specific product
used in sectors such as cement,
power plants, and tube mills at customer facilities. This
resulted in a total absolute
reduction of 13,35,322 tonnes of CO2e
controlled/avoided based on the volume
of products sold.
Total tonnage of liner castings sold amounted to 28,949 MT,
contributing significantly to
the reduction of 13,35,322 tonnes of GHG emissions.
Remarks: Conversion of energy kWh to carbon considered
factors such as specific coal
consumption (0.5 Kg/kWh) and carbon content in coal (40%
fixed carbon + volatile matter).
Calculations were based on operational hours of various
cement plants, power plants, and
tube mills where AIA conducted business.
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Tonnage of liner castings sold: 28,949 MT, which helped to
control CO2
and 13,35,322 tonnes of GHG emissions. Total absolute
reduction as CO2e
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We utilize medium frequency induction furnaces for all our
melting operations, which
operate on electricity. This closed-loop process is designed
to minimise energy loss and
heat dissipation, thereby contributing to the reduction of
greenhouse gas emissions.
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There is minimal loss of energy and heat, which helps in
reducing greenhouse gas (GHG)
emissions.
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We utilise direct energy for the heat treatment process
across all our foundry units. To
mitigate Scope 1 emissions, we have transitioned to Piped
Natural Gas (PNG) and Liquid
Petroleum Gas (LPG). Additionally, we have implemented flue
gas recuperators on all our
PNG-fired heat treatment furnaces. These recuperators
enhance furnace efficiency by
recovering heat from flue gases. The recovered waste heat is
then utilized to preheat the
combustion air supplied to the burners.
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Helping in the reduction of GHG Emissions Scope -1
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AIA has installed 11 wind energy turbines and 3 sets of
hybrid (wind + solar) systems in
Gujarat, with a total installed capacity of 37.38 MW of
renewable energy. During F.Y.
2023-24, The Company generated 85,127.199 MWh of electricity
from renewable sources and
supplied it to the grid.
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85,127.199 MWh of renewal energy were generated.
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Rainwater Harvesting: AIA has implemented a rainwater
harvesting system aimed at
replenishing groundwater resources. This system includes
installation of recharge wells at
various locations: four wells at Kerala GIDC Plant and two
at Moraiya Plant, complemented
by an onsite pre-filtration system. Additionally, three
recharge wells have been
established outside the premises—one each at Chiloda and
Moraiya Villages to further
support groundwater recharge efforts. The total estimated
rooftop recharge water amounts
to 82,708 kiloliters, calculated based on an average
rainfall of 744 mm.
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Estimated water recharge: 82,708 KL
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Zero Liquid Discharge (ZLD) practices are upheld across all
our plants, supported by
various initiatives aimed at minimizing water consumption.
At Kerala GIDC Plant, we've
implemented a dry-type cooling tower that significantly
reduces blow down. This discharged
water is now reused for sand mold preparation and cooling
sand/slag. Greywater and sewage
undergo treatment in our STP (Sewage Treatment Plant), with
the treated water repurposed
for gardening, toilet flushing, and cooling towers.
Furthermore, we've adopted automatic
and spring-operated water taps to mitigate potable water
wastage, along with the
installation of waterless urinals.
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42,749 kiloliters of treated water from the STP was reused.
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Eco-friendly Bricks and Paver
Blocks Production
The brick and paver block making machine, with a capacity of
200 units per day and
operating on average for 24 days per month, produces
approximately 57,600 bricks and paver
blocks annually across 288 operational days. Each brick or
paver block weighs an estimated
2.8 kg.
Composition and
Waste Material
Utilization
The production process utilises materials in the ratio of 30%
plastic, 35% sand, and 35%
dust. For instance, a single 2.8 kg product consists of 840
grams of plastic, 980 grams of
sand, and 980 grams of dust. Alternatively, a ratio of 20%
plastic, 40% sand, and 40% dust
can also be used.
Annual Waste Material
Utilization
- Plastic:
Approximately 48 tonnes of waste HDPE bags
recycled.
- Sand: Approximately
56 tonnes of waste silica sand recycled.
- Dust: Approximately
56 tonnes of waste dust recycled.
- Total Waste Material
Recycled: 160 tonnes annually.
Revenue
Generation
The initiative generates revenue amounting to ₹
2,88,000 through the
conversion of waste into wealth (calculated at
₹ 5 per unit, with 57,600
units produced).
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Approximately 160 tonnes of waste reused to produce 57,000
bricks and blocks, generating
revenue of ₹ 2,80,000.
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Recycling Foundry Sand in Cement Industry for Co-processing:
Discarded molding sand from
foundries is a solid waste and a by-product of our
production process. We have established
a Memorandum of Understanding (MOU) with Ambuja Cement
Limited (Adani Group Co.) to offer
a sustainable solution for managing this sand waste. The
discarded sand waste is reused in
cement manufacturing through co-processing, ensuring
compliance with regulatory standards
and adhering to the highest Occupational Health and Safety
(OH&S) norms. Ambuja Cement
safely utilizes AIA's generated waste in its cement kilns
located at Kodinar, Dist. Gir
Somnath, Gujarat.
Sustainable Waste Disposal & Certification: For each
batch of waste co-processed at
Ambuja Cement, they issue a disposal certificate detailing
the quantity of waste utilized.
In total, 16,307 tonnes of foundry waste sand were
co-processed at Ambuja Cement Limited.
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Total: 16,307 metric tonnes of foundry waste sand were
utilized for co-processing at
Ambuja Cement Limited (a company within the Adani Group).
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Slag Processing Unit - We reprocess slag in our dedicated
slag processing plant to
recover metal, which is then reused as raw material in our
foundry operations. In the
reporting period, we processed a total of 12,922 metric
tonnes of slag in the plant,
recovering a total of 1,099 tonnes of metal for reuse in
casting production.
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A total of 12,922 metric tonnes of slag underwent processing
at our Slag Processing
Plant, resulting in the recovery of 1,099 tonnes of metal
that was subsequently reused in
our plant for casting production.
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Energy Reduction
Initiatives in F.Y. 2023-24:
- Efficient machine usage
resulting in energy savings: 710,054 units saved
(kWh/annum).
- Technology upgrade resulting in
energy savings: 5,40,296 units saved (kWh).
- Optimization of temperature and
pressure through technology upgrades: 3,90,640 units
saved.
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Total energy saved per annum: 1,640,990 kWh.
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Carbon reduction initiative through the use of innovative
heaterless vaporizers in LPG
installations at our major GM plants has resulted in an
estimated accumulated carbon
offset of 221 metric tonnes of CO2 per manifold
per year.
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The estimated accumulated carbon offset from both sets is 442
metric tonnes per year.
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AIA through its CSR Foundation, in partnership with the ARC
Foundation Gandhinagar, has
launched a significant tree plantation campaign aimed at
reducing GHG emissions. To date,
a total of 470,000 trees have been planted, including
approximately 100,000 trees in the
year F.Y. 2023-24. These plantations are located at various
sites such as BDE-Chiloda,
Deesa-BSF, Chiloda Air-Force Colony, Air Force Recruitment
Board Gandhinagar, Ahmedabad,
Military Cantonment Board Baroda, and Baroda Air Force.
Quarterly assessments are
conducted to evaluate the impact of this initiative. The
tree plantation effort is ongoing
and forms a continuous programme for AIA.
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Approximately 2,500 metric tonnes of CO2
equivalent greenhouse gases are
estimated to be reduced per year for every 10,00,000 trees
planted.
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