IMPLEMENTATION OF ISO 50001:2011 & BEST PROJECTS ON ENERGY CONSERVATION @ THE RAMCO CEMENTS LIMITED JAYANTHIPURAM
Ramco Group Cement Ready Mix Concrete Cement Fiber Products Cotton and Synthetic Yarn Software Systems Total Employees : 15,000 Wind Farms Research & Development Dry Mortar Plants Cotton Textiles Surgical. Turnover : Rs. 6,700 crores The Ramco Cements Ltd., (formerly Madras Cements Ltd.) Integrated Plants : 1. RR Nagar Plant near Virudhunagar, TN (2.0MTPA) (Established in 1959) 2. KSR Nagar Plant, Jaggaiahpeta, Andhra Pradesh (3.65 MTPA) (Estd. in1986), Turnover-662 crores, No. of Employees- 431 3. Alathiyur near Vridhachalam, Tamil Nadu (3.0 MTPA) (Established in 2002) 4. Mathod near Chitradurga, Karnataka (0.3 MTPA) (in Operation since 2000) 5. Ariyalur, Tamil Nadu (5.5 MTPA) (Established in 2009). Cement Grinding Units : Packing Unit : 1. Kattuputtur (0.75MTPA) 2. Valapadi (2.0 MTPA) 3. Kolaghat (1.0 MTPA) 4. Vizag (0.95 MTPA) 1. Nagercoil,TN 2
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ENERGY ROAD MAP Quarterly review of Energy Consumption target & Achievement 2 New Teams Monthly Project & Energy Consumption Discussion & Review 11 Teams formed Monthly Project Discussion & Review 4 Road Map
MANAGEMENT SYSTEM CERTIFICATES 5
Energy Conservation Organization APEX COMMITEE Sl. No. Name Designation 01 Sri PB Gopalakrishna Sr. President - Mfg. 02 Sri T Sridhar Reddy Asst. Vice President - Works 03 Sri AV Satyanarayana Sr. Mgr.- Mech. CORE COMMITTEE Sl. No. Name Designation 01 Sri S Rajasekharan GM Process & Quality Control 02 Sri D Sitaramaiah Dy. GM - Mech. 03 Sri S Kesavaperumal Dy. GM Inst. 04 Sri V Venkatapathi Asst. GM Elec. 05 Sri VV Trinadha Rao Asst. GM - Elec. 06 Sri SVSN Raju Sr. Manager - Mech. 07 Sri P Sreekanta Reddy Manager Inst. 08 Sri R Venkatapathi Gupta Dy. Manager - Mech. 09 Sri Chandan Kumar Parasar Dy. Manager - Process 10 Sri M Sreedhar Asst. Manager - Elec. 6
SAVINGS ACHIEVED Year Savings (Lakh KWH) 2012-13 10.50 2013-14 7.25 2014-15 40.84 2015-16 17.91 10
ENERGY CONSERVATION ACTIVITIES Competitions are being conducted twice in a year on Energy Conservation Day (December,14 th ) & Our Founder s Day (April,24 th ). These Competitions include: Energy Conservation Projects Presentation among Energy Teams. For employees, contract workmen, ladies club members, school children: Slogans, Essays, Paintings, Skit programs, etc. 12
ENERGY CONSERVATION ACTIVITIES The winners are felicitated with suitable rewards / awards. As a motivation for energy conservation, LED Bulbs are being distributed as gift to: Apex Committee Members Core Committee Members All Energy Team members 13
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ENERGY PERFORMANCE IMPROVEMENT Sl. No Description Units 2014-15 2015-16 1 MTOE reduction MTOE -- -- 2 Kiln Thermal SEC kcal/kg clinker 727.26 710.15 3 Specific Electrical Energy - clinkering kwh/t of clinker 58.17 58.50 4 Specific Electrical Energy Grinding (Inc of OPC & PPC) Capacity Utilization KWH/T of Avg Cement 35.01 36.18 Clinker (%) 32.95 23.04 Cement (%) 50.75 36.48 5 CPP Heat rate kcal/kwh 3175.56 2868.51 6 CPP auxiliary consumption % 11.61 12.07 7 Thermal Substitution Rate % 0.05 0.15 8 Clinker factor % 78.11 75.72 9 Blended cement *%) of total cement % 64.57 68.25 10 Renewable Energy (RPO) -- -- 11 REC Purchased Solar REC -- -- 12 REC Purchased Non Solar REC -- -- 13 Specific CO2 emission Kg CO2/ kg cement 0.67 0.65 15
TOP TEN ENERGY PROJECTS IN 2015-16 S.No Project Details Savings achieved in KWh (Upto 31-03-16) (Rs. In Lacs) Remarks 1 To stop the 500T bin feed bucket elevator, elevator receiving and discharge airslides while one kiln is running with respect to 500T bin level. 28536.00 1.12 2 Removal of Line 2 Cooler Fans (6 Nos) Silencer. 196600.20 7.71 3 Stopping of line 2 TAD Damper Cooling Blower for In-filtration of False Air while Damper Worn Out (0.9 TPD of Coal Consumption + Saving of Rs. 4.21 Lakhs after replacement of Present Hollow Damper with Plate Damper) 9750.02 9.02 Power Cost Saving : 38220.06 [ 4.5 KW/hr (Power Saving) * 2166.67 Hrs (Kiln Run Days) * Rs. 3.92/KWH (Unit Cost)] Material Cost Saving : 420632.87 [Rs. 949512.87 (Hollow Damper Cost Inc Castable) - 5, 28,880.00 (Plate Damper Cost Inc Castable)] Fuel Cost : 443440.17 (0.90 TPD of Coal Saving * 81 Run Days * Rs. 5474.57/ MT of Annual Fuel Cost) Total Saving : 902293.10 4 To reduce Line 2 Cooler esp fan power by optimizing the cooler esp fan speed through providing modified auto loop with Kiln Hood Draft 56131.25 2.20 5 Replacement of SV lamps with LED fittings -100 nos in silo's and work shop. 43560.00 1.71 16
TOP TEN ENERGY PROJECTS IN 2015-16 S.N o Project Details Savings achieved in KWh (Upto 31-03- 16) (Rs. In Lacs) Remarks 6 Power reduction by reducing run hours of Plant incoming 180 kw pump by installing level indicator at TPP tank & running 132 kw pump during tank high level.low level indicator at 4.5 mts and high level indication at 6.0 mts 78492.00 3.08 7 Reduce the Fuel consumption in Wheel Loaders by Reducing it's maximum Engine RPM from 2300 tom 2150. HSD saving - 5336 Liters 2.80 8 To reduce the power consumption of North Band Mines Dewatering pumps by increasing the suction pipe size.(8" to 10") 46605.00 1.83 9 To increase the pump discharge quantity of plant water supply pump (132KW) by interchanging the delivery pipe line.(6" to 10" size) 74480.00 2.92 10 Optimization of cooling tower and condenser performance to reduce the specific steam consumption. 947576.00 37.14 Condenser-2 Re-tubing (19/09/15) Nozzles & Adaptors replacement (31/10/15) Cooling tower Fills replacement U/P 17
Removal of Line-2 Cooler Fans Inlet Silencers Before After ΔP : 35-180 mmwg ΔP : 21-56 mmwg Unit Savings : 1320 KWH/Day Cost Savings : Rs. 17.82 Lakhs/Annum Sound: 74-76 db 19
Modification of Line II Tertiary Air Duct Damper Design Kiln Feed TA Duct Kiln 21
Kiln 22
TA Duct Damper Blower Running for TA duct Damper Cooling TERTIARY AIR DUCT
Blower Idle Running
New TA DUCT DAMPER Unit Savings : 108 KWH/day Fuel Saving : 1 TPD Total Cost Savings : Rs. 9.02 Lakhs/Annum Material Cost Saving : Rs. 420632.87 TERTIARY AIR DUCT
INNOVATIVE ENERGY CONSERVATION PROJECTS Replacement of LRS with GRR in Cement Mill Separator Fan Description : The Mill Separator Fan is running in LRS with Damper Opening of 65-70% only to get the required flow. But the Pressure Loss across the Damper was maintaining in the range of 130-150 mmwg. During the Line-1 Upgradation we have reused the spare GRR from our Coal Mill Fan to this separator Fan. After GRR installation, we are now running the fan with full damper opening by controlling the speed. With this the Pressure Loss across the damper has reduced to 15-20 mmwg only & the Power saving achieved to 55 KW. Savings (KWH) : 660 KWH/Day Cost Savings (INR) : Rs. 9.42 Lakhs/Annum Project Investment : In House shifting only 27
RENEWABLE ENERGY PROJECTS Sky Lights were installed at the areas like Store Room, Packing Plant Bag Storage Area, Workshop, Wagon Loading Platforms, Instrument Panel room etc to control the Day time lighting Power Consumption. Total No of SV Lamps switched off during Day time : 50 Nos Each Lamps Power Consumption : 0.40 KW Saving Achieved : 0.40 KW*50 Nos.*12 hrs = 240 KWH/Day : Rs. 3.50 Lakhs/Annum 30
BEST PRACTICES ON ENERGY CONSERVATION Engaged CSIR-CSIO, Chennai to study the Performance/Efficiency of significant motors regularly. Water Audit was conducted to establish water consumption in Plant & Mines, there by reduced the power consumption of Water Pumps. Compressed Air Audit is being conducted to optimize Air Consumption. Energy Efficient motors only are being procured for any future. Next 31
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BEST PRACTICES ON ENERGY CONSERVATION 100 % High Sulfur (>9%) Petcoke usage as a Fuel in Pyro System Specific Coal Consumption has reduced by 4.5% (From 14% to 9.5%) Coal Mill Specific Power Consumption also reduced by reduction in the Coal requirement Before with Imp Coal : 4.5-5.0 KWH/T Clinker After with Petcoke : 3.8-4.0 KWH/T Clinker 33
BEST PRACTICES ON ENERGY CONSERVATION (PROJECT UNDER IMPLEMENTATION) Replacement of Flyash Bulk tanker unloading Conventional Screw Compressor with Energy Efficient Low Pressure Lube Compressor Description : Replacement of existing 110 kw Screw Compressor with 55 kw energy efficient Godrej make Screw Compressor Total Projected savings (KWH) : 331730 Cost Savings (INR) : 1393266 Cost savings in maintenance Rs. : 80000 Total annual saving Rs. : 1473266 Project Investment Rs. : 13,00,000 Payback : 11 months 34
PROPOSED LOW PRESSURE LUBE COMPRESSOR OF M/S GODREJ MAKE- (55KW) 35
BEST PRACTICES ON ENERGY CONSERVATION IN (PROJECT UNDER IMPLEMENTATION) Line-1 Up-gradation Capacity enhancement from 3500 TPD to 4600 TPD by New ABC Cross Bar Cooler with HRB New Additional Preheater Installation New ESP to reduce the Dust Emission from 50 mg/nm 3 to <30 mg/nm 3 Thermal energy savings : 30 Kcal/Kg clinker Electrical energy savings : 5.10 KWh/T Clinker Project Under Progress 36
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