The Ramco Cements Limited RR Nagar P.M.RAMASUBRAMANIAN GM Process & QC V.SURESH Sr. Manager - Process S.V.Veeraraghavan Asst.Manager-Electrical
Salient Futures of Ramasamy Raja Nagar Unit A flagship company of RAMCO Group, having five Cement manufacturing and 4 Grinding units with a capacity of 16.5 MTPA We are the leaders in First to introduce latest technologies like Surface Miner, Vertical roller mill, SF cross bar cooler, Limestone Beneficiation Plant, Optical sorter, Cross Belt Analyser, X-Ray analyser, ESPs, Cambidan Mill etc., Manufacturing 100% Portland Pozzolana Cement In 1976, we were the first to introduce 1200TPD Dry process kiln in South India.
Integrated Management System Certification IS/ISO 9001: 2008 Quality Management System IS/ISO 14001: 2004 Environment Management System IS 18001: 2007 IS/ISO 50001: 2011 Occupational Health & Safety Management System Energy Management System (Implemented awaiting for Certification) 5S Workplace Management System 3
ENCON PROJECTS WITH ZERO INVESTMENT No. of Projects : 31 Savings on Electrical Energy Savings on Thermal Energy Total Cost savings : 38.34 Lakh Kwh : 1595 MT of Coal : Rs.239.7 Lakhs
ENCON Projects with Zero Investment Sl.No ENCON Projects Implemented for the year 2014-15 Savings (Rs. in Lakhs) 1 Modification of Y piece in kiln -1 secondary firing circuit 53.04 2 Reduction of excess air in TPP Boiler from 16 % to 12 % 13.43 3 Interlinking of stacker and reclaimer compressor line 7.18 4 Optimization of set point and arresting air leaks in Kiln-2 CF Silo compressor 2.77 5 Removal of damper in Cement mill vent bag filter fan 1.63 6 Modification of raw meal silo extraction screw 1.63 7 Optimization of set point and arresting air leaks in Cement mill roller press compressor 0.88
ENCON Projects with Zero Investment Sl.No ENCON Projects Implemented for the year 2014-15 Savings (Rs. in Lakhs) 8 Optimization of set point and arresting air leaks in Packing plant compressor 0.85 9 Reduction of blower run hours in Blending & storage silo 0.65 10 Optimization of set point and arresting air leaks in Cement silo compressor 0.42 11 Installation of GRR in Raw mill VRMP Main motor 0.41 12 Reduction of Raw mill VRMP Circulating air fan speed by process optimization 0.16 13 Interlinking of compressors in raw grinding circuit 0.16 14 Optimization by stopping the aeration blower in Cement intermediate feed bin 0.15 15 Optimization by stopping the aeration blower in Fly ash feed bin 0.15
ENCON Projects with Zero Investment Sl.N o ENCON Projects Implemented for the year 2015-16 Savings (Rs. in Lakhs) 1 Installation of VFD in Kiln-1 primary firing blower 39.7 2 Productivity optimization in Raw mill 34.0 3 Productivity optimization in kiln 20.9 4 Reduction of idle run hours in fly ash unloading 11.9 5 Removal of Damper in Cement mill Bag house fan 3.7 6 Replacement of reciprocating compressors in Packing Plant 2.9 7 Compressor air usage optimization 2.8 8 Removal of Damper in Raw mill-1 Separator fan 2.1 9 Removal of Damper in Raw mill-1 Hot gas fan 1.0
ENCON Projects with Zero Investment Sl.No 1 2 ENCON Projects Implemented for the year 2016-17 Reduction of False air and Elimination of Top Cyclone Water spray in Kiln-1 Preheater fan Improvement of excavator productivity and reduction of fuel consumption by reducing the marching time Savings (Rs. in Lakhs) 3 Reduction of False air in Kiln-2 Preheater from 11 % to 8.5 % 5.6 4 Removal of Damper in Roller press bag house fan 4.2 5 Replacement of de-dusting ducts in Kiln Tunnel venting bag filter 1.4 14.1 9.9 6 7 Elimination of DG operation in SVP-North mines and switch over to electrical supply by upgrading the existing transformer Elimination of unnecessary pipeline in the pump delivery to reduce the line losses 1.3 0.7
ENCON PROJECTS WITH INVESTMENT No. of Projects : 19 Total Cost Investment : 256 Lakhs Savings on Electrical Energy : 25.1 Lakh Kwh Savings on Thermal Energy : 938 MT of Coal Total Cost savings : Rs.130.5 Lakhs
ENCON Projects with Investment S. No ENCON Project Implemented for the year 2014-15 Savings (Rs. in Lakhs) Investment made (Rs. in Lakhs) 1 Installation of GRR in Raw mill ball mill Separator fan 29.4 9.0 2 Installation of Pillard Burner in Kiln-1 26.5 43.0 3 Optimization by modifying the Kiln -2 raw meal feeding circuit 11.1 0.5 4 Installation of VFD in Raw mill ball mill hot gas fan 4.9 7.0 5 Installation of VFD in Cement mill vent bag filter fan 4.9 3.5 6 Optimization of ejector input in Thermal power plant 3.5 2.0 7 Reduction of pulley size in kiln feed extraction blower 1.6 0.1
ENCON Projects with Investment S. No ENCON project implemented for the year 2015-16 Savings (Rs. in Lakhs) Investment made (Rs. in Lakhs) 8 Installation of VFD in Kiln-1 bag house fan 5.6 3.5 9 Installation of VFD in Kiln-2 ESP fan 5.6 13.0 10 Elimination of Elevator in raw mill limestone feeding circuit 5.3 104.0 11 Installation of new dilution damper in Kiln-1 bag house 1.4 1.0 12 LED lights replaced in place of Sodium vapour & fluorescent lamps 0.3 1.6
ENCON Projects with Investment S. No ENCON Project Implemented for the year 2016-17 Savings (Rs. in Lakhs) Investment made (Rs. in Lakhs) 13 Installation of gas analyser in Kiln-2 inlet 17.9 10.0 14 Compressor stopped in Kiln bag filter by inter linking 7.0 0.5 15 Installation of VFD in Raw mill-1 Vent fan 5.6 25.0 16 Installation of VFD in Primary Air fan of Thermal Power Plant 4.2 15.0 17 Installation of VFD in Kiln-2 Primary air fan 2.8 9.0 18 Transmission Loss reduced in Mines power line 2.5 7.0 19 A/C unit system Replaced with Split A/C 1.9 1.6
Kcal/Kg Clinker Specific Thermal Energy Consumption 740 735 730 720 721 710 700 705 690 2014-15 2015-16 2016-17
Kwh / MT Cement Specific Electrical Energy Consumption 82 81.23 80 78 76 76.60 74 72 70 68 73.78 72.20 2013-14 2014-15 2015-16 2016-17
Kcal/Kg Cement BEE PAT Scheme 840 820 800 902 828 Gate to Gate Energy Consumption 820 806 780 760 740 720 700 761 2013-14 2014-15 2015-16 2016-17 PAT Target
Sl.N o ENCON Projects Planned for the year 2017-18 Expected Electrical Saving (Kwh/Year) Expected Thermal Saving (MT/Year) 1 Installation of Pillard burner for Kiln-2 35,160 430 2 ENCON Projects Proposed Reduction of DP in Kiln -1 Bag house by modifying purging pipes 1,20,600 3 Installation of occupancy sensor in kiln substation 7,008 4 Installation of VFD in Kiln-2 primary firing blower 36,000 160 5 Installation of VFD in Coal mill 1 Hot gas fan 40,200 6 Installation of VFD in Coal mill 2 Bag filter fan 80,400 7 Installation of VFD in Coal mill 2 Hot gas fan 40,200 8 Installation of VFD in Coal mill 2 Bag filter fan 80,400
ENCON Projects Proposed Sl.N o ENCON Projects Planned for the year 2017-18 Expected Electrical Saving (Kwh/Year) 9 Installation of VFD in VRM Venting bag filter fan 1,20,600 10 Installation of VFD for feed water pump 7,23,600 11 12 13 14 15 Compressor optimization in Kiln-1 & 2 by inter linking LED light replacement in place of Conventional lights Replacement of reciprocating by Screw compressor in Coal mill 2 bag filter Installation of Energy efficient motor for primary crusher To install capacitor at the pump switch board to boost voltage for the dewatering operation 1,60,800 20,100 24,120 80,400 40,200 Expected Thermal Saving (MT/Year)
Baseline 2014-15 2015-16 2016-17 Road Map To Reduce Carbon Foot Print Activities Year Scope 1 Emissions CO 2 e (MT) Scope 2 Emissions CO 2 e (MT) Scope 3 Emissions CO 2 e (MT) kg CO2e/MT of cement Baseline 9,55,158 1,21,410 35,738 893 2014-15 9,67,956 3,78,350 44,246 891 2015-16 11,47,927 2,24,008 50,252 834 2016-17 10,98,303 1,42,932 55,121 752 We have reduced 17.0 % Carbon Emissions compared with baseline year. Further to reduce carbon emissions we have planned the following: 1. Installation of high efficiency Pillard Burner for Kiln-2 900 850 800 750 700 650 2. Installation of stacker & Reclaimer for Limestone and Fuel
Renewable Energy Replacement of Electrical Energy with Renewable Energy Annual Energy Generated (Lakhs kwh) 2014-15 2015-16 2016-17 % Share Annual Energy Generated (Lakhs kwh) % Share Annual Energy Generated (Lakhs kwh) % Share Wind 2312.4-1807.0-3013.4 - During the year 1996, wind mill installed capacity is 33.235 MW, which was the Single Largest Wind Farm in the South East Asia. Present Capacity is 160 MW Replacement of Thermal Energy with Renewable Energy Equivalent Fuel Saving (Lakhs Kcal) 2014-15 2015-16 2016-17 % Share Equivalent Fuel Saving (Lakhs Kcal) % Share Equivalent Fuel Saving (Lakhs Kcal) % Share Biogas - - - - 95.8 12.9
Utilization of Waste as Fuel 2014-15 2015-16 2016-17 Name of the Fuel Quantity (MT) Waste fuel as % of Energy used Quantity (MT) Waste fuel as % of Energy used Quantity (MT) Waste fuel as % of Energy used TPP Coal Ash 485 0.45 2192 1.77 9133 4.97 Saw Dust 28 0.02 - - - - Wood Chips - - - - 308 0.17
Innovative Project - 1 : Optical sorter
Constraints in present operation Presently we are mining crystalline limestone from our four captive mines. The limestone contains average of 18% of black stone. We are adding Imported limestone and High grade limestone as sweetener to meet the Quality Requirement. There are three magnetic separators in our mines after the crusher, which is used in removal of a part of black stones from limestone which are magnetic in nature. As a result, of the total 18% black stones, out of which 16% of black stones are non magnetic will remain in the product even after separation. Hence the quality of limestone will be inferior by a greater extent.
Optical sorter - Overview Introduced State of the Art Technology Optical Sorter which separates the Blackstone from Limestone on the basis of colour of the material. There are three sorters classified based on their handling sizes, namely Primary sorter Secondary sorter Tertiary sorter : 75 mm to 250 mm : 30 mm to 75 mm : 10 mm to 30 mm
Performance Improvement & Benefits achieved The black stone content in the limestone has been reduced to less than 2% thereby usage of Imported / High Grade limestone is totally avoided. We have consumed 36,746 MT of low grade Limestone which enhanced the limestone recovery from 78 to 86% resulted increase in Mines life The savings in limestone cost by avoiding Imported limestone is 60/- Per MT. The overall savings is 9 Crores per annum and the payback is less than 2 years.
Innovative Project - 2 : Drum Diverter in place of Motorized Diverters In our packing plant, we have motorised belt diverter for diverting bags in to the loading point Based on truck availability & loading machine availability the diverter is changed for the loading point. One discharge point is having two loading machines. In our operation, it needs to divert the bags several times. The belt diverter is stopped frequently, bags gets jam in diverter and thus affected the packer performance due to the following reasons Drive bearing failure Idler damage Geared motor pinion damage and Diverter belt problem
In-house Powerless Drum An innovative drum diverter locally designed, fabricated and installed in place of motorised diverter Power Saving : 16,630 units/ annum Maintenance Cost Saving : Rs. 0.42 Lakhs/annum
Innovative Project - 3 : Overhead Transmission Line to Mines Crushing plant The crushing plant is located 23 Kms from the factory at our Pandalgudi Mines. The average power requirement for operation of this plant is 1.5 MVA. This power requirement was fulfilled with TNEB power & Diesel Generators. We had frequent power failures, power fluctuations, high power cost resulting in lower productivity and higher limestone cost. To over come these issues, we have decided to provide power from our 25 MW power plant available at factory. 11 KV overhead line was laid and power transmitted across 23 Kms with 470 poles. Benefits : Run hours of crushing plant improved from 14 hours per day to 18 hours per day. Productivity improved from 242 TPH to 273 TPH Cost savings : Rs.24.87 Lakhs/annum
Team Work Project 1 : Kiln-1 feed extraction screw modification There are 2 nos. of 47 meters length screw conveyor in our kiln feed extraction We have faced the following problems in the screws Screw cut off, Connecting shaft damage and Hanger bearing failure One of the Mechanical Engineer suggested to reduce the screw length from 47 to 18 meters and provide the air connection from existing blowers Due to reduction in screw length the power consumption is reduced Power Saving: Cost Saving : 32160 Units/annum Rs. 11.25 Lakhs/annum
Team Work Project - 2 : Prevention of Coal mill inlet jam In Kiln 1 Coal mill, we frequently noticed coal accumulation in the inlet chute. Due to this accumulation the productivity of the mill was poor and there was occasional firing of the accumulated coal. Engineer suggested the idea to modify the inlet feed chute by providing a guide plate to uniformly feed coal to the mill without accumulation. Implementation of that idea resulted in the reduction of coal mill run hours from 15:30 Hours to 15:00 hours a day. Power Saving : 89700 Units/annum Cost Saving : Rs. 2.71 Lakhs/annum
Team Work Project - 3: Cement Bag Weight optimization We are operating two 12-spout packer supplied by M/s. FLSmidth with Ventomatic electronics. Due to frequent additional dosing the productivity of the packer was low. Instrumentation & Mechanical workmen together gave an idea to provide an additional dosing valve so that the slide gate cylinder opening is controlled during fine feed. Implementation of that idea resulted in increased productivity by 5%. Power Saving : 1.2 Lakh units/annum Cost Saving : Rs. 3.72 Lakhs/annum
Team Work Project - 4: Coal Ash feeding system for Raw meal In Raw mill, our TPP Coal ash was fed for silica correction by mixing the same in limestone yard and feeding to the hopper. Our Engineer suggested the idea to provide a dedicated Loss-in-weight system for feeding TPP Coal ash to Rawmill. Implementation of that idea resulted in uniform feeding of coal ash for silica correction which improved the quality of Clinker. Improvement in Clinker quality resulted increase in fly ash addition by 0.5% in Cement Power Saving : Net Cost Saving : 0.28units/ Ton of Cement Rs. 51.0 Lakhs/annum
Environmental Projects Sl. No List of the Major Environmental Projects Investment (Rs. Lakhs) 1 12 Nos. of unit bag filters installed in Mines crusher area 638.0 2 3 4 5 6 Surveillance camera is located at all the hopper discharge and transfer points to monitor and avoid any spillage External Clinker Unloading hopper and Packer-2 de-dusting bag filter capacity increased from 25000 to 55000 m3/hr Dramix fibre Concrete road at lorry yard of 10,000 sq.m, to reduce the fugitive dust generation. Concrete road development for 3000 sq.m. to reduce the fugitive dust generation Additionally 5 Nos. of de-dusting bag filters are installed in Raw mill & Coal mill area 300.0 250.0 170.0 30.0 25.0 7 High efficiency bag filter installed in Coal mill-2 18.0
Environmental Projects Sl. No 8 9 10 11 12 List of the Major Environmental Projects New de-dusting bag filter for Kiln-2 coal firing to avoid fugitive dust emission Gas analyzer is installed at the kiln inlet, to monitor the kiln condition and thereby improve the combustion, and to predict the quality of clinker Re routing of de-dusting ducts in Roller press to avoid the fugitive dust generation 16 Nos. of Solar lights in place of 16 Nos. of Sodium vapour lights in Colony 60 Nos. of LED lights in place of tube lights, Sodium vapour lights and BC Bulbs in Colony and Guest house Investment (Rs. Lakhs) 8.0 6.0 3.0 4.0 2.92 13 Dust suppression system for coal storage yard to avoid dust emission 0.75 14 CO reduction in Kiln preheater by reducing secondary firing coal pipe bends 0.5
Future Environmental Projects Sl.No 1 List of the Future Environmental Projects 5 Nos. of additional Dust Collectors for transfer points at plant Investment (Rs. Lakhs) 220.0 2 2 Nos. of Dust Collectors for transfer points at mines crushing plant 90.0 3 Stacker & Reclaimer with closed shed for Coal 48.0 4 Stacker & Reclaimer with closed shed for Limestone 35.0 5 15 Nos. LED lights in place of Conventional lights 0.67
Green Belt development Sl. No Location Area in Acres 2016-17 Up to 2017 No. of Trees Area in Acres No. of Trees 1 Mines 20 12,200 253 2,53,700 2 Factory 15 9000 38.7 14,750 3 Colony 2 2000 11.1 5,060 4 School 7 3000 23 7,500 5 Nearby Villages 11 7500 54.8 25,760 Grand total 55 33,700 380 3,06,770