Presentation onProductivity of

The Ramco Cements LimitedRamasamy Raja Nagar Unit

ISO 9001ISO 14001 &

IS 18001

Presentation onProductivity of

The Ramco Cements LimitedRamasamy Raja Nagar Unit

Capacity Utilisation

Sl.NoProduction and capacityutilization details

UOM 2013-2014 2014-2015 2015-2016

1Annual Installed ProductionCapacity (Clinker)

Tonne 1000500 1000500 1000500

2Annual Installed ProductionCapacity (Cement)

Tonne 1741590 2000000 20000002Annual Installed ProductionCapacity (Cement)

Tonne 1741590 2000000 2000000

3 Total Clinker Production Tonne 739722.07 624068.3 926065

4Total Cement Production(Allvarieties)

Tonne 1247064.02 1558069 1704495.3

5 Capacity utilisation(Clinker) % 73.94 62.38 92.56

6 Capacity utilisation(Cement) % 71.60 77.90 85.22

Page 1

Conservation of Raw Materials & Fuels

a) Use of alternate raw materials

b) Use of Alternate Fuel

c) Amount of Waste Heat recovery powergenerated – Not applicable

Sl.No Material description UOM 2013-14 2014-15 2015-16

1 Power Plant Ash Tonne 2,724 5,989 4,255

2 Slag Tonne 15,839 66,175 36,678

a) Use of alternate raw materials

b) Use of Alternate Fuel

c) Amount of Waste Heat recovery powergenerated – Not applicable

Page 2

2 Slag

Sl.No Material description UOM 2014-15 2015-16

1 Power Plant Ash Tonne 485 2637

Approach to theImplementation of Best

Practices

Energy Conservation Best practices

Approach to theImplementation of Best

Practices

Energy Conservation Best practices

Page 3

ENCON best practices ImplementedENCON best practices Implementedwithout Investmentwithout Investment

Sl.NoSl.No YOIYOI ENCON best practices Implemented without InvestmentENCON best practices Implemented without InvestmentSavings inSavings in

LakhsLakhs1 2013-14 Optimization of Raw Mill VRMP 107.72 2013-14 Air balance optimization in Raw mill VRMP separator circuit and in Kiln-1 19.33 2013-14 Optimization of false air level in Kiln 1 preheater 3.34 2013-14 Optimization of coal mill power by auto stop sequence mode 1.65 2013-14 Optimization by re-routing of pipe lines in Roller press compressor area 1.36 2013-14 Optimization of lighting levels in all office areas 16 2013-14 Optimization of lighting levels in all office areas 17 2013-14 Optimization of Set point & air leak arresting in Packing plant 1 compressor 0.98 2013-14 Optimization of Set point & air leak arresting in Packing plant 2 compressor 0.89 2013-14 Cleaning of Blending silo to reduce the blower run hours 0.8

10 2013-14 Optimization by stopping air slide blower in Kiln feed elevator section 0.3

11 2013-14 Optimization by stopping the raw water pump 0.312 2013-14 Reduction of run hours in Effluent transfer pumps 0.313 2013-14 Optimization by stopping the CT pump 0.1

14 2014-15 Modification of Y-piece in kiln-1 secondary firing circuit 5315 2014-15 Reduction of excess air in TPP Boiler from 16 % to 12 % 13.416 2014-15 Interlinking of stacker and reclaimer compressor line 7.2

Page 4

Sl.No YOI ENCON best practices Implemented without InvestmentSavings in

Lakhs17 2014-15 Modification of raw meal silo extraction screw 1.618 2014-15 Removal of damper in Cement mill vent bag filter fan 1.619 2014-15 Optimization of set point and arresting air leaks in Cement mill compressor 0.920 2014-15 Optimization of set point and arresting air leaks in Cement silo compressor 0.421 2014-15 Reduction of Raw mill VRMP Circulating air fan speed by process optimization 0.222 2014-15 Interlinking of compressors in raw grinding circuit 0.2

ENCON best practices ImplementedENCON best practices Implementedwithout Investmentwithout Investment

22 2014-15 Interlinking of compressors in raw grinding circuit 0.223 2014-15 Optimization by stopping the aeration blower in Cement intermediate feed bin 0.124 2014-15 Optimization by stopping the aeration blower in Fly ash feed bin 0.125 2015-16 Installation of VFD in Kiln-1 primary firing blower 39.726 2015-16 Productivity optimization in Raw mill-2 3427 2015-16 Productivity optimization in kiln-1 20.928 2015-16 Reduction of idle run hours in fly ash unloading 11.929 2015-16 Removal of Damper in Cement mill Bag house fan 3.730 2015-16 Replacement of reciprocating compressors in Packing Plant 2.931 2015-16 Compressor air unwanted usage optimization 2.832 2015-16 Removal of Damper in Raw mill-1 Separator fan 2.133 2015-16 Removal of Damper in Raw mill-1 Hot gas fan 1

Page 5

ENCON best practicesImplemented with Investment

S.No YOI ENCON best practices Implemented with InvestmentSavings in

Lakhs

Investmentmade in

Lakhs1 2013-14 Installation of Roller Press as a pre-grinder in Cement mill 489.6 10,0002 2013-14 Separate grinding of Coal & Pet Coke 51.1 0.053 2013-14 Installation of SPRS for raw mill VRM Circulating Air fan 19.6 4.64 2013-14 Installation of coal mill 2 main bag filter 15.2 25 2013-14 Installation of VFD in CEP 10.9 25 2013-14 Installation of VFD in CEP 10.9 26 2013-14 Optimization of compressor in Kiln feed CF silo 2.8 0.057 2014-15 Installation of Pillard Burner in Kiln-1 26.5 438 2014-15 Optimization by modifying the Kiln -2 raw meal feeding circuit 11.1 0.59 2014-15 Installation of VFD in Raw mill ball mill hot gas fan 4.9 7

10 2014-15 Installation of VFD in Cement mill vent bag filter fan 4.9 3.5411 2014-15 Optimization of ejector input in Thermal power plant 3.5 212 2014-15 Reduction of pulley size in kiln feed extraction blower 1.6 0.0513 2015-16 Installation of VFD in Kiln-1 bag house fan 5.6 3.514 2015-16 Elimination of Elevator in raw mill limestone feeding circuit 5.3 10415 2015-16 Installation of new dilution damper in Kiln-1 bag house 1.4 116 2015-16 LED lights replaced in place of Sodium vapour & fluorescent lamps 0.3 1.6

Page 6

Best practices to reduceenvironmental impact

7 Nos. of unit bag filters installed in Mines crusher area 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 fiber 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 2 Nos. of de-dusting bag filters are installed across the plant Installation of high efficiency bag filter in Coal mill-2 New de-dusting bag filter for Kiln-2 coal firing to avoid fugitive dust emission NOx analyzer is installed at the kiln inlet, to 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 65 Nos. of LED lights in place of tube lights, Sodium vapour lights and BC Bulbs in Colony and Guest

house Dust suppression system for coal storage yard to avoid dust emission CO reduction in Kiln preheater by reducing secondary firing coal pipe bends

7 Nos. of unit bag filters installed in Mines crusher area 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 fiber 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 2 Nos. of de-dusting bag filters are installed across the plant Installation of high efficiency bag filter in Coal mill-2 New de-dusting bag filter for Kiln-2 coal firing to avoid fugitive dust emission NOx analyzer is installed at the kiln inlet, to 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 65 Nos. of LED lights in place of tube lights, Sodium vapour lights and BC Bulbs in Colony and Guest

house Dust suppression system for coal storage yard to avoid dust emission CO reduction in Kiln preheater by reducing secondary firing coal pipe bends

Page 7

Productivity

4) DC in PAT CycleWe are included in PAT Cycle III and our base line is 0.0847 TOE/T of Product

5) Do you have RPO obligation If Yes, Specify the obligation and measures takento fulfil (Certificates procured or renewable energy used by purchase or by selfgeneration)

Not Applicable

6) Blended Cement Produced out of total production for 2014-15(%)

100 % Blended Flyash based Portland Pozzolana cement

4) DC in PAT CycleWe are included in PAT Cycle III and our base line is 0.0847 TOE/T of Product

5) Do you have RPO obligation If Yes, Specify the obligation and measures takento fulfil (Certificates procured or renewable energy used by purchase or by selfgeneration)

Not Applicable

6) Blended Cement Produced out of total production for 2014-15(%)

100 % Blended Flyash based Portland Pozzolana cement

Page 8

Productivity

7) Low grade/sub grade limestone used out of the total limestone consumptionfor 2014-15

8) Cement mix for 2014-15 (Flyash & Gypsum)

We are using 100 % Synthetic /Chemical Gypsum in Cement

9) Spares Consumption for 2014-15 : Rs 101.1 / T of Cement

Description Quantity UOM 2014-15

High grade Limestone Tonne 3,46,006

Low grade LimestoneTonne 4,48,585

% 56.5

7) Low grade/sub grade limestone used out of the total limestone consumptionfor 2014-15

8) Cement mix for 2014-15 (Flyash & Gypsum)

We are using 100 % Synthetic /Chemical Gypsum in Cement

9) Spares Consumption for 2014-15 : Rs 101.1 / T of Cement

Page 9

% 56.5

Description Quantity UOM 2014-15

Flyash Used Tonne 465121.7

Synthetic Gypsum Used Tonne 75984.8

Productivity

10. Man Power Utilization (Permanent & Contract):5.59 Tonne of Product/Manpower

11. Compliances with Environmental Norms (Dust, SOx & NOx Emission): Data givenwith Environment sheet

12. Industrial Relations Issues, Please Specify : No

13. Management System Implementation, Please specify the name of Systema) Integrated management system

1. Quality Management System - IS/ISO 9001: 20082. Environment Management System - IS/ISO 14001: 20043. Occupational Health & Safety Management System - IS 18001: 2007

b) Five S’ Workplace Management Systemc) Energy Management System IS/ISO 50001:2011 (Under Implementation)

10. Man Power Utilization (Permanent & Contract):5.59 Tonne of Product/Manpower

11. Compliances with Environmental Norms (Dust, SOx & NOx Emission): Data givenwith Environment sheet

12. Industrial Relations Issues, Please Specify : No

13. Management System Implementation, Please specify the name of Systema) Integrated management system

1. Quality Management System - IS/ISO 9001: 20082. Environment Management System - IS/ISO 14001: 20043. Occupational Health & Safety Management System - IS 18001: 2007

b) Five S’ Workplace Management Systemc) Energy Management System IS/ISO 50001:2011 (Under Implementation)

Page 10

14. Maintenance Practice(Preventive/Proactive/Condition Monitoring)

Sl.No Activity description1 Running the plant as per Annual maintenance plan

2 Critical equipments Condition monitoring(Vibration & Lubrication) - Fortnightly

3 Critical equipments Lub analysis - Yearly twice

4 Critical equipments Ultra sonic test - Yearly once

5 Reviewing Plant performance weekly by conduting Regulr MMS meeting

6 Checking the Standby equipment availability - Monthly

7 Conducting Root cause analysis for Unplanned Stoppages & Implementing the actions - to avoid Repeatability

8 Covering all the equipments through Preventive maintenance schedule - Strictly following to avoid Unplanned Breakdowns

9 Identification of common spares & Brought out under single indent for minimizing Inventory

10 Followup of Work order, Work contract, Gate pass & Man power system for Better utilization

Maintenance Management system activities

Page 11

Sl.No Activity description1 Running the plant as per Annual maintenance plan

2 Critical equipments Condition monitoring(Vibration & Lubrication) - Fortnightly

3 Critical equipments Lub analysis - Yearly twice

4 Critical equipments Ultra sonic test - Yearly once

5 Reviewing Plant performance weekly by conduting Regulr MMS meeting

6 Checking the Standby equipment availability - Monthly

7 Conducting Root cause analysis for Unplanned Stoppages & Implementing the actions - to avoid Repeatability

8 Covering all the equipments through Preventive maintenance schedule - Strictly following to avoid Unplanned Breakdowns

9 Identification of common spares & Brought out under single indent for minimizing Inventory

10 Followup of Work order, Work contract, Gate pass & Man power system for Better utilization

Maintenance Management system activities