The Ramco Cements Limited RR...

The Ramco Cements Limited RR Nagar

P.M.RAMASUBRAMANIAN GM Process & QCV.SURESH Sr. Manager - ProcessS.V.Veeraraghavan Asst.Manager-Electrical

The Ramco Cements Limited, RR Nagar

Salient Futures of Ramasamy Raja Nagar Unit

In 1976, we were the first to introduce 1200TPD Dry process kiln in South India.

Manufacturing 100% Portland Pozzolana Cement

A flagship company of RAMCO Group, having five Cementmanufacturing and 4 Grinding units with a capacity of 16.5MTPA

We are the leaders in First to introduce latest technologieslike Surface Miner, Vertical roller mill, SF cross bar cooler,Limestone Beneficiation Plant, Optical sorter, Cross BeltAnalyser, X-Ray analyser, ESPs, Cambidan Mill etc.,


Integrated Management System Certification

3

IS/ISO 9001: 2008

IS/ISO 14001: 2004

IS 18001: 2007

IS/ISO 50001: 2011

5S

Quality Management System

Environment Management System

Occupational Health & Safety Management System

Energy Management System

(Implemented awaiting for Certification)

Workplace Management System


ENCON PROJECTS WITH ZERO INVESTMENT

No. of Projects : 31

Savings on Electrical Energy : 38.34 Lakh Kwh

Savings on Thermal Energy : 1595 MT of Coal

Total Cost savings : Rs.239.7 Lakhs


Sl.NoENCON 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

4Optimization of set point and arresting air leaks in Kiln-2 CF Silocompressor

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

7Optimization of set point and arresting air leaks in Cement millroller press compressor

0.88

ENCON Projects with Zero Investment



2014-15


8Optimization 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

10Optimization 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

12Reduction of Raw mill VRMP Circulating air fan speed by process optimization

0.16

13 Interlinking of compressors in raw grinding circuit 0.16

14Optimization 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



Sl.No

ENCON Projects Implemented for the year 2015-16


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




2016-17Savings

(Rs. in Lakhs)

1Reduction of False air and Elimination of Top Cyclone Water spray in Kiln-1 Preheater fan

14.1

2Improvement of excavator productivity and reduction of fuel consumption by reducing the marching time

9.9

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

6Elimination of DG operation in SVP-North mines and switch over to electrical supply by upgrading the existing transformer

1.3

7Elimination of unnecessary pipeline in the pump delivery to reduce the line losses

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 2014-15Savings (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

3Optimization 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



S.No

ENCON project implemented for the year 2015-16Savings (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

10Elimination 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

12LED lights replaced in place of Sodium vapour & fluorescent lamps

0.3 1.6



S.No

ENCON Project Implemented for the year 2016-17Savings (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

16Installation 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


Specific Thermal Energy Consumption

690

700

710

720

730

740

2014-152015-16

2016-17

735

721

705Kca

l/K

g C

linke

r


Specific Electrical Energy Consumption

68

70

72

74

76

78

80

82

2013-142014-15

2015-162016-17

81.23

76.60

73.78

72.20

Kw

h /

MT

Ce

me

nt


BEE PAT Scheme

700

720

740

760

780

800

820

840

2013-142014-15

2015-162016-17

PATTarget

902

828820

806

761

Kca

l/K

g C

em

en

tGate to Gate Energy Consumption


Sl.No

ENCON Projects Planned for the year 2017-18

Expected Electrical

Saving (Kwh/Year)

Expected ThermalSaving

(MT/Year)

1 Installation of Pillard burner for Kiln-2 35,160 430

2Reduction of DP in Kiln -1 Bag house by modifyingpurging 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.No

ENCON Projects Planned for the year 2017-18

Expected Electrical

Saving (Kwh/Year)

Expected ThermalSaving

(MT/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

11Compressor optimization in Kiln-1 & 2 by inter linking

1,60,800

12LED light replacement in place of Conventional lights

20,100

13Replacement of reciprocating by Screw compressor in Coal mill 2 bag filter

24,120

14Installation of Energy efficient motor for primary crusher

80,400

15To install capacitor at the pump switch board to boost voltage for the dewatering operation

40,200

ENCON Projects Proposed


Road Map To Reduce Carbon Foot Print Activities

YearScope 1

EmissionsCO2e (MT)

Scope 2 EmissionsCO2e (MT)

Scope 3EmissionsCO2e (MT)

kg CO2e/MTof cement

Baseline 9,55,158 1,21,410 35,738 8932014-15 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 % CarbonEmissions compared with baselineyear. Further to reduce carbonemissions we have planned thefollowing:

1. Installation of high efficiency Pillard Burner for Kiln-2

2. Installation of stacker & Reclaimer for Limestone and Fuel

650

700

750

800

850

900

Bas

elin

e

20

14

-15

20

15

-16

20

16

-17


Renewable Energy

Replacement of Electrical Energy with Renewable

Energy

2014-15 2015-16 2016-17

Annual Energy

Generated (Lakhs kWh)

% Share

Annual Energy


% Share

Annual Energy


% Share

Wind 2312.4 - 1807.0 - 3013.4 -

Replacement of Thermal Energy with Renewable

Energy

2014-15 2015-16 2016-17

Equivalent Fuel Saving(Lakhs Kcal)

% Share


% Share


% Share

Biogas - - - - 95.8 12.9

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


Utilization of Waste as Fuel

Name of the Fuel

2014-15 2015-16 2016-17

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 fourcaptive mines. The limestone contains average of 18% of blackstone.

We are adding Imported limestone and High grade limestone assweetener to meet the Quality Requirement.

There are three magnetic separators in our mines after thecrusher, which is used in removal of a part of black stones fromlimestone which are magnetic in nature.

As a result, of the total 18% black stones, out of which 16% ofblack stones are non magnetic will remain in the product evenafter separation.

Hence the quality of limestone will be inferior by a greaterextent.


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 : 75 mm to 250 mm

Secondary sorter : 30 mm to 75 mm

Tertiary sorter : 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.


In our packing plant, we have motorised belt diverter for divertingbags in to the loading point

Based on truck availability & loading machine availability thediverter is changed for the loading point.

One discharge point is having two loading machines. In ouroperation, it needs to divert the bags several times.

The belt diverter is stopped frequently, bags gets jam in diverterand thus affected the packer performance due to the followingreasons

Drive bearing failure

Idler damage

Geared motor pinion damage and

Diverter belt problem

Innovative Project - 2 : Drum Diverter in place of Motorized Diverters


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


The crushing plant is located 23 Kms from the factory at our PandalgudiMines.

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 18hours per day.

Productivity improved from 242 TPH to 273 TPHCost savings : Rs.24.87 Lakhs/annum

Innovative Project - 3 : Overhead Transmission Line to Mines Crushing plant


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: 32160 Units/annum

Cost Saving : 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



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



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 : 0.28 units/ Ton of Cement

Net Cost Saving : Rs. 51.0 Lakhs/annum


Environmental Projects

Sl.No

List of the Major Environmental ProjectsInvestment(Rs. Lakhs)

1 12 Nos. of unit bag filters installed in Mines crusher area 638.0

2Surveillance camera is located at all the hopper discharge and transfer points to monitor and avoid any spillage

300.0

3External Clinker Unloading hopper and Packer-2 de-dusting bag filter capacity increased from 25000 to 55000 m3/hr

250.0

4Dramix fibre Concrete road at lorry yard of 10,000 sq.m, to reduce the fugitive dust generation.

170.0

5Concrete road development for 3000 sq.m. to reduce the fugitive dust generation

30.0

6Additionally 5 Nos. of de-dusting bag filters are installed in Raw mill & Coal mill area

25.0

7 High efficiency bag filter installed in Coal mill-2 18.0


Sl.No

List of the Major Environmental ProjectsInvestment(Rs. Lakhs)

8New de-dusting bag filter for Kiln-2 coal firing to avoid fugitive dust emission

8.0

9Gas analyzer is installed at the kiln inlet, to monitor the kiln condition and thereby improve the combustion, and to predict the quality of clinker

6.0

10Re routing of de-dusting ducts in Roller press to avoid the fugitive dust generation

3.0

1116 Nos. of Solar lights in place of 16 Nos. of Sodium vapour lights in Colony

4.0

1260 Nos. of LED lights in place of tube lights, Sodium vapour lights and BC Bulbs in Colony and Guest house

2.92

13 Dust suppression system for coal storage yard to avoid dust emission 0.75

14CO reduction in Kiln preheater by reducing secondary firing coal pipe bends

0.5

Environmental Projects


Future Environmental Projects

Sl.No List of the Future Environmental ProjectsInvestment(Rs. Lakhs)

15 Nos. of additional Dust Collectors for transfer points at plant

220.0

22 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

2016-17 Up to 2017

Area in Acres

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

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