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JAYANTHIPURAM WORKS
Integrated Plants :
1. RR Nagar Plant near Virudhunagar, Tamilnadu (2.0MTPA) (Estd. in 1959)
2. KSR Nagar Plant, Jaggaiahpet, Andhra Pradesh (3.65 MTPA) (Estd. In
1986),
3. Alathiyur near Vridhachalam, Tamil Nadu (3.0 MTPA) (Estd. in 2002)
4. Mathod near Chitradurga, Karnataka (0.3 MTPA) (Estd. in 2000)
5. Ariyalur, Tamil Nadu (5.5 MTPA) (Estd. in 2009).
Cement Grinding Units :
1. Kattuputtur, Chengalpet, Tamilnadu (0.75MTPA)
2. Valapadi, Salem, Tamilnadu (2.0 MTPA)
3. Kolaghat, East Midnapore, West Bengal (1.0 MTPA)
4. Gobburupalem, Vizag, Andhra Pradesh (0.95 MTPA)
Packing Unit :
1. Nagercoil, TN
2
Best Practices on Productivity Sl.
No.Parameters UoM 2017-18
1 Capacity Utilization %
Clinker (%) 53.03
Cement (%) 33.72
2
Conservation of Raw Materials & Fuels
• % Alternative raw material used
• % Alternative fuel used
• Amount of Waste Heat recovery power
generated
%Alternate Raw Mat : 2.05%
Alternate Fuel : ----
3
Approach to the Implementation of Best
Practices
If Yes, Please Specify.
Y/N Yes
4
DC in PAT Cycle
If Yes , Specific Energy Consumption
(Target & Achievement)
Y/N
TOE/T of Product
Yes (PAT Cycle-III)
Target : 0.0684 TOE/T of Product
5
Do you have RPO obligation
If Yes, Specify the obligation and measures
taken to fulfill (Certificates procured or
renewable energy used by purchase or by
self generation)
Y/N -NA-
Sl.
No.Parameters UoM 2017-18
6Blended Cement Produced out of total
production% 57.63
7
Low grade (>18% SiO2) /sub grade
limestone used out of the total limestone
consumption
% 4.61
8
% of Synthetic gypsum used out of total
gypsum.
% of Fly ash used in cement (in PPC)
% of slag used in cement (in PSC)
%100.00%
32.13%
--
9 Spares Consumption Rs/T of Product 80.14
10Man Power Utilization
(Permanent & Contract)
T of Product
(Cement)/Man Hour110
Best Practices on Productivity
Sl. No. Parameters UoM Values
11
Compliances with
Environmental Norms
(Dust, SOx & NOx Emission)
mg/Nm3
Dust : <30 mg/Nm3
Sox : ~ 10 mg/Nm3
Nox : ~ 400 mg/Nm3
12Industrial Relations Issues,
Please Specify--
No IR Issues, because of harmonious
relationship between Workmen & the
management. Hence, received the best
management award by AP Govt on the eve of
May Day’2016.
Management System
Implementation, Please
specify the name of System
(ISO/IS/IMS Systems etc)
Nos
5 Nos
QMS-ISO 9001
EMS-ISO 14001
OHSMS-ISO 18001
EnMS-ISO 50001
5-’S’
14
Maintenance Practice
(Preventive/Proactive/Conditio
n Monitoring)
-- All the three Practices are being carried out
Best Practices on Productivity
Product Capacity
(MMTPA
)
Clinker 3.185
Cement 3.650
40%
33%
23%
26%
34%
63%
51%
36%39%
53%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
2013-14 2014-15 2015-16 2016-17 2017-18
Ca
pa
cit
y U
tiliza
tio
n
(%
)
FY
Capacity Utilization (At a Glance)
Cement Capacity Utilization Clinker Capacity Utilization
Management System Certificates
Back
BEST MANAGEMENT AWARD to Sri P R Ramasubrahmaneya Rajha, Chairman & Managing
Director, Ramco Cements Limited and the award is being received by Sri P B Gopala Krishna,
President-Mfg., Sri M. Chidambaram, Vice President - Admn, Sri T. Sridhar Reddy, AVP -
Works and Sri E. Alwar, DGM - Personnel on the occasion of MAY DAY on 01.05.2016.Back
Back
Best Practices in Productivity
Raw Mill-1 Optimization
➢ Description
◦ Gear Box changed from 1440 KW rating to 1800 KW rating for 2000
KW rating motor
◦ Earlier with lower rating Gear Box, there was a restriction of Feed to
215 tph only.
◦ The same was increased to 230 tph after changing the Gear Box and
simultaneously increasing the Grinding Pressure by 10-15 Bar.
➢ Benefits
◦ Feed rate increased by 10 tph.
◦ SPC reduced by 0.30 KWH/T Mat.
➢ Monetary Saving
◦ Cost Saving incurred : INR 14.17 Lakhs /Annum
12
220
230
12.93
12.63
11.98
12.48
12.98
13.48
13.98
200
205
210
215
220
225
230
235
240
Before After
KW
H/T
Mat
TPH
Raw Mill-1 Optimization
Productivity SPC
Raw Mill-2 Optimization
➢ Description
◦ Accumulator Pressure increased from 55 bar to 60 bar; thereby
increased the Grinding pressure from 110 Bar to 120 Bar.
◦ And also the table dam ring increased by 7 mm.
➢ Benefits
◦ Feed rate increased by 10 tph.
◦ SPC reduced by 0.20 KWH/T Mat.
➢ Monetary Saving
◦ Cost Saving incurred : INR 18.80 Lakhs /Annum
14
518
528
11.46
11.26
11
11.1
11.2
11.3
11.4
11.5
11.6
11.7
11.8
500
505
510
515
520
525
530
535
540
Before After
KW
H/T
Mat
TP
H
Raw Mill-2 Optimization
Productivity SPC
Cement Mill Optimization
➢ Description
◦ To avail the power for Clinker handling, Mines Dewatering Pump etc
during single CPP running.
◦ Grinding Media Filling level reduced by 5% (from 30% to 25%) as per
the production requirement for Cement Dispatch.
◦ Mill feed rate optimized as per the new GM pattern.
◦ Specific Air Optimization in both VRPM and Ball Mill.
◦ VRPM Bag Houses (2 Nos) purging system kept in DP mode
◦ Water Spray in VRPM introduced to improve the Grinding.
➢ Benefits
◦ SPC reduced by 1.43 KWH/T Mat.
➢ Monetary Saving
◦ Cost Saving incurred : INR 49.55 Lakhs/Annum
16
230
220
29.27
27.84
26.79
27.79
28.79
29.79
30.79
31.79
200
205
210
215
220
225
230
235
240
Before After
KW
H/T
Mat
TP
H
Cement Mill Optimization
Productivity SPC
Novaflam Burner Installation
➢ Description
◦ Novaflam Burner from M/s Pillard installed in Line-2 by replacing the
FLS designed Duoflex Burner.
➢ Benefits
◦ Kiln Feed rate increased by 15 tph.
◦ Primary Air Consumption reduced by 4-5%.
◦ SHC reduced by 5 Kcal/Kg Clinker.
◦ Brick Life increased by 4-5 months.
➢ Monetary Saving
◦ Cost Saving incurred : INR 78.29 Lakhs/Annum
CB Cooler & New ESP Installation in Line-1
➢ Description
◦ Old CIS+CFG+RFT Grate Cooler replaced with ABC inlet Cross Bar
Cooler.
◦ This Cooler with better Clinker transport and recuperation efficiency
installed and commissioned in Line-1.
◦ New ESP installed to meet the New Emission norms of < 30 mg/Nm3.
➢ Benefits
◦ Cooler Loss reduced by 30 Kcal/Kg Clinker.
➢ Monetary Saving
◦ Cost Saving incurred : INR 308.07 Lakhs/Annum
Installation of 3-Phase Transformer in Line-2 Cooler
Vent ESP
➢ Description
◦ Collection Efficiency of ESP was improved with 3-phase transformer.
➢ Benefits
◦ SPM emission reduced from 50 mg/Nm3 to 20-25 mg/Nm3.
➢ Monetary Saving
◦ Cost Saving incurred : INR 0.60 Lakhs/Annum
Alternate Fuel in Kiln & CPP
➢ Description
◦ While restart up of Kiln and CPP after shutdown.
◦ Kiln : Alternate Fuel Pyrolysis Oil is being used by 100% replacement
of Non-Renewable fuel like HSD.
◦ CPP : Alternate Fuel Charcoal is being used by 100% replacement of
Non-Renewable fuel like HSD.
➢ Benefits
◦ Conservation of Non-Renewable Fuel.
➢ Monetary Saving
◦ Cost Saving incurred in Kiln : INR 1.04 Lakhs/Light Up
◦ Cost Saving incurred in CPP : INR 3.15 Lakhs/Light Up
Preheater Flow Optimization
➢ Description
◦ After up-gradation the Preheater Gas Velocity is maintaining in higher
range of 22-25 m/sec, which was causing the imbalance of Hot gases
among the two Preheater (Old & New) towers.
◦ Thereby the heavy coating formation observing at the KRTP (Kiln
Riser Transition Piece) area.
◦ To reduce the Gas velocity from 22 m/sec to 15 m/sec, The Area of
Kiln Raiser Duct was increased in Old and New Preheater.
➢ Benefits
◦ Coating formation reduced with reduced velocity.
◦ Kiln Operation was also smoothen.
➢ Monetary Saving
◦ Cost Saving incurred : INR 2.71 Lakhs/hr of stoppage
22
Air Blaster installation in Kiln hood slope area
➢ Description
◦ To avoid Manual cleaning as well as sudden material rush to Cooler
and DPC.
➢ Benefits
◦ Safe Working Environment
➢ Monetary Saving
◦ Nil
24
Burner Pipe castable pre-heat up before keeping in
operation
➢ Description
◦ Proper in-house arrangement were made for Burner Pipe preheat up
to enhance the refractory life.
➢ Benefits
◦ Castable life increased by 4-5 months.
➢ Monetary Saving
◦ Cost Saving incurred : INR 6.51 Lakhs/Annum
Burner pipe heating
Refractory application by Gunning Method
➢ Description
◦ Gunning Method is being used to carry out the castable application in
Kiln Hood Roof.
➢ Benefits
◦ Application hrs reduced from 15 days to 4-5 days.
➢ Monetary Saving
◦ Cost Saving incurred : INR 0.47 Lakhs
Inter Connection of Line-1 and Line-2 LST Pile
➢ Description
◦ Earlier the Line-1 & 2 LST pile was separately forming to meet out the
respected Mills.
◦ In case of any correction required in Raw Mix, The complete pile used to
be emptied and reforming.
◦ After inter-connection of Line-1 & 2 LST pile, the both pile is being
formed with short range of Si content.
◦ With this inter-connection, the Raw Mix correction can be done at any
point of requirement.
➢ Benefits
◦ Easy in Quality control of Raw Materials.
◦ Kiln Feed LSF Standard Deviation 1.20% to 0.50% reduced.
➢ Monetary Saving
◦ Nil
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