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The Ramco Cements Limited RR Nagar
P.M.RAMASUBRAMANIAN GM Process & QCV.SURESH Sr. Manager - ProcessS.V.Veeraraghavan Asst.Manager-Electrical
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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.,
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The Ramco Cements Limited, RR Nagar
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
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The Ramco Cements Limited, RR Nagar
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
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The Ramco Cements Limited, RR Nagar
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
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The Ramco Cements Limited, RR Nagar
Sl.NoENCON Projects Implemented for the year
2014-15
Savings (Rs. in Lakhs)
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
ENCON Projects with Zero Investment
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The Ramco Cements Limited, RR Nagar
Sl.No
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
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The Ramco Cements Limited, RR Nagar
Sl.NoENCON Projects Implemented for the year
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 Zero Investment
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The Ramco Cements Limited, RR Nagar
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
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The Ramco Cements Limited, RR Nagar
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
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The Ramco Cements Limited, RR Nagar
ENCON Projects with Investment
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
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The Ramco Cements Limited, RR Nagar
ENCON Projects with Investment
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
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The Ramco Cements Limited, RR Nagar
Specific Thermal Energy Consumption
690
700
710
720
730
740
2014-152015-16
2016-17
735
721
705Kca
l/K
g C
linke
r
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The Ramco Cements Limited, RR Nagar
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
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The Ramco Cements Limited, RR Nagar
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
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The Ramco Cements Limited, RR Nagar
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
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The Ramco Cements Limited, RR Nagar
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
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The Ramco Cements Limited, RR Nagar
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
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The Ramco Cements Limited, RR Nagar
Renewable Energy
Replacement of Electrical Energy with Renewable
Energy
2014-15 2015-16 2016-17
Annual Energy
Generated (Lakhs kWh)
% Share
Annual Energy
Generated (Lakhs kWh)
% Share
Annual Energy
Generated (Lakhs kWh)
% 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
Equivalent Fuel Saving(Lakhs Kcal)
% Share
Equivalent Fuel Saving(Lakhs Kcal)
% 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
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The Ramco Cements Limited, RR Nagar
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
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The Ramco Cements Limited, RR Nagar
Innovative Project - 1 : Optical sorter
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The Ramco Cements Limited, RR Nagar
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.
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The Ramco Cements Limited, RR Nagar
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
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The Ramco Cements Limited, RR Nagar
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.
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The Ramco Cements Limited, RR Nagar
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
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The Ramco Cements Limited, RR Nagar
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
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The Ramco Cements Limited, RR Nagar
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
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The Ramco Cements Limited, RR Nagar
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
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The Ramco Cements Limited, RR Nagar
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
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The Ramco Cements Limited, RR Nagar
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
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The Ramco Cements Limited, RR Nagar
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
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The Ramco Cements Limited, RR Nagar
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
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The Ramco Cements Limited, RR Nagar
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
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The Ramco Cements Limited, RR Nagar
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
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The Ramco Cements Limited, RR Nagar
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