8/29/2013

A flagship company of RAMCO Group, having five Cement manufacturing units, three grinding units and two packer units with the total capacity of 14 MTPA. The plant at Alathiyur, Ariyalur District was setup in two phases. Line-I was installed with a capacity of 2200 TPD (Clinker) in the year 1997 & Upgraded to 3400 TPD. Line-II was installed with a capacity of 3000 TPD (Clinker) in the year 2001 & Upgraded to 3400 TPD. The manufacturing products are Ordinary Portland Cement as per BIS & SLS standards, Portland Pozzolana Cement and SRPC. We have a thermal power plant (2X18 MW) at Alathiyur.

8/29/2013

IS/ISO 9001: 2008 Quality Management System

IS/ISO 14001: 2004 Environment Management System

IS 18001: 2007 Occupational Health & Safety Management System

IS/ISO 50001:2011 Energy Management System under implementation

8/29/2013

Energy Conservation Projects Implemented for the years 2010-11, 2011-12 & 2012-13

8/29/2013

S. No.

Energy Saving Project

Savings Investments (Rs. Lacs) (Rs. Lacs)

1 2 3 4 5 6

Replacement of conventional grate cooler for line-1 with high efficiency SF cooler Installation of new limestone crusher Installation of new Generation High Efficiency Classifier for Raw Mill Line-1. Installation of VFD for line-2 Cement mill bag filter fan Installation of new high efficiency Preheater fan for line-1 Modification of line-1 cement mill fan inlet duct

1134.6 1029.6 774.5 81.6 821.4 65.3

2000 30.9 200 155 125 1.0

S. No. 1 2 3 4

Energy Saving Project Installation of VFD for line-2 Preheater fan Installation of Booster fan for line-1 Cement mill Steam tracer for DG aux. instead of electrical heating Replacing 250 W HPSV street lights by 2x36 W CFL Installation of low capacity compressors for Cement mill Bag filters in fly ash handling section Installation of GRR for line-2 coal mill fan Installing fuel catalyser in mines EME equipments

Savings Investments (Rs. Lacs) (Rs. Lacs) 49 31 28.5 3.3 110 67 39.5 10

5 6 7

14.7 12.2 7.9

6 3 0.2
8

8/29/2013

S. No. 1 2 3 4 5

Energy Saving Project Power saving in Line-2 Kiln due to installation of membrane filter bags in RABH with revised bag cleaning cycle Installation of VFD for boiler 1 FD Fan Replacing diesel pumps by high efficiency electrical pumps Line-1 RABH Fan inlet duct modification Modification of Line-1 cement mill fan outlet duct from 1.8m to 2.8m Installation of Wireless communication system for wagon loading and PID for Motorized Flow Control Gate to control material from Silo to the Elevator

Savings Investments (Rs. Lacs) (Rs. Lacs) 20.6 36 18.8 9.2 19.6 82 55 31 14 13.8

39.7

S. No. 7 8

Energy Saving Project Installation of 45 Kw VFD for fly ash unloading Bag Filter Fan with photo sensor Motorized valve for CCR A/C AHU to control chilled water

Savings Investments (Rs. Lacs) (Rs. Lacs) 3.2 4.4 1.8 1.6

10

8/29/2013

11

S. No.

Energy Saving Project Installation of VFD for reverse air fan in raw mill bag house Installation of SPRS for line-2 Raw Mill Installation of VFD in cooling tower fan Level controller for DM water transfer pump Modification of fly ash conveying air nozzle Installation of GRR for the FD fan in boiler-2

Savings (Rs. Lacs) 6.5 62.6 5.8 1.8 3 4.4

1 2 3 4 5 6

8/29/2013

S. No. 1 2 3 4 5 6 7 8 9 10

Energy Saving Project Removal of I/l damper in line-2 Cement mill fan Installation of VFD for line-2 Cement mill Booster fan Removal of I/l damper in line-2 cooler vent fan Installation of VFD for compressors in Kiln, Coal Mill and Preheater Installation of VFD with level switch in main cooling water pump Optimization of i/o room temperature Optimization of line-2 RABH fan Elimination of bag filter at Cement Mill-2 Elevator Optimization of bag filter fan at clinker DPC Cement mill-2 Replacement of line-2 CF silo top air slide blower in

Savings (Rs. Lacs) 13.1 6.6 6.5 26.1 6.5 1.4 19.6 13.8 5.2 4.6
13

S. No. 1 2 3 4 5 6 7

Energy Saving Project Optimization of L-1 Kiln section compressor Regulating the operation Line-1 silo feed elevator bottom boot bag filter during OPC & export running Heating mode & cooling mode was introduced in line1 & line-2 cement mill By closing the damper in fly ash unloading bag filter fan when not required One air slide blower (260 AB5) was stopped in cement mill main air slide by optimization By stopping the line-1 cooling tower fan & pump during winter season One air slide blower was stopped in fly ash air slide by optimization

Savings (Rs. Lacs) 0.3 2.9 1.8 1.4 1.4 1.3 0.5
14

8/29/2013

S. No. 8 9 10 11 12

Energy Saving Project ID Fan suction Damper removed in both boiler Removal of Boiler 1 SCAPH Replacement of 9.3 kw borehole pump in mines office with 3.7 kw pump Line-2 kiln feed elevator top venting unit bag filter : Replaced fan motor rated 1500 rpm with 1000 rpm. Line-2 CF silo top venting unit bag filter : Replaced fan motor rated from 1500 rpm to 1000 rpm

Savings (Rs. Lacs) 7.8 7.0 0.03 1.6 1.6

15

715 715 710

705

705
700 695 690 685 680 675 690 690

2009-10

2010-11

2011-12

2012-13

16

8/29/2013

74.37 75

16

15.4 14.6

74
Kwh / MT of Cement

72.69

% 15 14 2011-12 2012-13

73 72
71

69.19
68.51

70 69 68
67

66 65 2009-10 2010-11 2011-12 2012-13

17

Reference: 8th NCB International Seminar 2003

8/29/2013

19

20

10

8/29/2013

The Raw mill was designed for a feed moisture of 5% normal & 10% maximum. Over a period of time, the normal feed moisture increased to more than 10% causing the reduced raw mill output to 205-210 t/h from 215-220 t/h. During monsoon, Mill output was further reducing to 190 t/h. Hot Gas Generator had to be operated to meet the clinker production. Since more heat was required for drying, the gas volume was to be increased in mill and thereby causing higher product residue. Kiln feed had to be reduced as the Raw mill was unable to support the raw meal requirement. At high residue of raw meal on 212 m and high quartz %, problems related to clinker burning resulted in high free lime of >2.5%.
21

22

11

8/29/2013

Replacing the existing classifier from LSKS 52 by a larger size LSKS 57 with inbuilt Vortex Rectifier.

This was the first VORTEX RECTIFIER in India.

Modified louvre and armour ring to maintain uniform gas flow/velocity profile inside the mill.

Increase the capacity of the raw mill fan by replacement/ retrofitting

Increase the size of the following ducts due to higher gas flow Mill inlet duct , Mill Outlet duct & Duct from Cyclone to mill fan inlet
23

Old Classifier Without Vortex Rectifier

New Classifier With Vortex Rectifier

24

12

8/29/2013

25

239
240

235

230

TPH

219 220
210

210 207

213

200 190
2007-08 2008-09 2009-10 2010-11 2011-12 2012-13

26

13

8/29/2013

27

28

14

8/29/2013

Idea and Installation of Vortex rectifier is the First of its kind in the country

Vortex rectifier gives us a rich benefits in the areas of Production, Quality, maintenance & Energy

There are more than 200 vertical roller mills in Indian cement industry.

29

Tangible Benefits: Investment Cost Cost Savings : Rs. 200 Lacs : Rs. 42.48 Lacs/Year

Cost Savings Due To Additional Realization of Cement : Rs. 734 Lacs/Year Simple Pay Back Period Intangible Benefits: Improvement In Quality Of Clinker Free Lime <2% And C3S >55% Stable Kiln Operation
30

: 3 Months

15

8/29/2013

31

The efficiency of the conventional grate cooler is low and the breakdown was high and also the cooler is designed for the production of 2200 TPD only. Due to higher loading of the cooler, the efficiency is also very less. So we had replaced the conventional grate cooler by the high efficient third generation cooler SF crossbar cooler.

SF crossbar gives heat savings of 30 kcal/kg clk and electricity savings of 1.3 Kwh/T clk and an additional clinker production of 150 tons per day.

By the installation of SF crossbar cooler, we have constantly reduced the total thermal specific fuel consumption from 715 to 690 Kcal/ kg of clinker from 2009-10 to 2012-13.
32

16

8/29/2013

33

Tangible Benefits: Investment Cost Cost Savings Simple Pay Back Period Thermal energy savings Electrical energy savings Intangible Benefits: : Rs. 2000 Lacs : Rs. 1135 Lacs/Year : 22 Months : 30 Kcal/kg clk : 1.35 Kwh/MT clk

Vital role in the achievement of the BEE-PAT Target

34

17

8/29/2013

900 851
Kcal/ Kg of Cement

853 796 802 758 717

850 800 750 700 650 600

816

2007-08 2008-09 2009-10

Target

2010-11 2011-12 2012-13

35

36

18

8/29/2013

We have 3 nos. (2 x 6 MW and 1 x 4 MW) Diesel Generators in our plant

The DG became standby after installation of 2 x 18 MW Coal Based Thermal Power Plant in 2005. During idle time, lube oil and jacket water temperature is maintained at 60 0C to keep DG in warm up condition

To maintain the lube oil and jacket water temperature at 60 0C, the electrical heaters were used Since we have CBPP we get low pressure steam from the de-aerator, so planned to use this steam for heating the lube oil and the jacket water.

37

38

19

8/29/2013

39

Tangible Benefits:

40

20

8/29/2013

Energy consumption both electrical & thermal

: Daily

Energy conservation projects

: Weekly

Review meeting conducted by

: VP - Mfg

41

42

21

8/29/2013

43

Selection

Department - Plant Management, Production ,Maintenance Quality Control ,Accounting

Formation

Each department Provide one or more Representatives to the Energy Management team

Coordination

Each Energy management Clusters will be headed by Team leader and the whole is monitoring by Energy Manager

Responsibilitie s

Define Objectives, Prepare Energy Planning, Optimal Energy Operation, Detect Weakness Plan and Perform Measures/Projects Prepare Energy Performance & Reporting Establish & perform Energy Controlling Review achievements

44

22

8/29/2013

Energy management cell

Pre clinkerisation - 2 teams Post clinkerisation - 1 team 14 quality teams Heat balance in Pyro sectionPreheater, Kiln, Cooler Efficiency of Fans & Motors

Quality circle forum Thermal Energy audit

: :

Electrical Energy audit

5S implementation

Suggestion scheme

45

INCHARGE MINES

INCHARGE CRUSHER

INCHARGE RAW MILL

INCHARGE PYRO

INCHARGE CEM MILL

INCHARGE PACKING

46

23

8/29/2013

False air study in all major sections i.e., Kiln, Raw Mill, Coal Mill and Cement Mill on monthly basis. Monitor production performance vis--vis SEC. Monitor fan performance and initiative corrective action required, if any, on monthly basis. Identify/Evolve new Encon projects with and without investment. Encourage employee participation through effective implementation of Suggestion Box Scheme. Organise Quality Circle meetings and review their projects and its progress
47

48

24

8/29/2013

Corrective actions Line-1 hot fine clinker surging from the tertiary duct. To avoid hot fine clinker surging from TAD, air blasters are installed in the TAD take off duct. Bag filter is installed in the line-1 clinker truck extraction pan conveyor.

Preventive actions Air blasters nozzles direction routed parallel to the slope of TAD take off.

Line-1 clinker truck loading extraction pan conveyor dust emission is high.

Clinker extraction point is installed with telescopic chute vented by bag filter

Line-1 hood draft fluctuation which leads to puffing in the kiln platform.

Venturi in the TAD duct is shifted near to the kiln riser.

Kiln hood draft is given in fuzzy mode which is controlled by cooler vent fan

49

50

25

8/29/2013

Type of RES

2010-11 Energy Annual Generated Savings (kWh) (Rs.) 314374266 -

2011-12 Energy Annual Generated Savings (kWh) (Rs.) 285454322 9138 38654

2012-13 Energy Annual Generated Savings (kWh) (Rs.) 322219670 10968 49356

Wind Solar photovoltaic

Total installed capacity during the year 1996 is 33.235 MW, which was the SINGLE LARGEST WIND FARM IN THE SOUTH EAST ASIA at that time. The wind mill capacity is constantly upgraded and now at present the capacity is 159.185 MW with 229 individual Wind Electric Generators The PLF% has increased from 21.21% to 24.01% for the years 2011-12 and 201213 respectively
51

Type of RES

2010-11 Equ Fuel Annual Savings Savings (MT) (Rs. Million) 1198 6.83

2011-12 Equ Fuel Annual Savings Savings (MT) (Rs. Million) 2653 18.57

2012-13 Equ Fuel Annual Savings Savings (MT) (Rs. Million) 2677 19.14

Biomass No

Type of Biomass used

Quantity of Biomass used (MT) 968 26 803 2717

Equivalent of fuel savings (Ton of coal)

1 2 3 4

Cashew Shell Saw dust Fire wood Biocompost

800 20 575 1282

26

8/29/2013

S. No

Type of Waste Fuel used

1 2 3 4 5 6 7 8 9

Oil soaked cotton waste Shredded tyre ETP sludge Paint sludge Coolant filter waste Used waste oil Oil soaked saw dust Power plant pet coke reject Municipality waste

Quantity Equivalent of Waste fuel as % of waste Conventional of total energy fuel used energy used (Ton (MT) of coal) 37 28 0.02 170 460 112 94 14 30 4447 448 49 221 59 103 71 17 35 2075 194 58 0.09 0.25 0.06 0.05 0.01 0.02 2.42 0.24 0.03
53

10 Oil sludge

5861 6000 5000 4000 3000 2000 1000 0

3339 2208

2861

2011-12
Alt Fuel

2012-13
Equ. Coal

75.53 % Increase In Alternate Fuel Consumption 29.6% Increase In Replacement Of Coal Quantity.
54

27

8/29/2013

S. Name of associate No / vendor

Name of service provided to vendor Transport ation of Reject

Energy consume d before Encon

energy % consume improv d after ement Encon

Type of inputs / projects provided to the vendor/ associate Fuel catalyzer is installed in the tippers

Sri Vinayaga Transports Gukan Earth Movers Balasubramanian Agencies Pavai Infratech Sri Vinayaga Transports Gukan Earth Movers Balasubramanian Agencies Pavai Infratech

2.1 kmpl 2.0 kmpl 5%

Transport ation of Reject

1.5 3 50% liters/trip liters/trip

Lead distance reduced is by developing a new road.

55

Installation of High efficiency SF cooler Installation of fuel catalyser in the mines EME equipments Installation of VFD for boiler -1 FD fan

: 14144 MT CO2 : 55 MT CO2 : 665 MT CO2

Replacing diesel pumps with high efficiency electrical pumps : 114 MT CO2 Utilization of waste heat from cooler in cement mill Total CO2 reduction : 71125 MT CO2 : 86103 MT CO2

56

28

8/29/2013

57

S. No
1 2 3 4 5 6 7 8 9

Title of the project Installation of additional ESP in cooler vent Dramix fiber Concrete road at lorry yard of 20,000 sq.m Concrete road development for 1250 sq.m. Installation of Surveillance camera Installation of Pressurization and ventilation system Installation of NOx analyzer at Kiln inlet Ambient air quality monitoring station Installation of New Clinker drop test bin for Kiln-1 Chrome free basic bricks

Investment made (Rs.Lacs) 125 378 194 80 71 6 17 22.5 81.5 85 15 1075

10 Installation of Membrane bags in RABH 11 Water cooled CCTV camera for Cooler-1 TOTAL INVESTMENT MADE (RS. LACS)

29

8/29/2013

Additional ESP In Cooler Vent

Dramix Fiber Concrete Road At Lorry Yard

Steel Saved : 69 MT
59

Surveillance Camera

Pressurization And Ventilation System

60

30

8/29/2013

Continuous Ambient Air Quality Monitoring Station (CAAQMS)

New Clinker Drop Test Bin For Kiln-1

61

Chrome Free Basic Bricks

Water Cooled CCTV Camera For Cooler-1

62

31

8/29/2013

Turbo Ventilators

CFL Lamps

Solar Lighting

Clinker Truck Loading System 63

Solar Water Heater

Plantation Of 9450 Tree Samplings

Water Tanker At Mines

Additional Storage Shed For Coal 64

32

8/29/2013

New Road Sweeping Machine

Water Sprinkler At Mines Roads

Additional Storage Shed For Gypsum

Ambient Air Quality Monitoring Station 65

Concrete Road Near Wagon Loading

Pavement Road Near CDS

Solar Blinker

Sewage Treatment Plant 66

33

8/29/2013

Online Stack Emission Display

Separate Shed For Alternate Fuels.

Kevlar Suit And Hand Gloves

Installation Of Shredder 67

Near Colony Ground

Main Gate Entrance

Flats Top View

Temple Front 68

34

8/29/2013

Colony Ground

Colony Pharmacy

Health Center

Guest House 69

Factory Entrance

Factory Boulevard

Training Centre

Admin Block 70

35

8/29/2013

Rain Water Harvesting Inside Plant

Additive Crusher Area

Thermax Conveyor Area

Water Sprinkler Near Raw Mill 71

Tower Light Area

CPP Bird View

Preheater Top Bird View

Greeneries Near Admin Block 72

36

8/29/2013

Stores Yard

Packing Plant Area

Wagon Loading Area

Work Shop 73

Colony Skating Ground

Near Security Gate

Coal Shed

Near Recreation Club 74

37

8/29/2013

Sl. No. 1 2 3

Location Mines Factory Colony 6.66 0.77 1.73 9.16

Area in acres 2012-2013 165.81 65.79 54.18 285.78 7850 500 1100 9450

No. of Trees Up to 2013 119403 64600 52500 236503

Up to 2013 2012-2013

Grand Total

45.51 % of total area is covered with green belt

76

38

8/29/2013

Limestone Wet Beneficiation Plant

- Rs.3800 Lakhs.

Coal Wagon Tippler, 60,000 MT capacity Raw material storage shed with stacker & reclaimer - Rs.13000 Lakhs

Dust Suppression System at coal transfer and unloading point.

New 6 MW turbine with the existing boiler

- Rs. 1500 Lakhs

77

78

39

8/29/2013

National Level Excellent Energy Efficient unit award (For the years 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 and 2007) by the Confederation of Indian Industry, Chennai National Level Best Electrical Energy Performance Award (For the years 1999-2000, 2001-02, 2002-03, 2004-05, 2005-06 and 2006-07) by NCCBM National Level Best Thermal Energy Performance Award (For the years 200506, 2006-07) by NCCBM. National Energy Conservation Award 2000 (First prize in Cement Sector) by The Ministry of Power, Government of India. National Level Best Environment Excellence in Plant operation Award (For the years 2001-02, 2002-03 and 2003-04) by NCCBM.
79

Innovative Environmental Project at the CII Environmental Best Practices Award 2011 for THE LIMESTONE SCREENING PLANT. Innovative Environmental Project at the CII Environmental Best Practices Award 2012 for REPLACEMENT OF ELECTRICAL HEATING SYSTEM BY STEAM HEATERS IN DG. National Energy Conservation Award 2012 (Second prize in Cement Sector) by The Ministry of Power, Government of India.

GREEN AWARD 2012 from TNPCB

Greentech Excellence in Environment Gold Award in Cement sector for the year 2011-12.

80

40

8/29/2013

81

82

41

8/29/2013

83

42