A flagship company of RAMCO Group, having five Cementgreenbusinesscentre.com/energyaward2017presentations/Cement/20... · Calcination, Fuel for kiln & CBPP, owned vehicle, Refrigeration

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A flagship company of RAMCO Group, having five Cement manufacturing units, four grinding units and two packer units with the total capacity of 16.5 MTPA.

Alathiyur plant was setup in two phases 1997 & 2001 with Cement capacity of 3.00 Million Tons / Annum and 2 X 3700 TPD Kilns.

The manufacturing products are Ordinary Portland Cement, Portland Pozzolana Cement and SRPC as per BIS & SLS standards.

2X18 MW - Coal based Thermal power plant

18th National Award for Excellence In Energy Management -2017

3

IS/ISO 9001: 2008

IS/ISO 14001: 2004

IS 18001: 2007

Quality Management System

Environment Management System

Occupational Health & Safety Management System

IS/ISO 50001:2011 Energy Management System


5S Certified Company

Energy Conservation Projects Implemented in the years

2014-15, 2015-16 & 2016-17

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No. of Projects : 49

Projects with NIL investment : 23 Nos.

Total amount invested : Rs. 509 Lacs

Cost savings achieved : Rs. 588 Lacs

Electrical energy saved : 136 Lac Kwh

Thermal Energy saved : 1455 MT of coal

Reduction in GHG emissions : 22833 MT of CO2



685690695700705710715720

2014-15 2015-16 2016-17

718

701 699

64

66

68

70

72

74

2014-15 2015-16 2016-17

72.6

68.7967.66

51

52

53

54

55

56

2014-15 2015-16 2016-17

55.41 55.35

52.76

750

760

770

780

790

800

Target Achieved

796

768K

wh

/ M

T o

f C

lin

ker

Kca

l /

Kg

Cli

nk

er

Kc

al/

Kg

of

Ce

me

nt

Kw

h /

MT

of

Cem

ent

6

International Benchmark

National

Benchmark

TRCL

Alathiyur

• SHC-665 Kcal/Kg Clk

• SEC-65 Kwh/T Cem


• SEC-65.0 Kwh/T Cem


• SEC-67.7 Kwh/T Cem


Reference:

National Benchmark: Energy Bench Marking For Cement Industry May 2015 Version 2

International Benchmark : Indian cement and construction industries-global

competitiveness-NCB-CMA special publication presented in 8th NCB International

Seminar



Year

Scope 1

emissions

CO2e (MT)

Scope 2

emissions

CO2e (MT)

Scope 3

emissions

CO2e (MT)

Total CO2e

(MT)

% Reduction

in emission

2013-14 1773538 -171,011 43865 1479154 Baseline Year

2014-15 1598639 -289,137 33620 1343122 9.2

2015-16 1285294 -224,392 30503 1091405 26.2

2016-17 1249099 -372909 29503 905693 38.8

Scope 1 emissionsCalcination, Fuel for kiln & CBPP, owned vehicle,

Refrigeration & AC

Scope 2 emissions Power consumption

Scope 3 emissions Raw Material Supply & Product delivery


In Line-2 Cement Mill, in reject handling system we have one belt conveyor to convey reject material from mill to the reject elevator. From elevator then it goes to the reject bin, then to the mill feed via another belt conveyor

The reject handling system will be running continuously irrespective of the reject.

We have extended the existing reject belt conveyor from the mill to the clinker hopper filling DPC.

Eliminated the running of reject elevator and belt conveyor below the reject bin

Savings achieved : 20.5 kW/hr

Cost savings : Rs.6 lacs

Investment Cost : Rs. 5 Lacs

Simple Pay Back Period : 10 Months


In Line-2 Cement Mill the fan outlet duct routing is designed in such a way that majority of the fan volume is taken back to mill inlet as recirculation air and remaining is let out through chimney

We carried out a detailed audit of the mill fan ducting by taking pressure readings at various locations in the fan inlet, outlet, recirculation and duct to chimney

The fan outlet pressure variation was less, but the pressure variation in the recirculation duct was by 10 mmwg and the duct to the chimney the variation was 20 mmwg.

From the audit we identified that there is some turbulence or flow disturbance in the fan outlet duct area.



Cost Savings : Rs. 8 Lacs/Year


Electrical energy savings : 27 kW/hr

We planned to conduct CFD at the fan outlet duct area to understand the flow behavior

We contacted M/s. Mechwell to carry out the CFD analysis and to suggest the suitable modification for reducing the flow disturbance.

In the CFD analysis, it was clear that there is flow separation at the fan outlet area.

They suggested for modification of outlet duct and installation of baffle plate in the recirculation duct for uniform flow.


In Line-1 Cement Mill main bag filter outlet to fan inlet duct we observed fluctuation /turbulence in the duct.

We carried out a detailed audit of the mill fan ducting by taking pressure readings at various locations in the bag filter inlet, outlet and fan inlet duct.

The bag filter outlet pressure variation was by 20 mmwg

We planned to conduct CFD at the fan outlet duct area to understand the flow behavior

We contacted M/s. Mechwell to carry out the CFD analysis and to suggest the suitable modification for reducing the flow disturbance.

In the CFD analysis, it was clear that there is flow separation at the bag filter outlet area.

They suggested for modification of Bag filter outlet duct and installation of baffle plate at the bag filter immediate outlet for uniform flow.



Cost Savings : Rs. 15 Lacs/Year


Electrical energy savings : 60 KW/hr

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Energy consumption both electrical & thermal : Daily

Energy conservation projects : Weekly

Review meeting conducted by : Unit Head


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Energy Manager GM –E&I AVP-Works



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Energy management cell : 7 Teams

Thermal Energy audit : Heat balance in Pyro section-

Preheater, Kiln, Cooler & False Air study.

Electrical Energy audit : Efficiency of Motors, Fans, Blowers,Compressors etc.,

Quality circle forum : 14 Quality teams

5S & Suggestion scheme implemented


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Type of RES

2014-15 2015-16 2016-17

Energy

Generated

(kWh)

Annual

Savings

(Rs.)

Energy

Generated

(kWh)

Annual

Savings

(Rs.)

Energy

Generated

(kWh)

Annual

Savings

(Rs.)

Solar

photovoltaic40583 162332 58194 203679 78619 275167

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 MW with 229 individual Wind Electric Generators


S. No Type of Waste Fuel used Quantity of

waste fuel

used (MT)

Equivalent of

Conventional

energy used

(Ton of coal)

Waste fuel

as % of total

energy

1 Power Plant reject 16488 11255

2 Reject from sugar plant 4294 1164

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S.

No

Name of associate /

vendor

Energy

consumed

before

EnCon

energy

consumed

after

EnCon

%

improve

ment

Type of inputs /

projects provided

to the vendor/

associate

1 Mariamman Transport

SM Transport

SS Transport

Thirumala Transport

5.5 Ltrs/

MT

2.75 Ltrs /

MT

50% Provided return

logistics for clinker

and coal

2 Visaka Roadways

Thirumala Transport

SM Transport

7 Ltrs/ MT 3.5 Ltrs /

MT

50% Provided return


and wet fly ash

3 RS Mines Transport 7.5 Ltrs/

MT

3.75 Ltrs /

MT

50% Provided return


and dry fly ash


Implementation of Energy saving projects : 22833 MT CO2

Utilization of waste heat from cooler in cement mill : 71125 MT CO2


Total CO2 reduction : 93958 MT CO2

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Sl. No. Location Area in acres No. of Trees

2016-17 Up to 2017 2016-17 Up to 2017

1 Mines 13.37 207.19 10000 155003

2 Factory 0.20 67.70 1100 67300

3 Colony 0.10 57.78 500 54600

Grand Total 13.67 332.67 11600 276903

41.81% of total area is covered with green belt


Addition of 6 MW Generator with the existing boiler - Rs. 1500 Lakhs

Installation of 0.5 MW solar plant - Rs. 700 Lakhs


National Level Excellent Energy Efficient unit award (For the years 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 ,2007,2013,2014) 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 2005-06, 2006-07) by NCCBM.

Best Improvement in Energy performance in Manufacture of Blended Cements –2011-12 & 2013-14.

Second best Environmental Excellence in Plant operation – 2011-12.

Best Environmental Excellence in Limestone Mines – 2011-12.

Second Best Environmental Excellence in Limestone Mines – 2012-13


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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.

National Level Best Environment Excellence in Plant operation Award (For the years 2001-02, 2002-03 and 2003-04) by NCCBM.

GREEN AWARD 2012 from TNPCB

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


A flagship company of RAMCO Group, having five Cementgreenbusinesscentre.com/energyaward2017presentations/Cement/20... · Calcination, Fuel for kiln & CBPP, owned vehicle, Refrigeration

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