THE RAMCO CEMENTS LIMITED JAYANTHIPURAM · 2016. 12. 21. · Ramco Group The Ramco Cements Ltd., (formerly Madras Cements Ltd.) Integrated Plants : 1. RR Nagar Plant near Virudhunagar,

IMPLEMENTATION OF ISO 50001:2011 & BEST PROJECTS ON ENERGY

CONSERVATION @

THE RAMCO CEMENTS LIMITED JAYANTHIPURAM

Cement Ready Mix Concrete Cement Fiber Products Cotton and Synthetic Yarn Software Systems Total Employees : 15,000

Ramco Group

The Ramco Cements Ltd., (formerly Madras Cements Ltd.)

Integrated Plants :

1. RR Nagar Plant near Virudhunagar, TN (2.0MTPA) (Established in 1959)

2. KSR Nagar Plant, Jaggaiahpeta, Andhra Pradesh (3.65 MTPA) (Estd. in1986),

Turnover-662 crores , No. of Employees- 431

3. Alathiyur near Vridhachalam, Tamil Nadu (3.0 MTPA) (Established in 2002)

4. Mathod near Chitradurga, Karnataka (0.3 MTPA) (in Operation since 2000)

5. Ariyalur, Tamil Nadu (5.5 MTPA) (Established in 2009).

Cement Grinding Units :

1. Kattuputtur (0.75MTPA) 2. Valapadi (2.0 MTPA)

3. Kolaghat (1.0 MTPA) 4. Vizag (0.95 MTPA)

Wind Farms Research & Development Dry Mortar Plants Cotton Textiles Surgical. Turnover : Rs. 6,700 crores

Packing Unit :

1. Nagercoil,TN

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ENERGY ROAD MAP

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Road Map

11 Teams formed

Monthly Project Discussion & Review

2 New Teams

Monthly Project & Energy Consumption Discussion & Review

Quarterly review of Energy Consumption target & Achievement

MANAGEMENT SYSTEM CERTIFICATES

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APEX COMMITEE

Sl. No. Name Designation

01 Sri PB Gopalakrishna Sr. President - Mfg.

02 Sri T Sridhar Reddy Asst. Vice President - Works

03 Sri AV Satyanarayana Sr. Mgr.- Mech.

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CORE COMMITTEE

Sl. No. Name Designation

01 Sri S Rajasekharan GM – Process & Quality Control

02 Sri D Sitaramaiah Dy. GM - Mech.

03 Sri S Kesavaperumal Dy. GM – Inst.

04 Sri V Venkatapathi Asst. GM – Elec.

05 Sri VV Trinadha Rao Asst. GM - Elec.

06 Sri SVSN Raju Sr. Manager - Mech.

07 Sri P Sreekanta Reddy Manager – Inst.

08 Sri R Venkatapathi Gupta Dy. Manager - Mech.

09 Sri Chandan Kumar Parasar Dy. Manager - Process

10 Sri M Sreedhar Asst. Manager - Elec.

Energy Conservation Organization

SAVINGS ACHIEVED…

Year Savings

(Lakh KWH)

2012-13 10.50

2013-14 7.25

2014-15 40.84

2015-16 17.91 10

ENERGY CONSERVATION ACTIVITIES…

• Competitions are being conducted twice in a year on Energy

Conservation Day (December,14th) & Our Founder’s Day

(April,24th).

• These Competitions include:

• Energy Conservation Projects Presentation among Energy Teams.

• For employees, contract workmen, ladies club members, school

children:

• Slogans,

• Essays,

• Paintings,

• Skit programs, etc. 12

ENERGY CONSERVATION ACTIVITIES…

• The winners are felicitated with suitable rewards / awards.

• As a motivation for energy conservation, LED Bulbs are being

distributed as gift to:

• Apex Committee Members

• Core Committee Members

• All Energy Team members

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ENERGY PERFORMANCE IMPROVEMENT

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Sl. No Description Units 2014-15 2015-16

1 MTOE reduction MTOE -- --

2 Kiln Thermal SEC kCal/kg clinker 727.26 710.15

3 Specific Electrical Energy - clinkering kWh/T of clinker 58.17 58.50

4 Specific Electrical Energy – Grinding (Inc of

OPC & PPC) KWH/T of Avg Cement 35.01 36.18

Capacity Utilization Clinker (%) 32.95 23.04

Cement (%) 50.75 36.48

5 CPP Heat rate kCal/kWh 3175.56 2868.51

6 CPP auxiliary consumption % 11.61 12.07

7 Thermal Substitution Rate % 0.05 0.15

8 Clinker factor % 78.11 75.72

9 Blended cement *%) of total cement % 64.57 68.25

10 Renewable Energy (RPO) -- --

11 REC Purchased – Solar REC -- --

12 REC Purchased – Non Solar REC -- --

13 Specific CO2 emission Kg CO2/ kg cement 0.67 0.65

TOP TEN ENERGY PROJECTS IN 2015-16

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S.No Project Details

Savings achieved in KWh

(Upto 31-03-16)

(Rs. In Lacs)

Remarks

1

To stop the 500T bin feed bucket elevator, elevator receiving and discharge airslides while one kiln is running with respect to 500T bin level.

28536.00 1.12

2 Removal of Line 2 Cooler Fans (6 Nos) Silencer. 196600.20 7.71

3

Stopping of line 2 TAD Damper Cooling Blower for In-filtration of False Air while Damper Worn Out (0.9 TPD of Coal Consumption + Saving of Rs. 4.21 Lakhs after replacement of Present Hollow Damper with Plate Damper)

9750.02 9.02

Power Cost Saving : 38220.06 [ 4.5 KW/hr (Power Saving) * 2166.67 Hrs (Kiln Run Days) * Rs. 3.92/KWH (Unit Cost)] Material Cost Saving : 420632.87 [Rs. 949512.87 (Hollow Damper Cost Inc Castable) - 5, 28,880.00 (Plate Damper Cost Inc Castable)] Fuel Cost : 443440.17 (0.90 TPD of Coal Saving * 81 Run Days * Rs. 5474.57/ MT of Annual Fuel Cost) Total Saving : 902293.10

4

To reduce Line 2 Cooler esp fan power by optimizing the cooler esp fan speed through providing modified auto loop with Kiln Hood Draft

56131.25 2.20

5 Replacement of SV lamps with LED fittings -100 nos in silo's and work shop.

43560.00 1.71

TOP TEN ENERGY PROJECTS IN 2015-16

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S.No

Project Details

Savings achieved in

KWh (Upto 31-03-

16)

(Rs. In Lacs)

Remarks

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Power reduction by reducing run hours of Plant incoming 180 kW pump by installing level indicator at TPP tank & running 132 kW pump during tank high level .Low level indicator at 4.5 mts and high level indication at 6.0 mts

78492.00 3.08

7 Reduce the Fuel consumption in Wheel Loaders by Reducing it's maximum Engine RPM from 2300 tom 2150.

HSD saving - 5336 Liters

2.80

8 To reduce the power consumption of North Band Mines Dewatering pumps by increasing the suction pipe size.(8" to 10")

46605.00 1.83

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To increase the pump discharge quantity of plant water supply pump (132KW) by interchanging the delivery pipe line.(6" to 10" size)

74480.00 2.92

10 Optimization of cooling tower and condenser performance to reduce the specific steam consumption.

947576 .00 37.14

Condenser-2 Re-tubing (19/09/15)

Nozzles & Adaptors replacement (31/10/15)

Cooling tower Fills replacement U/P

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Removal of Line-2 Cooler Fans Inlet Silencers

Before

After

ΔP : 35-180 mmwg

Unit Savings : 1320 KWH/Day

Cost Savings : Rs. 17.82 Lakhs/Annum

ΔP : 21-56 mmwg

Sound: 74-76 dB

TA

Duct

Kiln Feed

Kiln

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Modification of Line – II Tertiary Air Duct Damper Design

Kiln

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Blower Running for TA

duct Damper Cooling

TA Duct

Damper

TERTIARY AIR

DUCT

Blower Idle

Running

TERTIARY AIR

DUCT

New TA DUCT

DAMPER

Unit Savings : 108 KWH/day Fuel Saving : 1 TPD Total Cost Savings : Rs. 9.02 Lakhs/Annum Material Cost Saving : Rs. 420632.87

• Replacement of LRS with GRR in Cement Mill Separator Fan

• Description : The Mill Separator Fan is running in LRS with Damper Opening of

65-70% only to get the required flow. But the Pressure Loss across the Damper

was maintaining in the range of 130-150 mmwg. During the Line-1 Up-

gradation we have reused the spare GRR from our Coal Mill Fan to this

separator Fan. After GRR installation, we are now running the fan with full

damper opening by controlling the speed. With this the Pressure Loss across

the damper has reduced to 15-20 mmwg only & the Power saving achieved to

55 KW.

• Savings (KWH) : 660 KWH/Day

• Cost Savings (INR) : Rs. 9.42 Lakhs/Annum

• Project Investment : In House shifting only 27

INNOVATIVE ENERGY CONSERVATION PROJECTS

• Sky Lights were installed at the areas like Store Room, Packing Plant Bag Storage Area, Workshop, Wagon Loading Platforms, Instrument Panel room etc to control the Day time lighting Power Consumption.

• Total No of SV Lamps switched off during Day time : 50 Nos

• Each Lamps Power Consumption : 0.40 KW

• Saving Achieved : 0.40 KW*50 Nos.*12 hrs = 240 KWH/Day

: Rs. 3.50 Lakhs/Annum

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RENEWABLE ENERGY PROJECTS

BEST PRACTICES ON ENERGY CONSERVATION…

• Engaged CSIR-CSIO, Chennai to study the Performance/Efficiency of

significant motors regularly.

• Water Audit was conducted to establish water consumption in Plant &

Mines, there by reduced the power consumption of Water Pumps.

• Compressed Air Audit is being conducted to optimize Air Consumption.

• Energy Efficient motors only are being procured for any future .

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BEST PRACTICES ON ENERGY CONSERVATION

• 100 % High Sulfur (>9%) Petcoke usage as a Fuel in Pyro

System

• Specific Coal Consumption has reduced by 4.5%

(From 14% to 9.5%)

• Coal Mill Specific Power Consumption also reduced by reduction in the

Coal requirement

• Before with Imp Coal : 4.5-5.0 KWH/T Clinker

• After with Petcoke : 3.8-4.0 KWH/T Clinker

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BEST PRACTICES ON ENERGY CONSERVATION

(PROJECT UNDER IMPLEMENTATION)

• Replacement of Flyash Bulk tanker unloading Conventional Screw Compressor with

Energy Efficient Low Pressure Lube Compressor

• Description : Replacement of existing 110 kW Screw Compressor with 55 kW

energy efficient Godrej make Screw Compressor

• Total Projected savings (KWH) : 331730

• Cost Savings (INR) : 1393266

• Cost savings in maintenance Rs. : 80000

• Total annual saving Rs. : 1473266

• Project Investment Rs. : 13,00,000

• Payback : 11 months

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PROPOSED LOW PRESSURE LUBE COMPRESSOR OF M/S GODREJ MAKE-

(55KW)

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BEST PRACTICES ON ENERGY CONSERVATION IN

(PROJECT UNDER IMPLEMENTATION)

• Line-1 Up-gradation

• Capacity enhancement from 3500 TPD to 4600 TPD by

• New ABC Cross Bar Cooler with HRB

• New Additional Preheater Installation

• New ESP to reduce the Dust Emission from 50 mg/Nm3 to <30

mg/Nm3

• Thermal energy savings : 30 Kcal/Kg clinker

• Electrical energy savings : 5.10 KWh/T Clinker

• Project Under Progress …

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