ISO 9001ISO 14001 &

IS 18001

Presentation on Energy Best Practices

The Ramco Cements Limited

Ramasamy Raja Nagar Unit

National conclave on Recent advances in Cement Industry , 15th October, 2018

at HICC, Hyderabad

About The Ramco cements limited , RR Nagar

1. Our unit has Cement production capacity of 2.0 MTPA and the manufacturing

product is 100 % Portland Pozzolana Cement as per BIS

2. We have 25 MW Coal based Thermal power plant

3. We are included in PAT Cycle III and our base line is 0.0847 TOE/T of

Product

4. Integrated management system

1. Quality Management System - IS/ISO 9001: 2015

2. Environment Management System - IS/ISO 14001: 2015

3. Occupational Health & Safety Management System - IS 18001: 2007

5. Five S’ Workplace Management System

6. Energy Management System IS/ISO 50001:2011

7. Man Power Utilization (Permanent & Contract): 5.59 Tonne of

Product/Manpower

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Energy ConservationOrganization Structure

Sr. Vice President

MFG

AVP

WORKS

GM (P & QC)

GM (MINES) DGM (PROJECTS)

ENERGY MANAGER

AGM (MECH)

SDGM (E&I)

DGM (ACCOUNTS)

INCHARGE

MINES

INCHARGE

RAW GRINDING

INCHARGE

PYRO

INCHARGE

CEMENT

GRINDING

INCHARGE

PACKING PLANT

INCHARGE

POWER PLANT

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ISO 50001:2011 Certificate

Energy Conservation Activities

❖ Daily analysis of specific energy consumption and compare the

same with targets and taking corrective action immediately if any

deviation is observed

❖ Conducting energy audit and preparing proposal for energy saving

❖ Study and implementation of energy saving proposals from

suggestion scheme

❖ Involving energy team personnel in equipment procurement

activities to procure high efficient equipments

❖ Conducting energy conservation meeting to compile and discuss

energy conservation points with management

ISO 50001:2011

❖ Energy Policy formulated

❖ Energy Conservation Teams are formed for each boundary

❖ Specific Energy Usage identified for each boundary

❖ Energy management action plan formulated

❖ EnMS internal auditor training completed

Energy Performance

S No Description Units 2016-17 2017-18

1 MTOE reduction MTOE 107 206

2Kiln Specific Thermal Energy

ConsumptionKcal/Kg Clinker 705 699

3Specific Electrical Energy –

ClinkerisationkWh/T of Clinker 54.9 54.45

4 Specific Electrical Energy – Grinding kWh/T of cement 32.5 32.6

5 Specific Electrical Energy – Cement kWh/T of cement 72.20 71.50

6 CPP Heat rate kCal/kWh

7 CPP Auxiliary Consumption % 10.12 10.02

8 Thermal Substitution Rate % 3.11 6.67

9 Clinker Factor % 0.706 0.710

10Blended Cement (%) of Total

Cement%

100% Inter

Ground PPC

100% Inter

Ground PPC

11 REC Purchased – Solar REC - -

12 REC Purchased – Non Solar REC - -

13 Specific CO2 Emission Kg CO2/ kg cement 0.752 0.730

Top Energy Projects Implemented in 2017-18

S.No ENCON Best Practices ImplementedSavings in

Lakhs

1 Installation of VFD for Boiler feed water pump at TPP 38.8

2 Installation of high efficiency Pillard burner in Kiln-2 23.2

3 Interlinking of Kiln-1&2 CCTV compressors after changing the pipe size 9.1

4Factory lighting optimization by replacing LED lights in place of conventional lights

8.4

5 Eliminating Unwanted Running of Fly ash Unloading Bag filter fan 6.40

6DG power plant auxiliary system idle power consumption reduction by optimization of heaters

6.2

7 Elimination of 6.6kV/3.3kV transformer to reduce transmission loss 2.6

8Package AC cooling tower replaced with individual split AC in accounts department

1.5

Innovative Ideas Implemented in 2017-18

Kiln-1 Bag House Modification

Kiln-1 Bag House

Constraints in present operation

❖ Bag house differential pressure maintained 150-170 mmWG

❖ Compressed air pressure maintained 4.0 to 4.5 bar

❖ Bags damage and less life due to clustering of bags

❖ The bag house inlet temperature is high due to pressurization

❖ Not able to increase the preheater fan speed further

❖ The compressor is running always in loading condition

❖ Above condition resulted increase in bag house fan & compressor

power consumption

❖ Dust emission 40 - 50 mg/nm3

Development of In-House Solution:

❖ Newly designed & In-house fabricated Grid system installed at bag

filter bottom portion to hold each bags.

Kiln-1 Bag House

Before After

❖ Compressed air purging pipes replaced with new design

Insertion & U clamp fixing of purge pipe

Before After

Flange type fixing of purge pipes

Kiln-1 Bag House

❖ Height between purging pipe and tube sheet has been reduced

Before

350mm245mm

After

Kiln-1 Bag House

Performance Improvement & Benefits achieved:

❖ The Bag filter DP is reduced by 40 mmWG with reduced

compressed air pressure of 3.5 to 4.0 bar

❖ Power saving in Bag filter fan & Compressor is 25 Kw/hr

❖ Dust emission level reduced from 40 to 8 mg/nm3

❖ Kiln performance has improved by increasing preheater fan

flow rate

❖ Bags life increased due to reduction in purging air pressure &

avoiding clustering of bags

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Kiln-1 Bag House

Innovative Ideas Implemented in 2017-18

Auto Sampler Fabrication for Clinker Sampling

Constraints in Present Operation:

❖ Manual Spot sampling shows only the instantaneous clinker

quality

❖ Taking corrective action based on the spot sampling gives

wrong result some time

❖ In manual sampling, person to person the sampling techniques

are changing

❖ Man hour utilisation is high due to sampling and sieving

❖ Dust emission during sieving

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Clinker Auto Sampler

Development of In House Solution:

❖ In-house made auto sampler has been installed at clinker

crusher outlet DPC

❖ It collects the average sample for every 10 minutes.

❖ Its provide litre weight sample and raw clinker separately

❖ This sampler connected with CCR PLC

❖ We can adjust the sample collection period and quantity as

required

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Clinker Auto Sampler

Page 18

Working of Auto SamplerWorking of Auto Sampler

Guide

pulley

Clinker Collection

Tray

DPC

Drive pulley

Clinker

Silo

Cooler Outlet

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Working of Auto SamplerWorking of Auto Sampler

Vibrating screen

6mm to

12 mm

material

>12 mm

material

< 6 mm

material

Drive system

Pneumatic

cylinder

Sample for

Litre weight

analysis

Sample for

Elemental

analysis

To DPC

Benefits Achieved:

❖ Clinker sampling is more representative from hourly spot

sample to once in 10 minutes average sample collection.

❖ Consistency in quality improved due to more representative

sampling.

❖ Frequency of operating parameters changing has reduced.

❖ Specific fuel consumption reduced by 1.6 Kcal/Kg Clinker

❖ Coal Saving 248 MT/annum

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Clinker Auto Sampler

Innovative Ideas Implemented in 2017-18

Overhead Transmission Line Power Transformer Shifting From Receiving

End to Sending End

OH Transmission Line Power Transformer

Constraints in present operation:

❖ The crushing plant is located 23 Kms from the factory at our

Pandalgudi Mines, which crushes the limestone upto -25mm size.

❖ The average power requirement for operation of this plant is 1.5

MVA.

❖ This Power requirement is met through 11 KV Overhead

Transmission line from Factory to Mines.

❖ During Raining condition and Thunderstorm, Insulators in the

overhead line failed frequently and broken. Hence line tripped due

to earth fault frequently.

❖ During heavy fault condition, Thermal power plant generator

breaker has tripped causing complete block out of Cement plant.

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6.3 MVA POWER TRANSFORMER SHIFTED

FROM MINES TO FACTORY

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6.3 MVA POWER TRANSFORMER SHIFTED

FROM MINES TO FACTORY

Numerical Feeder Protection

Relay at Transformer Secondary (For Tripping

During Fault in Power Line)

OH Transmission Line Power Transformer

Solution & Benefits Achieved:

❖ To overcome this issue, we have planned to shift the Power

transformer used at receiving end side (Mines side) for voltage

step up purpose to sending end side (Cement Plant side).

❖ Also we have installed high accuracy Numerical protection relays

at the secondary side of Power transformer for tripping during

earth fault.

Benefits:

❖ By Installing the Power transformer Thermal Power Plant tripping

due to fault in overhead line is completely eliminated.

❖ Transmission loss reduced by 0.5% which is around 7 Lacs/

Annum.

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Energy conservation Projects/Renewable Energy projects under implementation

Sl.NoENCON Projects Planned for the year

2018-19

Expected Electrical Saving

(Kwh/Year)

Expected ThermalSaving

(MT/Year)

1Installation of SPRS for Kiln-2 preheater fan in place of GRR

3,37,920 -

2Replacement of efficient shell cooling fan (8 nos.) in Kiln-1

2,23,560 -

3Low pressure compressor installation for Kiln bag filter to avoid losses in regulator

1,24,200 -

4Installation of VFD for cement mill higher capacity (>450 CFM,75 KW) compressor

93,600 -

5Installation Dp transmitter for all the unit bag filters their by saving power in compressor

84,500 -

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Sl.NoENCON Projects Planned for the year

2018-19

Expected Electrical

Saving (Kwh/Year)

Expected ThermalSaving

(MT/Year)

6Kiln feed extraction to Pre-heater top air slide blower capacity to be reduced

72,864 -

7 Installation of VFD for Coal mill-1 Bag Filter fan 66,240 -

8Installation of VFD for Kiln-1 Secondary firing blower as same done for Primary firing

49,680 550

9Unit bag filter in fine coal bin-2 to be stopped by changing the common venting line

45,540 -

10 Installation of VFD for CM Ball mill-2 Bag Filter fan 43,200 -

11 Installation of VFD for Coal mill-1 Booster fan 39,745 -

12Fuzzy Logic System for Kiln-1 to reduce fuel consumption by improving kiln steady operation

- 686

Energy conservation Projects/Renewable Energy projects under implementation

Energy Conservation Day Celebration

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