ISO 9001ISO 14001 &

IS 18001

Presentationon

Best Environment Practices

THE RAMCO CEMENTS LIMITED

Ramasamy Raja NagarVirudhunagar District

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The Ramco Cements LimitedRamasamy Raja Nagar

5S Certified by

QCFI jointly with JUSE

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Environmental Policy

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CERTIFICATIONS

IS/ISO 9001 – 2015

Quality Management System

IS/ISO 14001 – 2015

Environment Management System

IS 18001 – 2007

Occupational Health & Safety Management System

IS/ISO 50001 – 2011

Energy Management System

‘5S’ Workplace Management System

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Environment Organization

Sr.Vice President (Mfg)

AVP (Works)

DGM

(Horticulture)

DGM (MS)In charge of Environmental

activity

JM (Civil)Environment Assistant

AM (MS)Environment Assistant

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IS/ISO 14001:2015 Certification

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Salient Futures of Ramasamy Raja Nagar Unit

In 1976, we were the first to introduce 1200TPD Dry process kiln in South India.In 1976, we were the first to introduce 1200TPD Dry process kiln in South India.

Manufacturing 100% Portland Pozzolana CementManufacturing 100% Portland Pozzolana Cement

A flagship company of RAMCO Group, having five Cementmanufacturing and 4 Grinding units with a capacity of 16.5MTPA

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.,

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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Manufacturing Process at RR Nagar Unit

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Sl.No OBJECTIVES TARGETS

1 Dust Emission from all the bag filter stacks < 30 mg/Nm3

2 Ambient air Quality - PM 2.5 < 60 µg/m3

3 Ambient air Quality - PM 10 < 100 µg/m3

4 Carbon Emission < 740 kg CO2e/MT of cement

5 Raw mill-1 Specific Power Consumption < 21.18 Kwh/T of Material

6 Raw mill-2 Specific Power Consumption < 14.07 Kwh/T of Material

7 Coal mill-1 Specific Power Consumption < 49.45 Kwh/T of Material

8 Coal mill-2 Specific Power Consumption < 45.32 Kwh/T of Material

9 Kiln-1 Specific Power Consumption < 24.49 Kwh/T of Material

10 Kiln-2 Specific Power Consumption < 31.75 Kwh/T of Material

11 Cement mill Specific Power Consumption < 32.97 Kwh/T of Material

12 Specific Power Consumption–Up to Clinker < 63.10 Kwh/T of Clinker

13 Specific Power Consumption–Up to Cement < 76.50 Kwh/T of Cement

14 Specific Heat Consumption in Kiln < 710 Kcal/Kg Cl

Environment Objectives and Targets

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❖ We are operating 4 nos. of mines

❑ PG Mines

❑ SVP Mines

❑ MVP Mines

❑ MPG Mines

❖ There are 3 nos. of Crusher in mines

❑ Primary Crusher (Jaw Crusher)

❑ Secondary Crusher (Hammer Crusher)

❑ Kankar Crusher (Hammer Crusher)

❖ State of the Art Technology “Optical Sorter” which separates theBlackstone from Limestone on the basis of colour of the material

❖ Cross Belt Analyser, supplied by M/s.Gamma Matrix, U.S.A, installedwhich helps to minimize variation in quality

Adoption of Latest Technology for

Environment Responsive

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❖ Optima Pre-Blending Control System – For better blending of Pilelimestone

❖ 13 nos. of unit bag filter for mines crusher circuit de-dusting

❖ Vertical Roller Mill Pre-grinder as a closed circuit for raw grinding tosave specific power consumption

❖ Optima Blending Control System for raw meal correction which willensure minimum deviation in quality

❖ Blending silos for raw meal to control the variation in raw mealquality

❖ High efficient Fives Pillard Burner for kiln firing

❖ Low pressure drop cyclone for pre-heater with inline calciner

❖ On line gas analyser for Kiln inlet, Calciner outlet and preheater exitto run the kiln in optimized condition.

❖ Latest SF cross bar cooler for clinker cooling

Adoption of Latest Technology for

Environment Responsive

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❖ High efficiency bag filter for kiln, emission level < 10mg/nm3

❖ High efficiency pulse jet bag filter for coal mills

❖ Roller press with ball mill for Cement grinding

❖ To avoid dust emission, 60 nos. of de-dusting bag filter for plant

operation

❖ We have 25 MW Thermal Power Plant

❖ We have 3 nos. of DG (2 x 4MW & 1 x 7MW)

❖ Preheater exhaust gas is utilized for limestone drying in raw mill

❖ Cooler exhaust is utilized in Coal mill for fuel drying

Adoption of Latest Technology for

Environment Responsive

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Road Map

To Reduce Carbon Foot Print Activities

We have reduced 18.0 % Carbon Emissions compared with baseline year.

Further to reduce carbon emissions we have planned the following Projects:

1. Installation of stacker & Reclaimer for Limestone and Fuel

2. Installation of VFD for Kiln-1 Secondary firing blower

3. Fuzzy Logic System for Kiln-1

650

700

750

800

850

900

950

Baseline 2015-16 2016-17 2017-18

891

834

752730

kg C

O2

e/M

T o

f ce

me

nt

CO2 Reduction

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House Keeping Infrastructure

5S – Mass Cleaning Activity

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Time Office to Colony RoadBefore After

Near by Kiln-1Before After

Plant Visuals

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Rain Water Harvesting Ponds

Sri Ram Primary School Near South Gate Compound Wall – 1

Near South Gate Compound Wall – 2 Ramco Vidyalaya School South

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Afforestation in Mines colony area Afforestation in Dump yard

Factory Colony Mines office entrance

Afforestation in Quarry & Factory

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SEWAGE TREATMENT PLANT

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Road Sweeper Vacuum Cleaner Water Sprinkler

House Keeping Infrastructure

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❖ Well equipped Ambulance is available

❖ Health Register System for all Employees and their family

❖ First Aid box provided for various Sections

❖ Periodic Medical Examination for all the Employees & Contract workmen once in year

❖ Audiometric Test conducted yearly once for Employees working at high noise area

❖ Special Eye test for drivers

❖ Lungs Test for Employees working at high dust area

❖ Camp for Thyroid test

Health Policy Statement Deployment Measures

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Occupational Health Centre

Health Register System & First Aid box

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Emergency Drills

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Safety InfrastructureFire hydrant system for Factory Premises

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CAAQM – Continuous Ambient Air Quality Monitoring Station

Electronic Display for Stack

Emission Monitoring

Tube Belt Conveyor Gypsum handling

Environmental Projects

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❖ Online monitoring system for 9 nos. of main stacks

1. Raw mill-1 Bag filter

2. Kiln-1 Bag filter

3. Kiln-2 Bag filter

4. Cooler-1 ESP

5. Cooler-2 ESP

6. Coal mill-1 Bag Filter

7. Coal mill-2 Bag Filter

8. Cement mill Bag Filter

9. TPP ESP

❖ Online gas analysers for Preheater section to run the Kiln optimizedcondition and thereby reducing environment

Online Monitoring Systems

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Online Sox & NOx MonitorOnline SPM Monitor

Pollution Control Equipments

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Green Belt development

Sl.No

Location

2017-18 Up to 2018

Area in Acres

No. of Trees

Area in Acres

No. of Trees

1 Mines 45 12,000 298.0 2,65,700

2 Factory 6 2000 44.7 16,750

3 Colony 4 2000 15.0 7,060

4 School 1 500 24.0 8,000

5 Nearby Villages 8 2300 63.0 28,060

Grand total 55 18,800 444.7 3,25,570

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World Environment day Celebration

Employees Drama

Environment function

Tree Plantation

Children's Drama

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Environment Segregation of Domestic Waste

•Dustbins provided for Colony houses for storing the Kitchen

wastes separately as Degradable and Non-degradable

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Environment improvement projects

implemented

Sl.No

List of the Major Environmental ProjectsInvestment(Rs. Lakhs)

1Surveillance camera is located at all the hopper discharge and transfer points to monitor and avoid any spillage

300.0

2External Clinker Unloading hopper and Packer-2 de-dusting bag filter capacity increased from 25000 to 55000 m3/hr

250.0

3 5.0 Nos. of de-dusting bag filters installed in the plant 42.0

4 3 Nos. of unit bag filters installed in Coal handlingarea and coal mill 32.0

5 3.0 Nos. of de-dusting bag filters installed in Crusher area 24.0

6Kiln-1 main bag filter modified and the dust emission reduced to less than 10 mg/nm3

12.0

7Gas analyzer is installed at the kiln-2 inlet, to monitor the kiln condition and thereby improve the combustion, and to predict the quality of clinker

6.0

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Sl.No

List of the Major Environmental ProjectsInvestment(Rs. Lakhs)

816 Nos. of Solar lights in place of 16 Nos. of Sodium vapour lights in Colony

4.0

9Re routing of de-dusting ducts in Roller press to avoid the fugitive dust generation

3.0

10 Change over from box vehicle to bulkers for dry fly ash handling 1.4

1135 Nos. of LED lights in place of Fluorescence tube light in material store

1.1

12Modification of crusher and its screen discharge chutes to avoid material spillage and dust emission

0.9

13Installation of water spray system at belt discharge in mines to avoid dust emission

0.6

Environment improvement projects

implemented

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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

5 120 Nos. LED lights in place of Conventional lights 6.0

Total Project Cost: Rs. 399 Lakhs Total Project Cost: Rs. 399 Lakhs

Environment improvement projects

implemented

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1. Energy Efficient Unit Award

for the Year 2013-14

2. Energy Efficient Unit Award

for the Year 2014-15

3. Excellent Energy Efficient Unit

Award for the Year 2015-16

4. Excellent Energy Efficient Unit

Award for the Year 2016-17

5. Best Innovative Project Award

2017

6. EHS Excellence Award 2017

Awards & Accolades

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