1

A flagship Company of The RAMCO group which divested in different sectors like Cement, Software, Fiber Cement, Textiles, Surgical, Bio-Tech,.

5th Largest Cement Producer in India with total installed capacity of 16.05 MTPA located at 11 places throughout in India

RAMCO - Ariyalur Plant is Ultra modern Plant with two Production Lines Of 4200 TPD & 5000 TPD capacity & Thermal Power plant of 66 MW Capacity

The Products manufactured are OPC as per BIS & SLS standards, PPC as per BIS.

Bulk Solid analyzers for quality control at the raw materials stage itself & Modern X-ray - XRD & XRF for analyzing elementary and chemical composition.

State of the art grinding Technology with 950 TPH Packing Plant having auto Packer truck loader arrangement

IS 18001

Occupational Health &

Safety Management

System

ISO 14001Environment

Management System

ISO 9001Quality Management

System

IS/ISO

50001:2011

Energy Management

System

“5S” Certified CompanyCertified Green

product by CII

RCL – Govindapuram, Ariyalur 4

No. of Projects Completed

48 Nos

Cost savings achieved

Rs.1069.43 Lakhs

Electrical energy saved

104.99Lakh Kwh

Thermal Energy saved

199.94 MT of coal

Projects with NIL investment 31 Nos.

Projects with Investment

RS 354.78Lakhs5

S.NO TITLE OF PROJECT

SAVINGS

(Rs in

Millions)

1Alternate Vortex plate Removal in Cement mill-

I Separator1.24

2Optimization of CF silo-2 aeration blowers by

stopping 1 excess blower.0.39

3Main Bag house Purging Modification in

Cementmill-10.31

4Compressor optimization by stopping 160CP01

in cementmill-10.31

5Optimization of CF silo-2 before and after

Rotoscale bin airslide aeration blowers.0.20

6 Line-2 coal mill water spray pump optimization 0.17

7Cement silo top 6 Nos of unit bag filters

compressed air optimization0.10

S.NO TITLE OF PROJECTSAVINGS (Rs

in Millions)

8 Interlock in Crusher Section - if crusher Stops, the

Compressor and Unit Bagfilter will trip with 5 mins

Delay to avoid idle run hours.

0.09

9 In Coal mill-1, Unit bagfilter 151FN05 will Trip After

surge bin feeding belt 151BC03 with the time Delay

of 10 mins to avoid idle run hours.

0.01

10 Idle run hours of 2 No’s unit bagfilter in top of

Flyash silos are avoided by interlocking with flyash

mechanical and pneumatic feeding systems with

time delay.

0.02

11 Idle run hours of 2 No’s unit bagfilter in bottom of

Flyash silos are avoided by interlocking with

respective flyash solid flowmeter with time delay.

0.02

12 Workshop and auto equipments individual switch

control for lighting0.04

S.NO TITLE OF PROJECT

SAVINGS

(Rs in

Millions)

1Crushed material to be brought to LSR 1 & 2 by

passing of LSR 3 & 4.9.09

2Line-2 raw mill inlet duct modification for reducing

pressure drop in hot gas duct.8.36

32 nos. of Boiler feed water pump 6.6 kV, 550 kW

Siemens make VFDs with off load isolators installed.6.02

4Switching over from diesel to electricity for

dewatering and tower lights.4.59

5Compressor air optimization - linking compressor air

from common source1.15

6Rotoscale bin aeration blower-240BL05 derating

from 1400 to 1000 rpm by changing pulley.0.56

7Providing fuel catalyzer for Ripper Dozer - to reduce

the Diesel/hr consumption0.52

S.NO TITLE OF PROJECT

SAVINGS

(Rs in

Millions)

8 Power savings in Line-I CF Silo Top Unit bag filter fan

motor derating from 1500 to 1000 rpm0.45

9 Power savings in Line-2 CF Silo Top Unit bag filter fan

motor derating from 1500 to 1000 rpm0.38

10 Power savings in Line-I Cooler discharge Unit Bagfilter

fan motor derating from 1500 to 1000 rpm0.34

11 Avoiding of under loading of 225BC16&17 by

installation VFD0.12

12 Raw material Conveyor idle run hours minimization

by installing belt weighers and 15 min time delay

tripping (adjusted based on belt empty time)

0.14

13Elimination of Cooler ESP-2 Drag chain by providing

Chute to DPC0.02

650

660

670

680

690

700

710

720

2013-14 2014-15 2015-16 2016-17

710714

688 684.56

Kcal

/ K

g C

linker

11

74

75

76

77

78

79

80

81

82

83

2013-14 2014-15 2015-16 2016-17

82.61

77.8477.46 77.15

Kw

h /

MT

of

Cem

ent

12

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

13

Parameters

2014-2015 2015-2016 2016-2017 Waste Fuel

as % of

total

energy

used

Quantity of

waste Fuel

used (MT

per year)

TSR

Quantity of

waste Fuel

used (MT

per year)

TSR

Quantity of

waste Fuel

used (MT per

year)

TSR

Power plant Ash 0 0 18535.05 0.67 5320 0.5 2.09

Tyre Oil 65.55755 1 77.9204 1 60.72695 1 0.127

Total

Consumption0.127

14

INN

OV

AT

IVE

PR

OJE

CT

S

EXTRA SEAL ARRANGEMENT IN VRM CLASSIFIER FOR MAINTAINING RESIDUE IN 90 micron

RAWMILL-2 VRM INLET DUCT MODIFICATION TO REDUCE THE TURBULANCE IN DUCT

40 MW STG EXTRACTION SET POINT REVISION FOR IMPROVING TURBINE EFFICIENCY

Out of our innovative projects done so far , We are happy to

present some of our Projects in detail as listed bellow

➢ In VRM classifier, internal and external seals are present to

avoid the bypass of ground material through the Rotor.

➢ The inner seal efficiency is decided based on the height of the

seal. If we increase the vertical it will further reduce the rotor

classifying area.

➢ In outer seal we maintain a minimum horizontal gap which is

based on the wobbling of the rotor.

➢ Wear in inlet and outer seal is also a big issue when mill

continuous running is needed.

➢ Hence we decided to reduce the bypass of ground material

without wear in classifier components.

➢ A new seal is proposed and it will reduce the 80% approx

airflow which is bypassing the classifier.

➢ Due to this wear in outer seal has been reduced significantly.

➢ The residue in R90 has been decreased from 2.5 to 1.5%.

PROJECT DESCRIPTION:

We have studied the duct from Preheater to Raw mill to

decrease the same and we found out the following.

➢ The pressure drop across the duct is relatively high

➢ By increasing the diameter, we can increase the flow rate.

➢ The pressure drop across the preheater fan outlet to Raw mill

inlet is high.

➢ After modification the Pressure Drop Across the junction box

has been reduced from 80mmwg to 20mmwg.

PROJECT DESCRIPTION:

Description Value UOM

Savings Achieved 3.3 Kwh/T of Clinker

Investment cost 20 Rs Million

Cost Savings 18 Rs Million per year

Payback period 3 month

PREVIOUS SET POINT REVISED SET POINT CONDITION

70 TPH (TURBINE

INLET)

50 TPH LP Heater Enable

90 TPH (TURBINE

INLET)

50 TPH and LP Heater

outlet Temp @ 70

Deg.C

De-aerator Enable

70 TPH (TURBINE

INLET)

50 TPH & De-aerator

QCNRV open feed back

HP Heater Enable

65 TPH 45 TPH LP Heater Disable

87 TPH 45 TPH De-aerator Disable

65 TPH 45 TPH HP Heater Disable

➢Thermal savings :80 kcals/KWh

➢Cost savings :Rs 9.7 million per year

➢Investment made :0

Page 19

APC Measures

• ILC Preheater with Low Nox

Calciner in Pyro section.

• Duo flex Burner for kiln firing

which consumes less primary

air which reduces the Nox

formation in the kiln.

• PTFE member woven fibre glass

bags.

• The Electro Static Precipitator

(ESPs) are controlled by Micro

controller based automatic

controller – this regulates,

monitors & optimizes the input

electric power to ESP to reduce

and maintain minimum stack

output.

Auto Truck Loading Machine Dust Suppression System

Dry Fog System Rehabilitation of Refilling

Area

We have installed sprinklers and drip

irrigation system for optimum utilization

of water to our greenery

development

Sewage Treatment plant (600 m3 / day)

installed is effectively used for treatment and utilized for green belt

development

S

.

N

o

Particulars Year Quanti

ty

1 CETP

Sludge

(in MT)

16-17 904.26

2

ETP Water

from TPP

(in KL)

14-15 26943

15-16 34070

16-17 27129

Bio Gas Plant to consume

kitchen waste from colony and canteen with a capacity of 400

kg/day

2014-15 2015-16 2016-17

75620

79511

77620

Year No. of

Trees

Area

in hectares

2007-08 450 0.405

Total no of

trees are

79511 i.e.

covering

35.08 %

with 90%

survival

rate

2008-09 3000 4.047

2009-10 2000 2.834

2010-11 1100 1.416

2011-12 2900 4.047

2012-13 17670 14.164

2013-14 46000 18.625

2014-15 2500 2.834

2015-16 2000 2.42

2016-17 1891 2.42

• 10 Cross functional ENCON Teams has actively participated in Implementing Energy Conservation activities & Executed 25 Nos Projects successfully.

ENCON

• Through EnMS we are following the Monitoring Reports IER , DEPTS, EMAP Regularly & discussed in monthly Review meeting

Monitoring& Reporting

• As a small step for reducing carbon Emission, We encourage usage of Bicycle by restriction of Automobiles monthly once

Use bicycle

• By implementing Suggestion scheme with rewards & recognition, Shop involvement floor workmen's was improved.

Suggestion scheme

• We are Certified 5S Practicing Organization. We achieved by Total Employee Involvement from all verticals

5S

• We are I SO 9001, IS 18001 & ISO 14000&ISO 50001 Certified Company.

Management System

24

Standard Non Conformities Corrective & Preventive Actions

IS 18001

Waste oil shed at LSR-1 to be

erected. Oil cotton waste to be

disposed properly

The waste oil storage shed

construction was in progress

ISO

14001

Bio-Medical waste / Disposal –

Records not available

TNPCB approved collection agent

identified and Mou signed for

disposal

ISO 9001

Performance evaluation system

to be evolved for reviewing the

AMC contract every year.

(Extent of Control)

Review meeting has been

organized at year end while

renewing the contract & the

performance of the AMC was

discussed

IS/ISO

50001:20

11

Energy-critical parameters of

Compressor not included in Key

M & M Parameters; consider

pressure settings (Cut-In cut

off)

Energy-critical parameters of

Compressor included in Key M & M

Parameters