The Ramco cements Limited,Jayanthipuram Works€¦ · Power reduction by reducing the air leakage through Blower safety valves through rpm reduction in 3 blowers . 0.13 0.075 4 Power

The Ramco Cements Limited

(Jayanthipuram Works)1

Year Milestone

CumulativeClinker Capacity

CumulativeCement Capacity

Million TPA Million TPA

1986 Line-1 commissioned 0.75 0.75

1995 Line-1 Up-gradation 1.10 1.10

1999 Slag Cement 1.10 1.60

2008 Line-2 commissioned 2.50 2.60

2010 Expansion (Installation of VRPM )

2.80 3.65

2016 Line-1 Upgradation 3.185 3.65

Mid-2021

Line-3 Commissioning 4.685 3.65

Plant Capacity at a Glance

2

Plant Capacity Enhancement

�Line-3 Clinkerization Unit with Energy Efficient Equipments like ABC Inlet Cooler, New Generation energy efficient motors and Blowers, Low Nox-Sox Calciner and Burner etc.

�Installation of Waste Heat Recovery Systems (WHRS) for27 MW.

�After commissioning of WHRS, there will be a reduction of 18 MW TPP generation, resulting in reduction of 1438 KLD of Water usage and 200 TPD of Coal consumption.

3

Quality Management

System

Occupational Health & Safety

Management System

Environment Management

System

Management System Certificates

4

Energy Management

System

5S JUSE Certificate

Management System Certificates

5

Thermal Specific Energy

Consumption

Kca

l / K

g C

linke

r

753746

724

700

710

720

730

740

750

2017-18 2018-19 2019-20

6

Electrical Specific Energy ConsumptionK

wh

/ MT

of C

emen

tFLY ASH ADDITION (%)

34.89

31.45

22.16

15

20

25

30

35

40

2017-18 2018-19 2019-20

7

0

10

20

30

40

50

60

2017-18 2018-19 2019-20

57.63 56.0951.07

42.3743.95 48.92

OPC Share PPC Sahre

Cement dispatch Share in Percentage (%)

8

9

0

10

20

30

40

50

60

70

80

90

2017-18 2018-19 2019-20

82.1 80.9185.44

57.63 56.0951.07

42.37 43.9548.9

kWh/T cement OPC Share PPC Share

Electrical Specific Energy Consumption34.89

31.45

22.16

15

20

25

30

35

40

2017-18 2018-19 2019-20

FLY ASH ADDITION (%)

(%) (%)

Electrical Specific Energy Consumption up to ClinkerK

wh

/ MT

of C

linke

r

60.46

56.78 57.01

54

55

56

57

58

59

60

61

2017-18 2018-19 2019-20

10

International Benchmark

National Benchmark

TRCL Jayanthipurm

• SHC-665 Kcal/Kg Clk• SEC-65 Kwh/T Cem

• SHC-686 Kcal/Kg Clk• SEC-65.0 Kwh/T Cem

• SHC-724 Kcal/Kg Clk• SEC- 85.4 Kwh/T Cem

Global Norms/Standards

Reference: National Benchmark: Energy Bench Marking For Cement Industry May 2015 Version 2International Benchmark : Indian cement and construction industries-global competitiveness-NCB-CMA special publication presented in 8th NCB International Seminar

11

Road Map To Achieve Benchmark

12

Energy Conservation Projects Implemented in the years

2017-18, 2018-19 & 2019-20

No. of Projects : 71

Projects with NIL investment : 47 Nos.

Total amount invested : Rs. 38 Lacs

Cost savings achieved : Rs. 113.8 Lacs

Electrical energy saved : 46 Lac Kwh

Thermal Energy saved : 479 MT of coal

Reduction in GHG emissions : 1901 MT of CO2

13

Energy Conservation Project 2017-18

S. No. Energy Saving ProjectSavings

(Rs. Lakhs)Investment(Rs. Lakhs)

1Power optimization in line 1 preheater compressor byreducing suction air temperature using exhaust fan and duct.

0.45 0.5

2Power optimization of CF silo aeration blower by replacingexisting 3 nos with new one

4.9 1.5

3Fly ash unloading refrigerator drier & cooling water supplypump power optimized by fixing auto drain valve

4.7 2.3

4Power optimization by removing reversible conveyor inlimestone feeding circuit and filling the hoppers with directchute.

0.63 0.22

5Avoid F- conveyor running for Laterite feeding to Line1 Raw mill with direct chute

0.59 0.35

6Power reduction in North band mines dewatering pump byproviding pump with lower discharge

1.64 1.0

7Slag baghouse purging Compressor optimization by reducing the Pr. by replacing the Neuron (5.5 to 3.8 kg/cm2)

0.25 0.12

8Power savings by stopping the New Preheater kiln feed bucket elevator discharge air slide blower by giving the airline from common blower for both strings

0.39 0.514


S. No. Energy Saving ProjectSaving

s(Lakhs)

Investments

(Lakhs)

1Reducing of power consumption in Line-1 Kiln by inter connecting the airline to Main 110 KW Compressor

9.18 1

2Reduction of power consumption by Re-arranging the existing lighting circuits in 132KV Substation & DG.

0.09 0.045

3Power reduction by reducing the air leakage through Blower safety valves through rpm reduction in 3 blowers .

0.13 0.075

4Power reduction by replacing the driers timer based auto drains with Combo type auto drain valves -

0.013 0.15

5Power reduction by providing level sensors in colony over head tank and operate the pump according to tank level.

0.43 0.1

6Power reduction in Plant water supply pump by replacing discharge pipeline NRV with higher size

0.12 0.1315


S. No. Energy Saving Project

Savings

(Lakhs)

Investments

(Lakhs)

7

Power reduction in compressor byInstalling PRV batteries and optimizethe pressure setting in Fly ash bulktankers.

0.23 0.2

8To reduce the power consumption in Packing Plant Compressors room by providing hot air vent duct .

0.026 0.24

9Optimization of TPP R.O pump energy by installing VFD .

0.027 0.35

16

S. No.

Energy Saving ProjectSavings(Lakhs)

Investments

(Lakhs)

1 CF Silo Gate operation existing Screw Compressor (22kw) was replaced with available (11 kW) Screw Compressor. 1.31 0.009

2 Optimization of Spillage Elevator power by reducing Chain Speed through VFD. 0.36 1.10

3To reduce the power consumption of cement bulk loading system by replacing the screw conveyor with air slide at Packing plant.

0.09 0.40

4 Corrossion resistance paint coated over MCW pump impellers to reduce power consumption 20.44 1.92

5 Optimization of service air compressor energy by installing VFD. 5.93 6.70

6 Reduction of fuel consumption in the Ashok Leyland tipper by extending the dump body side walls height. 1.51 0.14

7Reduction of battery power usage , head light bulbs & sealed beam failure in Hemm & Lcvs by providing LED lights in place of normal conventional lights.

0.39 0.03


17

Energy Conservation Project With Investment


Total Investment : Rs. 38 Lacs

Total savings : Rs. 53.826 Lacs

Electrical Energy saved : 29 Lacs Kwh

Thermal Energy saved : 479 MT of Coal

18

ENCON Projects with NIL Investment

19



(Rs)

1 Avoiding Idle running of Slag mill Baghouse fan motor GRR Blowers by giving interlock 0.45

2 Power savings by providing interlock for cooler ESP transport system

0.24

3 Power saving by providing interlock of Coalmill-2 baghouse drier CO2CP01 with Compressor

0.13

4Power reduction in STP tank aeration blowers by stopping one blower (7.5 kW ) through interconnecting both aeration Pipe lines and replacing blower motor with 9.3 kW

0.99

5 Power reduction in Line-2 Kiln baghouse fan by modification with Fuzzy New PID system 6.79

6Power reduction in Rawmill-2 by increasing the Output from 500 to 520 TPH by increasing Grinding pressure from 110 to 120 bar (Accumulator Pressure increased from 55 bar to 60 bar)

9.6120



(Rs)

7Reducing the Energy consumption in Crusher Baghouse Purging Compressor by optimizing the Baghouse DP

0.02

8To reduce the power consumption in Line-2 CF Silo Bin aeration circuit by using less capacity standby Airslide blower

0.04

9Optimization of VRPM vent Baghouse fan & 3 way separator vent fan (by optimizing the air flow in VRPM circuit )

0.14

10 Optimization of CA Fan flow to maintain the optimum gas flow in VRPM circuit 4.79

11Power Savings by stopping 1 No. AB7.75 model garage Compressor at Car shed( including maintenance cost savings )

0.48

12 Power Savings by giving interlock to H Conveyor Magnetic separator with Conveyor 0.63 21


S. No. Energy Saving ProjectSavings(Lakhs)

1Power savings in Raw mill-1 Baghouse Compressor by changing the Baghouse solenoid valves purging operation into Differential pressure mode.

1.23

2Power savings in Coal mill-1 Baghouse Compressor by changing the Baghouse solenoid valves purging operation into Differential pressure mode.

0.60

3Power savings in Coal mill-2 Baghouse Compressor by changing the Baghouse solenoid valves purging operation into Differential pressure mode.

0.66

4Power savings in Slag mill Baghouse Compressor by changing the Baghouse solenoid valves purging operation into Differential pressure mode.

0.44

5Reducing of power consumption in Line-2 Coal mill by by inter connecting the unit bag filter airline to Main Bag filter Compressor airline.

2.48

22



6Reducing of power consumption in Line-2 kiln by the by inter connecting the Clinker silo top B/Filter, Water spray Compressor airline to Preheater Compressor.

2.19

7

Reducing power consumption by Inter connecting Raw mill Hopper Conveyors Water spray Dry fog Screw Compressor and Hoppers Bag filter Garage Compressor.

0.25

8

Power reduction by1)Main Cooling water interconnection line between2X18MW and 1X6MW cooling water circuits.

2)Aux cooling water pump for 6MW lineinterconnected with 2X18MW Aux cooling watercircuit.

10.91

9Power reduction in NB mines 6th bench area pumping activity by avoiding the re-handling of water

1.94

10Power reduction by inter connecting Rawmill-2 Baghouse transport Air slide blowerwith other blower

0.1323



11Power optimisation in Cement silo aeration blowers by blower deselection interlock with 3rd silo extraction.

0.30

12Power optimisation in fly ash transmitters screw compressors by providing inter lock based on compressor loading/unloading pressure.

3.82

13 Power reduction in Line-1 kiln by providing kiln shell cooling fans inter lock with shell temperature

0.11

14 Power reduction in P/Plant by providing Compressor room hot air vent fan inter lock with compressors

0.10

15 Power optimisation by providing interlock for CBABC02 conveyor with C Conveyor.

0.002

24



1Avoiding of reject handling belt conveyor tripping on over load.

2.56

2To provide interlock for B conveyor with secondary screen(A1J18), Rejection Conveyors (A1J16R & A1J17R)

0.01

3Line-1 Coal mill Bag house purging automation by sequencer purging.

0.10

4Optimization of Coalmill-1 baghouse fan Bearings cooling fan power consumption by providing interlock with Bearing temperature.

0.15

5Avoiding of Unnecessary power consumption in Coal Mill-1 GRR cooling blower.

0.29

6FK Pump seal air Compressor E37(37kW) replacement with available E22(22 kW)Compressor.

2.51

7Optimisation of VRPM vent bag house discharge air slide blowers.

0.80

8 Optimization of Cement Mill fly ash bin venting bag filter. 0.05

9Avoiding of frequent tripping of 7th silo bottom ejector bin RAL on account of over load.

0.01925



10 Power optimization in 2nd packer air slide Blowers by providing interlock.

1.03

11Optimisation of Mega clinker silo bag filter fan while clinker extracting to Cement Mill & Slag Mill.

0.10

12Optimisation of bag printing machines (off line bag printing machines stopped) & 1no exhaust fan(3.7kW) stopped.

0.24

13 Power optimization of P.H. down comer tank filling Water pump.

1.09

14Power reduction in Time office by re-arranging the lighting circuit and replacing with LED fittings

0.05

15Replacing diesel operated mobile tower light in mines with electrically operated one.

0.78

26


Total savings : Rs. 60.18 Lacs

Electrical Energy saved : 17.53 Lacs Kwh

Energy Conservation Project with NIL investment

27

INNOVATIVE PROJECT-1

Hot air Duct tapping from TPP to Coal mill-2

28

Innovative project-1

The line-1 was upgraded from 3500 TPD to 4600 TPD of Clinker production. To cater this enhanced capacity of pyro system, the fuel requirement is as below…

Parameters TPD

Kiln Productivity 4600

Petcoke 443

Coal 636

Petcoke & Coal (50:50) 534

Fuel Requirement

Coal Mill-1

Capacity

Fuel available

form Coal Mill-1

Additional Fuel

required

Coal Mill-2

Productivity

Coal Mill to be

run for Line-1

TPH MT MT TPH hrs

Petcoke 15 330 113 35 3

Coal 22 484 152 42 4

Petcoke & Coal (50:50) 19 407 127 32 4

Parameters

29

� As per the above table the Coal Mill-2 has to run additional of 3-4 hrs per

day to cater the overall fuel requirement of Line-1.

� Coal Mill-2 is required to run during Line-2 shutdown also to avoid the

production loss in Line-1.

� During Line-2 shutdown, we have taken the trial of Coal Mill-2 running

without hot air. But, due to insufficient air and temperature the mill was not

able to run even with the reduced feed and reduced table speed.

� Hence, to run the Mill during Line-2 shutdown, it is proposed to tap the hot

air from TPP to Coal Mill Hot ESP Fan inlet. The temperature at the TPP ID

Fan outlet is maintaining around 150°C and 85000 m3/hr gas flow, which

can be utilized for the Coal grinding. The Coal Mill-2 availability requirement

will be as follows during Line-2 Shutdown.


30

Hot gas duct from TPP Hot gas duct joining coal mill-2 inlet duct


31

Additional Fuel

required

Coal Mill-2

Productivity

Coal Mill to be

run for Line-1

MT TPH hrs

Petcoke 113 15 8

Coal 152 19 8

Petcoke & Coal (50:50) 127 17 7

Parameters

Coal Mill-2 requirement during Line-2 Shutdown

The adequacy of existing Hot ESP Fan was checked and found that the fan can run with the available hot air from TPP.

The new duct (of diameter 1.60 m) has been laid for connecting the TPP ID Fan outlet to Coal Mill-2 Hot ESP Fan inlet.

Benefit :- Kiln-1 running with normal feed at 295 TPH.

Production loss Avoided – 35 TPH of kiln feed (21 MT clinker / hour)


32


Power reduction in cement mill

33


� We have 2*18 MW Coal based captive power plant in our cement plant.

� Whenever Single line was operating , we will run Single Thermal power plant (TPP) for plant operation and also mines de watering and development activities.

� Whenever both raw mill and slag mill run, not possible to run cement mill and mines dewatering activities.

� Whenever cement mill running also not possible to run mines de

� watering activities due to TPP load restriction.

� Now cement mill taking 8.5 MW for mill operation along with V.R.P.M, if we

reduce mill power to 7.8 MW we can able to provide power for Mines

dewatering and development activities.

34

We have measured the CA Fans flow and specific load of

separators data as shown

ZM O-Sepa Fan

VRPM CA Fan

Flow m3/hr 235000 195000

Steps/Speed #/% 26 32

Power KW 420 325

Material Load tph 280 220

Specific Material load to Separator

Kg/m3 of Air

1.19 1.13


35

Steps Carried Out Effect

Grinding Media Filling level reduced by 5% (from 30% to 25%) and maintaining at 25%

Mill Main drive Power reduced by 450-500 KW

Specific Air Optimization in both VRPM and Ball Mill connected separator

Connected Fans Power Consumption reduced by 90-100 KWConsistency in 45 & 90 µ residue and Blaine

Vent Air Optimization(Ball Mill, VRPM and connected separator) Connected Fans Power Consumption

reduced by 50 KWVRPM Bag Houses (2 Nos) purging system kept in DP mode

Water Spray in VRPM introduced indigenously

VRPM tripping on vibration was avoidedFineness (Blaine) improvement in VRPM Prod by 150-200 cm2/gm

Overall Benefit

Power Plant load reduced by ≈1.3 MW (Can able to run Mill along other utilities like Mines Dewatering and Clinker handling etc. while Single Boiler operation)

Total Unit Saving : 1.48 KWH/T Cement5.70 Lakhs KWH

Total Cost Saving : INR 26.05 Lakhs


36

ZM O-Sepa Fan VRPM CA Fan

Flow m3/hr 215000 160000

Steps/Speed #/% 24 22

Power KW 400 245

Material Load tph 280 225

Specific material load

to separator

Kg/m3 of

Air 1.30 1.41

After trial we have measured the CA Fans flow and specific

load of separators and tabulated after optimizing the gas

volume.


37


Replacement of high pressure conventional screw compressor with low pressure lube compressor

38

Innovative project - 3

� We are unloading fly ash from bulk tanker with conventional high

pressure screw compressor.

� Power consumption is high in fly ash bulk tanker unloading.

� We have replaced high pressure screw compressor with energy

efficient low pressure lube compressor.

� We have replaced existing 85 KW high pressure pump with 55 kW low

pressure lube compressor.

� Run hours for unloading is reduced.

� Savings achieved with new lube compressor – 30kW39

40

� No. Of Hours for unloading with high pressure screw compressor – 3249

Hrs.

� No. of Hours for unloading with low pressure Lube compressor – 2166 Hrs.

� Savings in Run hours of compressor – 1083 Hrs.

� Annual power savings achieved due to less run hours – 92055 kWh

� Annual Power consumption for Low pressure lube compressor – 64980

kWh

� Total power savings – 157035 kWh

� Cost savings/ Annum – 706658 INR

� Savings in Maintenance cost – 80000 INR

� Total Savings – 786658 INR

� Investment cost – 13,50,000 INR

� Pay back – 1.7 Years


41


Reduction of Overall Raw mill power consumption

42

43


� We have two Raw material grinding Mills (VRM) in 1986 and 2008 Raw mill-1 7 Raw mill-2 Respectively with single CF silo around 20,000 MT capacity in our plant.

� Due to this we would maintain same raw mix for both kilns.

� Our daily Kiln feed requirement is 12600 MT without Recirculation material.

� Raw mill-2 Capacity – 400 TPH (Make – Loesche)

� Raw mill-1 Capacity – 240 TPH (make – FLSmidth)

� In raw mill-2 we have upgraded Mill main drive motor from 2800 to 3200 kW to cater gearbox motor of 3500 kW.

� After that Raw mill -2 Operating 525 TPH (12600 TPD) after changing main drive gear box.

� So Our raw mill-2 Production alone is sufficient for our kiln feed requirement for both kilns.

44


� As our Raw mill-2 is more efficient than raw mill-1 in productivity, we are

operating raw mill-2 only daily by stopping Raw mill-1.

� Whenever Raw mill-2 under maintenance or CF Silo level reaches less

than 11000 MT, we run raw mill-1 for 12 Hrs.

� In a month, we mostly run Raw mill-1 7-8 days /month.

Benefits achieved :

• Raw mill-1 SPC – 21 kWh/T clinker

• Raw mill-2 SPC – 16.5 kWh/T clinker

• If we run both mills, Average SPC – 17.91 kWh/T clinker

• If raw mill-2 alone SPC – 16.5 kWh/ t Clinker

• Net savings – 1.4 kWh/T Clinker

Utilization of waste material as fuel

S. No Type of Waste Fuel usedQuantity of waste

fuel used (MT)

Equivalent of

Conventional energy used

(Ton of coal)

1Wood chips & Rice

Husk562.21 356.78

2 TPP reject Ash 3099 387.37

45

YearTotal

CO2e (MT)/T Cement

2016-17 660

2017-18 680

2018-19 662

2019-20 653

GHG Inventorisation

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

Scope 2 emissions Power consumption

Scope 3 emissions Raw Material Supply & Product delivery

46

Parameter

OTD MTD YTD OTD MTD YTD OTD MTD YTD OTD MTD YTD OTD MTD YTD OTD MTD YTD OTD MTD YTD OTD MTD YTD

JPM

Ravirala

Sub Total

Auxilliaries

Main Drive

Lighting

Maintenance

Sub totalCrusher Laterite Crusher Laterite

Additives

Auxilliaries

Raw Mill Fan

Latrite Crusher

Main Drive

Maintenance

Sub totalAdditives

Auxilliaries

Raw Mill Fan

Latrite Crusher

Main Drive

Maintenance

Sub totalAuxilliaries

Coal Mill Fan

Main Drive

Maintenance

Sub total

Auxilliaries

Coal Mill Fan

Main Drive

Maintenance

Sub total

Auxilliaries

Coal Mill Fan

Main Drive

Bin Transport

Maintenance

Sub total

Auxilliaries

Clinker Crusher

Cooler Fans

Bag House Fan

ID Fan -1

ID Fan -2

Kiln Feed

Maintenance

Kiln Stoppage

Sub Total

Auxilliaries

Bag House Fan

Cooler Fans

ID Fan

Kiln Feed

Maintenance

Kiln Stoppage

Sub Total

AC

Dist. Losses

Lighting

Water Pump

Workshop

Sub TotalLine1 Clinker Up to clinker Line-1

Line2 Clinker Up to clinker Line-2Up to clinker

CombinedTOTAL Upto Clinker

Auxilliaries

Main Drive

Maintenance

Sep Fan

VRPM Auxilliaries

VRPM CA Fan

VRPM Main Drive

Sub Total 0 0 0 #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!Auxilliaries

Main Drive

Maintenance

Sep Fan

VRPM Auxilliaries

VRPM CA Fan

VRPM Main Drive

Sub Total 0 0 0 #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

Packing plantPaddle Mixture

Clinker Export 0 0 0 4012 92378 629966 Clinker ExportFlyash to Silo

Power Report on

EquipmentR.Hrs. Production TPH KWH KW Kwh/ T of Material Kwh/ T of Clinker Kwh/ T of Cement

Mines Water works

Raw mill -1

LS Crusher

Coal mill -1

Raw mill -2

Kiln -1

Coal mill -2

Coal mill -2-1

Kiln -2

Cement mill

Pre Clinker Service

Slag mill

Post Clinker Services

Energy Reporting Format

47

Energy Management System

48

Selection

• Department - Plant Management, Production ,Maintenance Quality Control ,Accounting

Formation

• Each department Provide one or more Representatives to the Energy Management team

Coordination

• Each Energy management Clusters will be headed by Team leader and the whole is monitoring by Energy Manager

Responsibilities

• Define Objectives, Prepare Energy Planning, Optimal Energy Operation, Detect Weakness Plan and Perform Measures/Projects Prepare Energy Performance & Reporting Establish & perform Energy Controlling Review achievements

Implementing Strategy

49

WORKS HEAD

HOD

MINES

HOD

P & QC

HOD

MECH

ENERGY MANGER

HOD

E & I

HOD

CDS & PP

HOD

TPP

UNIT HEAD

Core Committee Team – Energy Cell

INCHARGEMINES & CRUSHER

INCHARGE

TPP

INCHARGE

PACKING

INCHARGE

CEM MILL

INCHARGE PYRO

INCHARGE RAW MILL & COAL MILL

INCHARGE

UTILITIES

50

Responsibilities of Steering Committee

False air study in all major sections i.e., Kiln, Raw Mill, Coal Mill and Cement

Mill on monthly basis.

Monitor production performance vis-à-vis SEC.

Monitor fan performance and initiative corrective action required, if any, on monthly basis.

Identify/Evolve new ENCON projects with and without investment.

Encourage employee participation through effective implementation of

Suggestion Box Scheme, 5S & Quality Circle.

IMS – EnMS Management Review Meetings, EMAP will be reviewed.

51

SNO DEPT TEAM NAME PROJECT TITLE NAME

N Rama Rao

SRINIVASA RAO B

YELLAMANDAIAH K

RAGHAVENDRA M

DURGA RAO P

SURA REDDY P V

A Siva Subrahmanyam

RAMANJANEYULU B

BALAJI R

NUKALA HAREESH

SK AZARUDDIN

B NARENDRA

Desing Rajan

VENKATA RAMA KRISHNA D

VIJAY KUMAR M

PRASADA RAJU A

JANAKIRAMA PRASAD B

GOPI CHANDU

VARAPRASAD GVB

U SITHA RAMA RAJU

P S CH NARESH KUMAR

K SREEKANTH

J HARIBHASKAR

P GOPINATH

3 ElectricalQC - 203

RamasethuFrequent Failure of LT Motors

4 HR Master Mind HRElimination of plastic in

department stationery items

1Auto

garageRamco spoorthy

Frequent failure of Pump

delivery system in mines

pontoon pumps

2 Mechanical Ramco ChallengersFrequent tripping of line-1 coal

mill with heavy vibration

Quality Circle

52

A R V SWAROOP

RAVI B

DEEPAK REDDY K

VENKATESWARA RAO CH

RAMESH VARMA P

UDAY RAJU B

Kiran Kumar N

PETCHIMUTHURAJAN

P VEERA BABU

P VEERA RAJU

TVV NARENDRA

B Rambabu

SATYANARAYANA RAO K

SRINIVASA SARMA P

MOHAMED MEERAN

POTHURAJU S

RATNA NAYAK

Rajesh Kumar A

CH CHANDRA MOHAN

NAGESWAR RAO P

LAKSHMANA RAO M

NAGUL MEERA SK

SAI NAGA RAJU B V

7 Mechanical Ramco DiamondsHeavy spillage at clinker export

conveyor.

8 Mechanical Ramco ParishkarFrequent DP problem in line-2

Coal mill bag house

5Instrument

ationRamco Rainbow

Delay in trouble shooting of

Limestone Reclaimer

6 Mechanical Ramco JagruthiIdle running of packer-1 or

packer -5.

Quality Circle

53

Environmental Projects

700KLD Capacity Sewage water treatment plant

54

200 Kg/day Capacity Bio-gas plant

55

Solar Plant in Budawada Mines

56

We have installed solar panel for borewell pump from underground to supply water to plantation in budawada mines.

Environmental Projects- Green Development

Colony Ground Main Gate Entrance

Consumer storesPlant top view

57

Environmental Projects- Green DevelopmentGuest house

Road sweeper

Health center

Park

58

Mines area Reclaimer Area

Colony Bird ViewTPP Area


59

Admin Admin entrance

Admin lobbyFounder statue Area


60

LED F i t t i ngs Factory Entrance gate Factory main road

Inside FactoryColony road

61


Road sweeping Machine

Water Sprinkler

62

NurseriesNurseriesNurseriesNurseries

63

YearNo of Saplings

PlantedArea covered (acres)

2012-19 18496 12.33

2019-20 11326 7.55

2020-21(Plan) 15000 10

% of Green belt area (1986- March 2019) 48.11 %

Green Belt Development

64

Awards

65

Best Management Award received from Hon’ble Chief Minister of AP on the occasion of May Day Celebrations - 2016

APPCB Award for Cleaner Production Measures

05-06-2012

The Ramco Cements Limited, KSR Nagar 05-06-2017

State Level Environmental Award for

Better Environmental Practices

Best Supporting Organization for Quality Circle Movement - 2018

69

Quality Leadership Award in Private Sector from QCFI – Gwalior Chapter

70

5S Conclave at Satyamangalam, Tamilnadu

71

5S Conclave at Satyamangalam, Tamilnadu

72

Nat iona l Leve l Energy Awards Mines Environment & Mines Conservation

Award 2018

73

India Green Manufacturing Challenge – 2018 Silver Award

74

75

Forward Way to Conserve Energy

�Installation of Waste Heat Recovery Systems (WHRS) for27 MW in 3 Phases.

� Phase – I (9 MW Capacity) is going to commission on 31-08-2020.

� Phase – II & III (9 MW each ) are under erection Stage.

� Implementation of 4 MW capacity of Solar plant, Technical Specifications are under review.

PH-2 (PHASE-1)

AQC-2 (PHASE-1)

78

Documents

The Ramco cements Limited,Jayanthipuram Works€¦ · Power reduction by reducing the air leakage through Blower safety valves through rpm reduction in 3 blowers . 0.13 0.075 4 Power