1 Ramco Cements

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A flagship company of RAMCO Group, having five Cement manufacturing units,

three grinding units and two packer units with the total capacity of 14 MTPA.

The plant at Alathiyur, Ariyalur District was setup in two phases.

Line-I was installed with a capacity of 2200 TPD (Clinker) in the year 1997 &

Upgraded to 3400 TPD.

Line-II was installed with a capacity of 3000 TPD (Clinker) in the year 2001 &

Upgraded to 3400 TPD.

The manufacturing products are Ordinary Portland Cement as per BIS & SLS

standards, Portland Pozzolana Cement and SRPC.

We have a thermal power plant (2X18 MW) at Alathiyur.



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IS/ISO 9001: 2008 Quality Management System

IS/ISO 14001: 2004 Environment Management System

IS 18001: 2007 Occupational Health & Safety Management System

IS/ISO 50001:2011 Energy Management System under implementation

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Energy Conservation Projects Implemented for the years 2010-11, 2011-12 &

2012-13

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S. No. Energy Saving Project Savings(Rs. Lacs)

Investments(Rs. Lacs)

1Replacement of conventional grate cooler

for line-1 with high efficiency SF cooler1134.6 2000

2 Installation of new limestone crusher 1029.6 30.9

3Installation of new Generation High

Efficiency Classifier for Raw Mill Line-1.774.5 200

4Installation of VFD for line-2 Cement mill

bag filter fan

81.6 155

5Installation of new high efficiency Preheater

fan for line-1821.4 125

6Modification of line-1 cement mill fan inlet

duct65.3 1.0

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S. No. Energy Saving ProjectSavings

(Rs. Lacs)

Investments

(Rs. Lacs)

1 Installation of VFD for line-2 Preheater fan 49 110

2Installation of Booster fan for line-1 Cement

mill31 67

3Steam tracer for DG aux. instead of

electrical heating28.5 39.5

4Replacing 250 W HPSV street lights by

2x36 W CFL3.3 10

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Installation of low capacity compressors for

Cement mill Bag filters in fly ash handling

section

14.7 6

6 Installation of GRR for line-2 coal mill fan 12.2 3

7Installing fuel catalyser in mines EME

equipments7.9 0.2



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S.

No. Energy Saving ProjectSavings

(Rs. Lacs)

Investments

(Rs. Lacs)

1

Power saving in Line-2 Kiln due to

installation of membrane filter bags in

RABH with revised bag cleaning cycle

20.6 82

2 Installation of VFD for boiler – 1 FD Fan 36 55

3Replacing diesel pumps by high efficiency

electrical pumps18.8 31

4 Line-1 RABH Fan inlet duct modification 9.2 14

5 Modification of Line-1 cement mill fanoutlet duct from 1.8m to 2.8m

19.6 13.8

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Installation of Wireless communication

system for wagon loading and PID for

Motorized Flow Control Gate to control

material from Silo to the Elevator

39.7 7

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(Rs. Lacs)

Investments

(Rs. Lacs)

7Installation of 45 Kw VFD for fly ash

unloading Bag Filter Fan with photo sensor3.2 1.8

8Motorized valve for CCR A/C AHU to

control chilled water4.4 1.6



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(Rs. Lacs)

1Installation of VFD for reverse air fan in raw mill bag

house6.5

2 Installation of SPRS for line-2 Raw Mill 62.6

3 Installation of VFD in cooling tower fan 5.8

4 Level controller for DM water transfer pump 1.8

5 Modification of fly ash conveying air nozzle 3

6 Installation of GRR for the FD fan in boiler-2 4.4



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(Rs. Lacs)

1 Removal of I/l damper in line-2 Cement mill fan 13.1

2 Installation of VFD for line-2 Cement mill Booster fan 6.6

3 Removal of I/l damper in line-2 cooler vent fan 6.5

4Installation of VFD for compressors in Kiln, Coal Mill

and Preheater26.1

5Installation of VFD with level switch in main cooling

water pump6.5

6 Optimization of i/o room temperature 1.4

7 Optimization of line-2 RABH fan 19.6

8 Elimination of bag filter at Cement Mill-2 Elevator 13.8

9Optimization of bag filter fan at clinker DPC in

Cement mill-25.2

10 Replacement of line-2 CF silo top air slide blower 4.6

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(Rs. Lacs)

1 Optimization of L-1 Kiln section compressor 0.3

2Regulating the operation Line-1 silo feed elevator

bottom boot bag filter during OPC & export running2.9

3Heating mode & cooling mode was introduced in line-

1 & line-2 cement mill1.8

4By closing the damper in fly ash unloading bag filter

fan when not required1.4

5One air slide blower (260 AB5) was stopped in cement

mill main air slide by optimization1.4

6By stopping the line-1 cooling tower fan & pump

during winter season1.3

7One air slide blower was stopped in fly ash air slide

by optimization0.5



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(Rs. Lacs)

8 ID Fan suction Damper removed in both boiler 7.8

9 Removal of Boiler – 1 SCAPH 7.0

10Replacement of 9.3 kw borehole pump in mines

office with 3.7 kw pump0.03

11Line-2 kiln feed elevator top venting unit bag filter :

Replaced fan motor rated 1500 rpm with 1000 rpm.1.6

12Line-2 CF silo top venting unit bag filter : Replaced

fan motor rated from 1500 rpm to 1000 rpm1.6

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675

680

685

690

695

700

705

710

715

2009-10 2010-11 2011-12 2012-13

715

705

690 690

K c a l / K g C l i n k e r



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65

6667

68

69

70

71

72

73

74

75

2009-10 2010-11 2011-12 2012-13

74.37

72.69

68.51

69.19

K w h / M T o f C e m e n t

14

15

16

2011-12 2012-13

14.6

15.4

%

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Reference: 8th NCB International Seminar 2003



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The Raw mill was designed for a feed moisture of 5% normal & 10%

maximum.

Over a period of time, the normal feed moisture increased to more than 10%

causing the reduced raw mill output to 205-210 t/h from 215-220 t/h.

During monsoon, Mill output was further reducing to 190 t/h. Hot Gas

Generator had to be operated to meet the clinker production.

Since more heat was required for drying, the gas volume was to be increased in

mill and thereby causing higher product residue.

Kiln feed had to be reduced as the Raw mill was unable to support the raw mealrequirement.

At high residue of raw meal on 212 μm and high quartz %, problems related toclinker burning resulted in high free lime of >2.5%.

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Replacing the existing classifier from LSKS 52 by a larger size LSKS 57 withinbuilt Vortex Rectifier.

This was the first VORTEX RECTIFIER in India.

Modified louvre and armour ring to maintain uniform gas flow/velocity profileinside the mill.

Increase the capacity of the raw mill fan by replacement/ retrofitting

Increase the size of the following ducts due to higher gas flow

Mill inlet duct , Mill Outlet duct & Duct from Cyclone to mill fan inlet

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Old Classifier Without

Vortex Rectifier

New Classifier With

Vortex Rectifier



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190

200

210

220

230

240

2007-08 2008-09 2009-10 2010-11 2011-12 2012-13

210

207

213

219

235

239

T P H



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Idea and Installation of Vortex rectifier is the First of its kind inthe country

Vortex rectifier gives us a rich benefits in the areas ofProduction, Quality, maintenance & Energy

There are more than 200 vertical roller mills in Indian cement

industry.

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Investment Cost : Rs. 200 Lacs

Cost Savings : Rs. 42.48 Lacs/Year

Cost Savings Due ToAdditional Realization of Cement : Rs. 734 Lacs/Year

Simple Pay Back Period : 3 Months

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Improvement In Quality Of Clinker

Free Lime <2% And C3S >55%

Stable Kiln Operation

Tangible Benefits:

Intangible Benefits:



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The efficiency of the conventional grate cooler is low and the breakdown was high

and also the cooler is designed for the production of 2200 TPD only.

Due to higher loading of the cooler, the efficiency is also very less. So we

had replaced the conventional grate cooler by the high efficient third

generation cooler SF crossbar cooler.

SF crossbar gives heat savings of 30 kcal/kg clk and electricity savings of

1.3 Kwh/T clk and an additional clinker production of 150 tons per day.

By the installation of SF crossbar cooler, we have constantly reduced the

total thermal specific fuel consumption from 715 to 690 Kcal/ kg of clinker

from 2009-10 to 2012-13.



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Investment Cost : Rs. 2000 Lacs

Cost Savings : Rs. 1135 Lacs/Year

Simple Pay Back Period : 22 Months

Thermal energy savings : 30 Kcal/kg clk

Electrical energy savings : 1.35 Kwh/MT clk

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Tangible Benefits:

Intangible Benefits:

Vital role in the achievement of the BEE-PAT Target



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600

650

700

750

800

850

900

2007-08 2008-09 2009-10 Target 2010-11 2011-12 2012-13

816

851 853

796 802

717

758

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K c a l / K g o f C e m e n t

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We have 3 nos. (2 x 6 MW and 1 x 4 MW) Diesel Generators in our plant

The DG became standby after installation of 2 x 18 MW Coal Based ThermalPower Plant in 2005.

During idle time, lube oil and jacket water temperature is maintained at 60 0C tokeep DG in warm up condition

To maintain the lube oil and jacket water temperature at 600C, the electrical

heaters were used

Since we have CBPP we get low pressure steam from the de-aerator, so plannedto use this steam for heating the lube oil and the jacket water.

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Tangible Benefits:



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Energy consumption both electrical & thermal : Daily

Energy conservation projects : Weekly

Review meeting conducted by : VP - Mfg

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Selection

• Department - Plant Management, Production ,Maintenance QualityControl ,Accounting

Formation

• Each department Provide one or more Representatives to the EnergyManagement team

Coordination

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

Responsibilities

• Define Objectives, Prepare Energy Planning, Optimal EnergyOperation, Detect Weakness Plan and Perform Measures/ProjectsPrepare Energy Performance & Reporting Establish & performEnergy Controlling Review achievements





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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, onmonthly basis.

Identify/Evolve new Encon projects with and without investment.

Encourage employee participation through effective implementation of

Suggestion Box Scheme.

Organise Quality Circle meetings and review their projects and its progress

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Line-1 hot fineclinker surging from

the tertiary duct.

Line-1 clinker truckloading extraction

pan conveyor dustemission is high.

Line-1 hood draftfluctuation whichleads to puffing inthe kiln platform.

To avoid hot fineclinker surging fromTAD, air blasters areinstalled in the TAD

take off duct.

Bag filter is installedin the line-1 clinkertruck extraction pan

conveyor.

Venturi in the TADduct is shifted near to

the kiln riser.

Air blasters nozzlesdirection routed

parallel to the slopeof TAD take off.

Clinker extraction point is installed with

telescopic chutevented by bag filter

Kiln hood draft isgiven in fuzzy modewhich is controlled by cooler vent fan

Corrective actions Preventive actions

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Type of RES 2010-11 2011-12 2012-13

EnergyGenerated

(kWh)

AnnualSavings

(Rs.)

EnergyGenerated

(kWh)

AnnualSavings

(Rs.)

EnergyGenerated

(kWh)

AnnualSavings

(Rs.)

Wind314374266 285454322 322219670

Solar

photovoltaic - - 9138 38654 10968 49356

Total installed capacity during the year 1996 is 33.235 MW , which was theSINGLE LARGEST WIND FARM IN THE SOUTH EAST ASIA at that time.

The wind mill capacity is constantly upgraded and now at present the capacity is159.185 MW with 229 individual Wind Electric Generators

The PLF% has increased from 21.21% to 24.01% for the years 2011-12 and 2012-13 respectively

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Type of

RES

2010-11 2011-12 2012-13

Equ Fuel

Savings

(MT)

Annual

Savings

(Rs.

Million)

Equ Fuel

Savings

(MT)

Annual

Savings

(Rs.

Million)

Equ Fuel

Savings

(MT)

Annual

Savings

(Rs.

Million)

Biomass 1198 6.83 2653 18.57 2677 19.14

No Type of Biomass

used

Quantity of

Biomass used

(MT)

Equivalent of fuel savings

(Ton of coal)

1 Cashew Shell 968 800

2 Saw dust 26 20

3 Fire wood 803 575

4 Biocompost 2717 1282



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S.

No

Type of Waste Fuel used Quantity

of waste

fuel used

(MT)

Equivalent of

Conventional

energy used (Ton

of coal)

Waste fuel as %

of total energy

1 Oil soaked cotton waste 37 28 0.02

2 Shredded tyre 170 221 0.09

3 ETP sludge 460 59 0.25

4 Paint sludge 112 103 0.06

5 Coolant filter waste 94 71 0.05

6 Used waste oil 14 17 0.01

7 Oil soaked saw dust 30 35 0.02

8 Power plant pet coke reject 4447 2075 2.42

9 Municipality waste 448 194 0.24

10 Oil sludge 49 58 0.03

0

1000

2000

3000

4000

5000

6000

2011-12 2012-13

3339

5861

2208 2861

Alt Fuel Equ. Coal

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75.53 % Increase In Alternate Fuel Consumption

29.6% Increase In Replacement Of Coal Quantity.



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S.

No

Name of associate

/ vendor

Name of

service provided

to vendor

Energy

consumed before

Encon

energy

consumed after

Encon

%

improvement

Type of inputs /

projects provided to the

vendor/

associate

1 Sri Vinayaga

Transports

Gukan Earth

Movers

Balasubramanian

Agencies

Pavai Infratech

Transport

ation of

Reject

2.1 kmpl 2.0 kmpl 5% Fuel catalyzer

is installed in

the tippers

2 Sri VinayagaTransports

Gukan Earth

Movers

Balasubramanian

Agencies

Pavai Infratech

Transportation of

Reject

3liters/trip

1.5

liters/trip 50% Lead distancereduced is by

developing a

new road.

Installation of High efficiency SF cooler : 14144 MT CO2

Installation of fuel catalyser in the mines EME equipments : 55 MT CO2

Installation of VFD for boiler -1 FD fan : 665 MT CO2

Replacing diesel pumps with high efficiency electrical pumps : 114 MT CO2

Utilization of waste heat from cooler in cement mill : 71125 MT CO2

Total CO2 reduction : 86103 MT CO2

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S.

No

Title of the project Investment made

(Rs.Lacs)

1 Installation of additional ESP in cooler vent 125

2 Dramix fiber Concrete road at lorry yard of 20,000 sq.m 378

3 Concrete road development for 1250 sq.m. 194

4 Installation of Surveillance camera 80

5 Installation of Pressurization and ventilation system 71

6 Installation of NOx analyzer at Kiln inlet 6

7 Ambient air quality monitoring station 17

8 Installation of New Clinker drop test bin for Kiln-1 22.5

9 Chrome free basic bricks 81.5

10 Installation of Membrane bags in RABH 85

11 Water cooled CCTV camera for Cooler-1 15

TOTAL INVESTMENT MADE (RS. LACS) 1075



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Additional ESP In Cooler VentDramix Fiber Concrete Road AtLorry Yard

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Steel Saved : 69 MT

Surveillance CameraPressurization And Ventilation

System

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Continuous Ambient Air QualityMonitoring Station (CAAQMS)

New Clinker Drop Test Bin ForKiln-1

61

Chrome Free Basic BricksWater Cooled CCTV Camera For

Cooler-1

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New Road Sweeping Machine

65

Water Sprinkler At Mines Roads

Ambient Air Quality Monitoring StationAdditional Storage Shed For Gypsum

Concrete Road Near Wagon Loading

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Pavement Road Near CDS

Sewage Treatment PlantSolar Blinker



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Online Stack Emission Display

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Separate Shed For Alternate Fuels.

Installation Of ShredderKevlar Suit And Hand Gloves

Near Colony Ground

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Main Gate Entrance

Temple FrontFlats Top View



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Colony Ground

69

Colony Pharmacy

Guest HouseHealth Center

Factory Entrance

70

Factory Boulevard

Admin BlockTraining Centre



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Rain Water Harvesting Inside Plant

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Additive Crusher Area

Water Sprinkler Near Raw MillThermax Conveyor Area

Tower Light Area

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CPP Bird View

Greeneries Near Admin BlockPreheater Top Bird View





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Sl. No. Location Area in acres No. of Trees

2012-2013 Up to 2013 2012-2013 Up to 2013

1 Mines 6.66 165.81 7850 119403

2 Factory 0.77 65.79 500 64600

3 Colony 1.73 54.18 1100 52500

Grand Total 9.16 285.78 9450 236503

45.51 % of total area is covered with green belt

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Limestone Wet Beneficiation Plant - Rs.3800 Lakhs.

Coal Wagon Tippler, 60,000 MT capacity

Raw material storage shed with stacker & reclaimer - Rs.13000 Lakhs

Dust Suppression System at coal transfer and unloading point.

New 6 MW turbine with the existing boiler - Rs. 1500 Lakhs

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National Level Excellent Energy Efficient unit award (For the years 1999, 2000,2001, 2002, 2003, 2004, 2005, 2006 and 2007) by the Confederation of IndianIndustry, Chennai

National Level Best Electrical Energy Performance Award (For the years1999-2000, 2001-02, 2002-03, 2004-05, 2005-06 and 2006-07) by NCCBM

National Level Best Thermal Energy Performance Award (For the years 2005-06, 2006-07) by NCCBM.

National Energy Conservation Award – 2000 (First prize in Cement Sector) byThe Ministry of Power, Government of India.

National Level Best Environment Excellence in Plant operation Award (For theyears 2001-02, 2002-03 and 2003-04) by NCCBM.

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Innovative Environmental Project at the CII Environmental Best Practices Award2011 for THE LIMESTONE SCREENING PLANT.

Innovative Environmental Project at the CII Environmental Best Practices Award2012 for REPLACEMENT OF ELECTRICAL HEATING SYSTEM BYSTEAM HEATERS IN DG.

National Energy Conservation Award – 2012 (Second prize in Cement Sector) byThe Ministry of Power, Government of India.

GREEN AWARD 2012 from TNPCB

Greentech Excellence in Environment Gold Award in Cement sector for the year2011-12.



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1 Ramco Cements