The Ramco Cements Limited, Alathiyur Profile

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The Ramco Cements Limited, Alathiyur Profile

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A flagship company of RAMCO Group, having five Cement manufacturing units, four grinding units and one packing unit with the total capacity of 16.5 MTPA.

Alathiyur plant was setup in two phases 1997 & 2001 with Cement capacity of 3.05 Million Tons / Annum and 2 X 3700 TPD Kilns.

The manufacturing products are Ordinary Portland Cement, Portland Pozzolana Cement and SRPC as per BIS & SLS standards.

2X18 + 6 MW - Coal based Thermal power plant

Integrated Management System Certification

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IS/ISO 9001: 2015

IS/ISO 14001: 2015

IS 18001: 2007

Quality Management System

Environment Management System

Occupational Health & Safety Management System

IS/ISO 50001:2011 Energy Management System

5S Excellence Certified Company

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Energy Monitoring & Reporting System

Energy consumption both electrical & thermal : Daily

Energy conservation projects : Weekly

Review meeting conducted by : Unit Head

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Energy Management System

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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

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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

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INCHARGEMINES & CRUSHER

INCHARGE

TPP

INCHARGE

PACKING

INCHARGE

CEM MILL

INCHARGE PYRO

INCHARGE RAW MILL & COAL MILL

INCHARGE

UTILITIES

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.

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Sl. No Description Units 2016-17 2017-18

1 MTOE reduction MTOE 175239 170800

2 Kiln Thermal SEC kCal/kg clinker 699 697

3 Specific Electrical Energy - clinkering kWh/T of clinker 52.76 52.58

4 Specific Electrical Energy – Grinding kWh/T of cement 26.16 25.02

5 CPP Heat rate kCal/kWh 3421 3496

6 CPP auxiliary consumption % 10.49 10.43

7 Thermal Substitution Rate % 2.2 5.95

8 Clinker factor % 0.77 0.78

9 Blended cement *%) of total cement % 94 92

10 Specific CO2 emission Kg CO2/ kg cement 702.42 700.35

Energy Performance Improvement

Energy Conservation Projects Implemented in the years

2017-18

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No. of Projects : 6

Projects with NIL investment : 5 Nos.

Total amount invested : Rs. 149 Lacs

Cost savings achieved : Rs. 233 Lacs

Electrical energy saved : 52.5 Lac Kwh

Thermal Energy saved : 350 MT of coal

Reduction in GHG emissions : 5305 MT of CO2

Energy Conservation Project 2017-18

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Sl. No. Title of Project

Annual Electrical

Saving (kWh)

Annual Electrical

Cost Saving (Rs

million)

Annual Thermal Saving (Ton/ye

ar)

Annual Thermal Saving

(Rs million)

Total Annual Savings

(Rs million)

Investment Made (Rs million)

Payback (Month

s)

1Modification of Line-1 Coal mill main bag filter purging from low pressure to high pressure

792,000 3.17 0 0 3.17 2.5 10

2 Retrofitting of Line-1 Cement Mill fan 3,896,640 15.59 0 0 15.59 5 4

3 Removal of damper in Line-1 RABH fan 216,000 0.86 0 0 0.86 0 0

4 Installation of Pillard burner in Line-1 Kiln 0 350 2.3 2.31 5.2 27

5Installation of VRF AC System in Rawmill-2 IO Room

275,800 1.1 0 0 1.1 1 11

6Replacement of 70W / 250W SON light fittings by energy efficient 36W / 100W LED fittings

68,240 0.27 0 0 0.27 1.2 53

750

760

770

780

790

800

Target Achieved

796

768

Gate to Gate Energy Consumption for PAT Cycle-I

19th National Award for Excellence In Energy Management -2018 14

BEE-PAT Scheme : 8946 Nos. of Energy saving certificates issuedK

cal/

Kg

of

Cem

en

t

650

670

690

710

730

750

Baseline Target 2017-18

756

718

697

Gate to Gate Energy Consumption for PAT Cycle-II

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Kcal/

Kg

of

Cem

en

t

Road Map To Achieve Benchmark

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Innovative Project -1

In our Alathiyur plant we have 2 nos. of Vertical Roller Mill for Clinker grinding.

Line-1 mill FLS make OK 33.4 capacity of 160 TPH for PPC and Line-2 mill LOESCHE make LM 56.2 capacity of 260 TPH for PPC.

Line-1 Cement mill is consuming about 4kWh/MT higher than Line-2 Cement mill, due to this we are operating Line-1 Cement mill very less.

We have identified the difference is in the specific power consumption of fan.

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Fan Power consumption high: We have identified the reasons for low fan efficiency and done stage wise modifications like:

Increasing the fan inlet duct dia from 2 m to 2.8 m

Modification of fan outlet to chimney duct

Modification of bag filter outlet duct by conducting CFD

Modification of fan inlet suction box.

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By carrying out above all modifications, the fan inlet turbulence has reduced,

but the fan outlet turbulence did not reduce and Reason is due to the recirculation duct tapping immediately after the fan outlet, due to this the fan

outlet pressure is varying from -100mmwg to -200mmwg.

Action taken to reduce fan power:

Replacement of existing low efficiency fan (50% eff.) with high efficiency fan

(83% eff).

Installation of junction box at the mill fan outlet and rerouting recirculation duct

to eliminate turbulence at the fan outlet duct.

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Modified recirculation duct routing from the junction box

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Savings achieved : 6.6 Kwh/Mt of Cement

Productivity Improvement : 15 TPH

Cost savings : Rs. 155.9 lacs

Investment Cost : Rs. 50 Lacs

Simple Pay Back Period : 4 Months


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Line-1 Coal Mill Main Bag Filter is designed for low pressure high volume purging.

During normal operation in Line-1 Coal mill, Bag filter DP is high which causes the frequent disturbances in Mill operation.

The disturbances causes reduction in mill output, increase in specific power consumption. Due to this we have even forced to reduce the kiln feed occasionally.

We observed that when ever there is mill trip, lot of material is collected from the bag filter to the fine coal bins.

We have taken trial with increased purging pressure up to 3.5 bar and increased the on time of purging, but there is no any significant improvement.

From the above trials we observed that the bag cleaning (purging) is not adequate.

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We studied the root cause for inadequate bag cleaning:

Line-1 coal mill is designed for Lignite / Coal grinding.

During pet coke grinding, the mill output is low and also not able to achieve the desired residue.

We have modified the mill internals and classifier to suit pet coke grinding, due to this the mill Dp has increased by 250 – 300 mmwg.

The bag filter is designed for the inlet draft of -650 mmwg. After the modification of the mill it has increased to -900 to -950 mmwg.

Due to increase in the bag filter draft, the low pressure high volume purging is not adequate for cleaning of the bags.

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We have decided to change the purging from low pressure high volume to high pressure low volume purging.

The modification was carried out in-house.

We designed and fabricated the purging air headers, purging pipes. We procured the solenoid valves, venturi.

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DescriptionBefore modification After modification

Low pressure purging High pressure purging

Bag Ø in mm 127 127

Bag length in mm 5040 5040

Bag seating type Snap band Snap band

Qty in Nos 1024 1024

Venturi Availability No Yes ( Provided )

Purge pipe Ø 80 NB 50 NB

Tube sheet to purge pipe height

190 mm 120mm

Purge pipe purge hole dia16mm (Nozzle pipe Ø

36mm)4.5mm (Nozzle pipe Ø 6.3mm)

Operating air pressure 2.5 bar 5.5 bar

Compressor air volume 380 CFM 260 CFM

Purging Sequence 1,2 - 3,4 - 5,6 …….. 1,33 - 2,34 - 3,35 …….

On Time 0.120 Sec 0.175 Sec

Off Time (Pass Time) 7 Sec 6 Sec

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Before After


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Before After


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Before Bag filter purging modification

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After Bag filter purging modification

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Investment Cost : Rs. 25 Lacs

Cost Savings : Rs. 32 Lacs/Year

Simple Pay Back Period : 10 Months

Electrical energy savings : 5.08 kWh/T matl

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Best

Improvement

in Energy

performance

in

Manufacture

of Blended

Cements –

2016-17 from

NCCBM

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Documents

The Ramco Cements Limited, Alathiyur Profile