best practices for energy conservation jayanthipuram

The Ramco Cements Limited

Jayanthipuram

Best practices for Energy

conservation

CementReady Mix ConcreteCement Fibre ProductsCotton and Synthetic YarnSoftware SystemsTotal Employees : 15,000

RAMCO GROUP

Shri P.A.C.

Ramasamy Raja

Founder

(1894 - 1962 )

Shri.P.R.

Ramasubrahmaneya Rajha

Former CMD (1935 – 2017)

The Ramco Cements Limited, (formerly known as Madras Cements Ltd.)- Second Largest in South India.- One of the most Reputed Cement Companies in India.- Sixth largest Cement Producer in India- Single largest Cement Brand in South

Plants :1. RR Nagar Plant near Virudhunagar, TN (2.0MTPA) (Established in 1959)2. KSR Nagar Plant, Jaggaiahpet near Amaravathi, Andhra Pradesh (3.65 MTPA) (Estd. in1986)3. Alathiyur near Vridhachalam, Tamil Nadu (3.0 MTPA) (Established in 2002)4. Mathodu near Chitradurga, Karnataka (0.3 MTPA) (in Operation since 2000)

5. Ariyalur, Tamil Nadu (5.5 MTPA) (Established in 2009).

Cement Grinding Units :

1. Kattuputtur (0.75MTPA)

2. Valapadi (2.0 MTPA)

3. Kolakhat (1.0 MTPA)

4. Vizag (0.95 MTPA)

Wind FarmsResearch & DevelopmentDry Mortar PlantsCotton TextilesSurgical.Turnover : Rs. 5,500 crores

Well diversified Group:

Packing Unit :

Nagercoil, TN

Shri.P.R. V. Raja

CMD

Management System Certificates

Energy Policy

4

Energy Road Map

5

Sl. No. Name Designation

01 Sri N Ravi Shankar President - Mfg.

02 Sri S Rajasekharan Sr. GM – Process & Quality Control

03 Sri AV Satyanarayana Asst. GM - Mech.

Sl. No. Name Designation

01 Sri D Sitaramaiah Sr. Dy. GM - Mech.

02 Sri S Kesavaperumal Sr. Dy. GM – Electrical & Inst.

03 Sri P Raghuram Dy. GM – Elec.

04 Sri I.Hariprasad Asst. GM - Env.

05 Sri SVSN Raju Asst. GM - Mech.

06 Sri P Sreekanta Reddy Manager – Inst.

07 Sri R Venkatapathi Gupta Manager - Mech.

08 Sri Chandan Kumar Parasar Dy. Manager - Process

09 Sri M Sreedhar Asst. Manager - Elec.

Apex committee

Core committee

Energy Conservation Organization

Energy Performance Improvement

9

Sl. No Description Units 2016-17 2017-18

1 MTOE reduction MTOE -- --

2 Kiln Thermal SEC kCal/kg cli 684 736

3 Specific Electrical Energy - clinkering kWh/T of clinker 58.14 60.46

4 Specific Electrical Energy – Grinding kWh/T of cement 79.75 82.10

5 CPP Heat rate kCal/kWh 3876 3706

6 CPP auxiliary consumption % 13.63% 12.29%

7 Thermal Substitution Rate % 0 0

8 Clinker factor % 77.89 78.75

9 Blended cement *%) of total cement % 61.62 57.63

10 Renewable Energy (RPO) -- --

11 REC Purchased – Solar REC -- --

12 REC Purchased – Non Solar REC -- --

13 Specific CO2 emission Kg CO2/ kg cement 0.66 0.67

10

Top Ten Energy Projects in 2017-18

S.No Project DetailsSavings In

KW

KWHRs (@ INR 4.62/KWH

1

To avoid the Line-1 Preheater compressors (75 kW)tripping due to high lube oil temperature and to minimize the power Consumption by reducing the suction air temperature with Exhaust fan and duct arrangement (2.8*3497*4.62)

2.80 9792 45239

2

Reducing power consumption in CF Silo aeration Standby Blowers by replacing existing VR4 model 18.5 kW -3nos with GR22 model 37 kW single blower (15*7169*4.62)

15.00 107535 496812

3

Reduction of Power consumption in Packing plant by optimizing the compressors ( running PP3CP02 -55 kw compressor for Packers operation and P1X21-110 kW compressor for Flyash bulk tankers unloading. Savings=129.9 kWh/day ( 129.9*365*4.62)

129.90 47414 219052

4Reduction of fuel consumption per hour in BH 40 Ton Dumpers-2nos. by reducing the engine RPM from 2100 to 1900 ( 200)- (1.42*2672*62.4)

1.42 lphHSD

3794 236761

5Avoiding Idle running of Slag mill Bag house fan motor GRR Blowers by giving interlock (1462*6*4.62)

6.00 8772 40527

Top Ten Energy Projects in 2017-18

11

6Replacement of timer based auto drain valves with zero energy loss auto drain valves -8nos.in line-1 compressor Receiver tanks ( 96kW* 365*4.62)

96 35040 161885

7

Power 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 (6*3600*4.62)

6.00 21600 99792

8Power reduction in Line-2 Kiln bag house fan by modification with Fuzzy New PID system (43*3417*4.62)

43.00 146931 678821

9

Power reduction in 132 kw dewatering pumps of North band mines by providing suitable head pump(higher discharge) in place of existing pump.(lower discharge). 450 cum/hr to 650 cum/hr during Pit levels high. (11.7*123*24*4.62)

11.70 34538 159566

10Slag bag house purging Compressor optimization by reducing the Pr. by replacing the In-Built PLC controllerNeuron (5.5 to 3.8 kg/cm2) (9.8*2500*4.62)

9.8 24500 113190

Journey to ISO : 50001-2011

Implementation

We have started the Energy Conservation activity in the year 2011-12.

In the starting, we have divided the whole plant into 11 Teams.

There was a Review meeting being conducted on monthly basis.

In the meeting Each team has to present their Working on Energy Conservation in front of Management.

There by the project was being implemented.

Again in the next month of Meeting the project status will be reviewed.

The consolidated Annual Achievement has shown in the next slide.

Year Savings(Lakh KWH)

2012-13 10.50

2013-14 7.25

Savings Achieved…

We have implemented the ISO : 50001-2011 EnMS in the year

2013-14 with the External Certification Agency BSI.

It has taken approx 6 months for completion of all the

Documentation.

In the month of August’2014, we had the Certification Audit.

After successful completion of the Audit, we have certified for

EnMS (ISO:50001-2011) in August’2014.

The Old Energy Teams were continued (with addition of 2

more teams) on the way of Energy Conservation with this

Management System.

ISO : 50001-2011

Implementation/Certification

Energy Conservation Activities…

The Energy consumption & deviation is being monitored by

individual team members on daily basis .

Review of the same with Corrective Actions (If any) is being

discussed in meeting with HOD’s & Management on daily

Basis.

Monthly Once we will have the meeting of Energy

Consumption & Conservation with all the Team Members.

There is also a Competition being conducted twice in a year on

Energy Conservation Day & Our Founder’s Day.

Energy Conservation Activities…

This Competition will consist of several activities like Energy

Conservation Projects Presentation, Slogans, Essays, Painting &

Skit programs.

In this competition we are involving the Ladies Club members &

School Children also along with the Regular and contract

employees.

This competition will be followed by the Award distribution for

the Best Presentation in each area.

The LED Bulbs also being distributed as gift to the All the Energy

Team members as a part of Energy Conservation.

Re-certification audit conducted in Aug.2017 and certificate

issued.

Savings Achieved…

Year Savings(Lakh KWH)

2014-15 40.84

2015-16 17.91

2016-17 4.42

2017-18 10.83

Best Practices for Energy ConservationIn2017-18

Best Practices for Energy Conservation in 2017-18

Project details -Reducing power consumption in CF Silo aeration Blowers by replacing existing VR4 model 18.5 kW -3nos. with GR22 model 37 kW single (available )blower of equalent capacity.

Savings (KWH) : 15

Annual Cost Savings (INR) : Rs . 4.96Lakhs (15*7169*4.62)

Project Investment : In House Works

Payback : -Nil-

GR22 Blower VR4 Blower


Project details -Reduction of fuel consumption per hour in BH 40 Ton Dumpers-2nos. by reducing the engine RPM from 2100 to 1900 ( 200)

Savings (L/h) : 1.42 HSD L/h

Cost Savings (INR) : Rs . 2.37Lakhs (1.42*2672*62.4)

Project Investment : In House Works

Payback : -Nil-

BH 40 Dumper


Project details -Replacement of timer based auto drain valves with zero energy loss auto drain valves -8nos.in line-1 compressor Receiver tanks

Savings (KWH) : 96 kWh/day

Cost Savings (INR) : Rs . 1.62 Lakhs (96*365*4.62)

Project Investment : Rs. 2.00 Lakhs

Payback : - 1.2 Years

Timer model Auto Drain Valve Zero Energy loss Auto Drain Valve

Best Practices for Energy Conservation

in 2017-18

Project details - Power reduction in 132 kw dewatering pumps

of North band mines by providing suitable head pump(higher discharge) in place of existing pump(lower discharge). 450 cum/hr to 650 cum/hr (Rainy season 4 monts-123 days)

Savings (KWH) : 11.7 kW/hr

Annual Cost Savings (INR) : Rs . 1.60 Laks (11.7*123*24*4.62)


Payback : -7 months

Dewatering Pump at Mines


Project details - Power reduction by eliminating idle running

of refrigerated driers by giving interlock with compressors of-12 driers.

Savings (KWH) : 60kW/hr

Annual Cost Savings (INR) : Rs . 2.70 Laks (60*1000*4.6)


Payback : -5 months

Driers interlock

Project details - Power reduction in Line-1 Compressors room

By reducing the room temperature by providing hot air vent duct with exhaust fan

Savings (KWH) : 2.80

Annual Cost Savings (INR) :0.45 Lakhs (2.8*3497*4.62)


Payback :1 Year


Radiator Vent duct

Project details :Slag baghouse purging Compressor optimization by reducing the Purging Pr. by replacing the Compressor inbuilt PLC Controller Neuron (5.5 to 3.8 kg/cm2).Savings=9.8 kW

Annual Cost Savings (INR) : Rs .1.13 lakhs (9.8*2500*4.62)

Project Investment:0.50 Lakhs

Payback : 5.3 months



Project details -. Power savings in Line-1&2 process Bag filters-8nos. by changing the Bag house solenoid valves purging operation from Timer mode to DP mode .

Modifications carried out for all Process Bag filters (Total 9 nos ,Lime-1& 2 Coal mill Bag houses, Cement mill, Slag mill ,P/Plant Bag houses)

Savings (KWH) : 50 kW/hr

Annual Cost Savings (INR) : Rs .11.0Lakhs (50*4800*4.60)

Project Investment 0.90 lakhs

Payback : - 1 month

Rawmill-1 Bag house

Crusher kw 5

Raw Mill-1 kw 10

Coal Mill-1 kw 5

Coal Mill-2 kw 5

Slag Mill kw 5

Cement Mill Vent kw 5

Cement Mill O-Sepa Vent kw 5

VRPM Vent kw 5

VRPM Sep Vent kw 5

Total kw 50

Modified Bag filters to DP mode


Project details : Reducing of power consumption in Line-1 Kiln by stopping the 75 kW screw Compressor (20 hrs/day)by inter connecting the airline to Main 110 KW Compressor W1X11 airline which is running in more unload condition 70% with erection of additional Radiator of 11 kw fan. After modification Unloading reduced to 30%.

Net savings/day=1060 kWh

Savings (KWH) : 1060kWh/day

Cost Savings (INR) :9.75 lakhs (1060*200*4.6 )

Project Investment: 0.20 lakhs

Payback : 0.2 Months

Line-1 Kiln Compressor


Similar modification carried out for 5 Compressors i.e interconnecting of compressors which are running in more time in Unloading mode.(70-80%)

Ideal operation of Screw Compressors is 80% loading and 20%unloading.

Savings in 5 Compressors : 80 kW/hr

Annual savings (INR) : 17.7 Lakhs (80*4800*4.6)

Project cost : 1.0

Payback : 0.7 months.


Project details :Reducing of power consumption by interchange of product in Cement silos as Silos nos 1&2 -for Storage of OPC 43 grade cement from Slag mill and Silo nos.3&5- for Storage of PPC Cement from Cement mill .There by we can avoid running of Screw conveyors No.3,5 silos .(15+17 kW=32 kW)

Savings (KWH) : 32kW/hr

Annual Cost Savings (INR) :7.07 lakhs (32*4800*4.6)

Project Investment: In-House sources

Payback : NA

BU

CK

ET

EL

EV

AT

OR

INCLINEDSCREW

CONVEYOR-2

AIR SLIDE BLOWER

OPC SILO-4

PPC SILO-1

PPC SILO-2

OPC SILO-3

JUNCTION BOX

SCREW CONVEYOR

INCLINEDSCREW

CONVEYOR-1

SLAG MILL OUTPUT

BEFORE

53

Before QC we used to run one screw conveyor-1 for 3rd silo feeding and where as for 4th silo feeding we used to run screw conveyors -3 nos. During transportation

we are facing the following problems 1.Frequent breakdowns of screw conveyors,2.High maintenance cost 3.High power consumption.

Cement Mill :PPC:1 and 2 silosSlag Mill :OPC :3 and 4 silos

INCLINEDSCREW

CONVEYOR-2

AIR SLIDE BLOWER

PPC SILO-4

OPC SILO-1

OPC SILO-2

PPC SILO-3

JUNCTION BOX

SCREW CONVEYOR

INCLINEDSCREW

CONVEYOR-1

BU

CK

ET

EL

EV

AT

OR

SLAG MILL OUTPUT

AFTER

54

To overcome above experienced problem based on suggestions given by our team members, we have interchanged the storage of product from 3rd and 4th silos to

1st and 2nd silos. By this we have avoided running of 2 screw conveyors. After changing our previous problems are solved

Cement Mill :PPC:3 and 4 silosSlag Mill :OPC :1 and 2 silos

Energy saving proposals

Sno.Area Project Details

Power

Savings

Kw/hr

Projected

Annual

Power

Savings

kWh

Projected

Annual

savings

Rs. Project cost Rs Payback

1 Pumphouse

Pumphouse pumps automation a) Plant

incoming pumps, b)Colony utility water

pumpc) Cooling water Pumps by

providing level sensors and auto on/off

.savings =160-110=50 kW /hr ( for 160

days )

50 kW 192000 960000 10,00,000 1 Year

back

Energy saving Proposals

TPP TANK

WATER FLOW

CRUSHER

WATER SPRAY

MK. PUMP No.3

T

AN

K

T

AN

K

T

AN

K

No.5 No.7

MG FILTERS

NRV

NRV

VALVE

VALVE

MOTORISED

VALVEVALVE

(10 “ )WATER LINE FROM MINES TO TPP TANK

IN

No

1&2

FLYASH SILO

BULK TANKER

RE

CE

IVE

R

TA

NK

Flyash Bulk Tanker unloading

COMPRESSOR

Low pressure Compressor

RAMCO CEMENTS LTD., JAYANTHIPURAM.

Section : Compressors

Project No. Date 10/8/2018

Area of the Project Flyash handling

Project details

To replace the existing 110 kW old High pressure Screw compressor with 55kW Godrej make low Pressure Compressor

Present condition

110 kW old high pressure KG Khosla Compressor is in operation .Its specific power consumption is =10 kwh/cum/min

Proposed scheme and Projected savingsPlanned to replace with 55kW low pressure Godrej make Screw Compressor ,Specific power consumption = 3 kWh/Cum/min . Flyash avg.yearly Consumption= 2,20,000 MT,

No of trucks @ 30 T/each(with 110 kW compressor) = 1.20,000/30=4000 No.of hrs with existing 110 kW high pressure compressor@45min = 3000hrs No.of hrs with proposed 55 kW low pressure compressor@30min = 2000hrs , Power consumption with the existing 110 kW Screw compressor = 90 kW* 3000 =270000 kWh Power consumption with the proposed 55 kW Godrej compressor =55*2000 = 110000 kWh

Annual Power savings = 160000 kWh = Rs 8,00,000/-

Maintenance cost reduction = Rs 1,00,000/-Total savings = Rs.9,00,000/-Project cost (Compressor+Drier) = Rs 14,00,000/-

Payback = 1.5 years

Remarks

best practices for energy conservation jayanthipuram

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