JAYANTHIPURAM WORKS

Integrated Plants :

1. RR Nagar Plant near Virudhunagar, Tamilnadu (2.0MTPA) (Estd. in 1959)

2. KSR Nagar Plant, Jaggaiahpet, Andhra Pradesh (3.65 MTPA) (Estd. In

1986),

3. Alathiyur near Vridhachalam, Tamil Nadu (3.0 MTPA) (Estd. in 2002)

4. Mathod near Chitradurga, Karnataka (0.3 MTPA) (Estd. in 2000)

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

Cement Grinding Units :

1. Kattuputtur, Chengalpet, Tamilnadu (0.75MTPA)

2. Valapadi, Salem, Tamilnadu (2.0 MTPA)

3. Kolaghat, East Midnapore, West Bengal (1.0 MTPA)

4. Gobburupalem, Vizag, Andhra Pradesh (0.95 MTPA)

Packing Unit :

1. Nagercoil, TN

2

Best Practices on Productivity Sl.

No.Parameters UoM 2017-18

1 Capacity Utilization %

Clinker (%) 53.03

Cement (%) 33.72

2

Conservation of Raw Materials & Fuels

• % Alternative raw material used

• % Alternative fuel used

• Amount of Waste Heat recovery power

generated

%Alternate Raw Mat : 2.05%

Alternate Fuel : ----

3

Approach to the Implementation of Best

Practices

If Yes, Please Specify.

Y/N Yes

4

DC in PAT Cycle

If Yes , Specific Energy Consumption

(Target & Achievement)

Y/N

TOE/T of Product

Yes (PAT Cycle-III)

Target : 0.0684 TOE/T of Product

5

Do you have RPO obligation

If Yes, Specify the obligation and measures

taken to fulfill (Certificates procured or

renewable energy used by purchase or by

self generation)

Y/N -NA-

Sl.

No.Parameters UoM 2017-18

6Blended Cement Produced out of total

production% 57.63

7

Low grade (>18% SiO2) /sub grade

limestone used out of the total limestone

consumption

% 4.61

8

% of Synthetic gypsum used out of total

gypsum.

% of Fly ash used in cement (in PPC)

% of slag used in cement (in PSC)

%100.00%

32.13%

--

9 Spares Consumption Rs/T of Product 80.14

10Man Power Utilization

(Permanent & Contract)

T of Product

(Cement)/Man Hour110

Best Practices on Productivity

Sl. No. Parameters UoM Values

11

Compliances with

Environmental Norms

(Dust, SOx & NOx Emission)

mg/Nm3

Dust : <30 mg/Nm3

Sox : ~ 10 mg/Nm3

Nox : ~ 400 mg/Nm3

12Industrial Relations Issues,

Please Specify--

No IR Issues, because of harmonious

relationship between Workmen & the

management. Hence, received the best

management award by AP Govt on the eve of

May Day’2016.

Management System

Implementation, Please

specify the name of System

(ISO/IS/IMS Systems etc)

Nos

5 Nos

QMS-ISO 9001

EMS-ISO 14001

OHSMS-ISO 18001

EnMS-ISO 50001

5-’S’

14

Maintenance Practice

(Preventive/Proactive/Conditio

n Monitoring)

-- All the three Practices are being carried out

Best Practices on Productivity

Product Capacity

(MMTPA

)

Clinker 3.185

Cement 3.650

40%

33%

23%

26%

34%

63%

51%

36%39%

53%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

2013-14 2014-15 2015-16 2016-17 2017-18

Ca

pa

cit

y U

tiliza

tio

n

(%

)

FY

Capacity Utilization (At a Glance)

Cement Capacity Utilization Clinker Capacity Utilization

Management System Certificates

Back

BEST MANAGEMENT AWARD to Sri P R Ramasubrahmaneya Rajha, Chairman & Managing

Director, Ramco Cements Limited and the award is being received by Sri P B Gopala Krishna,

President-Mfg., Sri M. Chidambaram, Vice President - Admn, Sri T. Sridhar Reddy, AVP -

Works and Sri E. Alwar, DGM - Personnel on the occasion of MAY DAY on 01.05.2016.Back

Back

Best Practices in Productivity

Raw Mill-1 Optimization

➢ Description

◦ Gear Box changed from 1440 KW rating to 1800 KW rating for 2000

KW rating motor

◦ Earlier with lower rating Gear Box, there was a restriction of Feed to

215 tph only.

◦ The same was increased to 230 tph after changing the Gear Box and

simultaneously increasing the Grinding Pressure by 10-15 Bar.

➢ Benefits

◦ Feed rate increased by 10 tph.

◦ SPC reduced by 0.30 KWH/T Mat.

➢ Monetary Saving

◦ Cost Saving incurred : INR 14.17 Lakhs /Annum

12

220

230

12.93

12.63

11.98

12.48

12.98

13.48

13.98

200

205

210

215

220

225

230

235

240

Before After

KW

H/T

Mat

TPH

Raw Mill-1 Optimization

Productivity SPC

Raw Mill-2 Optimization

➢ Description

◦ Accumulator Pressure increased from 55 bar to 60 bar; thereby

increased the Grinding pressure from 110 Bar to 120 Bar.

◦ And also the table dam ring increased by 7 mm.

➢ Benefits

◦ Feed rate increased by 10 tph.

◦ SPC reduced by 0.20 KWH/T Mat.

➢ Monetary Saving

◦ Cost Saving incurred : INR 18.80 Lakhs /Annum

14

518

528

11.46

11.26

11

11.1

11.2

11.3

11.4

11.5

11.6

11.7

11.8

500

505

510

515

520

525

530

535

540

Before After

KW

H/T

Mat

TP

H

Raw Mill-2 Optimization

Productivity SPC

Cement Mill Optimization

➢ Description

◦ To avail the power for Clinker handling, Mines Dewatering Pump etc

during single CPP running.

◦ Grinding Media Filling level reduced by 5% (from 30% to 25%) as per

the production requirement for Cement Dispatch.

◦ Mill feed rate optimized as per the new GM pattern.

◦ Specific Air Optimization in both VRPM and Ball Mill.

◦ VRPM Bag Houses (2 Nos) purging system kept in DP mode

◦ Water Spray in VRPM introduced to improve the Grinding.

➢ Benefits

◦ SPC reduced by 1.43 KWH/T Mat.

➢ Monetary Saving

◦ Cost Saving incurred : INR 49.55 Lakhs/Annum

16

230

220

29.27

27.84

26.79

27.79

28.79

29.79

30.79

31.79

200

205

210

215

220

225

230

235

240

Before After

KW

H/T

Mat

TP

H

Cement Mill Optimization

Productivity SPC

Novaflam Burner Installation

➢ Description

◦ Novaflam Burner from M/s Pillard installed in Line-2 by replacing the

FLS designed Duoflex Burner.

➢ Benefits

◦ Kiln Feed rate increased by 15 tph.

◦ Primary Air Consumption reduced by 4-5%.

◦ SHC reduced by 5 Kcal/Kg Clinker.

◦ Brick Life increased by 4-5 months.

➢ Monetary Saving

◦ Cost Saving incurred : INR 78.29 Lakhs/Annum

CB Cooler & New ESP Installation in Line-1

➢ Description

◦ Old CIS+CFG+RFT Grate Cooler replaced with ABC inlet Cross Bar

Cooler.

◦ This Cooler with better Clinker transport and recuperation efficiency

installed and commissioned in Line-1.

◦ New ESP installed to meet the New Emission norms of < 30 mg/Nm3.

➢ Benefits

◦ Cooler Loss reduced by 30 Kcal/Kg Clinker.

➢ Monetary Saving

◦ Cost Saving incurred : INR 308.07 Lakhs/Annum

Installation of 3-Phase Transformer in Line-2 Cooler

Vent ESP

➢ Description

◦ Collection Efficiency of ESP was improved with 3-phase transformer.

➢ Benefits

◦ SPM emission reduced from 50 mg/Nm3 to 20-25 mg/Nm3.

➢ Monetary Saving

◦ Cost Saving incurred : INR 0.60 Lakhs/Annum

Alternate Fuel in Kiln & CPP

➢ Description

◦ While restart up of Kiln and CPP after shutdown.

◦ Kiln : Alternate Fuel Pyrolysis Oil is being used by 100% replacement

of Non-Renewable fuel like HSD.

◦ CPP : Alternate Fuel Charcoal is being used by 100% replacement of

Non-Renewable fuel like HSD.

➢ Benefits

◦ Conservation of Non-Renewable Fuel.

➢ Monetary Saving

◦ Cost Saving incurred in Kiln : INR 1.04 Lakhs/Light Up

◦ Cost Saving incurred in CPP : INR 3.15 Lakhs/Light Up

Preheater Flow Optimization

➢ Description

◦ After up-gradation the Preheater Gas Velocity is maintaining in higher

range of 22-25 m/sec, which was causing the imbalance of Hot gases

among the two Preheater (Old & New) towers.

◦ Thereby the heavy coating formation observing at the KRTP (Kiln

Riser Transition Piece) area.

◦ To reduce the Gas velocity from 22 m/sec to 15 m/sec, The Area of

Kiln Raiser Duct was increased in Old and New Preheater.

➢ Benefits

◦ Coating formation reduced with reduced velocity.

◦ Kiln Operation was also smoothen.

➢ Monetary Saving

◦ Cost Saving incurred : INR 2.71 Lakhs/hr of stoppage

22

Air Blaster installation in Kiln hood slope area

➢ Description

◦ To avoid Manual cleaning as well as sudden material rush to Cooler

and DPC.

➢ Benefits

◦ Safe Working Environment

➢ Monetary Saving

◦ Nil

24

Burner Pipe castable pre-heat up before keeping in

operation

➢ Description

◦ Proper in-house arrangement were made for Burner Pipe preheat up

to enhance the refractory life.

➢ Benefits

◦ Castable life increased by 4-5 months.

➢ Monetary Saving

◦ Cost Saving incurred : INR 6.51 Lakhs/Annum

Burner pipe heating

Refractory application by Gunning Method

➢ Description

◦ Gunning Method is being used to carry out the castable application in

Kiln Hood Roof.

➢ Benefits

◦ Application hrs reduced from 15 days to 4-5 days.

➢ Monetary Saving

◦ Cost Saving incurred : INR 0.47 Lakhs

Inter Connection of Line-1 and Line-2 LST Pile

➢ Description

◦ Earlier the Line-1 & 2 LST pile was separately forming to meet out the

respected Mills.

◦ In case of any correction required in Raw Mix, The complete pile used to

be emptied and reforming.

◦ After inter-connection of Line-1 & 2 LST pile, the both pile is being

formed with short range of Si content.

◦ With this inter-connection, the Raw Mix correction can be done at any

point of requirement.

➢ Benefits

◦ Easy in Quality control of Raw Materials.

◦ Kiln Feed LSF Standard Deviation 1.20% to 0.50% reduced.

➢ Monetary Saving

◦ Nil