the ramco cements limited,jayanthipuram works€¦ · power reduction by reducing the air leakage...
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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
Energy Conservation Project 2018-19
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
Energy Conservation Project 2018-19
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
Energy Conservation Project 2019-20
17
Energy Conservation Project With Investment
No. of Projects : 24
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
Energy Conservation Project 2017-18
S. No. Energy Saving ProjectSavings
(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
Energy Conservation Project 2017-18
S. No. Energy Saving ProjectSavings
(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
Energy Conservation Project 2018-19
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
Energy Conservation Project 2018-19
S. No. Energy Saving ProjectSavings(Lakhs)
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
Energy Conservation Project 2018-19
S. No. Energy Saving ProjectSavings(Lakhs)
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
Energy Conservation Project 2019-20
S. No. Energy Saving ProjectSavings(Lakhs)
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
Energy Conservation Project 2019-20
S. No. Energy Saving ProjectSavings(Lakhs)
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
No. of Projects : 47
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.
Innovative project-1
30
Hot gas duct from TPP Hot gas duct joining coal mill-2 inlet duct
Innovative project-1
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)
Innovative project-1
32
INNOVATIVE PROJECT-2
Power reduction in cement mill
33
Innovative project-2
� 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
Innovative project-2
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
Innovative project-2
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.
Innovative project-2
37
INNOVATIVE PROJECT-3
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
Innovative project - 3
41
INNOVATIVE PROJECT-4
Reduction of Overall Raw mill power consumption
42
43
Innovative project - 4
� 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
Innovative project - 4
� 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
Environmental Projects- Green Development
59
Admin Admin entrance
Admin lobbyFounder statue Area
Environmental Projects- Green Development
60
LED F i t t i ngs Factory Entrance gate Factory main road
Inside FactoryColony road
61
Environmental Projects- Green Development
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