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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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Capacity Utilization

Sl. No. Particulars Quantity (MT)

1 Clinker production capacity 2520000

2 Cement production capacity 3050000

3 Clinker production 1588085

4 Cement Production 1305451

5 Clinker Capacity Utilization (%) 63.02

6 Cement Capacity Utilization (%) 42.80

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Conservation of Raw Materials

Sl. No. Particulars Quantity (MT) %

1 Blast Furnace Slag 7834 0.32

2 Granulated Slag 24187 1.0

3 EOF Slag 64060 2.64

4 Flue Dust 2173 0.1

5 Crusher Dust 104810 4.33

6 TPP Reject bed ash 1183 0.05

Alternate Raw Materials used

Low grade / Sub grade Limestone used

Sl. No. Particulars Quantity (MT) %

1 Low Grade Limestone 1105454 45.6

2 Sub Grade Limestone 36709 1.5

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Conservation of Fuels

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 Power Plant reject 10634 6885 5.04

2 Reject from sugar plant 7969 1238 0.91

Alternate Fuels used

Waste heat from Preheater exit gases is completely utilized in Raw Mil and Coal Mill, for Raw material and fuel grinding and drying.

Waste heat from Cooler exhaust is completely used in Cement Mill by usage of wet fly ash.

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Blended Cement & Additives

Sl. No. Particulars Quantity (MT) %

1 Total Cement Production 1305451

2 Blended Cement Production 1203813 92.2

3 Synthetic Gypsum 47478 100

4 Fly ash 225910 18.8

Spares Consumption

Sl. No. Particulars Rs. / T cement

1 Up to Clinker 44.41

2 Cement 27.36

3 Total up to Cement 62.76

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Man Power Utilization / Ton Product

Sl. No. Description Nos.

1 Permanent Man power 154520

2 Contract Man Power 260758

3 Total Man power 271139

4 Blended Cement Production 1305451

5 T of Product / Man power 4.81

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Compliance with Environmental Norms

S.

No.Stack

Pollutants (mg/Nm3)

PM SOx NOx

1Kiln-1

APC - RABH 22 53 179

2Cooler-1

APC - ESP 27

3Coal Mill-1

APC – Bag Filter 23

4Cement Mill-1

APC – Bag Filter 20

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Compliance with Environmental Norms

S.

No.Stack

Pollutants (mg/Nm3)

PM SOx NOx

1Kiln-2

APC - RABH21 63 192

2Cooler-2

APC - ESP28

3Coal Mill-2

APC – Bag Filter25

4Cement Mill-2

APC – Bag Filter22

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 11

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

12

Kcal/

Kg

of

Cem

en

t

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Implementation of Best Practices

1. Safe Zone Declaration, safety rolling trophy of individual section. Separate team periodically

reviews for sustaining.

2. safety rolling trophy of individual section. Separate team reviews quarterly for sustaining.

3. Near miss reporting system - Reward is given to make our plant so safe.

4. All level safety committee meetings conducted every month and reviewed the activity status.

5. Daily departmental power consumption reviews conducted with respect to plan and actual data's,

6. Employee suggestion system conducted and reviewed every month. Reward is given based on

the good suggestion and its implementation.

7. MTBF/MTTR/Reliability – Monitored periodically.

8. Effective work procedures (SOP) are written and followed.

9. 95% of all work (Scheduled) is planned.

10. 100% maintenances are covered by scheduled work order.

11. RCA practice is applied to any failure that is costly and repeats itself.

12. Key data's are collected and disseminated to determine the health of an asset.

POTENTIAL FAILURE CURVE

Catastrophic failure

P

r

e

d

i

c

t

i

v

e

Pre

ve

nti

ve

Run to failure

P

r

e

c

i

s

i

o

n

Ultrasonic energy

detected

Cost to Repair

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Conditional Monitoring:

1. Critical Equipments Vibration Monitoring Services:

As per AMC – Frequency - 3 Months once by External agency,As per internal schedules every 1 Month and Need Based.

2. Ferrography and Oil Analysis:As per AMC – Frequency – 6 Months once by External agency &

Need Based,

3. Ultra Sonic test:

As per AMC - Frequency – 6 Months once by External agency &Need Based,

4. Other Internal Service –Need Based Laser alignment for Coupling and V-Belt alignments,

Need Based Material Hardness Testing for Equipment Belts, strips etc., and metals.Need Based VFD drive inspection with electric discharge detector.

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AMC for Condition Monitoring on critical equipments

1.4 visits conducted vibration measurement service at Plant and CBPP asper AMC schedule by M/s. Tribocare, Chennai.

2. 2 visits conducted to collect oil samples for ferro-graphy and Oil analysis

by M/s. Predict Technologies, Hyderabad.

3. 3 Visits carried out for Ultra sonic testing on critical equipments by M/s

Super Quality Services, Trichy.

AMC - Condition Monitoring Yearly Activity

2018 - 2019 Details of Activ ity

Apr - 17 May June Activity

Su M Tu W Th F Sa Su M Tu W Th F Sa Su M Tu W Th F Sa

1 2 3 4 5 6 7 1 2 3 4 5 1 2 Month :- May'18

8 9 10 11 12 13 14 6 7 8 9 10 11 12 3 4 5 6 7 8 9 14 - 15/05/2018 - M/s Sqs Ultrasonic testing 1st Visit

15 16 17 18 19 20 21 13 14 15 16 17 18 19 10 11 12 13 14 15 1622 23 24 25 26 27 28 20 21 22 23 24 25 26 17 18 19 20 21 22 23 Month :- June'18

29 30 27 28 29 30 31 24 25 26 27 28 29 30 11 - 13/06/2018 - M/s Tribocare Vibration inspection 1st Visit

Month :- August'18

July August September 06 - 08/08/2018 - M/s Sqs Ultrasonic testing 2nd Visit

Su M Tu W Th F Sa Su M Tu W Th F Sa Su M Tu W Th F Sa 24 - 25/08/2018 - M/s Predict Oil sample collection 1st Visit

1 2 3 4 5 6 7 1 2 3 4 1

8 9 10 11 12 13 14 5 6 7 8 9 10 11 2 3 4 5 6 7 8 Month :- September'1815 16 17 18 19 20 21 12 13 14 15 16 17 18 9 10 11 12 13 14 15 04 - 05/09/2018 - M/s Tribocare Vibration Inspection 2nd Visit

22 23 24 25 26 27 28 19 20 21 22 23 24 25 16 17 18 19 20 21 2229 30 31 26 27 28 29 30 31 23 24 25 26 27 28 29 Month :- November'18

30 13 - 15/11/2018 - M/s Tribocare Vibration Inspection 3rd Visit

October November December Month :- January'19

Su M Tu W Th F Sa Su M Tu W Th F Sa Su M Tu W Th F Sa 14/01/2019 - M/s Predict Oil sample collection 2nd Visit

1 2 3 4 5 6 1 2 3 1

7 8 9 10 11 12 13 4 5 6 7 8 9 10 2 3 4 5 6 7 8 Month :- Febraury'19

14 15 16 17 18 19 20 11 12 13 14 15 16 17 9 10 11 12 13 14 15 05 - 07/02/2019 - M/s Tribocare Vibration Inspection 4th Visit21 22 23 24 25 26 27 18 19 20 21 22 23 24 16 17 18 19 20 21 22 18 - 20/02/2019 - M/s Sqs Ultrasonic testing 3rd Visit

28 29 30 31 25 26 27 28 29 30 23 24 25 26 27 28 29

30 31

Jan - 18 Feb March

Su M Tu W Th F Sa Su M Tu W Th F Sa Su M Tu W Th F Sa

1 2 3 4 5 1 2 1 2 Sanctioned AMC Schedule

6 7 8 9 10 11 12 3 4 5 6 7 8 9 3 4 5 6 7 8 9 1. M/s Tribocare - 3 days X 4 visits / Year + Need Based

13 14 15 16 17 18 19 10 11 12 13 14 15 16 10 11 12 13 14 15 16 2. M/s Tribocare - 8 oil sample collection / Year + Need Based

20 21 22 23 24 25 26 17 18 19 20 21 22 23 17 18 19 20 21 22 23 3. M/s SQS - 3 days / Year + Need Based27 28 29 30 31 24 25 26 27 28 24 25 26 27 28 29 30 4. M/s Predict - 68 oil sample collection / Year + Need Based

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Best

Improvement

in Energy

performance

in

Manufacture

of Blended

Cements –

2016-17 from

NCCBM

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