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Presentation onEnvironment Best Practices
The Ramco Cements LimitedRamasamy Raja Nagar Unit
National conclave on Recent advances in Cement Industry , 21st October, 2016at HICC, Hyderabad
ISO 9001ISO 14001 &
IS 18001
Presentation onEnvironment Best Practices
The Ramco Cements LimitedRamasamy Raja Nagar Unit
National conclave on Recent advances in Cement Industry , 21st October, 2016at HICC, Hyderabad
About The Ramco cements limited ,RR Nagar
1. Our unit has Cement production capacity of 2.0 MTPA and the manufacturing
product is 100 % Portland Pozzolana Cement as per BIS
2. We have 25 MW Coal based Thermal power plant
3. We are included in PAT Cycle III and our base line is 0.0847 TOE/T of Product
4. Integrated management system
1. Quality Management System - IS/ISO 9001: 2008
2. Environment Management System - IS/ISO 14001: 2004
3. Occupational Health & Safety Management System - IS 18001: 2007
5. Five ’ S’ (Workplace Management System) Certified by QCFI
6. Energy Management System IS/ISO 50001:2011 (Under Implementation)
7. Man Power Utilization (Permanent & Contract): 5.59 Tonne of Product/Manpower
1. Our unit has Cement production capacity of 2.0 MTPA and the manufacturing
product is 100 % Portland Pozzolana Cement as per BIS
2. We have 25 MW Coal based Thermal power plant
3. We are included in PAT Cycle III and our base line is 0.0847 TOE/T of Product
4. Integrated management system
1. Quality Management System - IS/ISO 9001: 2008
2. Environment Management System - IS/ISO 14001: 2004
3. Occupational Health & Safety Management System - IS 18001: 2007
5. Five ’ S’ (Workplace Management System) Certified by QCFI
6. Energy Management System IS/ISO 50001:2011 (Under Implementation)
7. Man Power Utilization (Permanent & Contract): 5.59 Tonne of Product/Manpower
Page 1
IS/ISO 14001:2004 Certification&Environment cell
Page 2
Environment performance improvementover one year (from 2014-15 to 2015-16)
Reduction in CO2 emission from 0.891 Kg CO2/ kg cement to 0.834 Kg CO2/ kg cement
Rainwater harvesting ponds has been increased from 4 to 7 Nos and recharge Pit have been
increased from 4 to 8 established to harvest rain water.
Greenery developed in and around factory premises increased from 4500 to 10000 trees
Drip irrigation introduced in 2015 for watering gardens to minimise water usage.
Water sprinkler system installed in 2015 for the effective utilization of water resources.
Bagfilter installed to avoid fugitive dust emission in material transfer areas.
Page 3
Reduction in CO2 emission from 0.891 Kg CO2/ kg cement to 0.834 Kg CO2/ kg cement
Rainwater harvesting ponds has been increased from 4 to 7 Nos and recharge Pit have been
increased from 4 to 8 established to harvest rain water.
Greenery developed in and around factory premises increased from 4500 to 10000 trees
Drip irrigation introduced in 2015 for watering gardens to minimise water usage.
Water sprinkler system installed in 2015 for the effective utilization of water resources.
Bagfilter installed to avoid fugitive dust emission in material transfer areas.
Environment Projects
CO2 Reduction Measures
Plantation of 66800 nos. tree samplings
Supply of 9725 nos. tree guard to nearby villages
CO reduction in Kiln preheater by reducing secondary firing coal pipe bends
60 Nos. of CFL lights in place of 90 Nos. of tube lights in Administration Building
20 Nos. of CFL lights in place of 20 Nos. of BC Bulbs in Guest house
8 Nos. of LED lights in place of 8 Nos. of tube lights in Guest house
12 Nos. of Solar lights in place of 12 Nos. of Sodium vapor lights in Colony
NOx Reduction Measures
NOx analyzer is installed at the kiln inlet, to improve the combustion, and to predict
the quality of clinker. There is also coal savings by installation of this NOx analyzer.
Investment cost. Investment cost – Rs. 6 Lacs.Page 4
CO2 Reduction Measures
Plantation of 66800 nos. tree samplings
Supply of 9725 nos. tree guard to nearby villages
CO reduction in Kiln preheater by reducing secondary firing coal pipe bends
60 Nos. of CFL lights in place of 90 Nos. of tube lights in Administration Building
20 Nos. of CFL lights in place of 20 Nos. of BC Bulbs in Guest house
8 Nos. of LED lights in place of 8 Nos. of tube lights in Guest house
12 Nos. of Solar lights in place of 12 Nos. of Sodium vapor lights in Colony
NOx Reduction Measures
NOx analyzer is installed at the kiln inlet, to improve the combustion, and to predict
the quality of clinker. There is also coal savings by installation of this NOx analyzer.
Investment cost. Investment cost – Rs. 6 Lacs.
Environment Projects
Control of Fugitive dust Emission
Clinker silo 2 Nos. with 16000 MT capacity each constructed to eliminate dust
emission during clinker feeding to cement mill with Crane system
Dramix fiber Concrete road at lorry yard of 20,000 sq.m, to reduce the fugitive dust
generation
Surveillance camera is located at all the hopper discharge, transfer points, and at
all important locations and are continuously monitored to avoid any spillage
External clinker unloading system to avoid fugitive dust emission
Pressurization system for Polycom IMCC room and cooler hydraulic room
Drop test bin in Roller press to reduce the fugitive dust generation
Page 5
Control of Fugitive dust Emission
Clinker silo 2 Nos. with 16000 MT capacity each constructed to eliminate dust
emission during clinker feeding to cement mill with Crane system
Dramix fiber Concrete road at lorry yard of 20,000 sq.m, to reduce the fugitive dust
generation
Surveillance camera is located at all the hopper discharge, transfer points, and at
all important locations and are continuously monitored to avoid any spillage
External clinker unloading system to avoid fugitive dust emission
Pressurization system for Polycom IMCC room and cooler hydraulic room
Drop test bin in Roller press to reduce the fugitive dust generation
Environment Projects
Control of Fugitive Dust Emission
Re routing of de-dusting ducts in Roller press to avoid the fugitive dust generation
PID mode provided and running successfully in roller press circuit
Dust suppression system for coal storage yard to avoid dust emission
Dust collectors – 5 Nos for limestone conveying belts to avoid spillages in all
transfer points, Unit Bag filters installed.
New Unit Bag Filters are installed in the cooler, preheater, cement mill section
to control fugitive emission.
PTFE membrane bags are used for the bag filters resulting in very less emission.
Page 6
Control of Fugitive Dust Emission
Re routing of de-dusting ducts in Roller press to avoid the fugitive dust generation
PID mode provided and running successfully in roller press circuit
Dust suppression system for coal storage yard to avoid dust emission
Dust collectors – 5 Nos for limestone conveying belts to avoid spillages in all
transfer points, Unit Bag filters installed.
New Unit Bag Filters are installed in the cooler, preheater, cement mill section
to control fugitive emission.
PTFE membrane bags are used for the bag filters resulting in very less emission.
Environment Projects
Energy Conservation measures
Installation of high efficiency bag filter in Coal mill-2
New de-dusting bag filter for Kiln-2 coal firing to avoid fugitive dust emission
Water cooled CCTV installed for line-1 cooler, to predict the cooler performance
and clinker surging to take corrective action to reduce the spillage
Chrome free bricks are used in kiln refractory
Waste Heat Utilization/ Recovery
Waste oil from mines & Equipments are being pumped into calciner for disposal.
Power plant waste Fly ash is being used for blended cements.
Power plant waste ash is used in the kiln firing and its usage has reduced the
usage of pet coke and coal.Page 7
Energy Conservation measures
Installation of high efficiency bag filter in Coal mill-2
New de-dusting bag filter for Kiln-2 coal firing to avoid fugitive dust emission
Water cooled CCTV installed for line-1 cooler, to predict the cooler performance
and clinker surging to take corrective action to reduce the spillage
Chrome free bricks are used in kiln refractory
Waste Heat Utilization/ Recovery
Waste oil from mines & Equipments are being pumped into calciner for disposal.
Power plant waste Fly ash is being used for blended cements.
Power plant waste ash is used in the kiln firing and its usage has reduced the
usage of pet coke and coal.
Environment Projects
Conservation of Natural Resources (Raw Material and Fuel)
Pet coke a refinery waste enables us to use our Low grade limestone.
By usage of pet coke the natural resources like coal is conserved.
The waste and unburned pet coke from the power plant is again reused in the kiln
firing.
To conserve the natural Gypsum, 71,839 MT of phospho-Gypsum is consumed.
Steps taken for Environmental Protection
To reduce / eliminate fugitive emission plant, we converted all the roads to B.T. both
inside the plant as well as colony.
We have sewage treatment plant of cap 200 m3/day and working efficiently. The
treated sewage is being utilized for Green belt development.Page 8
Conservation of Natural Resources (Raw Material and Fuel)
Pet coke a refinery waste enables us to use our Low grade limestone.
By usage of pet coke the natural resources like coal is conserved.
The waste and unburned pet coke from the power plant is again reused in the kiln
firing.
To conserve the natural Gypsum, 71,839 MT of phospho-Gypsum is consumed.
Steps taken for Environmental Protection
To reduce / eliminate fugitive emission plant, we converted all the roads to B.T. both
inside the plant as well as colony.
We have sewage treatment plant of cap 200 m3/day and working efficiently. The
treated sewage is being utilized for Green belt development.
Environment Projects
Steps taken for Environmental Protection
In all the transfer points, we have unit bag filters to control dust emission. Major
equipments are equipped with following pollution control equipments.
Kiln / Raw mill : Reverse air bag houseCoal mill : Bag filterCooler : ESPCement mill : Bag filterPacking plant : Bag filter
In all the main stacks kiln/Raw mill, coal mill, cooler, cement mill – we have installed
on line monitor for monitoring SPM.
The ambient air quality and stack emission levels are being monitored as per TNPCB
guidelines and the reports are being sent to TNPC Board officials and MOEF
Page 9
Steps taken for Environmental Protection
In all the transfer points, we have unit bag filters to control dust emission. Major
equipments are equipped with following pollution control equipments.
Kiln / Raw mill : Reverse air bag houseCoal mill : Bag filterCooler : ESPCement mill : Bag filterPacking plant : Bag filter
In all the main stacks kiln/Raw mill, coal mill, cooler, cement mill – we have installed
on line monitor for monitoring SPM.
The ambient air quality and stack emission levels are being monitored as per TNPCB
guidelines and the reports are being sent to TNPC Board officials and MOEF
Environment Projects
Steps taken for Environmental Protection
Utilization of hot gases from Kiln to Raw mill and Cooler to Coal mill.
All conveying systems are covered with shed to arrest fugitive emission.
Utilisation of fly ash about 29.8 % on produced quantity as a value addition
product. This reduces the waste handling system at Thermal Stations.
All our Pollution Control equipments are interlocked with production equipment
through Software in our computer operating system.
PID logic system installed for Kiln ,Vertical roller mill and Cement roller press for
better process stability, increase in output, reduced fuel and power consumption.
Page 10
Steps taken for Environmental Protection
Utilization of hot gases from Kiln to Raw mill and Cooler to Coal mill.
All conveying systems are covered with shed to arrest fugitive emission.
Utilisation of fly ash about 29.8 % on produced quantity as a value addition
product. This reduces the waste handling system at Thermal Stations.
All our Pollution Control equipments are interlocked with production equipment
through Software in our computer operating system.
PID logic system installed for Kiln ,Vertical roller mill and Cement roller press for
better process stability, increase in output, reduced fuel and power consumption.
Environment Projects
Steps taken for Environmental Protection
Elimination of gas conditioning tower in our system results in tremendous power saving
(3000 units / day) also precious natural water saving of 240 TPD.
Vertical roller mill is installed for raw meal and Roller press is installed for clinker grinding.
The advantages of these equipments are noise free, dust free, less power and high efficient.
X-Ray analyzer is being used for analyzing the limestone quality online and is being
monitored for correction.
All material conveying is done by closed belt bucket elevators, belt conveyors.
A reverse osmosis plant has been installed at our colony at a cost of Rs.7 Lacs for our colony
residents.
We have procured road sweeping machine at a cost of Rs17 lacs, for cleaning the roads in
factory and colony.
Page 11
Steps taken for Environmental Protection
Elimination of gas conditioning tower in our system results in tremendous power saving
(3000 units / day) also precious natural water saving of 240 TPD.
Vertical roller mill is installed for raw meal and Roller press is installed for clinker grinding.
The advantages of these equipments are noise free, dust free, less power and high efficient.
X-Ray analyzer is being used for analyzing the limestone quality online and is being
monitored for correction.
All material conveying is done by closed belt bucket elevators, belt conveyors.
A reverse osmosis plant has been installed at our colony at a cost of Rs.7 Lacs for our colony
residents.
We have procured road sweeping machine at a cost of Rs17 lacs, for cleaning the roads in
factory and colony.
Environment Projects
Sl.No List of the Major Environmental ProjectsInvestment made
(Rs.Lacs)
1 Clinker silo 2 Nos. with 16000 MT capacity 36002 Dramix fiber Concrete road of 10,000 sq.m 2003 Ambient air quality monitoring station 184 Online stack monitoring directly connected to Air care TNPCB 15
Page 12
4 Online stack monitoring directly connected to Air care TNPCB 155 Installation of Surveillance camera 3006 NOx analyzer is installed at the kiln inlet 6
7 Pressurization system for Polycom IMCC & cooler hydraulic room 70
8 Installation of high efficiency bag filter in Coal mill-2 18
9 New de-dusting bag filter for Kiln-2 coal firing 8
10 Drop test bin in Roller press to reduce the fugitive dust generation 10
11 Water cooled CCTV installed for line-1 Kiln and cooler 15
Road Sweeper & Vacuum Cleaning machine
Page 13
Housekeeping infrastructure along withplant visuals
Ambient air quality monitoring Station Road sweeping machine
Page 14
Housekeeping infrastructure along withplant visuals
Water sprinkler Online stack monitoring
Page 15
Housekeeping infrastructure along withplant visuals
Clinker silo 2 Nos Dramix fiber Concrete road
Page 16
Housekeeping infrastructure along withplant visuals
Solar lighting in Township
Page 17
Housekeeping infrastructure along withplant visuals
Nitrogen plant Rain water harvesting pond
Page 18
Lawn In front of Admin Office
Page 19
Green Belt in Plant Main Gate Entrance area
Page 20
Green Belt in Admin area
Page 21
RAIN WATER HARVESTING POND
GROUND WATER LEVELPiezometer Reading
GROUND WATER LEVELPiezometer Reading
7.82 7.76 7.52 7.1 7.2 7.4 7.88.38 8.34 8.39
7.718.38
7.62
7.71 8.2 8.35 8.81 8.9 9.02
8.688.7
7.9
7.617.427.25 7.76
7.81
6.32 6.655.49
6.25 6.73 6.98 7
4.53.473.84 4.12
5.2 5.53 6.336.66 7.03
6.57 6.72
0123456789
10
JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC2013 2014 2015 2016
MTR
Rainfall for the year : 2013-544mm / 2014-875.5mm / 2015-851mm / 2016-173mm
2013
2014
2015
2016
GROUND WATER LEVELPiezometer Reading
7.82 7.76 7.52 7.1 7.2 7.4 7.88.38 8.34 8.39
7.718.38
7.62
7.71 8.2 8.35 8.81 8.9 9.02
8.688.7
7.9
7.617.427.25 7.76
7.81
6.32 6.655.49
6.25 6.73 6.98 7
4.53.473.84 4.12
5.2 5.53 6.336.66 7.03
6.57 6.72
0123456789
10
JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC2013 2014 2015 2016
MTR
Rainfall for the year : 2013-544mm / 2014-875.5mm / 2015-851mm / 2016-173mm
2013
2014
2015
2016
Green Belt in Colony area
Page 24
Green Belt in Colony area
Page 25
Green-PRO Award
Page 26
5S CERTIFICATION
Page 27
5S Certification issued on 15th August 2015, Independence day, The certificate was receivedby our Respected CMD, Ramco Group. Award issued by Sri.D.K. Srivatsava, ED, QCFI.
5S-Highest Scorer amongCement plants
Page 28
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