The Ramco Cements Limited

(Jayanthipuram Works) 1
 Plant Capacity at a Glance
Cumulative Cumulative
Year Milestone Clinker Capacity Cement 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 2.80 3.65

(Installation of VRPM )

2016 Line-1 Upgradation 3.185 3.65

Mid-
Line-3 Commissioning 4.685 3.65
2021
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) for

27 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
 Management System Certificates

Occupational Environment
Quality
Health & Safety Management
Management
Management System
System
System

4
 Management System Certificates

Energy 5S JUSE
Management Certificate
System

5
 Thermal Specific Energy
Consumption
750

753
740 746

730
Kcal / Kg Clinker

720
724

710

700
2017-18 2018-19 2019-20

6
 Electrical Specific Energy Consumption
FLY ASH ADDITION
(%)
40

34.89
35
31.45
30

25
22.16

20
Kwh / MT of Cement

15
2017-18 2018-19 2019-20

7
 Cement dispatch Share in Percentage (%)

60

50 57.63 56.09
51.07
40

30 42.37
43.95 48.92

20

10

0
2017-18 2018-19 2019-20
OPC Share PPC Sahre
8
 Electrical Specific Energy Consumption
40
34.89
35
31.45
90 85.44
82.1 80.91 30

80 25
22.16

20
70
15
57.63 56.09 2017-18 2018-19 2019-20
60
51.07 48.9 FLY ASH ADDITION
50 43.95 (%)
42.37
40

30

20

10

0
2017-18 2018-19 2019-20
kWh/T cement OPC Share PPC Share
(%) (%) 9
Electrical Specific Energy Consumption up to Clinker
61
60.46

60

59
Kwh / MT of Clinker

58

56.78 57.01
57

56

55

54
2017-18 2018-19 2019-20

10
Global Norms/Standards

International • SHC-665 Kcal/Kg Clk

Benchmark • SEC-65 Kwh/T Cem

National • SHC-686 Kcal/Kg Clk

Benchmark • SEC-65.0 Kwh/T Cem

TRCL • SHC-724 Kcal/Kg Clk

Jayanthipurm • SEC- 85.4 Kwh/T Cem

Reference:
National Benchmark: Energy Bench Marking For Cement Industry May 2015 Version 2
International 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

Savings Investment
S. No. Energy Saving Project
(Rs. Lakhs) (Rs. Lakhs)

Power optimization in line 1 preheater compressor by

1 0.45 0.5
reducing suction air temperature using exhaust fan and duct.

Power optimization of CF silo aeration blower by replacing

2 4.9 1.5
existing 3 nos with new one

Fly ash unloading refrigerator drier & cooling water supply

3 4.7 2.3
pump power optimized by fixing auto drain valve

Power optimization by removing reversible conveyor in

4 limestone feeding circuit and filling the hoppers with direct 0.63 0.22
chute.
Avoid F- conveyor running for Laterite feeding to Line1 Raw
5 0.59 0.35
mill with direct chute
Power reduction in North band mines dewatering pump by
6 1.64 1.0
providing pump with lower discharge

Slag baghouse purging Compressor optimization by reducing

7 0.25 0.12
the Pr. by replacing the Neuron (5.5 to 3.8 kg/cm2)

Power savings by stopping the New Preheater kiln feed bucket

8 elevator discharge air slide blower by giving the airline from 0.39 0.5
common blower for both strings 14
Energy Conservation Project 2018-19

Saving Investme
S. No. Energy Saving Project s nts
(Lakhs) (Lakhs)

Reducing of power consumption in Line-1 Kiln by inter

1 9.18 1
connecting the airline to Main 110 KW Compressor
Reduction of power consumption by Re-arranging the
2 0.09 0.045
existing lighting circuits in 132KV Substation & DG.
Power reduction by reducing the air leakage through
3 Blower safety valves through rpm reduction in 3 0.13 0.075
blowers .
Power reduction by replacing the driers timer based
4 0.013 0.15
auto drains with Combo type auto drain valves -
Power reduction by providing level sensors in colony
5 over head tank and operate the pump according to 0.43 0.1
tank level.
Power reduction in Plant water supply pump by
6 0.12 0.13
replacing discharge pipeline NRV with higher size 15
Energy Conservation Project 2018-19

Saving
Investmen
s
S. No. Energy Saving Project ts
(Lakhs
(Lakhs)
)
Power reduction in compressor by
Installing PRV batteries and optimize
7 0.23 0.2
the pressure setting in Fly ash bulk
tankers.
To reduce the power consumption in
8 Packing Plant Compressors room by 0.026 0.24
providing hot air vent duct .
Optimization of TPP R.O pump energy by
9 0.027 0.35
installing VFD .

16
Energy Conservation Project 2019-20
Investme
S. Savings
Energy Saving Project nts
No. (Lakhs)
(Lakhs)
CF Silo Gate operation existing Screw Compressor (22kw)
1 was replaced with available (11 kW) Screw Compressor.
1.31 0.009

Optimization of Spillage Elevator power by reducing Chain

2 Speed through VFD.
0.36 1.10

To reduce the power consumption of cement bulk loading

3 system by replacing the screw conveyor with air slide at 0.09 0.40
Packing plant.
Corrossion resistance paint coated over MCW pump
4 impellers to reduce power consumption
20.44 1.92

Optimization of service air compressor energy by installing

5 VFD.
5.93 6.70

Reduction of fuel consumption in the Ashok Leyland tipper

6 by extending the dump body side walls height.
1.51 0.14
Reduction of battery power usage , head light bulbs &
7 sealed beam failure in Hemm & Lcvs by providing LED 0.39 0.03
lights in place of normal conventional lights. 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

Savings
S. No. Energy Saving Project
(Rs)
Avoiding Idle running of Slag mill Baghouse fan motor
1 GRR Blowers by giving interlock 0.45
Power savings by providing interlock for cooler ESP
2 transport system 0.24
Power saving by providing interlock of Coalmill-2
3 baghouse drier CO2CP01 with Compressor 0.13
Power reduction in STP tank aeration blowers by
stopping one blower (7.5 kW ) through
4 interconnecting both aeration Pipe lines and 0.99
replacing blower motor with 9.3 kW

Power reduction in Line-2 Kiln baghouse fan by

5 modification with Fuzzy New PID system 6.79
Power reduction in Rawmill-2 by increasing the
Output from 500 to 520 TPH by increasing Grinding
6 pressure from 110 to 120 bar (Accumulator Pressure 9.61
increased from 55 bar to 60 bar) 20
Energy Conservation Project 2017-18

Savings
S. No. Energy Saving Project
(Rs)
Reducing the Energy consumption in Crusher
7 Baghouse Purging Compressor by optimizing the 0.02
Baghouse DP
To reduce the power consumption in Line-2 CF Silo
8 Bin aeration circuit by using less capacity standby 0.04
Airslide blower
Optimization of VRPM vent Baghouse fan & 3 way
9 separator vent fan (by optimizing the air flow in VRPM 0.14
circuit )

Optimization of CA Fan flow to maintain the optimum

10 gas flow in VRPM circuit 4.79

Power Savings by stopping 1 No. AB7.75 model

11 garage Compressor at Car shed( including 0.48
maintenance cost savings )

Power Savings by giving interlock to H Conveyor

12 Magnetic separator with Conveyor 0.63 21
Energy Conservation Project 2018-19
Savings
S. No. Energy Saving Project
(Lakhs)

Power savings in Raw mill-1 Baghouse Compressor

1 by changing the Baghouse solenoid valves purging 1.23
operation into Differential pressure mode.

Power savings in Coal mill-1 Baghouse Compressor

2 by changing the Baghouse solenoid valves purging 0.60
operation into Differential pressure mode.

Power savings in Coal mill-2 Baghouse Compressor by

3 changing the Baghouse solenoid valves purging 0.66
operation into Differential pressure mode.

Power savings in Slag mill Baghouse Compressor by

4 changing the Baghouse solenoid valves purging 0.44
operation into Differential pressure mode.

Reducing of power consumption in Line-2 Coal mill by

5 by inter connecting the unit bag filter airline to Main 2.48
Bag filter Compressor airline.
22
 Energy Conservation Project 2018-19
Savings
S. No. Energy Saving Project
(Lakhs)
Reducing of power consumption in Line-2 kiln by the
6 by inter connecting the Clinker silo top B/Filter, Water 2.19
spray Compressor airline to Preheater Compressor.
Reducing power consumption by Inter connecting Raw
mill Hopper Conveyors Water spray Dry fog Screw
7 0.25
Compressor and Hoppers Bag filter Garage
Compressor.
Power reduction by
1)Main Cooling water interconnection line between
2X18MW and 1X6MW cooling water circuits.
8 10.91
2)Aux cooling water pump for 6MW line
interconnected with 2X18MW Aux cooling water
circuit.
Power reduction in NB mines 6th bench area pumping
9 1.94
activity by avoiding the re-handling of water

Power reduction by inter connecting Rawmill-2

10 0.13
Baghouse transport Air slide blowerwith other blower 23
 Energy Conservation Project 2018-19
Savings
S. No. Energy Saving Project
(Lakhs)
Power optimisation in Cement silo aeration blowers
11 by blower deselection interlock with 3rd silo 0.30
extraction.

Power optimisation in fly ash transmitters screw

12 compressors by providing inter lock based on 3.82
compressor loading/unloading pressure.

Power reduction in Line-1 kiln by providing kiln shell

13 cooling fans inter lock with shell temperature
0.11

Power reduction in P/Plant by providing Compressor

14 room hot air vent fan inter lock with compressors
0.10

Power optimisation by providing interlock for

15 CBABC02 conveyor with C Conveyor.
0.002
24
Energy Conservation Project 2019-20
Savings
S. No. Energy Saving Project
(Lakhs)
Avoiding of reject handling belt conveyor tripping on over
1 2.56
load.
To provide interlock for B conveyor with secondary
2 0.01
screen(A1J18), Rejection Conveyors (A1J16R & A1J17R)
Line-1 Coal mill Bag house purging automation by
3 0.10
sequencer purging.
Optimization of Coalmill-1 baghouse fan Bearings cooling
4 fan power consumption by providing interlock with 0.15
Bearing temperature.
Avoiding of Unnecessary power consumption in Coal Mill-
5 0.29
1 GRR cooling blower.
FK Pump seal air Compressor E37(37kW) replacement
6 2.51
with available E22(22 kW)Compressor.
Optimisation of VRPM vent bag house discharge air slide
7 0.80
blowers.
8 Optimization of Cement Mill fly ash bin venting bag filter. 0.05
Avoiding of frequent tripping of 7th silo bottom ejector
9 0.019
bin RAL on account of over load. 25
Energy Conservation Project 2019-20
Savings
S. No. Energy Saving Project
(Lakhs)

10 Power optimization in 2nd packer air slide 1.03

Blowers by providing interlock.
Optimisation of Mega clinker silo bag filter fan
11 0.10
while clinker extracting to Cement Mill & Slag Mill.
Optimisation of bag printing machines (off line
12 bag printing machines stopped) & 1no exhaust 0.24
fan(3.7kW) stopped.

13 Power optimization of P.H. down comer tank 1.09

filling Water pump.
Power reduction in Time office by re-arranging
14 0.05
the lighting circuit and replacing with LED fittings
Replacing diesel operated mobile tower light in
15 0.78
mines with electrically operated one.
26
Energy Conservation Project with NIL investment

No. of Projects : 47

Total savings : Rs. 60.18 Lacs

Electrical Energy saved : 17.53 Lacs Kwh

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
Fuel Requirement
Petcoke 443
Coal 636
Petcoke & Coal (50:50) 534

Coal Mill-1 Fuel available Additional Fuel Coal Mill-2 Coal Mill to be
Parameters Capacity form Coal Mill-1 required Productivity 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 29
Innovative project-1
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
30
will be as follows during Line-2 Shutdown.
Innovative project-1
Hot gas duct from TPP Hot gas duct joining coal mill-2
inlet duct

31
Innovative project-1
Coal Mill-2 requirement during Line-2 Shutdown
Additional Fuel Coal Mill-2 Coal Mill to be
Parameters required Productivity run for Line-1
MT TPH hrs
Petcoke 113 15 8
Coal 152 19 8
Petcoke & Coal (50:50) 127 17 7

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)

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
 Innovative project-2
We have measured the CA Fans flow and specific load of
separators data as shown

ZM O-Sepa
VRPM CA Fan
Fan

Flow m3/hr 235000 195000

Steps/Speed #/% 26 32

Power KW 420 325

Material Load tph 280 220

Specific Material load to Kg/m3 of

1.19 1.13
Separator Air 35
 Innovative project-2
Steps Carried Out
Grinding Media Filling level reduced by 5%
(from 30% to 25%) and maintaining at 25%
Specific Air Optimization in both VRPM and
Ball Mill connected separator
Vent Air Optimization
(Ball Mill, VRPM and connected separator)
VRPM Bag Houses (2 Nos) purging system
kept in DP mode
Water Spray in VRPM introduced
indigenously
Overall Benefit
Effect
Mill Main drive Power reduced by 450-500
KW
Connected Fans Power Consumption
reduced by 90-100 KW
Consistency in 45 & 90 µ residue and Blaine
Connected Fans Power Consumption
reduced by 50 KW
VRPM tripping on vibration was avoided
Fineness (Blaine) improvement in VRPM Prod
by 150-200 cm2/gm
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 Cement
5.70 Lakhs KWH
Total Cost Saving : INR 26.05 Lakhs
36
Innovative project-2
After trial we have measured the CA Fans flow and specific
load of separators and tabulated after optimizing the gas
volume.

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 Kg/m3 of
Air 1.30 1.41
to separator
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 – 30kW

39
40
Innovative project - 3
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

41
INNOVATIVE PROJECT-4
Reduction of Overall Raw mill power
consumption

42
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.
43
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

44
 Utilization of waste material as fuel

S. No Type of Waste Fuel used Quantity of waste Equivalent of

fuel used (MT) Conventional energy used
(Ton of coal)

Wood chips & Rice

1 562.21 356.78
Husk

2 TPP reject Ash 3099 387.37

45
 GHG Inventorisation

Total
Year
CO2e (MT)/T Cement

2016-17 660
2017-18 680
2018-19 662
2019-20 653

Calcination, Fuel for kiln & CBPP, owned vehicle,

Scope 1 emissions
Refrigeration & AC
Scope 2 emissions Power consumption

Scope 3 emissions Raw Material Supply & Product delivery

46
 Energy Reporting Format
Pow e r Re port on
R.Hr s . Pr oduction TPH Param e te r KWH KW Kw h/ T of M ate rial Kw h/ T of Clink e r Kw h/ T of Ce m e nt
Equipm e nt
OTD M TD YTD OTD M TD YTD OTD M TD YTD OTD M TD YTD OTD M TD YTD OTD M TD YTD OTD M TD YTD OTD M TD YTD
JPM
M ine s Wate r w or k s Ravir ala
Sub Total
A uxilliaries
Main Drive
LS Cr us he r Lighting
Maintenance
Sub total
Crus he r Late r ite Cr us he r Late r ite
A dditives
A uxilliaries
Raw Mill Fan
Raw m ill -1 Latrite Crusher
Main Drive
Maintenance
Sub total
A dditives
A uxilliaries
Raw Mill Fan
Raw m ill -2 Latrite Crusher
Main Drive
Maintenance
Sub total
A uxilliaries
Coal Mill Fan
Coal m ill -1 Main Drive
Maintenance
Sub total
A uxilliaries
Coal Mill Fan
Coal m ill -2 Main Drive
Maintenance
Sub total
A uxilliaries
Coal Mill Fan
Main Drive
Coal m ill -2-1
Bin Transport
Maintenance
Sub total
A uxilliaries
Clinker Crusher
Cooler Fans
Bag House Fan
ID Fan -1
Kiln -1
ID Fan -2
Kiln Feed
Maintenance
Kiln Stoppage
Sub Total
A uxilliaries
Bag House Fan
Cooler Fans

Kiln -2 ID Fan
Kiln Feed
Maintenance
Kiln Stoppage
Sub Total
AC
Dis t. Los s e s
Lighting
Pr e Clink e r Se rvice
Wate r Pum p
Work s hop
Sub Total
Line 1 Clink e r Up to clink e r Line -1
Line 2 Clink e r Up to clink e r Line -2
Up to clinker TOTAL Upto Clink e r
Combined
A uxilliaries
Main Drive
Maintenance
Sep Fan
Ce m e nt m ill
V RPM A uxilliaries
V RPM CA Fan
V RPM Main Drive
Sub Total 0 0 0 #DIV /0! #DIV /0! #DIV /0! #DIV /0! #DIV /0! #DIV /0!
A uxilliaries
Main Drive
Maintenance
Sep Fan
Slag m ill
V RPM A uxilliaries
V RPM CA Fan
V RPM Main Drive
Sub Total 0 0 0 #DIV /0! #DIV /0! #DIV /0! #DIV /0! #DIV /0! #DIV /0!

Pos t Clink e r
Se r vice s

Pack ing plant

Clink e r Expor t 0 0 0 4012 92378 629966

Paddle M ixture
Clink e r Expor t
47
Flyas h to Silo
Energy Management System

48
 Implementing Strategy
• Department - Plant Management, Production ,Maintenance Quality
Selection Control ,Accounting

• Each department Provide one or more Representatives to the Energy

Formation Management team

• Each Energy management Clusters will be headed by Team leader and

Coordinati the whole is monitoring by Energy Manager
on

• Define Objectives, Prepare Energy Planning, Optimal Energy

Operation, Detect Weakness Plan and Perform Measures/Projects
Responsibili Prepare Energy Performance & Reporting Establish & perform
ties
Energy Controlling Review achievements

49
 Core Committee Team – Energy Cell

UNIT HEAD

WORKS
HEAD

HOD HOD HOD ENERGY HOD HOD HOD

MINES P & QC MECH MANGER E&I CDS & PP TPP

INCHARGE INCHARGE INCHARGE INCHARGE INCHARGE INCHARGE

INCHARGE
MINES & RAW MILL &
CRUSHER COAL MILL PYRO CEM MILL PACKING TPP 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
 Quality Circle
SNO DEPT TEAM NAME PROJECT TITLE NAME

N Rama Rao
SRINIVASA RAO B
Frequent failure of Pump
Auto YELLAMANDAIAH K
1 Ramco spoorthy delivery system in mines
garage RAGHAVENDRA M
pontoon pumps
DURGA RAO P
SURA REDDY P V
A Siva Subrahmanyam
RAMANJANEYULU B
Frequent tripping of line-1 coal BALAJI R
2 Mechanical Ramco Challengers
mill with heavy vibration NUKALA HAREESH
SK AZARUDDIN
B NARENDRA
Desing Rajan
VENKATA RAMA KRISHNA D
QC - 203 VIJAY KUMAR M
3 Electrical Frequent Failure of LT Motors
Ramasethu PRASADA RAJU A
JANAKIRAMA PRASAD B
GOPI CHANDU
VARAPRASAD GVB
U SITHA RAMA RAJU
Elimination of plastic in P S CH NARESH KUMAR
4 HR Master Mind HR
department stationery items K SREEKANTH
J HARIBHASKAR
P GOPINATH 52
Quality Circle
A R V SWAROOP
RAVI B
Instrument Delay in trouble shooting of DEEPAK REDDY K
5 Ramco Rainbow
ation Limestone Reclaimer VENKATESWARA RAO CH
RAMESH VARMA P
UDAY RAJU B
Kiran Kumar N
PETCHIMUTHURAJAN
Idle running of packer-1 or
6 Mechanical Ramco Jagruthi P VEERA BABU
packer -5.
P VEERA RAJU
TVV NARENDRA
B Rambabu
SATYANARAYANA RAO K
Heavy spillage at clinker export SRINIVASA SARMA P
7 Mechanical Ramco Diamonds
conveyor. MOHAMED MEERAN
POTHURAJU S
RATNA NAYAK
Rajesh Kumar A
CH CHANDRA MOHAN
Frequent DP problem in line-2 NAGESWAR RAO P
8 Mechanical Ramco Parishkar
Coal mill bag house LAKSHMANA RAO M
NAGUL MEERA SK
53
SAI NAGA RAJU B V
Environmental Projects
700KLD Capacity Sewage water treatment plant

54
200 Kg/day Capacity Bio-gas plant

55
Solar Plant in Budawada Mines
We have installed solar panel for borewell pump from underground to supply
water to plantation in budawada mines.

56
Environmental Projects- Green Development
Colony Ground Main Gate Entrance

Plant top view Consumer stores

57
Environmental Projects- Green Development
Health center Guest house

Road sweeper
Park
58
Environmental Projects- Green Development
Mines area Reclaimer Area

TPP Area Colony Bird View

59
Environmental Projects- Green Development
Admin Admin entrance

Founder statue Area Admin lobby

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LED Fittings
Factory Entrance gate Factory main road

Colony road Inside Factory

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Environmental Projects- Green Development
Road sweeping Water Sprinkler
Machine

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Nurseries

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 Green Belt Development

No of Saplings
Year Area covered (acres)
Planted

2012-19 18496 12.33

2019-20 11326 7.55

2020-21(Plan) 15000 10

% of Green belt area (1986- March 2019) 48.11 %

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Awards

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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

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Quality Leadership Award in Private Sector
from QCFI – Gwalior Chapter

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5S Conclave at Satyamangalam, Tamilnadu

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5S Conclave at Satyamangalam, Tamilnadu

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N a t i o n a l L e v e l E n e r g y Aw a r d s
Mines Environment & Mines Conservation
Award 2018

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India Green Manufacturing Challenge – 2018 Silver Award

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Forward Way to Conserve Energy
Installation of Waste Heat Recovery Systems (WHRS) for
27 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.

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PH-2 (PHASE-1)
AQC-2 (PHASE-1)
78