Chengalpet Grinding Unit - QCFI Hyderabad Chapter

THE RAMCO CEMENTS LIMITED

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Chengalpet Grinding Unit

Environment Best Practices

QCFI,CMA & NCBM/Hyderabad


Contents

RAMCO Group

Chengalpet Grinding Unit

Plant details

Environment initiatives

Improvement activities

Awards and Accolades

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It is one of the largest cement producers in India with

a current total production capacity of

16.5 Million MT per annum.


Shri P.A.C. Ramasamy Raja – Founder Ramco Group


Shri. P. R. Ramasubrahmaneya RajhaChairman and Managing Director


Shri.P.R.Venkatrama Raja- Vice Chairman


Shri. A.V.Dharmakrishnan-Chief Executive Officer


Ramco Group - Profile


CEMENT

READY MIX CONCRETE

DRY MORTAR

THE RAMARAJU SURGICAL COTTON MILLS LIMITED SURGICAL DRESSING & YARN

RAMCO INDUSTRIES LIMITED FIBRE CEMENT SHEET / RCC Pipes

RAMCO SYSTEMS INFORMATION TECHNOLOGY

SHRI RAMCO BIOTECH HYBRID SEEDS

RAJAPALAYAM TEXTILES, RAJAPALAYAM MILLS TEXTILES

RAMCO RESEARCH & DEVELOPMENT RESEARCH & DEVELOPMENT

RAMCO WINDFARMS POWER GENERATION

SUDHARSANAM SPINNING MILLS LIMITED YARN

SRI VISHNU SHANKAR MILL LIMITED YARN

RAJAPALAIYAM SPINTEXT YARN

SRI RAMCO SPINNERS YARN

SANDHYA SPINNING MILL LIMITED YARN

THANJAVUR SPINNING MILL LIMITED YARN

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Plant Details

Complete plant Designed and supplied byM/s Enexco Technologies,Beumer Group


Process Flow Sheet

Clinker stockpile Cement Mill

Cement SiloPacker

Clinker Unloading

Dispatch

Truck Loading

Beumer

Video

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BEUMER Technology at Ramco Cement Plant in Chennai, India_new.mp4


TOTAL PLANT 21.5 acres

Cement plant 7.00 acres

Truck parking 3.00 acres

Greenbelt 10.89acres

Roads & Walk Ways /others 4.50 acres

Plant Area

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The Ramco Cements LimitedTHE RAMCO CEMENTS LIMITED


Description Unloading System Storage

Clinker Truck Tippler RCC Silo

Fly ash Pneumatic Pumping Unit RCC Silo

Gypsum Backhoe Loader Covered Shed

Cement - RCC SILO 2 No's

Raw material & Product Storage

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Cement Mill- Beumer MakeMill size : 3.8 dia x 12.5 m long;

Throughput: 80 tph Speed :16.6 rpmMill drive : 2 x 1350 kw

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Roto Packers 2 Nos - Beumer MakeCapacity : 180 tph No of Spouts : 12

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Truck Loaders- Beumer Make

Model : ENTL 1000 T (12 meters travel) ENTL 1000 S (6 meters travel)

Capacity: 90 tph

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MCC and VFD Panels17



On line control for monitoring MD

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Environmental Initiatives

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ENVIRONMENT POLICY


ISO CERTIFICATION FROM BIS

Environment Management System IS/ISO 14001:2004


TNPCB CONSENT ORDERS AIR ACT & WATER ACT

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Bag filters installed at all material transfer points.

Inside the plant all roads are made up of Cement road.

Road sweeper is being engaged for roads cleaning

Continous Ambient Air Quality Monitoring Station installed.

Online and continuous Stack monitoring system installed.

AIR POLLUTION CONTROL MEASURES (APC)

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Cement SilosClinker Silo Fly ash Silo

Covered Storage Silos

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All Conveyors are installed within covered shed

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S.No DESCRIPTION EQUIPMENTAG NO MOTOR RATING (KW) LOCATION

1 Bag Filter Fan (11000m3/hr.) 45FN03 15 CLIKER EXTRACTION AREA

2 Bag Filter Fan (22000 m3/hr.) 45FN02 30 CLINKER SILO TOP

3 Bag Filter Fan (33000 m3/hr.) 45FN01 45 TRUCK TIPPLER HOPPER

4 Bag Filter Fan (33000 m3/hr.) 45FN01A 45 TRUCK TIPPLER HOPPER

5 Bag Filter Fan (11000m3/hr.) 45FN01B 15 TRUCK TIPPLER HOPPER

6 Bag filter fan, 11000 m3/hr 45FN05 15 TRANSFER TOWER

7 Bag Filter Fan (13200 m3/hr.) 35FN01 18.5 GYPSUM YARD

8 Bag filter fan (27500 m3/hr.) 45FN04 37 CLINKER EXTARCTION

9 Bag filter fan (8250 m3/Hr.) 76FN03 11 CEMENT SILO2 TOP

10 Bag Filter Fan (8250 m3/Hr.) 76FN01 11 CEMENT SILO1 TOP

11 Bag Filter Fan (33000 m3/Hr.) 60FN03 75 SEPARATOR

12 Bag Filter Fan (44000 m3/Hr.) 60FN02 90 MILL VENT

13 Bag Filter Fan (22000 m3/Hr.) 60FN01 30 CLINKER HOPPER

14 Bag Filter Fan (4400 m3/Hr.) 70FN02 11 FLYASH HOPPER

15 Bag Filter Fan (22000 m3/Hr.) 70FN01 30 FLYASH SILO TOP

16 Bag Filter Fan(19800 m3/hr) 80FN02 30 PACKER-1


18 Bag Filter Fan(5500 m3/hr) 76FN02 11 CEMENT SILO1 BOTTOM



21 Bag Filter Fan(5500 m3/hr) 76FN04 11 CEMNET SILO2 BOTTOM

22 Bag Filter Fan (10000 m3/hr) 45FN07 15 ADDTIVE HOPPER CEMENT MILL

23 Bag Filter Fan (5500m3/hr) 45FN06 11 TRANSFER TOWER

BAG FILTERS

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Bag Filters in different Locations 27


S.No MONTHSTACK EMISSION

(mg/Nm3)

1 Apr-15 22.06

2 May-15 20.77

3 Jun-15 22.73

4 Jul-15 19.22

5 Aug-15 26.07

6 Sep-15 25.70

7 Oct-15 31.26

8 Nov-15 33.09

9 Dec-15 28.49

10 Jan-16 27.21

11 Feb-16 26.14

12 Mar-16 25.42

13 April-16 24.31

14 May-16 26.58

15 June-16 25.31

16 July-16 23.92

17 Aug-16 22.67

Average of Online Analysis

ReadingsONLINE STACK MONITORING

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On Line Stack Emission Monitoring Display Board

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Online Monitoring Equipment Details30


Roads Cleaning by Road Sweeping Machine

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S.NO Location/Place of samplings UnitANALYSIS REPORT

PM 2.5* PM10* SO2 NOX

1 Plant area (Time Office Building) ug/m3 25.17 49.83 8.25 10.00

2 Plant Area (Stores Building) ug/m3 25.58 49.58 7.92 9.17

3 Ash unloading Area ug/m3 28.33 54.50 8.08 9.83

4 Karikalli Village ug/m3 19.58 40.83 6.08 6.75

5 Vedanthangal Village ug/m3 23.42 45.25 7.42 9.17

6 Kattuputhur Village ug/m3 21.25 44.17 6.58 8.25

7 Pulipakam village ug/m3 19.00 41.00 6.17 7.17

8 NAAQ Norms* (8/24-hly) ug/m3 60.00 100.00 80.00 80.00

*PM2.5 - Particle Matter (Size less than 2.5 um)

*PM10 - Particle Matter (Size less than 10 um)

Ambient Air Monitoring Report by TNPCB

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High Volume Samplers

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Overall view Wind vane – Wind direction

Anemometer – Wind velocity Rain gauge – Rain fall

Meteorological Station

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CAAQMS(Continuous Ambient Air Quality Monitoring Station)

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Silencers are provided in DG and Compressors.

DG and Cement mill are located in fully enclosed building.

Ear plugs and Ear Muffs are provided at DG/Compressor room/Cement mill area.

Periodical Noise monitoring by TNPCB as well as by our Consultant(Ensyscon)

Monthly Noise level monitoring by Safety Department

Noise Control Measures

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Rain Harvesting Pits 37


Environment Day 5th June 2016

Celebration

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39393939

THE RAMCO CEMENTS LIMITED - KATTUPUTHUR

BIO GAS PLANT at Mess erected and commissioned. Fencing

around the bio gas plant done.


Year No of Saplings planted Area covered(acres)

2009-11 6250 4.24

2011-12 2750 2.15

2012-13 1500 1.50

2013-14 1100 1.10

2014-15 1350 1.30

2015-16 950 1.00

2016-17 750 0.5 In Progress

Green Belt Development

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Green Belt41


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Paddy cultivation around our Unit

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The Ramco Cements LimitedHerbal Garden developed in our unit; about 63 varieties of Herbal

Saplings planted



CSR Activities

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CSR Activities-Road work

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Medical Camps Conducted

Year Camp Details Hospital / Institution ServedNo of beneficiaries

2012

First Aid Training Camp EMRI - 108

269HIV/AIDS Awareness Programmed Freedom Foundation - Mylapore

Dental Awareness Programmed Dentistree Dental Care Hospital – Anna nagar

Eye Screening Programme K.K.Eye Hospital & Research Centre - Tambaram

2013

Immunization - Polio Drops (Labor shed Children's PHC Atsalavakkam Village

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Screening Programme for Pre & Postnatel Women PHC Atsalavakkam Village

Founder's Day General Health Camp at Ozhaiyur village Ranga Hospital - Chengalpattu

Kidney Stone Screening Camp R.G.Stone Hospital - Saidapet

Vaccination for H1N1 - Influenza A (swine flu) Ranga Hospital - Chengalpattu

2014 Founder's Day General Health Camp at Ozhaiyur village Ranga Hospital – Chengalpattu

567Dental Check up for Village people Ranga Hospital – Chengalpattu

2015Eye camp for all our Employees Dr. Agarwal – Chennai

612Founders Day Health camp at Ozhaiyur Village SRM Hospital

2016

Blood donation by our employees & villagers Essar Blood Bank 52 Units

General Check up for village people Ranga Hospital – Chengalpattu

641Dental check up for village people Ranga Hospital – Chengalpattu

Eye Check up for village people Ranga Hospital – Chengalpattu

Diabetes Check up for village people Ranga Hospital – Chengalpattu

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Corporate Social Responsibility Activities

Year CSR Details Cost Incurred

2012

Providing free food to around 600 people in the surrounding villages

1.76 LakhsProviding School Bags, Dictionaries, Geometry Boxes and sweets to the school children in Ozhaiyur

Distribution of Butter Milk for Village people

Development of Children Park at Samathavapuram Kadalmangalam village, Uthiramerur

2013

Laid3.8 km road for Kattuputhur village by bearing 50% cost of Namaku Naame Govt. Scheme

51.35 Lakhs

Donation of daily usable items to Old age home and Udhayam Rehabilitation Centre

Providing free Food and Butter Milk to around 700 people in the surrounding villages

Donation of Cement Bags to Palliagaram Government School

Donation of Cement Bags to Palliagaram Temple

Providing School Bags, Glasses and sweets to the school children in Ozhaiyur

2014

Donation of Cement Bags for Vallalar Temple

2.87 Lakhs

Providing free food for around 1000 orphanage children and for surrounding village people

Donation of Plates, Ceiling Fans, Water drums, School Bags and other essentials to School, Orphanage and Rehabilitation

Centre Children

Distribution of Butter Milk for Village people

Donation of Cement Bags for Thulukathamman Temple

2015 Medical Camp organized ifor nearby Village people

2016 Flood relief activities in kancheepuram salavakkam ozhaiyur

2016 Medical Camp organized for Company & Contract employees 48


Distribution of welfare measures to Udayam Rehabitational center & KalimpoondiOrphanage

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Donation of Cement for temple and Orphanage constructions-Ozhaiyur & Kavithandalam

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Cement donated to Shree Sivasakthi Vinayagar Temple, Seempoondi and

Shree Muthumariamman Temple Alancheri respectively.

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Cement bags/RTS rods donation to Vembathamman Kovil

Coconut trees plantation at Oziyur Panchayath School52


Medical camp organized for Nearby villagers

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Maternity Table donated to Primary health centre, Salavakkam by our SRT

Transport during Founder day Celebration on 01-05-2016. 54


Inverter with Battery donated to Public Health Centre,

Salavakkam55


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Our Unit and Primary Health Center/Salavakkam jointly organized

Sidha camp at Salavakkam on 08-04-16


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To promote awareness about Eye donation and Blood donation,LIONS CLUB

and our Ramco Chengalpet Grinding Unit organized Marathon(16 kms)for college students at

Uthiramerur on 28/12/15


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SWACCH BHARATH Mission organized at Ozhaiyur Panchayath School

and Amman temple On January 09 2016


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23 Employees have pledged Eye donation to M/S Sankara Nethralaya , Chennai

Blood donation camp during

Founders Day celebration

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23 units of blood have been donated by our employee. Lions club has send the

Blood Donor Card to our employees

Blood Donation

Camp



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Improvement Initiatives


Benefits of ISO systems Implementation

Training for employees has improved their performance

Break down hours has reduced tremendously

Packer efficiency was improved to 97.49%

Energy reduction measures were improved andenergy is being saved continuously

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Breakdown hours reduction

IS/ISO9001

Benefits of ISO systems Implementation

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Year Mechanical Electrical Process Instrumentation Total

2011 -12 255.15 27.15 135.35 35.05 453.50

2012-13 82.40 15.25 271.30 12.50 382.05

2013-14 36.05 11.35 44.30 2.00 94.10

2014-15 21.50 9.50 27.00 3.15 61.15

2015-16 12.15 4.30 14.00 2.45 32.90

2016-17 08.12 02.70 09.00 00.50 20.32*


Area Particulars Savings

Backhoe Loader Installed turbo cleaner to enhance the life of components

Rs 800/month

Backhoe Loader Installed centrifugal filter to enhance the life of oil and components

Rs 500/month

Road Sweeping Machine Installed centrifugal filter to enhance the life of oil and components

Rs 800/month

RO Plant Installed pH booster and UV system Rs 6000 /month

BACKHOE LOADER R S M RO PLANT

Life enhancement

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Area Particulars Savings

5.1 MW Wartsila Engine Lub oil preheating by Solar instead of using electrical energy

15.78 lacs/year

725 KVA Genset Centrifugal filter installation to enhance the life of components

1.40 lacs/year

250 KVA Genset Centrifugal filter installation to enhance the life of components.

0.30 lacs/year

725 KVA Genset Proposed Solar Heating layout

Energy reduction

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Life enhancement/cost saving

Dept Description Location

Captive Power PlantInstallation of Centrifugal Filter in 725 KVA Genset and saving of Rs 1.40 Lakhs per year, 725 KVA DG

Captive Power PlantInstallation of Centrifugal Filter in 250 KVA Genset and saving of Rs 0.30 Lakhs per year, 250 KVA DG

Captive Power PlantInstallation of Centrifugal Filter in Hydra Crane and saving of Rs 0.30 Lakhs per year, Hydra crane

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Awards and Accolades

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Quality Management System IS/ISO 9001:2008



Environment Management System IS/ISO 14001:2004



Occupational Health and Safety System IS 18001:2007




Energy Management System ISO 50001

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5S Award

Winner 2015

Certification Chief Guest Venue/Date

5S Mr.Seiji Baba Chennai (26-06-2015)



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Convention Team Awards Venue/Date

Quality Circle Empower Gold Silver

Tuticorin(CCQC) 27-

09-15

Quality Circle Caliber Gold Silver Tuticorin(CCQC)



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Quality Circle Empower Par Excellence Excellence

Pune(NCQC)

19-12-15

Quality Circle Calliber Par Excellence Excellence Pune(NCQC)



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Kaizen Mela Empower 1st prize Rs - 8,000 Madurai (30-05-2015)

Kaizen Mela Conservators 2nd Prize Rs - 5,000 Madurai (30-05-2015)



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Convention Team Awards Organizer Venue/Date

Poka yoka Empower Gold AOTS Chennai (18-07-2015)



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Award Organized by Venue/Date

Best safety award M/s SAFE Association & SEED Chennai (09-08-2015)



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Quality Circle Empower Gold Chennai(CCQC) 20-09-15

Quality Circle Caliber Gold Chennai(CCQC) 20-09-15




Quality Circle Empower Par Excellence

Chennai(NCQC)

19-12-15

Quality Circle Conservators Par Excellence Chennai(NCQC)

Quality Circle Paradigm Par Excellence Chennai(NCQC)

Quality Circle Zen Par Excellence Chennai(NCQC)


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ABK - AOTS DOSOKAI Tamilnadu center Conducted SMEDCompetition Our Team participated in the competition and wonthe Gold trophy.


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Our Unit had won the “4th Prize during Inter unit Quality Circleconvention(IUQC 2016) held at RR Nagar on 1st and 2nd March 2016. OurTeam Received Awards from our beloved CMD.


Plant Performance – July 2016

Birthday Celebration for Employees – July 16

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3THE RAMCO CEMENTS LIMITED - KATTUPUTHUR

From Our Unit, one team participated and presented two Kaizens.

@ Kaizen Mela/Madurai on 24-07-16 and won second prize with Rs.5000/

Cash award

THE RAMCO CEMENTS LIMITED - KATTUPUTHURTHE RAMCO CEMENTS LIMITED

Plant Performance – July 2016

Birthday Celebration for Employees – July 16

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3THE RAMCO CEMENTS LIMITED - KATTUPUTHUR

From Our Unit, one team participated and presented a Kaizen @ Kaizen

Competition for Support Function, Chennai conducted by ABK-AOTS DOSAKAI.

Won “Platinum Award” in this occasion


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THE RAMCO CEMENTS LIMITED - KATTUPUTHUR

National Energy Conservation Award for the Year 2015

From BEE, Appreciation of Merit award for the year 2015 received


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Team from our Unit, presented Maintenance Improvement Project

and received the Gold Award Conducted by ABK-AOTS Chennai on

18-06-16


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Our SGM-Works received Certificate of appreciation towards “Regular Voluntary Blood Donating Unit” from District Collector-Kancheepuram


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On going process of Implementing 5s Excellence level.



Way Forward

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When we heal the earth, we heal ourselves

~ David Orr

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Chengalpet Grinding Unit - QCFI Hyderabad Chapter

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