demonstration on gp implementation at malabar cements

PRESENTED BYDEEPA.K

GP( Green Productivity) DEMONSTRATION

IN MALABAR CEMENTS

Chapter 1 Introduction

Background of the study Concept was established by the Asian Productivity Organization

(APO) in 1994

A strategy used to address environmentally sustainable development and aims to enhance productivity and socio-economic development whilst ensuring environmental protection.

It applies environmental management tools, techniques and technologies to reduce the impact of an organization’s activities, goods and services on the environment.

GP is applicable to the manufacturing, agricultural and service sectors.

The benefits gained from GP implementation within these enterprises are significant in terms of productivity enhancement and environmental protection.

Definition:

Green Productivity (GP) is a strategy for enhancing productivity and environmental performance for overall socio-economic development. It is the application of appropriate productivity and environmental management tools, techniques, technologies to reduce the environmental impact of organization’s activities, goods and services

Background of the Topic

. POLLUTION in Malabar cements.

  The pollution problem encountered in cement industry is air

pollution, in which the main pollutant is the particulate matter.

The intermediate as well as the final product in cement industry is in the form of powder. The accompanying phenomenon of , handling and processing of the material components which finally form Portland cement.

The raw material received from mines is crushed in a double stage crushing plant where relatively large amount of dust is produced. The transfer of lime stone through conveyors to open stockpile also adds up to the pollution. Grinding and homogenizing of raw material also contribute pollution.

  The vent air from high speed hammer crushers,

vibrating screens, , open storage dumps, raw grinding ill, rotary kiln, clinker cooler , Finish grinding mill, coal mill, bucket elevators, Mechanical air separators, transfer points of belt conveyors , pneumatic conveying systems, all contribute to air pollution.

Depending on the manufacturing process and on the level of technical development of the cement plant 6 – 12 m3 of dust laden gas is discharged from every one Kg of cement produced. The size of the dust particle may range from 1-100 micron and above.

OBJECTIVESPrimary Objective

To create an awareness on the importance of green productivity in Malabar cements

Secondary Objective

1) Setting up of GP EMS team in the company.

2) Identification of problems (departmental wise )in terms of environment & productivity.

3) Listing of various problems , identifying its causes & generating options

4) Options evaluation with respect to technical. Economic & environmental aspect.

5) Setting up of an action plan.

Industry & Company Profile

Industry profile…

Cement- Opus Caementicium means binder- Invented by Joseph Aspdin, in 1824.

Introduction to Indian cement industry

- In 1914, the first licensed cement-manufacturing unit in India was set-up by the India Cement Company Ltd

Second largest cement producer , total capacity -151.2 Million Tones, contributed by around 125 large & 300 mini cement plants.

Exports – 2.5 to 3 million tonnes of cement

It is expected that by FY12, the cement production capacity will rise upto 262.61 MT.

Major players: ACC Ltd, Grasim Cement, Ambuja Cement, Ultratech Cement.( Market share-39.80%)

Mid-large players (like Shree Cement,Madras Cement, India Cement) -36%

Small players (like My Home IndustriesLtd, Orient, Binani) -24%,

New players (like Reliance, Murli Agro, JSWCement) -6%

Company profile- Malabar Cements

Vision… Help to build better habitable Kerala by

providing best solution in the field of construction.

Mission... Provide quality products & services to the

public through effective intervention in the market.

Objective of the

company…

To manufacture & Supply Quality cement at a reasonable price by making an optimum profit.

To ensure fair dealings to customers.

To provide employment opportunities to the public.

Company Profile in detail Incorporated on August 11, 1978

Commenced production on April 24, 1984.

Produces 4.2 lakh tones cements per annum.

Meets about 10 % of total cement consumption in Kerala.

Turnover-Rs 300 crores.

Market share- 6%

No of employees- 1000-1200

Main markets- Kerala( Ekm to Kasargode)

Units- Main unit at Walayar & Grinding unit at Cherthala.

Main competitors-Sankar cements, Coramental cement, ACC, Rassi, Chettinad & others.

Products…

Dy. ManagerDy. Manager

M.MiningM.Mining M.EnggM.Engg M. ProdnM. Prodn M.MaintM.Maint

Dy. ManagerDy. Manager Dy. ManagerDy. Manager Asst. ManagerAsst. Manager

AssosiatesAssosiatesAsst MgrAsst MgrSupervisorsSupervisorsAsst MgrAsst Mgr

othersothers LaboursLabours OthersOthers

Assistant Manager & offficer costing

Assistant Manager & offficer costing

M. Humen ResourceM. Humen Resource M.FinanceM.Finance M.CommercialsM.Commercials

Assistant ManagerAssistant Manager

Purchase ManagerPurchase Manager

Marketing Manager

Marketing Manager

ExecutivesExecutives

OthersOthers

GENERAL MANAGER TECHNICALGENERAL MANAGER TECHNICAL GENERAL MANAGER ADMINISTRATIONGENERAL MANAGER ADMINISTRATION

EXECUTIVE ADMINISTRATOREXECUTIVE ADMINISTRATOR

BOARD OF DIRECTORSBOARD OF DIRECTORS

PLANT HEADPLANT HEAD

MANAGING DIRECTORMANAGING DIRECTOR

PLANT CO-ORDINATORPLANT CO-ORDINATOR

PRODUCTION DEPT The cement production involves different

phases such a raw mill, kiln, cement mill and packaging section, etc. However every aspects of production are carefully & constantly looked after by production department so as to ensure high quality & to reduce wastage.

The company has separate lab which is established to check the quality parameter of the sample which they produce.

Has four packing machines, and the packed cement are transported to the distributors or retailers through roadways , railways, etc.

ManagerManager

Dy ManagerDy Manager

Asst. ManagerAsst. Manager

Asst. AnalystAsst. Analyst

Tester/GaugerTester/Gauger

Lab BoyLab Boy

Chapter 3Review of literature

Review of literature

Nineteen countries throughout Asia and the Pacific are members of the APO and GP methodology has been and continues to be applied to many different sized enterprises within these countries.

The benefits gained from GP implementation within these enterprises are significant in terms of productivity enhancement and environmental protection.

The Vietnam Productivity Centre (VPC), under the Directorate for Standards and Quality (STAMEQ), is the National Productivity Organization for Vietnam. Since 1998, the VPC has successfully implemented GP projects in villages throughout

Management commitment

1. Getting started

2. Planning

3. Generation and evaluation of GP options

4.implementation

5.Monitoring and review

6. Sustaining GP

Chapter 4Methodology

Methodology

Methods of data collection:

Through Direct interview with the GP EMS team

Questionnaire

Company manual.

Tools used…

Cause & Effect diagrams

Evaluation Matrix

Limitations….

Data constraints

Time constraints

Chapter 5Analysis & Interpretation

Getting started…1) GP EMS team formation.

LIST OF GP-EMS TEAM IN THE COMPANY Chairman

MD

  CONVENOR

Manager representative and Deputy Manager( IT)

  MEMBERS

G M ( works)

Dept GM( Eng)

Manager(T&D)

Chief Engineer( Mech)

Senior Chemist

Manager (Materials) Deputy Manager( Marketing) Mines manager Deputy Chief Engineer(Mech)- Plant Deputy Chief Engineer(Mech)- Mines Deputy Chief Engineer( Electrical) Plant Engineer (Chemical) Plant Engineer (Instrumentation) Safety Officer Plant Engineer(Civil) Asst Engineer (Mech)- Ropeway

Asst Engineer (Mech)- Packing Plant

Senior officer (Production)- Mr. Dharmadas

Shift Officer(Production)- P.K.Madhu

Responsibilities of the team :

 To identify problems related to environment and

productivity in the company

To identify causes of those problems

To generate options to overcome those problems

To set up the environmental objectives, and targets

  To conduct the chosen options

To establish EMS document system

To evaluate the results of the program

To maintenance EMS – GP system

To report to the releted management organisations

PRODUCTION FLOWCHART

Mining

Crushing

Raw mill preparation

Clinkering

Cement grinding

Cement packing

Input & output of all processes

INPUT PROCESSES OUTPUT

Coal, limestone, gypsum, flyash Transportation Dust, noise, air emission

Limestone, clay, electricity Crushing Dust, noise, small limestone and clay

Limestone, gypsum, electricity, flyash

Milling Dust, noise, raw material

Raw material, electricity, air flow

Homogeneous Raw material homogeneous

Raw material homogeneous, coal, air flow, electricity

Kiln Clinker, heat, dust air emission, noise

Clinker, electricity Clinker cooling Clinker, heat, dust , noise

Clinker, additives, electricity Cement milling Cement powder, dust, noise

Cement powder, electricity, air flow, bag

Cement packaging Cement bag, dust, noise

Cement bag Transportation Cement bag, dust

Specific environmental impacts

1) Dust

Total air volume to be handledPLANT DEPARTMENT M3/Min

Crusher Dept 600

Clay drying 1200

Raw grinding 3400

Kiln,coal drying, Clinker cooler 13300

Finish mill 4700

Cement silo, Packing area 2000

TOTAL 25200

Normal air flow

MACHINE AIR VOLUME UNIT

Crusher 60 Nm3/min/m2 opening area

Raw material drier 0.8-2.0 Nm3/kg dried material

Roller mill 1.5-2.5 Nm3/kg ground material

Coal mill 1.5-2.0 Nm3/kg clinker

Kiln 1.4-2.3 Nm3/kg clinker

Clinker cooler 2.5 Nm3/kg clinker

Dust content in exit gassesLOCATION OR SOURCE OF DUST g/nm3

Crushers 5-15

Raw material drier 40-90

Roller mill 650

Coal mill with drier 100-120

Kiln, preheater 70-75

Finish grinding 20-80

Std <50mg/nm3

2) Noise

Loading machine 85 Db

Dumper 78 Db

Dozer 95 Db

Drill 100.3 Db

Compressor 99.3 DbP. crusher 87.6 Db

Rope outside 85.1 Db

Rope inside 90.2 Db

Sec crusher in 87.6

Sec crusher out 77

Primer in 85

Primer out 83.5

Std 85 Db

Problems identification

Department / process

Environmental problems

Productivityproblems

Mining and transportation of raw material

- Dust from mining explosions, transportation and loading and unloading of raw materials

Limestone crusher process

- Noise pollution- Dust generation

- Short lifetime of hammer

- Low capacity

Clay crusher process

- Noise pollution- Dust generation

Low performance of clay crusher. Large amounts of clay get stuck between the metal pieces of the crusher. As the clay hardens and compacts, it bends and breaks the metal, which reduces its performance.

Conveyer belt transportation from crusher to storage

- Dust generation at direction change points (from this conveyer to other conveyer)

Kilns

- Waste heat- Air emissions- Waste oil- Oil leakage- Solid waste

- Low inefficiency of kiln

- Energy consumption

Compressor room- Noise - Oil leakage

Cement mill

Production lower than design capability

- Energy consumption

Loading clinker and cement

- Dust generation

Packaging area

- Dust generation- Solid waste

Raw material

High water content in clay & coal

Raw material drier

Increased dust generation surrounding the air

The drier is not reducing the water content in the raw materials enough

Limestone silo

DustThe transportation process of grounded limestone to the silo produces dust

Mixing Raw Materials

Dust generation is high Manual feed causes inconsistencies in the composition of the mix leading to unstable clinker quality.

Additive

The cost of gypsum is high. Currently iron ore and gypsum are being used as additives. Gypsum, however, is very expensive.

Raw mill

NoiseNoise is generated from milling process. It affected to the health of the operator

Cement silo

Cement is sticking to the wall of the cement silo. This is reducing the quality of the cement; old cement may be lodged for a long time and then falls down. When the older cement joins fresher cement it reduces the quality.

Transportation of cement

DustDust is generated in loading area and transport out of Company

CAUSE IDENTIFICATIONUSING

CAUSE & EFFECT DIAGRAM

Management problems

Material

EquipmentOperation

method

Noise pollutionOperator

contacts directly with the machine

No automatic feeder

Operator controls

machine by listening

Operator controls

machine by listening

ENERGY

METHOD

Capacity of the milling

machine is low

Management problems

Raw material

EquipmentMethod

The nature of material

Moisture of material is

high

Size is not suitable

Material feeding manually

Temperature inside

machine in not

controlled

Bad design of lifting

linerThe partition

between 2 chambers is not

well designed

Training

Material is open-stored

Old design from producer

No technical instruction

No technical

instruction

Short life time of hammer

List of problems causes & optionsDepartment/Process

Problems Causes Options

Mining and transportation of raw material

- Dust from mining explosions, transportation and loading and unloading raw materials

- Material too dry - A lot of dust on the road

- Spray water on the limestone before upload and unload

Limestone crushing process. Clay crushing process

- Noise pollution _ Old crushers Wearing ear protection equipment or replacing old crushers.

- Dust emissions - Bag filter operate inefficiency and bag damaged

- Periodical maintenance of bag filter and should change damaged bags filter diligently.`

- Short lifetime of the limestone crusher’s hammer

- Low capacity

- See fish bone diagram - Reduce SiO2 in limestone by change mixer formula

- Install a pre-crusher and screen.

Conveyer belt transportation from crusher to storage of line I

- Dust generation at direction change points (from this conveyer to other conveyer)

- The bag filter efficient and has low capacity

- Not cover all conveyor belt at that point

- Replace by new bag filter ( bag house filter)

Raw material mill- Capacity lower than

design capacity- Material out put fine - Increase size of

material out put

Kilns

- Low inefficiency of kiln

- See the fish bone diagram - Modify lifting liner in

clinker cooler- Modify the capacity of

exhaust fan and suction fan so they are equal.

- Install auxiliary furnace for preheater

Compressor room

- Noise - Old compressor- Lack of noise

prevention facility

- Install noise protection box to cover individual compressors

- Build a separate operation room

- Oil leakage - Old compressors - Increase maintenance activities

- Replace to new compressors

Cement mill

- Lower capacity - Install a pre-griding system upstream of the existing ball mill.

Clinker Loading

- Dust generated when loading the clinker onto the truck.

- Existing dust collector’s capacity is too small.

- Dust suction pipe too small

- The cover of suction head is not inadequate

- Replace Electrostatic precipitator (EP) with bag house filter

- Change to higher capacity motor

- Replace suction pipe a with larger one

- Change the cover with one that has improved material and design

Un-loading material

Dust generated Raw material such as limestone, coal, clay... is transported and unloaded by truck. The unloading area is located near to company & has no cover to prevent dust from escaping.

Install a cover or warehouse.

Raw Materials

High water content in clay and coal.

Coal and clay are purchased from an outside source, thus the initial water content in the raw materials received at the factory cannot be controlled. On arrival at the factory raw materials are stock piled outside. In dry weather this stock piling is effective for drying, however in wet weather it is a problem.

- The water content of the clay and coal is high as they were stored outdoors. Installing a cover or warehouse to keep clay and coal dry could reduce the moisture content in wet weather and also reduce the sticking situation in the clay crusher.

Limestone Crusher

Dust generation from crushing limestone is high. This is affecting the health and safety of workers throughout the factory.

There is no cover over the crusher, thus as the limestone is being crushed, dust generated is easily dispersed throughout the factory.

- To reduce the dust generated from crushing limestone through the installation of a cover. Thus as the limestone is being crushed, dust generated is prevented from dispersing

Raw Materials Drier

The drier is not sufficiently reducing the water content in the raw materials.

The speed of the drier is not fast enough and the temperature is too high. The current temperature of the drier is 700-C, and the dried material is 96-105-C.

- Periodic maintenance of raw material drier.

Increased dust generation surrounding the drier.

The current conveyer belt is not covered and dust is generated during transportation.

Replace the open conveyer with a covered one from drier to silo to reduce dust.

Clay Silo

Clay is sticking to the wall of the silo. This causes blocks in the outlet of the clay silo and slows down production rates.

The moisture content of the clay is causing the clay to stick to the silo. This moisture content is due to the drier that is not drying the raw materials sufficiently. And the other factor causing sticking is the surface of silo, which enables the clay to stick easily.

Cover the silo with anti-sticking material such as Teflon. This option could prevent the clay from sticking to the wall of the silo.

Mixing Raw Materials

Dust generation is high Manual labour No appropriate machines were present in the factory for mixing the correct ratios of raw materials together.

- Install an additive mixing system in the raw materials preparation process to reduce dust generated, labour and improve the homogeneity of additives

Separator

The efficiency of separator is low. After milling the clinker, the cement was 60% fine and 40% coarse materials. However, it should be80% fine and 20% coarse materials.

The separator is too old and out of date, thus the efficiency is low.

Update the separator to increase the separation efficiency of cement mill.

Cement Silo

Cement sticks to the wall of the cement silo. This is reducing the quality of the cement; old cement may be lodged for a long time and then falls down. When the older cement joins fresher cement it reduces the quality.

This is due to excess water in the cement and the roughness of surface of the silo

- Cover the silo with anti-sticking material such as Teflon

Additive

The cost of gypsum is high. Currently iron ore and gypsum are being used as additives.

The company wants to reduce production costs, and so if they can identify a cheaper additive this would contribute to lowered production costs.

- Barite is a cheaper alternative to gypsum.

Cement Mill

Operation of cement millThe cement mill is not reaching its designed capacity. The time cement remains in the mill is too long, the electricity costs are too high and the overall production time is to long.

The design of the lifting liner does not crush the mix well enough. This is increasing the time cement remains in the mill, electricity costs and production time.

- Re-design the lifting liner of the milling machine to increase milling efficiency

Noise in Cement MillEmployees use the noise of the cement mill to indicate when the mill is empty. When the mill is empty it is noisier, therefore employees enter data into the computer and the conveyer belt starts feeding the mill quicker.

There is no computerised system for feeding the mill.

- Equip with a computerised system to control the feeding speed of milling machine

Clay Crusher

Low performance of clay crusher. Large amounts of clay get stuck inside the crusher, this sticking occurs between the metal pieces of the crusher. As the clay hardens and compacts, it bends and breaks the metal, which reduces the performance of the crusher.

1. Part of this problem is due to the moisture content of the clay, causing it to stick. 2. The second problem is due to the design of the clay crusher. The metal rings for crushing are to thin and bend easily when clay dries and compacts inside the crusher.

- Re-design the clay crusher to reduce the sticking of clay

Packaging area and cement loading

- Dust generation during packaging, transporting on conveyor belt, loading cement on ship truck on train

See fish bone diagram

- Periodic cleaning

- Modify the dust collection system at packaging machine

- Install 2 dust collector systems to collect dust on the cement bag surface at the delivery point on the conveyor belt

- Change bag design with out holes on the surface.

The various options generated were evaluated on the basis of technical, economic & environmental aspects

Chapter 6Findings, Suggestions &

Conclusion

Questionnaire

Evaluation matrix

Action plan

Conclusion…

By setting up a GP EMS team in the company, an awareness on the importance of green productivity was created.

This type of program is especially important in Walayar, which is experiencing an increase in urbanisation, and industrial activity that is in turn putting pressure on industries, such as the cement industry. Much of the technology and methodology used is out of date, and improvements need to be made so that the increase in production in this growing section does not have a harmful effect on the environment

Suggestions… Company should give more emphasis on

environmental protection activities

Some of the options that were not inclded in action plan because of a lack of funding, or resources may become more feasible and further options may also be incorporated using the management techniques and expertise introduced in the program.

Thankyou…