June 15 presentation

SL NOPARTICULA

RSTARGET ACHIEVED REMARKS

1PRODUCTI

ON28830 26781

1.Kiln 1 Inlet cone Castable got damaged , 2.

Air tube was broken resulting feed was cut-

down from 21.4 to 19 Mt/ Hr.

3. Poor quality of Iron Ore fed to Kiln 4

2 OFF GRADE 6.5 7.77K 1 : Off Grade gone 12 % due to coal throw

problem

DESKTOP PRESENTATION FORTHE MONTH OF JUNE-15

3 FEED RATE 21.40 20.49 Due to above reasons.

4

PLANT

AVAILABILIT

Y99 99.62

5 POWER 67 68.42

6 Mz 90.5 90

7 ACCIDENT 0 0

TARGET & PERFORMANCE:-

Remarks

Director was pleased with performance

TARGET & PERFORMANCE:-

Remarks

Director was pleased with performance

Plan

K1 K2 K4 Total

Working days 93 28 29 28 85Prod 292

509307 8976 8829 27112

Des -SMS-Out side

- - - -15749.169604.14

% Tgt 100 94.01

90.67 93.43 92.69

% Cap 100 95.3

1

91.92 90.41 92.55

REVIEW OF PREVIOUS MONTH’S MOM

He suggested that for the further improvement in all the areas should be identified

and action initiated as per requirement of IMS

Current Status : We have initiated in following areas : EnergyConservation, Increase the Product Fe M 78 +

He suggested that for the further improvement in all the areas should be identified

and action initiated as per requirement of IMS

Current Status : We have initiated in following areas : EnergyConservation, Increase the Product Fe M 78 +

INPUT:-

RemarksPELLET :-.

Director expressed that all parameters of pellet are more or less ok except Fe(T).

INPUT:-

RemarksPELLET :-.


Plan Actual %Pellet receipt 42794 35550.11 83.07

Quality

Fe(t)

CCS

AI

TI

+18 mm

-4 mm

64

210

3

92.5

5

10

63.51

202

2.95

93.66

0

6.5

99

96.19

98.33

101.25

0

65

Unscreened

%

0 14.25



Unless HG proportion in feed in pellet plant becomes viable, further Fet

improvement will be increasingly difficult.

Director also remarked that S.A. coal fines is posing a new major problem in

production. He asked to Atto work out and calculate how to address this issue, He

asked to make presentation on this next month

Current Status :Analysis data incorporated in the presentation.


Unless HG proportion in feed in pellet plant becomes viable, further Fet

improvement will be increasingly difficult.

Director also remarked that S.A. coal fines is posing a new major problem in

production. He asked to Atto work out and calculate how to address this issue, He

asked to make presentation on this next month

Current Status :Analysis data incorporated in the presentation.

MAINTENANCE:-

Remarks

MAINTENANCE:-

Remarks

DESCRIPTION

K1 K2 K4 Total %

Calenda

r hrs

744 744 744 2232 100

Running

hrs

709.02 686.27 671.38 2066.67 92.49

S/D hrs 0 0 0 0 0Delay% 4.71 7.76 9.75 165.33 7.51Process 0.37 7.74 8.95 124.57 5.69Mech 4.17 0 0.19 32.42 1.45RMP 0 0 0 0 0Elec 0.46 0 0.59 7.83 0.35Others 0.03 0.02 0.022 0.51 0.02


Director praised the team for good maintenance. However how and why

preventive maintenance of support roller bearing was not identified should

be looked into and suggested

Current Status :Sir, PM was done during shutdown we have checked all points likeclearance, Cage, lock plate , Inner and outer race, foreignmaterial exc.

Director praised the team for good maintenance. However how and why

preventive maintenance of support roller bearing was not identified should

be looked into and suggested

Current Status :Sir, PM was done during shutdown we have checked all points likeclearance, Cage, lock plate , Inner and outer race, foreignmaterial exc.

PROCESS

REMARKS;-

Director asked. However he expressed that opportunity for reducing C/Fe

should continually be explored by further optimizing the process . We

have scope for further reducing C/Fe

PROCESS

REMARKS;-

Director asked. However he expressed that opportunity for reducing C/Fe

should continually be explored by further optimizing the process . We


K1 K2 K4 T

Feed /Hr 21.11 21.51 21.06 21.22

C/Fe 0.454 0.46 0.467 0.46

Kwh/ton 65.68 65.68 71.53 67.59

Campaign life

76+ 90+ 127+ 97.67



Current Status : Sir C/ Fe is totally depend on coal FC and Coal Size our draw back is Coal Size we have used 60 % fines in injection Coal.


Current Status : Sir C/ Fe is totally depend on coal FC and Coal Size our draw back is Coal Size we have used 60 % fines in injection Coal.

QUALITY:-

Remarks

Director pleased with performance. Off grade is under control . Non mag can further be brought down.

QUALITY:-

Remarks

Director pleased with performance. Off grade is under control . Non mag can further be brought down.

K1 K2 K4 T

Off grd % 5.78 3.89 5.38 4.99

-1 mm % 13.51 13.22 13.02 13.25

Fem % 77.1 77.21 77.13 77.07

Fe(t) % 85.14 85.24 85.19 85.19

DM % 90.31 90.57 90.53 90.47

Gangue % 12.51 12.46 12.5 12.49

NM % 0.76 0.76 0.77 0.76


Non mag can further be brought down.How to improve Fem level more consistency should be looked into. Marketing report says that from similar pellets others are able to get 78+ Fe m . This should be gone into detail and report submitted

Current Status : Sir now we have also maintain 78 + Femthrough out the month and given new specs to MarketingDepartment.

Non mag can further be brought down.How to improve Fem level more consistency should be looked into. Marketing report says that from similar pellets others are able to get 78+ Fe m . This should be gone into detail and report submitted

Current Status : Sir now we have also maintain 78 + Femthrough out the month and given new specs to MarketingDepartment.

Inventory :-

Remarks

Inventory of stores and spares should be looked into with more focus.

Inventory :-

Remarks

Inventory of stores and spares should be looked into with more focus.

Item Closing stock

Consp/t ICC/T

Pellet 1296 1.59 t/t

Dolo

mite

1209 40 kg/t

DRI 1026


more focus.

Current Status : Detail is incorporated in the presentation.

more focus.

Current Status : Detail is incorporated in the presentation.

SAFETY :-

Remarks

Director advised that accidents should be brought down to 0.

SAFETY :-

Remarks

Director advised that accidents should be brought down to 0.

Process

Maint Contractors lab

Total

Reportable

Accidents

0 0 0 0

Near miss 0 0 0 0Minor 0 0 1 1


Director advised that accidents should be brought down to 0. Hazard identification and corrective action is a must. The safety committee should deliberate on this aspect.

Current Status :Unfortunately one accident occurs in RMP (Safety helmetsave life )

Director advised that accidents should be brought down to 0. Hazard identification and corrective action is a must. The safety committee should deliberate on this aspect.

Current Status :Unfortunately one accident occurs in RMP (Safety helmetsave life )

5 S & SAFETY

RemarksDirector appreciated DRI maintaining 3S and keeping the flag flying. He asked that SID should initiate for 4S now.SID has introduced the IMS Business excellence model in SID and work is going on to achieve the award.

Current status:

5 S & SAFETY

RemarksDirector appreciated DRI maintaining 3S and keeping the flag flying. He asked that SID should initiate for 4S now.SID has introduced the IMS Business excellence model in SID and work is going on to achieve the award.

Current status:


Current status:

Maintain 3s and got 48 marks in 4S (last mark 40 )

Current status:

Maintain 3s and got 48 marks in 4S (last mark 40 )

Thrust area for next month :

1. Coal Shed sheeting is must before monsoon.2. Coal lifting from railway siding, 5 rakes is on pipeline.3. Coal screening during monsoon.4. Maintain C/ Fe5. Safety

Thrust area for next month :

1. Coal Shed sheeting is must before monsoon.2. Coal lifting from railway siding, 5 rakes is on pipeline.3. Coal screening during monsoon.4. Maintain C/ Fe5. Safety


5. Safety

Remarks

Director advised that increase in cost due to high C/Fe to be considered in the slide on cost control.

Current Status : C/Fe was maintain 0.463

5. Safety

Remarks

Director advised that increase in cost due to high C/Fe to be considered in the slide on cost control.

Current Status : C/Fe was maintain 0.463

KRAKRA

COAL SIZING

BIN LEVEL ABOVE 60%

PELLET SIZING

REHANDLING <5%

TARGET ACTUAL ANALYSIS

MATERIAL IN

SURGE BIN60% 60.67%

Fines % was

higher side due to

excess moisture

and 25 % material

was directly fed to

circuit due to dryer

output is not meet

our daily

requirement.

FEED COAL

SIZE : – 4MMMax 12% 15.82%

COURSE COAL

SIZE : – 4MMMax 15% 35.34%

PELLET SIZE :

– 3 MMMax 3% 2.03%

PELLET SIZE : + 18MM

Max 5.0% 0 %

Processing

Raw Material Processing & Handling

PARAMETER PLANNED ACTUAL ANALYSIS

TOTAL PELLET RECEIVED FROM PELLET PLANT

43108 40417.60

PELLET DIRECT UNLOADING AT GROUND HOPPER

95% 98.41 %

PELLET YARDUNLOADING

5 % 1.59%

COAL DIRECT UNLOADING AT SHED

95% 100 %

COAL DUMP OUTSIDE YARD

5% max 0

HANDLING

(PELLET & COAL MOVEMENT)

KRA

PRODUCTION AS PER TARGET

OFF GRADE <6.5%

Mz 90.5 %

C/Fe -0.48 %

PARTICULARS UNIT PLANNED ACTUAL Analysis

WORKING DAYS: (3KILNS)

NO 90 90Kiln 1 condition was deteriorate due to excess fines carry over in feed as well as Injection coal .

SHUT DOWN DAYS:(3 KILNS)

NO 0 0

PRODUCTION MT 28830 26781

FEED RATE MT/HR 21.40 20.49

Production Planning & Review

FEED RATE MT/HR 21.40 20.49

COAL FINES (GENERATED)

MT 1658 1615

PELLET TON/MT 1.58 1.63

COAL TON/MT 1.10 1.18

POWER KWH/T 67 68.42

DOLOMITE KG/MT 40 55

RAW MATERIAL CONSUMPTION

RAW MATERIAL KILN-01 KILN-02 KILN-04 TOTAL

PELLET 12224 15144 8993 35691

IRON ORE 0 - - 6209

I/O DUST 1148 - - 1148

COAL

S.A 7204 8183 7695 23082

MT

S.A 7204 8183 7695 23082

B GRADE FINES 40 0 0 40

D GRADE

D&F GRADE 543 463 453 1459

E GRADE - - - -

F GRADE 2145 2352 2578 7075

TOTAL COAL 9932 10998 10726 31656

DOLOMITE 406.3 390.66 572.84 1369.80

CHAR 2161 2515 2334 7010

KILN - UNITPLANNED /

TARGETACHIEVED

DAYS 150AVG last

FYAVG.

/TOTALK-1(+ 76) K-2 ( + 90)

K-4(+ 127)

Analysis

YIELD OF PELLET

% 61.2 63.53 62.63

FEED RATE TON/HR 22 20.11 20.49 19.13 21.13 21.26

KILN-1,2 & 4

POWER REQUIRED

KWH/T 67 70 68.42 67.56 70.10

OFF GRADE % <6.5 7.18 7.77 12.64 6.25 4.44

C/FE % 0.48 0.471 0.477 0.485 0.478 0.47

Production MT

28830

(9520+9879+

9430)

26500 26781 8285 9489 9007

KRA

CUSTOMER SATISFACTION

OFF GRADE LIQUIDIZATION

TIMELY REPORTING TO CONCERN DEPT.

PARAMETER PLANNED JUN-15 MAY-15 ANALYSIS

QTY 43108 40417.60 35550.11 Fines Generation was fluctuated from 4 to 15 %,

Moisture slightly increased.MOIST 0.5 - 2.52.52

(1.68-4.10)1.85

(1.30-4.52)

MAJOR INPUT REC: PELLET QUALITY ASSURANCE PLAN

(1.68-4.10) (1.30-4.52)

Fe(T)63.8 -

64.5

63.92(63.32-64.12)

63.51(62.60-63.91)

CCS 180 - 240198

(168-226)202

(170-226)

TI 91 – 9493.18

(90.26-94.3093.66

(91.06-94.46)

AI 2.5 – 3.53.09

(2.86-3.76)2.95

(2.66-3.66)

CD(-4MM)%

10 12.04

(6.30-44.51)6.50

(5.35-11.09)

ESP % 2020.33

(14.79-38.3)17.44

(13.6-20.86)

YIELD% 62 62.63 62.88

F

GRADETARGE

TJUNE MAY ANALYSIS

QUANTITY

(MT)5525 6958.97 1480

%

MOISTUR

E8 9.85 6.93

%

VOLATILE

MATTER25 23.52 20.16

% FIXED

CARBON25 24.71 23.05

- 04 MM 20 17.99 11.92SHALE/ST

ONE5 12.1 9.45

F grade

MAJOR INPUT REC: COAL QUALITY ASSURANCE PLAN

SOUTH AFRICA

TARGET

JUNE MAY ANALYSIS

QUANTITY (MT)

21103 31776.83 13070.46 Moisture

increased in SA

rake it was up

to 10 %

% MOISTURE

7 7.92 7.69

% VOLATILE MATTER

25 24.12 23.20

% FIXED CARBON

53 51.61 51.41

- 04 MM 35 31.55 33.8

South African

OUTPUT TARGET K1 K2 K4 OVERALL ANALYSIS

PRIME % 93% 88.29 88.27 90.57 89.04 Pellet DRI Fe M maintain 78 + in K2 and K 4.

Fe T of Pellet DRI also reaching 86

OFF GRADE 6.5% 12.64 6.25 4.44 7.78

FE(M) % 77% 76.6 78.01 79.09 77.75

FE(T)SPONGE%

86% 85.65 85.9 88.02 86.50

Mtz% 90.5% 89.43 90.81 89.85 89.88

FINSIHED PRODUCT

also reaching 86 % Gangue was came down < 12 %

Mtz% 90.5% 89.43 90.81 89.85 89.88

GANGUE% 12% 11.71 11.73 9.43 10.96

CARBON % 0.1% 0.07 0.08 0.10 0.08

CD

(-4 MM)% 10 8.44 8.76 18.91 12.04

CD

(-1 MM)% 20 12.98 13.03 16.9 14.30

N Mag % <1%

S% 0.03% 0.026 0.026 0.027 0.026

PHOS % 0.08% 0.072 0.072 0.064 0.069

Qty %

160 170 74.67 0.18

170 - 180 113.17 0.28

180 - 190 2456.31 6.08

190 - 200 23690.01 58.61

200 - 210 10504.77 25.99

210 -220 1964.03 4.86

220 Above 1614.64 3.99

Total 40417.60 100.00

Qty %

1.50 - 1.75 289.52 0.72

1.75 - 2.00 6314.31 15.62

2.00 - 2.25 4253.03 10.52

2.25 - 2.50 8643.57 21.39

2.50 &

Above20917.17 51.75

Total 40417.60 100.00

CCS

Fe (T)

REQUIRED – 180-230 kgfREQUIRED – 0.5 to 2.5 %

QUANTITY %

63.20 - 63.49 74.67 0.18

MOIST

PELLET QUALITY ANALYSIS

QUANTIT

Y%

2.75 - 2.99 11448.56 28.38

3.00 - 3.24 21930.63 54.36

3.25 - 3.49 6557.32 16.25

3.50 Above 406.42 1.01

Total 40342.93 100.00

QUANTITY %

92.74 BELOW 113.17 0.28

92.75 - 92.99 453.01 1.12

93.00 - 93.24 17258.81 42.78

93.25 -93.49 12047.99 29.86

93.50 -93.74 4088.45 10.13

93.75 -93.99 4047.29 10.03

94.00 ABOVE 2334.21 5.79

Total 40342.93 100.00

Ai

Fe (T)

REQUIRED – 2.5 to 3.5 %

REQUIRED 63.8-64.5%

REQUIRED 91 - 94%

63.20 - 63.49 74.67 0.18

63.50 - 63.79 3671.68 9.08

63.80 - 64.09 32039.07 79.27

64.10 & Above 4632.18 11.46

Total 40417.60 100.00

Ti

PLANT AVAILABILITY-100 %

ZERO ACCIDENT

POLLUTION CONTROLPOLLUTION CONTROL

COMPLAINCE OF MAINTAINANCE SCHEDULE

CONSUMPTION & INVENTORY CONTROL

S. No. Activity Planned Achieved Remarks for deviation

1 Plant availability (%) 100% 99.93%FY 14-15 -99.95%

FY 15-16 – 99.48% (till month)

2 Delay Hrs 0 hrs. 1.35 HrsFY 14-15 -0.94hrs

FY 15-16 -11.50 hrs.

1.Girth Gear spring plate welding

2.SAF -9 replacement

3Equipment Inspection

(Total No. of Equipments)1327 Nos 1327

MID REPORT : MECHANICAL

RMP 358Nos. 358

Kiln – 1 283Nos. 283

Kiln - 2 290Nos. 290

Kiln - 4 340 Nos. 340

Pollution Control 56 Nos. 56

4

Preventive Maintenance/

Annual Maintenance(No. of

Equipments)Nos. 39

K-1 – 1 no, K2 – 2 nos, K4 -11 nos, RMP- 25 nos, pollution- nil

S. No. Activity Planned Achieved Remarks for deviation

5

Equipment Health A-Grade(MID Report, ProcessParameter & PhysicalInspection)

95% 95 A – 95 %, B – 5 %, C – 0%

6Repair Plan as per

Schedule01 01

Repair plan of Kiln-2 CD Dedustingfan for health up gradation .

MID REPORT : MECHANICAL

7Maintenance cost

(Rs./MT)90 42.28

Average of F.Y. 2014-15 – Rs.98.38Average of F.Y. 2015-16 – Rs.60.35(till month)

8 Inventory (Rs. Lacs) 65 92.16Non-Moving – 6.69 Lacs

Consumables – 23.17 LacsInsured Items -62.30 Lacs

9No. of Development

Projects1 1

Vibrating screen & Belt conveyor installation for PGP coal feeding . Target date July 20th 2015.

S.NO. EQUIPMENT MID REPORTPHYSICAL

INSPECTIONPROCESS

OBSERVATIONHEALTHSTATUS

1 KILN-1 COOLER MAIN DRIVE B A A B

CRITICAL EQUIPMENT HEALTH REPORT



4 LOBE COMPRESSOR-3 KILN-2 B A A B

5 ESP ID FAN KILN-4 B A A B

KRA

POWER

PLANT AVAILBILITY

MAINTAINANCE SCHEDULE COMPLAINCE

MAINTAIN POWER FACTOR

SAFETY

SR. NO. ACTIVITY PLANNED ACHIEVED REMARK

1 Maintenance Cost (Rs/Mt) 20 18.33 AVG. FY 2014-15 : 15.82

2

Preventive Inspection

KILN - 1 & 2 752 752

KILN - 4 532 532

3 Annual Maintenance 15 15

* Kiln 1 :Kiln 1 :Kiln 1 :Kiln 1 : NCF C ooler I/L * Kiln 2 : * Kiln 2 : * Kiln 2 : * Kiln 2 : NCF kiln O/l ,CD dedusting fan * Kiln 4 : * Kiln 4 : * Kiln 4 : * Kiln 4 : Bagfilter - 1, CD-1A & 1B, CD 2B, CD - 3A &3B, Drum sep conv. motors motors motors motors overhauled overhauled overhauled overhauled * RMP : * RMP : * RMP : * RMP : Sec crusher 2 I/O ,Lub pump crusher 3, GH VIB 1 &2 (New CHP), Mobery pump (PGP)------ motors overhauled motors overhauled motors overhauled motors overhauled

4Equipment health A grade (As per MID, physical inspection & process parameter)

95% 100%

S.

No.Activity Planned Achieved Remarks for deviation

5 Plant availability (%) 100 99.91 AVG. FY 2014-15 : 99.75 %

6 Delay Hrs (%) 0 0.09 AVG. FY 2014-15 : 0.25 %

7 Inventory (Rs. Lacs) 28

8 Major / Improvement workPLC UPGRADTION WORK IOF K1&2 IS UNDER

PROGRESS

Power Consumption (KWH/T)AVG. FY 2014-15 : 69.12 (K-1 & 2)

9

Power Consumption (KWH/T)AVG. FY 2014-15 : 69.12 (K-1 & 2) AVG. FY 2014-15 : 75.04 (K-4)

KILN - 1

70 67.57

KILN - 2

KILN - 4 70 70.11

KRA

EFFECTIVE PLANNING

PRODUCTION APPROVED AT NORM COST & QUALITY

MAINTAIN PEOPLE DICIPLINE, HEALTH & SAFETY

DEVELOP & TRAINED DIRECT REPORTING OFFICERS

ENSURE COMPLAINCE OF SAFETY& ENVN. NORM

PLANT AVAILABILITY

DESCRIPTION UNIT TARGET K1 K2 K4Total(hrs)

% ANALYSIS

CALENDER HRS HRS 720 720 720 720 2160 100

RUNNING- HRS HRS 716.96

(99.57%)717.12

(99.60%)717.7

(99.68%)2151.75 99.62

S/D HRS HRS 0 0 0 0 0 0.00

3.07 2.88 2.30

BREAK DOWN ANALYSIS

DELAY HRS HRS 303.07

(0.43%)2.88

(0.40%)2.30

(0.32%)8.25 0.38

PROCESS HRS 7.440.57

(0.08%)2.23

(0.31%)1.63

(0.23%)4.43 0.21

MECH HRS 7.441.23

(0.17%)0.12

(0.02%)0 1.35 0.06

ELECT HRS 7.440.92

(0.13%)0.20

(0.03%)0.67

(0.09%)1.79 0.08

RMP HRS 7.440.35

(0.05)0.33

(0.05%)0 0.00 0.03

POWER HRS 7.44 0 0 0 0.0 0.00

Sl no PARTICULARS TARGET MARKSOBTAINE

D MARKS

S.NO.

1 QUANTITY MT/DAY 500/DAY 30 30

Fe(m)%77% min to 80%

max5 2

CUSTOMER FEED BACK:SMS

2QUALITY

Fe(m)%max

5 2

Fe(t)%86% min to 88%

max10 3

-1% in DRI FINES

20% max 10 10

S%0.02% min to 0.03% max

5 5

P% 0.080% max 5 5

C% 0.10% max 5 5

Qty. of fines 20% in total 20 20

3CUSTOMER SERVICE (%)

10 10

4SATISFACTION LEVEL

100 90

OPENNING GENERATION

DISPATCHBACK LOG

BY PRODUCT INVENTORY

MATERIALSO/P (MT) GEN (MT) DESP (MT) B/LOG (MT)

JUNE MAY JUNE MAY JUNE MAY JUNE MAY

CHAR COAL LUMPS/FINES

16.87 36.59 7010 6502 6334.99 6521.72 691.88 16.87

COAL FINES BY PASS 200 30 1615.73 2658.64 1615.73 2488.64 200 200

PELLET FINES BY PASS 300 110 463.49 844.98 463.49 654.98 300 300

TOTAL 416.87 176.59 9089.27 9905.62 8414.21 9664.34 1191.88 416.87

OBJECTIVES TARGET ACTUAL ANALYSIS

House Keeping 3s 3s3S :- 3S is well maintained. 4s :- 48 Marks Achieved

Safety compliance is

Accident 0 0

Safety Audit Compliance

100 % 100%

SAFETY & HOUSEKEEPING

Safety compliance isdone 100 %Elimination of

Identified Hazard100% 100%

PPE usage 100% 100 %

Safety Committee meeting complianceof points

100% 100 %

HR Issue

Month Company Manpower Contract Manpower

April, 15 221/ Day 180 / Day

May, 15 221 / Day 182 / Day

June,15 221 / Day 182 / Day

Manpower shall be cut down further by 10 % in next 4 months.

Review of last month Plan (Thrust Area )

� Review of Thrust area of last month :

1.Coal Shed sheeting is must before monsoon : Completed.

2.Coal lifting from railway siding, 5 rakes is on pipeline : Done it.pipeline : Done it.

3.Coal screening during monsoon : affected due to heavy monsoon.

4.Maintain C/ Fe: Maintain 0.463

5.Safety : One but helmet safey his life.

(Thrust Area ) For Next Month

1. Manpower reduction.

2. Feed rate maintain as per the production plan.

3. Again C/ Fe Maintain < 0.463. Again C/ Fe Maintain < 0.46

4. Fe m Maintain 78 +

5. Safety : First priority.

THANKS

June 15 presentation

Engineering