Manufacturing of GREEN CLINKER UltraTech Cement Limited ... Cement Ltd-Unit Rawan Cement...Rawan Cement Works conducts SWOT analysis through a brainstorming session. As per practice

Manufacturing of GREEN CLINKER

UltraTech Cement LimitedRawan Cement Works

Rawan Cement Works| Vision & Mission

VISION

To be a Leader in Cement ManufacturingDivision of Aditya Birla Group,with focus on:

1. Safety, Health and Environment2. Quality & Customer satisfaction3. Employee Satisfaction4. Cost Effectiveness5. Corporate Social Responsibility

MISSION

To delight the customer through continual improvement,innovation and skill upgradation.

Last Reviewed - Mar’2016

Stakeholder InvolvementStakeholder Involvement

StrategyStrategy

SWOT AnalysisSWOT Analysis

Unit MissionUnit Mission

Unit VisionUnit Vision

Strategic Objective / IssuesStrategic Objective / Issues

QCDIP Target -(Team Level)QCDIP Target -(Team Level)

Action Plan

(Unit Level)

Action Plan

(Unit Level)

Group VisionGroup Vision

Group MissionGroup MissionBusiness ProcessesBusiness Processes

Key BusinessProcess

Key BusinessProcess

Critical SuccessFactor

Critical SuccessFactor

Team Action PlanTeam Action Plan

Short term, MT, LT Goal & Target

(Unit Level)

Short term, MT, LT Goal & Target

(Unit Level)

Vision & Strategy Development Process

Unit SWOT Analysis

Rawan Cement Works conducts SWOT analysis through a brainstorming session.As per practice all the Management Cadre employees are invited for this sessionand detailed deliberation is done on each point to reach a consensus and basedon this SWOT Unit Vision is carved.

About the Unit

Genesis• Kiln 1 commissioned in 1995 with tag capacity 3300 TPD clinker production• Currently running at 5600 TPD by process optimisation and other changes

• Kiln 2 commissioned in 2013 with tag capacity 10000 TPD clinker production• Currently running at 11000 TPD by process optimisation and other changesHow to produce clinker at lower cost?

Constraint - Fan capacity & other auxiliary equipment were loaded

Requirement – To increase Productivity without affecting quality

Brainstorming

Cause & Effect:Man Material

Quality Checking ofproduct

Quality & quantiy ofLime Stone

Process control fromCCR Consistent fuel MixPacking of Cement Bags Bed Ash from TPPMaintainence Skill Iron Ore

AFRBi-Product (Flue dust)

Method MachineMaintain LSF 98-106 Preventive MaintenanceControlling processparameters as permaterial flow

Calibration of alltemperature, pressure &weighing guages

Maintaining Temp profilein Pyro section

Damper operation/condition

Conitnuous flow ofmaterial, clinkerization

HEMM Maintainence, BeltConveyors, VRM's, PH,Kiln

Cooling temperatureprofile Slag heating & Grinding

Free lime controlMixing of Gr Clinker withslag

Cost ofProduction

LS Mining & Raw Meal Grinding

Probable Causes ImpactEase of

implementation

Time toimplemen

t

Overallscore

Lead to

Powder Factor 3 2 3 18Handling ofexplosives

Truck Movement LeadTime

5 4 3 60Fuel

consumption

SD of LS blast size forcrushing

2 2 2 8R&M and

Power

False air in Raw MillCircuit

3 3 3 27 Power

NVA process steps 4 2 3 24 Power

LS Crusher to feed bothlines

5 4 4 80S&S and

R&M

Pyro Process

Probable Causes Impact

Ease ofimplementa

tionTime to

implementOverall

score Lead to

Running of motors/blowers at full 3 2 2 12 Power

Inconsistency in Fuel Mix 5 4 4 80Fuel

consumption

Poor burner condition 3 3 2 18Fuel

ConsumptionPoor condition of Air &fuel lines 2 2 2 8

FuelConsumption

False Air in Process 5 5 4 100 PowerImproper kiln atmosphereat various zones. 4 3 2 24

ProductQuality

Kiln Feed – Raw Material 5 4 5 100 Material Cost

Clinker & Slag Grinding


Ease ofimplementation

Time toimplement

Overallscore Lead to

Consistent Blaine Quality 3 3 3 27 Grinding rate

Consistent Slag BlaineQuality 5 4 3 60

S&S andR&M

Poor condition of DBC 2 3 3 18MaterialSpillage.

Burner Condition in HAGfor Slag 2 3 2 12

FuelConsumption

Leakages in Conveyingsystems 5 4 3 60

MaterialSpillage &

Power

Packing & Dispatch


Ease ofimplementatio

nTime to

implementOverall

score Lead to

Bag Burstage 2 2 2 8MaterialSpillage

Excess time for CementLoading in Rake 2 3 3 18 Demurrage

Calibration of WeighingGuages 3 2 2 12

Unloading ofTrucks &

Rakes

Fall of bags from BC 2 2 3 12 Bag RejPoor condition ClinkerBelt Conveyors for BulkLoading 4 3 4 48

MaterialSpillage,

R&M

Truck Trun Around Time 4 4 4 64Truck

Availability

Brainstorming | Impact Matrix

ProcessFunction

Potential FailureMode

Potential Effect offailure SEV Potential causes OCC Current Process

control DET RPN Recommended Action

TruckAvailability Truck Turn

Around TimeTruck Waiting Time 7 Manual

Intervention5

Card Punching byeach drivers atvarious locations

5 175 RFID system

FuelConsumption

Truck MovementLead Time inMines

Mining in remotelocations/ long lead 8 Improper route

planning 6 Manual Supervision 7 336 GPS & RFIDsystem

Inconsistency inFuel Mix

Inconsistent Quality ofLime Stone as per finalproduct

9 Fuel Mix Planning 8 Fuel Flexible Tool 8 576 AFR system

Raw MaterialConsumption

High qualityLime Stonerequirement asper market

Un-availability of LimeStone 9

Reduced MinesLife with higherproduction

8 Quality Checking ofProcess 8 576

AlternateRaw Materialto LimeStone

PowerConsumption

False Air in PyroSection

Leakages in materialconveying system/processes

9Non-complianceto PreventiveMaintenance

8False airmeasurement as perrequirement

8 576

Weekly FAmeasurement & arrestingby nextstoppage

Stores &Spares andRepair &

Maintenance

Over Capacity ofLS Crushers

Higher lead time ofTrucks, Increase in S&Sand R&M cost

8 Higher installedcapacity 7 Manual Supervision 6 336

SingleCrusherrunning tofeed bothlines

Poor Conditionof BeltConveyors forClinker BulkLoading

Material Spillage andR&M cost 9 Hot clinker from

silo 7 Monitoring Siloretention time 7 441 HR belts

installation

Regular B/D ofSlag Roller Press

Inconsistent Slag BlaineQuality 6 Coarse Slag 5 Quality Control at

Site 4 120Developmentof newVendors

PowerConsumption

Abrasive natureof material

Leakages in materialconveying system inCement Mill

6 Corrosion atJoints 5 Time based

maintenance system 4 120

ConditionbasedmaintenanceSystem

Root Cause Analysis | FMEA

SlNo

Failure Mode Measure takento overcome the

Failure

Contribute toProcess

Timeline

1Truck Turn AroundTime

RFID system –Eye On Wheels

Availability ofTrucks in

competitiveenvironment

Project startedon Apr’15 & End

on June’16

2 High quality LimeStonerequirement asper market

Alternate RawMaterial to LimeStone

Increase MinesLife


on Mar’16

3 Over Capacity ofLS Crushers

Single Crusherrunning to feedboth lines

Reduced S&Sand R&M cost


on Mar’16

Project Identification

Team “ANVESHAK”

Identity Name & Role Responsibility

S. P. Chandrawal(Leader)GM- QC

Developing the Project concept, Teamselection, estimate financial benefits provideresources by coordinating & planning.

U. N. Mishra(Member)Manager - QC

Data collection, analysis & Product design.

D. K. Agrawal(Member)AGM - Process

Process control, initiating corrective &preventive actions.

S. Verma(Member)Manager - Projects

Material Indenting, Equipment Erection &Commissioning.

R. Singh(Member)Asst. Officer - QC

Technology scanning, monitoring & processcontrol

Target: Manufacturing of Green Clinker

ProjectObjective

To reduce cost of production while maintaining the everdemanding quality requirement by customers.

Impact onbusiness &Reason forprojectselection

As per cement manufacturing process, Lime Stone miningis basic & essential need and it has been optimized as perbusiness benchmark. Hence, only way to reduce cost ofproduction is by modifying the pyro process as it involveslarge energy & all raw material consumption.

Target setting Reduce cost by Rs. 5 crore/ annum.

Projecttimeline

Start Date : April 2015Completion Date : June 2016

Background of the project – Brief Charter

Analysis• Clinker is produced by pyro-processing of raw mix• Raw mix (natural minerals – such as calcite, quartz)

Clinker (artificial minerals – C3S, C2S, C3A, C4AF)

Principal Theory• Characteristics of Blast Furnace Slag was found very near to Clinker• Compatibility of BFS with Raw Mix established keeping in mind chemical

constituents such as MgO, Mn2O3 & Al2O3• Embodiment of BFS in Clinker phase is possible by presence of acrystalline

high-energy state of BFS

Heat

Green Clinker | Do

Theory of Execution

• Lab trial taken with modification in Raw Mix quality by adding BFS directlyin Kiln

• Confirmatory trial taken as this doesn’t require BFS grinding or heating• Plant Scale trial taken to check compatibility with the Kiln firing with

calculated risk• Commercial production planning through automation was prepared

Lab Scale trial Confirmatory trial Plant Scale trial Commercial production

Green Clinker | Do

Execution• Manual feeding of slag started from AFR feeding point• Retention time in Kiln & Cooler kept at appx. 1.15 Hrs• Trial taken in four steps @ 1%, 2%, 3% & 5% of BFS addition to clinker

Green Clinker | Do

Mineralogical Phases Cement Clinker CompositionNormal Clinker Green Clinker

C3S 46.80 46.89C2S 26.33 26.83C3A 9.15 9.69C4AF 10.52 11.07

Chemical Analysis:

Strength:

Green Clinker | Check

This process doesn’t require –

• Electrical energy for grinding

• Heat energy for pyro process

• No bottlenecks of process fan capacity

• No GHG emission

Thereby a process innovation of producing Green Clinker


Process Outcome

Operation Observation:• Kiln was behaving normal

• All the parameter were within the range.

• Clinker Lt. wt. and other characteristic within

the normal range

Quality Observation:• Normal sieve analysis.

• Slightly Better strength than the normal clinker in all ages

• Cement Strength at par with Customer requirement


Green Clinker | Act

Improvement No.1

Mechanised Slag Feeding system through Kiln Inlet

Problem: Slag was being fedmanually through the hopperalong with Alternate Fuel.

Solution: Loading by pay loaderthrough a hopper & mechanisedbelt conveyor.

Benefits: Thereby reducing manual labour & feeding also increasedmanifold.

Green Clinker | Act

Improvement No.2

Slag feeding hopper modification

Problem: Slag was beingdumped by incoming trucks onthe floor, then pay loader usedfor feeding on conveyor.

Solution: A ramp was made &hopper size enhanced toaccommodate larger volume.

Benefits: This system has made the process quicker & now feeding of slagcan be done by directly unloading of trucks on the feeding hopper

Green Clinker | Act

Improvement No.3

Slag feeding ramp area visuals improvement

Problem: Slag feeding ramparea did not have signages.Drivers were getting confusedand there were safety concerns.

Solution: Area was developedaesthetically. Radium stickers arepasted on the walls for bettervisibility during dark hours.

Benefits: This has helped in creating a safe & systematic work environment.

Green Clinker | Act

Improvement No.4

Controlling the flow of slag feeding

Problem: The slag being fedthrough the hopper did not haveany control over the amount.

Solution: A gate was fixed torestrict the amount of slag beingfed. Also vibrator installed toavoid hopper jamming.

Benefits: There are no more jamming of material.

Green Clinker | Act

Improvement No.5

Auto feeding of Slag in Line 2

Problem: The slag was being fedmanually through the hopper.

Solution: Grab bucket conveyorsystem being installed for autofeeding.

Benefits: Increase in productivity and safe work environment.

Green Clinker | Feeding System

Line 1 : Slag feeding throughbelt conveyor & bucket elevatorinto Kiln Inlet.

Line 2 : New grab bucketconveyor system being installedunder CAPEX.

Benefits

Group Level

• Increase in clinker production by @2%.

• Savings of 5.02 Crore INR per annum @ 2% BFS addition.

• CO2 emission reduction 744.2 Lacs kgCO2 per annum.

• Conservation of natural resources (Limestone) 1.49 times of slag.

• Converting waste to wealth.

Green Clinker | Benefits

Benefits

Global Level

• Reduction in GHG emission - CO2 Calculated emission reduction is 525 gCO2/Kg material i.e. 2% reduction per ton of Clinker.

• Specific emission of SOx/NOx fuel component reduction.

• Reduction in fuel & power for material handling.

• Conversion of waste to wealth.

Green Clinker | Benefits

Green Clinker | Future Issues

Future Issues

• Patent for controlled horizontal replication

• Identify BFS availability across the country

• Proper methodology for PAT project


Major Challenges

• To attain progressive increase in strength

• To contain the granulometry of clinker

• Availability of Coal

• Satisfy Central R&D about quality compatibility

Sustainability

• Sustainability studies- Reduction in CO2 emission

• Long term quality performance

• Quality certification


Horizontal Replication

• Shared with Group Units

• RWCW as nodal center

• Step-wise harnessing of the potential of this innovation


One Step Ahead | The Next Big Change

Directed by BIS –Composite cement under Plant Scale Trial

A) Composite Cement Trial, Patna GU.

B) Composite Cement Trial, RWCW GU.14.48 14.08

12.44 12.0211.02

20.0 22.5 25.0 27.5 30.0

25.0 25.0 25.0 25.0 25.0

1-D C. Strength -Patna GUMpa

Slag & Flyash % addition

11.2210.20 9.79

8.577.55

20.0 22.5 25.0 27.5 30.0

15.0 15.0 15.0 15.0 15.0

1-D C.Strength –RWCW GU.

1-day

Slag & Flyash % addition

Manufacturing of GREEN CLINKER UltraTech Cement Limited ... Cement Ltd-Unit Rawan Cement...Rawan Cement Works conducts SWOT analysis through a brainstorming session. As per practice

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