A Project Study Report On Training Undertaken at BIRLA CEMENT WORKS, CHITTORGARH, RAJ. Titled “ ORGANIZATION CLIMATE” Submitted in partial fulfillment for the Award of degree of Master of Business Administration Submitted By: - Submitted To:- Nikita Malviya SONAL JAIN (HOD) MBA Part II (2007-2009 ) Regional college of Education Research and Technology Sitapura, Jaipur 1
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A
Project Study Report
On
Training Undertaken at
BIRLA CEMENT WORKS, CHITTORGARH, RAJ.
Titled
“ ORGANIZATION CLIMATE”
Submitted in partial fulfillment for the
Award of degree of
Master of Business Administration
Submitted By: - Submitted To:-
Nikita Malviya SONAL JAIN (HOD)
MBA Part II
(2007-2009 )
Regional college of Education Research and Technology
Sitapura, Jaipur
1
DECLARATION
I NIKITA MALVIYA D/o Mr. PRADEEP MALVIYA declare that the project report titled
“ORGANIZATION CLIMATE” is based on my project study. This project report is my
original work and this has not been used for any purpose anywhere.
Student Name
NIKITA MALVIYA
MBA IVth Sem.
2
CERTIFICATE FROM COLLEGE
TO Whom So Ever It May Concern
This is to certify that MISS. NIKITA MALVIYA has prepared this project report title
“ORGANIZATION CLIMATE” based on this project study. This project report is his original
work and it is submitted for the fulfillment of the MBA Degree.
Wish him good success for his future career.
Satish Sharma
( Project Guide)
3
PREFACE
Cement industry is one of the core industries in India like iron and steel. It has its primary
role in almost all development plans of the country. Birla cement works is a well establish
unit in the market of cement industries.
HRD is an important function of every organization. Hence, undertook the project to analyze
various aspect of HRD with a detailed study of “organization climate” of Birla cement work..
NIKITA MALVIYA
4
ACKNOWLEDGEMENT
I express my sincere thanks to my project guide, Mr. S.K. JAIN, HR MANAGER(HRD) , for
guiding me right form the inception till the successful completion of the project. I sincerely
acknowledge him/her/them for extending their valuable guidance, support for literature,
critical reviews of project and the report and above all the moral support he/she/they had
provided to me with all stages of this project.
I would also like to thank the supporting staff _MUKESH SAXENA ASST. HR MANAGER,
for their help and cooperation throughout our project.
(Signature of Student)
NIKITA MALVIYA
5
EXECUTIVE SUMMARY
India’s cement industry, which rode on a building boom to become the world’s second largest cement manufacturer after China with an installed capacity of more than 200 million tones (mt), is all set to take big hits. India’s cement industry has 132 large plants and 365 small plants with a cumulative installed capacity of 204mt at the end of August.The main Indian manufacturers in terms of capacity are ACC Ltd, UltraTech Cement Ltd, Ambuja Cements Ltd, Grasim Industries Ltd, Binani Cement Ltd, India Cements Ltd and JK Cement Ltd. In addition, several international cement manufacturers such as France’s Lafarge, Switzerland’s Holcim Ltd, Italy’s Italcementi and Germany’s Heidelberg Cement.
Birla cement works is a well established unit in the market of cement industries. The
Cement Division of Birla Corporation Limited has seven plants, having an installed
capacity of 5.8 million tons. After the completion of the ongoing expansion projects,
the capacity will increase to 7 million tons.
This ongoing project was study of Organizational climate at Birla Cement Works; Chittorgarh was focused on enduring quality of the internal environment that is experienced by the members, which in turn influences their behavior. Data was collected with the help of a questionnaire. The questionnaire is of structured non-disguised type. The contact method used in the survey was personal interview method. The study helps to understand the Organizational climate at Birla Cement Works, Chittorgarh. .
6
TABLE OF CONTENTS
DECLARATION 2Certificate 3
Preface 4
Acknowledgement 5
Executive summery 6
1 Introduction to the Industry 8-43
2. Introduction to the Organization 44-79
3 Research Methodology 80-85
3.1 Title of the Study
3.2 Duration of the Project
3.3 Objective of Study
3.4 Type of Research
3.5 Sample Size and method of selecting
sample3.6 Scope of Study
3.7 Limitation of Study
4 Result And Finding 86-87
5 Analysis and Interpretation 88-101
6 SWOT 102-103
7 Conclusion 104-106
8 Recommendation and Suggestions 107-109
9 Questionnaire 110-112
10 Bibliography 114-115
7
8
INTRODUCTION TO CEMENT INDUSTRY
INDUSTRY PROFILE
1.1 INTRODUCTION
Definition of cement:
Cement is binding material. Cement is one of the cheapest readily available, strong and
long life materials. The weathering effect on cement is very low. For the manufacturing of
cement basis raw material is lime stone. The purest form of limestone is marble.
Manufacturing process:
Heating mixture of limestone & clay at 1350-1400 degree temperature which produces the
modules of clinker due to fusion occurred by the heating. This clinker is then mixed with
gypsum & finely ground to make cement.
1. Mining – the mining of lime stone is done in such way so as to get 78%to 82%pure
limestone.
2.Crushing- the limestone is then crushed to 16to 25mm size .this is done at mines it self
and their crushed limestone is send to factory through the conveyer belt.
3. Grinding- The limestone is then grinded with literate so as to extend it setting. After this
mixture is send to silos.
4. Blending- In the silos blending is done so as to maintain the uniform mixture from the
silos the mixture is sending to pre- heater.
5. Burning- The mixture is pre-heated then it goes to where burning take place. In
calcinations burning zone of kiln pulverized coal is used as fuel in the process.
6. Grinding- The grinding of clinker with gypsum is done in cement mill.
9
7. Packing- cement is send to packing plant. Where it is packed in the bags using the
electronic packing machine.
1.2 PRODUCTION PROCESS OF CEMENT :
10
PACKAGING
1.3 CURRENT SCENARIO OF INDIAN CEMENT INDUSTRY
Cement industry is a core sector and forms the back bone of infrastructure development of
the country. Cement manufacturing began in India in 1911.the first plant had capacity of
200 tones per day. The industry was uncontrolled in 1989. the investment cost per ton of
installed capacity in 2002 for a cement plant is 4500 per ton As compared to 650 per ton in
late 70 ‘s India is one of the best quality cement manufacture of the world .it stand in the
top five producing nations of the world.
India is the world’s second largest producer of cement after China with industry capacity of
over 200 million tones (MT). With the boost given by the government to various
infrastructure projects, road network and housing facilities, growth in the cement
consumption is anticipated in the coming years.
The Indian cement industry comprises of nearly 132 large plants and another 365 small
plants. While the Cement Corporation of India, a central public sector undertaking,
comprises 10 units; the various State governments own 10 large cement plants. Among the
leading domestic players in terms of cement manufacturing are: Ambuja Cement, Aditya
Birla Group (which owns UltraTech Cement), ACC Ltd., Binani Cement, India Cements and
J K Cement. They are not only the foremost producers of cement but also enjoy a high level
of equity in the market.
The cement industry in India has added a whopping 46 MT capacity in just a little over three
years, taking the total installed capacity to 204.29 MT as on August 31, 2008. This includes
India Cements Ltd’s new grinding unit at Vallur, Tamil Nadu with an installed capacity of
1.10 MT.
The industry added over 30 MT to its installed capacity in just one year during previous
fiscal (April 2007–March 2008).
Almost all players of the industry, small to medium to large, have added capacity ranging
between a minimum of 200,000 tones and a maximum of 3 MT in the last three years (April
2005 to March 2008), effecting a total addition of 45 MT to the installed capacity by setting
up Greenfield projects, and expanding and upgrading the existing plants.
11
Simultaneously, with almost total capacity utilization levels in the industry, cement
dispatches continued to maintain a 10 per cent growth rate. Total dispatches grew to 170
MT during 2007–08, as against 155 MT in 2006–07. Region-wise, western region grew
fastest with a growth rate of 15 per cent, followed by northern region (12 per cent) and
southern region (10 per cent).
Future Outlook
Considering an expected production and consumption growth of 9 to 10 per cent, the
demand-supply position of the cement industry is expected to improve from 2008-09
onwards, resulting in an expected price stabilization. The cement industry is poised to add
111 million tones of annual capacity by the end of 2009-10 (FY 10), riding on the back of an
estimated 141 outstanding cement projects.
Major Players
The major players in the cement sector are:
• Ultratech Cement
• Century Cements
• Madras Cements
• ACC
• Gujarat Ambuja Cement Limited
• Grasim Industries
• India Cements Limited
• Jaiprakash Associates and
• JK Cements.
• Holcim
• Lafarge
• Heidelberg Cemex
• Italcementi
12
Statistics
Cement
(million tonnes)
2006-07 2007-2008
(Apr-Mar)
(a) Production 155.66 168.31
(b)Despatches
(Including Export)155.26 167.67
(c) Export 3.65 5.89
(d) Cap. Uti.(%) 96 94
Source: Cement Manufacturers’ Association
1.4 Region wise Capacity
The Indian cement industry has to be viewed in terms of five regions:-
North (Punjab, Delhi, Haryana, Himachal Pradesh, Rajasthan, Chandigarh, J&K and
East (Bihar, Orissa, West Bengal, Assam, Meghalaya, Jharkhand and Chhattisgarh); and
Central (Uttar Pradesh and Madhya Pradesh).
Northern Region
13
TABLE 1.1
Punjab 2173.34
Delhi 500.00
Haryana 172.00
Himachal Pradesh 4060.00
Rajasthan 16299.34
J&K 200.00
TOTAL 23404.68
West
Maharashtra 8950.00
Gujarat 12937.00
TOTAL 21887.00
South
Tamil Nadu 12913.18
Andra Pradesh 19831.02
Karnataka 9744.00
Kerala 420.00
TOTAL 42908.20
East
Bihar 1000.00
Orissa 2761.00
West Bengal 2291.66
Assam Meghalaya 400.00
Jharkhand 3475.01
Chattisgarh 11287.33
TOTAL 21215.00
Central
U.P. 6297.00
M.P. 16185.00
TOTAL 20482.00
1 .5 Per Capita Cement Consumption
Per capita cement consumption in India is 82 kgs against a global average of 255 kgs and
Asian average of 200 kgs.
14
TABLE 1.2
Fast rising Government Expenditure on Infrastructure sector in India has resulted a higher demand of cement in the country. In the same direction, participation of larger companies in the sector has increased.
For raising efficiency in the sector, the Planning Commission of India in the 10th plan has formed a 'Working Group on Cement Industry'.
There is a total number of 125 large cement plants and more than 300 small cement plants operating in India presently.
Well Cement, Rapid Hardening Portland Cement, Sulphate Resisting Portland Cement,
White Cement etc. Production of these varieties of cement conform to the BIS
Specifications. It is worth mentioning that some cement plants have set up dedicated
jetties for promoting bulk transportation and export.
19
Total productionThe cement industry comprises of 125 large cement plants with an installed capacity of 148.28 million tonnes and more than 300 mini cement plants with an estimated capacity of 11.10 million tonnes per annum.
The Cement Corporation of India, which is a Central Public Sector Undertaking, has 10 units. There are 10 large cement plants owned by various State Governments. The total installed capacity in the country as a whole is 159.38 million tonnes. Actual cement production in 2002-03 was 116.35 million tonnes as against a production of 106.90 million tonnes in 2001-02, registering a growth rate of 8.84%. Major players in cement production are Ambuja cement, Aditya Cement, J K Cement and L & T cement.
Apart from meeting the entire domestic demand, the industry is also exporting cement and clinker. The export of cement during 2001-02 and 2003-04 was 5.14 million tonnes and 6.92 million tonnes respectively. Export during April-May, 2003 was 1.35 million tonnes. Major exporters were Gujarat Ambuja Cements Ltd. and L&T Ltd.
The Planning Commission for the formulation of X Five Year Plan constituted a 'Working Group on Cement Industry' for the development of cement industry. The Working Group has identified following thrust areas for improving demand for cement;
i. Further push to housing development programmes;
ii. Promotion of concrete Highways and roads; and
iii. Use of ready-mix concrete in large infrastructure projects.
Further, in order to improve global competitiveness of the Indian Cement Industry, the Department of Industrial Policy
KPMG Consultancy Pvt. Ltd. The report submitted by the organization has made several recommendations for making the Indian Cement Industry more competitive in the international market. The recommendations are under consideration.
Cement industry has been decontrolled from price and distribution on 1st March 1989 and de-licensed on 25th July 1991. However, the performance of the industry and prices of cement are monitored regularly. Being a key infrastructure industry, the constraints faced by the industry are reviewed in the Infrastructure Coordination Committee meetings held in the Cabinet Secretariat under the Chairmanship of Secretary (Coordination). The Committee on Infrastructure also reviews its performance.
Technological changeContinuous technological upgrading and assimilation of latest technology has been going on in the cement industry. Presently 93 per cent of the total capacity in the industry is based on modern and environment-friendly dry process technology and only 7 per cent of the capacity is based on old wet and semi-dry process technology. There is tremendous scope for waste heat recovery in cement plants and thereby reduction in emission level. One project for co-generation of power utilizing waste heat in an Indian cement plant is being implemented with Japanese assistance under Green Aid Plan. The induction of advanced technology has helped the industry immensely to conserve energy and fuel and to save materials substantially.
India is also producing different varieties of cement like Ordinary Portland Cement (OPC), Portland Pozzolana Cement (PPC), Portland Blast Furnace Slag Cement (PBFS), Oil Well Cement, Rapid Hardening Portland Cement, Sulphate Resisting Portland Cement, White Cement etc.
20
& Promotion commissioned a study on the global competitiveness of the Indian Industry through an organization of international repute, viz.
Production of these varieties of cement conform to the BIS Specifications. Also, some cement plants have set up dedicated jetties for promoting bulk transportation and export.
21
Cement Industry
Cement is one of the key infrastructure industries. Price and distribution controls were lifted
on 1st March 1989 and licensing was dispensed with since 25th July 1991. However, the
performance of the industry and prices of cement are monitored on a regular basis. The
industry is subject to quality control order issued on 17.2.2003 to ensure quality standards.
Capacity, Production and Exports The cement industry comprises 128 large cement plants with an installed capacity of 151.69 million tonnes and more than 300 mini cement plants with an estimated capacity of 11.10 million tonnes per annum resulting in total installed capacity of 163 million tonnes. Actual cement production in 2003-04 was 123.50 million tonnes as against a production of 116.35 million tonnes in 2002-03, which is an increase of 6.15% over 2002-03. Cement production during the year 2004-05 (April-January, 2004-05) was 108.06 million tonnes (provisional), registering a growth of 7.10%. The Cement Corporation of India, which is a central public sector undertaking, has 10 units. Besides, there are 10 large cement plants owned by various state governments. Keeping in view the past trends, a production target of 133 million tonnes has been set for the year 2004-05. During the Tenth Plan, the industry is expected to grow at the rate of 10% per annum and is expected to add capacity of 40-52 million tonnes, mainly through expansion of existing plants and use of more flyash in the production of cement. Apart from meeting the domestic demand, the cement industry also contributes towards exports. The export of cement and clinker during the last three years is as under: -
Table - 7.1
Export of Cement
(in million tonnes)Year Cement Clinker Total2001-02 3.38 1.76 5.142002-03 3.47 3.45 6.922003-04 3.36 5.64 9.002004-05(Apr-Jan)
3.31 4.82 8.13
22
Overview of the performance of the Cement Sector The Indian cement Industry not only ranks second in the production of cement in the world but also produces quality cement, which meets global standards. However, the industry faces a number of constraints in terms of high cost of power, high railway tariff; high incidence of state and central levies and duties; lack of private and public investment in infrastructure projects; poor quality coal and inadequate growth of related infrastructure like sea and rail transport, ports and bulk terminals. In order to utilize excess capacity available with the cement industry, the government has identified the following thrust areas for increasing demand for cement: (i) Housing development programmes; (ii) Promotion of concrete highways and roads;(iii) Use of ready-mix concrete in large infrastructure projects; and(iv) Construction of concrete roads in rural areas under Prime Ministers Gram Sadak Yojana. Technological advancements Indian cement industry is modern and uses latest technology. Only a small segment of industry is using old technology based on wet and semi-dry process. Efforts are being made to recover waste heat and success in this area has been significant. India is also producing different varieties of cement like Ordinary Portland Cement (OPC), Portland Pozzolana Cement (PPC), Portland Blast Furnace Slag Cement (PBFS), Oil Well Cement, Rapid Hardening Portland Cement, Sulphate Resisting Portland Cement, White Cement, etc. Production of these varieties of cement conforms to the BIS Specifications. It is worth mentioning that some cement plants have set up dedicated jetties for promoting bulk transportation and export.
23
CEMENT INDUSTRIES
A. PROCESS DESCRIPTION
Cement industries typically produce portland cement, although they also produce masonry
cement (which is also manufactured at portland cement plants). Portland cement is a fine,
typically gray powder comprised of dicalcium silicate, tricalcium silicate, tricalcium
aluminate,
and tetracalcium aluminoferrite, with the addition of forms of calcium sulfate. Different types
of
portland cements are created based on the use and chemical and physical properties
desired.
Portland cement types I - V are the most common. Portland cement plants can operate
continuously
for long time periods (i.e., 6 months) with minimal shut down time for maintenance.
The air pollution problems related to the production, handling, and transportation of portland
cement are caused by the very fine particles in the product.
Exhibit 1 illustrates the stages of cement production at a portland cement plant:
1. Procurement of raw materials
2. Raw Milling - preparation of raw materials for the pyroprocessing system
3. Pyroprocessing - pyroprocessing raw materials to form portland cement clinker
4. Cooling of portland cement clinker
5. Storage of portland cement clinker
6. Finish Milling
7. Packing and loading
1. Raw Material Acquisition
Most of the raw materials used are extracted from the earth through mining and quarrying
and
can be divided into the following groups: lime (calcareous), silica (siliceous), alumina
(argillaceous),
and iron (ferriferous). Since a form of calcium carbonate, usually limestone, is the
predominant raw material, most plants are situated near a limestone quarry or receive this
material from a source via inexpensive transportation. The plant must minimize the
transportation24
cost since one third of the limestone is converted to CO2 during the pyroprocessing and is
subsequently lost. Quarry operations consist of drilling, blasting, excavating, handling,
loading,
hauling, crushing, screening, stockpiling, and storing.
2. Raw Milling
Raw milling involves mixing the extracted raw materials to obtain the correct chemical
configuration,
and grinding them to achieve the proper particle-size to ensure optimal fuel efficiency in
the cement kiln and strength in the final concrete product. Three types of processes may be
used: the dry process, the wet process, or the semidry process. If the dry process is used,
the raw materials are dried using impact dryers, drum dryers, paddle-equipped
Exhibit 1
rapid dryers, air separators, or autogenous mills, before grinding, or in the grinding process
itself. In the wet process, water is added during grinding. In the semidry process the
materials
are formed into pellets with the addition of water in a pelletizing device.
3. Pyroprocessing
In pyroprocessing, the raw mix is heated to produce portland cement clinkers. Clinkers are
hard, gray, spherical nodules with diameters ranging from 0.32 - 5.0 cm (1/8 - 2") created
from
the chemical reactions between the raw materials. The pyroprocessing system involves
three
steps: drying or preheating, calcining (a heating process in which calcium oxide is formed),
and
burning (sintering). The pyroprocessing takes place in the burning/kiln department. The raw
mix is supplied to the system as a slurry (wet process), a powder (dry process), or as moist
pellets (semidry process). All systems use a rotary kiln and contain the burning stage and
all
or part of the calcining stage. For the wet and dry processes, all pyroprocessing operations
take place in the rotary kiln, while drying and preheating and some of the calcination are
performed
outside the kiln on moving grates supplied with hot kiln gases.
4. Clinker Cooling
The clinker cooling operation recovers up to 30% of kiln system heat, preserves the ideal
product qualities, and enables the cooled clinker to be maneuvered by conveyors. The most25
common types of clinker coolers are reciprocating grate, planetary, and rotary. Air sent
through
the clinker to cool it is directed to the rotary kiln where it nourishes fuel combustion. The
fairly
coarse dust collected from clinker coolers is comprised of cement minerals and is restored
to
the operation. Based on the cooling efficiency and desired cooled temperature, the amount
of
air used in this cooling process is approximately 1-2 kg/kg of clinker. The amount of gas to
be
cleaned following the cooling process is decreased when a portion of the gas is used for
other
processes such as coal drying.
5. Clinker Storage
Although clinker storage capacity is based on the state of the market, a plant can normally
store
5 - 25% of its annual clinker production capacity. Equipment such as conveyors and bucket
elevators is used to transfer the clinkers from coolers to storage areas and to the finish mill.
Gravity drops and transfer points typically are vented to dust collectors.
6. Finish Milling
During the final stage of portland cement production known as finish milling, the clinker is
ground with other materials (which impart special characteristics to the finished product)
into a
fine powder. Up to 5% gypsum and/or natural anhydrite is added to regulate the setting time
of
the cement. Other chemicals, such as those which regulate flowability or air entrainment,
may
also be added. Many plants use a roll crusher to achieve a preliminary size reduction of the
clinker and gypsum. These materials are then sent through ball or tube mills (rotating,
horizontal
steel cylinders containing steel alloy balls) which perform the remaining grinding. The
grinding process occurs in a closed system with an air separator that divides the cement
particles according to size. Material that has not been completely ground is sent through the
system again.
7. Packing and Loading26
Once the production of portland cement is complete, the finished product is transferred
using
bucket elevators and conveyors to large, storage silos in the shipping department. Most of
the
portland cement is transported in bulk by railway, truck, or barge, or in 43 kg (94 pound)
multiwalled paper bags. Bags are used primarily to package masonry cement. Once the
cement leaves the plant, distribution terminals are sometimes used as an intermediary
holding
location prior to customer distribution. The same types of conveyor systems used at the
plant
are used to load cement at distribution terminals.
B. SOURCES OF POLLUTION
Although portland cement plants generate the same final product using similar processes,
plant layouts vary according to fuels and raw materials used, location, climate, site
topography,
and the manufacturer of the equipment. The flow diagram in Exhibit 1 depicts the
manufacturing
process at a portland cement plant and indicates emission points throughout the process.
C. POLLUTANTS AND THEIR CONTROL
This section briefly discusses the nature of the pollutants generated from, and controls used
at,
several sources in the cement manufacturing process. Air pollutants are typically of greater
concern than solid or liquid wastes.
1. Air Pollutants
Air pollutants generated during the cement manufacturing process consist primarily of
particulates
from the raw and finished materials, and fuel combustion by-products. Exhibit 2 indicates
sources of air pollution, and differentiates between particulates and other air pollutants.
Controlling particulate emissions from sources other than the kiln usually entails capturing
the
dust using a hood or other partial enclosure and transporting it through a series of ducts to
the
collectors. The type of dust collector used is based on factors such as particle size, dust
loading, flow rate, moisture content, and gas temperature. The best disposal method for
collected27
dust is to send it through the kiln creating the clinker. However, if the alkali content
Exhibit 2: Air Pollution and Control at Cement Production FacilitiesEmission Point Pollutants Emission Rate
(gr/acf1) Control Device Percent
Efficiency
Quarries Particulates 5-40 Fabric Filter:
. Pulse Jet
. Reverse Air/Shaker 99.6
Raw Mill
Systems Particulates 5-20 Fabric Filter:
. Pulse Jet
. Reverse Air/Shaker
. Cartridge 99.6
Kiln System Particulates 4-18 Dust Collectors:
. Reverse Air
. Precipitator 99.5
Clinker Coolers Particulates 5-10 Fabric Filters:
. Pulsed Plenum/Pulse Jet
. Reverse Air
. Precipitator 99.6
Finish Mill
Systems Particulates
5-20 Fabric Filter:
. Reverse Air/Shaker 99.6
Finish Mill
Systems Particulates 5-100 Fabric Filters:
. Pulse Jet
. Pulsed Plenum 99.6
For use with
High-
Efficiency
Separators Particulates 150-300 Fabric Filters:
. Pulse Jet
. Pulsed Plenum 99.9
Packing and
28
Loading
Departments Particulates 5-40 Fabric Filters:
. Pulse Jet
. Reverse/Air Shaker
. Cartridge 99.6
1 gr/acf = grains/actual cubic foot
of the raw materials is too high, the dust must be discarded, or must be pretreated before
introduction into the kiln. The highest allowable alkali content is 0.6 percent (as sodium
oxide).
Exhibit 3 summarizes the general applicability of a number of collection systems for use by
the
cement industry.
Exhibit 3: Applicability of Emission Control Methods
Operation Mechanical
Collector Wet
Scrubber Fabric
Collector Electrostatic Gravel Bed
Filter
Primary
grinding Unsatisfactory
efficiency Not
applicable Successful Not
applicable None in use
Air
separators Not
applicable Not
applicable Successful A few
installations Questionable
application
Mills Not
applicable Not
applicable Successful A few
installations Questionable
application
Storage29
silos Not
applicable Not
applicable Successful Not
applicable Impractical
Feeders
and belt
conveyors Not
applicable Not
applicable Successful Not
applicable Impractical
Packing and
loading Not
applicable Not
applicable Successful Not
applicable Impractical
Coal
dryer Preliminary
cleaning only Practicable Successful Not
common Practicable
Kiln
gases Preliminary
cleaning only Impractical 12 x 30 Glass
Successful Successful Practicable
Clinker
cooler Preliminary
cleaning only Not
applicable Successful Not
common Successful
Additional air pollutants emitted include such materials as sulfur oxides and nitrogen oxides
generated from the kiln and drying processes. Sulfur dioxide is generated from the sulfur
compounds in the ores and the combusted fuel and varies in amount produced from plant
to
plant. The efficiency of particulate control devices is inconclusive as the result of variables
such as feed sulfur content, temperature, moisture, and feed chemical composition, in
addition30
to alkali and sulfur content of the raw materials and fuel. The combustion of fuel in rotary
cement kilns generates nitrogen oxides from the nitrogen in the fuel and incoming
combustion
air. The amount emitted depends on several factors including fuel type, nitrogen content,
and
combustion temperature. Both sulfur dioxide and some of the nitrogen oxide react with the
alkaline cement and are removed from the gas stream.
a. Raw Material Acquisition
During raw material acquisition the primary air pollutant emitted is particulate matter.
Particulate
matter is also emitted from the handling, loading, unloading, and transport of raw materials,
such as coal, purchased from another source. In certain areas, exhaust from portable
equipment
may also be a consideration.
The following methods are used to control particulate emissions generated from the quarry
and
handling of purchased raw materials:
. fabric filters (pulse-jet or reverse-air/shaker)
. equipment enclosures
. water sprays (with and without surfactants)
. enclosures
. silos (with and without exhaust venting to
. wind screens fabric filters)
. foams
. mechanical collectors
. bins
. chemical dust suppressants
. paving
. material storage buildings
Dust that is collected by these means is restored to the process. For quarry operations,
newer
plants typically use the pulse-jet fabric filters while older plants employ the reverse-air or
shaker-type fabric filters.
b. Raw Milling
31
Fugitive dust is emitted from raw material feeders, stackers, blenders, reclaimers, conveyor
belt
transfer points, and bucket elevators used for transferring materials to the mill department
from
storage. Particulate emissions from the dry raw mills and subsequent equipment occur
during
temporary failure or from improperly designed or maintained seals. The following devices
are
used to collect particulate matter in the raw mill and raw mix storage areas:
. mechanical cyclones (usually used in series with another control)
. fabric filters (pulse jet or reverse air/shaker)
. electrostatic precipitators (rarely used)
Newer plants typically use the pulse-jet fabric filters while older plants employ the reverse-
air or
shaker type fabric filters.
c. Pyroprocessing
The main pyroprocessing system emissions are nitrogen, carbon dioxide, water, oxygen,
nitrogen
oxides, sulfur oxides, carbon monoxide, and hydrocarbons. Cement kiln dust (CKD) is
also produced.
The cement kiln itself has been designated as best available control technology (BACT) for
the
control of SO2. The highly alkaline conditions of the kiln system enable it to capture up to
95%
of the possible SO2 emissions. However, if sulfide sulfur (pyrites) is present in the kiln feed,
this absorption rate can decline to as low as 50%. Therefore, sulfur emissions can be
decreased
through careful selection of raw materials.
No device to control cement kiln NOx emissions has been developed, but there are several
prospects:
. stable kiln operation (reduces long term NOx emissions);
. burner configurations for the rotary kiln (efficiency varies);
. staged combustion for precalciner kilns;
. recirculation of the flue gas (oxygen deficient air in the rotary kiln); and
. alternative/low-nitrogen fuels.32
Cement kiln dust (CKD) is the powder retrieved from the exiting gases and is either all or
partly
returned to the operation or removed entirely. The type of system, the chemical makeup of
the
raw materials and fuel, and the condition of the system operations all affect the chemical
configuration
of the CKD. Portland cement specifications usually limit the amounts of sodium and
potassium. Because bypass CKD contains a large quantity of these minerals, CKD is
usually
removed from the process. The CKD from a preheater tower is composed of the same
general
elements as the kiln feed and therefore is returned to the process. The handling, storage,
and
deposition of CKD can generate fugitive dust emissions.
The following methods are used to control particulate emissions from the kiln system:
. reverse-air fabric filters
. electrostatic precipitators (ESPs)
. acoustic horns (sometimes used in conjunction with the two devices above)
d. Clinker Cooling
Reciprocating grate clinker coolers most often employ fabric filters, but ESPs and gravel
bed
filters are also used with a mechanical cyclone or multiclone dust collector sometimes
placed in
front. Newer plants typically use pulse-jet or pulsed-plenum fabric filters and older plants
use
reverse-air type fabric filters which may simply be a smaller form of a kiln fabric filter. Gravel
bed filters, which are also used by the cement industry, contain quartz granules;
contaminated
gas passes through this filter and the dust settles to the bottom of the bed.
e. Clinker Storage
The devices used to control dust emissions from clinker storage areas are similar to those
used in the raw milling process. The particulate emissions generated by dropping clinkers
onto
storage piles can be reduced by using a rock ladder or variable-height, automatic, stacker
belt33
conveyor systems. Fugitive dust generated from open storage piles is tempered by rain and
snow, wind breaks, and pile covers. Clinker in open piles is moved using front-end loaders;
in
storage halls overhead bucket cranes are used. Fugitive clinker dust emitted from open
storage
piles is common and very difficult to control.
f. Finish Milling
Particulate matter is emitted from mill vents, air separator vents, and material-handling
system
vents. Newer plants usually use pulse-jet or pulsed-plenum fabric filters with high-efficiency
separators, while older plants use reverse-air/shaker fabric filters. The cement dust
collected
by the fabric filter is restored to the system. In cold weather, a plume may develop at the
baghouse vent; this may be mistaken for particulate matter, but actually is condensed water
vapor from the cooling system.
g. Packing and Loading
In the shipping department particulate matter is emitted from the silos and the handling and
loading operations. Active and passive fabric filters are used to collect this dust. During
loading
of the product, particulate emissions are controlled by a fabric filter connected to the
transport
vessel; collected dust is restored to the shipment. To ensure dust-free loading onto the
transport vessel, a flexible loading spout consisting of concentric tubes is used. The
outermost
tube seals the delivery spout to the transport vehicle. The product is then delivered
through the inner tube and displaced air drawn up the outer tube to a filter. At distribution
terminals, fabric filters are again used and the collected dust is returned to the product. New
plants typically use pulse-jet fabric filters while older plants use reverse-air or shaker-type
fabric
filters.
2. Liquid and Solid Wastes
The overflow from slurry concentrating equipment (i.e. thickeners) constitutes the main
water
pollution problem. For new plants that process slurry, closed-cycle water systems are used
to34
return the overflow water to the process. Another source of waste is the stripped
overburden,
which is used as a raw material or disposed of in a local landfill. An estimate of overburden
deposited in a landfill varies from 0 - 3 metric tons per metric ton of cement produced.
The combustion processes of cement kilns and rotary kilns have been used to dispose of
hazardous waste material. For the cement kiln, waste material is burned with a primary fuel.
For a wet process kiln, the raw materials are introduced into the top of the kiln and exit at
the
bottom as cement clinker. The burner is located at the lower end of the kiln where the fuel
and
waste are ignited. The hot gases move up the kiln and heat the raw materials, exit the kiln,
and
are then cleaned in a baghouse prior to exiting through a stack. When waste is fired, any
ash
generated becomes a part of the cement product.
D. REFERENCES
1. Air and Waste Management Association. Air Pollution Engineering Manual. New York:
Van Nostrand Reinhold, 1992.
2. Hall, F.D. Evaluation of the Feasibility of Incinerating Hazardous Waste in High-
Temperature
Industrial Process, 1984.
3. Reding, J. T., P.E. Muehlberg, and B.P. Shepherd (Dow Chemical). Industrial Process
35
Cement Industry Expects to Grow Steadily in 2009May 15, 2009
cement industry is steadily growing and is set to add on 50 Million Tones additional
capacity during the current year as the demand still remains high.
The Indian cement industry will continue to show steady performance by increasing its
capacity another 50 Million Tones in 2009 despite the recession and slump in the country’s
housing industry, stated H M Bangur, President of Cement Manufacturers’ Association
(CMA) and reported by economictimes.
While the construction sector has got deeply affected by the global crisis, the cement sector
is improving day-by-day, recording a YOY growth of 9.4% in the fourth quarter of FY09. The
cement prices are also shooting up. The Association has predicted that the cement sector
will grow by 9-10%, provided the GDP of the country grows at the rate of 7%.
According to a new RNCOS report “Indian Cement Industry Forecast to 2012”, India ranks
second worldwide in the cement production after China. The Indian cement industry is
continuously expanding, with rising production capacity of major players in the past few
months. This indicates to no impact of recession on the industry.
Moreover, the cement production and consumption are expected to grow rapidly during
2009-2012. Housing industry makes up for over 50% of the cement consumption in India
and the same trend is expected to continue in coming years, says the report.
However the government took some infrastructure initiatives, but they proved inadequate.
The construction sector is severely hit by the increase in prices of cement, which were
driven by the rise in demand due to the infrastructure projects of the public sector.
Although the manufacturing sector registered slow year-on-year growth, some of the
sectors, such as the cement industry, displayed a fractional upturn during the later six
months of FY09 as compared to the first six months.
ISO 9002 certification for Satna Cement Works, Birla Vikas Cement and Durgapur Cement Works.
ISO 9001 - 2000 (QMS) certification for Birla Cement Works, Chanderia Cement Works from BVQI, UK.
IS/ISO 14001 certification in 1999-2000 for Satna Cement Works and Birla Vikas Cement, in 2002-2003 for Birla Cement Works & Chanderia Cement Works for environment management systems.
"Best Productivity Performance" award from NPC for Birla Vikas Cement in 1987-88. Also recognised by NCB as.
"Best in Energy Performance" in 1986-87.
"Best in Energy Performance" for Satna Cement Works in 1993-94, 1994-95, 1995-96, 1997-98.
"Best Productivity Performance" award from NPC for Chanderia Cement Works in 1998-90 and again in 1993-94.
2nd "Best Productivity Performance" award for Chanderia Cement Works in 1991-92 &
"Certificate of Merit" in 1998-99
"Best improvement in Thermal Energy Performance" recognition from NCB for Birla Cement Works in 1992-93 and Chanderia Cement Works in 1993-94.
"Best improvement in Energy Performance" recognition for Birla Cement Works in 1992-93.
"Bhama Shah Samman" from the Rajasthan Government for Educational Activities for Birla Cement Works in 1996-97.
VEC-IIT, Madras recognised Chanderia Cement Works and Birla Cement Works For "Excellence in Improving Machinery Health Condition" in 1997.
"Workers Education Trophy" awarded by Central Board of Workers Education, Udaipur Ministry of Labour, Government of India, for Birla Cement Works & Chanderia Cement Works in 1998-99 and again in 2001-02.
"Lal Bahadur Shastri Memorial National Award" for Excellent Pollution Control Implementation by Chanderia Cement Works in 2002-03.
53
CAPEXIL 'Special Export Award'
BIRLA CEMENT AND CHANDERIA CEMENTWORKS,
CHITTORGARH, RAJASTHAN
In Chittorgarh Birla Corporation Ltd. Has two plants namely B.C.W. & C.C.W. B.C.W. was
set up in 1967, the first dry process plant with two stage suspension pre heating technology
in the country. Its initial capacity of 2 lacks tones was increased to 4 lacks tones in 1992. In
modernization drive, the two stage pre heater is converted into five stage pre heater, and a
modern computerized system is installed.
C.C.W. Was set up in 1986, with new technologies and environment friendly atmosphere.
This plant is equipped with state of art equipment like 5 stage heater and in built clinker.
With sophisticated quality control system and central computerized control system with x-
ray analyzer provides to ensure best quality cement production. This unit was also
modernized and its production capacity is increased from 5 lacks tones per annum to 8
lacks tones per annum.
The company carried out various modified de-bottle necking in these plants, as a result of
which the installed capacity of the cement division has been increased to 24 lacks tones
from 14 lacks tones.
B.C.W. & C.C.W. has received the quality certification ISO 9001-2000 for quality
management system and ISO-14001 for environment management system.
B.C.W. & C.C.W. has also received many Excellency awards.
54
Quality policy
Birla Corporation limited Chanderia is committed to comply with the requirements of
customers to their satisfaction and continually improve the effectiveness of quality
management system by
Enhancing customer satisfaction by supplying consisted quality cement.
Regular up gradation of technology: optimum utilization of resources and upkeep of
equipment for reducing the cost.
Training and involvement of employee to develop quality culture in the units.
55
MAJOR DEPARTMENTS
Birla cement work and Chanderia cement work
• Mines
• Production
• Engineering
• Electrical power plant
• Thermal power plant
• Diesel power plant
• Enviourment safety
• Store and raw material
• Building
• Purchase
• Accounts
• information system
• Personal and welfare
• Gernal administration
• HRD
• Legal
• Sales and marketing
• Security
56
HRD-AN OVERVIEW
BIRLA CEMENT WORKS
Chanderia, Chittorgarh (Rajasthan)
( Unit of M/s. BIRLA CORPORATION LIMITED )
Unit Profile
BIRLA CEMENT WORKS (BCW) is a unit of Birla Corporation Limited, which is a major
producer of cement in India, particularly in the States of Rajasthan, MP, UP & WB. It is a
part of Rs. 5000 crores Birla Corporation Limited (BCL), which manufactures Jute products,
Synthetic Yarn, Linoleum, Carbide, Steel Castings, Auto Trims etc. in addition of cement
having registered office at Kolkata. BCL is having six manufacturing units – two in the State
of Rajasthan located at Chanderia, two in Madhya Pradesh located at Satna, one in Uttar
Pradesh located at Raebareli and one in West Bengal located at Durgapur. BCW is
producing different types of cement like 43 grade OPC & PPC, which represents the best
quality, easy workability, high strength & durability alongwith operational stability and
economy.
Birla Cement Works has a well established market in Rajasthan, Gujarat, Haryana, and