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
Probable Causes Impact
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
Probable Causes Impact
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
Project startedon Apr’15 & End
on Mar’16
3 Over Capacity ofLS Crushers
Single Crusherrunning to feedboth lines
Reduced S&Sand R&M cost
Project startedon Apr’15 & End
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
Green Clinker | Check
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 | Check
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
Green Clinker | Future Issues
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
Green Clinker | Future Issues
Horizontal Replication
• Shared with Group Units
• RWCW as nodal center
• Step-wise harnessing of the potential of this innovation
Green Clinker | Future Issues
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