ACC Thane - clinker factor.ppt

7/28/2019 ACC Thane - clinker factor.ppt

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Strength. Performance. Passion.

2012 Legal entity

EARN (Energy Activation across our Regional Network)05 to 08 Nov12 (ACC Thane)

Presentations with title image


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Content

Beat The Best

Objective of EARN

Tools development for EARN Performance Heat Map best practices Heat Map

Design principle to creation of performance heat Map EARN Target for Clinker factor HEAT map insight Input from the plants


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EARN objective

Achieve and sustain 10% annual reduction (~ USD 200 mn reduction) in Total Energy cost forthe region by 2015 and create a sustainable platform to continue to achieve substantial

energy improvements beyond 2015

EARN journey will complement, accelerate and systemize, NOT replace currentimprovement efforts


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Tool Development for EARN

Performance Heat Map.

Best practices Heat Map.


5/17 Holcim Group Support Ltd 2012

Design principles for creation of performance heat map

The heat map for each pillar will consist of a cascaded drill down of metrics from L1 levelto L2/ L3 level

L1: one metric which is indicative of that pillars performance e.g. Specific thermalenergy consumption for the TE pillar

L2: multiple metrics which constitute L1 performance or impact L1 performance e.g.MTBF is a metric that impacts specific electrical energy consumption

L3: next level metrics which impact/constitute performance of certain L2 metrics

L1 data will be normalised for external factors/market factors which impact performance

e.g. overall clinker factor is used to normalise specific electrical energy consumption Different categories will be made for plants running different processes, e.g., for EE

Dry, semi-wet and wet plants will be separated

Metrics are of 3 types: Output metrics which must be compared in the heat map Normalising metrics which are used to normalise/ adjust the output metric Input metrics which are used to calculate certain output metrics


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Clinker factor performance HEAT map structure 1/2


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Clinker factor performance HEAT map structure 2/2


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Take away from HEAT MAP for clinker factor (ACC) 1/3

L1 On the basis of overall clinker factor data we decidedthe plant ranking ( xy /45), which is easy to identificationthe high potential plant at initial stage.

L2 Color coding decided on the basis of data range, Datarange decided on the basis of 70 % plant fall in this range.

L1 L2 L2 L2 L2 L2 L2 L2 L2

Overall

plant CF

Overall

rank

PPC

Clinker

Factor

% PPC in

product

mix

PPC

rank

PSC

Clinker

Factor

% PSC in

product

mix

PSC

Rank

Blended

cement CF

%

Blended

cement in

productmix

Blended

cement

rank

OPC Clinker

Factor

% OPC in

product

mix

OPC rank

Units % % % % % % % % %

Plant name

Bargarh 51.71 5 72.54 17 25 41.60 69 2 54.40 6 1 95.09 1 17

Bellary Kudithini 47.57 4 47.57 100 7

Damodhar 45.33 3 45.33 100 5

Gagal 1 70.55 24 66.90 86 21 92.20 14 6

Gagal 2 66.83 17 66.83 100 20Chanda 74.83 30 64.65 63 9 72.75 4 7 95.07 32 16

Jamul 43.63 1 43.30 100 4

Chaibasa 55.21 6 71.38 30 24 47.32 62 6

Kolar Thondebhavi 73.80 28 66.60 76 19

Kymore 64.13 11 61.96 93 2 90.97 7 4

Lakheri 68.10 20 66.22 92 16 89.50 8 2

Madukkarai 77.18 34 76.68 91 28 52.77 2 8 91.68 7 5

Sindri 44.36 2 42.79 87 3

Tikaria 62.78 7 62.78 100 3

Wadi 1 91.96 41 74.11 15 26 95.37 85 18

Wadi 2 69.83 22 65.35 85 14 95.49 15 19


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Take away from HEAT MAP for clinker factor (ACC) 2/3

L1 L2 L2 L3 L3 L3 L3 L3 L4 L4 L4 L4 L4 L4 L4 L4

Overall

plantCF

Overal

l rank

PPC

ClinkerFactor

% PPC

in

productmix

PPC

rank

PPC

Cement

1 daystrength

% clinker in

PPC cement

% gypsum in

PPC cement

% fly ash in

PPC cement

%

performance

enhancers/additives in

PPC cement

Clinker

1 day

strength

Clinker

LSF

Clinker

CaO

Clinke

r C3S

Fly ash

Residue

% (45micron)

Fly ash

CR or

pozzala

nincityof fly

ash

Fly ash

LOI

Cement

Fineness

(45micron

residue)

Units % % % MPa % % % % MPa

Absolu

te

numb

er

% % % % % %

Plant name

Bargarh 51.71 5 72.54 17 25 15.10 72.54 5.00 22.30 0.16 29.10 93.28 65.30 53.39 32.13 85.00 1.38 15.5

Gagal 1 70.55 24 66.90 86 21 14.60 66.90 5.53 27.57 21.50 93.24 64.23 49.55 38.70 3.40 11.6

Gagal 2 66.83 17 66.83 100 20 14.60 66.83 5.48 27.68 21.30 93.19 64.15 47.27 38.70 3.40 11.8

Chanda 74.83 30 64.65 63 9 17.60 64.65 4.14 31.20 0.11 29.05 92.57 64.39 49.29 38.00 1.80 23.5

Chaibasa 55.21 6 71.38 30 24 14.90 71.38 4.34 24.28 0.01 27.80 93.40 64.10 48.20 46.50 6.25 18.0

Opportunity:-

L3 metrics help to set the aspirational target among the region Like, Ex:-

Chanda have PPC CF 64.65 % with 17.6 Mpa one day strength but Bargarh have72.54% CF with 15.10 Mpa one day strength. So Bargarh have a potential to reducemore.

L4 metrics give insight to identify the technical as well as chemical difference toidentify the way forward or set the action plan to reduce clinker factor further.


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EARN target for clinker factor

Focus AreaMarket Product portfolioRegulatory constraint .MIC availability and quality.Technology and processPeople and mindset

-6%Reduction across

region

2015 Aspirations

2015 aspiration setting (EARN kickoff, Bangkok)


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HEAT map insight

1 Establish a version 1.0 tool to benchmarkindicators of energy performance for all plants inthe region

Ready reference L1 L4metrics for all pillars for allplants

Objectives Where are we against it

Establish a version 1.0 tool to initiate a dialog andhelp spot opportunity on energy improvement

2 Best in class indicators toinitiate aspiration dialog

L3, L4 metrics to provideclues on L1 performance

Create a language of best practices that can bemeasured and used to improve performance

3 Over 150 best practicescollected

Survey of 700 plant people

Develop a mechanism to share best practicesacross the region, and help a plant assess theiroperations against best practices

4 PEER methodology createdand piloted in three plants


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Do and Donts

Benchmark to define aspirations(moons) by looking at best in class and

comparable plants performance

Use as a tool to identify opportunityareas through L3, L4 metrics andpractices

Initiate a dialog between plants acrossthe region on sharing best practices

Treat Red as potential opportunity andnot a performance score card

For areas which are Green push forachieving best in class performance

Use equipment and process differenceto generate capex proposals

How to use HEAT maps How not to use HEAT maps

HEAT maps are not a replacement for adiagnostic / deep dive to determineopportunity and initiatives. Providesdirection and not the answer

Do not expect HEAT maps to determinethe exact $ improvement potential

Do not use performance and practicesHEAT maps separately, use them inconjunction

HEAT maps are a dynamic tool thatneeds to be constantly updated and finetuned as it is used. Do not consider best

practices list to be static Do no attempt to account for all

contextual differences for a plant in theHEAT map


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Plant best practices score vs clinker factor

Practices


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More insight in to Best Practices approach in the Clinker

factor pillar which compares plants on best practices applied

Quality of RM Periodic assessment to improve availability of micro fine fly ash

(dedicated grinding mills for available fly ash, assessing new sources)

Minimize usage of aged raw material by using FIFO, traceability

Storage andhandling of RM

No open storage of clinker, gypsum and other raw material with cleardemarcation for different types to avoid mixing

Maintain fly ash and cement homogeneity with blending arrangements

Feeding Monthly optimization of grinding aid dosing rate

Increase degree of automation for fly ash / slag / additive feedingsystem using DCS to control dosing

Grinding

Optimizing mill efficiency using periodical regrading or top ups of the

grinding media, longtitudinal sieving and circuit sampling every 15 days

Optimizing SO3 in cement using frequent sulphation tests

Others Ensure exhaustive SLAs between GU and mother plants to ensure

quality of clinker supply Benchmarking of CF across products every quarter

Oranization Dedicated cross functional team with a champion on clinker factor Separate team in the plant that is focused determine and developing

alternate sources of mineral components

Performancemanagement

Review of clinker factor such as in daily operations review, weekly byHead Plant Operations, monthly by Plant Director

Training calendar and rewards and recognition mechanism

Technology Plants spend time and resources to explore / study impact of

technology changes in mineral component drying, separate grindingof mineral components, blending and mixing, f lyash separation

Plant can improveclinker factor withlittle capex byimproving

availability andstorage of rawmaterials

Technology canbe an importantlever to increaseclinker factor, butwill need capex

Practice (L2) ScoreSample L3 practices (not exhasutive)

Lunch Talk, Southeast and South Asia, CHBU, 2012-09-12


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Plant practices score Vs Clinker factor(LS)

# We have to look into to increase our plant best practicescore. Which help to reduce clinker factor. Like Bargharplant ( practice scor e 2.9 vs clinker factor 72.5%


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Point to improve the practices score (Five from each plant)

1. Point


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Thank You

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