demonstration on gp implementation at malabar cements
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Transcript of demonstration on gp implementation at malabar cements
PRESENTED BYDEEPA.K
GP( Green Productivity) DEMONSTRATION
IN MALABAR CEMENTS
Chapter 1 Introduction
Background of the study Concept was established by the Asian Productivity Organization
(APO) in 1994
A strategy used to address environmentally sustainable development and aims to enhance productivity and socio-economic development whilst ensuring environmental protection.
It applies environmental management tools, techniques and technologies to reduce the impact of an organization’s activities, goods and services on the environment.
GP is applicable to the manufacturing, agricultural and service sectors.
The benefits gained from GP implementation within these enterprises are significant in terms of productivity enhancement and environmental protection.
Definition:
Green Productivity (GP) is a strategy for enhancing productivity and environmental performance for overall socio-economic development. It is the application of appropriate productivity and environmental management tools, techniques, technologies to reduce the environmental impact of organization’s activities, goods and services
Background of the Topic
. POLLUTION in Malabar cements.
The pollution problem encountered in cement industry is air
pollution, in which the main pollutant is the particulate matter.
The intermediate as well as the final product in cement industry is in the form of powder. The accompanying phenomenon of , handling and processing of the material components which finally form Portland cement.
The raw material received from mines is crushed in a double stage crushing plant where relatively large amount of dust is produced. The transfer of lime stone through conveyors to open stockpile also adds up to the pollution. Grinding and homogenizing of raw material also contribute pollution.
The vent air from high speed hammer crushers,
vibrating screens, , open storage dumps, raw grinding ill, rotary kiln, clinker cooler , Finish grinding mill, coal mill, bucket elevators, Mechanical air separators, transfer points of belt conveyors , pneumatic conveying systems, all contribute to air pollution.
Depending on the manufacturing process and on the level of technical development of the cement plant 6 – 12 m3 of dust laden gas is discharged from every one Kg of cement produced. The size of the dust particle may range from 1-100 micron and above.
OBJECTIVESPrimary Objective
To create an awareness on the importance of green productivity in Malabar cements
Secondary Objective
1) Setting up of GP EMS team in the company.
2) Identification of problems (departmental wise )in terms of environment & productivity.
3) Listing of various problems , identifying its causes & generating options
4) Options evaluation with respect to technical. Economic & environmental aspect.
5) Setting up of an action plan.
Industry & Company Profile
Industry profile…
Cement- Opus Caementicium means binder- Invented by Joseph Aspdin, in 1824.
Introduction to Indian cement industry
- In 1914, the first licensed cement-manufacturing unit in India was set-up by the India Cement Company Ltd
Second largest cement producer , total capacity -151.2 Million Tones, contributed by around 125 large & 300 mini cement plants.
Exports – 2.5 to 3 million tonnes of cement
It is expected that by FY12, the cement production capacity will rise upto 262.61 MT.
Major players: ACC Ltd, Grasim Cement, Ambuja Cement, Ultratech Cement.( Market share-39.80%)
Mid-large players (like Shree Cement,Madras Cement, India Cement) -36%
Small players (like My Home IndustriesLtd, Orient, Binani) -24%,
New players (like Reliance, Murli Agro, JSWCement) -6%
Company profile- Malabar Cements
Vision… Help to build better habitable Kerala by
providing best solution in the field of construction.
Mission... Provide quality products & services to the
public through effective intervention in the market.
Objective of the
company…
To manufacture & Supply Quality cement at a reasonable price by making an optimum profit.
To ensure fair dealings to customers.
To provide employment opportunities to the public.
Company Profile in detail Incorporated on August 11, 1978
Commenced production on April 24, 1984.
Produces 4.2 lakh tones cements per annum.
Meets about 10 % of total cement consumption in Kerala.
Turnover-Rs 300 crores.
Market share- 6%
No of employees- 1000-1200
Main markets- Kerala( Ekm to Kasargode)
Units- Main unit at Walayar & Grinding unit at Cherthala.
Main competitors-Sankar cements, Coramental cement, ACC, Rassi, Chettinad & others.
Products…
Dy. ManagerDy. Manager
M.MiningM.Mining M.EnggM.Engg M. ProdnM. Prodn M.MaintM.Maint
Dy. ManagerDy. Manager Dy. ManagerDy. Manager Asst. ManagerAsst. Manager
AssosiatesAssosiatesAsst MgrAsst MgrSupervisorsSupervisorsAsst MgrAsst Mgr
othersothers LaboursLabours OthersOthers
Assistant Manager & offficer costing
Assistant Manager & offficer costing
M. Humen ResourceM. Humen Resource M.FinanceM.Finance M.CommercialsM.Commercials
Assistant ManagerAssistant Manager
Purchase ManagerPurchase Manager
Marketing Manager
Marketing Manager
ExecutivesExecutives
OthersOthers
GENERAL MANAGER TECHNICALGENERAL MANAGER TECHNICAL GENERAL MANAGER ADMINISTRATIONGENERAL MANAGER ADMINISTRATION
EXECUTIVE ADMINISTRATOREXECUTIVE ADMINISTRATOR
BOARD OF DIRECTORSBOARD OF DIRECTORS
PLANT HEADPLANT HEAD
MANAGING DIRECTORMANAGING DIRECTOR
PLANT CO-ORDINATORPLANT CO-ORDINATOR
PRODUCTION DEPT The cement production involves different
phases such a raw mill, kiln, cement mill and packaging section, etc. However every aspects of production are carefully & constantly looked after by production department so as to ensure high quality & to reduce wastage.
The company has separate lab which is established to check the quality parameter of the sample which they produce.
Has four packing machines, and the packed cement are transported to the distributors or retailers through roadways , railways, etc.
ManagerManager
Dy ManagerDy Manager
Asst. ManagerAsst. Manager
Asst. AnalystAsst. Analyst
Tester/GaugerTester/Gauger
Lab BoyLab Boy
Chapter 3Review of literature
Review of literature
Nineteen countries throughout Asia and the Pacific are members of the APO and GP methodology has been and continues to be applied to many different sized enterprises within these countries.
The benefits gained from GP implementation within these enterprises are significant in terms of productivity enhancement and environmental protection.
The Vietnam Productivity Centre (VPC), under the Directorate for Standards and Quality (STAMEQ), is the National Productivity Organization for Vietnam. Since 1998, the VPC has successfully implemented GP projects in villages throughout
Management commitment
1. Getting started
2. Planning
3. Generation and evaluation of GP options
4.implementation
5.Monitoring and review
6. Sustaining GP
Chapter 4Methodology
Methodology
Methods of data collection:
Through Direct interview with the GP EMS team
Questionnaire
Company manual.
Tools used…
Cause & Effect diagrams
Evaluation Matrix
Limitations….
Data constraints
Time constraints
Chapter 5Analysis & Interpretation
Getting started…1) GP EMS team formation.
LIST OF GP-EMS TEAM IN THE COMPANY Chairman
MD
CONVENOR
Manager representative and Deputy Manager( IT)
MEMBERS
G M ( works)
Dept GM( Eng)
Manager(T&D)
Chief Engineer( Mech)
Senior Chemist
Manager (Materials) Deputy Manager( Marketing) Mines manager Deputy Chief Engineer(Mech)- Plant Deputy Chief Engineer(Mech)- Mines Deputy Chief Engineer( Electrical) Plant Engineer (Chemical) Plant Engineer (Instrumentation) Safety Officer Plant Engineer(Civil) Asst Engineer (Mech)- Ropeway
Asst Engineer (Mech)- Packing Plant
Senior officer (Production)- Mr. Dharmadas
Shift Officer(Production)- P.K.Madhu
Responsibilities of the team :
To identify problems related to environment and
productivity in the company
To identify causes of those problems
To generate options to overcome those problems
To set up the environmental objectives, and targets
To conduct the chosen options
To establish EMS document system
To evaluate the results of the program
To maintenance EMS – GP system
To report to the releted management organisations
PRODUCTION FLOWCHART
Mining
Crushing
Raw mill preparation
Clinkering
Cement grinding
Cement packing
Input & output of all processes
INPUT PROCESSES OUTPUT
Coal, limestone, gypsum, flyash Transportation Dust, noise, air emission
Limestone, clay, electricity Crushing Dust, noise, small limestone and clay
Limestone, gypsum, electricity, flyash
Milling Dust, noise, raw material
Raw material, electricity, air flow
Homogeneous Raw material homogeneous
Raw material homogeneous, coal, air flow, electricity
Kiln Clinker, heat, dust air emission, noise
Clinker, electricity Clinker cooling Clinker, heat, dust , noise
Clinker, additives, electricity Cement milling Cement powder, dust, noise
Cement powder, electricity, air flow, bag
Cement packaging Cement bag, dust, noise
Cement bag Transportation Cement bag, dust
Specific environmental impacts
1) Dust
Total air volume to be handledPLANT DEPARTMENT M3/Min
Crusher Dept 600
Clay drying 1200
Raw grinding 3400
Kiln,coal drying, Clinker cooler 13300
Finish mill 4700
Cement silo, Packing area 2000
TOTAL 25200
Normal air flow
MACHINE AIR VOLUME UNIT
Crusher 60 Nm3/min/m2 opening area
Raw material drier 0.8-2.0 Nm3/kg dried material
Roller mill 1.5-2.5 Nm3/kg ground material
Coal mill 1.5-2.0 Nm3/kg clinker
Kiln 1.4-2.3 Nm3/kg clinker
Clinker cooler 2.5 Nm3/kg clinker
Dust content in exit gassesLOCATION OR SOURCE OF DUST g/nm3
Crushers 5-15
Raw material drier 40-90
Roller mill 650
Coal mill with drier 100-120
Kiln, preheater 70-75
Finish grinding 20-80
Std <50mg/nm3
2) Noise
Loading machine 85 Db
Dumper 78 Db
Dozer 95 Db
Drill 100.3 Db
Compressor 99.3 DbP. crusher 87.6 Db
Rope outside 85.1 Db
Rope inside 90.2 Db
Sec crusher in 87.6
Sec crusher out 77
Primer in 85
Primer out 83.5
Std 85 Db
Problems identification
Department / process
Environmental problems
Productivityproblems
Mining and transportation of raw material
- Dust from mining explosions, transportation and loading and unloading of raw materials
Limestone crusher process
- Noise pollution- Dust generation
- Short lifetime of hammer
- Low capacity
Clay crusher process
- Noise pollution- Dust generation
Low performance of clay crusher. Large amounts of clay get stuck between the metal pieces of the crusher. As the clay hardens and compacts, it bends and breaks the metal, which reduces its performance.
Conveyer belt transportation from crusher to storage
- Dust generation at direction change points (from this conveyer to other conveyer)
Kilns
- Waste heat- Air emissions- Waste oil- Oil leakage- Solid waste
- Low inefficiency of kiln
- Energy consumption
Compressor room- Noise - Oil leakage
Cement mill
Production lower than design capability
- Energy consumption
Loading clinker and cement
- Dust generation
Packaging area
- Dust generation- Solid waste
Raw material
High water content in clay & coal
Raw material drier
Increased dust generation surrounding the air
The drier is not reducing the water content in the raw materials enough
Limestone silo
DustThe transportation process of grounded limestone to the silo produces dust
Mixing Raw Materials
Dust generation is high Manual feed causes inconsistencies in the composition of the mix leading to unstable clinker quality.
Additive
The cost of gypsum is high. Currently iron ore and gypsum are being used as additives. Gypsum, however, is very expensive.
Raw mill
NoiseNoise is generated from milling process. It affected to the health of the operator
Cement silo
Cement is sticking to the wall of the cement silo. This is reducing the quality of the cement; old cement may be lodged for a long time and then falls down. When the older cement joins fresher cement it reduces the quality.
Transportation of cement
DustDust is generated in loading area and transport out of Company
CAUSE IDENTIFICATIONUSING
CAUSE & EFFECT DIAGRAM
Management problems
Material
EquipmentOperation
method
Noise pollutionOperator
contacts directly with the machine
No automatic feeder
Operator controls
machine by listening
Operator controls
machine by listening
ENERGY
METHOD
Capacity of the milling
machine is low
Management problems
Raw material
EquipmentMethod
The nature of material
Moisture of material is
high
Size is not suitable
Material feeding manually
Temperature inside
machine in not
controlled
Bad design of lifting
linerThe partition
between 2 chambers is not
well designed
Training
Material is open-stored
Old design from producer
No technical instruction
No technical
instruction
Short life time of hammer
List of problems causes & optionsDepartment/Process
Problems Causes Options
Mining and transportation of raw material
- Dust from mining explosions, transportation and loading and unloading raw materials
- Material too dry - A lot of dust on the road
- Spray water on the limestone before upload and unload
Limestone crushing process. Clay crushing process
- Noise pollution _ Old crushers Wearing ear protection equipment or replacing old crushers.
- Dust emissions - Bag filter operate inefficiency and bag damaged
- Periodical maintenance of bag filter and should change damaged bags filter diligently.`
- Short lifetime of the limestone crusher’s hammer
- Low capacity
- See fish bone diagram - Reduce SiO2 in limestone by change mixer formula
- Install a pre-crusher and screen.
Conveyer belt transportation from crusher to storage of line I
- Dust generation at direction change points (from this conveyer to other conveyer)
- The bag filter efficient and has low capacity
- Not cover all conveyor belt at that point
- Replace by new bag filter ( bag house filter)
Raw material mill- Capacity lower than
design capacity- Material out put fine - Increase size of
material out put
Kilns
- Low inefficiency of kiln
- See the fish bone diagram - Modify lifting liner in
clinker cooler- Modify the capacity of
exhaust fan and suction fan so they are equal.
- Install auxiliary furnace for preheater
Compressor room
- Noise - Old compressor- Lack of noise
prevention facility
- Install noise protection box to cover individual compressors
- Build a separate operation room
- Oil leakage - Old compressors - Increase maintenance activities
- Replace to new compressors
Cement mill
- Lower capacity - Install a pre-griding system upstream of the existing ball mill.
Clinker Loading
- Dust generated when loading the clinker onto the truck.
- Existing dust collector’s capacity is too small.
- Dust suction pipe too small
- The cover of suction head is not inadequate
- Replace Electrostatic precipitator (EP) with bag house filter
- Change to higher capacity motor
- Replace suction pipe a with larger one
- Change the cover with one that has improved material and design
Un-loading material
Dust generated Raw material such as limestone, coal, clay... is transported and unloaded by truck. The unloading area is located near to company & has no cover to prevent dust from escaping.
Install a cover or warehouse.
Raw Materials
High water content in clay and coal.
Coal and clay are purchased from an outside source, thus the initial water content in the raw materials received at the factory cannot be controlled. On arrival at the factory raw materials are stock piled outside. In dry weather this stock piling is effective for drying, however in wet weather it is a problem.
- The water content of the clay and coal is high as they were stored outdoors. Installing a cover or warehouse to keep clay and coal dry could reduce the moisture content in wet weather and also reduce the sticking situation in the clay crusher.
Limestone Crusher
Dust generation from crushing limestone is high. This is affecting the health and safety of workers throughout the factory.
There is no cover over the crusher, thus as the limestone is being crushed, dust generated is easily dispersed throughout the factory.
- To reduce the dust generated from crushing limestone through the installation of a cover. Thus as the limestone is being crushed, dust generated is prevented from dispersing
Raw Materials Drier
The drier is not sufficiently reducing the water content in the raw materials.
The speed of the drier is not fast enough and the temperature is too high. The current temperature of the drier is 700-C, and the dried material is 96-105-C.
- Periodic maintenance of raw material drier.
Increased dust generation surrounding the drier.
The current conveyer belt is not covered and dust is generated during transportation.
Replace the open conveyer with a covered one from drier to silo to reduce dust.
Clay Silo
Clay is sticking to the wall of the silo. This causes blocks in the outlet of the clay silo and slows down production rates.
The moisture content of the clay is causing the clay to stick to the silo. This moisture content is due to the drier that is not drying the raw materials sufficiently. And the other factor causing sticking is the surface of silo, which enables the clay to stick easily.
Cover the silo with anti-sticking material such as Teflon. This option could prevent the clay from sticking to the wall of the silo.
Mixing Raw Materials
Dust generation is high Manual labour No appropriate machines were present in the factory for mixing the correct ratios of raw materials together.
- Install an additive mixing system in the raw materials preparation process to reduce dust generated, labour and improve the homogeneity of additives
Separator
The efficiency of separator is low. After milling the clinker, the cement was 60% fine and 40% coarse materials. However, it should be80% fine and 20% coarse materials.
The separator is too old and out of date, thus the efficiency is low.
Update the separator to increase the separation efficiency of cement mill.
Cement Silo
Cement sticks to the wall of the cement silo. This is reducing the quality of the cement; old cement may be lodged for a long time and then falls down. When the older cement joins fresher cement it reduces the quality.
This is due to excess water in the cement and the roughness of surface of the silo
- Cover the silo with anti-sticking material such as Teflon
Additive
The cost of gypsum is high. Currently iron ore and gypsum are being used as additives.
The company wants to reduce production costs, and so if they can identify a cheaper additive this would contribute to lowered production costs.
- Barite is a cheaper alternative to gypsum.
Cement Mill
Operation of cement millThe cement mill is not reaching its designed capacity. The time cement remains in the mill is too long, the electricity costs are too high and the overall production time is to long.
The design of the lifting liner does not crush the mix well enough. This is increasing the time cement remains in the mill, electricity costs and production time.
- Re-design the lifting liner of the milling machine to increase milling efficiency
Noise in Cement MillEmployees use the noise of the cement mill to indicate when the mill is empty. When the mill is empty it is noisier, therefore employees enter data into the computer and the conveyer belt starts feeding the mill quicker.
There is no computerised system for feeding the mill.
- Equip with a computerised system to control the feeding speed of milling machine
Clay Crusher
Low performance of clay crusher. Large amounts of clay get stuck inside the crusher, this sticking occurs between the metal pieces of the crusher. As the clay hardens and compacts, it bends and breaks the metal, which reduces the performance of the crusher.
1. Part of this problem is due to the moisture content of the clay, causing it to stick. 2. The second problem is due to the design of the clay crusher. The metal rings for crushing are to thin and bend easily when clay dries and compacts inside the crusher.
- Re-design the clay crusher to reduce the sticking of clay
Packaging area and cement loading
- Dust generation during packaging, transporting on conveyor belt, loading cement on ship truck on train
See fish bone diagram
- Periodic cleaning
- Modify the dust collection system at packaging machine
- Install 2 dust collector systems to collect dust on the cement bag surface at the delivery point on the conveyor belt
- Change bag design with out holes on the surface.
The various options generated were evaluated on the basis of technical, economic & environmental aspects
Chapter 6Findings, Suggestions &
Conclusion
Questionnaire
Evaluation matrix
Action plan
Conclusion…
By setting up a GP EMS team in the company, an awareness on the importance of green productivity was created.
This type of program is especially important in Walayar, which is experiencing an increase in urbanisation, and industrial activity that is in turn putting pressure on industries, such as the cement industry. Much of the technology and methodology used is out of date, and improvements need to be made so that the increase in production in this growing section does not have a harmful effect on the environment
Suggestions… Company should give more emphasis on
environmental protection activities
Some of the options that were not inclded in action plan because of a lack of funding, or resources may become more feasible and further options may also be incorporated using the management techniques and expertise introduced in the program.
Thankyou…