Ful A. Inf-4

8/8/2019 Ful A. Inf-4

http://slidepdf.com/reader/full/ful-a-inf-4 1/22

8/8/2019 Ful A. Inf-4


Functional Area Information

Every organization’s success depends upon the proper functioning

and co-ordination of its departments. This company is supposed to be one

of the best companies as far as departments functioning are concerned.

Management Process Consists of several function and distinction

should be maintained between management functions (Planning,

Organizing, Staffing, Directing, and Controlling) Organizational function

(Production, Marketing, finance, etc.)

The number and types of functional areas of management aredetermined by nature of the organization and the types of classifications of

various activities. U.K. Ministry of Education, in its reports on

‘Management Education’, has classified functional management areas intonine parts: Production, finance, development, distribution, purchasing,

transport, maintenance, personnel, and office. This classification is very

intensive. A more acceptable and practical classification includes four broad functional areas – Production, marketing, finance, and personnel.

These areas have their own organization, Policies, Procedures, and sub

activities.

In order to get a clear understanding of various AETs & SETs their

roles, areas, functions, we have defined them separately into five

important departments.

♦ Production Department

♦ Marketing Department

♦ Account Department

♦ Personnel & Administration Department

8/8/2019 Ful A. Inf-4


8/8/2019 Ful A. Inf-4


Production Department

Contents

Sr. Particulars Page

1. Introduction

2. Purchase Department

3. Material Management

4. Production Process

5. Quality Control

6. Technology

7. Product

8. Jetty

8/8/2019 Ful A. Inf-4


INTRODUCTION:

Sanghi Cement is engaged in manufacturing of Clinker

and Cement for dispatch to Domestic & International markets.

The raw materials are limestone from captive mine andother additives such as Iron Ore, Bauxite, High-grade limestone,

Gypsum and Fly ash procured f rom other sources . Other

products, which are purchased, are spares & consumables for the

maintenance of plant and machinery.

The manufacturing process for clinker consists of

crushing, grinding and preprocessing of raw materials . Thisclinker is either dispatched as product or further grinded to make

cement. Both the product s a re t es ted in quali ty control

department, with national and international standards.

These products are dispatched either by Road or Rail

and Seaway to destination specified by internal customer i.e.,

cement marketing divis ion. Clinker i s dispatched in bulk whereas the cement either in bulk or in bags.

Major portion of the land under plant and colony wasunproductive land without history of any industrial usage. The

leased land for the captive mine consists of both agriculture and

unproductive land.

This area is normally kept under the control of a production

manager who is responsible for the performances of entire relatedactivities. This are many further be classified into major sub activities.

8/8/2019 Ful A. Inf-4


PURCHASE DEPARTMENT:

Purchase department comes under purview of Production

Department. Purchase Department’s main area of work is to find thesuppliers of raw material and spare parts of machinery, then to negotiate

the prices and also to ensure the quality of material.

Purchase Department co-ordinates with the production department

in order to know the requirement of raw material to manufacture thedemanded item.

Process followed by the department:

1st Proper Communication with supplier

2nd Negotiation

3rd To form an Agreement

4th Follow up actions

Responsibility and Authority of HOS Purchase:

The HOS (PUR) shall be responsible for establishing,

implementing and maintaining the Instructions of Materials Department

related to Purchase activities, in line with the Quality Procedures andEnvironmental

The HOS (PUR) shall be responsible for procuring Materials andServices, as required by the user departments, in time, of the right quality,

at optimum cost and which are eco friendly.

8/8/2019 Ful A. Inf-4


Material Management:

This sub area deals with the storing of the materials, materialcontrol, and issue of material to department where these are needed. This

works in close Coordination with purchasing management.

Raw Material:

The area where the plant is located, is very rich in all the raw

materials required for the production of superior quality – high grade

cement. All the raw materials such as limestone, bauxite, laterite, lignite,

gypsum etc, are available with in a radius of 25-50 kms from the plant site.High quality, soft and chippable limestone is available in the mines

located just adjacent to plant. State-of-the-art surface miners, therefore

obviating the need for blasting & drilling thus making it the most eco-friendly, safe and cost effective way of procuring limestone, do the

mining. No wonder we have won national acclaim for our mining

activities.

This cement plant is the first in India to employ 100% lignite as

fuel, which is superior to coal in more ways than one Of course, it also

helps that the lignite mines are situated with in a radius of just 25 kms.

From the plant.

Even the other raw materials like laterite, bauxite, silica and clayare all available with in a small radius of 50 kms from the site.

8/8/2019 Ful A. Inf-4


WATER :

MED PLANT Multi Effect Desalination Plant

Sanghi cement has put up a multi-effect Desalination plant of 5500

m3 / day based on sea water for plant requirement as well as for supplying

potable water to near by villages. The unit exceed on the multi-effect

Distillation power utilizes the efficient horizontal tube, falling - film typeevaporator condensers. The principle is low temperature, vacuum multi

effect distillation.

Treated water is added with measured quantities of calcium

carbonate and sodium bicarbonate converts it to retable water with a total

dissolved solid (TDS) count around 225 to 250 ppm.

ELECTRICITY:

CAPTIVE POWER PLANT

A 45.33 Mw capacity power plant operated on residual fuel

(Heavy Furnace oil) is set up to meet uninterrupted power requirement.

The power plant is equipped with four Man B&W, 16MB 430 engines of

11.333 mw each.

Captive power is 50% cheaper than gird power. The ensures that

the power costs are considerably low. Add to this the efficient system andthe large scale of operation employed in the plant and what we get is the

lowest power consumption compared to any other plant in the country.

8/8/2019 Ful A. Inf-4


PRODUCTION PROCESS:

PROCESS MACHINE

LIMESTONE MINING MINE PLANT

CURSING CRUSHER

GRINDING RAW MILL

HOMOGENIZATION CF SILO

PRE-HEATING PRE-HEATER

BURNING KILN

COOLING COOLER

STORAGE + ADD GYPSUM CLINKER SILO

GRINDING CEMENT MILL

STORAGE CEMENT SILO

PACKAGE PACKAGING PLANT

DISPATCH DISPATCH MACHINE

(BY ROAD, RAIL OR SEA)

8/8/2019 Ful A. Inf-4


PROCESS WITH DESCRIPTION : Lime Stone stock pile:

The basic raw material for cement and clinker is limestone. Near about 90% of finished product is limestone. The requirement of limestone

is half more than finished product, means if 100-tones cement is to be

manufactured, than 150-tones limestone required.

Sanghi Cement has its own mine for limestone. The area where the

plant is located, is very rich in all the raw materials required for the

production of superior quality – high grade cement. All the raw materialssuch as limestone, bauxite, laterite, lignite, gypsum etc, are available with

in a radius of 25-50 kms from the plant site. High quality, soft and

chippable limestone is available in the mines located just adjacent to plant.State-of-the-art surface miners, therefore obviating the need for blasting &

drilling thus making it the most eco-friendly, safe and cost effective way

of procuring limestone, do the mining. No wonder we have won national

acclaim for our mining activities.

Sanghi Cement is first company, which is use cross Belt analyzer

in the India. All the limestone reaches to the plant through conveyor beltor trucks.

CRUSHER :

After mining the limestone it is crushed by Crusher. Crusher crushes the stone type limestone into powder form. Its capacity of

crushing is 950 tones per hour. Than it is collected and stocked as piles by

Dampers. In the store, the crushed stone is stacked in several layers by the

Stacker, so that a variation in quality of incoming limestone is equalized.

8/8/2019 Ful A. Inf-4


Grinding:

The machine, which grinds the raw material, is calledRAW MILL. That converts raw material into powder form by grinding it.

Crushed limestone, shale & hematite are fed in the required proportion to

the raw grinding unit.

Sanghi Cement has world’s largest vertical roller mill.

Homogenization:

In this stage mixed powder from raw mill transfers to CF Silo,

where some additives are added to mixture. Here drying process of raw

material is also carried out, because the basic raw material contains somemoisture.

Preheating & Calcinations:

Before moving the mixture to Kiln, the powder must obtain some

temperature. Pre-heater performs that task. Calcinations is defined asremoving of carbon-di-oxide and other organic matters from the raw

material. The process of calcinations before Kiln reduces the thermal load

in the rotary Kiln. The advantage of this system is that the Kiln capacityincreases by 2-2.5 times.

Sanghi Cement has world’s largest pre-heater plan, (148 meter)and also world’s largest kiln (80.6 meter).

8/8/2019 Ful A. Inf-4


Burning:

The pre-calcined raw material is fed into the rotary kiln and coal is

fired at a temperature of 1600-1800 degree centigrade on the other end.

Here after burning process the powder form is transferred into small stonetype form, which is called Clinker.

This cement plant is the first in India to employ 100% lignite as

fuel, which is superior to coal in more ways than one Of course, it also

helps that the lignite mines are situated with in a radius of just 25 kms.From the plant.

Sanghi cement is one and only company in the country, which isuse lignite as fuel in production process. Cooling:

The clinker is cooled in cooler, because it is very hot after passing

though a very high temperature. There are three high power fans, which

reduces the temperature of the clinker. Cooler brings down thetemperature of clinker from 1200 centigrade to 200 centigrade.

Store: Clinker is stored in the Clinker Silo. For converting it into cement,

gypsum is mixed and grinded further in grinding process.

Sanghi Cement has world’s largest raw mill silo. Its capacity is

40,000 tones.

Grinding: In this stage raw material is passed to Cement Mill, where the

clinker and gypsum are mixed and grinded to make powder form. Here

some needed chemical are also added to mixture. This gray mixture iscalled “cement.”

8/8/2019 Ful A. Inf-4


Storage:

Cement is stored in Cement Silo in powder form before packing.

From cement silo, needed quantity is taken for packing, while the bulk

quantity without packing is goes to Jetty though conveyer belt.

Packing:

Packing plant for packing of cement in bags is located in the plant

itself. There are four numbers of electronic packers supplied by Enexco,

and the capacity of each is 120 MT/Hr. the electronic packing machinesare having eight spouts each. Cement is extracted from the silos through

extraction system, which is equipped with air slides, solenoid valves and

dozing valves and fed to the packer hoppers through screens. The packersare designed for packing 50 kg cement per bag.

Dispatch:

After packing, cement is dispatched to various locations through

road, rail or sea. Here cement is loaded in truck by machine automatically.

There is provision for bulk loading of cement and clinker into the

ships with a capacity of the single loading system at 1000 TPH. The filled

cement bags shall also be transported to trucks and through ships by

means of belt conveyor, diverting gates and chutes.

8/8/2019 Ful A. Inf-4


QUALITY CONTROL:

The Company

Have dedicated team of quality control department with 18 persons withan average experience of 11years. The number includes two experts with

Ph D in Cement technology.

Sanghi Cement holds Customer Satisfaction central to their

business. They are committed to this satisfaction through continuous

improvement of all key processes in operation.

Sanghi Cement posses latest equipment of fourth generation

instrumental techniques, as described bellow, resulting in reduced sampleanalysis time with accurate results

Cross belt analyzer (Gamma Matrix): for online elemental raw

material analysis.

Raw mix Proportioning Package: for the close loop optimization

of the product in order to produce the required kiln feed with consistent

material composition.

Auto Sampling System: for automatically collecting samples at

regular intervals at all stages of manufacturing.

Robo Lab: for accurate analysis without human error

X-Ray analyzer: is a fluorescence spectrometer for simultaneousquantitative determination of elements in raw materials, raw mill, Kiln

feed, hot meal, clinker and cement.

Particle size Analyzer: to measure the size of all particles as well

as particle distribution in raw meal, powder lignite and cement.

Physical and Chemical Labs: to test Setting time, Fineness,

Compressive Strength, Expansion, Normal Consistency.

8/8/2019 Ful A. Inf-4


POLLUTION CONTROL MEASURES:

Sanghi cement is equipped with state of the art pollution control

equipment and technology to control pollution.

Combination of bag-filters and ESP's are being used for efficient

and effective control of pollution. Dedusting bag filters are installed in all

transfer points of conveyors to make the site totally pollution free

complex. The Electro static precipitator is 99.9% efficient, while main plenum pulse bag filter is 99.99% efficient. By the use of such equipments

the dust emission levels are be restricted to less than 50 mg/Nm3, though

the State and central Pollution Control Board permit a dustloading of 150mg /Nm3.

Dedusting bag filters are provided right from clinker stock pile atgrinding unit to berthing jetty at various points to take care of dust

nuisance. Out of which one jet pulse bag filter is provided at clinker

hopper trough and one jet pulse bag filter near clinker stockpile, three

numbers of insertible bag filters are for clinker transport system fromstock pile to cement mill feeding clinker hopper. Nine numbers of jet

pulse bag filters single compartment, are provided with each cement mill

circuit at various discharge points. Three bag filters are provided in thesingle compartment silo. Similarly, six numbers jet pulse bag filters are

provided in the multi-compartment silo for venting and to control dust

nuisance. One jet pulse bag filter is given in screening plant. One bag filter is also given at berthing jetty and provision for one jet pulse bag filter is

kept at one transfer point.

The local environmental and pollution control norms are met

thorough periodic monitoring of surroundings with the help of pollution

control and monitoring equipments. A green belt is be developed in and

around plant. There is no effluent generated from the facility. As there isno chemical process involved in the operation at jetty, there will not be

any hazardous pollutants like NOx & SOx present.

8/8/2019 Ful A. Inf-4


DETAILS OF AIR POLLUTION CONTROL DEVICES

SL.

NO.ATTACHED TO NAME OF EQUIPMENT NO

EFFICIENCY

%

STACK

HEIGHT

(MTS)

1 Lime stone crusher Dedusting nuisance bag filter 1 99.9 NA

Stacker & Reclaimer 2

2 Additive crusher Dedusting nuisance bag filter 4 99.9 NA

Stacker & Reclaimer

3 Raw material grinding Bag house 1 99.99 125

Dedusting nuisance bag filter 11 99.9

4 Clinkerisation

a Cooler ESP 1 98.0 52.5

b Alkali Bypass ESP 1 98.0 75

5 Lignite grinding Bag filter Plennum pulse 2 99.957.3 (2 Nos.)

Dedusting nuisance bag filter 3 99.9 NA

6 Lignite crusher Dedusting nuisance bag filter 7 99.9 NAstacker & reclaimer

7 Clinker transport Dedusting nuisance bag filter 7 99.9 NA

8 Clinker transport - jetty Dedusting nuisance bag filter 9 99.9 NA

8/8/2019 Ful A. Inf-4


TECHNOLOGY:

The improvement in productivity with respect to rate of

production, energy consumption and product quality could be achievedthrough possession of modern technology and Sanghi Cement is well

equipped in this regard the principal components being as under:

♦ Mines Management System.

♦ EV crusher of FL Smith & Co makes.

♦ Limestone stacker and Reel aimer of 1200 tph capacity.

♦ Limestone stockpile and additives stockpile.

♦ Lignite Stacker and reclaimer.

♦ Vertical roller mill if 670-tph capacity, Fuller -Loesche make, one

of world's biggest.

♦ 2 lignite mills of 37.5 TPH of Fuller-Loesche.

♦ Controlled flow site of FL Smith & Co.

♦ 7500 TPD Rotary kiln, largest in Asia, of Fuller International.

♦ A central control Room with latest process control equipment

Supplied by F.L.S. automation, Robo labs.

8/8/2019 Ful A. Inf-4


PRODUCTS: The Company sells OPC Grade 53 cement, which is most

common cement. It is super fine cement used in structure and concreting.Minimum strength of Grade 53 cement is 53 MPa.

OPC GRADE 53

CHARACTERISTICS UNIT REQUIREMENT (AS PER IS:269-1989)

PHYSICAL REQUIREMENTS

Fineness: Specific Surface M2/Kg Min 225.00

Soundness:

a) Lechatelier Method b) Autoclave Method

MM%

Max 10.000.80

Setting Time:a) Initial Set

b) Final Set

Minute

Minute

Min 30.00

Max 600.0

Compressive Strength:a) 3 Days

b) 7 Days

c) 28 DaysTemp.during testing

MPaMPa

MPa0c

Min 33.00Min 43.00

Min 25.00Min 29.00

Chemical Requirements

Lime Saturation Factor (LSF) RatioMin 0.66

Min 1.02

Alumina Iron Ratio

Insoluble Residue

Ratio

%

Min 0.66

Max 4.00

Magnesia % Min 6.00

Sulphuric Anhydride % Max 3.00

Loss on Ignition % Max 5.00

Alkalies % Max 0.60

Chlorides % Max 0.10

8/8/2019 Ful A. Inf-4


The Cement Features:

1. Low Tri calcium Aluminate (C3A):

The Sanghi cement consists low amount C3A content ranging 6-7 percent of mineral formation. The C3A is one of the main minerals formedduring the cement hardening and has negligible affect on strength and

other performance requirements. But, the increased percentage of C3A

above 8, the concrete thus produced is easily affected to sulphates andchlorides that are present in marine environment, ground water, or active

soils consisting above substance in predominant proportion.

In general most Ordinary Portland Cements consist C3A more than

8 and some times up to 10 percent, and increases the vulnerability of

sulphate attack. The advantage of low C3A content enables the Sanghi

cement can increase the durability up to two times in comparison to other OPC cements.

2. Adequate Fineness Of Cement:

8/8/2019 Ful A. Inf-4


Sanghi Cement produced with a minimum fineness of 300 Sq.M/

Kg. This enables the concrete mix designer to easily design general as

well as high performance concrete with a workability requirement up to200 mm slump with good cohesiveness and low permeable concrete. The

additional fineness helps to make cohesive mortars and better surface

finishing is possible in plasters. The additional fineness provides results insavings in mortars and painting costs.

3. Low Heat Of Hydration:

The Sanghi cement produces very low heat of hydration of 312KJ/Kg, the limit is much below 314 KJ/ Kg at 28 days for low heat

Portland cement IS 12600. Thus there will be no chance of occurrence of

cracks due to shrinkage and other vulnerable problems due to high heat of hydration.

4. Low Chloride content:

The Sanghi Cement consists the chloride content much less than0.05% to total mass. Thus more friendly material for protection of rebar and enables durability of not only concrete but also reinforcement, thus

enhancing durability beyond normal lifetime.

5. High Strength Development At All Ages:

The strength development curve of Sanghi cement is much above

the requirements of BIS for 53-grade cement. This enhances speedy

construction. Another advantage of high strength development is the

concrete produced can perform well even if there are some inconsistencieshappened during batching, mixing and placing of concrete etc.

8/8/2019 Ful A. Inf-4


CAPTIVE JETTY:

The facility has a captive jetty at Kharo creek, leading to the

Arabian Sea. As the area is desert and free from monsoons and as the jetty is in a creek and not on high seas, it is capable of all weather

operations.

The jetty is fitted with Combi-loaders of technology from

SMB Germany, capable of loading ships with bulk cement or clinker. A feed belt with maximum capacity of 2000 TPH and

loaders of 125 TPH capacity are installed for loading of bagged

cement. The facility's terminal allows access to local and exportsmarkets. While Europe has more than 150 such terminals and the Far

East has about 40, India has none.

A ship loader carries out loading of cement and clinker intothe ships through a long conveyer belt, which connects the plant to

the jetty. High speed of loading of clinker, bulk and bagged cement

ensures a high turn around time for the ships.

This is the first clean technology cement loading jetty of country.

8/8/2019 Ful A. Inf-4


Jetty Features:

• CAPABLE OF HANDLING SHIPS UPTO 45000 DWT

• SINGLE CONVEYOR FOR HANDLING CLINKER, BULK CEMENT,

BAG CEMENT AND COAL.

• DIRECT AUTOMATIC FEEDING FROM STORAGES INTO SHIPS

• CENTRALISED OPERATIONS FROM CONTROL ROOM

• CLOSED SYSTEM ENSURING CLEAN OPERATIONS

Ful A. Inf-4

Documents

Transcript of Ful A. Inf-4