Pictorial Depiction of Plants

Pictorial Depiction of Plants We recently made visits to various cement plants and project sites across the country. For better and easy understanding of investors of the cement manufacturing process / distribution process etc., in this document we have made a brief pictorial depiction of cement plants and their functioning.

Mining Process at Limestone Mines ............................................................................................................. 2

Cement Manufacturing Process ................................................................................................................... 7

Packing / Distribution Mechanism of Cement Plants .................................................................................. 12

Fuels and Fly‐ash Storage / Samples at Site ................................................................................................. 15

Overview of Captive Power Plants ............................................................................................................... 16

Overview of Control Rooms / Laboratories of a Plant ................................................................................. 17

Initiatives at Labs / Other Promotional Initiatives ....................................................................................... 18

Water Treatment Plant for Demineralisation .............................................................................................. 19

Some Safety Initiatives / Preventive Measures at Site ................................................................................ 20

Accolades / Specifications / Other Initiatives at Site ................................................................................... 21

Some Under Construction Project Sites ....................................................................................................... 22

Bird’s Eye View of Various Cement Plants ................................................................................................... 23

Vaibhav Agarwal

28 January 2013 / INDIA EQUITY RESEARCH / PICTORIAL DEPICTION / CEMENT SECTOR

Mining Process at Limestone Mines

Mine model of a limestone mine at display at Mine’s office View point of mines nearby to a cement plant

View of limestone mine benches from view point Rain water (Natural) reservoirs in the used portion of mines

Potential size of reservoir at a reasonably exhausted mine Drillers used at a mine for digging holes for blasting

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A hole drilled and now ready to be charged for a blast Explosives / materials required to charge a hole for a blast

Controls and detonators for blasting Specifications of shock tube detonator used for charging

Specifications of in‐hole delay detonator used at blast site Precautions mentioned on explosive used while charging holes

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Manual hole charging at blast site (18th hole which is being charged at this site). A blast site has multiple charged holes like this.

Front / rear view of safety hut located at safe distance from blast site (made of iron rods ensuring safety while triggering blast)

A charged blast site of 18 holes now ready for a blast Sirens at mines ‐ blown to alert and make people stay away

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Freshly blasted limestone mine site (Minutes after the blast has been triggered)

Weak cracks developed on surface adjacent to blast site Limestone ready to get crushed in a crusher

Remains of explosives / materials used for charging holes at blast site after the blast

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Excavator at work at a limestone mine Dumper used to transport limestone to crusher

An excavator loading a dumper with limestone at a mine View of dumper movement at mines from view point

Inlet of a crusher Overview of a crusher

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Cement Manufacturing Process

Dumpers unloading limestone at a limestone crusher inlet. Crushers are located nearby to the mines itself in most cases.

View of a filled inlet of a crusher High‐grade limestone (Sweetener) used as an optional additive

Limestone used for white cement manually loaded in trucks Movement of limestone inside a crusher

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Conveyor belts used to transport crushed limestone to plant Conveyor belts to throw away rejections in material (If any)

Stacker and Reclaimer used to create stock piles of crushed limestone which is then used in raw meal

Creation of harmonised limestone stock pile in a roofed circular limestone blending bed (covered) / Similar piles are made of rawmeal as well after adding the necessary additives like red ochre, high grade limestone (Sweetener), etc., as per requirements

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Vertical Raw meal Mill (VRM) to grind raw meal at plant Inlet section of grey clinker Kiln at site

Mechanism of inlet section of white clinker Kiln at site View of an operational Kiln through window (~1400 Degree C.)

Under maintenance section of a Kiln with used refractory One of the older Kilns at a cement plant

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Kilns used at some of the newer production lines with technology improvements

Freshly made, burning and hot clinker rolling out from Kiln outlet to coolers (to get cooled to ~100 degrees) before it is stored

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Grinding mill section of a cement plant Fly ash being sucked out from tankers in silos near grinders

Grinding mill of a grey cement plant (Left) and grinding mill of a white cement plant (Right) to grind clinker, gypsum (OPC) and fly ash / slag (only, in case of blended grey cement)

Grinding media used in grinders Refractory storage at a cement plant

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Packing / Distribution Mechanism of Cement Plants

Packing plant – Packers filling empty 50 Kgs bag with cement Manual loading of empty bags to packers at packing plant

Bags get dispensed automatically with a cut‐off of 50 Kgs Bags rolling out on to conveyor belts and then trucks

Bulk cement orders may be disbursed in bulkers directly Automated printer panel on conveyor belts to print prices before bags are disbursed

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Stamps (Manual stamping) still used at few packing plants Price panel at packing plant to assist packers with right prices

Trucks queued up at packing plant waiting to get loaded Display for trucks to assist in loading at packing plant

Automated truck loader loading a truck at packing plant Outlet of an automated loader used at packing plant

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Automated wagon loader at rail yard to load bagged cement Main rail line connection to railway yard of a cement plant

View of railway yard of some cement plants in the country. Loading in some cases is automated while the rest is still manual.

Rail lines waiting to be installed at one of the recently commissioned brand new cement plants in the country

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Fuels and Fly‐ash Storage / Samples at Site

Coal storage facilities at some of the cement plants. The fuel might be imported or indigenous.

Open storage of pet coke at one of the white cement plants Open storage of fly‐ash at a cement plant

Pet coke (left) and coal Fly ash

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Overview of Captive Power Plants

Thermal Captive Power Plant (CPP) at a cement site Waste Heat Recovery Power Plant at a cement site

Process flow chart of CPP at one of the thermal plants Turbines of a thermal CPP

Specifications of a thermal CPP at a cement plant Manufacturer tag of one of the steam turbines

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Overview of Control Rooms / Laboratories of a Plant

Display screen of a control unit of CPP Control room of a cement plant

Screen of cement manufacturing process in control room Display screens monitoring Kiln/Cooler systems (Control Room)

Product samples of raw materials, finished products etc. kept at Laboratories and Control Rooms of few cement plants

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Initiatives at Labs / Other Promotional Initiatives

Block of white cement used to check whiteness / purity Machine used to test whiteness / purity of white cement

Tokens in cement bags entitling masons for monetary incentives (left) and value added product laboratory at white cement plant

Live test of surface smoothness on application / non‐application of putty on walls and indicative designs post putty application

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Water Treatment Plant for Demineralisation

Demineralisation water treatment plant Analysis report of a water treatment plant on display at site

Inside view of a water treatment plant and storage tanks for demineralised water in vicinity of such treatment plants

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Some Safety Initiatives / Preventive Measures at Site

Safety signals displayed in outskirts of mining site (Left) & within mines to ensure high safety standards in dangerous operations

Safety initiatives at one of the cement plants Precautionary safety measures displayed at a cement plant

Various safety instructions on display at cement plant to ensure risk‐free and safe operations

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Accolades / Specifications / Other Initiatives at Site

On display: Recognition received for executing power project in record time (Left) and daily production and despatches at a site

Detailed specifications of a Vertical Raw meal Mill and Kiln on display at cement plants

Signboards and display of information can be seen in various sections of plant emphasizing the importance of time and process

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Some Under Construction Project Sites

Signboard to one of the large under construction project sites Safety instructions on display at under construction site

View of a large under construction site (Greenfield) View of a Brownfield expansion site

Putty capacity expansion in progress at a white cement plant Progress display on Notice Board at Office of a cement plant

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Bird’s Eye View of Various Cement Plants

Only site in World with 6 clinker lines in one location Under construction 7th clinker line at the same site

View of a grey cement plant View of a white cement plant

A brand new grey cement plant Aerial view of a grey cement plant

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Pictorial Depiction of Plants

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