8/12/2019 PM Overview IBM Proj Team
1/17
deeper
IBM Global Services India, Business Consulting Services
2003 IBM Corporation
Updated May 2003
2003 IBM Corporation
Updated July 2005
Overview - IBM TeamCement Manufacturing & Maintenance Processes
Grasim Cements . . .
8/12/2019 PM Overview IBM Proj Team
2/17
IBM Global Services India, Business Consulting Services
2003 IBM Corporation
Updated July 2005Grasim Cements On the ERP Way2
Overview : History of Cement Manufacturing &Maintenance Processes
8/12/2019 PM Overview IBM Proj Team
3/17
IBM Global Services India, Business Consulting Services
2003 IBM Corporation
Updated July 2005Grasim Cements On the ERP Way3
In 1824, Joseph Aspdin, a British stone mason, obtained a patent for a
Cement he produced in his kitchen. The inventor heated a mixture of
finely ground limestone and clay in his kitchen stove and ground the
mixture into a powder to create a hydraulic Cement - one that hardens
with the addition of water. Aspdin named the product Portland Cement
because it resembled a stone quarried on the Isle of Portland off the
British Coast. With this invention, Aspdin laid the foundation for today'sPortland Cement industry.
HISTORY OF CEMENT
8/12/2019 PM Overview IBM Proj Team
4/17
IBM Global Services India, Business Consulting Services
2003 IBM Corporation
Updated July 2005Grasim Cements On the ERP Way4
Portland Cement, is a calcium silicate Cement made with a combination
of calcium, silicon, aluminum, and iron.
The first step is obtaining Raw Materialsconsisting of combinations of
limestone, shells or chalk, and shale, clay, sand, or iron orefrom a
quarry.
At the quarry, the Raw Materials are reduced by primary and secondary
crushers. Mountains of rock are fed through Crushers capable of
handling pieces as large as an oil drum. The first crushing reduces the
rock to a maximum size of about 6 inches. The rock then goes to
secondary crushers or Hammer Mills for reduction to about 3 inches or
smaller.
Once the Raw Materials arrive at the Cement Plant, they are
proportioned with additives to create a Cement with a specific chemical
composition and property.
HOW PORTLAND CEMENT IS MADE
8/12/2019 PM Overview IBM Proj Team
5/17
IBM Global Services India, Business Consulting Services
2003 IBM Corporation
Updated July 2005Grasim Cements On the ERP Way5
Producing a Cement that meets specific chemical and physical
specifications requires careful control of the Manufacturing Process.
The Dry Process: Dry, crushed Raw Materials are proportioned, ground
to a powder, blended together and made ready to be used in a dry state.
The Wet Process: Here, the Raw Materials, properly proportioned, arethen ground with water and thoroughly mixed in the form of a "slurry"
(containing enough water to make it fluid). The grinding and blending
operations are then completed with the materials in slurry form.
The next steps of both the Processes are essentially alike. . . .
THE TWO METHODS OF MAKING CEMENT - 1
8/12/2019 PM Overview IBM Proj Team
6/17
IBM Global Services India, Business Consulting Services
2003 IBM Corporation
Updated July 2005Grasim Cements On the ERP Way6
The next steps of both the Processes are essentially alike :
The blended mixture of Raw Materials is fed into the upper end of a
tilted, rotating, cylindrical Kiln. The mixture passes through the Kiln at a
rate controlled by the slope and rotational speed of the Kiln. Burning
fuel consisting of powdered coal or natural gas, that is forced into the
lower end of the Kiln. Inside the Kiln, raw materials reach temperatures
of 2600F to 3000F (1430C to 1650C). At this temperature, a seriesof chemical reactions cause the materials to fuse and become Cement
Clinker- grayish-black pellets, often the size of marbles.
Clinker is discharged red-hot from the lower end of the Kiln and
transferred to various types of Coolers to lower the Clinker to handling
temperatures.
Cooled Clinker is combined with Gypsum and ground into a fine gray
powder. The clinker is ground so fine that nearly all of it passes through
a No. 200 mesh (75 micron) sieve. This fine gray powder is known as
Portland Cement.
THE TWO METHODS OF MAKING CEMENT - 2
8/12/2019 PM Overview IBM Proj Team
7/17
IBM Global Services India, Business Consulting Services
2003 IBM Corporation
Updated July 2005Grasim Cements On the ERP Way7
Different typ es of Port land Cement are manufactured to meet var ious
phys ical and chemical requirements. The Am erican Society for Test ing and
Materials (ASTM) Specif icat ion C-150 pro vides for eigh t types of Port land
Cement :
Type I Portland Cementis a normal, general-purpose cement suitable for all
uses. It is used in general construction projects such as buildings, bridges,
floors, pavements, and other pre-cast concrete products.
Type IA PortlandCement is similar to Type I with the addition of air-
entraining properties.
Type II Portland Cementgenerates less heat at a slower rate and has a
moderate resistance to sulfate attack.
Type IIA Portland Cementis identical to Type II and produces air-entrained
concrete.
TYPES OF PORTLAND CEMENT - 1
8/12/2019 PM Overview IBM Proj Team
8/17
IBM Global Services India, Business Consulting Services
2003 IBM Corporation
Updated July 2005Grasim Cements On the ERP Way8
Type III Portland Cementis a high-early-strength cement and causes
concrete to set and gain strength rapidly. Type III is chemically andphysically similar to Type I, except that its particles have been ground finer.
Type IIIA Portland Cementis an air-entraining, high-early-strength cement.
Type IV Portland Cementhas a low heat of hydration and develops strength
at a slower rate than other cement types, making it ideal for use in dams and
other massive concrete structures where there is little chance for heat to
escape.
Type V Portland Cementis used only in concrete structures that will be
exposed to severe sulfate action, principally where concrete is exposed to
soil and groundwater with a high sulfate content.
TYPES OF PORTLAND CEMENT - 2
8/12/2019 PM Overview IBM Proj Team
9/17
IBM Global Services India, Business Consulting Services
2003 IBM Corporation
Updated July 2005Grasim Cements On the ERP Way9
In addition to the eight types of Portland cement, a number of special
purpose hydraulic cements are manufactured :
White Portland Cement-This is identical to gray Portland cement except in
color. During the manufacturing process, manufacturers select raw
materials that contain only negligible amounts of iron and magnesium
oxides, the substances that give gray cement its color. White cement is used
whenever architectural considerations specify white or colored concrete or
mortar.Blended Hydraulic Cements-These cements are produced by intimately
blending two or more types of cementitious material. Primary blending
materials are Portland cement, ground granulated blast-furnace slag, fly ash,
natural pozzolans, and silica fume. These cements are commonly used in
the same manner as Portland cements.
Expansive Cements-Expansive cements are hydraulic cements that expandslightly during the early hardening period after setting.They are used to
make shrinkage-compensating concrete that is used e.g. to compensate for
volume decrease due to drying shrinkage, or to induce tensile stress in
reinforcement, and (3) to stabilize long-term dimensions of post-tensioned
concrete structures.
TYPES OF PORTLAND CEMENT - 3
8/12/2019 PM Overview IBM Proj Team
10/17
IBM Global Services India, Business Consulting Services
2003 IBM Corporation
Updated July 2005Grasim Cements On the ERP Way10
CEMENT MFG. PROCESS - AN OVERVIEW1. Quarrying
2. Raw Grinding and Burning
3. Grinding, Storage, Packing and Dispatch
THE CEMENET MANUFACTURING PROCESS
8/12/2019 PM Overview IBM Proj Team
11/17
IBM Global Services India, Business Consulting Services
2003 IBM Corporation
Updated July 2005Grasim Cements On the ERP Way11
Plant Maintenance
THE CEMENET MANUFACTURING PROCESS
1.BLASTING : The raw materials that are used to manufacture Cement (mainlyLimestoneand Clay) are
blasted from the Quarry. The raw materials are loaded into a Dumper.
Quarry face
2. CRUSHING 3. TRANSPORT &
STORAGE
2. CRUSHING :The raw materials are crushed in Crusher Mills.
Quarry Management
3. TRANSPORT & STORAGE :After Crushing, it is transported to the Plant by Conveyors.The Plant stores the
materials before they are homogenized for further processing.
Crusher
Conveyor
Next
Dumper
Storage at
the Plant
Loader1. BLASTING
8/12/2019 PM Overview IBM Proj Team
12/17
IBM Global Services India, Business Consulting Services
2003 IBM Corporation
Updated July 2005Grasim Cements On the ERP Way12
Plant Maintenance
THE CEMENET MANUFACTURING PROCESS
1. RAW MILL GRINDING : The raw materials are very finely ground in order to produce the Raw Mix.
1. RAW MILL GRINDING
Raw Grinding and Burning
2. BURNING
2. BURNING : The Raw Mix is preheated before it goes into the Kiln, which is heated by a flame that
can be as hot as 2000 C. The Raw Mix burns at 1500 C producing Clinkerwhich, when it leaves the
Kiln, is rapidly cooled with air fans. So, the Raw Mix is burnt to produce Clinker : the basic material
needed to make Cement.
Conveyor
Next
Raw Mix
Kiln
Cooling
Back
Preheating
Clinker
Storage atthe Plant Raw Mill
8/12/2019 PM Overview IBM Proj Team
13/17
IBM Global Services India, Business Consulting Services
2003 IBM Corporation
Updated July 2005Grasim Cements On the ERP Way13
Plant Maintenance
THE CEMENET MANUFACTURING PROCESS
1.GRINDING : The Clinker and the Gypsum are very finelyground, giving a Pure Cement. Other secondary
additivesand Cementitiousmaterials can also be added to make a Blended Cement.
1. GRINDING
Grinding, Storage, Packing, Dispatch
2. STORAGE, PACKING, DISPATCH :The Cement is stored in Silosbefore being dispatched either in
bulk or in bags to its final destination.Back
Clinker
Storage
Gypsum and the secondary additives are addedto the clinker.
silos
Home page
dispatch
bags
Finish grinding
2.STORAGE,PACKING & DISPATCH
8/12/2019 PM Overview IBM Proj Team
14/17
IBM Global Services India, Business Consulting Services
2003 IBM Corporation
Updated July 2005Grasim Cements On the ERP Way14
CEMENT PLANT MAINTENANCE - AN OVERVIEW
Cement Plants - Manufacturing Business Functions :
1. Quarry / Mining Activities
2. Clinker Manufacturing
3. Cement Manufacturing
4. Storage in Silos
5. Bagging Plant Activities
6. FG Storage and Dispatch
THE CEMENT PLANT MAINTENANCE PROCESS
8/12/2019 PM Overview IBM Proj Team
15/17
IBM Global Services India, Business Consulting Services
2003 IBM Corporation
Updated July 2005Grasim Cements On the ERP Way15
It is now obvious that a large Process of Cement Manufacturing will require a
variety of high-tech Equipment that become Maintenance Objects in CementPlants. Some are detailed below :
1. Quarry Equipments:
- Mobile Equipment like Excavators, Dumpers and Loaders
- Crushing Plants
- Blasting, Test & Safety Equipments- Conveyors
2. Clinker Manufacturing Plant Equipments:
- Conveyors
- Raw Mill Grinders
- Pre-heating Equipments- Rotary Kiln/s
- Coolers
- Flue-gas Recovery Equipment
- Pollution Control Equipment / Systems
THE CEMENT PLANT MAINTENANCE PROCESS
8/12/2019 PM Overview IBM Proj Team
16/17
IBM Global Services India, Business Consulting Services
2003 IBM Corporation
Updated July 2005Grasim Cements On the ERP Way16
Details of Maintenance Objects in Cement Plants (contd.) :
3. Cement Manufacturing Equipments
- Pre-Grinding Equipments
- Finish Grinding Equipments
- Pollution Control Equipment / Systems
4. Silo Storage Equipment for Cement
5. Bagging Plant Equipment
6. FG Bags Storage, Loading & Dispatch Equipments
7. Office & Laboratory Equipments
8. Material Handling, Maintenance & Repair Equipments
9 Transport Equipments like Cars,etc.
10. Residential Colony Maintenance
THE CEMENT PLANT MAINTENANCE PROCESS
8/12/2019 PM Overview IBM Proj Team
17/17
IBM Global Services India, Business Consulting Services
2003 IBM CorporationGrasim Cements On the ERP Way17
A cement Plant is, in some areas, a continuous Process Plant, like the
Clinker Manufacturing and the Cement Manufacturing sections. Thisobviously then demands sophisticated Maintenance & Planning Processes
to support the round-the-year Operational requirements. It also deprives the
maintenance man the luxury of laxity, in any area of his function.
Maintenance Processes in Cement Plants:
1) Management of Technical Objects in The Plant
2) Breakdown / Reactive Maintenance
3) Annual Shut down Planning
4) Preventive Maintenance
5) Calibration of Systems
6) Reporting of Maintenance Data & Analysis
THE CEMENT PLANT MAINTENANCE PROCESS
Top Related