Professional Documents
Culture Documents
Project
Plan
Actual
Start Date
4 April2016
4 April2016
Completion
Date
30 Oct2016
1
ACC/ Plant name
2016
Description
Name
Designation
Dept
Project Leader
Anil Kumar
Sr. Analyst
Quality
anilk.kumar@acclimited.com
Mentor
Ramesh Kumar
Gupta
Chief Manager
Quality
Ramesh.gupta@acclimited.com
Member 1
Deepak Jasuja
GM Production
Production
Deepak.jasuja@acclimited.com
Member 2
Ashok Kumar
Dwivedi
Manager
Quality
Ashokkumar.dwivedi@acclimit
ed.com
Member 3
Shaikh Abdul
hamid
Asst.Manager
Quality
Shaikh.hamid@acclimited.com
Member 4
Saurabh Srivastava
Production
Manager
P&QC
saurabhsrivastava@asianceme
nts.com
Member 5
Hunar Singh
Sr.Analyst
P&QC
Hunar.singh@asiancements.co
m
3
4
5
2
ACC/ Plant name
2016
3
ACC/ Plant name
2016
4
ACC/ Plant name
2016
At present, We are using High Purity Imported Gypsum at Asian Cements due to
which we are facing less mill availability due to shortage of fly-ash in 2015 (500
hrs), hence it is considered that during less fly ash availability, usage of Low Purity
gypsum will be beneficial as it helps to reduce clinker factor as well as increase
productivity.
a)
a)
Present Level:
Target:
2016
16,918
27.29
12,011,780
710
61,996
194
Imported Gyp
2,116
3.41
5,634,908
2,663
61,996
91
Clinker
42,962
69.30
143,922,700
3,350
61,996
2,321
Total
61,996.00 100.00
161,569,388
2,606
Year
Target :Cost Analysis For PPC Cement (With Low Purity Gypsum)
Asian
%
Consum
Rate/Cemen
Qty
ption
Amount
Rate
Cement t
Flyash
Low Purity
Gypsum
16,918
27.29
12,011,780
710
61,996
194
3,410
5.50
6,734,316
1,975
61,996
109
Clinker
41,668
67.21
139,588,537
3,350
61,996
2,252
Total
61,996.00 100.00
158,334,633
2,554
6
2016
Gypsum Consumption %
By using Low Purity
gypsum
2016
% Clinker Factor
By using Low Purity
Gypsum
8
2016
9
ACC/ Plant name
2016
2. Observation
Cement Mill Circuit block Diagram
Clinker
RC Fan
Gypsum
Fly-Ash
Bag Filter
Separator
Cyclone
Elevator
Hammer
Crusher
Weigh
Feeders
Grinding Mill
Bag Filter
PG
Conveyor
Fly mixing at
mill outlet
2016
2. Observation
Imported Gypsum Sieve Analysis
Sive Size in
mm
88.9
Wt.
% Residue
2.12
7.61
% Cum
Residue
7.61
76.2
1.89
6.78
14.39
85.61
63.5
2.76
9.90
24.29
75.71
50.8
6.27
22.50
46.79
53.21
38.1
1.92
6.89
53.67
46.33
25.4
3.12
11.19
64.87
35.13
19.05
0.22
0.79
65.66
34.34
12.7
2.23
8.00
73.66
26.34
6.35
1.23
4.41
78.07
21.93
3.18
0.912
3.27
81.34
18.66
5.2
18.66
100.00
27.87
100.00
% Passing
92.39
1.
2.
3.
2016
2. Observation
Low Productivity Due To Pet Coke Clinker
Asian-1
Month
Jan-15
Asian-2
TPH
12644
44.73
314.2
47017
149.64
2.
TPH
Feb-15
117
5224
44.65
337.95
51641
152.81
Mar-15
285.6
13048
45.69
364.07
56412
154.95
Apr-15
312.9
14219
45.44
360.7
56238
155.91
May-15
331.38
15726
47.46
460.25
69275
150.52
Jun-15
410.17
19374
47.23
483.62
68609
141.87
Jul-15
443.46
18809
42.41
424.97
57865
136.16
Aug-15
481.05
19567
40.68
444.6
61516
138.36
Sep-15
485.81
20804
42.82
500.1
69201
138.37
Oct-15
500.05
21558
43.11
552.43
78542
142.18
Nov-15
430.26
18155
42.2
442.57
62527
141.28
Jan-Nov 15
4080.35
179128
43.9
Coal
Clinker
4685.46
678843
144.88
Dec-15
536.64
18699
34.84
Pet Coke
Clinker
564.6
65103
115.31
Jan-16
558.47
16969
30.38
559.01
61996
110.9
Feb-16
567.36
17734
31.26
558.89
64286
115.02
Mar-16
510.34
16135
31.62
459.88
55540
120.77
Apr-16
283.75
10486
36.96
361.3
43613
120.71
May-16
348.8
13532
38.80
404.9
49386
121.97
Jun-16
311.2
10124
32.53
334.22
40821
122.14
Dec-15 To
June-16
3116.56
103679
33.2
3242.8
380745
117.4
1.
Microsoft Office
Word 97 - 2003 Document
3.
2016
2. Observation
Clinker Factor Optimization In Low Fly-Ash Availability Period
FA Unavailbilit
y
Jan-15
Feb-15
Mar-15
Apr-15
May-15
1.
2.
3.
Asian-1
Asian-2
Asian-1
Asian-2
Clinker
Gypsum
Fly-Ash
Total
Clinker
Gypsum
Fly-Ash
Total
0
50.9
17.83
35.50
63.9
64.45
5.78
5.34
30.32
30.21
100
100
63.93
64.59
5.82
5.30
30.25
30.11
100
100
115.6
224.35
25.54
58.98
140.82
32.63
65.93
69.93
64.15
5.25
5.16
5.14
28.82
24.9
30.71
100
100
100
Imported
67.47
71.85
64.86
5.28
5.13
5.14
27.25
23.02
30
100
100
100
Jun-15
0.00
63.61
5.61
30.78
100
63.77
5.63
30.61
100
Jul-15
Aug-15
Sep-15
4.65
17.93
0
13.62
27.40
13.35
63.94
63.8
64.7
5.4
5.51
5.22
30.67
30.68
30.08
100
100
100
63.96
64.03
64.66
5.44
5.37
5.22
30.6
30.6
30.12
100
100
100
Oct-15
Nov-15
Dec-15
16
0
13.30
0.00
64.46
63.59
65.47
5.29
6.92
6.27
30.24
29.49
28.26
100
100
100
64.53
64.69
66.05
5.11
4.84
5.72
30.36
30.47
28.23
100
100
100
Jan-16
Feb-16
0
6
4.53
3.95
100
100
100
Jun-16
July-16
5.65
100
Aug-16
Sept-16
0
0
0
0
0
16.33
Oct-16
68.46
69.05
69.75
64.42
64.67
64.96
65.66
63.52
64.67
65.2
4.25
3.45
3.62
7.54
7.20
6.94
6.99
8.31
7.09
6.42
27.29
27.50
26.63
28.04
28.13
28.10
27.35
28.17
28.24
28.39
100
100
5.05
4.10
0.00
27.40
27.53
27.01
27.55
28.25
28.14
28.25
0
28.13
0
55.61
0
0
4.71
3.76
3.56
7.27
7.47
6.88
7.22
0
6.87
0
100
100
Mar-16
Apr-16
May-16
67.89
68.71
69.43
65.18
64.28
64.98
64.53
0
65
0
100
0
100
0
100
100
100
100
100
100
100
100
In Month of April-15, Asian-1 and Asian-2 were running at low fly-ash absorption (24.90% in Asian-1 and 23.02 % in Asian-2) due to less availability in
market.
In year of 2015, there is 455 hrs of plant unavailability due to fly-ash shortage in Asian-1 and 354 hrs for Asian-2.
Low Purity gypsum will help in clinker optimization and to make the plant available.
2016
14
ACC/ Plant name
2016
Analysis
15
ACC/ Plant name
2016
Brain Storming has been done and following point have been identified
2016
Machine
Weigh Feeder Performance
Unskilled
Labour
Crusher/Grizzly
Reliability
Improper sampling
Fly-Ash Unavailability
Unavailability of SOP
Gypsum granulometry
XRF Calibration
Method
Material
17
2016
3. Analysis
No
Probable Cause
1.
2.
Fly-Ash Unavailability
Valid
Valid
3.
4.
Gypsum Granulometry
Valid
Ref Slide no.22
Valid
Microsoft Office
Excel Worksheet
Microsoft Office
Excel Worksheet
Microsoft Office
Excel Worksheet
18
ACC/ Plant name
2016
3. Why-why analysis
why
why
Fly-Ash Unavailability
2.
3.
Gypsum Granulometry (at
Supplier End)
4.
site;
b)Different source of mines
--
19
ACC/ Plant name
2016
Action
2016
4. ACTIONS
4.1 Actions Decided
Sl.No.
1
Root
Cause
Cause
Action Plan
Grizzly was
made with
scrap material
Prone of
damage its
screen
Gypsum
granulometr
y
Fly-Ash
Unavailab
ility
Increased
clinker factor
and per ton
cement cost.
Gypsum
blockage due
to higher
particle size at
grizzly and
other feeding
points
Resp.
25 July2016
Status
Mr.
Hardeep/Mr.Pre
m Sagar
Completed
Gypsum
Granulometr
y
Low purity
Low Purity
gypsum
supplied by
ACC/ Plant namevendor.
Gypsum purity
variation
Target
Date
30-June2016
30-Nov2016
Mr.Anil/Mr.Saura
bh
In progress
Adobe Acrobat
Document
30-June2016
Mr.Anil/Mr.Saura
bh
Completed
30-Sept2016
Mr.Anil/Mr.Hunar
In Progress
Adobe Acrobat
Document
21
2016
Before
After
2016
Action:
To start the Low Purity gypsum, trial has been done at Asian
Trial Results:
Trail with Low Purity Gypsum at Asian
Trial No.
Clinker %
Gypsum %
Fly-Ash %
Low Purity /
Imported Ratio
Chemical
Parameter
CaO
SO3
LOI
Blaine
Residue (R45 mic)
1 Day
3 Days
7 Days
28 Days
Normal (100%
imported)
Trial-1
Trial-2
Trial-3
Trial-4
UOM
64.20
5.00
30.80
63.40
5.80
30.80
62.50
6.70
30.80
61.10
8.10
30.80
59.00
10.20
30.80
%
%
%
0:100'
25:75'
50:50'
75:25'
100:0'
Averag
e
42.30 42.25
Normal PPC
Set-1
42.80
42.50
2.52
2.48
1.96
381
10.6
14.9
27.9
36.6
Awaited
Averag
Set-1
e
41.60 42.05 42.40
Set-2
2.62
2.55
2.40
Averag
Set-1
e
41.50 41.95 42.89
Set-2
2.42
2.41
2.57
Averag
Set-1
e
42.34 42.62 42.20
Set-2
2.34
2.46
2.38
Set-2
2.47
2.43
1.96
2.53
2.2
2.16
1.95
2.06
1.70
1.78
1.74
1.88
1.66
1.77
398
386
392
396
390
393
383
398
391
395
380
388
10.8
10.2
10.5
10.8
11.8
11.3
10.0
10.0
10.0
10.0
10.5
10.3
14.2
14.6
14.4
14.4
14.0
14.2
14.2
13.8
14.0
12.7
12.4
12.6
25.0
27.5
26.3
26.5
26.0
26.3
24.2
24.8
24.5 Awaited Awaited Awaited
31.8
34.0
32.9
32.0
33.5
32.8
31.8
34.2
33.0 Awaited Awaited Awaited
Awaited Awaited Awaited Awaited Awaited Awaited Awaited Awaited Awaited Awaited Awaited Awaited
Microsoft Office
Word Document
%
%
m2/kg.
%
MPa
MPa
MPa
MPa
23
ACC/ Plant name
2016
5. Check
2016
2016
2016
2016
SO3 Optimization
SO3 optimization has bee done for both type of clinker and gypsum.
a) - With Coal and High Purity Gypsum:- SO3 Range: 2.1-2.6%
b) - With Pet coke and Low Purity Range:- SO3 Range: 2.44-2.67%
Microsoft Office
Excel 97-2003 Worksheet
Microsoft Office
Excel Worksheet
28
ACC/ Plant name
2016
BENEFITS
Asian Cement Works
SPC- Process Improvement Project of 2016
Tangible saving validation sheet
Project Title:- SO3 optimization and Usage of Low Purity Gypsum at Asian Cement
Saving through:- Systematic Problem Solving Methodology
Project period:- 4 April 2016 to 30 Oct 2016
Improvement by reducing clinker factor by 3.52% with the use of low purity gypsum and
consequently, productivity, plant availability and per ton power consumption has been improved by
3 TPH productivity, 2874 MT PCC per month and 5-6 kWhr. Per ton of cement respectively.
Details of saving:-Calculation
a) Annual Saving in Clinker Consumption @3.52% Clinker Factor Reduced = 18837 MT = 4.20
Crore @ Rs. 2252 /MT of Clinker.
b) Annual Saving in Production By increasing Plant Availability in Low Fly-Ash Availability = 34488
MT cement produced = 8.99 Crore @ Rs. 2606 /MT of PPC
Mentor
Head Finance
Director Plant
2016
6. Standardization
6.1 Updation of documents:
1.
2.
6.2 Training:
Training given to Site Lab testers and CCR regarding SOP of SO3 Optimization and monitoring of
abnormal lumps received from low purity gypsum and checking of Grizzly Size.
2.
2016
7. Conclusion
7.1 Horizontal Deployment:
Cost reduction approach can be deployed to other department like minimization of waste
2016
Thank You
32
ACC/ Plant name
2016