pm overview ibm proj team

8/12/2019 PM Overview IBM Proj Team

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IBM Global Services India, Business Consulting Services

2003 IBM Corporation

Updated May 2003


Updated July 2005

Overview - IBM TeamCement Manufacturing & Maintenance Processes

Grasim Cements . . .


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Updated July 2005Grasim Cements On the ERP Way2

Overview : History of Cement Manufacturing &Maintenance Processes


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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


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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


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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


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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


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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


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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.



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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.



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CEMENT MFG. PROCESS - AN OVERVIEW1. Quarrying

2. Raw Grinding and Burning

3. Grinding, Storage, Packing and Dispatch

THE CEMENET MANUFACTURING PROCESS


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Plant Maintenance


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


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Plant Maintenance


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


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Plant Maintenance


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


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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


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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



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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



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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


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