Académique Documents
Professionnel Documents
Culture Documents
11:00 11:30 Brief Presentation by Sr. VP (Engineering) Shri. Sundaramoorthy Organization & History
11:35 13:30 Plant Visit Shri Narendra , Shri
Duraikannu, Shri
Santhanam, Shri Sairam
13:30 14:30 Team Lunch CII Team & All heads
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Chettinad Cement Promoters History of Chettinad Cement
His dreams & aspirations, to reach greater heights the reins were taken
over by equally visionary businessmen- his son, Dr.Rajah Sir Muthiah
Dr. M.A.M. RAMASWAMY, B.A(Lit)., Sri. M.A.M.R.MUTHIAH, B.E., Chettiar and grandson Dr. M.A.M. Ramaswamy.
Member of Parliament Managing Director & President-CMA
Chairman
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The values that we have imbibed from our Chettinad House serve to
strengthen our commitment to sustainable growth to our business,
community and the environment.
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To harness technology to its full potential in a safe and clean environment vGrowth
in the entire business cycle and integrate quality with continuous
improvement. vExcellence
To become a vibrant, learning organization by building skills and
competencies of employees for growth.
vTrust
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Companys Expansion
Plants
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Awards
Awards
National Level Best Award from NCCBM
BEST ENVIRONMENTAL EXCELLENCE IN PLANT OPERATION
NATIONAL SAFETY AWARD (For Mines & Best Performance)
2000-2001 , 2001-2002
NATIONAL AWARDS FROM NCCBM FOR BEST ENVIRONMENT AND THERMAL 1985-86 ,1986-87,1995-96,1996-97,1998-
ENERGY 99
2007-08 , 2006-2007 , 2004-05 , 2001-01 ,1998-99 , 1995-96, 1994-95
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Plant lay (Example of CCCL, Ariyalur) Main Equipment Details (CCCL, Ariyalur)
Total Area: Line-1-282743 sq.m
Line-2 97732 sq.m
Cement Mill LM Raw Mill fan -3350 kw, Pre heater fan -1450 kw,
56.3+3 ,Power- Speed-1000RPM Speed -750 RPM
19 5400kw, Output -270, 20
305tph
Important Events of the Plant Raw Materials for cement
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Special Features
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Special Features
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All belt Elevator in place of pneumatic conveyors VFD Compressor in all compressor unit
Efficient Mill Internals Particle size Analyser for optimising particle size distribution
in cement grinding fineness
SPRS for all HT Fans
For Kiln feed Mechanical mode of conveyors
VFD for Cooler ,Cooler ID fans, Booster fans, Reverse Air fan Optimise cooler exhaust chimney height to reduce the
exhaust fan power consumption
Installed Water spray in cooler to minimise the fan power High Efficiency coolers
consumption
Multi Channel burner Gamma Analyser for Crusher and Raw Mill
Minimise False air entry in Raw mill Switching OFF lighting around CCR
Feed size section building after office hours.
Mill feed size control (maintaining or reducing feed size contro ls)
Monitoring the performances of fan.
Compressed air Minimizing compressed air (use/leaks)
Increase operating Capacity of Primary
and secondary Crusher
Gas handling Efficient Gas handling Reduce Idle run of Crushers and belts.
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Energy Conservation Ideas
Energy Commitments
Energy conservation ideas
Coal General Ceme nt Mill Sr.No Ideas Owners Due date Remarks
1 Hopper levels to be brought down-Band to be increased for auto operation Mr. Muttiah 9/30/2011
Water spray on the clinker at clinker silo 2 List of motors to identify which is running < 50% load Mr. Sivashankar 9/30/2011
outlet. 3 Cone gaps to be checked for HT fans Mr.K.Selvaraj/Mr.Jaykumar Ongoing
11 Reducing the frequency of power generation from 50 to 49.5Hz Mr.Muttiah/Mr.Chitiraj Once trial taken in Line-1
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Energy Saving
Monthly Activities
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Bag filter suction at the top of Raw mill feeding Raw Mill cyclone doors
hoppers
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Improvements in Pull rod -Coal Mill area Cement Mill Mill Sampler
Before After
Soft coating
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Water spray location in Coal mill Modification in Raw Mill Nozzle ring
Past Present
New position
Roller 2
370 mm
Old Position
270 mm
ion
dir able
ect
T
450 mm m
450 m
Roller 1
Radius is increased by ~ 100 mm from 270 mm to 370 mm (armor ring
moved outward by 100 mm)
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Past Present
Expansion
bulged-
Opening
area
reduced
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Insulation required for Heat Balance Cement Mill Line-1
By pass duct Above 441LD2 4th cyclone cylinder
Due to low dry fly ash receipt, wet fly ash usage
increased in line I cement mill.
Feed chute & gas pipe 4th cyclone inlet duct Mill Inlet Duct
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Tiller Plough
Disc Plough
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Mill Inspections Measurements
measured.
0.4 m opening in grit cone.
Line II Amour ring is positioned at 20 o towards
mill.
Nozzle Coal mill cyclone
4.09 m2 In general higher wear rate is observed Size PH down comer Cyclone collection
ring area on grit cone tiles and separator housing. outlet
Nozzle
Dam ring
380 mm
position
Particle
height 5 42.12 18.9 54.62
380 mm Size 10 12.97 0 34.22
15 1.99 0 21.15
Distribu 30 0 0 5.32
-tion 45 0 0 0.51
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Line II
AFR feeding will be done in Precalciner.
Feed bin, screw feeder & flap gates are provided in PH 2nd
floor.
Fabrication drawing released for AFR transportation from
ground floor to feed bin in pre heater 2nd floor. (10 Lacs)
AFR storage yard Clearance to shift from Ariyalur site
Identified Storage yard behind Raw mill line-2 hopper 56
AFR Analysis of Various products AFR Appearance
GCV Bulk
on dry density Fixed
Price TM% Ash basis gm/cc VM Carbon Sulphur%
Rice brawn 3150 8.22 19.6 3564 0.26 34.9 37.3 0.27
Wood chips 3700 7.07 1.1 4753 0.16 17.5 74.4 0.12
Saw dust 3300 6.9 3.8 2141 0.162 24.9 64.4 0.3
Cashew shell 4500 5.2 1.6 4750 0.52 19.9 73.3 0.27
Palm coir 3600 6.8 8 4137 0.30 24.3 60.9 0.17 Palm Coir
Briquettes Rice Bran
Groundnut shell 3800 8.9 3.2 4287 0.20 23.5 64.4 0.18
Coffee husk 3500 8.8 4.1 4255 0.46 21.8 65.3 0.25
Shredded tyres 6500 0.94 1.25 7427 0.38
Juliflora 3200 9.00 2.41 4641 73.0 24.59 0.15
wood
chips(received
from HO) 8 1.68 4361 20.1
FRP 2.62 7980 0.28
Carbon waste 33.5 8.39 6310 24.1 1.37
Saw dust Cashew Shell Coffee husk
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AFR Appearance
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AFR Existing system Line I Injection at Burner
Process flow diagram Injection through
Central burner pipe
Injection Pipe
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Hopper
Double Flap
Calciner
Feeding
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chute
Ground Floor
Feeding
SHREDDER Assembly
Constr ucted
Blower
room To be
AFR feeding to Transport
Constr ucted
burner Pipe
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AFR Existing system Line II
Other Hazardous Waste for disposal
(From Asian Paints):
Double flap gate Feeding system
Feed bin
Multiple Effect Evaporator (Sludge) : 6MT /Month
Screw
conveying ETP Lime Sludge : 15MT /Month
Environment Initiatives:
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Environment Initiatives: Anti Pollution Measures ESP & Bag Filters
Kiln Raw Mill Coal Mill Bag Clinker Cooler Cement Mill
Bag House House ESP Bag House
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Water Harvesting
CSR Initiatives
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Employees Welfare Employees Welfare
Gymnasium Waking Track
Temple
Media personnel.
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Infra Structure Development
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Sponsoring Additional School Building at Disaster Relief
Vallalar Kalvi Nilayam, LINGATHADIMEDU
Fire and flood relief measures in the forms of Clothes, Food and
Money have been provided to the villagers in and around our factory.
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Liberal donation and cement bags are being donated to villagers in and
around our factory and mines area for the construction of basic amenities,
temples and for celebration of local festivals.
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Stakeholders Engagement Program
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