POM PROJECT REPORT ON

LOCATION AND LAYOUT OF BIRLA CEMENT CHANDERIA ASSIGNMENT 2

SUBMITTED TO
Dr.R.Jagadeesh

SUBMITTED BY
Mr.Harish Sankar N I PGDM NO: 11140 First Year Batch C

Contents
LAYOUT STRATEGIES OF BIRLA CEMENTS ............................................................................................... 3 Manufacturing Process of Port Land Cement ..................................................................................... 4 Environmental Consideration in Chanderia Plant............................................................................... 5 Location Strategies.................................................................................................................................. 6 Factors affecting the choosing of the location ................................................................................... 6 Chittorgarh .......................................................................................................................................... 6 Location Advantages .................................................................................................................................. 6 References .............................................................................................................................................. 7

LAYOUT STRATEGY OF BIRLA CEMENT

Birla corporation cement unit at Chanderia,Chittorgarh,Rajasthan

Process layout of Cement Plant

A Note On Technology
The Chittorgarh Plant is equipped with state-of-the-art equipments like five stage pre heater, in link clinker, HOT ESP etc were commissioned in 1986. In the plant a central computerized control system with X- Ray analyzer and other sophisticated quality control systems have been provided to ensure the best quality cement production. Technological up-gradation being an ongoing policy of the company, this unit was modernized and its production capacity increased from 5 lakes per annum to 8 lakes per annum to, thereby raising the total production capacity at Chittorgarh to 14 lakes tonnes per annum, which has been again
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increased and is going to be further increased by 1.2 mt. The plant is using conveyor system in its plant to bring raw materials from the mine which reduces the need for continuous transport. The process layout uses stackers and reclaimers for crushed limestone and coal for better blending of the raw materials during processing. The plant has got 5stage pre heater with in line calciner and combustion chamber. There is also Modern laboratory with X-Ray Analyzer and Particle-size Analyzer for ensuring better quality. Waste Heat Recovery System from Pre-heater & Cooler is also installed to save energy. The system uses Electronic packing machines for faster processing and higher productivity

Layout Of Birla Cement Works Chanderia, Rajasthan

The layout used by the cement unit of Birla Corporation at Chanderia is Product Layout. The unit produces Portland cement by using dry process and produces about of 2.50 million tonnes per year. Here the layout is arranged in progressive steps, starting from raw storage till bulk storage for delivery mode. The Product layout helps reduce the bottle necks and time delay with fast processing one after another. The product processing method used in the Birla cements increases the production control. But this system faces challenges when there is a need for up gradation or increasing production capacity, which is going to happen in case of Birla cements plants in Chanderia plant. There is going to be an increase in production by 1.2 million tonnes.So this requires either complete reprocessing of layout or a completely separate layout set up from current plant. If the up gradation is in the current layout then, there will be a need to stop the cement production or reduction in capacity and there can be loss of operation revenue, if the plant goes for upgrading the existing plant. If its a completely new set up, it will require more investment and it will not affect the working of current plant.

Manufacturing Process of Port Land Cement

Step 1 - Quarrying Limestone and a 'cement rock' such as clay or shale are quarried and brought to the cement works. These rocks contain lime (CaCO3), silica (SiO2), alumina (Al2O3) and ferrous oxide (Fe2O3) - the raw materials of cement manufacture. Limestone is extracted from own mines, which are situated approx. 4 km. away from plant. The mining of limestone is done in such a way so as to get 78% to 82% pure limestone. Step 2 - Raw material preparation The extracted limestone is then transported to huge crusher by dumpers. To form a consistent product, it is essential that the same mixture of minerals is used every time. For this reason the exact composition of the limestone and clay is determined at this point, and other ingredients added if necessary. The rock is also ground into fine particles to increase the efficiency of the reaction. The limestone is crushed into small pieces of approximately 16 to 25 mm. sizes. The product formed is known as Raw Meal. Then the raw meal is blended to make it uniform in size. Step 3 Clinkering In presenters, the mixture is heated at various temperatures at various stages. This preheated material is now fed in to the rotator kiln where it is heated at the temperature of 14004

1500degree, where calcinations take place. Here the raw materials react at very high temperatures to form 3CaOSiO2 (tricalcium silicate),2CaOSiO2 (dicalcium silicate), 3CaOAl2O3 (tricalcium aluminate) and 4CaOAl2O3Fe2O3 (tetracalcium alumino-ferrate). Coal is used in the kiln to maintain the temperature and finally clinker emerge out of it. This clinker is through a conveyor into a storage Silo from where it taken out through vibratory feeders & fed into the open circuit cement grinding mill hoppers. Step 4 - Cement milling The 'clinker' that has now been produced will behave just like cement, but it is in particles up to 3 cm in diameter. These are ground down to a fine powder to turn the clinker into useful cement. - The grinding of clinker with gypsum is in done cement mill. It is basically done where the grade of cement is controlled gypsum is added to increase the setting time of the cement. Then cement is stored for some time. Storage & Packing- The cement is than conveyed to different cement storage soils according to their grades & from silos it is packed in paper bags by using electronic packing machines. Cement production has several quite serious environmental hazards associated with it. like dust, CO2 emissions and contaminated run-off water. Birla cement works Chanderia, Rajasthan have taken measures in place to minimise these hazards.

Environmental Consideration in Chanderia Plant

The Birla cements management has been alive to its social responsibility to protect the environment in and around its plants since inception. With this self commitment, the first unit which was commissioned in 1967 was equipped with Electro Static Precipitator, the first in the Indian Cement Industry. The plant is presently in operation with emission levels equivalent to the lowest in the industry. Some of the steps adopted for reducing the environmental impact are as follows: Computerized mine planning system is implemented for better efficiency, reducing dust and to increase safety. Rock-breaker in place of secondary blasting which ensures reduced noise and dust at the same time reduces the chances of accidents Transporting crushed limestone through 4 Km long covered overland belt conveyor. Electrostatic Precipitators - 12 Nos , Bag Dust Collector - 85 Nos , Cassette type Bag Dust Collector - 25 Nos for reducing the air pollution. Water spraying at all transfer points and at wagon & truck tipplers to reduce the air pollution. Gas conditioning towers - 3 Nos . Sewage Treatment Plant for recycling of waste water of colonies. Concrete storage silo for clinker. Specially designed tankers for transporting of fly ash. The firm has also planted 1.47 lakhs trees in the location to maintain the ecological and natural balance.

Location Strategies
The birla Cement Works cement plant located in Chittorgarh is one the best cement plants in North India. The location selected was based on the availability of raw materials, labour and also location advantage for being near to the states like Gujarat, Maharashtra and New Delhi. Birla Cement Works was commissioned in Feb. 1967, the first dry process plant with two stage suspension pre- heating technology in the country. Chief Minister of Rajasthan, Late Shri M.L.Sukhadia in the year1962, laid the foundation stone of Birla cement and the plant started functioning in the year1967. Its initial capacity of 2 lakhs tones was increased to 4 lakes tones in 1992.In an important modernization drive, the two stages pre-heater was converted into5- stage pre-heater, and a modern computerized system was installed in the plant.

Factors affecting the choosing of the location

The Birla cements considered the availability of raw materials like lime stone ,coal etc while starting the plant in the region which comes in between the prosperous reality boom happening states like Maharashtra, Gujarat and proximity to national capital region to cater to the needs.

Chittorgarh
The Birla plants Chittorgarh Cement Works and Birla Cement works are located in chanderia in Chittorgarh. The region is famous for cement factories and tourism. Other than Birla corporation there is also Aditya Birla Corp having its cement plant in the Chittorgarh District. The place also has mining of lime stone and gypsum. Birla Corporation is owns 5.98 sq.km lease area and mining area of 3.64 sq.km in Chanderia near Chittorgarh Fort. The plant recently faced an operation ban in this regard from the high court of Rajasthan. The place is well connected by roads through Golden quadrilateral connecting the metros and the plant also has rail connection. The major thing important for a cement plant to operate is the raw materials like Lime Stone, Gypsum, Coal, and Electricity. The area also needs to have proper transportation facility for the transportation of cement to places where reality boom is happening. Thus chanderia is a place which has all these facilities along with the support of Government of Rajasthan which actually laid the foundation of the plant in 1962. The plant being located in chanderia the advantage is also of being proximity to Madhya Pradesh which has coal reserves.

Location Advantages
Proximity to Reality boom areas Better connectivity by rail and road.

Availability of lime stones mine.

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Government support for the industries. Power from coal based power plant. Thermal Power Plant 14.5 MW Capacity. The production of the plant has increased heavily because of the location the plant started with 2lakh tonnes in 1967 now its 2.5 million tonnes.

References
http://www.scribd.com/doc/29557325/Brand-position-of-various-cement-brands http://www.scribd.com/doc/64455231/Training-Devlopment-Project-Report http://www.birlacorporation.com/cahnderia_infra.html http://www.thehindubusinessline.com/companies/article2141624.ece
http://www.synthlube.net/?page_id=87

http://www.worldcement.com/sectors/cement/articles/Environmental_and_business_news_fr om_across_India.aspx
http://www.scribd.com/doc/7369836/Facility-Layout www.wikipedia.com