Bin Ani Cement

8/4/2019 Bin Ani Cement

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BINANI CEMENT LIMITED

Unit Profile

Binani Cement was launched under the brand name BINANI in the year 1997. In the

beginning the capacity of kiln was 4750 TPD and with in-house effort of plant personnel,

the clinker production was raised to 5950 TPD in the year 2002-03. We have our own

captive Thermal Power Plant and 90% of the total power requirement is met from it. In

the financial year 2003-04, total 2.15

million tons cement was produced with a

capacity utilization of 102%.

Binani Cement has adopted the most

modern and latest dry-process pre-

calcination technology with sophisticated

control instruments ensuring uniform and

top quality cement. We have also attached utmost importance to the conservation of

environment in and around our unit by installing efficient dust collection equipment in

consonance with the international standards.

An Overview of Binani Cement Limited

The plant produces three types of cement viz. OPC-43 grade, OPC-53 grade & Portland

Pozzolona Cement. Company's product has the premium image in the market due to its

superior quality. The annual turn over of our company is Rs. 46267.5 Lacs for the year

2003-04. The Herculean task of selling the high quality cement at a competitive price

put the BCL at their toes to control the cost right from day one.

Energy Consumption

18.16 19.1819.97

0

5

10

15

20

25

2001-02 2002-03 2003-04

19.2121.12 22.02

0

5

10

15

20

25

2001-02 2002-03 2003-04


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In times of increasing cost and decreasing cement prices, optimization of plant

operation plays a major role.The cost of production should be brought down to the least

possible level without compromising on quality. All the employees of Binani Cement

are very energy conscious and they do not leave any stone unturned to reduce the

electrical as well as thermal energy consumption. Our Management provides free

hand, full cooperation and moral support in this regard and everyone is being motivated

to do so. Our percentage of energy cost comes out to 39.87 % of the total cost of

cement production in the year 2003-04. The electrical & thermal energy consumption

figures of last three years are shown below: -

Proportion of Energy Cost Vis--vis Production Cost

79.6378.00

76.83

65

70

75

80

85

2001-02 2002-03 2003-04

701 692 681

300

400

500

600

700

2001-02 2002-03 2003-04

Fuel

22.98%

Raw

Materials

Dep. & Int.30.07%

Sal &

Wages

2.86%

Others

13.76%

Electricity16.89%

13.45%


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Energy Conservation Commitment, Policy & Setup

Energy conservation receives top priority at Binani Cement. In view of fast depleting

natural resources of energy and galloping prices of energy, the commitment of the

management towards energy conservation measures is high. As we are an ISO-14001

certified company, we have well defined Environmental policy in which due emphasis is

given to conservation of raw materials, fossil fuels & electrical energy.

For the whole plant, Seven Sectional teams are formed from Mines Dept. to Packing

Plant including Power Plant also. These groups have been given free hand working to

identify problems, reason of break-down in their sections and coming forward with

techno-economic feasible solutions and implementing them in a scheduled time frame.

Monthly performance of their respective section is being apprised to the President

regularly.

The Daily Production report, Stoppage Report and Power Report is analysed by all the

responsible persons at different forum as given below.

Daily review of stoppage & power report by all team members for improving the

plant performance.

Daily Plant performance is reviewed in technical meeting by the top executives of

the plant. The meeting is chaired by the President.

Monthly Review Meeting is being held in the Conference Room, which is attendedby all the concerned persons of the plant. Monthly Production and Power targets

are being set in this meeting.

Yearly Plant Performance Review for setting up new benchmark for electrical and

thermal energy consumption.

Optimisation is an on-going process in all the industries. At BCL, people with innovative

ideas are nurtured and motivated; their ideas are given due respect and discussed at

various levels.

We have Energy Conservation Cell and Quality Cell, which is headed by Senior Vice

President (Operations). The activities of this cell are being carried out by all the

executives jointly. Based on the recommendation made by the Energy Conservation

Cell and reviewed by various level committees, the decisions are taken for


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implementation of energy conservation programme in short, medium and long term

basis.

The Energy Audit is being done on yearly basis either by an outside agency or by our

in-house team, which helps in identifying the energy saving potentials in different

sections of the plant. The internal energy audit team at BCL is also well equipped with

latest monitoring equipment & several competitive in-house developed softwares.

Binani Cement believes in all modern techniques like Quality Circle, Statistical Process

Control, Statistical Quality Control, 5-S Techniques etc. and is striving to become a

world class unit in all its operations.

Energy Conservation Achievement

Droplets Make Ocean, as rather big volume of production was involved, even a small

step taken in the direction turned out to be a great gain. With the sincere efforts of plant

personnel and motivation given by top management, the energy consumption of plant

has declined drastically.

Specific Electrical and Thermal Energy Consumption of the plant in the year 2001-02

was 79.63 kWh/ton of cement & 701 Kcal/kg clinker respectively. In the year 2003-

2004, specific Energy consumption reached to 76.83 kWh/ton of cement & 681 Kcal/kg

clinker. Hence, specific electrical energy consumption lowered by 3.52% & thermalenergy consumption by 7.06%.

In order to achieve the best energy level, Brain Storming Sessions are conducted for

getting innovative ideas. Hence, the different ideas are nurtured and motivated and the

resultant benefits are fruitful modification.

Few of such modification are enlisted below:-

1. Energy saving bricks(ACC-Refratherm) installed in the safety zones of kiln

2. Inlet boxes of Kiln & Calciner fans have been enlarged

3. Inlet boxes of Raw Mill Fan enlarged

4. EVASE angle of Sepax fan of both Cement Mills has been reduced from 30 to

19.5 degree

5. Speed reduction of Limestone hopper top JPF fan & removal of fan inlet damper

6. Power distribution system has been optimised to reduce the distribution losses


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7. Speed reduction of Surge Bin top JPF fan(211FN1) & removal of fan inlet

damper

8. Sand Sealing provided in the divertors of Preheater Cyclone's below K-6 & C-5

9. Shifted PH Fan 1 feeder from incomer 2 to incomer 1in LC3 HT board

10. Speed reduction of Limestone hopper top JPF fan 311FN2 & removal of fan inlet

damper

11. Speed reduction of Baghouse Transport JPF fan 391FN8 & removal of fan inlet

damper

Energy Conservation Plans & Targets

Our new benchmark for electrical energy consumption is 78.5 kWh/ton of cement

(Target revised due to pet-coke consumption) and for thermal energy consumption is688 Kcal/kg clinker. The following energy conservation related projects have been

identified for implementation in the plant.

Modification to be done in the preheater cyclones

Calciner string downcomer duct dia to be increased from 3 to 3.5 mtr.

Quantity of energy saving bricks to be extended from 10 mtr. to 30 mtr. length in

the kiln

Optimisation packages to be installed in Raw Mill, Kiln & Cement Mills

Environment and Safety

Utmost priority is always given on Industrial safety, occupational health and

environment protection in our unit. We have an effective Environment Management

system conforming to ISO 14001:1996 and Occupational Health & Safety Management

System conforming to OHSAS: 18001. The company has distinct and well-defined

safety, health and environment policy to provide a framework for further developing

system and procedure to achieve objectives/goals.

Environment

As of our prime concern, the technology and equipment selection was so keeping

environmental consideration as topmost priority. The various environmental aspects/

impacts were considered/envisaged and accordingly mitigatory measures were

adopted. Following are the few measures taken for environmental protection: -


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All the major venting points are provided with pollution control equipment like Bag

House (L.S. Crusher, Raw Mill/Kiln Section) and 4 Nos. of Electro Static Precipitator

ESP (Coal Mill, Clinker Cooler, and Cement Mills). The air is emitted out through a

stack, the stacks are regularly monitored for its emission of Particulate Matter and

found to be less to the norms of 150 mg/N-m3.

All the transfer points are provided with Jet Pulse Filter (JPF) so that no emission

occurs during transportation of material.

Dust suppression system has been installed at Coal & Limestone unloading points.

Provision of water sprinkling on the belt carrying raw material is made.

Provision of water injection in drilling machine to reduce the dust emission.

We maintain a status of Zero Discharge unit. The cement plant consumes water in

cooling the machines & for temperature control in process, hence no waste water

gets generated which is to be disposed off.

Our Domestic Waste-water is treated in a Sewage Treatment Plant and then reused

for Plantation.

The operators of HEMM are provided with Air Conditioned cabin to prevent them

from dust exposure and for improved efficiency.

The noise making machines like Compressors, Blower etc are provided with an

enclosure.

Regular monitoring of noise levels and initiation of corrective action if any for

increased noise levels.

We have already kept more than 47% of the land in our possession reserved for

plantation. Till date 83,000 numbers of saplings have been planted.

Safety

We have defined our own On-Site Emergency plan for handling any type of

emergency/eventuality. For handling emergencies & its speedy execution, we have

made a Central Safety Committee. The safety committee makes aware the plant

personnel about the hazards involved in their tasks through training, developing

procedures, investigation of accidents, maintaining statistics, active participation &

organizing safety meetings.

Our company is always one step ahead in taking care of employees health/ safety and

their well being. We have gone for OHSAS 18001 (Occupational Health & Assessment


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Series) just because to provide safe working place / environment to every employees.

We have identified all unsafe areas and where there is a chance of exposure to hazard,

accident and incident. Regularly our sectional teams are taking rounds and further

identifying the unsafe working place and person, and reviewing the same in OHS cell

meeting. As a part of welfare and well being of our employees, various improvements

have been carried out in the canteen for keeping raw material in hygienic condition,

dishwashing system for proper cleaning and manifold system to provide safety to our

employees in canteen. To timely check and maintain hygiene condition in canteen, a

committee has been framed with equal participation of workmen & Executive staff.

We are having our well-quipped, diagnostic and health center with qualified doctor and

para-medical staff in our residential area round the clock employees and the villagers

can get free medical aid. The company has also taken very good insurance policy for

their employees, which covers the employees security for twenty-four hours i.e. GPA,

Janta Policy & Mediclaim, which brings sense of security among the employees.

Documents

Bin Ani Cement