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7/28/2019 CF Academy - RJM- Nov'12 Thane.pptx
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09-04-07/SSA/DJ
Clinker factor Reduction
R J Modi
5thNov 2012
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ACC Limited 1
Our journey towards moon ACC ACC - Sep YTDYTD Best performing plant
Baseline2011
ACC Moon
PPC clinkerfactor (Percent)
1
3100 2900
2926
Thermalenergy (Mj/tClinker)3
73.5 61.063.273.3Electricalenergy(kwh/t clinker)4
41.4 32.034.441.0Electricalenergy(kwh/t grind)5
60.0 85.082.158.3CPP PLF(Percent)
6
3081
67.0 60.065.5 62.0
PPC clinkerfactor (Percent)
2 46.3 40.044.18 41.1
Significantprogress inclinker factor,thermalenergy
But nosubstantialimprovementin electricaland CPP PLF
At monthlylevelperformance,
few plantshave alreadyachievedbreakthroughperformance
60.9
39.6
2918
60.5
33.9
82.5
Sep Best performing plant
Board Presentation
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3
ACC-Q&PD,Thane 02.11-2012
Why SPC?
Appraisal Costs
Verification Quality Audits Inspection
Equipment Vendor rating
Failure Costs
Scrap Rework & rectification Re-inspection Downgrading Waste Failure analysis Customer complaints Warranty claims Liability Loss of goodwill
Prevention Costs
Quality planning Quality assurance Inspection Cost Training
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4
ACC-Q&PD,Thane 02.11-2012
Data Gathering
Raw Mix Pyro
Input
OutputCement
Grinding
Input
Output
Input
Process ControlVariables
Process ControlVariables
Process ControlVariables
Output
QualityAssuanran
ceInterface
Flow of Process
Quality Parameters for which Cpk value to be
measured
Raw Material
Preparation
LSF / TC
R90 Mic/ R212 Mic
Kiln FeedLSF / TC
R90 Mic / R212 Mic
MgO
ClinkerFree Lime
LSF
MgO
CementSO3
R45 Mic
Blaine (PSC)
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5
ACC-Q&PD,Thane 02.11-2012
Daily Weekly MonthlyEvery Shift
Review Mechanism
Process
EngineersShift Operators PPE Head - Production
Process Engineer to
update process control
chart . They should
discuss variations in
control charts with the
Operator during the shift
and log the corrective
action to be taken toeliminate assignable
causes
. The process
control charts to be
displayed inrespective control
room.
Analyze the charts
with the help of
process engineers.
Handover the charge
to the next shift
operator explaining
him about the
variations andcorrective action
taken.
On daily basis review
control charts and
plan for effective
corrective action in
the process and
equipments.
To hold weekly review
meetings with Process
engineers and operators
and ensure
implementation of the
acion plan. Development
of Control plan and
Preparation of SOPs isresponsibility of
Production Dept.
Plant Head
To review progress on
monthly basis with the
team and present status inregional monthly review
meetings.
0.35
0.45
0.55
0.65
0.75
0.85
0.95
1.05
1 3 5 7 9 11 13 15 17 19 21
ParameterValue
Value X avg UCL LCL
Signal
7/28/2019 CF Academy - RJM- Nov'12 Thane.pptx
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Reading the heat maps performance snapshot (1/2)
SCCC EE EXAMPLE
6
Raw meal preparation
Clinker production
Cement grinding
Opportunities Reduce false air % Raise kiln NAI
Start tracking fanefficiency in S2 (PH,Baghouse, Coal mill)
Opportunities
Room to raise powerabsorption in mills and
pregrinder/roller-presses Raise MTBF PRI needs to be further
raised Start tracking false air and
fan efficiency in S2
SEEC
upto
Cement
grinding
SEEC
(raw
mate-
rial
prepara
tion)
SEEC
(raw
meal
prepa-
ration)
SEEC
(clinker
produc-
tion)
SEEC
(cement
grinding)
Plant name kWh/t
cementkWh/t
clinkerkWh/t
clinkerkWh/t
clinkerkWh/t
cement
Saraburi 1 - 1.20 - - 55.23
Saraburi 2 90.12 1.55 28.13 23.07 40.91
Saraburi 3 93.17 1.15 28.86 32.98 40.29
Raw
millsMTBF,
hPRI, % NAI,
%False
air, %Fan
eff, %
Power
factor
Sara 2 22.28 95.50 92.41 54.00
Sara 2 18.05 93.90 89.77 31.00
Sara 2 27.58 101.40 93.26 9.00
Sara 2 24.28 98.68 92.06 65.00
Sara 3 27.04 87.71 97.50 23.60 67.50 0.85
Kiln MTBF,
hPRI, % NAI,
%False
air, %
PH1 fan
eff, %
Sara 2 961.94 100.50 81.11 10.82
Sara 2 674.55 101.24 95.89 10.11
Sara 3 321.85 94.09 88.49 9.30 66.91
Cem-
ent
mills
Power
absor-
bed, %
MTBF,
hPRI,
%NAI,
%Power
absorbed
(PG/RP), %
Sara 1 82.50 124.54 90.14 96.33 88.00
Sara 2 84.70 157.18 80.34 98.23 57.90
Sara 2 83.80 96.41 77.59 98.04 56.90
Sara 2 81.30 74.09 73.55 97.65 45.20
Sara 3 80.70 138.41 84.11 92.33 71.00
L2 - Colour coding is based on ranking across all the plants inregion. Top 20% Green, Next 40% Yellow, Next 40% Red
Cement grinding metrics Based on technical standards
L3 Ball mills and vertical mills have different colour codingthresholds
Opportunities Raise MTBF with better
maintenance Monitor and raise power
factor Start tracking power factor
in S2 Lower false air % Monitor/ improve fan
efficiency
L3L2L1
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Reading the heat maps performance snapshot (2/2)
Short title, Department, Name/Function or Event/Creator, Date yymmdd, Classification
Opportunity to increase AF, AR consumption by increasing the design capacity of plants working at about 100% design capacity utilization (Ambujanagar 1)
High potential savings through sourcing and increasing AR utilization in plants having good design capacities (Darlaghat, Rauri)
Definition of the
parameterSpecific GAV TSR TEE
Capacity utilization - AF Capacity utilization - AR
OverallSpecific
stock -
AF
OverallSpecific
stock -
AR
Overal
l
Design
Capa-
city
Design
Capa-
city
utiliza-
tion
Planne
d
utiliza-
tion
wrt to
availa-
bility
in
region
Overal
l
Design
Capa-
city
Design
Capa-
city
utiliza-
tion
Planned
utiliza-
tion
wrt to
availa-
bility
in
region
Units Rank CHF/
tons of
Clk.
% % tons/
000' t
clk.
% % % tons/
000' t
clk.
% % % tons/
000' t
clk.
tons/
000' t
clk.
Plant name 4.78 30% 16% 137.81 404% 271% 883% 148.08 361% 132% 100% 5370.88 36705.00
Ambuja Nagar 1 11/26 0.34 4.3% 1.7% 22.02 78.0% 143.7% 26.4% 0.0 23.4%
Ambuja Nagar 2 14/26 0.23 1.0% 0.9% 8.54 13.9% 31.8% 4.8% 0.0 60.0%
Bhatapara 1 15/26 0.22 0.2% -0.1% 0.00 0.0
Bhatapara 2 13/26 0.33 0.6% 0.3% 0.00 0.0
Darlaghat 16/26 0.21 0.9% 0.7% 12.52 17.4% 270.8% 98.8% 83.5 7.5% 129.7% 17.5% 1.54 5.08
Maratha 23/26 0.06 1.3% 0.4% 0.00 122.2% 8.7% 0.0 20.8%
Rabriyawas 25/26 0.00 0.5% 112.1% 73.2%
Rauri 24/26 0.02 NA NA 0.00 68.6 3.0% 34.8% 34.8% 1.67
Performance 2012 Jun YTD data
ACL GEOCYCLE EXAMPLE
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Reading of heat maps Practices snapshot (2/2)
Quality of RM
Storage and
handling of
RM
Feeding
Grinding
Others
Oranization
Performance
management
Technology
Plant can
improve clinker
factor with little
capex by
improvingavailability and
storage of raw
materials
Technology can
be an important
lever to
increase clinker
factor, but will
need capex
Practice (L2) Score
Periodic assessment to improve availability of micro fine fly ash (dedicated
grinding mills for available fly ash, assessing new sources)
Minimize usage of aged raw material by using FIFO, traceability
No open storage of clinker, gypsum and other raw material with clear
demarcation for different types to avoid mixing
Maintain fly ash and cement homogeneity with blending arrangements
Monthly optimization of grinding aid dosing rate
Increase degree of automation for fly ash / slag / additive feeding system
using DCS to control dosing
Optimizing mill efficiency using periodical regrading or top ups of the grinding
media, longtitudinal sieving and circuit sampling every 15 days
Optimizing SO3 in cement using frequent sulphation tests
Ensure exhasutive SLAs between GU and mother plants to ensure quality of
clinker supply
Benchmarking of CF across products every quarter
Dedicated cross functional team with a champion on clinker factor
Separate team in the plant that is focused determine and developing alternate
sources of mineral components
Review of clinker factor such as in daily operations review, weekly by Head
Plant Operations, monthly by Plant Director
Training calendar and rewards and recognition mechanism
Plants spend time and resources to explore / study impact of technology
changes in mineral component drying, separate grinding of mineral
components, blending and mixing, flyash separation
Sample L3 practices (not exhasutive)
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ACC Limited 9
Academy approach being used to drive performanceimprovement & capability building across plants
Dedicated COEchampions
Module &Handbook
Heat Maps
Facilitation of
plantexcellenceprojects
Model Plant
Key activities
8 full time (3 for EE, 3 for CF & 2 for CPP) has been nominated asCentre of Excellence (COE) Champions to drive improvement acrossplants
Module created for three critical areas EE, CF & CPP as guide book tohelp plants prepare road maps to reach aspiration values
Hand books for training of young engineers and plant teams
Critical performance & practice KPIs for the respective pillar at L1, L2and L3 levels
Plants to use this as a tool to identify opportunity areas
COE Champions to conduct plant visit & facilitate individual plant Observe performance and practices followed through plant walk-
aroundConducting workshop/ training in identified improvement areas
Training centre to be established in the respective model plants (e.g.,Chanda for EE & CPP, Tikaria for CF)
Model plants will also set example for break through performances forthe respective KPIs
1
4
3
2
5
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ACC Limited 10
EAST
SOUTH-WEST
NORTH
Plant
PPC Clinker factorPercent
YTD
SEP
Q4
2012
Diff2011
ACC 65.5 63.767.0
KY1 62.062.064.0
G1 63.065.665.7
G2 63.065.765.2
LK 66.366.467.1
TK 62.062.865.4
SD ---
JL ---
DM ---
BG 70.572.174.5
CH 70.071.668.9
EN ---
W1 72.074.872.1W2 64.065.968.2
CD 64.264.468.9
BE ---
MK 73.076.974.4
KO 62.865.870.6
1.8
0.1
0.0
2.6
2.7
0.8
1.6
-
-
-
1.6
-
3.9
2.81.9
0.2
-
3.0
Q1
2013
Diff
Q1
2013
63.30.4
Q4
2012
63.7
1.8
YTD
Sep
65.5
2011
67.0
ACC PPC Clinker factor
Percent
My
Moon
63.3
61.5
63.0
63.0
66.3
62.0
-
-
-
70.0
67
-
72.064.0
63.5
-
68.0
62.2
0.4
0.0
0.5
0.0
0.0
0.0
03
-
-
-
0.5
-
5.0
0.00.0
0.7
-
0.6
60.0
60.0
64.0
64.0
60.0
62.0
-
-
-
65.5
63.0
-
69.160.0
63.0
-
69.0
60.0
Recommitment towards our aspiration andmini-moons (1/6) x
Difference betweenQ412 YTD 2012 /Q113 - Q412
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ACC Limited 11
EAST
SOUTH-WEST
NORTH
Plant
PSC Clinker factorPercent
YTD
SEP
Q4
2012
Diff2011
ACC 44.2 42.846.3
KY1 ---
G1 ---
G2 ---
LK ---
TK ---
SD 42.742.744.3
JL 42.543.444.6
DM 43.045.150.2
BG 40.041.144.7
CH 44.047.047.5
EN 39.045.049.2
W1 ---W2 ---
CD ---
BE 47.047.249.4
MK 50.053.155.0
KO ---
1.4
-
-
-
-
-
3.0
0.0
0.9
2.1
1.1
6.0
3.1
--
-
0.2
-
Q1
2013
Diff
Q4
2012
42.8
1.4
YTD
Sep
44.2
Q1
2013
41.90.9
2011
46.3
ACC PSC Clinker factor
Percent
My
Moon
41.9
-
-
-
-
-
42.5
42.0
42.0
39.0
42.0
38.0
--
-
46.0
47.0
-
0.9
-
-
-
-
-
2.0
0.2
0.5
1.0
1.0
1.0
3.0
--
-
1.0
-
39.6
-
-
-
-
-
40.0
40.0
40.0
38.0
40.0
40.0
--
-
40.0
40.0
-
Recommitment towards our aspiration andmini-moons (2/6) x
Difference betweenQ412 YTD 2012 /Q113 - Q412
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ACC Limited 12
Two way approach for achieving our aspirations...
ContinuousImprovement
Breakthroughprojects
Use of micro fine fly ash from last field of ESPBeneficiation of fly ash by removing carbon particles by using
latest technologySeparate grinding of fly ash / slagTransfer of surplus mills from Chanda to different locationsOutsourcing of blending of grinding aid for PSCUse of a combination of accelerators and grinding aidUse of modified gypsum / low purity gypsum
Breakthrough activities
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ACC Limited
Lets work rigorously for next four days to prepare a
way out for achieving our aspirations