TABLE OF CONTENTS

Page No.Title Page Acknowledgements Table of Contents Introduction Achievements

Chapter 1Organizational Set-up & Profile of the Company

Unit 1.1 Historical Background of the CompanyUnit 1.2 Cement the Building Block of the SocietyUnit 1.3 Cement Industry in IndiaUnit 1.4 Profile of the Company

Chapter 2Description of the Processes & the Operational Methods Used in the

Cement IndustryUnit 2.1 Mining OperationsUnit 2.2 Stacking & ReclaimingUnit 2.3 CrushingUnit 2.4 Raw Milling & BlendingUnit 2.5 Intermediatory Parts & Processes of the Cement Manufacturing ProcessUnit 2.6 Burning & CoolingUnit 2.7 Einish MillingUnit 2.8 Pollution ControlUnit 2.9 Miscellaneous Chapter 3 Functioning of Various Departments of GACL

Unit 3.1Store DepartmentUnit 3.2Production DepartmentUnit 3.3Sales & DistributionUnit 3.4Quality Control DepartmentUnit 3.5Environment DepartmentUnit 3.6Personal DepartmentUnit 3.7Instrumentation DepartmentUnit 3.8Accounts DepartmentUnit 3.9Audit Department

Unit 3.10Electrical DepartmentUnit 3.11DG Power PlantUnit 3.12Civil DepartmentUnit 3.13MinesUnit 3.14EDPUnit 3.15Costing DepartmentUnit 3.16Packing DepartmentUnit 3.17Central Control Room

INTRODUCTION

Gujarat Ambuja Cements Ltd. (GACL) was established at Darlaghat,

village Suli, tehsil Arki, District Solan, Himachal Pradesh inn the year 1994. The

plant is located 45 km from Shimla and approximately 2km from Darlaghat.

As India is the second largest producer of cement in the world this cement

industry is one of the few industries in India to achieve the world

competitiveness. The cement industry matches world standards on all

parameters. The quality of cement compares with internationally accepted Britain

and American standards. Also the company’s productivity, energy efficiency and

environment standards are among the best in the world.

The plant started its commercial production in 1995 having a rated

capacity of 1.5 - 2 million tones per annum then, now around 6-7 million tones

per annum. It is the first plant in India which has been awarded ISO9002 Quality

system certified by Bureau of Indian Standards.

The company has always maintained the corporate philosophy of

sustainable development. It maintains the emission norms well below the

standard laid below the standards laid down by the Government Regulatory

Institutions. The company has been adjudged the best and the most effective

mines in its area by the Indian Bureau of Mines.

The mining activities of Ambuja cements is the best examples in Indian

mining industry scenario for state of the art mining with proper environment

control. The mining situated at the serial distance of km from the plant. Which is

situated around Kashlog village named Kashlog mines in Himachal Pradesh.

The area spread around 4.8 sq. km. and is located in the North West direction of

Shimla. It has a good transportation system by roads which are also connected

to the main cities near the place. This limestone deposits are located in the lower

Himalayas, the terrain is hilly with deep valleys.

This is one of the most famous once among the cement manufacturing

plants of the country and the main processes involved in the manufacture of

cement are mining and crushing, pyroprocessing, grinding. Storage and packing.

There is one operating kiln driven with one raw mill, two cement mills, a Dg hall,

quality laboratory and a cental control room (CCR).

Basically it consists of 16 departments working 24 hours each day and

seven days a week with three working shifts each day. Mainly this plant is run

automatically and is magnificent in terms of results, because of this it has

bagged many awards to add to its kitty. The main products of cement

manufactured here are OPC (Ordinary Portland cement) and PPC (Portland

pozzalana cement).

CHAPTER 1

ORGANIZATIONAL SETUP AND PROFILE OF THE COMPANY

Gujarat Ambuja cement Limited, one of the leading cement manufacturers

of India was initially incorporated in the joint sector with the government of the

state of Gujarat in the year 1983 as a private limited company. In the year 1985,

it went public and now is one of the 30 companies listed in the Mumbai stock

exchange.

Unit 1.1 Historical background of the company:

The co-started in the year 1983 at Ambuja nagar , in Gujrat with a company of

0.7 million tones. This plant was commissioned in 1985. The second plant came

up at the same place, near the plant with the name Gajambuja cement. This

plant was commissioned in 1993. Then the company made a plan to take

advantage of the demand in the Northern Region of India. As a result, it started

Unit at Darlaghat in Himachal Pradesh with a view to use the vast amount of raw

material i.e. Lime stone at Kashlog, which is quite near to Darlaghat. The plant

commissioned in 1995 is known as Gujrat Ambuja Cements, Himachal Unit.

Later the company put up another unit at Ambuja Nagar Gujrat.,near the two

existing unit in 1996. This unit was named as Gaj Line II. Apart from all these the

company has a grinding unit at Ropar (Punjab ), clinker is supplied to that unit

from Himachal Unit.

The company has its own fleets of ships and also jetties at Magdalla.

Muldwarka (Gujrat) and Panvel (Maharastra ) which are used for water mode of

transportation, both for domestically as well as export purposes . In 1997 itself

GACL took over Modi.Cement Ltd., in Madhya Pradesh now renamed as Ambuja

Cement Eastern Ltd. This plant added a capacity of 1.5 M.T. per annum.

The Himachal Unit of Ambuja Cement is unique in many ways. The site at

Darlaghat situated at 45 km from the capital city Shimla is fortified by lush green

mountains on both sides, rich with virgin soil, and attractive design with over land

belt conveyer nearly 2.8 km long from the mining site at Kashlog to the

production site, passing through tunnels carved through mountains. The plant

was installed and commissioned in a period of 22 months in spite of difficult

terrain and harsh weather conditions. The plant site is 1550 mts above mean

sea level. It is the highest altitude plant in Asia. It is a marble and monument of

human endeavor, team spirit, engineering skill “I Can “attitude. The production

capacity of the plant was upgraded from 2 M.T.P.A. to 6-7 M.T.P.A. The plant is

equipped with BAT (Best Available Technology).

Unit 1.2 Cement the building block of the society :

Construction of houses or shelter is one of the oldest industries of human

civilization and cement of one kind; other has been used in prehistoric times for

construction purposes.

Cement can be defined as any substance, which can join or unit

mass,Cement, as used for construction purpose is a fine powder which when

mixed with water allowed to set and harden can join different component

together to give mechanically a strong structure. Thus Cement can be used as a

bonding material for brick or other solid blocks of different sizes to form a

mamolith.

Cement is one of the most important building materials, which was

introduced in England in1824 by Joseph Aspidin, it is also called Portland

Cement because of its resemblance to the famous Portland rock of England.

Chemically, cement is a finally a hard mass when treated with water. Generally

three types of cements commonly in use these are:

I. Ordinary Portland cement (OPC).

II. Portland pozzoalana Cement (PPC).

III. Silicate cement.

Unit 1.3 Cement Industries in India:

The cement industry is 9 decades old. The first cement was made under

the auspices of the house of TATA at Porbandar (Saurashtra) in 1914. It started

with two vertical shaft kiln of stone masonry with the capacity of about 20 tones

of clinker per day each. In 1920 these vertical shafts kiln was replaced by two 50

tones per day dry processed rotary kiln with common waste boiler for generation

of power. These kilns are still in operation but without the waste heat boiler and

making whit cement. In 1925, the cement production capacity was 0.5 M.T.

Growth of cement industry was very slow in the sense that in 1930 when

the production was only 6 lakh tn cement per year the there was a cut-throat

competition indigenous cement manufacturers and cement imported from

England and Japan, because of this some factories had to stop its production

from time to time and even changed hand. By keeping in view a cement

marketing organization was set up in 1930 to ensure the equitable sale of

cement and to counteract competition from imported cement.

But it did not help much and in 1936 four out of five cement manufacturer

in India, eight factories to their credit joined together to from Associated Cement

Company Ltd. (ACC). As a matter of fact, the first factory with indigenously built

machinery was set up in Chaibasa (Bihar) in 1947.

The cement industry however, has been making commendable progress

in 90’s, with the execution of extension and other new schemes mainly by

established enterprises. The output excluding that of mini cement, has risen to

76.33 MT in 1998-99.

Ninth plan greatly emphasizing on the construction of houses in urban

and rural areas and the development or irrigation projects. This plan had also

given importance to formation of national as well as state highways. There is a

proposal to add about 30 millions tones of production capacity during this period.

The cement industry saw a prospective phase of boom. The growth has been

estimated on the basis of relatively low per capita consumption compared to

other countries but an accelerated growth in infrastructure may facilitate the

emergence of new trend and take off.

Unit 1.4 Profile of the company

Today GACL is a public limited company; Ambuja Cements has grown

from 0.7 million tones capacity to a remarkable 6.8 million tones per annum. It is

rated as the most profitable cement company in India, posting the highest profit

per tonne of cement produced and offering the highest returns to share holders

among cement companies. The board for industrial and financial reconstruction

(BIFR) sanctioned and rehabilitated some scenes giving birth to the name of

Ambuja Cement Eastern Limited (ACEL).

Subsidiary Companies:-

The list of subsidiary companies of Gujrat Ambuja Cements Limited is as

follows:

Ambuja Cements Eastern Limited (ACEL) formerly known a Modi

Cements Limited has become a subsidiary company since 1997 pursuant

to investments made by the company in terms of BIFR order.

Cement Ambuja International Limited, Mauritius.

Midigama Cements (Private) Limited, Sri Lanka.

GACL Finance Limited.

Concrete Investments Limited.

Indo Nippon Special Cements Limited.

Ganpati Greenfield’s limited.

Home trust Housing Finance Company Limited.

The Product:

All along the company has maintained a policy of providing a superior

product, which has achieved for the company a leading position in the

competitive market with total commitment to quality. The Ambuja team had

adopted latest quality equipment and techniques to constantly monitor quality in

fact and because of this the company has under its belt many prestigious

awards. The honorable ISO 9002 and ISO 14001 certification for Environment

Management System. The company manufactures two major kinds of cements

OPC and PPC. There are also several gradations found in the type of OPC as

55, 43 and 33 grades.

All the plants continued to run affectionately at 100% capacity utilization.

The total production during the year 1997-98 is given by the following table

(Quantity in lakh tonnes):

Sales during the year 1997-98 were 5.06 million tonnes, as against 4.09

million tones in the previous year.

Domestic Markets:-

The power of the brand: In Gujrat,the principle of Ambuja, went up by

56%,taking its share to 26% from 21%. In Mumbai sales increased by 48%.

Making Ambuja the number one brand of the countries largest cement market. In

northern markets of Punjab and Himachal Pradesh it has increased its share to

35% Ambuja cement continues to remain the brand of first choice in all its major

markets

Efficient commissioning:

- GACL has achieved excellence in commissioning and stabilizing plants

speedily.

- The first plant in Gujrat was set up in twenty-two months.

- The second plant at the same site was commissioned even faster, in thirteen

months time, as against the normal 3 years.

- The plant at Himachal Pradesh in the hilly terrain was established within four

months.

- These helped to keep the project cost at the lowest in the country.

Financial position of the company:

It is well know that the GACL is a leading manufacturer of the new

millennium. It had a turnover of Rs. 1130.95 crore in 1999-2000. Net profit after

tax was Rs. 131.66 crore.

The total project cost of the Himachal unit including the units at Darlaghat

and Ropar is about 600 crores.

Research and Development:

Specific is in which research and development is carried out by the

company:

Evaluation of the fly ash from power plant and utilize it for blended cement.

Evaluation of blast furnaces granulated slang from steel plant and utilize it for

blended cement.

Development of beneficiation system of gypsum. Benefits derived as a result of

above:

Increase in cement production.

Reduction in cost of production.

Future plan of action:

Development of blended cement using industrial wastes.

Utilization of furnace oil sludge and lube oil residue as fuel.

Establishment of full sludge concrete testing laboratory.

Grading management:-

The company believes that it owes success to the spiritualism of self

confidence behind working as a cohesive unit taking indivisually to its utmost

high always working with logic of ‘ I can’. This empowerment to people has been

inspiring the team to keep turning outstanding performance. Recognizing this,

the management has consciously encouraged this culture and has created

conductive atmosphere to foster this spirit.

Managerial Grade: M-0, M-0A, M-1A, M-2, M-2A, M-3.

Supervisory Grade: M-5A, M-5B.

Workers: Cement Wage Board Rates.

The motto of the company is “DO IT RIGHT THE FIRST TIME”. The

company till now had been having a successful run and still maintaining the

quality as well as the name-fame of the brand so called Ambuja cement.

Facilities at Site:-

(1) Housing facilities- Housing colonies are available at plant site.

(2) Medical facilities- There is a medical center situated in the campus itself,

led by a panel of Doctor.

(3) School- Ambuja Vidya Niketan Public School is affiliated to C.B.S.E .and

imparts education to children studying in nursery and KG classes to 10th

class.

(4) Recreation Clubs- There is adequate for recreation of their employees

and family members, especially at plant site. Various indoor and out door

games equipment, gymnasium(GYM), a library, cultural activities and

regular film shows in auditorium are also provided here.

(5) Bank and Post Office- Banking facilities are available in the company

premises along with the post office. HSBC, ICICI, Allahabad bank facilities

are also provided here.

(6) Co-operative society- For meeting the daily needs of the people here

GACL has set up a employees consumer co-operative store. It also has a

STD, ISD, PCO, Barber’s shop, vegetable fruit shop facilities available.

(7) Mess and Canteen- Mess facilities for bachelor employees and for

vocational trainees are also provided within dormitory. Canteen services

for employees are available at the factory gate and in plant as well as in

the co-operative store.

CHAPTER 2

DESCRIPTION OF PROCESSES AND OPERATIONAL METHODS USED IN

THE CEMENT INDUSTRY.

Cement is” a substance applied to the surface of the solid bodies to make

them cohere firmly” or, more specifically,” a soft and pasty state (which hardens

on drying) to bind together bricks, stones etc in building” (SOED). Portland

cement is a calcined material compressing lime and silicates which is mixed with

sand and stone and upon hydration forms a plastic material which sets and

hardens to a rock-like material, concrete. This is the main difference between

cement and concrete.

Limestone (Calcium carbonate) and other materials containing

appropriate proportions of calcium, silicon aluminum, and iron oxides are

crushed and milled to a fine flour- like raw metal. This is heated in the kiln firstly

to dissociate calcium carbonate to calcium oxide with the evolution of carbon

dioxide, and then to react calcium oxide with the other components to calcium

silicates and aluminates which partially fuse at material burning temperatures up

to 1450 degree Celsius. The reaction products leave the kiln as a black nodular

material, Clinker. The clinker is finally inter ground with a small proportion of

gypsum (to control the rate of hydration) and the fine product is cement. The

various manufacturing processes used in the cement plant are discussed below.

Unit 2.1 Mining Operation:

Fully mechanized open cast mining method is adopted for quarrying the

limestone. The ripper rips the deposit into a depth of 1m to loosen it and

thereafter make it in to heap of loose material. Blasting and drilling are carried

out on after initial opening of the quarry phases by ripping. All the big boulders

are broken using the hydraulic rock breaker. The hydraulic excavators and front

wheel loader are used for excavation and loading of blasting and ripped and

material in to 35 tonne rear damp trucks. The transportations of limestone from

the working face of the mines to the crushing plant and the stock pile is called

hauling. After hauling the limestone from the working faces are fed to the

limestone crusher. It can crush up to a maximum size of 1m x 1m x 1m sizes

limestone into required size, which is to be transported over land belt conveyor

for the cement manufacturing.

Raw Material:-

The composition of Portland cement varies from plant to plant due to

cement specifications and the mineralogy of available material. In general,

however, an eutectic mix is sought which minimizes the heat input required for

clinkering and the total cost of raw material, while producing the cement of

acceptable performance.

An approximate analysis for raw mix on ignited basis, or for clinker, is:

Reserves:-

Knowledge of limestone and, to a lesser extent, shale reserves is

necessary. There are various classes of reserves.

Class A or proven reserves: Extensive drilling has confirmed quality, mineralogy,

and variation, mining and legal availability.

Class B or probable reserves: Sufficient drilling to allow presumption of quality

and ability.

Class C or indicated reserves: Widely spaced drilling gives extent and some

knowledge of quantity.

Class D or inferred reserves: Initial exploration and consideration of geology

allow general assumption.

Cement contains the following raw material:-

(1). Limestone- brought to the site from the Kashlog mines. It is 3 km aerial

distance far conveyed by conveyer belts passing through three tunnels.

(2).Shale- It is also brought from kashlog mines in the same manner through

conveyor belts and tunnels.

(3) Iron ore- It is brought from Rajasthan to the site by the transportation by

trucks.

(4) Gypsum- It is also brought to the site from Rajasthan by trucks. It adds to the

clinker for the formation of cement (OPC).

(5) Red Ocher- It is also brought from Rajasthan by trucks.

(6) Fly ash- It is brought from Ropar (Thermal Plant) to the site by trucks. It

mixes with the clinker and the gypsum for the production of Pozzalana

Portland cement.

Unit 2.2 Stacking and Reclaiming

Stacking: The raw material is deposited by stacking device moving

continually to and fro over the central line of the stock pile. The function of the

stacker is mainly storage and compilation of the incoming coal and lime stone.

The material discharged from the the stacker site and rolls down the sides of the

pile, thus causing a degree of segregation of the material depending upon the

properties of the material concerned.

Reclaiming: The material is dislodged from the pile by the action of the racking

down device, which sweeps across the sectional face; Harrows are used for the

racking down purpose. Blades of scrapper chain conveyor shift the dislodged

material along the collecting conveyor that extends along one edge of the stock

pile.

At the factory there are two stacker and reclaimer. The basic difference is

that stacker stores and complies the coal and lime stone coming and also the

speed of the belt is adjusted by the stacker controls whereas the huge piles of

raw materials which are prism shaped are made with the help of the reclaimer.

These could be transported further through the conveyor belts to the various

manufacturing cells.

Unit 2.3 Crushing:

It is a process; the big boulders are crushed and are reduced in diameter

for convenience in work. Here in the factory we have impact crusher.

Impact Crusher: In impact crusher the feed material entering the crushing

chambers and encounters the impacting bar. The fragments are flung against

the upper breaker plates, rebound in to the crushing chamber, are again

subjected to the pass through the upper gap into the space between two plates.

Lime stone , clay or shale, coal, gypsum, are crushed to a maximum size of 25

mm, and are fed into the grinding site.

Primary crushers should be capable of accepting short rock with the minimum

of wastage or of preliminary size reduction. Typically feed should be less than

120cm which could be controlled by hydraulic brake. Commonly there are

primary, secondary, tertiary crushers are in series. Most of these crushers are

operated in open circuit. Frequently, sometimes the material is straight away fed

crushed by ball type raw mills and roller mills respectively.

Crushers may operate by compression or by impact. Compression

machines comprises of single and double jaw crushers and gyratory crushers.

Some of these types are discuss under-

Double toggle jaw crusher has simple compression motion with jaw angle of

15-20 degrees. It is effective for hard abrasive materials with low (<5%) moisture

and gives a reduction ratio of about 5:1.

Single toggle jaw crusher also has a measure of vertical jaw motion which

adds attrition to compression. Sticky materials can be handled but the wear rate

increases.

Gyratory crusher operates by pressure between a gyrated cone or a spring -

loaded crushing ring .Hard , abrasive materials can be handled with reduction

ratios about 5:1.

Compression type crushers normally produce a cubic product with a low

portion of fines; being choke fed, plugging will result with feed moisture in

excess of about 5%. Wear is low but the reduction ratio is about 8:1.

Impact machines may be hammer mills or impact crushers. These are

usually preferred for limestone with quartz contents of less than 10%, Wear is

grater than for compressions one,larger proportion of fines but moisture

contents upto 12% is accepted and reduction ratios upto 50:1 is possible as is

done in this industry.

Hammer mills (single and double horizontal shaft) operate by the materials

falling into the circle of rotating hammers and being impacted both by hammers

and the breaker plate. The feeder elevation and the velocity with which the

materials enters the circle is criti9cal; if too low, then the material bounces on top

of the hammers, and if too high, then it penetrates through the circle and can

damage the rotor discs. The discharge is partially and wholly screened by gates

against which secondary reduction by attrition takes place. There should be dry

material used for avoiding plugging.

Impact crushers (vertical or horizontal) are similar in operation is similar as

discussed above in hammer mills case but relatively wet material can be dealt

here.

DRYING here in the raw mills is taken care effected by either combined crusher-

dryers, or in rotary dryers which can either use dedicated hot gasses generators

or waste heat from kiln exhaust. In each case the air flows which involve dust

collection while the high humidity of the used gas usually favors electrostatic

precipitators over bag houses.

Unit 2.4 Raw milling and blending <Grinding>:

Grinding of raw mix:- This process takes place in a high capacity raw mill. The

raw mill has four -roller operation. The rollers are used to grind the raw mix. The

rollers are held in position and pressed down by a pressure ring, which is

stationary. The material is fed centrally on the grinding table and carried by

centrifugal force. The rollers are lubricated in order to avoid friction and increase

the efficiency of the grinding of the raw mix.

Raw Milling - Most modern raw mills are vertical roller mills, through ball mills

are still common and roll presses may be used for pre-grinding to increase

system capacity and reduce power consumption. Roller mills can typically handle

raw materials with aggregate moisture of 15% while ball mills are limited to 8%.

Ball mills are used for drying, which should be air-swept with an air velocity of

about 3 - 4 m/ sec above load. Normally five or six pre-heater system is issued

with the kiln minimally. Alternatively hot gas generators are used for the drying

purposes.

Most of the power consumed in the mills is converted to heat and this eqjuates to

drying

Approximately 1T moisture per 1000 KWH.

Virtually all the raw mills now a days incorporate closed circuits with classification

in a cyclone or mechanical separator and return of coarse material for

regrinding.

Roller mills have lower specific power consumption than ball mills.

Loesche mills comprise 2 - 4 conical which are hydraulically pressed onto a

horizontal rotating grinding table. The roller axis is inclined at 1.5 degrees to the

table and, as axis of rollers and the table do not interest in the plane of table ,

the relative motion includes both rolling and sliding which enhances

comminution. Feed material is directed on to the centre of the table and is

thrown outwards by the rotation under the rollers and into a rising air current at

the periphery which is directed by means of a lower ring. The air sweep passes

through an integral rotary classifier; fines pass out with the air current and the

coarse material falls back onto the feed table. Material drying ocher’s in air

suspension and classifier. Circulating load is about 800%. Smooth running

depends upon stability of the material bed; occasional vibration may be due to

abnormal feed, particularly dry or fine material. External circulation is frequently

employed to optimize mill efficiency.

Primary roller mill controls are:-

a) Mill differential pressure which controls circulating load(usually 500-

700 mm WG).

b) Inlet gas temperature(normally up to 500 degree Celsius).

c) Inlet gas flow.

Blending- A substantial amount of homogenization of raw material is achieved

in the blending silo before it is supplied to the raw grinding mill. So the raw mill

silo acts as a buffer store.

There are various blending silo designs. The two major type involves turbulence

(in which the material is tumbled about by the injection of air-pads on the silo

floor) and controlled flow (where sequenced light aeration of segments of air-

pads causes layers of material in the silo to blend by differential rates of descent

within the silo). Controlled flow silos may have multiple discharge chutes, or an

inverted cone over a center discharge with in the meal is fluidized. Compressor

power consumption is approximately:

Turbulent mixing (air-merge) 1.5-2.5 KWT/T

Controlled flow,

Inverted cone 0.25-0.50

Multi outlet 0.10-0.13

Turbulent mixing can be operated batch wise or continuously.

Modern blending silos are generally controlled flow type.

Unit2.5 Intermidiatory parts and processes of the cement manufacturing

process:

Glass bag house:- As the name suggests it is a chamber with glass covering on

the top. At the bottom of the house there are electrostatic precipitators. The

heavy raw material gets sunk in the bags at the bottom and the finer particles in

the form of gas are taken out to the main stack by a fan where they are let out

by a chimney.

Pulverization of coal:- The fuel used for the burning of clinker is coal. Coal with

a volatile content of 18-22% is used. Coal is stored in out side stock piles. It is

stacked and reclaimed in similar fashion s limestone. It is then conveyed to the

coal grinding mill where it is ground to the required fitness and is used as and

when required. Indirect firing method is used for the burning of the clinker. I this

system the coal is simultaneously ground and dried as it is stored in the bin and

with this system exhaust air from the mill is deduced and discharged into the

atmosphere.

Preheating and Precalcination:- Heat liberated in the rotary kiln can be

advantageously utilized for preheating the material. To this inlet zone of the kiln

may be equipped with steel or ceramic materials ,which assist the exchange.

Preheating and Precalcination:- Heat liberated in the rotary kiln can be

advantageously utilized for preheating the material. To this inlet zone of the kiln

may be equipped with steel or ceramic materials, which assist the heat exchnge.

Preheater cyclones:- In the preheater about 80% of the heat transfer takes

placetakes place in the gas ducts and only about 20%in the cyclones. Gas ducts

and cyclones are lined with some refractory material. The preheater consists of

six cyclones arranged upon the other. Gas ducts connect the cyclanes. The

cross-section of the uppermast gas ducts is circular.

Air Slides:- These are the means of internal transport. These have four slides

arranged alternatively. The fixed slides have the function of giving a push to the

moving slide carrying the material.

Kiln Feed:- Both the chemical composition and the rate of feed of raw mill to the

kiln must be consistent to avoid kiln instability and to minimize fuel consumption.

Short term feed fluctuation as well as average feed rate should be monitored.

Kiln feed is monitored by -

Chemical analysis on one or two hourly grab samples to determine

statistical variation. Analysis is of usually of major oxides but may also be

carbonate titration. If oxides measured, Statistics should use C3S or LSF.

Kiln feed is normally conveyed by bucket elevator to the top of the pre-

heater to minimize power consumption. If this conveying is effected

pneumatically, de-aeration is desirable before injection as an entraining air

otherwise add to the kiln ID fan load and may reduce the Kiln capacity. Kiln feed

to the clinker ratio is typically 1.65-1.75 and, after determination, should be

periodically reconciled with clinker and cement inventories and with measured

dust loss in the pre heater exhaust.

KILN FEED = CLINKER + LO1 + BYPASS DUST + DOWN COMER

DUST -COAL ASH.

Where both bypass dust and down comer dust are converted to ignited basis.

Unit 2.6 Burning and cooling (Kiln Operation):-

The basic cement kiln system comprises a pre heater in which feed

material is prepared by heat exchange with hot exhaust gas, a fired rotary kiln in

which the clinkering reaction occur, and a cooler in which the hot clinker

exchanges heat with the ambient air.

Kiln feed is subjected to successive reaction as its temperature increases-

TEMPERATURE PROCESS100 degree Celsius Evaporation of free water.>500 degree Celsius Evolution of combined water.>860 degree Celsius Caco3 = CaO + Co2>900 degree Celsius Reactions between CaO and Al2O3, Fe2O3 and SiO2.>1200 degree Celsius Liquid formation.>1280 degree Celsius Formation of C3S and complete reaction of CaO.

Cyclone preheated kiln have developed rapidly in past few years. The first

unit was 4-stage pre heated. Larger kiln now have even two or three strings

together with preclinker (secondary combustion vessel between kiln and

preheated) allowing to greatly increase the capacity per day by large. In cyclone

preheated kiln without precalciners the feed is 20-40% calcined at the kiln

entrance. In addition calciner vessel allows calcinations up to 90% before the

meal enters the kiln. Precalcination should not exceed 95% as completion of the

endothermic reaction would allow a dangerous material temperature rise before

entering the kiln with probable build up and plugging.

Kiln System

There are basically five types of kiln, defining the meaning of their names

-

Wet process kilns

Semi-dry process kilns

Dry kilns

Pre-heater kilns

Pre-calciner kilns

Here in GACL there is only one rotary kiln which is dry in nature.

Clinker free lime should be as high as possible to avoid the problems of

hard burning, but safety below the onset of mortar expansion, typically between

0.5-2% excessive heating should be investigated immediately and may be

indicative of incorrect feed rate measurement or feed chemistry. Over burning

always account for wastage of kiln repertories like fuel, increases power

consumption by cement mill and reduces cement strength.

Secondary air temperature should be as high as possible in order to

recover the maximum heat; usually 800-1000 degree celcius, this involves

optimizing clinker bed depth and air volumes injected to the first cooler

compartments. Measurement of temperatures in the kilns is done by

thermocouples which can be misleading due to radiation as this is done in the

hood. Mainly 60% of the fuel is fed to the calciner while 40% of fuel is burned in

the kiln. Kiln operation is noticeably also depends on the type of bricks used.

Basically, they are tapered fitted in a circle and in the end the last brick

fitted is called as key brick because of its shape as per the requirement which

works like a lock. This arrangement is laid once or twice in one year as per the

usage and the requirement of the company. For kiln with grate coolers, the

burner tip should be in the plane of the kiln nose (hot) or slightly inside the kiln

providing it does not suffer damage from the falling clinker. Kiln rings are

sections of heavy coating, usually in the burning zone.

Kiln Control

Kiln operation is a complex artof which the principal control variables are:

Typical Aim1. Burning zone temperature (pyrometer or indirectly from kiln drive power)

1500 degree celcius2. Feed-End temperature 1000 degree celcius3. Feed-End oxygen 2.0%

Control is affected by adjustments to the kiln speed. Kiln speed should be

such that volumetric loading is within the range of 10-13%. Typically in the

cyclone preheater kilns rotate at 2-2.4 rpm and have material retention time of

upto 20-40 mins. Precalciner kilns rotate at 3.5-4.5 rpm for similar retention

times. Kilns are frequently operated to the limit of the ID fan. In this case low

oxygen must be corrected by reducing both feed and fuel. The oxygen level

required at the kiln inlet will depend on kiln stability and combustion efficiency;

with a good flame, 1-2% 02 should result in less than 100 ppm CO while an

unstable flame may yield in excess of 0.1% CO with 3% O2.

Useful information on kiln operation can be obtained from frequent (2-

hourly) analysis of clinker for SO3, and periodic (8-hourly) sampling of the

underflow from the bottom cyclone stages for SO3 and Alkali determination.

Normal SO3 levels (0.6% in clinker and 2-3% in the underflow) should be

determined and maintained. In precalciner kilns, retention time and heat loading

are particularly low and alkalis (K,Na) tend to pass through to clinker while

sulphur is volatilized and builds a cycle at the back of the kiln. If the kiln is

burned too hot, this cycle increases excessively until build-up or cyclone

plugging occurs. This is matched by an abnormally low SO3 content in the

clinker. Eventually, if the kiln is allowed to cool, this sulphur is released and

transit high clinker SO3 results. Such variation in clinker SO3 will also give rise

to varying grindability in the finish mill. Here in this plant everything regarding

the kiln control is done automatically.

Kiln Start-Up and Shut-Down

The various steps in this process are kiln warm up; warm-up for shorter

stops where the kiln is still hot, say stops of less than 24 hrs., are conventionally

accelerate to half the shut down time. Shut down may either be:

Emergency, in which case all equipment up-stream of the failure must be

stopped immediately, or

Controlled, in which case feed bin and coal system should be emptied,

the kiln load run out as far as possible, and the cooler emptied. The burner pipe

is withdrawn, or cooling air is continued through the burner, and the kiln is

rotated on a schedule for about 2 hrs. until cold with the ID Fan running at

reduced speed.

Kiln Refractories

Typically, brick from the kiln nose to the back of the high alumina brick

section should be replaced if found to be 10 cms. or less thickness, but this rule

of thumb varies in different operating conditions. Normally the life period of

bricks is 6-8 months. A useful practice is to drill through the brick every meter

whenever the kiln is down and coating has been striped. Changes in fuels, feed,

or burning conditions will affect the location of the burning zone. Roughly the

basic brick should extend back to the top of the coated zone. Coating location

and refractory condition are usually monitored during operation with a shell

scanner. Warm areas of the shell can be controlled by the use of a fixed fan

array or moveable fans which can be directed at the area.

With considerable variation, installed brick thickness is related to internal

kiln diameter:

< 4.2 m Diameter 180 mm

4.2-4.7 m 200 mm

3.7-5.2 m 225 mm

> 5.2 m 250 mm

and brick specific gravities are approximately:

Magnesite 3.05 70% alumina 2.30

Spinel 2.95 % alumina 2.05

Dolomite 2.80

Preheater cleaning: It done by using air-lances, jack-hammers, high pressure air

and water blasters to avoid plugging and build-up materials.

Kiln Fuels

Traditional kiln fuels are gas, oil or coal. The choice is normally based on

price and availability. It must be noted, however, that fuels are usually priced in

terms of gross heat (heat available assuming water in combustion product is

condensed to recover latent heat of vaporization). In practice, the only net heat

employed (assumed that water in combustion gas is released as vapor).

Flame temp. (degree celcius) Combustion gas (Nm3/Million cal) Total exhaust gas (Nm3/Tonne clinker)COAL 2250 1.23 1360OIL 2350 1.31 1420GAS 2400 1.45 1550

Coal, much more than oil or gas, is liable to compositional variation.

Combustion Comprises (Mixing/Ignition/Combustion Reactions/Product

Dispersion)

In the most industrial processes, mixing is the slowest and therefore, rate

determining step.

Coal Firing

Coal firing for cement kilns falls into two basic systems. Direct firing

involves grinding of coal and feeding directly to the burner with all of the

drying/carrying entering as primary air (typically 15-30% of total combustion air).

Indirect firing involves intermediate storage of ground coal and separate cleaning

and venting of the drying/carrying air. There are several variations on the basic

coal firing systems.

There is a common assumption that indirect firing yields higher thermal

efficiency by reducing primary air and by excluding the waste vapor from coal

drying. Such claims are largely invalid due to the poor fuel/air mixing of low

primary air burners while water vapor in the flame has a catalytic effect on

combustion. Of more importance is the ability of an indirect system with a single

mill to supply two or more burners where a pure direct system requires one mill

per burner. Note that significantly volatile matter and with it the heat content

may be lost by venting the milling system.

Clinker Cooling

The clinker cooler serves to cool clinker form the 1200 degree celcius at

which it leaves the kiln to less than 100 degree celcius by exchange of heat with

ambient air which is, thereby, preheated before entering the kiln (or precalciner)

as combustion air.

By far the preponderant type is the Reciprocating Grade Cooler first

introduced by Fuller Company. This comprises of a series of undergrate

compartments with separate fans which allow individual control of pressure and

volume of injected cooling air. There are basically three types of coolers -

Rotary coolers which are simple rotating drums which lift the clinker to fall

through the incoming combustion air stream effecting heat exchange, these are

preferred for small kilns - planetary coolers comprise a ring of tubes attached to

the kiln shell and turning with the kiln, which serve as multiple rotary coolers,

they are not so fondly used due to some mechanical problems - g-coolers are

effective in producing low temperatures clinker in combination to the planetary

coolers, a low air volume grade cooler or to increase the cooling capacity.

Clinker, after the primary cooler and clinker breaker, is allowed to settle slowly in

a bed with heat exchange to air cooled tubes.

Kiln Mechanical

Although it appears to be a straight, cylindrical, steel tube it does, in sag

between support piers deform in cross-section. While the cross-section is

generally considered elliptical, the orientation of the long axis usually varies from

one area of the kiln to other. The kiln in GACL is 70 m x 30 m x 30 m approx.

the temperature of the kiln shell is measured with help of optical pyrometer. The

kiln shell is designed to provide a gas tight support to the refractory lining of the

kiln. The shell also imparts rotary motion to the refractory lining in order to

convey the raw meal through the kiln and to discharge the clinker produced.

There are roller shafts for providing roller thrusting.

Kiln Seals: These are required at the inlet and the discharge ends to exclude

false air. False air at the feed end not only reduces capacity and efficiency but,

introducing cold air in the middle of any volatile cycle, tends to cause serious

build-up and also interferes with both material and gas flow.

Kiln Shell Design: It has historically been based on consideration of kiln shell as

a beam of cylindrical cross-section. The shell thickness is selected to maintain

calculated material stress levels well within the steel’s capabilities as per the

particulate usage.

Tire Thrusting: It is the excessive thrust loading on a tire is indicated by hard

contact between the kiln tire and its retaining mechanism.

Kiln Drives: They generally utilize the girth gears and pinions designed to give

over 20 years of continuous service if lubrication and alignment are maintained.

As older kilns are upgraded it is common for drive speeds to be increased and

this is usually accomplished in one of three ways.

Gear reducer ratio changes.

Weakening of d.c. motor field strength.

Utilizing higher than rated motor frequency on a.c. induction motors with variable

frequency drives.

Kiln Alignment and Requirement

Most kiln designers limit bearing pressure between rollers shaft and

bearing. Kiln support rollers are designed to bear the weight of the kiln as well

as some of the downhill thrust acting along the axis of the inclined kiln.

Corrosion - In this the kiln shell is not normally a serious problem unless high

levels of sulphur or chloride are present.

Emergency Power: Electricity supply is always prone to interruption and this can

result in significant damage until precautions are taken. The best system to be

used is a Diesel Generator (of 1MW) to be used which starts automatically upon

failure of the main power supply.

Unit 2.7 Finish Milling

Cooling Air Fans: The correct choice of cooling fan is of major concern with

regard to efficiency and the electric energy or power consumption of cooler.

Good heat recovery is possible only if the cooler is operated with a bed of clinker

with a corresponding high air flow resistance. For this reason fan in the hot zone

should be able to develop a sufficiently high pressure. The minimum pressures

for the fan supplying air to the recuperative one are for single stage cooler 30

mm bar. There are two chambers in a cooler. One is a material chamber and

other is an air chamber. The material chamber has a conveying system called

pan conveyors. The raw material becomes red hot in this chamber from the heat

generated in the kiln.

Clinker Storage

Clinker as discharged from the cooler is liable to be, at least intermittently,

at high temperature. A convenient transport system avoiding intermediate

transfer is a steel deep-pan conveyor which can elevate the clinker at upto 45

degrees to the top of the clinker storage.

In combination with cement storage, there should be adequate clinker

capacity to maintain cement shipments during kiln maintenance. While total

clinker capacity should be equivalent to at least 14 days of kiln production, there

must also be separate storage for different types of clinker which is high lime

free also. Clinker is fed into it by two speed bucket elevators and discharged

through for bottom outlets. Clinker storage serves also to blend the clinker and a

silo should not be filled and discharged to milling at the same time unless the silo

has multiple discharge points to avoid short-circuiting.

Finish Milling

Finish milling is the grinding together of clinker with some 3-5% gypsum,

natural or systematic, for set control, and other additives (e.g. pozzolan, slag and

limestone) where appropriate for performance and permitted by specification.

Finish grinding involves the largest and consumption of power in cement

manufacture and should be optimized.

Separators

Several types of separators are employed in mill circuits and there are

numerous variations in each -

Grit Separators

Mechanical Separators

High Efficiency Cyclone Separators

Rotary Classifiers

Cement Storage and Dispatch

The storage of cement is dealt in the same silo fashion. There are four

big silos 20-25 ft. in height having capacity of 50 thousand tones. It is

dispatched after packed in 50 kg bags filling the trucks (25 T each approx.) as

the transportation here is by road to all other parts of the country. Daily 1000-

1500 trucks or even more are dispatched from the GACL unit of Himachal

Pradesh.

Cement Mill

In a cement mill there is a rotary furnace, which carries rollers inside it.

When the raw material in the form of clinker, gypsum, etc. gets internally it

through the belt conveyor from the kiln it is given a rotary motion. The rotary

motion refurnace, when the raw material in the form of clinker and gypsum etc.

then it comes in contact with so many rollers falling up and down the clinker gets

crushed and there are again recirculated to the furnace by an o-sepa fan. The

function of the o-sepa fan is mainly separation of course and fine particles during

crushing. The fine particles gets collection in the furnace, while the fine are

stored in a R.C.C. silo.

Unit 2.8 Pollution Control

Three principal types of dust collection are used in cement plants.

Cyclones Efficiency of cyclones is 95%. Normally inlet and outlet

validity is 10-20 m sec.

Electrostarts Precipitators: This comprises of an array of discharge

wires at 50-100 kv negative potential and earthed collected plates.

Bag ______: These filters comprise of either woven fabric (which

___________ shaking or reverse air flow for cleaning) or needle felts

(which are cleaned by reverse air pulse). Efficiency is round about 99%

and normally the fabric used is polyster which can be operated upto 150

degree celcius, while polyamide can be used to 230 degree celcius and

glass fiber to 280 degree celcius.

Conditioning of kiln exhaust gas is necessary before dust collection. The

exhaust gas from many kilns is used for drying raw materials and this process

serves both to cool the gas and to raise its humidity before dust collection.

Pollution Control

Environmental regulation is, of course, very much a matter of national and

local ordinance. However, certain generalizations can be made about air, water,

solid, and noise pollution. Cement plants are primarily concerned with air

emissions. It is done in various departments.

Water Discharge

Solid Waste

Noise

Air Pollution

Unit 2.9 Miscellaneous

The following points are among many which require constant or periodic

consideration:

Stockpile - This inventories are often calculated from production and

consumption figures. At least monthly, all piles should be surveyed and their

capacity calculated from standard bulk density assumptions.

Silos - These for most materials are prone to developing dead material which is

not wasteful of capacity and misleading as to inventory. Silos happens are

designed for mass flow, funnel flow.

Weigh-Feeders - They should be calibrated regularly and cross checked against

both inventories and indicated feed rates at other stages of the process.

Equipment Numbering - It is done to have easy identification and location. A

typical system comprises area, equipment type and a serial number like AES

where A is for area, E for equipment and S for serial number.

Safety Lockout - The electrical equipment for maintenance is vital and standard.

Operators Data logging - It is very important to know how the equipment

___________ and run. This helps us to know about the machine and explore

the working to the fullest.

The Shift Supervisor - Here in GACL there is three shift system (i) 6 AM-2 PM (ii)

2 PM - 10 PM (iii) 10 PM - 6 AM. The handling of charges during shifting of work

is a daily routine here.

Process Alarms - This is a safety precaution, a measure that should be designed

carefully. As certain events are critical and must be dealt immediately. Critical

alarms should be designed so that the problem can be dealt with and corrected

without any loss of life and equipment. It is also useful to devise such alarms to

give attention to the unit where failures can be dealt in a proper manner.

Chapter 3

Functioning of Various Departments of GACL

GACL Darlaghat is a big cement manufacturing organization. It has 16

main departments. The working of all of them will be discussed in this section of

this report.

Unit 3.1 Store Department

The main purpose for the formation is that every department require some

material for its proper functioning, and this comes from the store department.

This department performs the function of the receipt, issue and procurement of

material. It helps in the smooth functioning of an organization because it

supplies the required material as per the requirements. One of its main function

is inventory management i.e. the management of all tangible goods in store.

Inventory management is one of the most important job because there should be

optimum stock. Inventory includes the -

Raw material used in the process.

Work in progress includes the material that is in between the raw

material and finished goods.

Finished goods means the goods which are ready for sale.

It also manages store and spare which generally deals with consumable

items and the items of plant management. The inventory may increase (first two

reasons stated below) or decrease (all other) because of the following reason -

New Receipt - material received by the department.

Return Department - material issued but not accepted by the concerned

department.

Reject - material rejected due to some defects by the store department.

Consumption of plant material - the material consume in the plant for

production.

Chargeable item to the contractors - some works are given to the

contractors by the company so if the contractors need anything that provided on

chargeable basis.

Transfer to other sites - if some material is required by some other site

then it is issued to it and put into that sites account. In the case of recording

then the store department itself sends indent about to the purchase department

about the things which are used frequently.

Working of the store department - when a department needs an item that

will send an indent. Indent is the formal requirement of the material by the user

department. It indicates the items needed by the concerned department and the

items code as all the items are categorized and coded. After receiving the indent

the store department will scrutinize the physical stock of that department lying in

the store. If the demanded quantity will be available in the store then the store

department will issue the concerned material to that department and if not

available then it will purchase order first and then send to the purchase

department. Then the purchase department will negotiate and purchase the

material and send it to the store. Then they call the person of the particular

department for the checking and verification of that particular materials. After

inspection if there is no defect then the store department makes the goods

receipt note and handover the material to the custody section. One copy of the

goods receipt note made by the store department will send to accounts

department for payment and one to the concerned department and one it will

keep with itself for the personal records. Custody section means where all the

material is kept. Materials can be categorized in various types - Spares (Sp),

Consumable stores (Cs), Explosive (Ex), Repaired item (Rp), Capital item (CI),

Capital furniture (CF). This categorized material coded accordingly and kept in

bins made for it. These materials are kept according to their weight, category.

Also sheds are used here for keeping the heavy materials. Materials are also

issued to contractors on loan basis.

Store department receives the goods on the credit term of 30 days. If the

goods return within 30 days then these will not take return back by the

department but if suppose the item (machine) has installed and it is in operation

and rejected after 30 days then this item will be on returnable basis.

It also deals with the unloading of raw material. When the trucks of raw

material come to the site, first they take the gate entry and then they are weight-

bridge the weight of the truck is measured, and afterwards the truck is unloaded

at the unloading point. By weighting the truck the store department comes to

know that how much material has come to the store what is its total quantity.

It also helps in selecting the sacks which is the method of consumer

satisfaction by performing this function. There are certain standards regarding

the bag sizes, therefore only those sacs are selected who fulfill this condition this

done because company name and customer satisfaction. Each sack when filled

with cement weighs 50 kg each.

Unit 3.2 Production Department

Production here means conversion of raw material into finished goods.

GACL is a cement manufacturing unit and it produces cement. Cement is

the main finished goods. It produces two types of cement namely:

1. Ordinary Portland cement

2. Pozzalona Portland cement

Production department is the principal department in a manufacturing unit

management fixes some target (weekly/monthly) for the production of cement

and now it depends upon the production department to achieve that target.

Production department with the help of other department viz. electrical,

instrumentation, quality control, mechanical etc. achieves that target.

Production department uses machine and material with greater care and

efficiency so that to achieve that target within the time Perivale.

This department is adjacent to electrical for continuous supply of

electricity, instrumentation for the control mechanism. Quality control for the

information regarding the cement produced is of good quality or not.

Production process is fully computerized the production department

employees see on computer the working process, if there will be any problem or

disturbance then they easily find it and inform the concern department e.g.,

electrical, instrumentation and mechanical department. So the main aim of the

production department is to achieve the target with (efficiency) optimum

utilization of machine and material.

Functioning of Various Departments of GACL

Unit 3.3 Sales and Distribution

Distribution outlet GACL Plant:

Transporter,

Stockiest, Direct Party, Dumps,

Sub-dealer, Customer

Distribution Channels

1. Stockiest or Dealer:

Stockiest have direct link with the company. The company appoint

stockiest on security or non-security basis. But stockiest must be in a

good financial position and they must have the right place for dealing.

2. Sub-Dealer:

These are not linked with company. They purchase cement direct from

the stockiest and sell it according to their convenience.

3. Direct Party:

A person/firm purchase cement in truck from company for their use e.g.

Supplies to Government orders. They are of M/s based.

4. Dump:

Dumps are GACL’s stock house from where company distribute the

cement to its dealers. There are four dumps in north:

1. Ambuja Nagar

2. Panchkula

3. Saharanpur

4. Delhi

Transport Company

GACL has made an agreement with truck transport companies which are

used for transportation of cement. There are:

1. S.D.T.O. Transport Company

2. ADKM Transport Company

3. B.L.L. Transport Company

4. Auto Hirer.

Order Processing System

This is one of the major logistic function for company. It involves the flow

of information about orders from point to point to achieve the objective of placing

the order.

Both the company and its customers are benefited when the order

processing system is carried out efficiently. Effective order processing involves

transmission of the customer order, paper processing retrieval from the

warehouse, packing and dispatch through the transporter, adjustment of the

inventory level and transmission of the information to the department of

production planning.

In Gujarat Ambuja Cement Limited also processing is given importance.

Previously it had a lengthy and cumbersome process with the order being

transmitted to the place of production via a fax or telephone, even sometimes

with the help of courier service. But now the company has adopted the modern

concept of electronic data exchange. According to this system all the major

offices of the company are linked by a network system commonly called as wide

are network. This includes the production site at Darlaghat, Marketing office at

Shimla, Regional Marketing office at Chandigarh. All the orders are fed into the

computers of the respective offices, which are linked to the central network.

Then the data gets transferred to the computers of the production site through

the modern which are connective links of the network. This is called distribution

and management system (VASMIS). The working process of the system is as

follows.

The company is involved in trading with three categories of customer.

They are Stockiest, Direct Party and Dumps.

As per the customer categorization the orders also come in three types.

All the orders are collected by the respective office i.e. the Marketing offices at

Chandigarh. The respective offices at Shimla and Chandigarh sends these

orders to the production unit through Modem. These orders come in certain for

mat. It mainly contains areas like order number, stockiest code and consignee

address. As such stockiest has a unique identification code and rate per each

stockiest is fixed according to its location. So the total amount in monetary

terms gets executed automatically after entering the stockiest code.

The orders of the direct parties are generally collected by the respective

marketing offices and sent to the production site via Modem. These orders also

come in a certain format. These orders contains orders linked consignee, party,

product specification (type of cement required) packing specification, total

quantity required, rate per metric tones, total amount of price to be paid, delivery

specification etc. First these orders come to the accounts department where the

details of pricing are filled up, then they come to the sales and distribution

department for execution he orders from the dumps also come through the

office at Chandigarh as there are no dumps available in Himachal Pradesh.

They come in form of bulk a orders. These orders do not contain any detects

like party consignee etc. They place the requirement as per the forecast made

by the marketing department. They come directly to the sales and distribution

department and subjected to execution.

Then it is the duty of the sales and distribution department to execute the

orders according to the degree of their priority. As the beginning of each day

analysis of new orders and the pending ones are done and as per laid policy

decision is taken as to which orders are to be executed on that day. Then such

orders are put on the network. Which are then displayed on the screen of the

computers at the transport organization offices.

Unit 3.4 Quality Control Department

Gujarat Ambuja Cement Ltd. is a modern cementing plant. It is the first

plant in India, which has been awarded ISO-9002 quality system certification by

Bureau of Indian Standards.

The plant laboratory is responsible for -

analysis of raw material and fuel.

mix design which should reflect individual raw materials costs,

production costs (principally drying, grindability, burnability) and product

quality.

preblending of raw materials and blending of kiln feed to minimize

chemical variation into the kiln.

process controls involves raw materials moisture, raw meal fineness,

clinker free lime, degree of calcinations and volatile components of hot

meal at the kiln inlet, proportioning of clinker and gypsum, and fineness of

milled cement.

chemical analysis and physical testing of cement to confirm and certify

compliance with specification.

miscellaneous functions such as water treatment and laboratory

measurements associated with process engineering and pollution control.

Quality means commitment made by the producer regarding product to

the consumer. Here in this laboratory segregated raw material from the feed

and mines is tested and passed. Here is placed an imported machine of X-Ray

from Denmark with its samples for verificational check, setted-up by FLS

(FULLER). Various other apparatus are also present here like Blain’s for

measuring the cement strength. It is here where it is told how much percent of

various components should be added or removed or maintained by checking the

percentages (%) of all the components of cement likely Lime, Shale, Gypsum,

Iron Ore. It is in this section where a check on mixing of SiO2, A12O3, Fe2O3,

CaCO3 is kept under vision. This is the one department mainly responsible for

the difference between manufactured OPC and PPC.

Quality Policy and Implementation

The quality policy of Gujarat Ambuja Cement Ltd. is: ‘To achieve total

customer satisfaction by providing product and services that meet or exceed

customer expectation based on agreed specifications’.

All the people and element of our organization be committed to

excellence; it means that “Do it right the first time”. To built quality operations to

ensure quality product and services and thereby achieving excellence in

consistent quality satisfying the consumer needs has been the objective of the

Ambuja cement quality policy.

Quality Planning

The requirement of quality system are met by following procedure which

is described in detail as follows: -

The identification and acquisition of any control/process equipment

(including inspection and test equipment) fixtures, resources and skill that may

be needed to achieve the required quality procedure and applicable

documentation.

The updating, as necessary, of quality control inspection and testing

techniques including the development of new instrumentation.

The identification of quality is the acceptability for all features and

requirement including those which contain a subjective element.

Quality Control Procedure

Calibration of process equipment is being done by instrumentation,

periodic calibration for various testing equipment are carried out and records of

such calibration are kept.

The measurement to be made and the accuracy required is determined

and accordingly appropriate inspection, measuring test equipment is selected,

which is capable of the necessary accuracy and precision.

All the measuring and test equipment are calibrated periodically using

standard calibration devices. Standards suitable tags are provided to identity the

calibration status.

Proper calibration records for inspection measuring the test equipment

are maintained.

The validity of previous inspection and test result will be assessed and

documented when inspection measuring or test equipment is found to be out of

calibration.

It is ensured that the environmental condition for inspection, calibration

and measurement are suitable.

The inspection measuring and test equipment are properly handled pre

served and stored to ensure it accuracy and reliability.

Chemical Analysis - process control requires on-line or rapid off-line analyses in

order to adjust the raw material proportions to the raw mill. Here in this plant X-

Ray Flouroscence is employed using either pressed powder or fuse disk

samples to draw better inferences. Sampling or samples tested here are every

one or half hour basis.

The strength of cement depends on six basic factors -

1. Chemical Composition

2. Mineralogy

3. Particle Size

4. Retardation, mainly sulphate form and activity gypsum control with lime.

5. Dilution of active components

6. Prehydration of hydraulic components

Quality Policy

To achieve total customer satisfaction by providing products and ensure

service that meet or exceed customer expectation based on agreed satisfactory.

All the people and element of our organization be committed to

excellence. It means that

Do it right the first time”.

To build quality into operation and to ensure quality product and services,

thereby achieving excellence in organizational performance.

Unit 3.5 Environmental Department

Right at the time when company started its operation it had promised the

people to keep the environment clean the company has managed to live upto

the promise. The pollution levels at the company plant are even lower than the

stringent Swiss standard. The people at Ambuja have taken it upon themselves

the responsibility of greening the mining area.

This plant is located in an ecologically sensitive zone.

A separate department called environment department has set up hot

only to check the pollution level in plant site and nearby villages but also

engaged in the plantation and other community welfare programmes.

Environmental Policy

The Gujarat Ambuja Cement Ltd. an environmentally conscious company

has always been committed to sustainable development. We at Himachal Unit

both plant and mines, therefore will strive to:

Adopt Eco-Friendly practices and technologies.

Maintain and strive to go beyond compliance with environmental

regulations.

Build environmental awareness amongst the employees and neighbouring

community.

Utilize all resources efficiently.

Join together in common endeavour for continual improvement.

Accelerate plantation within outside our facilities.

We shall achieve our goals by setting appropriate objective and targets,

the Ambuja way.

Unit 3.6 Personal Department

The various function that this department performs are recruitment,

selection and training of the employees.

Recruitment

IN GACL the recruitment based process is need based analysis of

recruitment process in GACL reveal that whenever vacancies are created by ill

health demotions and separation the young talented and experienced personnel

are recruited and selected.

After deciding about the number of people to be recruited, the qualification

for individual positions are identified and then vacancy is advertised in leading

newspaper of India. Recruitment can be internal also. Vacancies are filled by

promotion of the existing employees.

After responding to the vacancies in the newspaper candidates apply for

the job. All the candidates who fit for the job their qualification matches the job

then they are called for the interview by the company.

Selection

Then comes the selection of the suitable candidates. Selection of the

suited candidates is promoted by company is interviewed by one or more people

(interviewers).

The panel for interview consists of different persons from different

department.

Mainly there must be one person from personnel department and other

from the concerned department. Panel asks different questions to the

candidate. Interview may be structured, semi structured or unstructured.

After evaluating the performance of candidate the candidate are short

listed. Interview is supplemented by data from the application form and the

information obtained from persons listed as references. References checks and

letters of recommendation may be necessary to verify the information given by

the candidates.

Short listed candidates who are suited for the job then selected for the job

before the formal selection prospective employees are interviewed by the vice

president operation and then only candidate is selected for the job.

Selection procedure is followed by approval and issuing a letter for * M-O.

O-OAA. To M-1 Grade approval & offer letter is issued by managing director.

For * M-1A Grade selection is approved by managing director and appointment

letter is issued by concerned director.

For * M-2A, M-3, M-4, M-5, M-SB, S & S-2 grade selection is approved by

concerned director and appointment letter is issued by joint president or vice

president. These are applicable at site at production department.

Mechanical, instrumentation and electrical for commercial department

approval is made by concerned director and appointment letter is issued by Dr.

Vice President or V.P. Commercial for mines and geology department approved

is made by concerned director and appointment letter is issued by joint president

mines and geology. For Account or EDP (info. Tech) system and Audit approval

is made by concerned director and letter is issued by joint president finance.

Total No. of employees - 385.

Grading in the Co. is done in the following manner:

Managerial grade include top level Mgr. and Middle level Managers total

No. of employees in Managerial grade

GRADE DESIGNATION

M-OA. M-1. M-1A Asstt. Vice President

M.D.G.M.

M-2, M-2A Sr. Mgrs. & Mgrs.

M-3 Dy. Mgrs. & Asstt. Mgrs.

M-4 Sr. Officers, Sr. Engineers

Sr. Account Officers

& Engineers

At the supervisory level the Co- has 98 employees and their grade is M-

5A, for the clerical job the no. of employee- 18 M-5A, M-5B-Sr. Asstt. Sr. Officer.

Sr. Engineer foreman. Charge head. Asstt. Charge head.

At the lowest level

The grades are:

WRK & W - B Total No. of employees in these grades are 116

These grades includes:

Hemo: Heavy earth equipment movement operators

Machine attendees, spotters, Blaster. Helpers. Electricians.

Training of the Employees

Training provided by the company to its employees is need based. Head

of every department identifies the training needs of his subordinates and sends

the list of the personnel department and personnel department prepare a training

calendar for the year and the trainees. They have to work as per the training

calendar. The training is imparted both on job and off the job. Often outside

facility from various professional institutes and from the industry are invited for

training of the employees. The company not only conduct training programmers

to input technical skill to the employees but workshop on personality

development and quality control etc. are also often conducted by renowned

person from the industry are also invited to give lectures and valuable

suggestion and answer to the queries of the employees.

The company owns a regional training centre at Ambuja Nagar in Gujarat

which offers specialized training course. Employees from other plants and office

are also sent here for training courses the company also sends and employees

to other training institute if necessary.

Welfare Measures

One of the main strength of Gujarat Cement Ambuja Cement Ltd. is the

dedicated work force, which has played a crucial role in the growth and success

of the company. This has been possible due to the various facilities provided by

the company for the welfare of its employees the various welfare measures

adopted by the company at its Himachal plant are as following:

a) Housing: The company provides good housing accommodation to its

employees at the Darlaghat plant of separate residential colony has been

built by company for its employees having 264 flats.

b) Education: The company has opened school named D.A.V. Ambuja Vidya

Niketan which provides quality education to the employee’s children and also

to the children of resident nearby village. The company has also provided

hostel facilities at Shimla and Chandigarh for the employees children who are

pursuing higher education in the above mentioned cities.

c) Medical: The company provide excellent medical facilities to its employees

inside the plant. There is a hospital in the premises of the plant having four

well qualified doctors twelve other people in the medical staff. The company

has also arranged for these visiting specialists doctors who visit the plant

once in a week the company also runs a mobile van which provides medical

facilities to the nearby village.

d) Transportation: The company provides good transport facilities to the workers

to enable them to reach their work place at time also bus facility to Shimla

and Chandigarh. The company provides car and motorbike to its employees

for their routine needs and convenience.

e) Library: There are two library in Himachal Plant. One is the technical library

staff of the plant and the other is general library having subscription of many

renowned magazines and journals.

f) Recreation: The company provides samples recreation facilities to its

employees. A club at the Himachal Plant is a good source of entertainment

for the employees.

g) Cooperative Stores: A cooperative store in the plant cater to the daily needs

of the employees. Every daily needs item is available in the store.

h) Intramural: These services provides within the establishment. These include

free uniform, raincoats, gum boot, free tea and snacks coupons, canteens

and mess etc. The company also provides safety shoes and safety helmets

to its employees and workers.

Personal Manuals (Personal Policies)

1) Leave entitlement (for on grade employees)

Privilege leave - 30 days leave with full pay after every 11 months continuous

employment. The PL is counted from the date of joining in employment and it

can be only availed after conformation of service or on completion of six

months of continuous employment whichever is later.

Casual leave - 10 days leave with full pay every year. The CL is counted

from the date of confirmation or the conformation of 6 months of employment

whichever is earlier.

Leave entitlement for engineers/officers on 1 year probation - 10 days PL

with full pay during 1 year probation period on month wise calculation.

Leave entitlement for trainees - for first year training stiffened 10 days leave

and for second year 20 days with full pay.

Leave entitlement for wage board objectives -

a) 18 days earned leave (EC) is 1 day EL for every 20 days attendance. It is

clarified that no earned leave shall be earned during the period when an

employee is on leave.

b) 7 days casual leave (CL) in one calendar year. CL is credited proportionately

if the employee does not complete one year.

c) 12 days sick leave (SL), 1 day SL per month. However, if it is a fraction of

leave less than one day it will be counted as one day for calculation

purposes.

Compensatory off: employees cover under M-4, M-5A and M-5B

grades and work trainees are entitled for compensatory off against

duty on paid holiday, weekly offs or normal additional 8 hrs.

working.

Holiday - 7 holidays (3 national and 4 festival ones) are observed at plant site

every year. The list of holidays is declared on the 1st of January of every

year.

2) Traveling rules - traveling rules as described below are applicable for all the

officers tours undertaken by the employees of the company at all the location.

Mode of Travelling and Conveyance

Grade Mode ConveyanceM-O Air/1st AC TaxiM-OA Air/1st AC TaxiM-1/M-1A Air/1st AC TaxiM-2/M-2A Air/2nd AC Public taxi/3 wheeler/coachesM-3, M-4 Air/2nd AC/1st 2nd 3rd class Public taxi/pb.tpt./autorksM-5A/M-5B 3rd AC/1st class Public taxi/auto/public tpt.

3) Regarding Transfer -

# rules regarding expenses on transfer.

# additional increment for staff transferred on green field locations.

# rules regarding deputation and deputation allowances.

# rules regarding transit leave and doing time.

# displacement allowances.

4) Policy regarding allotment of accommodation of staff in township.

5) Policy regarding loans -

$ loans provided are interest free.

$ loan scheme for employee and for house old items, computers, two

wheelers, cars.

$ medical expenses for self and family member.

$ higher education expense for self and family members.

$ major repairing expenses for self and children.

$ major repair of house or flat owned by the employees.

6) Policy to provide scholarships to employees children - this is based on the

merit provided based on the stream. For medical/engineering these are given

every year.

7) Scheme for educational allowances - with a view to improve the quality for

every staff member, the company encourages those who wish to acquire

additional professional qualification as relevant to their responsibility and

expenses incurred on their count by the staff is reimbursed by the management.

This scheme is available to all confirmed employee at M-3 grade and who have

served at last three years for the company. The various qualification and the

amounts are as follows -

half year degree/PG degree prog.

Rs.2500/year

half year diploma/PG diploma prog. Rs.1500/year

prog. of less than one year but more than three month duration Rs.1000/year

8) Regarding issue of uniforms, safety shoes, helmet and rain coats and gum

boots - all image board operative are provided two sets of uniform, one pair of

safety shoes every year. Each employee working inside the plant and mines are

provided with safety helmets which they have to wear compulsory while at work.

All employees working at the plant are provided with rain coats for a period of 3

years and for those working at the mines are given rain coats and gum boots for

a period of 2 years.

Unit 3.7 Instrumentation Department

The main function of this department is also related to maintenance and

upkeep of plant and machinery. The department also looks for

telecommunication and the cable network in the plant. Overall control of the

plant is managed by this department. This is the department which looks after

each and every activity going in the plant. Anything to inquire about or to ask go

to this department.

Unit 3.8 Accounts Department

Accounts department deals in receipt and payment. This department is

divided into three sectors: -

i) Sales Accounting - This sales department deals with the receipt and

payment concerned with the sales of cement. The department to various

parties, dealers, stockiest and credit note are also issued by this

department to the stockiest.

ii) Purchase Accounting - This department keeps all the records related to

the purchase and transportation cost of that purchase.

iii) General Accounting - This section does all the work except sales and

purchase accounting. This section makes trial balance and consolidated

balance sheet for all other branches. It marks on daily bases each flow

statement and sends it to corporate office Mumbai. Other records which

it keeps are scarp sales accounting. It also does the insurance related

work. Insurance of those machine and items which are very costly mean

capital items.

Unit 3.9 Audit Department

Audit is the examination of the books, accounts and vouchers of the

business. The purpose of this department is to satisfy criterion of balance sheet

shows a true and fair view of the state of affairs of the business and the profit or

loss incurred by the business during the financial period, and for this particular

purpose a system called the systems audit department has been set up there.

This department is called so as per its functioning, also of each and every

department in this organization a designed procedure has been given by this

department and frequently checks are done by the employees of this

department to see that there should be no malfunctioning in the organization.

The various checks, timely execution of orders, invoicing, material

reconciliation, rates, etc. are dealt within this department.

Unit 3.10 Electrical Department

This department caters to the entire plant related electrical joint, as it has

electrical workshops scattered in all the plant. Basically, the machinery

necessary equipment is designed and given by Kirloskar. Income supply of

electricity is of 132 KV has step down into 6.6 KV and 415 KV for distributing in

the pant, residential colony, offices and for other purposes.

This department helps the production department to produce the cement

by supplying uninterrupted stable power. This department also takes up

maintenance jobs for the smooth functioning of the plant. Here there is set a big

electric power switchyard station where there are big transformers for stepping

up and stepping down the electricity supply.

In the electrical workshops the motors which are not working properly are

repaired, oiled and checked before taking them again in work. There are

roundabout 15-20 DC Motors which cost about Rs.70,000-80,000 each. Then

comes AC Motors which are roundabout 1300-1500 in number in the plant and

are costing 15,000-20,000 each. After this there are HT Motors which are 20-25

in number in the plant and depending on there capacity is their cost like a HT

Motor of 2000 KW costs about 25 lakhs.

DC Motor - It basically consists of main poles and inter poles, with armature

winding on rotor (moving) and field winding on stator (static). It also has carbon

brushes for output current.

AC Motor - It consist of rotor and stator a arrangement just as opposite in above

case i.e. AC Motor and has a basket winding, a laminated coil which is stamped

called core, duty, insulation, connections (Delta or Star), phases (1/2/3), may be

of ckh or kh i.e. with gear or without any gear. If gearbox present then it

consists of three pinion arrangement primary, secondary, final to reduce the

rpm. AC Motor also has a squirrel gauge arrangement. Here always the length

of stator is always equal to the length of the rotor.

HT Motor - This is an extended version of AC Motor with a slip ringed version.

Gear oil is used here for lubrication purposes along with grease and sealant is

used to seal off the motor.

Unit 3.11 DG Power Plant

Gujarat Ambuja Cement Ltd. has a captive power plant of 24 MW DG hall

at Himachal Pradesh. Here there are 4 diesel generators stated up for providing

necessary power supply to the plant. This power plant ensure uninterrupted

stable power to the cement plant during the time of power failure, low voltage,

etc.

These diesel generators are setted-up here by WARTSILA DIESEL, which

are made in Finland and imported here. The main concern of this section is to

run the kiln drive which requires about 9 MW of power supply in case of a

breakdown. These are IC Engines (internal combustion) with V-type cylindrical

arrangement than L-type of model type 18V32 where 18 is the no. of cylinders.

V is the type of arrangement. 32 is the diameter in cm of the bore. Generally

here Furnace Oil is used instead of Diesel or Petrol. These are 4-Stroke engines

with a crank shaft and cam shaft arrangement. The concepts of Turbo Chargers

(TC) put into action for increasing the efficiency of the engine. The basic

process goes in this manner that FO is fed to the storage tanks then to settling

tanks for purification then to day tanks and FO separator where there are pump

and heaters used to further purify this oil fed to the generators. After this it goes

to the feeder unit to the booster unit to pump and filter units and lastly according

to the load is fed to the Engine. Here there are three stages first the valves

open then close and lastly fuel is fed. At this point the ignition starts in this

manner according to the V branches of cylinders A,B 1-7-4-2-8-6-3-9- according

to mass balance relations. In the engine there is an alternator, a fly wheel,

water used as coolant, air pressure rotation, Lube Oil used as a lubricant and for

the extraction of heat. At every 40 degree movement of fly wheel there occurs a

Power-Stroke. Spur gears are also used here.

Unit 3.12 Civil Department

Civil department handles jobs like cleanliness of the plant, maintenance of

the building and construction jobs, etc. This department has mainly three wings

-

a) Project wing - this project does also the major construction work.

b) Developing wing - this wing does all the modification in the existing projects.

c) Maintenance wing - this does all the maintenance, repair-jobs and keep

everything clean at the plant site.

Additional function performed by this department are - rural department,

construction of the road, construction of temples and pedestrians.

Unit 3.13 Mines

Limestone is the main raw material for the production of cement.

Limestone mines are 3 KM (serial distance) a far from plant site. The limestone

from mines situated at Kaslog is transferred to the plant from the conveyor belt

which is 2.8 KM long.

Mining Operation - Fully mechanized open cast mining method is adopted for

quarrying the limestone. The ripper rips up to a depth of 1M to loosen it and

there after marks of heap of loose material. Blasting and drilling is carried on

after initial opening of the quarry phase by ripping. All the big boulders are

broken by using the hydraulic rock broker. The hydraulic excavators and front

wheel loaders are used for excavations and toaching of blasted and ripped

limestone into 35 tones rear dump trucks. The transportation to the limestone

from the working faces of mines to the crushing plant and stock pile yard is

called hauling. After hauling the limestone from here is fed to the limestone

crusher (impact crusher) by rear dump truck. A push feeder arrangement is

made at the inlet point of the cursor. It can crush a maximum of 1Mx1Mx1M

sized limestone into required size, which is to be transported through over land

belt conveyor for the cement manufacturing.

Unit 3.14 EDP

GACL is a fully computerized manufacturing unit. All the computers are

connected through LAN. The main function of this department is to development

software for the plant to take care of the various commercial application. The

department also provided software support to the plant. This department also

provides computer training to the employees of the organization when new

system develops.

Unit 3.15 Costing Department

The costing department is one of the main departments in the calculation

of profit or loss for the year by valuation of stock. This department takes into

consideration all the expenditure done in the company and compare the

budgeted than the department inform the management and particular

department to control the expenditure. By making these statements the cost

department helps the management to take important decision.

Cost by process area Cost by natural expenseQuarrying and crushing Operating salariesOn-site raw materials to raw milling Operating and service laborRaw milling and additives Supplies, rentals, servicesBlending Purchased raw materialsBurning and Cooling FuelFinish milling and additives PowerBulk handling and load out Mobile equipmentManufacturing overhead Maintenance including laborSub-total Grinding mediaBag premium Refractories

Unit 3.16 Packing Department

Packing department related with the packing of cement.

Process - After grinding the finished product is collected in cement silo, from the

cement silo the cement is sent to packing plant for packing through air slides. In

this process, firstly cement comes to cement hopper and the bucket elevator.

Through bucket, cement comes to packing plant. The cement is then packed in

plastic bags and loaded in trucks. The packing is three fully automatic rotary

packing.

Rotary Packers - There are three rotary packers in this plant. Every packer has

six nozzles. Capacity of each nozzle is 80 TPH. In one hour 1600 boys are

filled by rotary packer.

Truck Loader - After the packing of the cement in the bags, the bags are loaded

into the truck with the help of truck loader machine which consist of moveable

conveyors and luffing conveyors. These conveyors make the loading process

fast and convenient. In 10 minute 200 bags are loaded into the truck.

Bulk Loading of Clinker - There are three belts loading terminal in plant. By this

clinker are loaded into the truck and sent to Ropar grinding unit.

Unit 3.17 Central Control Room

All the control operations pertaining to the control of the accessories

involved in the plant are done through this room. All the units if anyone of them

malfunctions will have direct access to operational computers installed in the

central control room.

For a brief description of this CCR there are 3 pannels of touch sense

oriented computers setted by TATA Honeywell having model number TDC3000,

each panel shows similar thing and gives same information. Besides, this there

is one more panel along side for running any machine by giving command and

one panel at instrumentation section runned manually for line process. This in

the main attention oriented area of the plant which gives an overall view of the

plant (detailed in nature) by just pressing a few buttons. This is the place to

gather each and every bits and pieces of information. Here also there are

sections like Technical Library where all the books, journals, magazines and

other reading material is available taken care of cement plant operations plus a

Drawing Office which has a record of all the mechanical and particular drawings

of each and every equipment working in the plant. It also has the quality control

laboratory inside it which checks every hourly feeded raw meal.

Conclusion

GACL is a fast growing enterprise. A detailed study of the company shows

that it has a bright prospective future. Cement industry itself shows a growth

rate of 8-15%. In future, the company has also set-up its operational plants

abroad in other countries where the cement demand is in excess of supply.

Therefore the company has got a good chance there also. The company’s sale

has grown by 10.54%. The net profit has jumped to 16% in 1998-99. The

earning per share is rising, which rose by 16.93%. All these points infer to one

conclusion i.e. the company has a very good and positive future.

The dedicated workforce at Ambuja is the main reason for its tremendous

success. It is because of sheer devotion and commitment by this workforce,

therefore the company has achieved a regular production of 6-7MTPA by only

consuming 5MT. Making the most efficient use of existing asset and working

hard is the key to success.

“Give a man an order and he’ll

do the work reasonably well. But

let him see his own target, give

him freedom and authority and

his tasks becomes a personal

mission I Can”

This has worked miracles for the company. The company owes it

success will to this spirit. But the company should constantly review the needs

and requirements of its employees and take necessary steps to fulfill them. Also

the channel in the cement manufacturing should be constantly kept under the

vision of check so the work can go hand in hand easily without any problems and

this unit can compete with many other Foreign and Indian plants in this market of

cement without any problem.

This excellence performance is the reflection of the responsible and the

mature attitude of its major players. Their individual performance sets an

example for others to follow. Among those who played a major role in taking the

cement industry to the present high position, one name will always shine bright -

GUJARAT AMBUJA CEMENTS.

GLOSSARY

State Location Million TonnesGujarat Ambujanagar 4.00H.P. Darlaghat 1.16Punjab Ropar (G) 1.34Punjab Bhatinda (G) 0.50Rajasthan Rabriyawas 1.50M.P. Raipur 1.50Maharashtra Gadchandur 2.00W.B. Sankrail (G) 0.50Total 12.50

(G) - Grinding Unit

Board of Directors

Suresh Neotia Non-Executive Chairman

Vinod Neotia Non-Executive Director

M.L. Bhakta Non-Executive Director

N.N. Pal Non-Executive Director

Nmesh Kampani Non-Executive Director

M.T. Patel Non-Executive Director

Harshavardhan Neotia Non-Executive Director

O.V. Bundellu Non-Executive Director (Nominee -

IDBI)

A.L. Kapur Whole-Time Director

P.B. Kulkarni Whole-Time Director

A.V. Rao Whole-Time Director

Pulkit Sekhsaria Whole-Time Director

Anil Singhvi Whole-Time Director

B.L. Taparia Whole-Time Director & Company

Secretary

N.S. Sekhsaria Managing Director

Awards and Recognition

“National Award for Commitment to Quality” by the Prime Minister of India.

“National Award for Outstanding Pollution Control” by the Prime Minister of

India.

“ISO: 9002 Quality Certification”

“ISO: 14001” certification for environmental systems.

“Best Award for the highest exports” by CAPEXIL.

Economic Times Harvard Business School Association Award for “Corporate

Excellence”

“Best Productivity Award”

“Mines Safety Awards”

Location of the Plants and Offices

Ambujanagar 40 Kms. away from Veraval in Saurashtra, Gujarat. This location has 3 units namely Ambuja, Gajambuja and Gajambuja II. To reach Ambujanagar, there are two trains available namely Girnar Express and Somnath Express from Ahmedabad at 9.50 p.m. and 11.00 p.m. respectively. Ambujanagar is accessible by air from Mumbai. There is flight form Mumbai to Diu. Diu is around 42 Km. away from Ambujanagar.Darlaghat Near Shimla in Himachal Pradesh with one unit. Accessible by rail and road. Shatabadi Express plies between New Delhi and Kalka. You may go by road to Darlaghat, which is 92 Kms. away.Gadchandur Near Chandrapur, Maharashtra, one unit. Accessible by road from Chandrapur. Flights are also available to Nagpur from Mumbai. The plant site is around 72 Kms. from Nagpur.Bhatinda Punjab, Grinding unit. 203 Kms. by road from Chandigarh and rail from Delhi.Ropar Punjab, Grinding unit. 40 Kms. by road from Chandigarh and rail from Delhi.Muldwarka 8 Kms. away from Ambujanagar, coastal line. It’s a Bulk Cement Terminal (BCT) which dispatches Cement and Clinker and receives imported coal.Magdalla Near Surat in Gujarat. Bulk Cement Terminal (BCT). Surat is accessible by road and rail.Panvel Near Mumbai, Maharashtra. Bulk Cement Terminal (BCT). Accessible by road and harbour line local trains from Chatrapatti Shivaji Terminus Station - Mumbai.Corporate Office Nariman Point, Mumbai/Kalina, Santacruz (E), Mumbai.Regional Offices Ahmedabad, Calcutta, Delhi.

Associate Companies Capacity (million tones)Ambuja Cement Eastern Ltd. (ACEL) 18 million - Bhatapara, M.P. 100 million - Sankrail, W. BengalAmbuja Cement Rajasthan Ltd. (ACRL) 1.5 million - Rabriyawas, RajasthanTerminal in Sri Lanka 0.5 million - Galli - 120 Kms. from Colombo

General Information

1.0 Working Decorum

1.1 Work Culture

There are professional teams of people who take care all the functional

and operational requirements. We are professionally managed organization,

which encourages performance oriented productive environment. We value

employees, who have sense of integrity, loyalty, responsibility and a high degree

of commitment.

1.2 Dress Code

Most of the colleagues observe a formal code of dressing. Male members

are usually dressed in formal attire whereas ladies prefer to follow the

conventional mode of dressing. This code also applies, when employees

undergo training or go on official tours.

1.3 Hours of Work

You might like to know the office timings of other locations.

Sites

Ambujanagar

General office timings are from 9.00 a.m. to 6.00 p.m. with one hour

lunch break from 1.00 p.m. to 2.00 p.m., Monday to Saturday.

Shifts Timing

Morning shift 6.00 a.m. to 2.00 p.m.

Evening shift 2.00 p.m. to 10.00 p.m.

Night shift 10.00 p.m. to 6.00 a.m.