Grasim- South D E F I N UNIT : Grasim South TEAM LEADER : Mr.S.K.Raut TEAM MEMBERS : Mr. B.R.Sharma : Mr. Anil Bajaj : Mr. N.Ravikumar : Mr. G.Suresh Kumar TEAM CHAMPION : Mr. R.Rajagopal WCM FACILITATOR : Mr. Anurag Seksaria D E F I N

IMPROVEMENT IN CEMENT MILL PRODUCTIVITY Project Title D E F I N IMPROVEMENT IN CEMENT MILL PRODUCTIVITY

Project Charter D E F I N

Grasim- South- Process Map Cement Grinding F I N

Grasim- South- Process Map Cement Grinding F I N

CEMENT MILL OUTPUT RATE CTQ/KPOV/KPIV D E F I N CEMENT MILL OUTPUT RATE KPIV KPIV PROCESS KPOV CTQ KPIV Define Phase

CTQ/KPOV/KPIV CTQ – CEMENT MILL OUTPUT RATE (TPH) KPOV – CEMENT MILL TPH - CEMENT MILL POWER CONSUMPTION KPIVS – 1. ROLLER PRESS POWER 2. ROLLER PRESS HYDRAULIC PRESSURE 3. ROLLER PRESS OPERATING GAP 4. CEMENT MILL POWER 5. GYPSUM PERCENTAGE 6. ROLLER PRESS BIN LEVEL 7. FINE CLINKER BIN LEVEL 8. SEPERATOR POWER D E F I N Define Phase

CTQ/KPOV/KPIV KPIVS – 9. SEPERATOR SPEED 10. SEPERATOR FAN SPEED 11. SEPERATOR FAN POWER 12. SEPERATOR DIFFRENTIAL PRESSURE 13. CLINKER C3S 14. CLINKER GRINDABILITY 15. PETCOKE PERCENTAGE D E F I N Define Phase

CTQ/KPOV/KPIV PROJECT GOAL TO REDUCE CEMENT MILL POWER CONSUMPTION FROM 30 KWH PER TON OF CEMENT TO 26 KWH PER TON OF CEMENT D E F I N Define Phase

CTQ/KPOV/KPIV PROJECT GOAL CEMENT MILL PER TON POWER CONSUMPTION IS INVERSLY PROPORTIONAL TO CEMENT MILL PRODUCTION RATE TO INCREASE THE CEMENT MILL PRODUCTION RATE (TPH) FROM 130 TPH TO 175 TPH. D E F I N Define Phase

BASE LINE DATA MEASURE

BASE LINE DATA MEASURE

BASE LINE DATA PROCESS CAPABILITY POWER CONSUMPTION TARGET – 26 KWH / T OF CEMENT AVERAGE – 32 KWH / T OF CEMENT STANDARD DEVIATION – 2 Cpk - -11 PRODUCTION RATE - TPH TARGET – 175 TPH AVERAGE – 132 TPH STANDARD DEVIATION – 9 Cpk - -14 MEASURE

BASE LINE DATA MEASURE FACTOR TARGET AVERAGE SD CAPABILITY POWER CONSUMPTION 26 KWH / T OF CEM 32 2 - 11 TPH 175 TPH 132 TPH 9 - 14

MEASURMENT SYSTEM ANALYSIS THE PRODUCTION RATE AND POWER CONSUMPTION IS MEASURED ONLINE BY WEIGH FEEDER AND POWER TRANSDUCERS THE INSTRUMENTS ARE CAILBRATED ONCE IN A SIX MONTHS UNDER ISO 9000 CALIBRATION SCHEDULE. THE READINGS ARE CROSSCHECKED WITH DROP TEST. THE DATA IS AVAILABLE TO PROCESS FOR 24 HOURS ON OPERATOR SCREEN. ONLINE DATA IS LOGGED IN TO KNOWLEDGE MANAGER, WHICH IS AVAILABLE FOR ANALYSIS. MEASURE

CAUSE AND EFFECT DIAGRAM ANALYSE Material Methods GRINDABILITY OF CLINKER OPERATING CONDITION CHEMICAL COMPOSITION CONTROL SYSTEM CEMENT MILL TPH ROLL PRESS WEAR IMPROPER OPERATION BALL CHARGE IN MILL FREQUENT CHANGES SEPERATOR EFFICIENCY ACCURACY Men Machine Measurement

CAUSE AND EFFECT DIAGRAM ANALYSE SL NO CAUSE EFFECT CORRECTIVE ACTIONS 1 MAN IMPROPER OPERATION PDCA CYCLE TO BE APPLIED BEFORE MAKING ANY ADJUSTMENT IN THE PROCESS TRAINING TO BE IMPARTED

CAUSE AND EFFECT DIAGRAM ANALYSE SL NO CAUSE EFFECT CORRECTIVE ACTIONS 2 MATERIAL GRINDABILITY OF CLINKER 1. USAGE OF PETCOKE FUEL REDUCES THE GRINDABILITY OF CLINKER CAUSING UNSTABLE OPERATION OF MILL

CAUSE AND EFFECT DIAGRAM ANALYSE SL NO CAUSE EFFECT CORRECTIVE ACTIONS 2 MATERIAL 2. MORE FINES IN CLINKER USAGE OF PETCOKE FUEL MAKES UNSTABLE OPERATION IN KILN CAUSING MORE FINES GENERATION CAUSING UNSTABLE OPERATION MILL

CAUSE AND EFFECT DIAGRAM ANALYSE SL NO CAUSE EFFECT CORRECTIVE ACTIONS 2 MATERIAL 2. MORE FINES IN CLINKER 3. USAGE OF PETCOKE FUEL INCREASES SO3 % IN CLINKER WHICH REDUCES GYPSUM % IN CEMENT MILL WHICH AFFETCS THE GRINDABILITY

CAUSE AND EFFECT DIAGRAM ANALYSE SL NO CAUSE EFFECT CORRECTIVE ACTIONS 2 MATERIAL 3. LUMPS IN LIME STONE LIME STONE ADDITION IN CEMENT MILL TO BE DONE WITH –50 MM SIZE ONLY. THE REQUIRED SIZE CAN BE CRUSHED AT U-II CRUSHER

CAUSE AND EFFECT DIAGRAM SL NO CAUSE EFFECT CORRECTIVE ACTIONS 2 MATERIAL 3. LUMPS IN CLINKER -50 MM SCREEN MESH TO BE PROVIDED AT CLINKER HOPPER TOP. REGULAR INSPECTION OF CLINKER CRUSHER HAMMERS TO BE DONE AND TO BE REPLACED ANALYSE

CAUSE AND EFFECT DIAGRAM SL NO CAUSE EFFECT CORRECTIVE ACTIONS 2 MATERIAL 3. LUMPS IN CLINKER 3. GRIZZELY BAR AND HAMMERS GAP TO BE OPTIMISED FOR CRUSHING THE CLINKER BELOW -50 MM ANALYSE

CAUSE AND EFFECT DIAGRAM SL NO CAUSE EFFECT CORRECTIVE ACTIONS 3 MACHINE 1. WEAR OF ROLL PRESS ROLLERS TO BE REPLACED WITH NEW ONE ONCE ROLLERS REPLACED, ROLL PRESS SURFACE TO BE MAINTAINED IN EVERY WEEKLY SHUTDOWN ANALYSE

CAUSE AND EFFECT DIAGRAM SL NO CAUSE EFFECT CORRECTIVE ACTIONS 3 MACHINE 2. GRINDING MEDIA CHARGE IN BALL MILL GRINDING MEDIA CHARGE TO BE OPTIMISED IN BALL MILL REGULAR WEAR MAKE UP OF MEDIA TO BE DONE ANALYSE

CAUSE AND EFFECT DIAGRAM SL NO CAUSE EFFECT CORRECTIVE ACTIONS 4 METHOD 1. REGULAR VARIATION IN BLAINE BECAUSE VARIATION IN GYPSUM % GYPSUM % TO BE VARIED ONCE IN FOUR HOURS GYPSUM HOPPER AIR BLASTERS TO BE PROVIDED IF GYPSUM % GOES LOW, TRIP THE CLINKER WEIGHFEEDER ANALYSE

CAUSE AND EFFECT DIAGRAM SL NO CAUSE EFFECT CORRECTIVE ACTIONS 4 METHOD 2. ROLLER PRESS PRESSURE VARIATION ROLL PRESS CONTROL SYSTEM TO BE TAKEN TO DCS FOR EASY IDENTIFICATION OF PROBLEMS AND SIMPLE OPERATION HYDRAULIC SYSTEM TO BE SET RIGHT ANALYSE

REGRESSION ANAYSIS OPERATING DATA ANALYSE S = 6.727 R-Sq = 80.6% R-Sq(adj) = 75.7%

REGRESSION ANAYSIS OPERATING DATA The regression equation is prod rate = 110 - 0.245 Pr Left + 0.413 Pr.right + 0.573 gap left + 0.449 gap right + 0.0364 power - st - 0.0314 power - mv - 0.0987 mill o/l draft - 0.222 deg of filling - 0.00405 mill power - 0.0765 SKS SEPERATOR SPEED + 0.0576 sep INLET DRAUGHT + 0.0225 sep OUTLET DRAUGHT + 0.308 sep POWER + 10.5 Chlorides - 196 SIO2 + 134 AL2O3 + 90 FE2O3 + 59.5 CAO + 49.7 MGO - 47.3 SO3 - 2.7 NA2O + 25.2 K2O + 267 SM + 4.5 AM - 558 LSF + 0.1 C3S + 16.6 C2S - 23.0 C3A - 5 C4AF - 34.7 LIQ - 52.4 F.CAO + 0.0355 % Petcoke ANALYSE

REGRESSION ANAYSIS OPERATING DATA Source DF Seq SS Pr Left 1 7675.80 Pr.right 1 1260.74 gap left 1 3858.33 gap righ 1 350.25 power - 1 2496.91 power - 1 804.04 mill o/l 1 0.25 deg of f 1 327.43 mill pow 1 4.02 SKS SEPE 1 2501.42 sep INLE 1 712.94 sep OUTL 1 134.45 sep POWE 1 2380.58 Chloride 1 5.10 SIO2 1 103.30 AL2O3 1 153.04 FE2O3 1 5.10 CAO 1 1.29 MGO 1 27.10 SO3 1 218.27 NA2O 1 96.25 K2O 1 11.10 SM 1 47.38 AM 1 21.14 LSF 1 21.15 C3S 1 35.76 C2S 1 60.29 C3A 1 89.79 C4AF 1 0.41 LIQ 1 67.32 F.CAO 1 59.06 % Petcok 1 12.30 ANALYSE

REGRESSION ANAYSIS OPERATING DATA ANALYSE AFTER ROLLER REPLACEMENT

REGRESSION ANAYSIS OPERATING DATA ANALYSE S = 6.813 R-Sq = 77.7% R-Sq(adj) = 75.0%

REGRESSION ANAYSIS OPERATING DATA Source DF Seq SS Pr Left 1 7675.8 Pr.right 1 1260.7 gap left 1 3858.3 gap righ 1 350.3 power - 1 2496.9 power - 1 804.0 deg of f 1 318.0 SKS SEPE 1 2423.9 sep INLE 1 657.8 sep OUTL 1 96.1 sep POWE 1 2191.1 SIO2 1 122.3 AL2O3 1 200.5 SO3 1 212.6 C3S 1 23.1 ANALYSE

REGRESSION ANAYSIS OPERATING DATA OBSERVATIONS / FINDINGS RP PARAMETERS PRESSURE AND GAP LEFT SIDE HAS THE MAXIMUM RELATION WITH OUTPUT PRESSURE AND GAP ARE NOT HAVING EQUAL RELATION WITH OUTPUT SO IT IS CLEAR THAT FOLLOWING PARAMETERS ARE RESPONSIBLE ROLLER OVALITY FEED NOT UNIFORM HYDRAULIC SYSTEM FAULTY ANALYSE

REGRESSION ANAYSIS OPERATING DATA AFTER HYDRAULIC SYSTEM MADE SET RIGHT ANALYSE

REGRESSION ANAYSIS OPERATING DATA OBSERVATIONS / FINDINGS THE NEXT RELATION COMES AS MOVABLE ROLLER POWER MOVABLE ROLLER POWER IS DIRECTLY PROPORTIONAL TO OPERATING PRESSURE PRESENT STATUS AFTER BUILDING RP WE ARE GETTING HIGH OUTPUT FOR PERIOD OF ONE WEEK REGRESSION SHOWS DECLINE IN OUTPUT WITH INCREASE IN PET COKE, BUT IS VERY MINIMUM ( 15%) ANALYSE

REGRESSION PERCENTAGE ANALYSE S = 11.26 R-Sq = 70.0% R-Sq(adj) = 63.3%

- 1.16 CM Bin Level + 0.0877 CM Power - 0.123 Sep fan il draft REGRESSION EQUATION ANALYSE FEED RATE = 216 - 0.326 RP Bin LV - 0.264 Sep fan speed + 0.537 Sep fan Power - 1.16 CM Bin Level + 0.0877 CM Power - 0.123 Sep fan il draft + 1.01 Sep fan ol draft - 5.89 GD diff + 0.123 Fixed load - 0.241 mov load

REGRESSION FINDINGS ANALYSE FEED RATE IS INVERSELY PROPORTIONAL TO CEMENT MILL FEED BIN LEVEL ( 14.8%) ROLLER PRESS BIN LEVEL (8.5%) GAP DIFFERENCE ( SKEW) (12.5%)

WHY WHY ANALYSIS ROLLER PRESS BIN LEVEL (14.8%) WHY : ANALYSE HIGH SKEWING OF RP WHY: UNUNIFORM FEED SIZE +50 mm LIME STONE BOULDERS SUGGESTION: CRUSHED LIME STONE SHOULD BE RECYCLED THROUGH UNIT-II CRUSHER ENSURING MAXIMUM SIZE OF +50 mm ONLY. ANALYSE

WHY WHY ANALYSIS HIGH SKEWING OF RP ANALYSE WHY: UNUNIFORM FEED SIZE VARIATION IN CLINKER SIZE SUGGESTION: WORN OUT HAMMERS OF HAMMER CRUSHER TO BE REPLACED GRIZZELY AND HAMMER GAP TO BE OPTIMISED WEIGHFEEDER DISCHARGE GRILL TO BE INSTALLED ANALYSE

WHY WHY ANALYSIS ROLLER PRESS BIN LEVEL (14.8%) WHY : ANALYSE HIGH SKEWING OF RP WHY: FREQUENT VARIATION IN OPERATING PARAMETERS DUE TO BLAIN VARIATION UN BLENDED FLY ASH OF DIFFERENT BLAINS FREQUENT CHANGE IN GYPSUM PERCENTAGE WEAR OF ROLLER SURFACE ANALYSE

WHY WHY ANALYSIS ROLLER PRESS BIN LEVEL (14.8%) UN BLENDED FLY ASH OF DIFFERENT BLAINS SUGGESTION: RECIRCULATION SYSTEM TO BE INSTALLED AND REGULAR RECIRCULATION TO BE DONE. ANALYSE

WHY WHY ANALYSIS ROLLER PRESS BIN LEVEL (14.8%) ANALYSE 2. FREQUENT CHANGE IN GYPSUM PERCENTAGE SUGGESTION: GYPSUM PERCENTAGE MADE CONSTANT ( MADE INDEPENDENT FROM LINKMAN) GYPSUM JAMMING TO BE AVOIDED ANALYSE

WHY WHY ANALYSIS ROLLER PRESS BIN LEVEL (14.8%) ANALYSE WEAR OF ROLLER SURFACE SUGGESTION: REGULAR BUILD UP OF ROLLER SURFACE ANALYSE

WHY WHY ANALYSIS ROLLER PRESS BIN LEVEL (14.8%) ANALYSE MORE RECIRCULATION WHY: DUE TO LOW VELOCITY ACROSS V-SEPERATOR SUGGESTION: TO BLOCK 2X2 NOZZLE AREA ANALYSE

WHY WHY ANALYSIS ROLLER PRESS BIN LEVEL (14.8%) ANALYSE MORE RECIRCULATION WHY: IMPROPER CAKE BREAKING SUGGESTION: TO PROVIDE IMPACT PLATE AT THE V-SEP INLET (DISCHARGE OF 531BC3) ANALYSE

WHY WHY ANALYSIS ANALYSE ROLLER PRESS BIN LEVEL (14.8%) CEMENT MILL BIN LEVEL (8.5%) WHY : VARIATION IN C3S SUGGESTION: TO MAINTAIN CONSISTENCY IN CLINKER COMPOSITION

WHY WHY ANALYSIS CEMENT MILL FEED BIN LEVEL (8.5%) WHY: ANALYSE HIGH CIRCULATING LOAD ACROSS BALL MILL SUGGESTION: OPTIMISE GRINDING MEDIA PATTERN AND LOADING REGULAR WEAR MAKE UP OF MEDIA NEW PID LOOPS TO BE INSTALLED ( MILL OUTLET ELEVATOR LOAD VS MILL INLET DOSING VALVE POSITION) MILL FEED BIN LEVEL VS DIVERTOR GATE ANALYSE

WHY WHY ANALYSIS MAJOR CHANGE: SWITCHING OVER FROM PETCOKE TO LIGNITE (OLD REGRESSION WAS SHOWING 15% RELATION FOR REDUCTION IN FEED RATE) ANALYSE

ACTION PLAN IMPROVE

ACTION PLAN IMPROVE

ACTION PLAN IMPROVE

PRESENT DATA IMPROVE

PRESENT DATA IMPROVE

PRESENT DATA IMPROVE FACTOR TARGET AVERAGE SD CAPABILITY Cpk POWER CONSUMPTION 26 KWH / T OF CEM 25.96 1.78 0.06 TPH 175 TPH 177 TPH 4.94 -1.7

CONTROL – ACTION PLAN CONTROL

CONTROL – ACTION PLAN CONTROL

COMPARISON DATA - TPH CONTROL PROJECT START AVG – 130 TPH PROJECT COMPLETION AVG – 165 TPH

COMPARISON DATA – POWER CONSUMPTION CONTROL PROJECT START AVG – 32.5 UNITS PROJECT COMPLETION AVG – 27.5 UNITS