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Rotary presentation February 23th, 2009
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Pueblo Plant Overview 89 Employees 54 Hourly @ $30.59/ hour average 35 Salary @ $73,263/ year average 78% Hired Locally Total Annual Payroll $6,524,422 Taxes $3,400,000 County $700,000 Sales Tax
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Pueblo Plant Overview Royalties $750,000 State Education Fund $32,800 State Education Fund Purchase Locally $18,000,000 Annually Pueblo County and Colorado Community Budget $38,950 Annually GCC Competitive Advantage HP/CI Self Directed Work Teams
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Plant Overview
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Quarry Crushing capacity of 500 tph Product size 5” to fines Mobile crusher due the type of quarry
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Limestone storage Continuous stacking and reclaiming Blending ratio 8 to 1 Capacity 17,000 ton
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Longitudinal storage One stacker for raw materials (Mill scale, Sandstone, kaolin, coal ) 2 reclaimers (one for raw materials and one for coal)
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Raw mill 4 materials ( limestone 88%, sandstone 5%, kaolin/clay 5%, mill scale 2% ) 225tph Active vibration damping (AVD) system
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Raw mill and Finish mill
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Blending silo 7,500 ton capacity ( 1.5 days of kiln operation ) Blending ratio 8 to 1 7 programmed outlets to blend the material
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Pyro system 2,900 tpd capacity 5 stages preheater with calciner Heat consumption 725 kcal/kg Friction drive Tangensial tyre suspension DeSOx Low NOx calciner
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Kiln Low NOx calciner Reduction zone At high temperature
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Kiln DeSOx system Dry scrubber for sulfur Fix sulfur in the raw mix avoiding emissions
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Kiln Tangential suspension Free radial expansion of the shell to minimize ovality and maximize refractory life Bracket are bolted onto the tyre “Dog bone” keep the tyre in position Welded blocks rest on elastic brackets bolted to sides of tire with spring-loaded wedges in between Spring keeps wedge on position as dimension change with heat expansion
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Kiln Friction drive No lubrication needed usage Roller-tire friction Maintenance free
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Clinker cooler Cools clinker from 2600 F to 150 F Mechanical flow regulator system for air control Hydraulic drive Hydraulic roller breaker
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Clinker cooler Mechanical Flow Regulator ( MFR ) system in the cooler Automatic control of cooling air Energy savings Transport separate from cooling
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Clinker cooler Hydraulic Roller braker (HRB): Uniform clinker size of clinker for the finish mill Less maintenance Smooth operation
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Coal system Capacity 26 tph Prepare for high moisture coal grinding CO2 system for fire protection Coal tube/pipe conveyor
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Clinker dome storage 110,000 ton capacity 6 outlets Concrete wall design
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Finish mill 180 tph Type I/II low alkali cement 95% clinker 5% gypsum Active vibration damping (AVD) system
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Raw mill and Finish mill Active vibration damping system (AVD) Raise roller to stabilize operation Reduced vibration levels Maintain high mill runtime factor Minimize restarts that affects the main motor Better control of grinding pressure
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Cement silos and shipping 4 silos 10,000 ton each 385 tph loading capacity Railcar and truck load spouts Certified scales for railcars and trucks
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GCC Rio Grande Pueblo Plant
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Team Building Vision Statement Key on Team Leaders Leadership team Weekly meetings Training No one better than anyone No lies Union defense Pay and Benefits Process Overview General Operations Methodology
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Vision We are a world class producer of quality cement. We are highly productive and profitable because we are well trained, highly motivated employees who are dedicated to using state-of-the- art technology and continuously improving our processes in a safe and clean environment. Our commitment to all employees is based on trust, mutual interest, respect and honesty. We create opportunities that allow all to seek their level of excellence. We reach our shared vision through a plant wide philosophy that empowers all employees through leadership and the practice of Continuous Improvement. >
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Leadership Key on Team Leaders Lead and understand Leadership Team Every…is an apprentice
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Communication Weekly meetings Communicate expectations Listen!! Respond with business reasons Reinforce operations values Safety Environment Equipment Quality Production High Performance and CI
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Ownership NO ONE IS BETTER THAN ANYONE ELSE! Through our actions Communicate all, everything Answer all, everything ALL RESPONSES- BUSINESS BASED NO LIES!!
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Training Basic platform PCC In house Specific OJT (L-0, L-1) and Process Operation Guideline (POG) PMR development Equipment parts catalog Sister operations visit/run Vendors
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Skilled workforce Pay and benefits Leader in community $23.78/ hour average- hourly $73,650 annual average- salary Expect more Involvement and participation CI methodology Ideas for improvement JOBS-verification and versatility
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Cement manufacturing process
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Structure Plant Leadership Team S1(6) S2 (6) S3 (6) S4 (6) Quarry (7) Clinker and Cement BU Maintenance Support Quality Shipping RRU (10) Maintenance Support One electrician/instrumentation on each area of responsibility team (3) PC PACC Plant Mgr ENV HR HP&ISO Raw Materials BU Shipping BU One electrician and one mechanic within each shift team Admin Support Procurement Reliability Raw Materials Raw Mill-Kiln Finish Mill-ShippingElectrical Engineer System administrator
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CI Methodology A disciplined DATA driven process involving every team in the organization
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