1.1.2 Objectives of Industrial Training
The purpose of the Industrial Training is to provide exposure for the students on practical practical engineering fields. Through this exposure, students will have better understanding of engineering practice in general and sense of frequent and possible problems. Industrial training is compulsory for all PUO students s tudents because from this training student have several objectives such as:
•
To introduce student to environment and culture of work place in their field study.
•
To cultivate student to work in team work.
•
To expose student to Engineering practice and Engineer professional attitude.
•
To introduce student the relationship between theory and practical.
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To train student about communication to all level in work place.
•
To train student to prepare technical report in connection with industrial training.
•
To enable students build and improve creativity skills and sharing ideas with other.
1.1.3
Objectives of Report
This training is part of the learning process. So, the exposure that that uplifts the knowledge and experience of a student needs to be properly documented in the form of a report. Through this report, report, the experience gain gain can be delivered to their peers. A properly prepared report can facilitate the presentation of the practical experience in an orderly, precise and interesting manner.
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1.1.4 Importance Importance of Industrial Training for the Student Student
It is compulsory for a PUO student to pass the Industrial Training to fulfil their diploma requirement. Student attached to government departments, firms or companies for a specified period time to expose to the actual working environments whereby students will encounter many new problems and challenges. The primary purpose of this guideline to provide guidance for student to prepare themselves to face new challenges and to ensure they abide by the rules and regulations of PUO and the training organisations. The Importance of Industrial Training:
To expose students to actual working environments.
To enhance student‟s knowledge and ability.
To instil the qualities of integrity, responsibility and self-confidence.
To expose students to safety practices and regulation in industry.
To instil the spirit of teamwork and good relationships between students and fellow workers.
To assess students ability and competency in their preparation to join the workforce upon completion of their study s tudy in UTEM.
To expose and disciplined me about safety practice and regulation in industry.
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1.2
Company’s Profile
Figure 1.2.1: Company logo
1.2.1 Introduction Introduction of Company
Company Name
:
Lafarge Malaysia Bhd.
Address
:
Teluk Ewa, Mukim Air Hangat, 07000 Pulau Langkawi, Kedah Darul Aman.
Cemen export destination
:
1) Singapura 2) Bangladesh 3) Myanmar 4) Hong Kong 5) Sri Lanka 6) Mauritus Nigeria 7) Australia
Lafarge Malaysia Berhad (formerly known as Lafarge Malayan Cement Berhad) is the leader in the Malaysian Malaysian construction materials industry. Incorporated in 1950, its first cement plant was built in i n Rawang in 1953.
Lafarge Malaysia Berhad (LMB) is today the parent of a group of companies in Malaysia and Singapore whose core businesses are in the manufacturing and sale of cement, ready-mixed concrete and other related building materials.
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In the Cement business, LMB currently employs more than 1,150 people and operates a nationwide network of facilities, which includes three integrated cement plants in Langkawi, Kedah; Kanthan, Perak and Rawang, Selangor, a grinding plant in Pasir Gudang, Johor with distribution channels by road, rail and sea.
It employs about 90 people in its Aggregates business and operates five quarries in Malaysia.
Whereas in its Concrete business, there are more than 30 ready-mixed batching plants throughout Peninsular Malaysia and East Malaysia with a workforce of more than 300 employees.
A world leader in building materials, Lafarge employs 65,000 people in 64 countries, and posted sales of €15.8 billion in 2012. As a top-ranking player in its Cement, Aggregates and Concrete businesses, it contributes to the construction of cities around the world, through its innovative solutions providing them with more housing and making them more compact, more durable, more beautiful, and better connected.
With the world‟s leading building materials research facility, Lafarge places innovation at the heart of its priorities in order to contribute to more sustainable construction and to better serve architectural creativity.
Since 2010, the Lafarge Group has been part of the Dow Jones Sustainability World Index, the first global sustainability benchmark in recognition of its sustainable development actions.
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1.2.2 History of Lafarge Bhd (Langkawi)
Langkawi Works formally known as Kedah Cement Sdn Bhd was incorporated on 31 st March 1980. The plant covering 175 acres, located at Teluk Ewa, the centre-north Zone of Langkawi Island. The fifth integrated cement factory set up at that time. Built by Ishikawajima Harima Heavy Industries Co. Ltd. (IHI) of Japan and commissioned in May 1984. In 1991, Kedah Cement Sdn Bhd became a 100% owned subsidiary company of Malaya Industrial and Mining Corporation Bhd. (MIMCO). In September 1995, the company commissioned its second production line of 1.8 million tons clinker per annum, engineered and built by Krupp Polysius of Germany and became the largest integrated cement plant in Malaysia at that time. In June 1999, Malayan Cement Bhd., a subsidiary of Blue Circles Industries PLC of England, acquired 65% equity of the company and thus Kedah Cement Sdn Bhd became a member of the Malayan Cement Bhd. group of companies. Kedah Cement Sdn Bhd became known as Malayan Cement Industries Sdn Bhd officially in April 2000 when the new name was registered with the Registry Of Companies. In July 2001, Lafarge completed acquisition of Blue Circles Industries PLC and became the ultimate parent of Malayan Cement Bhd. and its subsidiaries. Malayan Cement Bhd. is later change to Lafarge Malayan Cement Bhd. with effect from 31st May 2003. Then it was changed to Lafarge Malaysia Berhad(LMB).
YEAR
1978 1980 – 31March 1982 1984 - May 1996
DESCRIPTION
Idea of cement plant in Langkawi by Tun Dr. Mahathir Mohamad Incorporated as Kedah Cement Sdn Bhd Cement plant first construction. Commissioning 4000 tpd (tonne per day) cement plant. Commissioning expansion 6000 tpd (tonne per day) cement plant.
2000 – April
Acquisition by blue circle group.
2001 – July
Lafarge and blue circle group merger.
2002-Present
Acquisition by Lafarge group.
Table 1.2.1: Lafarge Malaysia Bhd (Langkawi works) History
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Figure 1.2.2: The front look of Lafarge Langkawi
Lafarge Malaysia Bhd. operates an integrated cement plant in Langkawi and a clinker grinding plant in Pasir Gudang together with cement service terminals at Port Klang and Prai. The integrated cement plant has the single largest kiln in the country with an annual rated capacity of 1.5 million metric tones and clinker grinding capacity 1.8 million metric tons per annum.
Langkawi Works, which is located 25 kilometers from Kuah and about 23 kilometers from Padang Mat Sirat Airport, is ideally located at a natural harbour with sheltered waters for sea transport of both incoming and outgoing cargo. The plant is the only one, which operates an ultra-modern jetty equipped with fast-mechanized bulk loading and unloading facilities. Its seafront location has the following distinct advantages such as:
a. An abundance of locally available basic raw material, limestone and clay, which comprise 83% and 15% of the total raw materials respectively in the production of cement, makes for significant savings in costs in comparison with some of the company‟s competitors. b. Opportunity for a plant expansion since the location does not face the problems of urban enrichment and conflicts in land use. c. Some of its inputs such as raw materials and machinery parts are tax exempted due to the duty free status of Langkawi.
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Figure 1.2.3: Top view of Lafarge Malaysia, Langkawi Plant.
(Include of factory, quarry and jetty.)
Langkawi Works continues into 2006 to export the surplus of LMB Group‟s clinker and cement volume. About one third of it is destined to Indonesia in supporting the Group‟s recovery of Acheh Plant. By strengthening customer orientation through efforts of compliance to EN certification, it would be able to adapt more adequately to offer its products tailored to the requirement of the expanded customers. Safety, as integral part of the Plant‟s performance, remains the top priority. Effort are focus on behavioral change and mindset of the people, employees and contractors included, to improve the safety practices, develop strict procedures and ensuring compliance to the best practices. Improving plant cleanliness is the Works daily management as it a key to safety and to industrial mastery.The real challenge is the reliability of the kilns to distinguish the plant industrial performance excellence. The capability of using alternative fuel like shredded scrap tires and with Lucie now in placed will make the fuel management better.
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1.2.3 The Executive Committee of Lafarge Malaysia
Bradley Mulroney President & Chief Executive Officer
Jim Ruxton Senior Vice President, Industrial Operations
Rick Pucci Vice President, Concrete
Choong Ju Tang Vice President, Industrial Sales
Seet Hooi Ping Vice President, Human Resources
Shirley Low Vice President, Marketing
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Chen Theng Aik Executive Vice President, Finance & Chief Financial Officer
Vigneswaran Velautham Vice President, Aggregates
Yeap Khoon Cheun Vice President, Retail Sales
Paul Yap Poh Onn Vice President, Supply Chain
Ian Pughsley Vice President, Health & Safety
Figure 1.2.4: The Executive Committee of Lafarge Malaysia
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1.2.4 Organisation’s Activities
The organisation‟s activities are mainly in processing and manufacturing cement Cement is a material for bonding stone or brick. The term cement is most commonly used to refer more specifically to powdered materials which develop strong adhesive qualities when combined with water. These materials are more properly known as hydraulic cements. Hydraulic limes, natural pozzolana and Portland cements are the more common hydraulic cements, with portland cement being the most important in construction. Gypsum plaster and common lime are not hydraulic cements. Cement is an important ingredient in concrete. Below is the stages in manufacture of cement :
Table 1.2.1: Process of Clinker and Cement making
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Figure 1.2.5: Stages in Cement Manufacturing
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Stage 1: Quarrying of Raw Materials
Crusher is the first section of the cement processing. In this section, the limestones are blasted from the quarry and transported using Dump Truck. The limestones are then unloaded into an hopper.(Figure 1.2.6)
Figure 1.2.6: Mammoth truck unloaded the limestone into the hopper
The lime-stones from the hopper are moved by the apron feeders to the crushing below. The materials that drops intro the crusher are pre-crushed by a rotating hammer due to the centrifugal force of the rotor.
The impact effect by the rebounds of the materials to the impact wall can crush and reduce the size of the lime-stones. At the grate basket, the lime stones are reduced according to the grate basket width to the desired final grain size. The final sizes of the lime stones fall down to the crusher discharge conveyor to deliver to the lime stones dome (Figure 1.2.7) .
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Figure 1.2.7: Limestone dome
Clay is extracted from various reserves and transported by Lorries to the Works for crushing and stacked in covered storage. Clay (white shale) is taken from Kilim Quarry which is situated 10km from Plant.
After that, the shale and clay are transported to the Plant by using lorry and keep at raw material storage. Then it will transport to the secondary by belt conveyors where they are screened and run through a hammer crusher. Once the raw materials from the quarry are reduced to the desired size, they are carried to the raw material silos in the plant called Pharmacy House by belt conveyors.
Gysum , anhydrite and iron ore are from other places. Gysum and anhydrites are imported from Thailand and Iron ore is imported domestically. These are sub materials used in making of clinker and cement.
Stage 2: Raw Material Preparation
Raw material preparations are done in the pharmacy.
The function of
Pharmacy is to weigh all the materials and additive materials such as anhydrite and
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iron ore for the material preparation before it is send to closed-circuit ball mills and vertical spindle mills as raw meal fine powder. After grinding and milling , the fine material are transported into a homogeneous silo via air slides and kept storage there.
Figure 1.2.8: Ball Mill
Figure 1.2.9: Roller in Vertical Raw Mill grinds the raw meal into fine powder
Stage 3: Clinker Burning
The blending silos or homogenous silos mix and store feed to the kiln .They consist of two upper silos and two lower silos .The material in the upper silos may be moved to either one of the two lower silos .This allows the kiln feed to be mixed to ensure a equal uniform composition.
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Feed leaves the upper silos through air slides into the lower silos, Material carried from the bottom of the homo silos to one of two schenck bins by screw conveyors, and then with bucket elevators .
The schenck bins used to maintain a constant head of material available for kiln feed. The feed to the kiln controlled by impact flow meters, which determine the weight of the material leaving the Scheck bins.
Figure 1.2.10: Rotary kiln
The raw meal air-lifted to the top of preheater where as the raw meal flows down the cyclones, it is progressively heat by rising hot gases through the cyclones and precalciner before entering the kiln. In the kilns, successive chemical reactions occur and the heated raw meal is sintered to cement clinker at about 1450°C.
The feed entering the kiln and calcinations process occur. Calcinations are a process in which calcium carbonate is dissociated to calcium oxide and carbon dioxide .This reaction starts to occur when the material is heated to 100°C
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Figure 1.2.11: Cyclone
pre-heater typical temperature & pressure profile and efficiency.
Stage 4: Clinker Cooling
The red hot clinker leaves the rotary kiln and is rapidly cooled in ad air quenching grate-cooler before being conveyed by pan-conveyors into clinker storage silos. On a grate cooler too dusty clinker will cause excessive dust circulation between cooler and kiln with bad effect on the burning in the burning zone.
Dusty clinker can also cause overheating and damage to the steel parts of cooler, mainly because the clinker segregates on the grate, so that the cooling air does not penetrate evenly through the linker layer, leaving parts of the cooler with insufficient air.
Dusty clinker can also be the cause for a so-called dust-ring in the kiln outlet or “snow-man” in the cooler inlet. Clinker from the kiln can contain some liquid, either because of a high temperature or because of alkali-compounds with a low melting point, maybe under cool.
When such liquid solidifies the clinker may stick together, but only when they contain sufficient fines to give the charge a h igh specific surface.
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Figure 1.2.12: Air Quenching Cooling (AQC)
In a planetary cooler, the effect of dusty clinker is not so critical for the operation, but it is very desirable to have clinker within reasonable size limits. As the cooling is based on cascading clinker will blow back into the kiln. This can make it impossible to see anything in the kiln, but it can be discussed whether this really is disadvantage.
Another consequence can be problems with wear on the burner pipe. If dust blowing back from the cooler would make nice clinker in the burning zone no problems would arise, but more often it is so that the dust spoils the clinker formation and thus circulation tends to accelerate.
If the dust circulation becomes very heavy the result is that an amount of clinker, say 1 ½ times the actual clinker-production, and comes down in the cooler. This can give a transport problem, if the cooler is not able to transport such quantity, back-spilling will result.
Dust circulation also means that the amount of heat contained in the clinker going down in the cooler increases and thus can result in a higher temperature of the clinker after the cooler. Too many big clinker, say over 40mm are also harmful. Such clinker can damage the refractory lining and result in a higher temperature of the clinker after the cooler.
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The second reason is to emphasize clinker formation is that the same chemical and physical processes which giver a good clinker formation also normally promotes a good c\coating in the burning zone, essential for the life of the lining. Finally the clinker grading is of importance to the grind-ability of the clinker. It is often found that a fine dusty clinker requires a higher specific power consumption than an ordinary nodule clinker and also arrangement of internals of the cement mill will depend on the granularity of the clinker, and so will the composition of the grinding media charge.
The grate cooler has recently been completely redesigned and improved both with respect to wear and maintenance and to operation. The improvements aim at a well-controlled air distribution along the cooler, an adequate and adjustable transport capacity of the grate and ample air pressure to permit operation with a t thick clinker layer on the grate.
The disadvantages of the planetary cooler are that the clinker temperature for economical dry kilns sometimes is rather high, 150˚C to 175˚C, depending on the clinker size, and also need maintenance, but this mostly implies renewal of the ceramic parts, bricks or cast able.
Within this filed there has over the last few years been remarkable development, which still goes on, and it is now realistic to expect a long lifetime of the cooler parts, so that cooler repairs ought not have any significant influence on the run factor of the kiln.
Stage 5: Cement Grinding
Clinker, added with about 5% gypsum, is ground in closed-circuit grinding mills to produce cement at the required product fineness and conveyed to respective cement storage silos. Cement from the mills in transferred either directly or through cement cooler to the storage silos. During the passage from the mill department to
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the silos, only slight cooling takes place in the transport equipment amounting to 510 ˚C.
Figure 1.2.13: Cement Ball Mill
Figure 1.2.14: Cement silo
In the cement silos, heat is removed from the cement by the ventilating air and through the cement silo walls. However, measurements have indicated that this cooling off of the cement in the silos takes place slowly. This means that the cement temperature will be within 5-10 ˚C of the temperature it had taken when entering the silos, even after 3-4 weeks.
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Stage 6: Packing and Loading For Dispatch
The cement drawn from the silos is fed to rotary packers for bagging to 50kg bags which are loaded into trucks for delivery. Bulk cement road tankers are loaded directly from silos. Bulk cement is also extracted directly from the silos to be conveyed by belt system for loading into ships berthing alongside the jetty next to the Plant.
Figure 1.2.15:Jetty Stage 7: Quality Control
The proportioning of raw materials is strictly controlled at all stages of the process to ensure that the quality of the finished product well exceeds the standards set by the Standards and Industrial Research Institute of Malaysia (SIRIM).
Stage 8: Environment Control
The Plant is well equipped with highly efficient electrostatic precipitators and bag filters for dust recovery from all stages of the process to ensure that emission levels always maintained well below the limits stipulated by the Authorities.
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Figure 1.2.16: Dust collector
The proportioning of raw materials is strictly controlled at all states of the process to ensure that the quality of the finished product well exceeds the standards set by the Standards and Industrial Research Institute of Malaysia (SIRIM) The Works is well-equipped with highly efficient electrostatic precipitators and bag filters for dust recovery from all stages of the process to ensure that emission levels are always maintained well below the limits stipulated by the Authorities.
Figure 1.2.17: Electrostatic precipitator
In order to achieve a good efficiency of the electrostatic precipitator, the gases to clean must have certain physical condition. The gas temperature and moisture will have the main influence on the treatment in the precipitator. This is the reason that foe certain application an evaporation cooling tower will be installed in
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front of the precipitator. In this tower the gases will be cooled and conditioned by evaporation of injected water droplets.
The gases flow inside the cooling tower must be uniform over the entire cross section. This is an important feature for an efficient evaporation of the injected water and will be achieved by the installed gas distribution plates and baffles.
Below the gas distribution devices, water droplets with diameter of maximum (0.3mm) are injected through lances. The nozzles lances are equally arranged over the whole tower circumference. At the end of the cooling zone the gas temperature is measured and kept to a set value by continues regulation of t he water quantity.
Langkawi Plant Products
Product innovation takes priority at Lafarge Malayan Cement. We are constantly seeking new ways to improve our products and to fulfil customers‟ requirements with excellence. 1. Masonry Cement
Figure 1.2.18: Example of Masonry Cement
The name “Walcrete” is synonymous with masonry cement. This type of cement is widely used, as it is an easy, efficient and economical way of mixing mortar. Its easy handling and smooth finishing makes it ideal for plastering and brickwork.
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2. Portland Pulverized Fuel-Ash Cement (PPFA)
Figure 1.2.19: Example of PPFA Cement
The first in Malaysia, „Mascrete‟ specially engineered for durable concrete, ideal for mass concrete Structures and for marine environments. It provides low heat of hydration and high resistance to sulphates and chlorides. It has been use in landmark projects like Kuala Lumpur International Airport, Malaysia-Singapore Second Crossing, Pergau Dam and Petronas Twin Towers. PPFA cement is also available in bags under the brand name of “Phoenix”. 3. Ordinary Portland cement
Figure 1.2.20: Example of PLC Cement
“Rumah” and “Harimau” are leading brand names in the construction industry. This cement used extensively in projects of all sizes.
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4. EN CEM II: Portland Limestone Cement
Figure 1.2.21: Kedah Cement Jetty
Portland Limestone Cement is specially developed for Lafarge Semen Andalas, Indonesian which many of the construction now rapidly growth in Acheh after Tsunami Asia 2004. The product is delivered by Ship Vessels directly to Belawan and Lhokseumawe, Indonesia. 5. Dry-Mix Cementitious Products
Figure 1.2.22: Dry Mix Products
“Quick mix” is the brand specially developed for the convenience of contractors. Its „ready-made‟ concept provides the customer with an easy and efficient way of achieving a high quality finish for interior works, renovations and home repairs.
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6. Oil well Cement
Figure 1.2.23: Oil Well Cement
Produced under the trade name of “Blue Circle‟ it is specialized cement used in oil exploration and production activities. It conforms to standards set by the American Petroleum Institute.
7. Ready-Mixed Concrete
Figure 1.2.24: Ready Mix Product
All industry standard grades of ready-mixed concrete for infrastructure, commercial, housing projects, and specially designed grades to meet customers‟ specific requirements.
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Summary of the Whole Process
There are many types of cement plants. Cement plants nowadays using "dry" process. Since a dry process is the more modern, a typical dry process plant that incorporates with advanced equipment and energy conservation techniques. In the dry process, the materials are crushed and fed through a tube mill, which reduces them to a fine meal. The meal is then stored in a silo from where it is transported to the Kiln pre-heater and pre-calciner. The material then cascades downwards while warm exhaust gas from the Kiln passes through it. In pre-calciner, burner gun is used to pre-heat the feed before entering kiln. At this point, calcinations can reach up to 93%. The raw materials are fed through the Kiln, which can be up to 72m long, and 5m in diameter, the length of the Kiln depending on which process is used. In the Kiln-firing zone, the material reaches a temperature of 1450 oC before leaving the Kiln in the form of clinker. Cement is made from limestone or chalk and shale or clay (calcium carbonate, siliceous and aluminates material). Limestone and clay could be barged from a quarry and unloaded using commonly dumpers. It is then fed into crusher for size reduction. The types of crusher used are normally jaw crusher and hammer crusher. A lot of cement plants do not have to barge in all raw materials and have their quarry in nearby properties. For Langkawi works, limestone quarry situated about 5 km from the plant and clay quarry about 20 km from the plant. Clay is introduced into the process along with the limestone. Depending on the blend, the raw material is stored in different Raw Material Storage for the different blends. For limestone, dome storage is used with stacking and reclaiming facilities. For clay and fuel, longitudal stockpile is used.
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Other materials are dumped at the storage area to be used later. Limestone, clay and iron, are proportion in the dosing house (pharmacy) before fed into the Raw Mill system where the material is reduced to a desired size called raw meal. There have two types of raw mill in Langkawi Plant, a Ball Mill and Vertical Roller Mill. Ball Mill is a very large round pipe looking structure about the size of a large room, only round. Inside there are metal balls that are from 1 to 2 inches in diameter. The mill spins around and the balls roll around inside. When the crushed rock enters, the balls fall on it breaking it into smaller pieces until finally it's a dustlike powder. Air is being sucked through the mill all this time and when the powder is fined enough, the air can carry it out of the mill. But it still may not be fine enough. In the air stream, the powder is again separated using a separator. Material that's too heavy or course is sent back to the mill and the fine raw meal is sent to storage in the blending silos where it's also mixed again to even out any minor materials variations. Vertical Roller Mill feed is controlled not only by the total amount of feed but also by the percent composition of feed. This composition varies to correct for the desired characteristics of the cement and any inconsistencies in the raw material. Then the precisely proportioned mix is ground and at the same time dried in a raw mill. The raw materials are passed through a chute and are deposited in the center of rotating horizontal grinding table. The material is moved outward and eventually off the table by centrifugal force. The large rollers grind the material against the table. These rollers are pressed against the table by their own weight and force from hydraulic cylinders of a hydro pneumatic spring system. The rollers are not driven out rotate due to friction from contact with the material being ground. If it is very dry and fine, water is sprayed at the material on the table. This increases the efficiency of the grinding process.
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Then it transferred to the homogenizing silos. Further homogenization is carried out in the following silos for the intermediate storage of the raw meal. After being blended through, the material is sent to the top of a Homo Silo for blending effect. Then, it enters at about 200 degrees and falls through 4 stages of cyclones that not only mix the hot air from the Kiln and pre-calciner burner but separates the hot gasses from the material. When it reaches the bottom about 30 seconds, the temperature is 1000oC where it then enters the Kiln. The Kiln is a very large pipe that's 16 ft. in diameter and 280 ft long. It will turn anywhere from 1 to 3.5 rpm. As it turns, it picks up the heat from the „Kiln Burner‟, (ignited fuel) and the meal begins a chemical reaction in the heat, transforming the beige powder to a molten goop (like volcanic lava) at around 1450 oC, to a burned looking rock called a clinker. Clinker is too hot to handle at around 1450 oC, so the Kiln discharges into a clinker cooler. A dozen fans blow cool outside air up through special metal grates that have holes in them, into the bed of hot clinker. The clinker is cooled from about 1450 oC down to only 100 oC. It's then transported into clinker silos. At the bottom of the clinker silos there could be as many as 28 feeding devices that weigh the clinker and put it on belts that lead to Finish Mills. The finish mills are like the raw mill in that they have balls that tumble and crush the clinker and gypsum whiles the mill is turning. Clinker and gypsum are conveyed to the finish mill inlets from the silos by belt conveyors and bucket elevator. Weigher belts coming out of the silos control feed the two mills. Grinding aid, mixed with water can be added to make the grinding process more efficient. Grinding aid mixed with water can be added to make the grinding process more efficient. Grinding aid is a liquid that changes the electrical charge of the material, causing particles to repel each other rather than attract.
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The clinker is ground with steel alloy balls that crush the clinker when the mill is rotated. These balls slowly wear down and become smaller in sized. This finish mill has two compartments. The first compartment is filled with larger balls while the second compartment is filled with smaller balls. In a two mill, smaller particles are moved from the first stage to the second stage where cement leaves the mill. Material leaves the finish mill and is taken to a separator that works much like the classifier does. The coarse material is returned to the mill for regrinding while finished cement is run through a dust collector to remove any air. The cement is then moved to coolers by air slides. The cooled cement is then pumped into cement silos for storage. The finished cement is pumped into the top of the storage silos. A typical silo can contain about 5 000 tons up to 20 000 tons of cement. Cement is discharged through the bottom of the silos by rotary feeders into one of two conveyors. These conveyors lead to another screw conveyor that takes the cement to a bucket elevator. Cement is leaving the top of the elevator is carried to the two load out silos. For shipment loading, cement or clinker is taken directly from cement or clinker silo and transported through belt conveyor to ship loader. Land silos can fill trucks, and also include areas to bag cement for sale in local stores under many logos and brand names. The primary source of fuel is usually coal and pet coke. Coal and pet coke is stored in piles and transported to Coal Mill for grinding. Large balls race around pulverizing the coal until its fine enough to be sucked up by a powerful fan. The air passes through filters that separates and collects the coal, placing it in a small storage bin. As fuel is needed in the Kiln and pre-calciner, it is blown from the bin to the burners in the system and ignited. Natural gas, oil and tire chips and wood chips also serve as alternative fuels in some plants.
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1.2.5 Vision and Mission of the Company
Vision
To achieve total plant mastery for our customer wit h Safety as our way of life
Priorities
Health & Safety-cultured workforce in all the sites
Towards mastered and robust plant with sustainable improvement
Clean and Environmental friendly plant for our employees & community
Meeting external and internal customers‟ expectations
Leadership through performance culture
KPIs
Health & Safety
Zero total injury frequency rate
Area ownership JHP and HKI =>80.00%
Practice safety interventions
Zero environmental infringements
16 hours safety training
Compliance with group standards and advisories
Implementations of new Health Standard
Plant Mastery
POM Compliance
Industrial standards (LQTS, Power & Heat – full implementation of 5 basic rules)
Kiln RF => 97.42%
Kiln PF => 92.13%
Cement mill RF => 97.43% @ UF 72.91% 31
Cementations C/K => 1.1854
Cost ownership & control (CV HC3,357 MJ/ton clk, Clk Power 49.98 kwhr/Cmt, IFC compliance RM73.57m)
AF replacement 10.10%
Maintenance project, MCI =>1.20
Eng.Spares : RM51.34m, Gr.media : RM 0.3m Refractory : RM 0.8m
Customer‟s Satisfaction
OTIFIC => 92%, for both Domestic and Export
Consistent Product Quality IQP => 95%
Product quality complaints (≥ 10% lower than previous year)
LP Ship loaders RF => 96% PEOPLE MOBILIZATION
Succession Planning
Retention of talents
Follow up on IPD program implementation and close coaching
Front Line Supervisor development program
Job ownership/Core functions competency
Improve competency of our talent
5G 3S operation
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1.2.6
Organisation’s chart
Figure 1.2.25: Organisation Chart of Head of Department
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Figure 1.2.26: Organisation Chart of Maintenance Department
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