Scribd
Upload
78 views18 pages

Training Company: Ambuja: Cement LTD

Ambuja Cements Ltd. is one of India's leading cement manufacturers. It was founded in 1983 and commenced cement production in 1986. The company has grown its cement capacity to 27.25 million tonnes. It has expanded its operations over the past decade through new plants and capacity increases at existing plants. Ambuja Cements enjoys a reputation as one of the most efficient cement producers in the world.

Uploaded by

Mandeep Singh
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
78 views18 pages

Training Company: Ambuja: Cement LTD

Ambuja Cements Ltd. is one of India's leading cement manufacturers. It was founded in 1983 and commenced cement production in 1986. The company has grown its cement capacity to 27.25 million tonnes. It has expanded its operations over the past decade through new plants and capacity increases at existing plants. Ambuja Cements enjoys a reputation as one of the most efficient cement producers in the world.

Uploaded by

Mandeep Singh
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
You are on page 1/ 18

TRAINING COMPANY: AMBUJA

CEMENT Ltd.

Submitted by: SAMRAT SHARMA


BRANCH: AE&I

Ambuja Cements Ltd. (ACL) is one of the leading cement


manufacturing companies in India. The Company, initially
called Gujarat Ambuja Cements Ltd., was founded by
Narotam Sekhsaria in 1983 with a partner, Suresh Neotia.
Sekhsarias business acumen and leadership skills put the
company on a fast track to growth. The Company commenced
cement production in 1986. The global cement major Holcim
acquired management control of ACL in 2006. Holcim today
holds little over 50% equity in ACL. The Company is currently
known as Ambuja Cements Ltd. . ACL enjoys a reputation of
being one of the most efficient cement manufacturers in the
world.
ACL has grown dynamically over the past decade. Its current
cement capacity is about 27.25 million tonnes. The Company
has its own fleet of ships. ACL has also pioneered the
development of the multiple bio-mass co-fired technology for
generating greener power in its captive plants.

Milestones!
2012
ACL announces the expansion of Grinding Unite Sankrail, West
Bengal, increasing the capacity from 1.5 MTPA to 2.4 MTPA
2011
Completes 25 years of operation. Celebrates silver jubilee at all
integrated plants.
Commissioned 2 cement mills at Bhatapara plant,Chattisgarh
and Maratha Cement Works,Maharashtra increasing the total
grinding capacity of the Company to 27.35 million tonnes.
Commisssioned 5 Wind Turbine Generators, having total
capacity of 7.5 MW at Kutch , Gujarat.
2010
Opening of Dadri Plant
On 24th February 2010, Ambuja Cements Ltd (ACL) inaugurated
its cement plant (grinding unit) at Dadri, Uttar Pradesh.
Capacity: 1.5 million tonnes..
In December 2010, the Dadri Grinding Unit in its very first year
of operation received the Integrated Management System (IMS)
Certification, including ISO 9001:2008, ISO 14001:2004, and
OHSAS 18001:2007 by BSI (U.K.).

Delighted Customers
Inspired Employees
Enlightened partners
Energised Society
Cleaner Environment - Pollution
control
Cleaner Environment natural
resources
Safety

Performance Management System (PMS) is


a vital tool to review performance and
develop employees. PMS is effectively
used to help set performance
expectations, ongoing dialogues between
the manager and the employees. The
focus is on helping achieve set targets.
The dialogue provides a platform to the
employee to discuss his performance and
obtain
feedback for his growth and development.
The Company has a systematic process of
identifying
training needs across the breadth of the
Organisation
and care is taken to design training
programs to
address skill gaps required for bringing
proficiency in
jobs.

DEVELO
P

ATTRACT

RETAIN

Ambuja
Bulk transportation
CSR
Differentiation
Environment protection
Fly ash
Growth
Holcim
ISO Standards
Just in time
Kiln
Lowest cost producer in the world
Multiplier
Name dropping
Opportunity
People power
Quality
Raw materials
Surface miner
Types of cement
Uses
Values
Workforce
The unknown (X) factor
Yin and Yang
Zero harm

At every step we found that new and innovative solutions could be found if we kept an open
mind.
The result is that today we are not only self-sufficient but are in a position to sell excess
power capacity to the local state government.
Our sea-borne bulk cement transportation facilities have meanwhile brought many coastal
markets (domestic as well as export markets) within easy reach.This has been a major
factor in making Ambuja Cement India's largest exporter of cement - consistently for
the last fifteen years.
It can be done!
Over 25-30% of the production cost of cement is power.
It quickly became clear to us that if we were to run an iconic company, we needed to keep
to get more output for less power.
power costs to the minimum. So we focused our efforts on improving efficiency at our kilns
Next we set up a captive power plant at a substantially lower cost than the national grid. We
sourced higher quality coal from South Africa and better furnace oil from the Middle East.

The quarry is the starting point


Cement plants are usually located closely either to hot spots in the market or to areas
with sufficient quantities of raw materials. The aim is to keep transportation costs low.
Basic constituents for cement (limestone and clay) are taken from quarries in these
areas.
A two-step process
Basically, cement is produced in two steps: first, clinker is produced from raw materials.
In the second step cement is produced from cement clinker. The first step can be a dry,
wet, semi-dry or semi-wet process according to the state of the raw material.
Making clinker
The raw materials are delivered in bulk, crushed and homogenised into a mixture which
is fed into a rotary kiln. This is an enormous rotating pipe of 60 to 90 m long and up to 6
m in diameter. This huge kiln is heated by a 2000C flame inside of it. The kiln is slightly
inclined to allow for the materials to slowly reach the other end, where it is quickly
cooled to 100-200C.
Four basic oxides in the correct proportions make cement clinker: calcium oxide (65%),
silicon oxide (20%), alumina oxide (10%) and iron oxide (5%). These elements mixed
homogeneously (called raw meal or slurry) will combine when heated by the flame at
a temperature of approximately 1450C. New compounds are formed: silicates,
aluminates and ferrites of calcium. Hydraulic hardening of cement is due to the
hydration of these compounds.

From clinker to cement


The second phase is handled in a cement grinding mill, which may be
located in a different place to the clinker plant. Gypsum (calcium
sulphates) and possibly additional cementitious (such as blastfurnace
slag, coal fly ash, natural pozzolanas, etc.) or inert materials (limestone)
are added to the clinker. All constituents are ground leading to a fine and
homogenous powder. End of phase two. The cement is then stored in silos
before being dispatched either in bulk or bagged.
What is concrete?
Concrete is a solid material made of cement, sand, water, aggregates and
often with admixtures. When fresh, it has a certain workability and takes
the form of the mould into which it is put. When set and hardened, it is as
strong as natural stone and resists time, water, frost, mechanical
constraints and fire. Typically, concrete is the essential material used in all
types of construction [residential (housing), non-residential (offices) and
civil engineering (roads, bridges, etc.)].

The kiln is a cylindrical vessel, inclined slightly to the horizontal, which


is rotated slowly about its axis. The material to be processed is fed into
the upper end of the cylinder. As the kiln rotates, material gradually
moves down towards the lower end, and may undergo a certain amount
of stirring and mixing. Hot gases pass along the kiln, sometimes in the
same direction as the process material (co-current), but usually in the
opposite direction (counter-current). The hot gases may be generated in
an external furnace, or may be generated by a flame inside the kiln.
Such a flame is projected from a burner-pipe (or "firing pipe") which acts
like a largebunsen burner. Thefuelfor this may be gas, oil or pulverized

Fig: Different zones in a basic rotary kiln.


Every zones have a specific importance in the manufacturing process
of raw materials to slurry to clinkers to cement and finally to concrete
if needed.

Fig: Demonstration on how cement can be formed using waste


products.

Fig: Different temperature zones in Rotary Kiln.

Length 72 feet and 10 inches.


Width 11feet and 6 inches.
Height 14 feets.

Force Flow
(Air) Valve
Bag Filler

Integrated Valve
Bag Packer

Robotic Bag
Handling Systems
(applicator &
palletizer) for valve
bags

You might also like