- The document provides production and quality parameters for June 2015 for an iron and steel plant. It includes targets versus actuals achieved and remarks from the director on various parameters like production, quality, maintenance, safety, and inventory.
- Overall the director was pleased with the plant performance but suggested some areas for improvement like reducing carbon in iron ratio (C/Fe) further and bringing down accidents to zero.
- For pellet quality, the director expressed it was okay overall except for total iron content (Fe(T)) and asked to work on further improving this.
Call Girls in Nagpur Suman Call 7001035870 Meet With Nagpur Escorts
DRI Plant Performance Report Summary
1.
2. SL NO
PARTICULA
RS
TARGET ACHIEVED REMARKS
1
PRODUCTI
ON
28830 26781
1.Kiln 1 Inlet cone Castable got damaged , 2.
Air tube was broken resulting feed was cut-
down from 21.4 to 19 Mt/ Hr.
3. Poor quality of Iron Ore fed to Kiln 4
2 OFF GRADE 6.5 7.77
K 1 : Off Grade gone 12 % due to coal throw
problem
DESKTOP PRESENTATION FOR
THE MONTH OF JUNE-15
3 FEED RATE 21.40 20.49 Due to above reasons.
4
PLANT
AVAILABILIT
Y
99 99.62
5 POWER 67 68.42
6 Mz 90.5 90
7 ACCIDENT 0 0
3. TARGET & PERFORMANCE:-
Remarks
Director was pleased with performance
TARGET & PERFORMANCE:-
Remarks
Director was pleased with performance
Pla
n
K1 K2 K4 Total
Working days 93 28 29 28 85
Prod 292
50
9307 8976 8829 27112
Des -SMS
-Out side
- - - -
15749.16
9604.14
% Tgt 100 94.0
1
90.67 93.43 92.69
% Cap 100 95.3
1
91.92 90.41 92.55
REVIEW OF PREVIOUS MONTH’S MOM
He suggested that for the further improvement in all the areas should be identified
and action initiated as per requirement of IMS
Current Status : We have initiated in following areas : Energy
Conservation, Increase the Product Fe M 78 +
He suggested that for the further improvement in all the areas should be identified
and action initiated as per requirement of IMS
Current Status : We have initiated in following areas : Energy
Conservation, Increase the Product Fe M 78 +
4. INPUT:-
Remarks
PELLET :-.
Director expressed that all parameters of pellet are more or less ok except Fe(T).
INPUT:-
Remarks
PELLET :-.
Director expressed that all parameters of pellet are more or less ok except Fe(T).
Plan Actual %
Pellet receipt 42794 35550.11 83.07
Quality
Fe(t)
CCS
AI
TI
+18 mm
-4 mm
64
210
3
92.5
5
10
63.51
202
2.95
93.66
0
6.5
99
96.19
98.33
101.25
0
65
Unscreened
%
0 14.25
REVIEW OF PREVIOUS MONTH’S MOM
Director expressed that all parameters of pellet are more or less ok except Fe(T).
Unless HG proportion in feed in pellet plant becomes viable, further Fet
improvement will be increasingly difficult.
Director also remarked that S.A. coal fines is posing a new major problem in
production. He asked to Atto work out and calculate how to address this issue, He
asked to make presentation on this next month
Current Status :Analysis data incorporated in the
presentation.
Director expressed that all parameters of pellet are more or less ok except Fe(T).
Unless HG proportion in feed in pellet plant becomes viable, further Fet
improvement will be increasingly difficult.
Director also remarked that S.A. coal fines is posing a new major problem in
production. He asked to Atto work out and calculate how to address this issue, He
asked to make presentation on this next month
Current Status :Analysis data incorporated in the
presentation.
5. MAINTENANCE:-
Remarks
MAINTENANCE:-
Remarks
DESCRI
PTION
K1 K2 K4 Total %
Calenda
r hrs
744 744 744 2232 100
Running
hrs
709.02 686.27 671.38 2066.67 92.49
S/D hrs 0 0 0 0 0
Delay% 4.71 7.76 9.75 165.33 7.51
Process 0.37 7.74 8.95 124.57 5.69
Mech 4.17 0 0.19 32.42 1.45
RMP 0 0 0 0 0
Elec 0.46 0 0.59 7.83 0.35
Others 0.03 0.02 0.022 0.51 0.02
REVIEW OF PREVIOUS MONTH’S MOM
Director praised the team for good maintenance. However how and why
preventive maintenance of support roller bearing was not identified should
be looked into and suggested
Current Status :
Sir, PM was done during shutdown we have checked all points like
clearance, Cage, lock plate , Inner and outer race, foreign
material exc.
Director praised the team for good maintenance. However how and why
preventive maintenance of support roller bearing was not identified should
be looked into and suggested
Current Status :
Sir, PM was done during shutdown we have checked all points like
clearance, Cage, lock plate , Inner and outer race, foreign
material exc.
6. PROCESS
REMARKS;-
Director asked. However he expressed that opportunity for reducing C/Fe
should continually be explored by further optimizing the process . We
have scope for further reducing C/Fe
PROCESS
REMARKS;-
Director asked. However he expressed that opportunity for reducing C/Fe
should continually be explored by further optimizing the process . We
have scope for further reducing C/Fe
K1 K2 K4 T
Feed /Hr 21.11 21.51 21.06 21.22
C/Fe 0.454 0.46 0.467 0.46
Kwh/ton 65.68 65.68 71.53 67.59
Campaig
n life
76+ 90+ 127+ 97.67
REVIEW OF PREVIOUS MONTH’S MOM
have scope for further reducing C/Fe
Current Status : Sir C/ Fe is totally depend on coal FC and
Coal Size our draw back is Coal Size we have used 60 %
fines in injection Coal.
have scope for further reducing C/Fe
Current Status : Sir C/ Fe is totally depend on coal FC and
Coal Size our draw back is Coal Size we have used 60 %
fines in injection Coal.
7. QUALITY:-
Remarks
Director pleased with performance. Off grade is under control .
Non mag can further be brought down.
QUALITY:-
Remarks
Director pleased with performance. Off grade is under control .
Non mag can further be brought down.
K1 K2 K4 T
Off grd % 5.78 3.89 5.38 4.99
-1 mm % 13.51 13.22 13.02 13.25
Fem % 77.1 77.21 77.13 77.07
Fe(t) % 85.14 85.24 85.19 85.19
DM % 90.31 90.57 90.53 90.47
Gangue % 12.51 12.46 12.5 12.49
NM % 0.76 0.76 0.77 0.76
REVIEW OF PREVIOUS MONTH’S MOM
Non mag can further be brought down.
How to improve Fem level more consistency should be looked
into. Marketing report says that from similar pellets others are able
to get 78+ Fe m . This should be gone into detail and report
submitted
Current Status : Sir now we have also maintain 78 + Fem
through out the month and given new specs to Marketing
Department.
Non mag can further be brought down.
How to improve Fem level more consistency should be looked
into. Marketing report says that from similar pellets others are able
to get 78+ Fe m . This should be gone into detail and report
submitted
Current Status : Sir now we have also maintain 78 + Fem
through out the month and given new specs to Marketing
Department.
8. Inventory :-
Remarks
Inventory of stores and spares should be looked into with
more focus.
Inventory :-
Remarks
Inventory of stores and spares should be looked into with
more focus.
Item Closing
stock
Consp/t ICC/T
Pellet 1296 1.59 t/t
Dolo
mite
1209 40 kg/t
DRI 1026
REVIEW OF PREVIOUS MONTH’S MOM
more focus.
Current Status : Detail is incorporated in the presentation.
more focus.
Current Status : Detail is incorporated in the presentation.
9. SAFETY :-
Remarks
Director advised that accidents should be brought down to 0.
SAFETY :-
Remarks
Director advised that accidents should be brought down to 0.
Proce
ss
Maint Contract
ors lab
Total
Reportable
Accidents
0 0 0 0
Near miss 0 0 0 0
Minor 0 0 1 1
REVIEW OF PREVIOUS MONTH’S MOM
Director advised that accidents should be brought down to 0.
Hazard identification and corrective action is a must. The safety
committee should deliberate on this aspect.
Current Status :
Unfortunately one accident occurs in RMP (Safety helmet
save life )
Director advised that accidents should be brought down to 0.
Hazard identification and corrective action is a must. The safety
committee should deliberate on this aspect.
Current Status :
Unfortunately one accident occurs in RMP (Safety helmet
save life )
10. 5 S & SAFETY
Remarks
Director appreciated DRI maintaining 3S and keeping the flag flying. He asked that SID should
initiate for 4S now.
SID has introduced the IMS Business excellence model in SID and work is going on to achieve
the award.
Current status:
5 S & SAFETY
Remarks
Director appreciated DRI maintaining 3S and keeping the flag flying. He asked that SID should
initiate for 4S now.
SID has introduced the IMS Business excellence model in SID and work is going on to achieve
the award.
Current status:
REVIEW OF PREVIOUS MONTH’S MOM
Current status:
Maintain 3s and got 48 marks in 4S
(last mark 40 )
Current status:
Maintain 3s and got 48 marks in 4S
(last mark 40 )
11. Thrust area for next month :
1. Coal Shed sheeting is must before monsoon.
2. Coal lifting from railway siding, 5 rakes is on pipeline.
3. Coal screening during monsoon.
4. Maintain C/ Fe
5. Safety
Thrust area for next month :
1. Coal Shed sheeting is must before monsoon.
2. Coal lifting from railway siding, 5 rakes is on pipeline.
3. Coal screening during monsoon.
4. Maintain C/ Fe
5. Safety
REVIEW OF PREVIOUS MONTH’S MOM
5. Safety
Remarks
Director advised that increase in cost due to high C/Fe to be
considered in the slide on cost control.
Current Status : C/Fe was maintain 0.463
5. Safety
Remarks
Director advised that increase in cost due to high C/Fe to be
considered in the slide on cost control.
Current Status : C/Fe was maintain 0.463
13. TARGET ACTUAL ANALYSIS
MATERIAL IN
SURGE BIN
60% 60.67%
Fines % was
higher side due to
excess moisture
and 25 % material
was directly fed to
circuit due to dryer
output is not meet
our daily
requirement.
FEED COAL
SIZE : – 4MM
Max 12% 15.82%
COURSE COAL
SIZE : – 4MM
Max 15% 35.34%
PELLET SIZE :
– 3 MM
Max 3% 2.03%
PELLET SIZE
: + 18MM
Max 5.0% 0 %
Processing
Raw Material Processing & Handling
PARAMETER PLANNED ACTUAL ANALYSIS
TOTAL PELLET
RECEIVED FROM
PELLET PLANT
43108 40417.60
PELLET DIRECT
UNLOADING AT
GROUND HOPPER
95% 98.41 %
PELLET YARD
UNLOADING
5 % 1.59%
COAL DIRECT
UNLOADING AT
SHED
95% 100 %
COAL DUMP
OUTSIDE YARD
5% max 0
HANDLING
(PELLET & COAL MOVEMENT)
15. PARTICULARS UNIT PLANNED ACTUAL Analysis
WORKING DAYS: (3
KILNS)
NO 90 90
Kiln 1 condition was deteriorate due to
excess fines carry over in feed as well as
Injection coal .
SHUT DOWN DAYS:
(3 KILNS)
NO 0 0
PRODUCTION MT 28830 26781
FEED RATE MT/HR 21.40 20.49
Production Planning & Review
FEED RATE MT/HR 21.40 20.49
COAL FINES
(GENERATED)
MT 1658 1615
PELLET TON/MT 1.58 1.63
COAL TON/MT 1.10 1.18
POWER KWH/T 67 68.42
DOLOMITE KG/MT 40 55
16. RAW MATERIAL CONSUMPTION
RAW MATERIAL KILN-01 KILN-02 KILN-04 TOTAL
PELLET 12224 15144 8993 35691
IRON ORE 0 - - 6209
I/O DUST 1148 - - 1148
COAL
S.A 7204 8183 7695 23082
MT
S.A 7204 8183 7695 23082
B GRADE FINES 40 0 0 40
D GRADE
D&F GRADE 543 463 453 1459
E GRADE - - - -
F GRADE 2145 2352 2578 7075
TOTAL COAL 9932 10998 10726 31656
DOLOMITE 406.3 390.66 572.84 1369.80
CHAR 2161 2515 2334 7010
19. PARAMETER PLANNED JUN-15 MAY-15 ANALYSIS
QTY 43108 40417.60 35550.11 Fines Generation was fluctuated
from 4 to 15 %,
Moisture slightly increased.MOIST 0.5 - 2.5
2.52
(1.68-4.10)
1.85
(1.30-4.52)
MAJOR INPUT REC: PELLET QUALITY ASSURANCE PLAN
(1.68-4.10) (1.30-4.52)
Fe(T)
63.8 -
64.5
63.92
(63.32-64.12)
63.51
(62.60-63.91)
CCS 180 - 240
198
(168-226)
202
(170-226)
TI 91 – 94
93.18
(90.26-94.30
93.66
(91.06-94.46)
AI 2.5 – 3.5
3.09
(2.86-3.76)
2.95
(2.66-3.66)
CD
(-4MM)%
10
12.04
(6.30-44.51)
6.50
(5.35-11.09)
ESP % 20
20.33
(14.79-38.3)
17.44
(13.6-20.86)
YIELD% 62 62.63 62.88
20. F
GRADE
TARGE
T
JUNE MAY ANALYSIS
QUANTITY
(MT)
5525 6958.97 1480
%
MOISTUR
E
8 9.85 6.93
%
VOLATILE
MATTER
25 23.52 20.16
% FIXED
CARBON
25 24.71 23.05
- 04 MM 20 17.99 11.92
SHALE/ST
ONE
5 12.1 9.45
F grade
MAJOR INPUT REC: COAL QUALITY ASSURANCE PLAN
SOUTH
AFRICA
TARGE
T
JUNE MAY ANALYSIS
QUANTITY
(MT)
21103 31776.83 13070.46 Moisture
increased in SA
rake it was up
to 10 %
%
MOISTURE
7 7.92 7.69
%
VOLATILE
MATTER
25 24.12 23.20
% FIXED
CARBON
53 51.61 51.41
- 04 MM 35 31.55 33.8
South African
21. OUTPUT TARGET K1 K2 K4 OVERALL ANALYSIS
PRIME % 93% 88.29 88.27 90.57 89.04 Pellet DRI Fe M
maintain 78 + in
K2 and K 4.
Fe T of Pellet DRI
also reaching 86
OFF GRADE 6.5% 12.64 6.25 4.44 7.78
FE(M) % 77% 76.6 78.01 79.09 77.75
FE(T)SPONG
E%
86% 85.65 85.9 88.02 86.50
Mtz% 90.5% 89.43 90.81 89.85 89.88
FINSIHED PRODUCT
also reaching 86
%
Gangue was
came down < 12
%
Mtz% 90.5% 89.43 90.81 89.85 89.88
GANGUE% 12% 11.71 11.73 9.43 10.96
CARBON % 0.1% 0.07 0.08 0.10 0.08
CD
(-4 MM)% 10 8.44 8.76 18.91 12.04
CD
(-1 MM)% 20 12.98 13.03 16.9 14.30
N Mag % <1%
S% 0.03% 0.026 0.026 0.027 0.026
PHOS % 0.08% 0.072 0.072 0.064 0.069
25. S. No. Activity Planned Achieved Remarks for deviation
5
Equipment Health A-
Grade(MID Report, Process
Parameter & Physical
Inspection)
95% 95 A – 95 %, B – 5 %, C – 0%
6
Repair Plan as per
Schedule
01 01
Repair plan of Kiln-2 CD Dedusting
fan for health up gradation .
MID REPORT : MECHANICAL
7
Maintenance cost
(Rs./MT)
90 42.28
Average of F.Y. 2014-15 – Rs.98.38
Average of F.Y. 2015-16 – Rs.60.35(till
month)
8 Inventory (Rs. Lacs) 65 92.16
Non-Moving – 6.69 Lacs
Consumables – 23.17 Lacs
Insured Items -62.30 Lacs
9
No. of Development
Projects
1 1
Vibrating screen & Belt conveyor
installation for PGP coal feeding .
Target date July 20th 2015.
26. S.NO. EQUIPMENT MID REPORT
PHYSICAL
INSPECTION
PROCESS
OBSERVATION
HEALTH
STATUS
1 KILN-1 COOLER MAIN DRIVE B A A B
CRITICAL EQUIPMENT HEALTH REPORT
2 KILN-2 COOLER MAIN DRIVE B A A B
3 KILN-4 COOLER MAIN DRIVE B A A B
4 LOBE COMPRESSOR-3 KILN-2 B A A B
5 ESP ID FAN KILN-4 B A A B
30. KRA
EFFECTIVE PLANNING
PRODUCTION APPROVED AT NORM COST & QUALITY
MAINTAIN PEOPLE DICIPLINE, HEALTH & SAFETY
DEVELOP & TRAINED DIRECT REPORTING OFFICERS
ENSURE COMPLAINCE OF SAFETY& ENVN. NORM
32. Sl no PARTICULARS TARGET MARKS
OBTAINE
D
MARKS
S.NO.
1 QUANTITY MT/DAY 500/DAY 30 30
Fe(m)%
77% min to 80%
max
5 2
CUSTOMER FEED BACK:SMS
2
QUALITY
Fe(m)%
max
5 2
Fe(t)%
86% min to 88%
max
10 3
-1% in DRI
FINES
20% max 10 10
S%
0.02% min to
0.03% max
5 5
P% 0.080% max 5 5
C% 0.10% max 5 5
Qty. of fines 20% in total 20 20
3
CUSTOMER
SERVICE (%)
10 10
4
SATISFACTION
LEVEL
100 90
33. OPENNING GENERATION
DISPATCH
BACK LOG
BY PRODUCT INVENTORY
MATERIALS
O/P (MT) GEN (MT) DESP (MT) B/LOG (MT)
JUNE MAY JUNE MAY JUNE MAY JUNE MAY
CHAR COAL
LUMPS/FINES
16.87 36.59 7010 6502 6334.99 6521.72 691.88 16.87
COAL FINES BY PASS 200 30 1615.73 2658.64 1615.73 2488.64 200 200
PELLET FINES BY PASS 300 110 463.49 844.98 463.49 654.98 300 300
TOTAL 416.87 176.59 9089.27 9905.62 8414.21 9664.34 1191.88 416.87
34. OBJECTIVES TARGET ACTUAL ANALYSIS
House Keeping 3s 3s
3S :- 3S is well
maintained.
4s :- 48 Marks Achieved
Safety compliance is
Accident 0 0
Safety Audit
Compliance 100 % 100%
SAFETY & HOUSEKEEPING
Safety compliance is
done 100 %Elimination of
Identified Hazard 100% 100%
PPE usage 100% 100 %
Safety Committee
meeting compliance
of points
100% 100 %
35. HR Issue
Month Company Manpower Contract Manpower
April, 15 221/ Day 180 / Day
May, 15 221 / Day 182 / Day
June,15 221 / Day 182 / Day
Manpower shall be cut down further by 10 % in next 4 months.
36. Review of last month Plan (Thrust Area )
Review of Thrust area of last month :
1.Coal Shed sheeting is must before monsoon :
Completed.
2.Coal lifting from railway siding, 5 rakes is on
pipeline : Done it.pipeline : Done it.
3.Coal screening during monsoon : affected due to
heavy monsoon.
4.Maintain C/ Fe: Maintain 0.463
5.Safety : One but helmet safey his life.
37. (Thrust Area ) For Next Month
1. Manpower reduction.
2. Feed rate maintain as per the production plan.
3. Again C/ Fe Maintain < 0.463. Again C/ Fe Maintain < 0.46
4. Fe m Maintain 78 +
5. Safety : First priority.