Production & Operations Management
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Lafarge is the largest cement manufacturer in the world, with a presence in 90 countries and 115,000 employees. It was formed by the merger of Holcim and Lafarge in 2015. The cement production process involves quarrying raw materials, crushing and transporting them to the plant for grinding, preheating, burning in a kiln at 1500°C to produce clinker, final grinding with gypsum, storage, and packing for shipping. Lafarge India's cement business was acquired by Nirma group for $1.4 billion and LafargeHolcim's net sales fell 7.5% in the first nine months of 2016 compared to the same period in 2015.
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- Refractory bricks experienced severe thermal and chemical stresses due to variation in clinker chemistry and the use of petcoke, which increases liquid viscosity and damages bricks. Cracks in bricks showed they were under mechanical stress from shell distortion.
- Installation errors like non-perpendicular brick rings led to gaps that formed hot spots, shortening refractory life. Proper installation is needed to avoid subjecting bricks to unnecessary mechanical stresses.
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- A heat balance of the rotary kiln found the surface temperature was high, indicating potential for heat recovery.
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In this presentation, similarities and differences between AERMOD and AUSLPUME are discussed and analysed with the ultimate goal of easing the transition from AUSPLUME to AERMOD in Victoria, as well as Australia as a whole. Topics discussed include source types, treatment of terrain, plume rise algorithms, low wind speed conditions, and chemical transformations.
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3. Finely grinding the clinker with gypsum and other additives to produce pure cement powder.
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This document outlines the process for manufacturing cement. It begins with quarrying raw materials like limestone and transporting them to the plant for crushing. The crushed materials are then homogenized and ground into raw meal. The raw meal goes through preheating and precalcining before being fired in a rotary kiln at high temperatures to produce clinker. The clinker is cooled, stored and later ground with gypsum and other additives to produce cement powder. The final cement is stored in silos and packed into bags for transport to customers. The process aims to efficiently produce cement from raw materials through steps like preheating and using modern technologies for grinding.
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Holcim is a major global cement producer operating in 70 countries. It has over 90,000 employees and annual net sales of 15 billion euros. Holcim's subsidiary GEOCYCLE operates platforms in Belgium, France, and the Netherlands to pretreat hazardous and non-hazardous industrial waste for use as fuel and raw materials in Holcim's cement kilns. In 2006, GEOCYCLE pretreated 125,000 tons of waste via its platforms and another 260,000 tons were sent directly to cement kilns, totaling 385,000 tons. GEOCYCLE has 55 employees and follows ISO environmental and safety standards.
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3) The clinker is cooled, ground with gypsum, and packaged for distribution.
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- 1. PRODUCTION AND OPERATIONS PROCESS IN CEMENT INDUSTRY
- 2. • Lafarge is a manufacturer of building materials (primarily cement, aggregates and concrete) which claims to be the largest in the world, with a presence in 90 countries and 115,000 employees. It was formed by the merger on 10 July 2015 of cement companies Holcim and Lafarge which had combined net sales of CHF 33 billion (EUR 27 billion) in 2014. • The Group is based in Switzerland but its central functions remain divided between Zurich and Paris. The company's research facilities are in Lyon, France. THE COMPANY
- 3. • The entire plant is operated from central control room where the process operating personnel closely monitor, the plant operation on visual display unit. The computerized process control system with field instrumentation ensures the steady and smooth operations of the plant. • Flow chart of the cement production process: i. Raw material extraction/ Quarry ii. Grinding, Proportioning and Blending iii. Pre-heater Phase iv. Kiln Phase v. Cooling and Final Grinding vi. Packing & Shipping OPERATIONS
- 4. THE CEMENT MANUFACTURING PROCESS 1. BLASTING : The raw materials that are used to manufacture cement (mainly limestone and clay) are blasted from the quarry. Quarry face 1. BLASTING 2. TRANSPORT 3. CRUSHING AND TRANSPORTATION : The raw materials, after crushing, are transported to the plant by conveyor. The plant stores the materials before they are homogenized. Quarry 3. CRUSHING & TRANSPORTATION 2. TRANSPORT : The raw materials are loaded into a dumper. crushing conveyor dumper storage at the plant loader
- 5. THE CEMENT MANUFACTURING PROCESS 1. RAW GRINDING : The raw materials are very finely ground in order to produce the raw mix. 1. RAW GRINDING Raw grinding and burning 2. BURNING 2. BURNING : The raw mix is preheated before it goes into the kiln, which is heated by a flame that can be as hot as 2000 °C. The raw mix burns at 1500 °C producing clinker which, when it leaves the kiln, is rapidly cooled with air fans. So, the raw mix is burnt to produce clinker : the basic material needed to make cement. conveyor Raw mix kiln cooling preheating clinker storage at the plant Raw mill
- 6. THE CEMENT MANUFACTURING PROCESS 1.GRINDING : The clinker and the gypsum are very finely ground giving a “pure cement”. Other secondary additives and cementations materials can also be added to make a blended cement. 1. GRINDING Grinding, storage, packing, dispatch 2. STORAGE, PACKING, DISPATCH 2. STORAGE, PACKING, DISPATCH : The cement is stored in silos before being dispatched either in bulk or in bags to its final destination. Clinker Storage Gypsum and the secondary additives are added to the clinker. silos dispatch bags Finish grinding
- 7. • The Gujarat-based Nirma group, with presence in detergent, soap and chemicals sector, has bought Lafarge India’s cement business, consisting of 11 MT production capacity, for US$ 1.4 billion. • LafargeHolcim’s net sales have fallen by 7.5% year-on-year to Euro18.9bn in the first nine months of 2016, from Euro20.4bn in the same period of 2015 • The Government of India plans to enact a law that will allow the companies which have received mining licenses without having gone through the auction process, to transfer these leases, in a move that is expected to make mergers and acquisitions (M&As) easier in the steel, cement, and metals sectors. • India has joined hands with Switzerland to reduce energy consumption and develop newer methods in the country for more efficient cement production, which will help India meet its rising demand for cement in the infrastructure sector. INVESTMENTS