nikita malviya birla cement

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A

Project Study Report

On

Training Undertaken at

BIRLA CEMENT WORKS, CHITTORGARH, RAJ.

Titled

ORGANIZATION CLIMATE

Submitted in partial fulfillment for the

Award of degree of

Master of Business Administration

Submitted By: - Submitted To:-

Nikita Malviya SONAL JAIN (HOD)

MBA Part II

(2007-2009 )

Regional college of Education Research and Technology

Sitapura, Jaipur

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DECLARATION

I NIKITA MALVIYA D/o Mr. PRADEEP MALVIYA declare that the project report titled

ORGANIZATION CLIMATE is based on my project study. This project report is my

original work and this has not been used for any purpose anywhere.

Student Name

NIKITA MALVIYAMBA IVth Sem.

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CERTIFICATE FROM COLLEGE

TO Whom So Ever It May Concern

This is to certify that MISS. NIKITA MALVIYA has prepared this project report title

ORGANIZATION CLIMATE based on this project study. This project report is his original

work and it is submitted for the fulfillment of the MBA Degree.

Wish him good success for his future career.

Satish Sharma

( Project Guide)

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PREFACE

Cement industry is one of the core industries in India like iron and steel. It has its primary

role in almost all development plans of the country. Birla cement works is a well establish

unit in the market of cement industries.

HRD is an important function of every organization. Hence, undertook the project to analyze

various aspect of HRD with a detailed study of organization climate of Birla cement work..

NIKITA MALVIYA

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ACKNOWLEDGEMENT

I express my sincere thanks to my project guide, Mr. S.K. JAIN, HR MANAGER(HRD) , for

guiding me right form the inception till the successful completion of the project. I sincerely

acknowledge him/her/them for extending their valuable guidance, support for literature,

critical reviews of project and the report and above all the moral support he/she/they had

provided to me with all stages of this project.

I would also like to thank the supporting staff _MUKESH SAXENA ASST. HR MANAGER,

for their help and cooperation throughout our project.

(Signature of Student)

NIKITA MALVIYA

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EXECUTIVE SUMMARY

Indias cement industry, which rode on a building boom to become the worlds second

largest cement manufacturer after China with an installed capacity of more than 200million tones (mt), is all set to take big hits. Indias cement industry has 132 large

plants and 365 small plants with a cumulative installed capacity of 204mt at the end of

August.

The main Indian manufacturers in terms of capacity are ACC Ltd, UltraTech Cement

Ltd, Ambuja Cements Ltd, Grasim Industries Ltd, Binani Cement Ltd, India Cements

Ltd and JK Cement Ltd. In addition, several international cement manufacturers such

as Frances Lafarge, Switzerlands Holcim Ltd, Italys Italcementi and Germanys

Heidelberg Cement.

Birla cement works is a well established unit in the market of cement industries. The

Cement Division of Birla Corporation Limited has seven plants, having an installed

capacity of 5.8 million tons. After the completion of the ongoing expansion projects,

the capacity will increase to 7 million tons.

This ongoing project was study of Organizational climate at Birla Cement Works;Chittorgarh was focused on enduring quality of the internal environment that is

experienced by the members, which in turn influences their behavior.

Data was collected with the help of a questionnaire. The questionnaire is of structured

non-disguised type. The contact method used in the survey was personal interview

method. The study helps to understand the Organizational climate at Birla Cement

Works, Chittorgarh. .

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TABLE OF CONTENTS

DECLARATION 2

Certificate 3

Preface4

Acknowledgement 5

Executive summery 6

1 Introduction to the Industry 8-43

2. Introduction to the Organization 44-79

3 Research Methodology 80-85

3.1 Title of the Study

3.2 Duration of the Project

3.3 Objective of Study

3.4 Type of Research

3.5 Sample Size and method of selecting

sample

3.6 Scope of Study

3.7 Limitation of Study

4 Result And Finding 86-87

5 Analysis and Interpretation 88-101

6 SWOT 102-103

7 Conclusion 104-106

8 Recommendation and Suggestions 107-109

9 Questionnaire 110-112

10 Bibliography 114-115

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8

INTRODUCTION

TO CEMENTINDUSTRY


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INDUSTRY PROFILE

1.1 INTRODUCTION

Definition of cement:

Cement is binding material. Cement is one of the cheapest readily available, strong and

long life materials. The weathering effect on cement is very low. For the manufacturing of

cement basis raw material is lime stone. The purest form of limestone is marble.

Manufacturing process:

Heating mixture of limestone & clay at 1350-1400 degree temperature which produces the

modules of clinker due to fusion occurred by the heating. This clinker is then mixed with

gypsum & finely ground to make cement.

1. Mining the mining of lime stone is done in such way so as to get 78%to 82%pure

limestone.

2.Crushing- the limestone is then crushed to 16to 25mm size .this is done at mines it self

and their crushed limestone is send to factory through the conveyer belt.

3. Grinding- The limestone is then grinded with literate so as to extend it setting. After this

mixture is send to silos.

4. Blending- In the silos blending is done so as to maintain the uniform mixture from the

silos the mixture is sending to preheater.

5. Burning- The mixture is pre-heated then it goes to where burning take place. In

calcinations burning zone of kiln pulverized coal is used as fuel in the process.

6. Grinding- The grinding of clinker with gypsum is done in cement mill.

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7. Packing- cement is send to packing plant. Where it is packed in the bags using the

electronic packing machine.

1.2 PRODUCTION PROCESS OF CEMENT :

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PACKAGING


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1.3 CURRENT SCENARIO OF INDIAN CEMENT INDUSTRY

Cement industry is a core sector and forms the back bone of infrastructure development of

the country. Cement manufacturing began in India in 1911.the first plant had capacity of

200 tones per day. The industry was uncontrolled in 1989. the investment cost per ton of

installed capacity in 2002 for a cement plant is 4500 per ton As compared to 650 per ton in

late 70 s India is one of the best quality cement manufacture of the world .it stand in the

top five producing nations of the world.

India is the worlds second largest producer of cement after China with industry capacity of

over 200 million tones (MT). With the boost given by the government to various

infrastructure projects, road network and housing facilities, growth in the cement

consumption is anticipated in the coming years.

The Indian cement industry comprises of nearly 132 large plants and another 365 small

plants. While the Cement Corporation of India, a central public sector undertaking,

comprises 10 units; the various State governments own 10 large cement plants. Among the

leading domestic players in terms of cement manufacturing are: Ambuja Cement, Aditya

Birla Group (which owns UltraTech Cement), ACC Ltd., Binani Cement, India Cements and

J K Cement. They are not only the foremost producers of cement but also enjoy a high level

of equity in the market.

The cement industry in India has added a whopping 46 MT capacity in just a little over three

years, taking the total installed capacity to 204.29 MT as on August 31, 2008. This includes

India Cements Ltds new grinding unit at Vallur, Tamil Nadu with an installed capacity of1.10 MT.

The industry added over 30 MT to its installed capacity in just one year during previous

fiscal (April 2007March 2008).

Almost all players of the industry, small to medium to large, have added capacity ranging

between a minimum of 200,000 tones and a maximum of 3 MT in the last three years (April

2005 to March 2008), effecting a total addition of 45 MT to the installed capacity by setting

up Greenfield projects, and expanding and upgrading the existing plants.

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Simultaneously, with almost total capacity utilization levels in the industry, cement

dispatches continued to maintain a 10 per cent growth rate. Total dispatches grew to 170

MT during 200708, as against 155 MT in 200607. Region-wise, western region grew

fastest with a growth rate of 15 per cent, followed by northern region (12 per cent) and

southern region (10 per cent).

Future Outlook

Considering an expected production and consumption growth of 9 to 10 per cent, the

demand-supply position of the cement industry is expected to improve from 2008-09

onwards, resulting in an expected price stabilization. The cement industry is poised to add

111 million tones of annual capacity by the end of 2009-10 (FY 10), riding on the back of an

estimated 141 outstanding cement projects.

Major Players

The major players in the cement sector are:

Ultratech Cement

Century Cements

Madras Cements

ACC

Gujarat Ambuja Cement Limited

Grasim Industries

India Cements Limited

Jaiprakash Associates and

JK Cements.

Holcim

Lafarge

Heidelberg Cemex

Italcementi

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Statistics

Cement

(million tonnes)

2006-07 2007-2008

(Apr-Mar)

(a) Production 155.66 168.31

(b)

Despatches

(Including Export) 155.26 167.67

(c) Export 3.65 5.89

(d) Cap. Uti.(%) 96 94

Source: Cement Manufacturers Association

1.4 Region wise Capacity

The Indian cement industry has to be viewed in terms of five regions:-

North (Punjab, Delhi, Haryana, Himachal Pradesh, Rajasthan, Chandigarh, J&K and

Uttranchal);

West (Maharashtra and Gujarat);

South (Tamil Nadu, Andhra Pradesh, Karnataka, Kerala, Pondicherry, Andaman & Nicobar

and Goa);

East (Bihar, Orissa, West Bengal, Assam, Meghalaya, Jharkhand and Chhattisgarh); and

Central (Uttar Pradesh and Madhya Pradesh).

Northern Region

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TABLE 1.1


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Punjab 2173.34

Delhi 500.00

Haryana 172.00

Himachal Pradesh 4060.00

Rajasthan 16299.34

J&K 200.00

TOTAL 23404.68

West

Maharashtra 8950.00

Gujarat 12937.00

TOTAL 21887.00

South

Tamil Nadu 12913.18

Andra Pradesh 19831.02

Karnataka 9744.00

Kerala 420.00

TOTAL 42908.20

East

Bihar 1000.00

Orissa 2761.00

West Bengal 2291.66

Assam Meghalaya 400.00

Jharkhand 3475.01

Chattisgarh 11287.33

TOTAL 21215.00

Central

U.P. 6297.00

M.P. 16185.00

TOTAL 20482.00

1.5 Per Capita Cement Consumption

Per capita cement consumption in India is 82 kgs against a global average of 255 kgs and

Asian average of 200 kgs.

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TABLE 1.2


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Fast rising Government Expenditure on Infrastructure sector in India has resulted a higherdemand of cement in the country. In the same direction, participation of larger companies inthe sector has increased.

For raising efficiency in the sector, the Planning Commission of India in the 10th plan hasformed a 'Working Group on Cement Industry'.

There is a total number of 125 large cement plants and more than 300 small cement plantsoperating in India presently.

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Jobs in Cement Industry

L & T Cement Plants

ACC Ltd. Cement Plants

CCI Cement Plants

Export of Indian Cement

Types of Cement in India

Gujarat Ambuja Plants in India

Top 10 Companies

Mangalam Cement

J K Lakshmi Cement

J K Cement

Madras Cement

India Cement

Sanghi Industries

Dalmia Cement

ITD Cementation India

Dalmia Cement Bharat

Gujarat Ambuja Cements

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CEMENT INDUSTRY

Introduction

Cement is a key infrastructure industry. It has been decontrolled from price and

distribution on 1st March, 1989 and delicensed on 25th July, 1991. However, the

performance of the industry and prices of cement are monitored regularly. The constraints

faced by the industry are reviewed in the Infrastructure Coordination Committee meetings

held in the Cabinet Secretariat under the Chairmanship of Secretary (Coordination). Its

performance is also reviewed by the Cabinet Committee on Infrastructure.

Capacity and Production

The cement industry comprises of 125 large cement plants with an installed capacity of

148.28 million tonnes and more than 300 mini cement plants with an estimated capacity

of 11.10 million tonnes per annum. The Cement Corporation of India, which is a

Central Public Sector Undertaking, has 10 units. There are 10 large cement plants

owned by various State Governments. The total installed capacity in the country as a

whole is 159.38 million tonnes. Actual cement production in 2002-03 was 116.35

million tonnes as against a production of 106.90 million tonnes in 2001-02, registering a

growth rate of 8.84%.

Keeping in view the trend of growth of the industry in previous years, a production target

of 126 million tonnes has been fixed for the year 2003-04. During the period April-June

2003, a production (provisional) was 31.30 million tonnes. The industry has achieved a

growth rate of 4.86 per cent during this period.

Exports

Apart from meeting the entire domestic demand, the industry is also exporting cement

and clinker. The export of cement during 2001-02 and 2003-04 was 5.14 million

tonnes and 6.92 million tonnes respectively. Export during April-May, 2003 was 1.35

million tonnes. Major exporters were Gujarat Ambuja Cements Ltd. and L&T Ltd.

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Recommendations on Cement Industry

For the development of the cement industry Working Group on Cement Industrywas constituted by the Planning Commission for the formulation of X Five Year Plan.

The Working Group has projected a growth rate of 10% for the cement industry during

the plan period and has projected creation of additional capacity of 40-62 million tonnes

mainly through expansion of existing plants. The Working Group has identified

following thrust areas for improving demand for cement;

(i) Further push to housing development programmes;

(ii) Promotion of concrete Highways and roads; and

(iii) Use of ready-mix concrete in large infrastructure projects.

Further, in order to improve global competitiveness of the Indian Cement Industry, the

Department of Industrial Policy & Promotion commissioned a study on the global

competitiveness of the Indian Industry through an organization of international repute,

viz. KPMG Consultancy Pvt. Ltd. The report submitted by the organization has made

several recommendations for making the Indian Cement Industry more competitive in

the international market. The recommendations are under consideration.

Technological change

Cement industry has made tremendous strides in technological upgradation and

assimilation of latest technology. At present ninety three per cent of the total capacity in

the industry is based on modern and environment-friendly dry process technology and

only seven per cent of the capacity is based on old wet and semi-dry process

technology. There is tremendous scope for waste heat recovery in cement plants and

thereby reduction in emission level. One project for co-generation of power utilizing

waste heat in an Indian cement plant is being implemented with Japanese assistance

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under Green Aid Plan. The induction of advanced technology has helped the industry

immensely to conserve energy and fuel and to save materials substantially. India is

also producing different varieties of cement like Ordinary Portland Cement (OPC),

Portland Pozzolana Cement (PPC), Portland Blast Furnace Slag Cement (PBFS), Oil

Well Cement, Rapid Hardening Portland Cement, Sulphate Resisting Portland Cement,

White Cement etc. Production of these varieties of cement conform to the BIS

Specifications. It is worth mentioning that some cement plants have set up dedicated

jetties for promoting bulk transportation and export.

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Total productionThe cement industry comprises of 125 large

cement plants with an installed capacity of148.28 million tonnes and more than 300mini cement plants with an estimatedcapacity of 11.10 million tonnes per annum.

The Cement Corporation of India, which is aCentral Public Sector Undertaking, has 10units. There are 10 large cement plantsowned by various State Governments. Thetotal installed capacity in the country as a

whole is 159.38 million tonnes. Actualcement production in 2002-03 was 116.35million tonnes as against a production of106.90 million tonnes in 2001-02, registeringa growth rate of 8.84%. Major players incement production are Ambuja cement,Aditya Cement, J K Cement and L & Tcement.

Apart from meeting the entire domesticdemand, the industry is also exporting

cement and clinker. The export of cementduring 2001-02 and 2003-04 was 5.14million tonnes and 6.92 million tonnesrespectively. Export during April-May, 2003was 1.35 million tonnes. Major exporterswere Gujarat Ambuja Cements Ltd. and L&TLtd.

The Planning Commission for theformulation of X Five Year Planconstituted a 'Working Group on Cement

Industry' for the development of cementindustry. The Working Group hasidentified following thrust areas forimproving demand for cement;

i. Further push to housing developmentprogrammes;

ii. Promotion of concrete Highways androads; and

iii. Use of ready-mix concrete in largeinfrastructure projects.

Further, in order to improve globalcompetitiveness of the Indian CementIndustry, the Department of Industrial Policy

KPMG Consultancy Pvt. Ltd. The reportsubmitted by the organization has made

several recommendations for making theIndian Cement Industry more competitive inthe international market. Therecommendations are under consideration.

Cement industry has been decontrolledfrom price and distribution on 1st March1989 and de-licensed on 25th July 1991.However, the performance of the industryand prices of cement are monitoredregularly. Being a key infrastructure

industry, the constraints faced by theindustry are reviewed in the InfrastructureCoordination Committee meetings held inthe Cabinet Secretariat under theChairmanship of Secretary (Coordination).The Committee on Infrastructure alsoreviews its performance.

Technological changeContinuous technological upgrading andassimilation of latest technology has been

going on in the cement industry. Presently93 per cent of the total capacity in theindustry is based on modern andenvironment-friendly dry process technologyand only 7 per cent of the capacity is basedon old wet and semi-dry processtechnology. There is tremendous scope forwaste heat recovery in cement plants andthereby reduction in emission level. Oneproject for co-generation of power utilizingwaste heat in an Indian cement plant isbeing implemented with Japaneseassistance under Green Aid Plan. Theinduction of advanced technology hashelped the industry immensely to conserveenergy and fuel and to save materialssubstantially.

India is also producing different varieties ofcement like Ordinary Portland Cement(OPC), Portland Pozzolana Cement (PPC),

Portland Blast Furnace Slag Cement(PBFS), Oil Well Cement, Rapid HardeningPortland Cement, Sulphate ResistingPortland Cement, White Cement etc.

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& Promotion commissioned a study on theglobal competitiveness of the Indian Industrythrough an organization of internationalrepute, viz.

Production of these varieties of cementconform to the BIS Specifications. Also,some cement plants have set up dedicatedjetties for promoting bulk transportation andexport.

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Cement Industry

Cement is one of the key infrastructure industries. Price and distribution controls were lifted

on 1st March 1989 and licensing was dispensed with since 25th July 1991. However, theperformance of the industry and prices of cement are monitored on a regular basis. The

industry is subject to quality control order issued on 17.2.2003 to ensure quality standards.

Capacity, Production and Exports

The cement industry comprises 128 large cement plants with an installed capacity of

151.69 million tonnes and more than 300 mini cement plants with an estimated capacity of

11.10 million tonnes per annum resulting in total installed capacity of 163 million tonnes.

Actual cement production in 2003-04 was 123.50 million tonnes as against a production of

116.35 million tonnes in 2002-03, which is an increase of 6.15% over 2002-03. Cement

production during the year 2004-05 (April-January, 2004-05) was 108.06 million tonnes

(provisional), registering a growth of 7.10%.

The Cement Corporation of India, which is a central public sector undertaking, has 10 units.

Besides, there are 10 large cement plants owned by various state governments. Keepingin view the past trends, a production target of 133 million tonnes has been set for the year

2004-05. During the Tenth Plan, the industry is expected to grow at the rate of 10% per

annum and is expected to add capacity of 40-52 million tonnes, mainly through expansion

of existing plants and use of more flyash in the production of cement. Apart from meeting

the domestic demand, the cement industry also contributes towards exports. The export of

cement and clinker during the last three years is as under: -

Table - 7.1

Export of Cement

(in million tonnes)

Year Cement Clinker Total

2001-02 3.38 1.76 5.14

2002-03 3.47 3.45 6.92

2003-04 3.36 5.64 9.00

2004-05(Apr-Jan)

3.31 4.82 8.13

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Overview of the performance of the Cement Sector

The Indian cement Industry not only ranks second in the production of cement in the world

but also produces quality cement, which meets global standards. However, the industry

faces a number of constraints in terms of high cost of power, high railway tariff; high

incidence of state and central levies and duties; lack of private and public investment in

infrastructure projects; poor quality coal and inadequate growth of related infrastructure like

sea and rail transport, ports and bulk terminals. In order to utilize excess capacity available

with the cement industry, the government has identified the following thrust areas for

increasing demand for cement:

(i) Housing development programmes;(ii) Promotion of concrete highways and roads;(iii) Use of ready-mix concrete in large infrastructure projects; and(iv) Construction of concrete roads in rural areas under Prime Ministers Gram SadakYojana.

Technological advancements

Indian cement industry is modern and uses latest technology. Only a small segment of

industry is using old technology based on wet and semi-dry process. Efforts are being

made to recover waste heat and success in this area has been significant.

India is also producing different varieties of cement like Ordinary Portland Cement (OPC),

Portland Pozzolana Cement (PPC), Portland Blast Furnace Slag Cement (PBFS), Oil Well

Cement, Rapid Hardening Portland Cement, Sulphate Resisting Portland Cement, White

Cement, etc. Production of these varieties of cement conforms to the BIS Specifications. It

is worth mentioning that some cement plants have set up dedicated jetties for promoting

bulk transportation and export.

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CEMENT INDUSTRIES

A. PROCESS DESCRIPTION

Cement industries typically produce portland cement, although they also produce masonry

cement (which is also manufactured at portland cement plants). Portland cement is a fine,

typically gray powder comprised of dicalcium silicate, tricalcium silicate, tricalcium

aluminate,

and tetracalcium aluminoferrite, with the addition of forms of calcium sulfate. Different types

of

portland cements are created based on the use and chemical and physical properties

desired.

Portland cement types I - V are the most common. Portland cement plants can operate

continuously

for long time periods (i.e., 6 months) with minimal shut down time for maintenance.

The air pollution problems related to the production, handling, and transportation of portland

cement are caused by the very fine particles in the product.

Exhibit 1 illustrates the stages of cement production at a portland cement plant:

1. Procurement of raw materials

2. Raw Milling - preparation of raw materials for the pyroprocessing system

3. Pyroprocessing - pyroprocessing raw materials to form portland cement clinker

4. Cooling of portland cement clinker

5. Storage of portland cement clinker

6. Finish Milling

7. Packing and loading

1. Raw Material Acquisition

Most of the raw materials used are extracted from the earth through mining and quarrying

and

can be divided into the following groups: lime (calcareous), silica (siliceous), alumina

(argillaceous),

and iron (ferriferous). Since a form of calcium carbonate, usually limestone, is the

predominant raw material, most plants are situated near a limestone quarry or receive this

material from a source via inexpensive transportation. The plant must minimize the

transportation

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cost since one third of the limestone is converted to CO2 during the pyroprocessing and is

subsequently lost. Quarry operations consist of drilling, blasting, excavating, handling,

loading,

hauling, crushing, screening, stockpiling, and storing.

2. Raw Milling

Raw milling involves mixing the extracted raw materials to obtain the correct chemical

configuration,

and grinding them to achieve the proper particle-size to ensure optimal fuel efficiency in

the cement kiln and strength in the final concrete product. Three types of processes may be

used: the dry process, the wet process, or the semidry process. If the dry process is used,

the raw materials are dried using impact dryers, drum dryers, paddle-equipped

Exhibit 1

rapid dryers, air separators, or autogenous mills, before grinding, or in the grinding process

itself. In the wet process, water is added during grinding. In the semidry process the

materials

are formed into pellets with the addition of water in a pelletizing device.

3. Pyroprocessing

In pyroprocessing, the raw mix is heated to produce portland cement clinkers. Clinkers are

hard, gray, spherical nodules with diameters ranging from 0.32 - 5.0 cm (1/8 - 2") created

from

the chemical reactions between the raw materials. The pyroprocessing system involves

three

steps: drying or preheating, calcining (a heating process in which calcium oxide is formed),

and

burning (sintering). The pyroprocessing takes place in the burning/kiln department. The raw

mix is supplied to the system as a slurry (wet process), a powder (dry process), or as moist

pellets (semidry process). All systems use a rotary kiln and contain the burning stage and

all

or part of the calcining stage. For the wet and dry processes, all pyroprocessing operations

take place in the rotary kiln, while drying and preheating and some of the calcination are

performed

outside the kiln on moving grates supplied with hot kiln gases.

4. Clinker Cooling

The clinker cooling operation recovers up to 30% of kiln system heat, preserves the ideal

product qualities, and enables the cooled clinker to be maneuvered by conveyors. The most

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common types of clinker coolers are reciprocating grate, planetary, and rotary. Air sent

through

the clinker to cool it is directed to the rotary kiln where it nourishes fuel combustion. The

fairly

coarse dust collected from clinker coolers is comprised of cement minerals and is restored

to

the operation. Based on the cooling efficiency and desired cooled temperature, the amount

of

air used in this cooling process is approximately 1-2 kg/kg of clinker. The amount of gas to

be

cleaned following the cooling process is decreased when a portion of the gas is used for

other

processes such as coal drying.

5. Clinker Storage

Although clinker storage capacity is based on the state of the market, a plant can normally

store

5 - 25% of its annual clinker production capacity. Equipment such as conveyors and bucket

elevators is used to transfer the clinkers from coolers to storage areas and to the finish mill.

Gravity drops and transfer points typically are vented to dust collectors.

6. Finish Milling

During the final stage of portland cement production known as finish milling, the clinker is

ground with other materials (which impart special characteristics to the finished product)

into a

fine powder. Up to 5% gypsum and/or natural anhydrite is added to regulate the setting time

of

the cement. Other chemicals, such as those which regulate flowability or air entrainment,

may

also be added. Many plants use a roll crusher to achieve a preliminary size reduction of the

clinker and gypsum. These materials are then sent through ball or tube mills (rotating,

horizontal

steel cylinders containing steel alloy balls) which perform the remaining grinding. The

grinding process occurs in a closed system with an air separator that divides the cement

particles according to size. Material that has not been completely ground is sent through the

system again.

7. Packing and Loading

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Once the production of portland cement is complete, the finished product is transferred

using

bucket elevators and conveyors to large, storage silos in the shipping department. Most of

the

portland cement is transported in bulk by railway, truck, or barge, or in 43 kg (94 pound)

multiwalled paper bags. Bags are used primarily to package masonry cement. Once the

cement leaves the plant, distribution terminals are sometimes used as an intermediary

holding

location prior to customer distribution. The same types of conveyor systems used at the

plant

are used to load cement at distribution terminals.

B. SOURCES OF POLLUTION

Although portland cement plants generate the same final product using similar processes,

plant layouts vary according to fuels and raw materials used, location, climate, site

topography,

and the manufacturer of the equipment. The flow diagram in Exhibit 1 depicts the

manufacturing

process at a portland cement plant and indicates emission points throughout the process.

C. POLLUTANTS AND THEIR CONTROL

This section briefly discusses the nature of the pollutants generated from, and controls used

at,

several sources in the cement manufacturing process. Air pollutants are typically of greater

concern than solid or liquid wastes.

1. Air Pollutants

Air pollutants generated during the cement manufacturing process consist primarily of

particulates

from the raw and finished materials, and fuel combustion by-products. Exhibit 2 indicates

sources of air pollution, and differentiates between particulates and other air pollutants.

Controlling particulate emissions from sources other than the kiln usually entails capturing

the

dust using a hood or other partial enclosure and transporting it through a series of ducts to

the

collectors. The type of dust collector used is based on factors such as particle size, dust

loading, flow rate, moisture content, and gas temperature. The best disposal method for

collected

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dust is to send it through the kiln creating the clinker. However, if the alkali content

Exhibit 2: Air Pollution and Control at Cement Production Facilities

Emission Point Pollutants Emission Rate

(gr/acf1) Control Device Percent

Efficiency

Quarries Particulates 5-40 Fabric Filter:

. Pulse Jet

. Reverse Air/Shaker 99.6

Raw Mill

Systems Particulates 5-20 Fabric Filter:

. Pulse Jet

. Reverse Air/Shaker

. Cartridge 99.6

Kiln System Particulates 4-18 Dust Collectors:

. Reverse Air

. Precipitator 99.5

Clinker Coolers Particulates 5-10 Fabric Filters:

. Pulsed Plenum/Pulse Jet

. Reverse Air

. Precipitator 99.6

Finish Mill

Systems Particulates

5-20 Fabric Filter:

. Reverse Air/Shaker 99.6

Finish Mill

Systems Particulates 5-100 Fabric Filters:. Pulse Jet

. Pulsed Plenum 99.6

For use with

High-

Efficiency

Separators Particulates 150-300 Fabric Filters:

. Pulse Jet

. Pulsed Plenum 99.9

Packing and

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Loading

Departments Particulates 5-40 Fabric Filters:

. Pulse Jet

. Reverse/Air Shaker

. Cartridge 99.6

1 gr/acf = grains/actual cubic foot

of the raw materials is too high, the dust must be discarded, or must be pretreated before

introduction into the kiln. The highest allowable alkali content is 0.6 percent (as sodium

oxide).

Exhibit 3 summarizes the general applicability of a number of collection systems for use by

the

cement industry.

Exhibit 3: Applicability of Emission Control Methods

Operation Mechanical

Collector Wet

Scrubber Fabric

Collector Electrostatic Gravel Bed

Filter

Primary

grinding Unsatisfactory

efficiency Not

applicable Successful Not

applicable None in use

Air

separators Not

applicable Not

applicable Successful A few

installations Questionable

application

Mills Not

applicable Not

applicable Successful A few

installations Questionable

application

Storage

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silos Not

applicable Not


applicable Impractical

Feeders

and belt

conveyors Not

applicable Not



Packing and

loading Not

applicable Not



Coal

dryer Preliminary

cleaning only Practicable Successful Not

common Practicable

Kiln

gases Preliminary

cleaning only Impractical 12 x 30 Glass

Successful Successful Practicable

Clinker

cooler Preliminary

cleaning only Not


common Successful

Additional air pollutants emitted include such materials as sulfur oxides and nitrogen oxides

generated from the kiln and drying processes. Sulfur dioxide is generated from the sulfur

compounds in the ores and the combusted fuel and varies in amount produced from plant

to

plant. The efficiency of particulate control devices is inconclusive as the result of variables

such as feed sulfur content, temperature, moisture, and feed chemical composition, in

addition

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to alkali and sulfur content of the raw materials and fuel. The combustion of fuel in rotary

cement kilns generates nitrogen oxides from the nitrogen in the fuel and incoming

combustion

air. The amount emitted depends on several factors including fuel type, nitrogen content,

and

combustion temperature. Both sulfur dioxide and some of the nitrogen oxide react with the

alkaline cement and are removed from the gas stream.

a. Raw Material Acquisition

During raw material acquisition the primary air pollutant emitted is particulate matter.

Particulate

matter is also emitted from the handling, loading, unloading, and transport of raw materials,

such as coal, purchased from another source. In certain areas, exhaust from portable

equipment

may also be a consideration.

The following methods are used to control particulate emissions generated from the quarry

and

handling of purchased raw materials:

. fabric filters (pulse-jet or reverse-air/shaker)

. equipment enclosures

. water sprays (with and without surfactants)

. enclosures

. silos (with and without exhaust venting to

. wind screens fabric filters)

. foams

. mechanical collectors

. bins

. chemical dust suppressants

. paving

. material storage buildings

Dust that is collected by these means is restored to the process. For quarry operations,

newer

plants typically use the pulse-jet fabric filters while older plants employ the reverse-air or

shaker-type fabric filters.

b. Raw Milling

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Fugitive dust is emitted from raw material feeders, stackers, blenders, reclaimers, conveyor

belt

transfer points, and bucket elevators used for transferring materials to the mill department

from

storage. Particulate emissions from the dry raw mills and subsequent equipment occur

during

temporary failure or from improperly designed or maintained seals. The following devices

are

used to collect particulate matter in the raw mill and raw mix storage areas:

. mechanical cyclones (usually used in series with another control)

. fabric filters (pulse jet or reverse air/shaker)

. electrostatic precipitators (rarely used)

Newer plants typically use the pulse-jet fabric filters while older plants employ the reverse-

air or

shaker type fabric filters.

c. Pyroprocessing

The main pyroprocessing system emissions are nitrogen, carbon dioxide, water, oxygen,

nitrogen

oxides, sulfur oxides, carbon monoxide, and hydrocarbons. Cement kiln dust (CKD) is

also produced.

The cement kiln itself has been designated as best available control technology (BACT) for

the

control of SO2. The highly alkaline conditions of the kiln system enable it to capture up to

95%

of the possible SO2 emissions. However, if sulfide sulfur (pyrites) is present in the kiln feed,

this absorption rate can decline to as low as 50%. Therefore, sulfur emissions can be

decreased

through careful selection of raw materials.

No device to control cement kiln NOx emissions has been developed, but there are several

prospects:

. stable kiln operation (reduces long term NOx emissions);

. burner configurations for the rotary kiln (efficiency varies);

. staged combustion for precalciner kilns;

. recirculation of the flue gas (oxygen deficient air in the rotary kiln); and

. alternative/low-nitrogen fuels.

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Cement kiln dust (CKD) is the powder retrieved from the exiting gases and is either all or

partly

returned to the operation or removed entirely. The type of system, the chemical makeup of

the

raw materials and fuel, and the condition of the system operations all affect the chemical

configuration

of the CKD. Portland cement specifications usually limit the amounts of sodium and

potassium. Because bypass CKD contains a large quantity of these minerals, CKD is

usually

removed from the process. The CKD from a preheater tower is composed of the same

general

elements as the kiln feed and therefore is returned to the process. The handling, storage,

and

deposition of CKD can generate fugitive dust emissions.

The following methods are used to control particulate emissions from the kiln system:

. reverse-air fabric filters

. electrostatic precipitators (ESPs)

. acoustic horns (sometimes used in conjunction with the two devices above)

d. Clinker Cooling

Reciprocating grate clinker coolers most often employ fabric filters, but ESPs and gravel

bed

filters are also used with a mechanical cyclone or multiclone dust collector sometimes

placed in

front. Newer plants typically use pulse-jet or pulsed-plenum fabric filters and older plants

use

reverse-air type fabric filters which may simply be a smaller form of a kiln fabric filter. Gravel

bed filters, which are also used by the cement industry, contain quartz granules;

contaminated

gas passes through this filter and the dust settles to the bottom of the bed.

e. Clinker Storage

The devices used to control dust emissions from clinker storage areas are similar to those

used in the raw milling process. The particulate emissions generated by dropping clinkers

onto

storage piles can be reduced by using a rock ladder or variable-height, automatic, stacker

belt

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conveyor systems. Fugitive dust generated from open storage piles is tempered by rain and

snow, wind breaks, and pile covers. Clinker in open piles is moved using front-end loaders;

in

storage halls overhead bucket cranes are used. Fugitive clinker dust emitted from open

storage

piles is common and very difficult to control.

f. Finish Milling

Particulate matter is emitted from mill vents, air separator vents, and material-handling

system

vents. Newer plants usually use pulse-jet or pulsed-plenum fabric filters with high-efficiency

separators, while older plants use reverse-air/shaker fabric filters. The cement dust

collected

by the fabric filter is restored to the system. In cold weather, a plume may develop at the

baghouse vent; this may be mistaken for particulate matter, but actually is condensed water

vapor from the cooling system.

g. Packing and Loading

In the shipping department particulate matter is emitted from the silos and the handling and

loading operations. Active and passive fabric filters are used to collect this dust. During

loading

of the product, particulate emissions are controlled by a fabric filter connected to the

transport

vessel; collected dust is restored to the shipment. To ensure dust-free loading onto the

transport vessel, a flexible loading spout consisting of concentric tubes is used. The

outermost

tube seals the delivery spout to the transport vehicle. The product is then delivered

through the inner tube and displaced air drawn up the outer tube to a filter. At distribution

terminals, fabric filters are again used and the collected dust is returned to the product. New

plants typically use pulse-jet fabric filters while older plants use reverse-air or shaker-type

fabric

filters.

2. Liquid and Solid Wastes

The overflow from slurry concentrating equipment (i.e. thickeners) constitutes the main

water

pollution problem. For new plants that process slurry, closed-cycle water systems are used

to

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return the overflow water to the process. Another source of waste is the stripped

overburden,

which is used as a raw material or disposed of in a local landfill. An estimate of overburden

deposited in a landfill varies from 0 - 3 metric tons per metric ton of cement produced.

The combustion processes of cement kilns and rotary kilns have been used to dispose of

hazardous waste material. For the cement kiln, waste material is burned with a primary fuel.

For a wet process kiln, the raw materials are introduced into the top of the kiln and exit at

the

bottom as cement clinker. The burner is located at the lower end of the kiln where the fuel

and

waste are ignited. The hot gases move up the kiln and heat the raw materials, exit the kiln,

and

are then cleaned in a baghouse prior to exiting through a stack. When waste is fired, any

ash

generated becomes a part of the cement product.

D. REFERENCES

1. Air and Waste Management Association. Air Pollution Engineering Manual. New York:

Van Nostrand Reinhold, 1992.

2. Hall, F.D. Evaluation of the Feasibility of Incinerating Hazardous Waste in High-

Temperature

Industrial Process, 1984.

3. Reding, J. T., P.E. Muehlberg, and B.P. Shepherd (Dow Chemical). Industrial Process

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Cement Industry Expects to Grow Steadily in 2009May 15, 2009

cement industry is steadily growing and is set to add on 50 Million Tones additional

capacity during the current year as the demand still remains high.

The Indian cement industry will continue to show steady performance by increasing its

capacity another 50 Million Tones in 2009 despite the recession and slump in the countrys

housing industry, stated H M Bangur, President of Cement Manufacturers Association

(CMA) and reported by economictimes.

While the construction sector has got deeply affected by the global crisis, the cement sector

is improving day-by-day, recording a YOY growth of 9.4% in the fourth quarter of FY09. The

cement prices are also shooting up. The Association has predicted that the cement sector

will grow by 9-10%, provided the GDP of the country grows at the rate of 7%.

According to a new RNCOS report Indian Cement Industry Forecast to 2012, India ranks

second worldwide in the cement production after China. The Indian cement industry is

continuously expanding, with rising production capacity of major players in the past few

months. This indicates to no impact of recession on the industry.

Moreover, the cement production and consumption are expected to grow rapidly during

2009-2012. Housing industry makes up for over 50% of the cement consumption in India

and the same trend is expected to continue in coming years, says the report.

However the government took some infrastructure initiatives, but they proved inadequate.

The construction sector is severely hit by the increase in prices of cement, which were

driven by the rise in demand due to the infrastructure projects of the public sector.

Although the manufacturing sector registered slow year-on-year growth, some of the

sectors, such as the cement industry, displayed a fractional upturn during the later six

months of FY09 as compared to the first six months.

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According to a Research Analyst at RNCOS, The Indian cement industry is expected to

grow rapidly in coming years due to heavy demand from housing, retail and infrastructure

industry. Moreover, several players have decided to raise their production capacity during

2009-2012, which, in turn, boosts the production volume of the cement industry.

Total production

The cement industry comprises of 125 large cement plants with an installed capacity of

148.28 million tonnes and more than 300 mini cement plants with an estimated capacity of

11.10 million tonnes per annum.

The Cement Corporation of India, which is a Central Public Sector Undertaking, has 10

units. There are 10 large cement plants owned by various State Governments. The total

installed capacity in the country as a whole is 159.38 million tonnes. Actual cement

production in 2002-03 was 116.35 million tonnes as against a production of 106.90 million

tonnes in 2001-02, registering a growth rate of 8.84%. Major players in cement

production are Ambuja cement, Aditya Cement, J K Cement and L & T cement.

Apart from meeting the entire domestic demand, the industry is also exporting cement and

clinker. The export of cement during 2001-02 and 2003-04 was 5.14 million tonnes and

6.92 million tonnes respectively. Export during April-May, 2003 was 1.35 million tonnes.

Major exporters were Gujarat Ambuja Cements Ltd. and L&T Ltd.

The Planning Commission for the formulation of X Five Year Plan constituted a

'Working Group on Cement Industry' for the development of cement industry. The

Working Group has identified following thrust areas for improving demand for

cement;

i. Further push to housing development programmes;

ii. Promotion of concrete Highways and roads; and

iii. Use of ready-mix concrete in large infrastructure projects.

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Further, in order to improve global competitiveness of the Indian Cement Industry, the

Department of Industrial Policy & Promotion commissioned a study on the global

competitiveness of the Indian Industry through an organization of international repute, viz.

KPMG Consultancy Pvt. Ltd. The report submitted by the organization has made several

recommendations for making the Indian Cement Industry more competitive in the

international market. The recommendations are under consideration.

Cement industry has been decontrolled from price and distribution on 1st March 1989

and de-licensed on 25th July 1991. However, the performance of the industry and prices of

cement are monitored regularly. Being a key infrastructure industry, the constraints faced

by the industry are reviewed in the Infrastructure Coordination Committee meetings held in

the Cabinet Secretariat under the Chairmanship of Secretary (Coordination). The

Committee on Infrastructure also reviews its performance.

Technological change

Continuous technological upgrading and assimilation of latest technology has been going

on in the cement industry. Presently 93 per cent of the total capacity in the industry is based

on modern and environment-friendly dry process technology and only 7 per cent of the

capacity is based on old wet and semi-dry process technology. There is tremendous scope

for waste heat recovery in cement plants and thereby reduction in emission level. One

project for co-generation of power utilizing waste heat in an Indian cement plant is being

implemented with Japanese assistance under Green Aid Plan. The induction of advanced

technology has helped the industry immensely to conserve energy and fuel and to save

materials substantially.

India is also producing different varieties of cement like Ordinary Portland Cement (OPC),

Portland Pozzolana Cement (PPC), Portland Blast Furnace Slag Cement (PBFS), Oil Well

Cement, Rapid Hardening Portland Cement, Sulphate Resisting Portland Cement, White

Cement etc. Production of these varieties of cement conform to the BIS Specifications.

Also, some cement plants have set up dedicated jetties for promoting bulk transportation

and export.

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Cement Industry in IndiaCement Industry in India is on a roll at the moment. Driven by a booming real estate sector,

global demand and increased activity in infrastructure development such as state andnational highways, the cement industry has witnessed tremendous growth. Production

capacity has gone up and top cement companies of the world are vying to enter the Indian

market, thereby sparking off a spate of mergers and acquisitions. Indian cement industry is

currently ranked second in the world.

The origins of Indian cement industry can be traced back to 1914 when the first unit was

set-up at Porbandar with a capacity of 1000 tonnes. Today cement industry comprises of

125 large cement plants and more than 300 mini cement plants. The Cement Corporation

of India, which is a Central Public Sector Undertaking, has 10 units. There are 10 large

cement plants owned by various State Governments. Cement industry in India has also

made tremendous strides in technological upgradation and assimilation of latest

technology. Presently, 93 per cent of the total capacity in the industry is based on modern

and environment-friendly dry process technology. The induction of advanced technology

has helped the industry immensely to conserve energy and fuel and to save materials

substantially. Indian cement industry has also acquired technical capability to produce

different types of cement like Ordinary Portland Cement (OPC), Portland Pozzolana

Cement (PPC), Portland Blast Furnace Slag Cement (PBFS), Oil Well Cement, Rapid

Hardening Portland Cement, Sulphate Resisting Portland Cement, White Cement etc.

Some of the major clusters of cement industry in India are: Satna (Madhya Pradesh),

Chandrapur (Maharashtra), Gulbarga (Karnataka), Yerranguntla (Andhra Pradesh),

Nalgonda (Andhra Pradesh), Bilaspur (Chattisgarh), and Chandoria (Rajasthan).

Cement industry in India is currently going through a consolidation phase. Some examples

of consolidation in the Indian cement industry are: Gujarat Ambuja taking a stake of 14 per

cent in ACC, and taking over DLF Cements and Modi Cement; ACC taking over IDCOL;

India Cement taking over Raasi Cement and Sri Vishnu Cement; and Grasim's acquisition

of the cement business of L&T, Indian Rayon's cement division, and Sri Digvijay Cements.

Foreign cement companies are also picking up stakes in large Indian cement companies.

Swiss cement major Holcim has picked up 14.8 per cent of the promoters' stake in Gujarat

Ambuja Cements (GACL). Holcim's acquisition has led to the emergence of two major

groups in the Indian cement industry, the Holcim-ACC-Gujarat Ambuja Cements combine

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and the Aditya Birla group through Grasim Industries and Ultratech Cement. Lafarge, the

French cement major has acquired the cement plants of Raymond and Tisco. Italy based

Italcementi has acquired a stake in the K.K. Birla promoted Zuari Industries' cement plant in

Andhra Pradesh, and German cement company Heidelberg Cement has entered into an

equal joint-venture agreement with S P Lohia Group controlled Indo-Rama Cement.

Issues concerning Cement Industry

High Transportation Cost is affecting the competitiveness of the cement industry.

Freight accounts for 17% of the production cost. Road is the preferred mode for

transportation for distances less than 250km. However, industry is heavily dependant

on roads for longer distances too as the railway infrastructure is not adequate.

Cement industry is highly capital intensive industry and nearly 55-60% of the inputs

are controlled by the government.

There is regional imbalance in the distribution of cement industry. Limestone

availability in pockets has led to uneven capacity additions.

Coal availability and quality is also affecting the production.

Outlook

Outlook for the cement industry looks quite bright. Given the sustained growth in the real

estate sector, the government's emphasis on infrastructure and increased global demand, it

looks as if the juggernaut of cement industry would continue to roll on the path of growth.

Slump in global cement industry momentary

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The slump in global cement market is temporary and it is expected to reach 3.77 billion

tonnes by 2012, according to a report by Global Industry Analysts, Inc.

"Cement: A Global Strategic Business Report" from Global Industry Analysts, Inc. provides

a comprehensive review of market trends, drivers, product profile, players, competition,

recent developments, mergers, acquisitions, and other strategic industry activities.

Emerging markets in Asia-Pacific, Latin America and Middle East & Africa are driving global

demand for cement. China alone produces and consumes slightly less than half the cement

produced and consumed worldwide. China and India, the second largest producer and

consumer of cement, together account for more than 50% of the total cement produced and

consumed in the world. Developed markets including the US, Western Europe and Japan

are mature and currently facing declining demand due to the global economic crisis.

Though, at present, demand is growing, but at a decelerated pace, the phase is

momentary. Long-term projections indicate healthy demand growths, as world economy

stabilizes and construction activity picks up across global markets into the next decade.

China, followed by India, United States, Japan and Russia, represent the largest producers

and consumers of cement worldwide.

Other countries featuring prominently on the global cement space include Spain, South

Korea, Italy, Iran, Turkey, and Brazil. Significant capacity expansions in China, India, Saudi

Arabia, UAE, Turkey, Egypt, and Brazil are underway and planned for the next few years.

Portland cement is the most widely consumed cement variety worldwide. The largest

geographic market is Asia-Pacific, and the fastest growth is forecast to take pace in the

Middle East & Africa and Asia-Pacific markets. In fact, China alone consumes more than

half the global Portland cement.

Blended cement, the less environment polluting varieties, would see demand grow in the

next few years, as their favorable environmental profile and excellent performance wins

end-user interest. Again Asia-Pacific represents the largest geographic market, though

share of Europe also stands out. Fastest growth would take place in Asia-Pacific, as

demand is expected to increase over the forecast years.

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In terms of market, China remains the largest regional market, where Construction

Contractors, followed by Concrete Products Producers represent the largest markets for

cement. The fastest growing market, however, would be Ready-mix Concrete Producers,

as they benefit from ban imposed by the Chinese government on mortar and concrete

mixing at construction sites.

Meanwhile, the second largest regional market, India, would see cement demand advance

the fastest for the Ready-mix Concrete Producers market. Though demand from

Consumers, the largest cement market, would continue to grow, it would lose share to

Ready-mix Concrete Producers and Concrete Products Producers markets.

The global marketplace is characterized by participants such as Lafarge (France), Holcim

(Switzerland), Cemex (Mexico), HeidelbergCement (Germany) and Italcementi (Italy), which

represent the five leading manufacturers of cement. Other international cement makers

include Buzzi Unicem (Italy), Cimpor (Portugal), CRH (Ireland), Votorantim Cimentos

(Brazil), Sumitomo Osaka Cement (Japan), Taiheiyo Cement (Japan), and Anhui Conch

(China). Other leading regional market leaders include: Anhui Conch, China Shanshui,

China National Building Material, and Tangshan Jidong in China; and ACC, Ambuja

Cement, Grasim, UltraTech, and India Cements in India.

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43

INTRODUCTION

TO THE

ORGANIZATION


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COMPANY PROFILE

Birla Corporation Ltd., a well known name in the business world was established by Late

Shri Ghanshyam Das Birla in the year1919. He set up first Indian jute mill near Calcutta

(now Kolkata) and named it Birla Jute Manufacturing Company Ltd. The name of the

company was changed to Birla Jute & Industries Ltd. in 1983 and finally to Birla Corporation

Limited in 1998.

From Late Shri Ghanshyam Das Birla the unit passed on to his nephew Late Shri M.P.

Birla, who expanded it into an industrial empire with manifold diversification in various

areas.

The company has following diversification:

Cement

Jute

Carbide & gases

Synthetics

Linoleum & Vinyl Flooring

Auto Trim

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CEMENT DIVISION:

LOCATION OF PLANTS IN INDIA:

The Cement Division of Birla Corporation Limited has seven plants, having an installed

capacity of 5.8 million tons. After the completion of the ongoing expansion projects, the

capacity will increase to 7 million tons.

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UNITS

BIRLA CEMENT WORKS

CHANDERIA CEMENT WORKS CHANDERIA (RAJASTAN)SATNA CEMENT WORKS

BIRLA VIKAS CEMENT SATNA (MADHYA PRADESH)

RAEBARELI GRINDING UNIT RAEBARELI (UTTAR

PRADESH)

DURGAPUR CEMENT WORKS

DURGA HITECH CEMENT DURGAPUR (WEST

BENGAL)

This plant manufacture varieties of cement, including Ordinary Portland Cement (OPC), 43

& 53 grades, fly ashbased Portland Pozzolana Cement (PPC), Portland Slag Cement

(PSC) and low- alkali Portland Cement. Recently, the Company has started producing

Sulphate Resistant Cement (SRC) and it has been well accepted in the market.

OPC is marketed under the name of Birla Cement Khajuraho and Birla Cement Chetak,

while PPc is marketed under the brand name of Birla Cement Samrat. PPC is marketed

under the barand name of Birla Cement.

The Birla Cement SAMRAT brand is ideal for mass concrete, RCC / pre-stressed / precast

structures (for reduced thermal crack), increased water tightness of concrete, increased

resistance to sulphate content in soil, aggressive water and alkali aggregate reaction,

besides corrosion resistant properties.

The brands have significant presence in the northern, western and eastern parts of the

country as well as central India. The company has a large network of dedicated distributors

and stockiest in all its marketing regions.

Durgapur Cement Works and the two cement units at Satna have received the ISO 9002

quality certification, covering production and marketing. The Satna units have also received

the IS/ISO: 14001 certificate for "implementation of the Environmental Management

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System". The two Chanderia units have received the ISO 9001: 2000 certification for

Quality Management System, as well as the IS/ISO: 14001 certification.

The quality control laboratories of both Birla Cement Works and Chanderia Cement Works

have been accredited by National Accreditation Board for Testing & Calibration

Laboratories, Department of Science & Technology, and Government of India.

The cement units have been receiving, since the past decade, prestigious awards for

productivity, pollution control, energy performance and worker's education.

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The Product and Brand names are as follows:-

Units Products Brand Name

Birla Cement Works

Chanderia Cement Works

OPC 43G, 53G, PPC

PPC

Birla Cement Chetak

Birla Cement Samrat

Satna Cement Works

Birla Vikas Cement

PPC & OPC (43 Gr.) Birla Cement Samrat

Birla Cement Khajuraho

Raebareli Grinding Unit Portland Pozzolana

Cement (PPC)

Birla Cement Samrat

Durgapur Cement Works Portland Slag Cement

(PSC)

Birla Cement

Birla Premium Cement

Durga Hitech Cement Portland Pozzolana

Cement (PPC)

Birla Cement Samrat

Special Cements

Sulphate Resistant Cement

Low-alkali Cement

Railway Sleeper Grade Cement IRS T-40

Low Heat Cement

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TABLE 2.1


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CAPACITY: 5.78 Mill. Ts.

STATE TOWN UNITS CAPACITY MILL. TS

M.P. SATNA 1.55

RAJASTHAN CHITTORGARH 2.00

WEST BENGAL DURGAPUR 1.60

UTTAR PRADESH RAEBARELI 0.63

DISCIPLINE OF QUALITY ASSURANCE

ISO 9002 Certification by M/s RWTUV Germany.

ISO 14001 Certification for Environment management system by B/S New Delhi.

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TABLE 2.2
http://www.birlacorporation.com/satna/satna.htmlhttp://www.birlacorporation.com/chittorgarh/bcw.htmhttp://www.birlacorporation.com/durgapur/profile.htmlhttp://www.birlacorporation.com/raebareli.htmlhttp://www.birlacorporation.com/satna/satna.htmlhttp://www.birlacorporation.com/chittorgarh/bcw.htmhttp://www.birlacorporation.com/durgapur/profile.htmlhttp://www.birlacorporation.com/raebareli.html


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APPLICATIONS

Birla Cement Khajuraho/Chetak - 43 grade Ordinary Portland Cement-

Brick and stone masonry.

Plastering and flooring.

Plain and reinforced cement concrete.

Pre-cast and pre-stressed concrete.

Birla Cement Khajuraho/Chetak-53 Grade Ordinary Portland Cement-

Railway sleepers

Pre-stressed girders and electric poles.

M25 & above concrete.

Roads, runways, industrial buildings, RCC bridges & lofty buildings.

Pre-cast concrete elements

Birla Samrat - Portland Pozzolana Cement-

Brick and stone masonry

Plastering and flooring.

Plain and reinforced cement concrete.

Ordinary Pre-cast concrete work.

Birla Cement Khajuraho - Sulphate Resisting Portland Cement-

Building near sea coast.

Below ground, where concrete or mortar is used in foundation, aqua ducts, canals &

culverts.

Desert conditions.

In swampy areas for footing, plinth beams, piles etc.

Industrial effluent treatment plant, cooling towers, chimneys, sewerage treatment

plant.

Marine structures

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Birla Cement Khajuraho - Low Alkali Cement -

Bridges

Dams

Reservoirs

Birla Cement Khajuraho - IRS-T40 Cement -

Railway sleepers.

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CONTINUOUS RECOGNITION FOR CONSISTENT QUALITY:

CAPEXIL awards every year, since 1990

ISO 9002 certification for Satna Cement Works, Birla Vikas Cement andDurgapur Cement Works.

ISO 9001 - 2000 (QMS) certification for Birla Cement Works, Chanderia CementWorks from BVQI, UK.

IS/ISO 14001 certification in 1999-2000 for Satna Cement Works and Birla VikasCement, in 2002-2003 for Birla Cement Works & Chanderia Cement Works forenvironment management systems.

"Best Productivity Performance" award from NPC for Birla Vikas Cement in1987-88. Also recognised by NCB as.

"Best in Energy Performance" in 1986-87.

"Best in Energy Performance" for Satna Cement Works in 1993-94, 1994-95,1995-96, 1997-98.

"Best Productivity Performance" award from NPC for Chanderia Cement Worksin 1998-90 and again in 1993-94.

2nd "Best Productivity Performance" award for Chanderia Cement Works in1991-92 &

"Certificate of Merit" in 1998-99

"Best improvement in Thermal Energy Performance" recognition from NCB forBirla Cement Works in 1992-93 and Chanderia Cement Works in 1993-94.

"Best improvement in Energy Performance" recognition for Birla Cement Worksin 1992-93.

"Bhama Shah Samman" from the Rajasthan Government for EducationalActivities for Birla Cement Works in 1996-97.

VEC-IIT, Madras recognised Chanderia Cement Works and Birla CementWorks For "Excellence in Improving Machinery Health Condition" in 1997.

"Workers Education Trophy" awarded by Central Board of Workers Education,

Udaipur Ministry of Labour, Government of India, for Birla Cement Works &Chanderia Cement Works in 1998-99 and again in 2001-02.

"Lal Bahadur Shastri Memorial National Award" for Excellent Pollution ControlImplementation by Chanderia Cement Works in 2002-03.

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CAPEXIL 'Special Export Award'

BIRLA CEMENT AND CHANDERIA CEMENTWORKS,

CHITTORGARH, RAJASTHAN

In Chittorgarh Birla Corporation Ltd. Has two plants namely B.C.W. & C.C.W.B.C.W. was

set up in 1967, the first dry process plant with two stage suspension pre heating technology

in the country. Its initial capacity of2 lacks tones was increased to 4 lacks tones in 1992. In

modernization drive, the two stage pre heater is converted into five stage pre heater, and a

modern computerized system is installed.

C.C.W. Was set up in 1986, with new technologies and environment friendly atmosphere.

This plant is equipped with state of art equipment like 5 stage heater and in built clinker.

With sophisticated quality control system and central computerized control system with x-

ray analyzer provides to ensure best quality cement production. This unit was also

modernized and its production capacity is increased from 5 lacks tones per annum to 8

lacks tones per annum.

The company carried out various modified de-bottle necking in these plants, as a result of

which the installed capacity of the cement division has been increased to 24 lacks tones

from 14 lacks tones.

B.C.W. & C.C.W. has received the quality certification ISO 9001-2000 for quality

management system and ISO-14001 for environment management system.B.C.W. & C.C.W. has also received many Excellency awards.

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Quality policy

Birla Corporation limited Chanderia is committed to comply with the requirements ofcustomers to their satisfaction and continually improve the effectiveness of quality

management system by

Enhancing customer satisfaction by supplying consisted quality cement.

Regular up gradation of technology: optimum utilization of resources and upkeep of

equipment for reducing the cost.

Training and involvement of employee to develop quality culture in the units.

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MAJOR DEPARTMENTS

Birla cement work and Chanderia cement work

Mines

Production

Engineering

Electrical power plant

Thermal power plant

Diesel power plant

Enviourment safety

Store and raw material

Building

Purchase

Accounts

information system

Personal and welfare

Gernal administration

HRD

Legal

Sales and marketing

Security

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HRD-ANOVERVIEW


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BIRLA CEMENT WORKS

Chanderia, Chittorgarh (Rajasthan)

( Unit of M/s. BIRLA CORPORATION LIMITED )

Unit Profile

BIRLA CEMENT WORKS (BCW) is a unit of Birla Corporation Limited, which is a major

producer of cement in India, particularly in the States of Rajasthan, MP, UP & WB. It is a

part of Rs. 5000 crores Birla Corporation Limited (BCL), which manufactures Jute products,

Synthetic Yarn, Linoleum, Carbide, Steel Castings, Auto Trims etc. in addition of cement

having registered office at Kolkata. BCL is having six manufacturing units two in the State

of Rajasthan located at Chanderia, two in Madhya Pradesh located at Satna, one in Uttar

Pradesh located at Raebareli and one in West Bengal located at Durgapur. BCW is

producing different types of cement like 43 grade OPC & PPC, which represents the best

quality, easy workability, high strength & durability alongwith operational stability and

economy.

Birla Cement Works has a well established market in Rajasthan, Gujarat, Haryana, and

Punjab & Delhi. Its cement brand SAMRAT (Portland Pozzolana Cement) was launched

in 1997 and is widely accepted by both urban and rural customers.

The company is awarded with ISO 9001-2000 and ISO 14001 certificates. In the year 2005,

the company has also been awarded with NABL certification.

In the changed scenario of globalization, Birla Corporation Limited has been able to

maintain its position in the market because of better customer care and energy

optimization. An Energy Cell has been working under the guidance of the Management.

PROCESS FLOW CHART:

Crushingg

Limestone stock Pile

Limestone transportation

Mining

Pyro processing

Cement Storage

Cement grinding

Raw grinding

Fuel Grinding

Cement Packing

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Contd....P/2

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Page.2

Energy Consumption

Energy conservation measures have been undertaken to reduce electrical energy

consumption. However, the increase in specific power in 2004-05 due to more production of

43 grades OPC & less production of PPC as compared to 2003-04.

DESCRIPTIO

N

UNIT 2005-06 2006-07 2007-08

Cement

Production

LTPA 7.82 8.31 8.49

Total electrical

energy

consumption

Lakh kWh 736.28 755.59 796.21

Specific

energy

consumption

Units / T

Cement

85.90 84.49 84.42

Total Thermal

consumption /

annum

M.KCals 542144 565035 588146

Specific

Thermal

energy

consumption

Kcal / Kg.

Cement

679 685 660

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HUMAN RESOURCE

Human resource is a term with which many organizations describe the combination of

traditionally administrative personnel functions with performance, Employee Relations and

resource planning. The field draws upon concepts developed in Industrial/Organizational

Psychology. Human resource has at least two related interpretations depending on context.

The original usage derives from political economy and economics, where it was traditionally

called labor, one of fourfactors of production. The more common usage within corporations

and businesses refers to the individuals within the firm, and to the portion of the firm's

organization that deals with hiring, firing, training, and other personnel issues. This article

addresses both definitions.

The objective of Human Resources is to maximize the return on investment from the

organization's human capital and minimize financial risk. It is the responsibility of human

resource managers to conduct these activities in an effective, legal, fair, and consistent

manner.

Human resource management serves these key functions:

1. Selection

2. Training and Development

3. Performance Evaluation and Management

4. Promotions

5. Redundancy

6. Industrial and Employee Relations

7. Record keeping of all personal data.

8. Compensation, pensions, bonuses etc in liaison with Payroll

9. Confidential advice to internal 'customers' in relation to problems at work &

10.Career development

60
http://en.wikipedia.org/wiki/Resource_(economics)http://en.wikipedia.org/wiki/Political_economyhttp://en.wikipedia.org/wiki/Economicshttp://en.wikipedia.org/wiki/Labor_(economics)http://en.wikipedia.org/wiki/Factors_of_productionhttp://en.wikipedia.org/wiki/Corporationhttp://en.wikipedia.org/wiki/Businesshttp://en.wikipedia.org/wiki/Human_resource_managementhttp://en.wikipedia.org/wiki/Resource_(economics)http://en.wikipedia.org/wiki/Political_economyhttp://en.wikipedia.org/wiki/Economicshttp://en.wikipedia.org/wiki/Labor_(economics)http://en.wikipedia.org/wiki/Factors_of_productionhttp://en.wikipedia.org/wiki/Corporationhttp://en.wikipedia.org/wiki/Businesshttp://en.wikipedia.org/wiki/Human_resource_management


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HRD An overview

It is a common fact that without development of employees competencies no organization

can survive today. To be effective every manufacturing organization need main component

people in all areas whether they be cost reduction, delays increase customer satisfaction,

better quality, prompt service, improved earning, improved market image and so on.

HRD definition:

HRD is a continuous process to ensure the development of employee competencies,

dynamism, motivation, and effectiveness in a systematic and planned way

T.N Rao

HRD is system of developing in a continuous and planned way the competence of

individual employees, dyadic group, team and total organization to achieve goal.

Keith Davis

A set of systematic and planned activities designed by an organization to provide its

members with the necessary skills to meet current and future job demands.

Werner & DeSimone

(2006)

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Evolution of HRD

Early apprenticeship programs

Early vocational education programs

Early factory schools

Early training for unskilled/semiskilled

Human relations movement

Establishment of training profession

Emergence of HRD

1. Early Apprenticeship Programs

Artisans in 1700s

Artisans had to train their own workers

Guild schools

Yeomanries (early worker unions)

2. Early Vocational Education Programs

1809 DeWitt Clintons manual school

1863 President Lincoln signs the Land-Grant Act promoting A&M colleges

1917 Smith-Hughes Act provides funding for vocational education at the state level

3. Early Factory Schools

Industrial Revolution increases need for trained workers to design, build, and repair

machines used by unskilled workers

Companies started machinist and mechanical schools in-house

Shorter and more narrowly-focused than apprenticeship programs

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4. Early Training for Unskilled/Semiskilled Workers

Mass production (Model T)

o Semiskilled and unskilled workers

o Production line one task = one worker

World War I

o Retool & retrain

o Show, Tell, Do, Check (OJT)

5. Human Relations Movement

nikita malviya birla cement

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