pramod shukla jaypee project new

8/8/2019 Pramod Shukla Jaypee Project New

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CEMENT MANUFACTURE PROCESS

Types of Cement

Cements are of two basic types-grey cement and white cement. Grey cement

is used only for construction purposes while white cement can be put to a variety

of uses. It is used for mosaic terrazzo flooring and certain cements paints. It is used

as a primer for paints besides has a variety of architectural uses. The cost of white

cement is approximately three that of grey cement. White cement is more

expensive because its production cost is more and excise duty on white cement is

also higher. jaypee does not manufacture white cement at present.

Raw material preparation

Limestone of differing chemical composition is freely available in the

quarries. This limestone is carefully blended before being crushed. Red mineral is

added to the limestone at the crushing

stage to provide consistent chemical

composition of the raw materials. Once

these materials have been crushed and

subjected to online chemical analysis they

are blended in a homogenized stockpile. A bucket wheel reclaimer is used to

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Fig 1: Limestone Extraction


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recover and further blend this raw material mix before transfer to the raw material

grinding mills. Transport belt conveyor transfers the blended raw materials to ball

mills where it is ground. The chemical analysis is again checked to ensure

excellent quality control of the product. The resulting ground and dried raw meal is

sent to a homogenizing and storage silo for further blending before being burnt in

the kilns.

FUELS

The heat required to produce temperatures of 1,8000C at

the flame is supplied by ground and dried petroleum

coke and/or fuel oil. The petcoke is imported via the

companies internal wharf, stored and then ground in

dedicated mills. Careful control of the mills ensures.

Optimum fineness of the petcoke and excellent combustion conditions within the

kilns system.

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Fig 2: Inside of Kiln


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BURNING

The raw meal is fed into the top of a pre-heater tower equipped with four

cyclone stages. As it falls, the meal is

heated up by the rising hot gases and

reaches 8000C. At this temperature, the

meal dehydrates and partially

decarbonizes. The meal then enters a

sloping rotary kiln, which is heated by a

1,8000C flame, which completes the burning process of the meal. The meal is

heated to a temperature of at least 1,4500C. At this temperatures the chemical

changes required to produce cement clinker are achieved. The dry process kiln is

shorter than the wet process kiln and is the most fuel-efficient method of cement

production available.

COOLER UNITS

The clinker discharging from the kiln is cooled by air to a temperature of

700C above ambient temperature and heat is recovered for the process to improve

fuel efficiency. Some of the air from the cooler is de-dusted and supplied to the

coal grinding plant. The remaining air is used as preheated secondary air for the

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Fig 3: Central Control Room


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main combustion burner in the kiln. Clinker is analyzed to ensure consistent

product quality as it leaves the cooler. Metal conveyors transport the clinker to

closed storages areas.

FILTERS

Dedicated electrostatic precipitators dedust the air and gases used in the

Clinker production line process. In this way, 99.9% of the dust is collected before

venting to the atmosphere. All dust collected is returned to the process.

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CONSTITUENTS

Different types of cement are produced by mixing and weighing

proportionally the following constituents.

Clinker

Gypsum

Limestone addition

Blast furnace slag

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Fig 4: Cement manufacturing from the quarrying of limestone to thebagging of cement.

Q1. In which of the following cement brands do you deal?

Options Response (%)

Prism 45.55

Birla 11.11

ACC 8.88

JAYPEE 33.33

Others 1.11TOTAL RESPONSES 100%

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Interpretation:

Maximum dealers & retailers deal in Jaypee & Prism, i.e. 45.55 of dealers and

retailers deals in Prism & 33.33% of dealers & retailers deals in Jaypee

whereas very few dealers and retailers deals in ACC, Birla & other brand.

Q2. Which factor influences you most to purchase any cement? Please

give rank.

Options Response (%) Rank

Price 8.88 3

Quality 72.22 1Better packaging 7.77 4

Time availability of

cement in season &non-

season

11.11 2

Total responses 100% ------

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Interpretation:

72.22% of dealers & retailers suggested that quality is an important feature

while dealing with cement. Thus quality is ranked 1st, whereas 11.11% of

dealers and retailers suggested that time availability of cement in season &

non-season should be given preference so it is ranked 2nd on the other hand

price is 3rd rank with 8.88% & packaging is at 4th rank with 7.77%.

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Q3. Which cement has more demand in market? Please give rank.


Prism 53.33 1Birla 4.44 4

ACC 7.77 3

Jaypee 32.22 2

Others 2.22 5

Total Responses 100% -----

Interpretation :

53.33% of dealers & retailers are in favor of Prism for maximum demand in

market so Prism is ranked 1st whereas 32.22% of dealers & retailers are in

favor of Jaypee, so Jaypee is ranked 2nd. On the other hand ACC is at 3rd rank

with 7.77% and Birla is at 4th rank with 4.44% & others is at 5th rank with

2.22%.

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Q 4. Which cement company gives more attractive advertisement?

Please give rank.


Prism 33.33 2

Birla 5.55 5

ACC 8.88 3

Jaypee 44.44 1

Others 7.77 4


Interpretation:

44.44% of dealers and retailers suggested that Jaypee gives maximumattractive advertisement so it is ranked 1st & 33.33% of dealers & retailers

agree with Prism so it is ranked 2nd on the other hand ACC is at 3rd rank with

8.88% & others is 4th rank with 7.77% & Birla is at 5th rank with 5.55%.

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Q 5. Does company brand Ambassador Increase company Brand Value?

Options Response (%)

Yes 25.55

No 74.44

Total Responses 100%

Interpretation:

74.44% dealers & retailers are in against for increase company brand

value by brand ambassador & 25.55% dealers & retailers are in favorfor increase company brand value by brand ambassador.

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Q 6. Which Cement Company gives you maximum Margin per Bag?

Please give rank.


Prism 28.88 2

Birla 43.33 1

ACC 7.77 4

Jaypee 13.33 3

Others 6.66 5

Total Responses 100% ------

Interpretation:

43.33% of dealers & retailers in favor of Birla for gives maximum

margin per bag because its cost of product is less compare to other

brands so it is ranked 1st whereas 28.88% of dealers & retailers are in

favor of Prism so it is ranked 2nd on the other hand Jaypee is at 3rd

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ranked with 13.33% & ACC is at 4th rank with 7.77% & others are at 5th

rank with 6.66%

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Following Questions are based on the rating vise.

Q 7. Which is Quality Brand of cement?


Prism 64.44 1

Birla 6.66 3

ACC 4.44 4

Jaypee 23.33 2

Others 1.11 5


Interpretation:

64.44% dealers and retailers are in favor of Prism for quality brand of

cement so it is ranked 1st whereas 23.33% dealers and retailers are in

favor of Jaypee so it is ranked 2nd on the other hand Birla is at 3rd rank

with 6.66% & ACC is at 4th rank with 4.44% & others are at 1.11%

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Q 8. Which Cement Company has a good packaging of their products?


Prism 71.11 1

Birla 6.66 4

ACC 7.77 3

Jaypee 13.33 2

Others 1.11 5


Interpretation:

71.11% of dealers and retailers are in favor of Prism for good packaging

of their product so it is ranked 1st and 13.33% of dealers & retailers are

in favor of Jaypee so it is ranked 2nd & ACC is at 3rd rank with 7.77% &

Birla is at 4th rank with 6.66% & others are at 1.11%

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Q 9. Which Cement Company has a good supply of their products?


Prism 64.44 1

Birla 6.66 3

ACC 4.44 4

Jaypee 23.33 2

Others 1.11 5

Total Responses 100

Interpretation:

64.44% of dealers and retailers are in favor of Prism for good supply of

their products so it is ranked 1st

& 23.33% of dealers and retailers are infavor of Jaypee so it is ranked 2nd on the other hand Birla is at 3rd rank

with 6.66% & ACC is at 4th rank with 4.44% & others are at 1.11%

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Q 10. What you aspect from any Cement Company to increase the sale?


Advertisement 24.44 2

Meeting with dealers 20 4

Price distribution 22.22 3

Quality Improvement 33.33 1


Interpretation:

33.33% of dealers & retailers are in favor of improved quality of their

product because binding capacity of the product is depend on the quality

so it is ranked 1st & 24.44% of dealers and retailers are in favor of

advertisement of their product because it is the best way to communicate

with the people so it is ranked 2nd & 22.22% of dealers and retailers are

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in favor of price distribution to dealers and consignee because it raise the

level of confidence so it is ranked 3rd & 20% of dealers and retailers are

in favor of doing meeting in particular intervals so it is ranked 4th.

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pramod shukla jaypee project new

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