Functional Area Information

Every organization’s success depends upon the proper functioning

and co-ordination of its departments. This company is supposed to be one
of the best companies as far as departments functioning are concerned.

Management Process Consists of several function and distinction

should be maintained between management functions (Planning,
Organizing, Staffing, Directing, and Controlling) Organizational function
(Production, Marketing, finance, etc.)

The number and types of functional areas of management are

determined by nature of the organization and the types of classifications of
various activities. U.K. Ministry of Education, in its reports on
‘Management Education’, has classified functional management areas into
nine parts: Production, finance, development, distribution, purchasing,
transport, maintenance, personnel, and office. This classification is very
intensive. A more acceptable and practical classification includes four
broad functional areas – Production, marketing, finance, and personnel.
These areas have their own organization, Policies, Procedures, and sub
activities.

In order to get a clear understanding of various AETs & SETs their

roles, areas, functions, we have defined them separately into five
important departments.

♦ Production Department

♦ Marketing Department

♦ Account Department

♦ Personnel & Administration Department

 Production Department

Contents

Sr. Particulars Page

1. Introduction

2. Purchase Department

3. Material Management

4. Production Process

5. Quality Control

6. Technology

7. Product

8. Jetty
INTRODUCTION:
Sanghi Cement is engaged in manufacturing of Clinker
and Cement for dispatch to Domestic & International markets.

The raw materials are limestone from captive mine and

other additives such as Iron Ore, Bauxite, High-grade limestone,
Gypsum and Fly ash procured from other sources. Other
products, which are purchased, are spares & consumables for the
maintenance of plant and machinery.

The manufacturing process for clinker consists of

crushing, grinding and preprocessing of raw materials. This
clinker is either dispatched as product or further grinded to make
cement. Both the products are tested in quality control
department, with national and international standards.

These products are dispatched either by Road or Rail

and Seaway to destination specified by internal customer i.e.,
cement marketing division. Clinker is dispatched in bulk
whereas the cement either in bulk or in bags.

Major portion of the land under plant and colony was

unproductive land without history of any industrial usage. The
leased land for the captive mine consists of both agriculture and
unproductive land.

This area is normally kept under the control of a production

manager who is responsible for the performances of entire related
activities. This are many further be classified into major sub activities.
PURCHASE DEPARTMENT:

Purchase department comes under purview of Production

Department. Purchase Department’s main area of work is to find the
suppliers of raw material and spare parts of machinery, then to negotiate
the prices and also to ensure the quality of material.
Purchase Department co-ordinates with the production department
in order to know the requirement of raw material to manufacture the
demanded item.
Process followed by the department:
1st Proper Communication with supplier
2nd Negotiation
3rd To form an Agreement
4th Follow up actions

Responsibility and Authority of HOS Purchase:

The HOS (PUR) shall be responsible for establishing,

implementing and maintaining the Instructions of Materials Department
related to Purchase activities, in line with the Quality Procedures and
Environmental

The HOS (PUR) shall be responsible for procuring Materials and

Services, as required by the user departments, in time, of the right quality,
at optimum cost and which are eco friendly.
Material Management:
This sub area deals with the storing of the materials, material
control, and issue of material to department where these are needed. This
works in close Coordination with purchasing management.

Raw Material:
The area where the plant is located, is very rich in all the raw
materials required for the production of superior quality – high grade
cement. All the raw materials such as limestone, bauxite, laterite, lignite,
gypsum etc, are available with in a radius of 25-50 kms from the plant site.
High quality, soft and chippable limestone is available in the mines
located just adjacent to plant. State-of-the-art surface miners, therefore
obviating the need for blasting & drilling thus making it the most eco-
friendly, safe and cost effective way of procuring limestone, do the
mining. No wonder we have won national acclaim for our mining
activities.

This cement plant is the first in India to employ 100% lignite as

fuel, which is superior to coal in more ways than one Of course, it also
helps that the lignite mines are situated with in a radius of just 25 kms.
From the plant.

Even the other raw materials like laterite, bauxite, silica and clay
are all available with in a small radius of 50 kms from the site.
WATER:

MED PLANT
Multi Effect Desalination Plant

Sanghi cement has put up a multi-effect Desalination plant of 5500

m3 / day based on sea water for plant requirement as well as for supplying
potable water to near by villages. The unit exceed on the multi-effect
Distillation power utilizes the efficient horizontal tube, falling - film type
evaporator condensers. The principle is low temperature, vacuum multi
effect distillation.

Treated water is added with measured quantities of calcium

carbonate and sodium bicarbonate converts it to retable water with a total
dissolved solid (TDS) count around 225 to 250 ppm.

ELECTRICITY:

CAPTIVE POWER PLANT

A 45.33 Mw capacity power plant operated on residual fuel

(Heavy Furnace oil) is set up to meet uninterrupted power requirement.
The power plant is equipped with four Man B&W, 16MB 430 engines of
11.333 mw each.

Captive power is 50% cheaper than gird power. The ensures that
the power costs are considerably low. Add to this the efficient system and
the large scale of operation employed in the plant and what we get is the
lowest power consumption compared to any other plant in the country.
PRODUCTION PROCESS:

PROCESS MACHINE
LIMESTONE MINING MINE PLANT

CURSING CRUSHER

GRINDING RAW MILL

HOMOGENIZATION CF SILO

PRE-HEATING PRE-HEATER

BURNING KILN

COOLING COOLER

STORAGE + ADD GYPSUM CLINKER SILO

GRINDING CEMENT MILL

STORAGE CEMENT SILO

PACKAGE PACKAGING PLANT

DISPATCH DISPATCH MACHINE

(BY ROAD, RAIL OR SEA)
PROCESS WITH DESCRIPTION :

Lime Stone stock pile:

The basic raw material for cement and clinker is limestone. Near
about 90% of finished product is limestone. The requirement of limestone
is half more than finished product, means if 100-tones cement is to be
manufactured, than 150-tones limestone required.

Sanghi Cement has its own mine for limestone. The area where the
plant is located, is very rich in all the raw materials required for the
production of superior quality – high grade cement. All the raw materials
such as limestone, bauxite, laterite, lignite, gypsum etc, are available with
in a radius of 25-50 kms from the plant site. High quality, soft and
chippable limestone is available in the mines located just adjacent to plant.
State-of-the-art surface miners, therefore obviating the need for blasting &
drilling thus making it the most eco-friendly, safe and cost effective way
of procuring limestone, do the mining. No wonder we have won national
acclaim for our mining activities.

Sanghi Cement is first company, which is use cross Belt analyzer

in the India. All the limestone reaches to the plant through conveyor belt
or trucks.

CRUSHER:

After mining the limestone it is crushed by Crusher. Crusher

crushes the stone type limestone into powder form. Its capacity of
crushing is 950 tones per hour. Than it is collected and stocked as piles by
Dampers. In the store, the crushed stone is stacked in several layers by the
Stacker, so that a variation in quality of incoming limestone is equalized.
Grinding:

The machine, which grinds the raw material, is called

RAW MILL. That converts raw material into powder form by grinding it.
Crushed limestone, shale & hematite are fed in the required proportion to
the raw grinding unit.

Sanghi Cement has world’s largest vertical roller mill.

Homogenization:

In this stage mixed powder from raw mill transfers to CF Silo,

where some additives are added to mixture. Here drying process of raw
material is also carried out, because the basic raw material contains some
moisture.

Preheating & Calcinations:

Before moving the mixture to Kiln, the powder must obtain some
temperature. Pre-heater performs that task. Calcinations is defined as
removing of carbon-di-oxide and other organic matters from the raw
material. The process of calcinations before Kiln reduces the thermal load
in the rotary Kiln. The advantage of this system is that the Kiln capacity
increases by 2-2.5 times.

Sanghi Cement has world’s largest pre-heater plan, (148 meter)

and also world’s largest kiln (80.6 meter).
Burning:

The pre-calcined raw material is fed into the rotary kiln and coal is
fired at a temperature of 1600-1800 degree centigrade on the other end.
Here after burning process the powder form is transferred into small stone
type form, which is called Clinker.

This cement plant is the first in India to employ 100% lignite as

fuel, which is superior to coal in more ways than one Of course, it also
helps that the lignite mines are situated with in a radius of just 25 kms.
From the plant.

Sanghi cement is one and only company in the country, which is

use lignite as fuel in production process.

Cooling:

The clinker is cooled in cooler, because it is very hot after passing

though a very high temperature. There are three high power fans, which
reduces the temperature of the clinker. Cooler brings down the
temperature of clinker from 1200 centigrade to 200 centigrade.

Store:

Clinker is stored in the Clinker Silo. For converting it into cement,

gypsum is mixed and grinded further in grinding process.

Sanghi Cement has world’s largest raw mill silo. Its capacity is
40,000 tones.

Grinding:

In this stage raw material is passed to Cement Mill, where the

clinker and gypsum are mixed and grinded to make powder form. Here
some needed chemical are also added to mixture. This gray mixture is
called “cement.”
Storage:

Cement is stored in Cement Silo in powder form before packing.

From cement silo, needed quantity is taken for packing, while the bulk
quantity without packing is goes to Jetty though conveyer belt.

Packing:

Packing plant for packing of cement in bags is located in the plant

itself. There are four numbers of electronic packers supplied by Enexco,
and the capacity of each is 120 MT/Hr. the electronic packing machines
are having eight spouts each. Cement is extracted from the silos through
extraction system, which is equipped with air slides, solenoid valves and
dozing valves and fed to the packer hoppers through screens. The packers
are designed for packing 50 kg cement per bag.

Dispatch:

After packing, cement is dispatched to various locations through

road, rail or sea. Here cement is loaded in truck by machine automatically.

There is provision for bulk loading of cement and clinker into the
ships with a capacity of the single loading system at 1000 TPH. The filled
cement bags shall also be transported to trucks and through ships by
means of belt conveyor, diverting gates and chutes.
QUALITY CONTROL:

The Company
Have dedicated team of quality control department with 18 persons with
an average experience of 11years. The number includes two experts with
Ph D in Cement technology.

Sanghi Cement holds Customer Satisfaction central to their

business. They are committed to this satisfaction through continuous
improvement of all key processes in operation.

Sanghi Cement posses latest equipment of fourth generation

instrumental techniques, as described bellow, resulting in reduced sample
analysis time with accurate results

Cross belt analyzer (Gamma Matrix): for online elemental raw

material analysis.

Raw mix Proportioning Package: for the close loop optimization

of the product in order to produce the required kiln feed with consistent
material composition.

Auto Sampling System: for automatically collecting samples at

regular intervals at all stages of manufacturing.

Robo Lab: for accurate analysis without human error

X-Ray analyzer: is a fluorescence spectrometer for simultaneous

quantitative determination of elements in raw materials, raw mill, Kiln
feed, hot meal, clinker and cement.

Particle size Analyzer: to measure the size of all particles as well

as particle distribution in raw meal, powder lignite and cement.

Physical and Chemical Labs: to test Setting time, Fineness,

Compressive Strength, Expansion, Normal Consistency.
POLLUTION CONTROL MEASURES:

Sanghi cement is equipped with state of the art pollution control

equipment and technology to control pollution.

Combination of bag-filters and ESP's are being used for efficient

and effective control of pollution. Dedusting bag filters are installed in all
transfer points of conveyors to make the site totally pollution free
complex. The Electro static precipitator is 99.9% efficient, while main
plenum pulse bag filter is 99.99% efficient. By the use of such equipments
the dust emission levels are be restricted to less than 50 mg/Nm3, though
the State and central Pollution Control Board permit a dust
loading of 150mg /Nm3.

Dedusting bag filters are provided right from clinker stock pile at
grinding unit to berthing jetty at various points to take care of dust
nuisance. Out of which one jet pulse bag filter is provided at clinker
hopper trough and one jet pulse bag filter near clinker stockpile, three
numbers of insertible bag filters are for clinker transport system from
stock pile to cement mill feeding clinker hopper. Nine numbers of jet
pulse bag filters single compartment, are provided with each cement mill
circuit at various discharge points. Three bag filters are provided in the
single compartment silo. Similarly, six numbers jet pulse bag filters are
provided in the multi-compartment silo for venting and to control dust
nuisance. One jet pulse bag filter is given in screening plant. One bag filter
is also given at berthing jetty and provision for one jet pulse bag filter is
kept at one transfer point.

The local environmental and pollution control norms are met

thorough periodic monitoring of surroundings with the help of pollution
control and monitoring equipments. A green belt is be developed in and
around plant. There is no effluent generated from the facility. As there is
no chemical process involved in the operation at jetty, there will not be
any hazardous pollutants like NOx & SOx present.
 DETAILS OF AIR POLLUTION CONTROL DEVICES
STACK
SL. EFFICIENCY
ATTACHED TO NAME OF EQUIPMENT NO HEIGHT
NO. %
(MTS)

1 Lime stone crusher Dedusting nuisance bag filter 1 99.9 NA

Stacker & Reclaimer 2
2 Additive crusher Dedusting nuisance bag filter 4 99.9 NA
Stacker & Reclaimer
3 Raw material grinding Bag house 1 99.99 125
Dedusting nuisance bag filter 11 99.9
4 Clinkerisation
a Cooler ESP 1 98.0 52.5
b Alkali Bypass ESP 1 98.0 75
57.3 (2
5 Lignite grinding Bag filter Plennum pulse 2 99.9
Nos.)
Dedusting nuisance bag filter 3 99.9 NA
6 Lignite crusher Dedusting nuisance bag filter 7 99.9 NA
stacker & reclaimer
7 Clinker transport Dedusting nuisance bag filter 7 99.9 NA
8 Clinker transport - jetty Dedusting nuisance bag filter 9 99.9 NA
TECHNOLOGY:
The improvement in productivity with respect to rate of
production, energy consumption and product quality could be achieved
through possession of modern technology and Sanghi Cement is well
equipped in this regard the principal components being as under:

♦ Mines Management System.

♦ EV crusher of FL Smith & Co makes.

♦ Limestone stacker and Reel aimer of 1200 tph capacity.

♦ Limestone stockpile and additives stockpile.

♦ Lignite Stacker and reclaimer.

♦ Vertical roller mill if 670-tph capacity, Fuller -Loesche make, one

of world's biggest.

♦ 2 lignite mills of 37.5 TPH of Fuller-Loesche.

♦ Controlled flow site of FL Smith & Co.

♦ 7500 TPD Rotary kiln, largest in Asia, of Fuller International.

♦ A central control Room with latest process control equipment

Supplied by F.L.S. automation, Robo labs.
PRODUCTS:
The Company sells OPC Grade 53 cement, which is most
common cement. It is super fine cement used in structure and concreting.
Minimum strength of Grade 53 cement is 53 MPa.

OPC GRADE 53
CHARACTERISTICS UNIT REQUIREMENT (AS PER IS:269-1989)
PHYSICAL REQUIREMENTS
Fineness: Specific Surface M2/Kg Min 225.00
Soundness:
MM Max 10.00
a) Lechatelier Method
% 0.80
b) Autoclave Method
Setting Time:
Minute Min 30.00
a) Initial Set
Minute Max 600.0
b) Final Set
Compressive Strength:
MPa Min 33.00
a) 3 Days
MPa Min 43.00
b) 7 Days
MPa Min 25.00
c) 28 Days
0c Min 29.00
Temp.during testing
Chemical Requirements
Min 0.66
Lime Saturation Factor (LSF) Ratio
Min 1.02
Alumina Iron Ratio Ratio Min 0.66
Insoluble Residue % Max 4.00
Magnesia % Min 6.00
Sulphuric Anhydride % Max 3.00
Loss on Ignition % Max 5.00
Alkalies % Max 0.60
Chlorides % Max 0.10
The Cement Features:

1. Low Tri calcium Aluminate (C3A):

The Sanghi cement consists low amount C3A content ranging 6-7
percent of mineral formation. The C3A is one of the main minerals formed
during the cement hardening and has negligible affect on strength and
other performance requirements. But, the increased percentage of C3A
above 8, the concrete thus produced is easily affected to sulphates and
chlorides that are present in marine environment, ground water, or active
soils consisting above substance in predominant proportion.

In general most Ordinary Portland Cements consist C3A more than

8 and some times up to 10 percent, and increases the vulnerability of
sulphate attack. The advantage of low C3A content enables the Sanghi
cement can increase the durability up to two times in comparison to other
OPC cements.

2. Adequate Fineness Of Cement:

 Sanghi Cement produced with a minimum fineness of 300 Sq.M/
Kg. This enables the concrete mix designer to easily design general as
well as high performance concrete with a workability requirement up to
200 mm slump with good cohesiveness and low permeable concrete. The
additional fineness helps to make cohesive mortars and better surface
finishing is possible in plasters. The additional fineness provides results in
savings in mortars and painting costs.

3. Low Heat Of Hydration:

The Sanghi cement produces very low heat of hydration of
312KJ/Kg, the limit is much below 314 KJ/ Kg at 28 days for low heat
Portland cement IS 12600. Thus there will be no chance of occurrence of
cracks due to shrinkage and other vulnerable problems due to high heat of
hydration.

4. Low Chloride content:

The Sanghi Cement consists the chloride content much less than
0.05% to total mass. Thus more friendly material for protection of rebar
and enables durability of not only concrete but also reinforcement, thus
enhancing durability beyond normal lifetime.

5. High Strength Development At All Ages:

The strength development curve of Sanghi cement is much above
the requirements of BIS for 53-grade cement. This enhances speedy
construction. Another advantage of high strength development is the
concrete produced can perform well even if there are some inconsistencies
happened during batching, mixing and placing of concrete etc.
 CAPTIVE JETTY:
The facility has a captive jetty at Kharo creek, leading to the
Arabian Sea. As the area is desert and free from monsoons and as the
jetty is in a creek and not on high seas, it is capable of all weather
operations.

The jetty is fitted with Combi-loaders of technology from

SMB Germany, capable of loading ships with bulk cement or
clinker. A feed belt with maximum capacity of 2000 TPH and
loaders of 125 TPH capacity are installed for loading of bagged
cement. The facility's terminal allows access to local and exports
markets. While Europe has more than 150 such terminals and the Far
East has about 40, India has none.

A ship loader carries out loading of cement and clinker into

the ships through a long conveyer belt, which connects the plant to
the jetty. High speed of loading of clinker, bulk and bagged cement
ensures a high turn around time for the ships.

This is the first clean technology cement loading jetty of country.

Jetty Features:
• CAPABLE OF HANDLING SHIPS UPTO 45000 DWT

• SINGLE CONVEYOR FOR HANDLING CLINKER, BULK CEMENT,

BAG CEMENT AND COAL.

• DIRECT AUTOMATIC FEEDING FROM STORAGES INTO SHIPS

• CENTRALISED OPERATIONS FROM CONTROL ROOM

• CLOSED SYSTEM ENSURING CLEAN OPERATIONS