SAFETY PLEDGE On this Day, /I solemnly affirm that/ I will rededicat e myself /to the caus e o f s afety health and protection of environment / and will do my best to observe/ rules, regulatio ns, and procedures / develop attitudes, habits conducive for/ ac hieving these objectives.
I fully realize that /accidents and dis eas es /ar e a dr ain on the national economy./ I will do everything possible/ for the prev ention of accidents and occupational diseas es/ protection of the environment /in the interest o f self, /my family , /my community, /my organizatio n /and the nation at large.
ORGANIZATION CHART OF DCBL – ARIYALUR PLANT
ORGANIZATION CHART OF DCBL – ARIYALUR PLANT
WE ARE A LARGE INDUSTRIAL AND DIVERSIFIED GROU P WITH A CHRONICLE OF 7 DECADES
Group profile 1. Histor y of entre prene urship
• Deve lopment of
specialty ce ment for airstrips, oil wel l and railwa y sleepers
• Retained customer trust • Scal e-up ca pacities
for 7 de cades
•
Promoted by Dalmia family in 1939. Second cement plant o f Sou th India
•
Entrepreneurs had the vision of setting up a na tional cement footprin t in 1939
• Ranked among the top
10 pla yers w ithin a short span of operations in terms of in come
• 22,500 TCD Sugar plants
with
• Power through therma l and rene wable en ergy
2. Countr y partition & fam ily restructuring limite d gr owth in ceme nt •
2 plants were in Pa kistan and were na tionalised after 1947 partition
•
2 plants were reallocated in family settlements
3. Strong pr om oters • Number 1 in high Alumina bricks in C ement indu stry • Overall 50 % market share in all Ind ia in Cement i ndustry
Group profile 4. Or ganization is k now n for its ethics, va lues & unblemis hed track record 5. Lea ding pla yers in India in Ceme nt a nd Sugar 6. Ha ving a vision of growth, expa nsion a nd diversifica tion participating in National gr owth 7. Pioneer in cement in Tam il Na du
•
Mr. YH Dalmia has been past president of Cement Manufacturer’s
•
Association Strong educa tional background o f the promoters (all ha ve Master’s degree)
•
Professional management team and in-depth knowledge o f the industry
OUR VALUES… We at DCBL be lie ve in ‘value creation’ for all stakeholders. Values for us are the means to our ends. We believe they are the core and the essence of doing things our way, the right way – the Dalmia way. These values, for us, not only hold the threads of the present and kee p us grounded, but are also the key to the future where the possibilities are endless. Our four core values are: v Learning v Teamwork v Speed v Excellence We have also coined an acronym to reme mber them easily by picking letters from each value – LETS EXCEL!
Our “VISION”
Our “MISSION”
Effectively utilize resources and be recognized as a benchmark in the Cement Industry
“To consistently surpass expectations of all stakeholders”
DALMIA CEMENT (BHARAT) LTD - ARIYALUR
IMS POLICY
Strong Brand…
We are committed to :
• One of the first cement manufacturers established in India
ü
Develop, implement and continually improve our process and systems to enhance quality, environment, occupational health & safety performance.
ü
Produce consistent quality of clinker and cement as per standards.
ü
Monitor, control and upgrade technology and operational practices.
ü
Comply with all applicable legal and other requirements.
ü
Prevent pollution, injury and ill-health.
ü
Conserve energy and natural resources.
• Strong distribution network of dealers
ü
Optimize utilization of resources for sustainable development.
• Strong customer awareness for Group brands
ü
Create a work environment conducive for enhanced employee participation and involvement.
– Built reputation by consistently providing high qua lity products – One of the first Indian compa nies to develop and market specialt y cements • Oil well cement – Incr easing oil explor ation activity in India • Railway/ air str ip cements – Incr eased emphasis on infr astr uctur e spending
RA. Krishnakumar Issue no . 01
Uni t Hea d 01.11.2010
–
“Vajram” & “Da lmia”
Location Map
DCBL ARIYALUR PROFILE • • • • • •
DALMIA CEM ENT ARIYALUR PLANT
•
State of the art technology 3.0 MN MT Per Annum Capacity 27 MW Captive Power Plant Situated in 346 acres of land Main Ra w materia l –Lime Stone (Sourced from own captive mines) Other industrial waste like fly ash, gypsum sourced from near by industries Producing OPC / PPC Catering to Ta mil Nadu Major ly and in s ma ll volumes to , Kerala, Karnataka & AP Markets
DALMIA CEM ENT BHARAT LTD ARIYALU R . PERFORM ANCE.2011-12
A Power Plant for making the Cement Plant self reliant
A Power Plant to augment Tamil Nadu’s power requirement
HIGHLIGHTS The Road Map to reach Business Excellence
P R O D U C T I O N
M A I N T E N A N C E SERVICES
CROSS FUNCTIO NAL TEAM APPRO ACH FO R OPERATIO NAL EXC ELLENCE
TREND OF MAJOR PARAMETERS TPD KILN
TREND OF MAJOR PARAMETERS POWER UP TO CLINKER..
4500 TPD foun d to be Optimum Cost Model
TREND OF MAJOR PARAMETERS HEAT RATE
TREND OF MAJOR PARAMETERS HSD - CVRM
TREND OF MAJOR PARAMETERS OVERALL POWER - CEMENT
SAFETY @ WORK
Preventable Acc ide nts , if not prevente d due to our ne glige nce, is nothing s hort of a mur der. - Dr. S. Radhakris hna n
SAFETY SCORECARD
*Ariyalur stan ds out First across the Cement Business
KEY ACHEIVEMENTS IN SAFETY
KEY ACHEIVEMENTS IN SAFETY
KEY ENVIRONMENT INITIATIVES IMPLEMENTED FOR THE YEAR 20112011-12
Go Green (Environment Theme) Acti vities Planned/ Implemented : Ø Ø Ø Ø Ø Ø Ø
Rainwater Harvesting / Waste water recycling Use of Solar Power No Passenger vehicle inside factory – on all Sa turda ys All Execu ti ves walk from main gate to work place on Sa turda ys No passenger vehicles beyond C CR on all da ys Plantation during all ke y functions Family in vol vement in En vironment Initiati ves
Green Belt Development
Our Commitment to Green and Clean Environment
Extensive greenery in the Plant A measure of Demonstration of our Environmental Performance
Cement Process Section wise Environmental Measures
Crushing & stacking Ø MMD crusher • Less noise pollution • Less power consumption
Ø Covered storage • Less air pollution • Avoiding wastages
Raw grinding Ø Vertical roller mill • Less noise pollution • Less power consumption
Pyro processing Ø 5 Stage Preheater
• Low power consumption • Low fuel consumption • Capable for using alternati ve fuels
Cement grinding Ø Vertical roller mill
• Less noise pollution • Less power consumption • More fl y ash usage
Cement Process Flue gas & fugitive control Ø Bag house for kiln gas • No tripping • Continuously very low emission • High Efficiency at higher cost • High maintenance & running cost Ø 162m high stack • Dust concentration less than stipulated norms Ø More than 30nos bag filters at transfer points • No fugitive dust emission
Investment for Pollution Control Equipment
Highlights – Automation over conventional manual control Sl.No
Description
S.No 1 2
Advantage
1
Hi gh level of Automa tion
Control of the enti re process from centralized l oca ti on ensuri ng safety
2
On line meas urement of CO, Sox, NOx
Online moni tori ng and control for better envi ronmental performa nce
3
Expert s ys tem for plant opera ti on
Low power a nd fuel consumption (5%) and better envi ronmental performa nce
4
On-line s ta ck moni tori ng s ys tem
On-line envi ronmental performance moni tori ng a nd control
Equipm ent Description Bag filte rs - Bulk loading system Bag filte rs - Cement m ill
Supplier Nam e
Cos t in Lakhs
EEL GEBR
3.55 51.8
3 4 5 6 7 8 9 10 11
Bag filte rs - Coal mill Bag filte rs - Ceme nt Silo Bag filte rs - Fly ash Silo Bag filte rs - Raw mill Bag filte rs - Roto packers Cement mill bag house Coal mill bag house Coole r Esp and fan Dust suppression system
GEBR EEL EEL GEBR EEL Himachal Env. Himachal Env. Himachal Env. PCE
50.65 31.06 18.31 29.57 101.21 782.4 189.54 685.85 103.01
12 13 14
Raw mill reverese air bag house Small - Nusiance bag filters Water treatment plant
Himachal Env. Rieco & FLS Ion exchange
1881.06 167.44 362.77
Total Cost in Lakhs (`)
4458.22
37
Meteorological Observation Station – Environment Monitoring ØLatest online weather monitoring station (WM 271) has been installed installed to monitor the Environmental condition parameters continuously, ü Temperature ü Relative humidity
Environment Monitoring & Management
ü Wind direction ü Wind velocity ü Rainfall
39
Meteorological Data
Meteorological Data Ø We are capturing live data for Meteorological by online monitoring monitoring
Air Quality Management Ø
Air Quality Management
Major atmospheric Emission control
Ø Stack height of 162 m for Raw Mill and pyro-processing.
S.No
Stack Attached to
Type of pollution control equipment
1
KILN/ RAW MILL
2
Stack Height (m) Above Roof
Above GL
Reverse air bag house
40
162
CLINKE R COOLER
Hot ESP
4
41
3
COAL MILL
Reverse air bag house
5
65
4
CEMENT MILL
Reverse air bag house
4
43
5
BOILE R CPP
ESP
40
81
Stack Top Square / Circular Circular Circular Circular Circular Circular
Ø Bag House – Dust Collector for all dust emitting sources. Gas Qty, (m3/hr)
Exit Velocity (m/s)
Flue Gas Temp ( OC)
Emission rate SPM (mg/Nm 3)
4.50
114000
20
225
