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ABSTRACT
As leading companies continue to look for innovative ways to
reduce costs and increase
in production, and labour is one of the main constrain of
present time, rail wagonunloading systems are generating more
attention. Our project gives a brief overview of
unloading coal by BOBRN (Bottom open broad gauge rail) type
wagon using track
hoppers instead of manual unloading.INTRODUCTION
1.1 An overview of the company
Malabar Cements Ltd is the only Portland cement manufacturer in
Kerala. The companywas incorporated in April 1978 commenced
commercial production in 1984, with a
capital outlay of Rs.680 Million and paid-up equity capital of
260 Million is owned fully
by the Govt. of Kerala.
The 1200 Tonnes per day plant at Walayar is continuously running
in profit. Geologicalsurvey of India has identified a cement
limestone in Walayar Reserve Forest way back in
1961-62.The Mineral Exploration Corporation Ltd confirmed its
efficiency.
Despite its difficult terrain and perilous conditions at the
deposit, Kerala State Industrial
Development Corporation (KSIDC) obtained the Industrial License
for setting up a unitin November 1976. The Malabar Cements Ltd thus
comes into existence at Walayar,
Palakkad District.The company is well equipped to set precedence
among public sector unit in the State. A
2.5MW multifold power plant was commissioned in June 1998 to
complement 25% of
the total power requirement for the Walayar plant operation. The
company was updatedby the plant with State Art Technology in
time.
Belt bucket elevators, Kiln automation, modification to cement
mill internals etc are few
to mention. The 0.42 Million capacities less than 10% of the
cement consumption in
Kerala, the company harness the market beyond care segments.
CALCULATION FOR MANUAL COAL UNLOADING
3.1 Time study
Time of arrival of wagons = 5.30 am Time of unloading start =
7.00 am
Time of unloading finish = 2.40 am
Time taken for unloading 5 wagons = 50 min
Dozing time for 5 wagons = 30 min Time taken for shifting 5
wagons = 15 min
Rest time for 5 wagons = 5 min
Total time for 5 wagons =50+30+15+5= 100 min
Total time for 1 wagon = 100/5
= 20 min Effective time for unloading 1 wagon of coal
carrying 65T = 20 min
Time for unloading 59 wagons = 20*59
= 1180 min
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Routine idle time for shunting of rake to
a safe track and detaching of railway
engine (5.30am to 7.00 am ) = 90 min Total time for unloading 59
wagons including
routine idle time = 1270 min
= 21 hrs 10 min Time allowed by railway without demurrage
for unloading = 9 hrs
Demurrage time = 12 hrs 10 min3.2 Cost study
Rate of unloading charge = Rs 36 /TONNE
Cost for unloading 1 wagon = 36*65
= Rs 2340 Cost for unloading 59 wagons = 2340*59
= Rs 138060
Time allowed without demurrage by railway= 9 hrs
Extra time taken = 12 hrs Rate of demurrage charge = Rs 100 /
wagon/hr
Demurrage charge for 59 wagons for 12 hrs = 100* 59*12= Rs
70800
Total cost per rake = 70800+138060
= Rs 208860 Cost of indigenous coal = Rs 3000/T
Cost of imported coal = Rs 6300/T
Yearly consumption of indigenous coal = 60000T/year
Yearly consumption of imported coal = 40000T/year Total
consumption of coal = 100000T/year
Labour cost per Tonne for manual unloading= Rs 36/Tonne
Labour cost per year for manual unloading(Excluding demurrage
charge) = Rs 36lakhs
Cost of coal in one year (coal value per year) = Rs
4320lakhs
Ratio of labour cost to coal value inmanual unloading =
0.83%
