TRAINING COMPANY: AMBUJA CEMENT Ltd.Submitted by: SAMRAT SHARMABRANCH: AE&I

Ambuja Cements Ltd. (ACL) is one of the leading cement manufacturing companies in India. The Company, initially called Gujarat Ambuja Cements Ltd., was founded by Narotam Sekhsaria in 1983 with a partner, Suresh Neotia. Sekhsarias business acumen and leadership skills put the company on a fast track to growth. The Company commenced cement production in 1986. The global cement major Holcim acquired management control of ACL in 2006. Holcim today holds little over 50% equity in ACL. The Company is currently known as Ambuja Cements Ltd. . ACL enjoys a reputation of being one of the most efficient cement manufacturers in the world.ACL has grown dynamically over the past decade. Its current cement capacity is about 27.25 million tonnes. The Company has its own fleet of ships. ACL has also pioneered the development of the multiple bio-mass co-fired technology for generating greener power in its captive plants.

Milestones!2012ACL announces the expansion of Grinding Unite Sankrail, West Bengal, increasing the capacity from 1.5 MTPA to 2.4 MTPA2011Completes 25 years of operation. Celebrates silver jubilee at all integrated plants.Commissioned 2 cement mills at Bhatapara plant,Chattisgarh and Maratha Cement Works,Maharashtra increasing the total grinding capacity of the Company to 27.35 million tonnes.Commisssioned 5 Wind Turbine Generators, having total capacity of 7.5 MW at Kutch , Gujarat.2010Opening of Dadri Plant On 24th February 2010, Ambuja Cements Ltd (ACL) inaugurated its cement plant (grinding unit) at Dadri, Uttar Pradesh. Capacity: 1.5 million tonnes..

In December 2010, the Dadri Grinding Unit in its very first year of operation received the Integrated Management System (IMS) Certification, including ISO 9001:2008, ISO 14001:2004, and OHSAS 18001:2007 by BSI (U.K.).

Delighted CustomersInspired EmployeesEnlightened partnersEnergised SocietyCleaner Environment - Pollution controlCleaner Environment natural resourcesSafety

ATTRACTRETAINDEVELOPPerformance Management System (PMS) is a vital tool to review performance and develop employees. PMS is effectively used to help set performance expectations, ongoing dialogues between the manager and the employees. The focus is on helping achieve set targets.The dialogue provides a platform to the employee to discuss his performance and obtain feedback for his growth and development.The Company has a systematic process of identifying training needs across the breadth of the Organisation and care is taken to design training programs to address skill gaps required for bringing proficiency in jobs.

AmbujaBulk transportationCSRDifferentiationEnvironment protectionFly ashGrowthHolcimISO StandardsJust in timeKilnLowest cost producer in the worldMultiplierName droppingOpportunityPeople powerQualityRaw materialsSurface minerTypes of cementUsesValuesWorkforceThe unknown (X) factorYin and YangZero harm

At every step we found that new and innovative solutions could be found if we kept an open mind.The result is that today we are not only self-sufficient but are in a position to sell excess power capacity to the local state government.Our sea-borne bulk cement transportation facilities have meanwhile brought many coastal markets (domestic as well as export markets) within easy reach.This has been a major factor in making Ambuja Cement India's largest exporter of cement - consistently for the last fifteen years. It can be done!Over 25-30% of the production cost of cement is power.It quickly became clear to us that if we were to run an iconic company, we needed to keep to get more output for less power.power costs to the minimum. So we focused our efforts on improving efficiency at our kilns Next we set up a captive power plant at a substantially lower cost than the national grid. We sourced higher quality coal from South Africa and better furnace oil from the Middle East.

The quarry is the starting pointCement plants are usually located closely either to hot spots in the market or to areas with sufficient quantities of raw materials. The aim is to keep transportation costs low. Basic constituents for cement (limestone and clay) are taken from quarries in these areas.A two-step processBasically, cement is produced in two steps: first, clinker is produced from raw materials. In the second step cement is produced from cement clinker. The first step can be a dry, wet, semi-dry or semi-wet process according to the state of the raw material.Making clinkerThe raw materials are delivered in bulk, crushed and homogenised into a mixture which is fed into a rotary kiln. This is an enormous rotating pipe of 60 to 90 m long and up to 6 m in diameter. This huge kiln is heated by a 2000C flame inside of it. The kiln is slightly inclined to allow for the materials to slowly reach the other end, where it is quickly cooled to 100-200C.Four basic oxides in the correct proportions make cement clinker: calcium oxide (65%), silicon oxide (20%), alumina oxide (10%) and iron oxide (5%). These elements mixed homogeneously (called raw meal or slurry) will combine when heated by the flame at a temperature of approximately 1450C. New compounds are formed: silicates, aluminates and ferrites of calcium. Hydraulic hardening of cement is due to the hydration of these compounds.

From clinker to cementThe second phase is handled in a cement grinding mill, which may be located in a different place to the clinker plant. Gypsum (calcium sulphates) and possibly additional cementitious (such as blastfurnace slag, coal fly ash, natural pozzolanas, etc.) or inert materials (limestone) are added to the clinker. All constituents are ground leading to a fine and homogenous powder. End of phase two. The cement is then stored in silos before being dispatched either in bulk or bagged.What is concrete?Concrete is a solid material made of cement, sand, water, aggregates and often with admixtures. When fresh, it has a certain workability and takes the form of the mould into which it is put. When set and hardened, it is as strong as natural stone and resists time, water, frost, mechanical constraints and fire. Typically, concrete is the essential material used in all types of construction [residential (housing), non-residential (offices) and civil engineering (roads, bridges, etc.)].

The kiln is a cylindrical vessel, inclined slightly to the horizontal, which is rotated slowly about its axis. The material to be processed is fed into the upper end of the cylinder. As the kiln rotates, material gradually moves down towards the lower end, and may undergo a certain amount of stirring and mixing. Hot gases pass along the kiln, sometimes in the same direction as the process material (co-current), but usually in the opposite direction (counter-current). The hot gases may be generated in an external furnace, or may be generated by a flame inside the kiln. Such a flame is projected from a burner-pipe (or "firing pipe") which acts like a largebunsen burner. Thefuelfor this may be gas, oil or pulverized coal.

Fig: Different zones in a basic rotary kiln.

Every zones have a specific importance in the manufacturing process of raw materials to slurry to clinkers to cement and finally to concrete if needed.

Fig: Demonstration on how cement can be formed using waste products.

Fig: Different temperature zones in Rotary Kiln.

Length 72 feet and 10 inches.Width 11feet and 6 inches.Height 14 feets.

Force Flow (Air) Valve Bag Filler

Integrated Valve Bag Packer

Robotic Bag Handling Systems (applicator & palletizer) for valve bags