Industrial Training Report at Lafarge Malayan Cement Langkawi Plant

INDUSTRIAL TRAINING REPORT: AT LAFARGE MALAYAN CEMENT LANGKAWI PLANT

BY MUHAMMAD FAHMI BIN ABD TALIB (ME 083597)

COLLEGE OF ENGINEERING UNIVERSITI TENAGA NASIONAL START DATE: 25 JANUARY 2012 END DATE: 18 APRIL 2012

MUHAMMAD FAHMI BIN ABD TALIB (ME 083597)

COLLEGE OF ENGINEERING

ACKNOWLEDGEMENT

Special thanks to my helpful supervisor, Ir. Dr. Azmi Ahmad. The supervision and support that he gave truly helps the progression and smoothness of my internship program. The cooperation is much indeed appreciation. My grateful thanks also to Lafarge Malayan Cement Plant Manager, Mr. E. R. Kim in giving me an opportunity to work in his plant and also for both host supervisors, Mr. Ibrahim bin Muhammad and Puan Nor Ain Yahya. A big contribution and hard worked from both of you during the 12 weeks is very great indeed. All knowledge obtained during the internship program would be nothing without the enthusiasm and passion from both of you. Besides, the internship program also make me realized the value of working together as a team and as a new experience in working environment, which challenges us each minute. Not forgotten teammates from both Maintenance and Process Department especially to Mr. Abu Yamin, Mr. Rusli and Mr. Rafie for their kindness on guiding me throughout my internship there. The whole program really brought us together to appreciate the true value of friendship and respect of each other. Great deals appreciated also to College of Engineering. The well planned and systemic procedures plus some useful advices help me in doing internship Lafarge Malayan Cement who is the biggest cement producer in the world. Last but not least, thanks to Lafarge Malayan Cement trainees from Kolej Polytech Mara Alor Setar (POLISAS) for their kindness. Discussions and memorable activities that we had done together give me enjoyment while completing this internship program. i

ABSTRACT

University Tenaga Nasional (UNITEN) offers an Industrial Training Program especially for third year students as a requirement for them to complete their engineering course in UNITEN Putrajaya campus. With 4 credits hours, students will be allocated in a hosted company decided by them in order to gain real life working experience. Throughout the 12 weeks industrial training, the students’ performance will be fully monitored by host supervisor and will be guided by UNITEN selected lecturer as their supervisors. Industrial Training Program is conducted with objectives to give opportunities for students to gain their own real life experience before entering actual working life. Besides, this could be an opportunity for them to gain as much knowledge as they could in the things that they have learnt before. In order to join an industrial training, students are needed to attend a Safety and Health briefing organized by CIDB. The industrial training could be a good starting point for students to gain their knowledge in the field that they want next preparing themselves with the real working life that they will experience soon. Hopefully, this report will be used as a reference for students and lecturers who interested in Cement Production.

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Industrial Training Objectives

Industrial training has its own objectives for students to work at any company or institution in order to fulfill the education syllabus requirements. The main objective of this industrial training is to give opportunities for students to gain experience and to be exposed in real working life, so that they could make a good preparation before starting their job after graduation. This opportunity is a one of the future challenges to practice their ability to do a given job or task as well as possible. This training also gives opportunity for students to know the association between theories studied with real practicalities practice and skill in career world. Nevertheless the other purpose of the Industrial Training is to provide exposure for students on practical engineering fields. Through this exposure, students will have better understanding of engineering practice in general and sense of frequent and possible problems. Industrial training also makes students to be high characteristics, proactive, dedicated, in discipline, dynamic, work in team work and trust. As we know, during training students is under pressure with many problems and new environment. So that, students should know how to handle it with the appropriate way and also try to solve all the problems with their best. Widen relationship and social intercourse nicely with current employee to improve team work spirit. At the same time, student also exposed up-to-date with technology such as computer system and technology used inside construction sector and maintenance. Indirectly it does also improve knowledge of the technology.

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WEEKLY TRAINING OVERVIEW

Week 1 I reached the Lafarge Malayan Cement Langkawi Plant and reported to HRA Executive, Mr Azis Bahari. I was given all the Personal Protective Equipment (PPE) like working attire, boots, helmets and safety goggle in order to ensure my safety throughout the industrial training there. After that, some interpersonal interviews between HR Manager, Mr Syafik and I was done. Throughout this week, I need to attend the Familiar Program organized by Human Resource where this program had introduced me the overall information regarding Lafarge Plant. At the end of this program, I had been given a chance to decide which department I would like to be undertrained. I decided that I will be undertrained by Maintenance Department for the first 1 and the half month and at the Process Department for the other 1 and the half month. Week 2 I was assigned to follow the Quarry Section Supervisor, Mr. Abu Yamin for this whole week. For the first day, I was brought to limestone and clay quarry in order to familiarize me with their daily routine. By using a pickup, I was brought to the limestone crushers (1200TPH and 850TPH). There, I had been explained and shown the mechanism of a clay crusher and how the process of crushing the limestone. Moreover, I also had been introduced to the limestone transportation, belt conveyor. For the second and the third day, I joined the execution team where a serious problem regarding the clay crusher had been reported. The clay crusher experienced some blockage at the chute thus causing the clay did not been crushed to the respective sizes properly. In order to overcome the problem, the chute was enlarged. The execution team took three days for this project. iv

Week 3 For the week 3, I was sent to the cement mill section in order to learn the last stage of cement production. At the early of the week, I was brought to see the Dust Collector System where this system is very important in maintaining the dust emission. Poor Dust Collector results high level dust emission thus polluting the environment. In that week also, I involved in replacing the outer slotted plate for Cement Mill 4. Moreover, I also attended a safety briefing organized by Safety Department on Procedures Working in Hole. Week 4 I had been brought by Mr. Rusli to see a problem occurred at Cement Mill 4 involving the leakage of shell liners. In the observation, we conclude that the leakage did not caused by shell liner but the bolts that loosen. Thus, process of retighten the bolts had been done. Together with the process was a Preventive Maintenance (PM). For this PM, iching had been done in order to identify the condition of the shell liners and the broken shell liners were replaced by the new one. Throughout this week also, I was given a project by a Young Engineer, Mr. Mahzuz where this project will be ran in July. It was a joint project leaded by Mr. Mahzuz and this project involves the Sealing Air Fan for Cement Mill 4. Week 5 In this week I was undertrained by Raw Mill Section Young Engineer, Mr. Joshter. I was assigned to follow an Inspector to do a Mechanical Vibration Test at Raw Mill 2. In this test, we had identified a problem in a gearbox. From the data obtained high level of vibrations occurred at the bearing of the gearbox. A report had been issued to Maintenance team. Besides joining the Raw Mill Section team, the Sealing Air Fan Project still ran by schedule. I was assigned by Mr. Mahzuz to calculate the volume of air

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in the lubrication system and determine what type of fan suitable for this project. For this assignment, I managed to obtain 4.1096 m3 of air needed and this volume was close to the value provided by a consultant company. Week 6 This week was the first week I was undertrained by Process Department. I was asked by Human Resources Executive, Mr. Azis Bahari to report myself to Puan Nor Ain who will be my supervisor for the next one and the half month. For the first day in Process Department, I was brought by Mr. Zakrullah, a Young Engineer to see the Raw Mill section in term of a Process Engineer view. Week 7 In this entire week, few programs had been successfully done by Human Resource and Process department. The programs were Quality Award program and Kill-A-Watt program. Besides the launched of both programs, I also had learned on how to calculate the fan performance curve for Line 2. Last but not least, I also helped Process engineers in determining the wet bulb temperature at Raw Mil 2 (RM2). Week 8 Some inspections were done in order to find leakages that occur in Silo Compressors and Coal Mill 2 (COM2). The inspections were done in order to find the source of leakages that affect the entire process before. In this week also I attended a safety briefing on the procedure and rules when working a confined space. Week 9 Week 9 was the week that I learned a lot on tests that had been done by Quality Control Department. The tests were Residue test for both Normal Blaine and High Blaine and

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Sieve test. Both tests are done daily in order to ensure cement that produced is under the required quality of cement needed by plant. I also helped one of the teammate in Process department in sealing leakage at hot ducting in Raw Mill 2. Week 10 Lafarge Malayan Cement had given me a one week holiday so that I can take some rest at home with my family. This holiday was given to all trainees there. In order to apply it, I was needed to fill up a form where the location I went for the whole week and days of holiday taken were asked. The form then was submitted to Human Resource Department for their record. Week 11 Inspections and fire drill had been done in this week. 2 inspections were done involving the dust collector system (purging air) and Grinding Mill at Coal Mill 2 (COM 2). Other than that, a preventive maintenance and a fire drill on Confined Space were done. Week 12 In took almost the entire week to do projects given to me. I was briefed by Mr. Zakhrullah, a young engineer from Process Department on my first project which was to trace the pressure vessels available in LMC Langkawi Plant started by Cement Mill section. To trace the vessels, I joined some inspectors to trace each of the pressure vessels. Through the visit, I was able to note the location, serial number and conditions of the pressure vessels. At the end of the week, I was able to draw a complete drawing for cement mill I presented it to the process engineers.

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Table of Contents

Acknowledgement

i

Abstract

ii

Weekly Training Overview

iv

Table of Contents

viii

Company Profiles 1.1

1.2

1.3

Lafarge Cement

1

1.1.1

History of Lafarge Cement

1

1.1.2

Lafarge Cement Timeline

2

Lafarge Malayan Cement

14

1.2.1

History of Lafarge Malayan Cement

14

1.2.2

Lafarge Malayan Cement Timeline

15

LMC Langkawi Plant Overview

21

1.3.1

Location of LMC Langkawi

21

1.3.2

Organizational Structure of LMC Langkawi

23

1.3.3

Technical Data in LMC Langkawi

24

1.3.4

LMC Langkawi Plant Visions and Missions

25

1.3.5

Components of LMC Langkawi

26

1.3.6

Products of LMC Langkawi

28

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Manufacturing Process of Cement 2.1

What is Cement?

31

2.2

Process

33

2.2.1

Raw Material Preparation

33

2.2.2

Grinding and Storage of Raw Material

35

2.2.3

The Firing of Raw Material

36

2.2.4

Storage and Grinding of Raw Material

38

2.2.5

Packaging and Shipment

40

2.3

Summary

41

Crushers 3.1

Introduction

43

3.2

Type of Crusher Used in LMC Langkawi

44

3.2.1

Jaw Crusher

44

3.2.2

Roller Crusher

47

3.2.3

Hammer Crusher

48

Preventive Maintenances

50

3.3.1

Modify Scraper Outlet Chute of Jaw Crusher

50

3.3.2

Change the Teeth of Jaw Crusher

52

3.3

Grinding Mill 4.1

Introduction

53

4.2

Vertical Mill (Roller Mill)

54

4.2.1

Introduction

54

4.2.2

Mechanism

55

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4.3

Ball Mill (Tube Mill)

56

4.3.1

Introduction

56

4.3.2

Mechanism

57

4.4

Grinding Aid

58

4.5

Preventive Maintenances

59

4.5.1

Outer Slotted Plate Renewed

59

4.5.2

Feed End Liner and Shell Liner Retighten

60

4.5.3

Alignment Motor for Driver Raw Mill 2 (RM2)

61

4.5.4

Taking Flow Rate Reading of Grinding Aid for Cement Mill 3

62

Dust Collector 5.1

Introduction

63

5.2

Type of Dust Collectors Used in LMC Langkawi

64

5.2.1

Gravity Settling Chamber

64

5.2.2

Cyclones

65

5.2.3

Multicyclones

66

5.2.4

Fabric Filters

67

5.2.5

Electrostatic Precipitators

69

5.3

Preventive Maintenances

70

5.3.1

Change the Air Bag Filter for Cement Mill 3

70

5.3.2

Inspection of COM 2 Dust Collector System Purging Air

71

Preheater 6.1

Introduction

72

6.2

Mechanism

73

6.3

Preventive Maintenances

76

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6.3.1

Measuring Temperature and Pressure Reading

76

6.3.2

Coating Leakage at Single Flap Damper, Hot Meal Duct

77

6.3.3

Take Pressure, Temperature and Air Flow Reading of Kiln

78

6.3.4

Measuring the Wet Bulb Temperature

79

Quality Control 7.1

Introduction

80

7.2

Hard Grain Index

81

7.3

Sieve Test

82

7.4

Residue Test

83

7.5

Drop Test

84

Projects 8.1

8.2

8.3

Project 1: Sealing Air Fan for Cement Mill 4 (CM4)

85

8.1.1

Background

85

8.1.2

Objective

87

8.1.3

Expected Benefits

87

8.1.4

Cost Justification

87

8.1.5

Resource Requirements

88

Project 2: Tracing Pressure Vessel Tank in Cement Mill Section

89

8.2.1

Introduction

89

8.2.2

Problem

90

8.2.3

Solution

90

8.2.4

Completed Drawing

91

Measuring the Actual Fan Performance Curve for LK1 and LK2 8.3.1

LK2 – Raw Mill EP Fan

92 93

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8.3.2

LK2 – Cooler Exhaust Fan

94

8.3.3

DOPOL Waste Gas Fan

95

8.3.4

Raw Mill Fan

96

Discussions 9.1

9.2

Safety at Workplace

97

9.1.1

Personal Protective Equipment (PPE)

99

9.1.2

Safety Reporting System (SRS)

100

Environmental Issue

101

9.2.1

Lafarge Group Policies

101

9.2.2

Lafarge Malayan Cement Initiatives

103

9.2.2.1 Biomass to Energy

103

9.2.2.2 Lafarge Roofing

105

Conclusion

107

References

108

Appendices

111

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CHAPTER 1: COMPANY PROFILES

1.1

LAFARGE CEMENT

1.1.1 HISTORY OF LAFARGE CEMENT Lafarge is a French industrial company specializing in four major products which are cement, construction aggregates, concretes and gypsum wallboard. The Lafarge Cement began operations in 1833 with lime operation in France leaded by Auguste Pavin de Lafarge. Through the numerous acquisitions of lime and cement industries throughout the countries, Lafarge became France’s largest cement producer by the late 1930s. The company first expanded internationally in 1864 with the supply of lime for construction of the Suez Canal. International expansion continued in the early twentieth century when operations began in North Africa, United Kingdom, Brazil and Canada. Through the 1981 acquisition of General Portland Inc., Lafarge became one of the largest cement manufacturers in North America. Further expansion of Lafarge continued with the purchase of Blue Circle Industries in 2001 next took on acquisitions around the Mediterranean Basin, Eastern Europe, the Middle East and Asia. By the expansion Lafarge has become the joint leader in the worldwide cement industry, with production facilities in almost 51 countries. The aggregates and concrete business, now operating in 29 countries, made a significant leap in 1997 with the acquisition of Redland plc, one of the principal manufacturers of aggregates and concrete worldwide at the time. 1

1.1.2 LAFARGE CEMENT TIMELINE

1833 The Beginning The story of the world leader in building materials began in the Ardèche region at a place called “Lafarge”, which means “the forge”, near the village of Teil. Joseph-Auguste Pavin de Lafarge began regular extraction operations in the limestone quarries. He had 2 major advantages which are geological and geographical. The geographical means the limestone of the region is of excellent quality and can be used to replace mortar and the Rhone River makes in relatively easy to transport goods. Joseph’s two sons, Eduord and Lèon developed the family company, which then became known as “Lafarge Frères” which means Lafarge Brothers in 1848.

1864 First major project: the Suez Canal Lafarge won the “contract of the century” in Egypt. 200,000 tons of hydraulic lime delivered in wooden barrels, were needed to build the piers of Suez canal. Although its production capacity was limited to just 20 kilns, which produced 50,000 tons per year, Lafarge rose to the challenge. The canal was inaugurated on 17 November 1869, connecting the Mediterranean Sea to the Red Sea.

1866 First operations in Algeria and development in North Africa The Suez Canal contract, the company’s first success in the Mediterranean basin, was the prelude to expansion and the opening of commercial offices in Marseilles, Sète, Tunis 2

and Algiers. Within a few years, the Group had become the leading producer of Portland Cement in Algeria.

1887 Creation of the world’s first research laboratory specialized in cement On the back of its commercial success, Lafarge opened a research laboratory near Teil, France. This laboratory was the first in the world to specialize in cement. The gifted scientists working there placed the laboratory at the forefront of technological progress. To this day, Lafarge works with the most talented research teams. Physical, chemical and mechanical research allows Lafarge to retain its position as the leader in building materials and respond ever more closely to customer requirements.

1889 Social policy rewarded at the Universal Exhibition From the outset, Lafarge has paid close attention to the living and working conditions of its employees and has invested in facilities ranging from dormitories, canteens and hospitals to schools, gardens and rent-controlled housing. The Group’s social policy was rewarded with a gold medal at the Universal Exhibition. Lafarge received this award again in 1900.

1899-1906 Elaboration of the “revolving extinction technique” Lafarge’s teams developed the “revolving roller extinction technique”, an innovative procedure used to create white lime, maritime lime and extra-white cement. The first buildings made with these Lafarge products were the New York Stock Exchange (cut

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stone with white cement joints) and prestigious buildings in the Mediterranean region including the pier in Venice, the port of Algiers and Corinth canal.

1908 Ciment Fondu®, resistant to external forces and high temperatures Lafarge research director Jules Bied filed a patent for Ciment Fondu®, obtained by mixing limestone and bauxite. This cement quickly acquired an excellent reputation thanks to its many properties, notably rapid hardening and resistance to corrosion and high temperatures. It was put to a range of uses and can be found in the Paris metro, on oil rigs, in equipment for the world’s leading steel manufacturers and more recently, in the launch pad for the Ariane rocket in Kourou, French Guiana. Ciment Fondu® is the base ingredient for a number of innovative products including special mortars and refractory concretes.

1921 First patent for white cement During the fabrication process for white cement, clay is replaced by kaolin, which contains low quantities of iron oxide. White cement has the same properties as comparable grey cement but offers additional esthetic qualities. White cement is still used today.

1930 First quarry rehabilitation in Draveil, France Lafarge has long been aware of the environmental impact of its extraction activities. In 1930, the Group carried out its first quarry rehabilitation project. Today, the Group plans

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the rehabilitation of each site before it begins extraction. An environmental impact study, carried out in advance of operations, identifies all measures that will be required to protect the environment, biodiversity and local communities.

1931 Diversification into gypsum, the production of gypsum powder In 1931, the Group acquired “Gypses et Plâtres de France”, a company based in the South France that owned a number of Gypsum quarries. This acquisition marked Lafarge’s entry into a promising market later it became the 3rd largest producer of gypsum in the world.

1947 The leading cement producer in France and North Africa Throughout the first part of the 20th century, the Lafarge lime and cement company continued to develop by acquiring companies across France. After the Second World War, Lafarge consolidated its position as the leading cement producer in France and International development increased while greater demand for building materials saw production double in just 10 years.

1956 The first cement plant in North America and the creation of Lafarge Cement of North America (LCNA) Lafarge built its first cement plant in North America at Richmond in western Canada. It was a bold move to locate a plant 10,000 km and 24 hours by plane from France.

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1959 First operations in Brazil Lafarge acquired a stake in Cominci, a Brazillian company, and built its first cement plant in Brazil at Matozhinos. This plant was the first to produce the famous “Campeâo” brand of cement.

1970 Creation of Canada Cement Ltd. (CCL), the country’s leading cement producer 1970 saw the merger between Lafarge Cement of North America (LCNA), founded in 1956, and Canada’s largest cement producer, Canada Cement Company which had been founded in 1909. The new company was called Canada Cement Lafarge Ltd. (CCL) became the largest cement producer in Canada with 11 plants.

1971 Agreement with the French Ministry for the Environment on dust emissions Since 1971, Lafarge has been taking active steps to reduce dust emissions from its cement plants. The Group does more than simply comply with regulations and the equipment and processes used in plants, such as chimney evacuation filters are constantly being improved through the use of new technologies.

1972 Development of superplasticizers and modernization of the Group Following the oil crisis, the Group was reorganized and the Lafarge holding company was created. New management methods and more effective industrial processes allowed the Group to pursue renewed growth. Lafarge’s research and development team (R&D)

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developed water-reducing admixtures also known as “superplasticizers” which create a fluid concrete without the addition of water.

1974 First use of industrial waste as an alternative fuel In the mid-70s, as petrol prices soared, Lafarge realized that industrial and agricultural waste products such as coffee pods, rice husks, tires, solvents and bone meal could be used to add value in its processes. This industrial ecology approach safely reduces the use of fossil fuels, diversifies energy sources and provides a service to communities by recycling waste. It also reduces CO2 emissions which is particularly important given that the cement industry is responsible for 5% global emissions.

1977 Publication of the Group’s Principles of Action Lafarge’s humanist traditions, passed down the generations since the company was founded, inspired the Group’s Principle of Action. As Olivier Lecerf, Chairman from 1974 to 1989, said “We try to manage by serving rather than by dominating. The true legitimacy of a leader lies in his capacity to serve.” The Principles of Action are a set of humanist values and commitments shared by all employees. They incorporated a vision of becoming the undisputed market leader, commitments to stakeholders and the Lafarge Way, which is a code of conduct that encourages individual success within a multi-local organization.

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1980 Lafarge achieves leadership on the North American cement market – Perfection of high performance concretes The newly-created Lafarge Coppèe Group, born of the merger between Lafarge and Coppèe, became North America’s leading cement producer. The Groups’s workforce increased from 12,000 to 17,000. The following year, Lafarge consolidated its position in North America when it acquired a majority shareholding in General Portland, the 3 rd largest cement producer in the world.

1985 First operations in Cameroon and sub-Saharan Africa Lafarge took its first steps in sub-Saharan Africa in 1985, when it opened a site in Cameroon. Lafarge now has activities in 10 countries in sub-Saharan Africa.

1995 Sustainable development at the heart of the Group' Lafarge implemented its first recycling programs which was production waste was used as an alternative to standard raw materials and fuels at all industrial sites where this was technically possible. The Group published its environmental policy and made commitments regarding the conservation of extraction sites. In the 1995 also Lafarge launched its first employee stock option plan to allow employees to share the Group’s financial success and encourage a sense of community. This operation has been repeated regularly and enjoys growing success.

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1997 Acquisition of Redland: a new business portfolio and further consolidation The acquisition of Redland, a British group strengthened Lafarge’s positions in aggregates and concrete, turned the Group into the leader in building materials in North America and allowed Lafarge to enter the roofing sector.

1998 First operations in India and South Korea Continuing its growth strategy in Asia, Lafarge acquired 2 plasterboard factories in South Korea, close to the town of Busan. The South Korea plasterboard market is the second largest in the region and offers excellent potential for further growth. Lafarge also entered the Indian cement market by purchasing the cement division of Tata Iron & Steel Company Ltd (TISCO), India’s leading steel manufacturer. This acquisition gave the Group a strong presence on the market in western Bengal and an efficient industrial operation in the form of a cement plant and a grinding plant.

2000 A turning point: acquisitions, new product launches and partnerships Lafarge and WWF, the world’s largest environmental protection organization, signed a 5year agreement as part of the “Conservation Partner” program. Besides, the merger between Lafarge’s Aggregates Business and that of the Warren Paving & Materials Group saw Lafarge became one of the leading aggregates producers on the North American market.

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2001 Lafarge, the world’s leading cement producer, targets sustainable growth With the acquisition of Blue Circe, the Group became the world’s leading cement producer and strengthened its position in emerging markets. Lafarge’s first sustainability report received an award for the private sector company which provides the best environmental communication tools.

2002 Framework agreement with the CNRS and the launch of PLAtecTM Lafarge and the French National Center for Scientific Research (CNRS), Europe’s leading research organization, signed a framework agreement to reinforce their cooperation. Besides, the Group launched PLAtecTM, a range of made-to-measure plasterboard solutions which has been used in interior design projects from government building in Vaucluse to the headquarters of Virgin, designed by Renzo Piano.

2003 Signature of the UN Global Compact, creation of the Stakeholder Panel and further efforts in the fight against AIDS Lafarge signed a 5-year partnership agreement with Care, a non-governmental organization, to fight against AIDS. The Group created a stakeholder panel to gain an external perspective on its activities and strategy.

10

2004 Expansion in emerging markets, the launch of SignaTM, humanitarian aid, sponsorship The Group developed its Businesses in emerging countries by building new plants in Asia (Thailand, India, Cambodia, etc.), by consolidating its position in Korea, by expanding its cement capacities in North Africa and Eastern Europe. Following the tsunami of December 2004, Lafarge acted quickly to bring emergency aid to employees and their families.

2005 Recognition for the Group’s sustainable development activities – Increased production capacities Through a joint venture, Lafarge doubled its production capacity in China and became the third largest cement producer in the country. It also invested 300 million euros to expand the production capacities of its Gypsum Business. Lafarge ranked among the 100 best performing multinationals in terms of sustainable development, and signed an agreement on Group social responsibility and international social relations with three international trade unions.

2006 Bruno Lafont and the Excellence 2008 Plan – Commercial launch of Sensium® Launch of the Hypergreen concept Bruno Lafont was appointed as CEO of the Group and launched the Excellence 2008 strategic plan. The program will improve industrial performance, consolidate positions on emerging markets and drive further action on sustainable development. Lafarge

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purchased Lafarge North America minority shares and became the leader in North America across all of its Businesses.

2007 Divestment of the Roofing Business, focus on sustainable growth, launch of 2 concretes with high added value Lafarge divested its Roofing Business to the PAI partners investment fund to concentrate on its core activities. The Group expanded its research center, adding a new experimental concrete plant that allows researchers to test laboratory research results in real time and on an industrial scale.

2008 Acquisition of Orascom Cement, the leading cement group in the Middle East and the Mediterranean Basin This operation is a decisive acceleration of the Group’s strategy in fast-growing, highly profitable emerging markets. Orascom cement is located in high-potential markets, with number-one positions in the key markets of Egypt, Algeria, United Arabs Emirates and Iraq. Its geographical presence is highly complementary with Lafarge’s emerging markets portfolio.

2009 Growth in emerging markets – Concrete innovation Lafarge continues to grow in emerging countries in Ecuador, Nigeria and Iraq. Innovation is in the spotlight with the launch of Thermedia® 0.6B, a new generation of insulating concretes.

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2010 Innovation strategy – Shanghai World Expo – Strengthening business in Brazil and Central Europe Lafarge accelerates its innovation strategy and introduces Aether – a project aiming at reducing CO2 footprint. In additions, Lafarge strengthens its presence in Brazil following the sale of its Cimpor stake to Votorantim and becomes one of the three main cement operators in the country. Lafarge and STRABAG, Central and Eastern Europe’s largest construction company then create a holding company located in Austria.

2011 Significant divestment and new organization Lafarge and Anglo American announce the creation of a leading UK construction materials company. Lafarge also presents a new organization project more agile and responsive, focused on its markets and its clients.

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1.2

LAFARGE MALAYAN CEMENT

1.2.1 HISTORY OF LAFARGE MALAYAN CEMENT Lafarge Malayan Cement Bhd (formerly known as Malayan Cement Bhd) is the producer of cement in Malaysia with plants strategically located in Rawang, Kanthan, Langkawi and Pasir Gudang in Peninsular Malaysia. In addition, it is the owner and operator of a cement grinding plant and a bulk import terminal in Singapore. The Group sells cement and other related building materials in Malaysia and Singapore. The acquisition of the operating companies and a majority interest in Kedah Cement Holdings Bhd in 1999 transformed the company into Malaysia’s largest cement producer with an increased presence in Singapore. Being a member of the Lafarge Group, the company is able to draw from an even wider international base of experience and technical expertise and a broader international trading network. On 30 July 2003, the company unveiled its proposal for an internal reorganization of the Group’s corporate structure of its Singapore subsidiaries, with the intent of streamlining its holdings in its various subsidiaries under one Singapore incorporated company wholly-owned by Lafarge Malayan Cement (LMC)

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1.2.2 LAFARGE MALAYAN CEMENT TIMELINE

1950 Incorporation of Malayan Cement Berhad (now known as Lafarge Malayan Cement Bhd) as a subsidiary of Blue Circle Industries PLC, United Kingdom.

1953 Establishment of Rawang Works, Malaysia’s first cement plant. (Rawang Kiln No.1110,000 tonnes per annum)

1958 Commisioning of Rawang Kiln No. 2 (190,000 tonnes per annum)

1961 Malayan Cement Berhad was listed in the Kuala Lumpur Stock Exchange Berhad on 17 March 1961.

1964 Opening of Kanthan Works by Pan Malaysia Cement Works Bhd (PMCW).

1965 Commisioning of Kanthan Kiln No. 2 (190,000 tonnes per annum). Opening of a grinding plant in Singapore by Pan Malaysia Cement Works Singapore (PMCWS)).

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1967 Merger of cement operations with PMCW and the formation of Associated Pan Malaysia Cement Sdn Bhd. Also acquired 50% stake in PMCWS.

1980 Commisioning of Rawang Kiln No. 3 (1,200,000 tonnes per annum). Incorporation of Supermix Concrete Pte Ltd (SPMS).

1983 Incorporation of Supermix Concrete (Malaysia) Sdn Bhd (SPMM)

1984 Kedah Cement Sdn Bhd (now known as Lafarge Cement Sdn Bhd) commissioned Langkawi Plant.

1985 Commisioning of Kanthan Kiln No.3 (800,000 tonnes per annum).

1989 The company launches its first differentiated bulk product, Mascrete.

1992-1993 Uprating of Rawang Kiln No. 3 and Kanthan Kiln No. 3 to 1.5 and 1.0 million tons per annum.

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1995 Rawang Plant becomes the first location within the Group and the first cement plant in Malaysia to be awarded the ISO 9002 (now changed to ISO 9001:2000) certification. Kanthan Plant received the same certification about three months later.

1997 Southern Cement Industries Sdn Bhd (SCI) commissioned its grinding plant with a rated capacity of 770,000 tons per annum in Pasir Gudang, Johor. Commisioning of Bulk Import Terminal with silo capacity of 55,000 tons in Jurong Port, Singapore to replace PMCWS grinding facility.

1998 Commisioning of Kanthan Kiln No. 4 (1,800,000 tonnes per annum) Acquisition of the remaining 50% stake in APMC). Rawang and Kanthan Plants were awarded the ISO 14001 certification, making us the first cement company in Malaysia to achieve this certification.

1999 Acquisition of Kedah Cement and merger between APMC and Kedah Cement.

2000 Opening of a dry-mix cementitious product plant in Tuas, Singapore. We become the first cement company to be awarded the OHSAS 18001 certification when Rawang Plant receives the certification on 8 December 2000 closely followed by Kanthan Plant on 15 December.

17

2001 Becoming part of Lafarge Group following Lafarge’s acquisition of Blue Circle. SPMM acquired Pengkalan Concrete and spread its wings to East Malaysia. The company celebrated the launch of the first fly ash bag cement, Phoenix. Besides, Malayan Cement was awarded the Corporate Awards 2001, Sectorial Award, Main Board – Industrial Products awarded by the Kuala Lumpur Stock Exchange.

2002 Malayan Cement launched a new corporate identity which reflects its membership in the Lafarge Group. In addition, Malaya Cement was awarded the Corporate Awards 2002, Merit Award, Main Board – Industrial Products, Kuala Lumpur Stock Exchange.

2003 Company name officially changed from Malayan Cement Berhad to Lafarge Malayan Cement Berhad to better reflect its corporate identity as a member of the Lafarge Group. Lafarge Malayan Cement was recognized as a Leader – Construction Sector by Malaysia 1000, Malaysia’s top corporate directory.

2005 We secured a long-term contract with Tanjung Bin power plant for the exclusive supply of all their fly ash production. Lafarge also launch the Logistics Safety Conference with the objective of increasing awareness on road safety amongst the company’s transporters and drivers towards achieving zero accident in loading and transportation. Lafarge Young Engineers Programme also had been launched where fresh graduates from local

18

universities are recruited and enrolled annually in a cement professional development programme to nurture them into skilled engineers.

2006 Launch of a new differentiated bulk product, Mascrete Pro and the Industrial Safety Conference in order to instill greater safety awareness amongst the company’s members. Besides the opening of the residential housing area, Desa Kuala Garing, built and contributed by LMC to relocate 124 squatters in Rawang.

2007 An annual production record of 3 million tons of clinker by Kanthan Plant. Pasir Gudang Plant launched its first Pulverized Fly Ash (PFA) blended cement.

2008 Lafarge Malayan Cement was honored with the Industry excellence Award (Construction) and Merdeka Corporate Award by Malaysia 1000, Malaysia’s top corporate directory.

2009 Lafarge Malayan Cement was selected as one of the twenty finalists (Marketplace dimension) in the StarBiz-ICR Malaysia Corporate Responsibility Awards. The award focuses on how well companies demonstrate their understanding of Corporate Responsibility throughout the business operations.

19

2010 Lafarge Malayan Cement was honored with “Technology Innovation Award for Sustainable Production of Cement” by Frost & Sullivan Green Excellence Awards on 9 June for demonstrating its firm commitment to a continuous focus on reducing the decency on finite resources and resolving to reduce the impact for climate change and overall ecological footprint. LMC also was honored with a plaque by StarBiz ICR Malaysia Corporate Responsibility for being one of the finalists in the segment above RM1 billion market capitalizations. Lafarge Malayan Cement also was placed 11th for Best Corporate Governance Company in Malaysia by Finance Asia, a Hong Kong-based publication reporting on Asia’s financial and capital markets.

2011 Lafarge Malayan Cement receives the Singapore Green Building Product certification for Mascrete LH cement and Phoenix cement by the Singapore Green Building Council. Moreover, LMC also has been awarded an Innovative Award for Sustainable Production of Building Materials by the Malaysian French Chamber of Commerce & Industry on 24 June 2011. Plus, Lafarge Malayan Cement was recognized as a sustainable development leader and was presented the “Enterprise Governance Award 2011 for Green initiative” by The Malaysia Business and the Chartered Institute of Management Accountants Malaysia on 27 September 2011 and short while later was awarded the SIRIM Eco-Label for Phoenix and Mascrete LH on November 2011.

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1.3

LAFARGE MALAYAN CEMENT LANGKAWI PLANT OVERVIEW

1.3.1 LOCATION OF LAFARGE MALAYAN CEMENT LANGKAWI PLANT

Figure 1.1: Langkawi Plant Layout

Figure 1.2: Location of LMC Langkawi 21

Figure 1.3: Plant Layout of LMC Langkawi 22

1.3.2 ORGANIZATIONAL STRUCTURE

23

1.3.3 TECHNICAL DATA

Lafarge Malayan Cement Langkawi Plant (LMC) formerly known as Kedah Cement Sdn Bhd is one of the plant built in Malaysia. First built by the 4th former Prime Minister, Tun Mahathir Mohamad in 1981, the plant had been named with Kedah Malayan Cement however the plant had been acquainted by Blue Circle, a UK cement producer in 1999. The Blue Circle has been acquainted by Lafarge Cement in 2001 short while later. Till now, the plant remains organized by Lafarge Malayan Cement centered at Petaling Jaya and supervised by the board of directors in Paris, France.

With the area of 1162.25 acres and 398 employees, the Lafarge Malayan Cement Langkawi Plant produces approximately 3.38 million of cement per annum thus becoming the largest producers and the only exporter of cement products in Peninsular of Malaysia to Singapore, Bangladesh, Myanmar, Hong Kong, Sri Lanka, Mauritius Nigeria and Australia.

The plant operates with 2 lines called line 1 (LK1) and line 2 (LK2) which use Japan technology and German technology respectively. Technology that is used from Japan technology is from Ishikawajima Harima Heavy Industries while for German technology of Krupp Polysius of Germany is implemented. Each line consist of Raw Mill, Cement Mill, Coal Mill and Preheater and these sections are monitored and ran under supervision of Maintenance, Quality, Process and Production Department.

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1.3.4 LMC LANGKAWI PLANT VISION AND MISSION

LANGKAWI PLANT 2012 HOUSE To achieve total Plant Mastery for our customer with Safety as our way of life

•Health & Safety-cultured workforce in all the sites •Towards mastered and robust plant with sustainable improvement •Clean and Environmental friendly plant for our employees & community •Meeting external and internal customers expectations •Leadership through performance culture

Health & Safety • Zero total injury frequency rate • Area ownership JHP and HK • Practice safety interventions • Zero environmental infringements • 12 hrs Safety training • Compliance with group standards and advisories

Plant Plant Mastery Mastery

Customer Satisfaction

• POM Compliance • Industrial standards (LQTS, LQMS, Power, heat to come, first 5 rules are mandatory)

• OTIFIC => 92%, for both Domestic and Export

• Kiln RF => 97.13%

• Consistent Product Quality IQP => 95%

• Kiln PF => 93.42% • Cement mill RF =>97.27% @ UF64.48% • Cementitious C/K => 1.1165 • Cost ownership & control (VC HC3,335 MJ/ton clk, Power 77.92 kwhr/Clk, grinding 51.26 kwhr, IFC compliance 74.54 mMYR

• Product quality complaints = Reduction by 50% vs. previous year • LP Ship loaders RF => 96%

• AF replacement 13.24% • Maintenance project, MCI <= 1.29,

• Engg.Spares: RM53.23m, Gr.media : RM 0.3m, Refractory: RM 0.8m People Mobilization • Succession Planning • Retention of talents • Follow up on IDP program implementation and close coaching • Front Line Supervisor development program

• Job ownership/Core functions competency • Improve competency of our talent • 5G 3S shift operation

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1.3.5 COMPONENTS OF LMC LANGKAWI

Human Resource Department Create and preserve relationship between company and stakeholders. Maintenance Department  Management Results-driven based upon delegation with clear goals and objectives.  Execution team o Mechanical team Service and repair machines in plant o Electrical team Service and repair electrical components in plant.

 Method team o Inspection team Maintain- in depth knowledge of equipment conditions.

o Mechanical Planner Every actions needed in each of the project is well planned.

o Electrical Planner Every actions needed in each of the project is well planned. 26

Production Department Monitoring production’s equipment ran in the plant. Finance Department Manage the cash flow and budget of Lafarge Malayan Cement Bhd. Health and Safety Department Responsible to give briefing and safety information plus ensuring the safety procedures are followed by each of members. Process Department Monitor and Control each of the process took place in each section.

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1.3.6

PRODUCTS OF LMC L ANGKAWI

Ordinary Portland Cement (OPC)

Rumah

Phoenix

Cement Products

Mascrete

Walcrete

Ordinary Portland Cement Ordinary Portland Cement (OPC) is the most common cement used in general concrete construction when there is no exposure to sulphates in the soil or groundwater. The raw materials required for the manufacture of OPC are calcareous material such as limestone or chalk and argilaceous materials such as shale or clay. A mixture of these materials is burnt at a high temperature of approximately 1400 0C in a rotary kiln to form clinker. The clinker is then cooled and grounded with a requisite amount of gypsum into fine powder known as Portland cement. OPC is a gray coloured powder. It is capable of bonding mineral fragments into a compact whole when mixed with water. This hydration process results in a progressive stiffening, hardening and strength development. 28

Portland Composite Cement (Phoenix)

PHOENIX is the brand name of specifically blended bagged Portland-composite cement. It is manufactured by grinding calcium sulfate as a setting regulator with Portland Cement clinker and

other

carefully

selected

secondary

constituents (pozzolanic materials, fly ash and other constituents permitted under BS EN 197-1:2000). There are some advantages provided by PHOENIX which are improved compactibility, improve cohesiveness, richer mix, improved surface finish, reduced bleeding and lastly it improves board life.

Masonry Cement (Walcrete)

Masonry Cement is an extremely versatile. It is recommended highly for bedding and pointing brickwork and blockwork, interior and exterior plastering and wall finishes. It is a homogenous blend of controlled amounts of Portland Cement, plasticizing material and air entraining agent, inter-ground to a high fineness to give consistent quality. Unlike conventional mortar which is a mixture of four ingredients (i.e. Portland Cement, lime, sand and water), WALCRETE masonry mortar requires only three ingredients, which are WALCRETE, sand and water.

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Its excellent water tetaining property prevents premature loss of water therefore ensuring strong bonding, low drying shrinkage, better weather resistance, good workability, easier handling and smoother finishing.

Portland Pulverised-Fly Ash Cement (MASCRETE LH) MASCRETE LH is the trade name of a specially manufactured Portland Pulverized-Fuel Ash Cement or also called Portland-fly ash cement. Mascrete LH is manufactured by intergrinding in order to ensure homogeneity and consistency in the quality of the product, under an effective system of testing, control and monitoring, confirming to requirements under SIRIM’s Product Certification Licence MS ISO/IEC 17025. This product is effective in reducing core temperature of big concrete structures, also to resist Chloride and Sulfate attack for marine situations and to improve overall concrete durability.

Portland Limestone Cement (RUMAH) RUMAH is the brand name for multi-purpose bagged cement suitable for any project. Compared to the conventional OPC, its good early strength, workability and cohesiveness make it suitable for use in wide variety of general applications.

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CHAPTER 2: MANUFACTURING PROCESS OF CEMENT

2.1

WHAT IS CEMENT?

Figure 2.1: Portland Cement

Cement is a hydraulic binder and is defined as a finely ground inorganic material which, when mixed with water, forms a paste which sets and hardens by means of hydration reactions and processes which, after hardening retains its strength and stability even under water. Ordinary Portland Cement (OPC) is one of several types of cement being manufactured in Lafarge. OPC consists mainly of Lime, Silica, Alumina, Iron and Sulphur Trioxide, Magnesium and other Oxide elements are present in small quantities as an impurity associated with raw materials. When cement raw materials containing the proper proportions of the essential oxides are ground to a suitable fineness and then burnt to incipient fusion in a kiln, chemical combination takes place, largely in the solid state resulting in a product named clinker. This clinker, when ground to a suitable fineness, together with a small quantity of gypsum is Portland cement. Gypsum is added at the grinding stage to retard the settling time of finished cement.

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Figure 2.2: Langkawi Works Flow Chart 32

2.2

PROCESS

2.2.1 RAW MATERIAL PREPARATION The raw materials required to manufacture cement are limestone, clay, iron and iron ore. Rocks extracted from the quarry either by extraction or blasting are routed to the nearby cement plant on a belt conveyor. Each quarry is subjected to a rehabilitation plan adopt to its situation, including promotion of local biodiversity, creation of a touristic and environmental park, residential, agricultural or redevelopment program.

Figure 2.3: Elements involved in the making of cement

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Figure 2.4: Blasting process

Figure 2.5: Raw materials crushed and transported via belt conveyor

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2.2.2 GRINDING AND STORAGE OF RAW MATERIALS

The minerals from the quarry are routed to the grinding plant where they undergo initial milling before being reduced to a fine powder. The raw materials (80% limestone and 20% clay) are then stored in the pre-homogenization pile. Grinding produces a fine powder called “raw meal” which is preheated and then sent to the kiln. In the wet process, each raw material is proportioned to meet a desired chemical composition and fed to a rotating ball mill with water. The raw materials are ground to a size where the majority of the materials are less than 75 microns. Materials exiting the mill are called "slurry" and have flow ability characteristics.

Figure 2.6 Raw Meal

This slurry is pumped to blending tanks and homogenized to insure the chemical composition of the slurry is correct. Following the homogenization process, the slurry is stored in tanks until required. In contrast with the process done in Lafarge Malayan Cement, each raw material is grinded in a dry condition so called dry process. In the dry process, each raw material is proportioned to meet a desired chemical composition and fed to either a rotating ball mill or vertical roller mill. The raw materials are dried with waste process gases and ground to a size where the majority of the materials are less than 75 microns. The dry materials exiting either type of mill are called "kiln feed". The kiln feed is pneumatically blended to insure the chemical composition of the kiln feed is well homogenized and then stored in silos until required.

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2.2.3 THE FIRING OF RAW MATERIALS

The raw mix is fed into a preheating tower at 800°C before returning to the rotary kiln where it is heated to a temperature of 1450°C. Combustion causes a chemical reaction called “decarbonation” which releases the CO2 contained in the limestone. The fired materials take the form of hard granules called “clinker”. Figure 2.7: Red hot clinker falls onto the grate, cooled by air blown from meal which is known as kiln feed at this stage has to beneath be heated to a temperature of about 1450°C in the long cylindrical rotating kiln. The kiln For the production of the clinker, the raw

feed enters the system at the top of the pre-heater and fall until the lower end of the kiln. The heat exchange occurs during this process when the hot gases from the kiln end rise up to the top of the pre-heater. The clinker formation process is divided into four parts which are drying, calcining, sintering and cooling. As the kiln feed moves towards the lower end of the kiln it undergoes some successive reactions. The red hot clinker is then discharged into the cooler, where it is quenched cooled to around 100 degrees centigrade. The heat dissipated by the clinker is used as secondary air for the combustion in the calciner. This hot gas is also used in the dryers at the raw materials preparation stage. Rapid cooling of the clinker is essential as this hampers the formation of crystals, causing part of the liquid phase to solidify as glass. The faster the clinker cooling the smaller the crystals will be when emerging from the liquid phase.

36

Figure 2.8: Burning process occur in the rotating kiln from 1200°C to 1400°C

Figure 2.9: Clinker that produced will be air quenched to reduce clinker temperature from 1400°C to 120°C

37

2.2.4 STORAGE AND GRINDING OF CEMENT

Following re-cooling, the clinker is stored in silos then transformed into cement according to production requirements. During the final manufacturing stage, gypsum is added to the clinker, in a proportion of 3% to 5%, and the mixture finally ground. Clinker, gypsum and grinding aid are ground together in ball mills to form the final cement product. Fineness of the cement product, amount of gypsum added, and the amount of process additions added are all varied to develop a desired performance in each of the final cement products.

Figure 2.10: Elements used in clinker milling

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Various substitute materials such as fly ash and slag can also be used in the composition of cement. The fly ash is the residue from thermal power plant activity while for slag, it comes from blast furnaces. Their use has the dual advantage of reducing the quantity of clinker required next creating a wider range of cements, with qualities corresponding to customers’ specific needs.

Figure 2.11: Clinker Silo - clinker storage before milling process for producing cement

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2.2.5 PACKAGING AND SHIPMENT

The cement is stored in silos before being delivered by tanker trucks or packaged into 2335kg bags and stacked on pallets. Various means of transport may be used according to the local infrastructure and topography. The use of transportation methods with a low carbon footprint is given preference wherever possible.

Tanker Truck

Ship Bulk

Ship Loader Figure 2.12: Product is exported via trucks or ships

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2.3

SUMMARY

Mining the raw material Limestone and clay are blasted from quarries by boring the rock and setting off explosives with a negligible impact on the environment, due to modern technology employed.

Transporting the raw material Once the huge rocks have been fragmented, they are transported to the plant in specialised trucks or by conveyor belt.

Crushing The quarry stone is then delivered through conveyor belt to the crushers, where it is reduced by crushing to chunks approximately less than 25 mm in size.

Prehomogenisation Prehomogenisation is the proportional mix of the different types of shale, limestones, or any other required material to form the right combination for cement.

Raw Material Storage Each of the raw materials is transported separately to silos, where it later will be added in specific amounts according to the particular type of cement being produced.

41

Raw Material Mill This takes place in ball or vertical steel mill, which grinds the material through the pressure exerted by three conical rollers which roll over a turning milling table. Horizontal mills, inside which the material is pulverized by means of steel balls, are also used in this phase.

Raw Meal Homogenization This process takes place in silos equipped for obtaining a homogenous mix of the material.

Calcination Calcination is the core portion of the process, in which huge rotary kilns come into play. Inside, at 1400 °C, the raw material is transformed into clinker; small, dark gray nodules 3-4 cm in diameter.

→

Cement Milling The clinker is ground by different size steel balls while it works its way through the mill's 2 chambers, with gypsum being added to extend cement setting times.

Cement packaging and shipping The cement is then housed in storage silos, from where it is hydraulically or mechanically extracted and transported to facilities where it will be packaged in bags or supplied in bulk. In either case, it can be shipped by rail car, freighter truck or ship. 42

CHAPTER 3: CRUSHERS

3.1

INTRODUCTION

Figure 3.1: Line 2 crusher Cement raw material blasted in the quarry, requires size reduction for further process. Size reduction is performed in crushers. Crushing is comminution in the coarse range which process amplified by mechanical advantage is transferred through material made of molecules that bond together more strongly and resist deformation more than those in the material being crushed do. Crushing devices hold material between two parallel or tangent solid surfaces and applies sufficient force to bring the surfaces together to generate enough energy within the material being crushed so that its molecules fractured and deformation in each other. In operation, the raw material is delivered to the primary crusher's hopper by dump trucks. A feeder device such as an apron feeder and belt conveyor controls the rate at which this material enters the crusher, and often contains a preliminary screening device which allows smaller material to bypass the crusher itself, thus improving efficiency. Primary crushing reduces the large pieces to a size which can be handled by the downstream machinery. 43

3.2

TYPES OF CRUSHERS 3.2.1 JAW CRUSHER

Figure 3.2: A jaw crusher

In the cement industry the jaw crusher is in general use due to its relatively simple design and also to the circumstance that this crusher is manufacturing large units. The jaw crusher serves mainly as primary crusher. This jaw crusher is one of the 3 crushers used in LMC Langkawi plant. The size reduction of the crusher feed is performed between two crusher jaws where one of it is stationary and the other is moved by toggle pressure. The jaws are lined with ribbed liners consisting of chill cast or quenched steel. To crush hard, semi-hard and brittle rocks, ribbed liners are used. The included angle of the rib amounts to 90-100°. For crushing of coarser and considerably harder rocks, the

44

ribs should be corrugated. For large and very hard rocks, liners with more widely spaced ribs are used. Depending on the size of the crusher feed, the width of the ribs in jaw crushers employed as primary crushers is 50-150mm. Jaw crushers employed as secondary crushers have ribs with a width of 10-40 mm. The width of the crusher’s discharge opening is being measured from the top of the rib of one liner to the opposite notching of the other liner. When working very hard materials, the ribs generate lateral forces which have a negative influence on the swing jaw shaft is such cases even jaw liners are preferred. The greatest wear shoes at the lower part of the fixed jaw plate. The constructional design of the jaw liners makes it possible to turn over a worn jaw liner 180° so that the worn side comes upwards. This will make the lifetime of the jaw liner becomes longer.

Figure 3.3: Jaw Crusher with convex-concave shaped crusher plate

45

Double-toggle jaw crusher

Figure 3.4: Movement of swing jaw

Figure 3.5: Schematic of the doubletoggle

In the double-toggle jaw crusher, the movement of the swing jaw is oscillating thus the crusher feed is being squashed. High compression is applied not only to the crushed material but also to the crusher jaws. This crusher serves for size reduction of hard and very hard material in the form of large size rocks. Single-toggle jaw crusher

Figure 3.7: Schematic of single-toggle

Figure 3.6: Movement of swing jaw

In the single-toggle jaw crusher, the motion of the swing jaw is differ from that of the double-toggle crusher. Here the swing jaw moves not only backwards and forwards but also up and down. The size reduction is characterized by attrition and squashing. Compression and friction work simultaneously. This crusher is employed for the reduction of semi-hard material in smaller feed sizes. 46

3.2.2 ROLLER CRUSHER

Figure 3.8: Schematic of a roller crusher

This is the second type of crusher operating in LMC Langkawi plant. Comminution in a roller crusher is based on the passage of material between two rotating rolls which crush the material by compression. The particle size of the crushed material depends on the distance of both rolls from each other. Depending on the kind of crusher feed, the surface of the crushing rolls can be smoothed, ribbed or toothed. Subject to the hardness of the crusher feed, the ribs can be arranged along or across to the axis of the rolls. In roller crusher, one of the crushing rolls is rigidly installed in the crusher frame, whereas the other roll slides horizontally under spring pressure. The elastic springing on one of the rolls is a safeguard against Figure 3.9: 1200tph limestone crusher

unbreakable material.

To prevent friction between crusher feed and the rolls, both crushing rolls have the same speed of rotation. The drive is off a motor through a V-belt sheave and a gear wheel to the fixed roll, and through a suitable linkage to the sliding roll. 47

3.2.3 HAMMER CRUSHER

Figure 3.10: A hammer crusher

The third crusher operating in LMC Langkawi plant, hammer crushers are widely used in the cement industry. They are used for size reduction of hard to medium hard limestone. Hammer mills work with reduction ratios as high as 1:60, depending on the crusher feed. However, this ratio can increase to 1:80. Sometimes the high reduction ratio of hammer crushers does away with the need for the installation of multi-stage crushing plants. Generally two types of hammer crushers are manufactured which are single shaft and double shaft hammer crushers. These crushers work with the impact effect of the hammers according to the formula for the kinetic energy of impact (P);

48

Starting from this point the mass of the hammers in hammer mills was reduced to a minimum while at the same time increasing the velocity v as far as possible. The result was greater impact force combined with reduced wear. In both types of crushers, the crusher feed first passes through the upper or primary grid. This follows preliminary size reduction of the material by the impact hammers. The final crushing then occurs on the bars of the lower grid. Because of the two grids with different spacing, the hammer mills can be considered two-stage crushers. The impact of the hammers upon the crusher feed is not even. This means the load upon the crusher and the drive motor is not continuous. Massive flywheels are used to stabilize the operation. The double rotor crusher has separate drive motors for each shaft.

Purpose

Crushing material

Type

Hammer Crusher

Processed Material

Limestone

Size of Processed Material

1200 mm maximum

Capacity

850 tph

Rotor Speed

185 rpm

Number of Hammer

84

Power Consumption

850 kW

Table 3.1: Information on Hammer Crusher Used in Lafarge Limestone Quarry

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3.3

PREVENTIVE MAINTENANCES

3.3.1 MODIFY SCRAPER OUTLET OF JAW CRUSHER

Problem The clay comes in clots block the rollers from keep rotating and functioning. Solution Enlarge the scraper outlet chute. Procedures 1. Power 21602, 21603 and 21604 are isolated. 2. The chute plate is cut out. 3. The crusher casing is cut out. 4. A new plate is fabricated. 5. The new plate is welded to the crusher. 6. New paint is painted on the crusher plate. 7. Test run is done. 8. Housekeeping the work area. 9. The power is connected back.

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Figure 3.12: Chute plate is cut out

Figure 3.11: Power is isolated and LOTOTO is applied

Figure 3.14: A new plate is fabricated and welded to the chute

Figure 3.13: Chute casing is cut out

Figure 3.15: The new plate is painted nicely

Figure 3.16: Housekeeping the work area

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3.3.2 CHANGE THE TEETH OF JAW CRUSHER Problem The continuous operation will cause the wear of rollers’ teeth thus the efficiency of the crusher has decreases. Solution The teeth of the rollers need to be changed with the new teeth. Procedures 1. Power of the rollers is isolated. 2. The dust on the rollers needs to be cleaned. 3. The teeth that have wear is welded and replaced. 4. The power is turned on again and the rollers can continue its operation.

Figure 3.17: A wear roller

Figure 3.19: New teeth welded

Figure 3.18: A cleaned roller

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CHAPTER 4: GRINDING MILLS

4.1

INTRODUCTION

Figure 4.1: Grinding mills

Grinding mill is a unit operation designed to break a solid material into smaller pieces. There are many different types of grinding mills and many types of materials processed in them. Historically mills were powered by hand, working animal, wind or water. Today they are also powered by electricity. The grinding of solid matters occurs under exposure of mechanical forces that trench the structure by overcoming of the interior bonding forces. After the grinding the state of the solid is changed: the grain size, the grain size disposition and the grain shape. In Lafarge, vertical and ball mills are used.

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4.2

VERTICAL MILL (ROLLER MILL)

4.2.1 INTRODUCTION

Figure 4.2: Vertical mill

Roller mills belong to the group of vertical mills and are particularly suitable for the grinding of medium-hard to soft minerals. They can, however, also be used for the grinding of comparatively hard substances. To increase the retaining time of the material on the grinding bowl and improve the structure of the bed of material, the roller path is designed in the form of a double groove. The different radii of the grinding elements have a great influence on the way the material is drawn under the rollers. Besides, this design also ensures the specific energy consumption remain practically constant in spite of the increasing wear. The grinding force is distributed to match the wear and ensure maximum utilization of the roller path.

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4.2.2

MECHANISM

Figure 4.3: Process in vertical mill

The material to be ground is fed to the roller mill via a flow-regulating device and a feed chute. It drops directly onto the center of the grinding bowl and for commination is carried under the roller by the rotation of the bowl. Due to the exerted centrifugal force, the crushed material is flung outwards over the edge of the grinding bowl and entrained in the stream of gas from the nozzle ring. All of the material ejected from the grinding bowl or a certain portion of it is carried in the gas stream to the dynamic separator located above the grinding chamber. The separator classifies the material entrained in the gas stream into finished product and oversize. The oversize material falls back onto the center of the grinding bowl while the finished product is carried by the gas stream to the dust collector where it is precipitated.

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4.3

BALL MILL (TUBE MILL)

4.3.1 INTRODUCTION

Ball Mill is a cylindrical device used to grind or mix materials like raw materials and clinker. The ball mill is an equipment to grind the crushed materials and carrying on the smashing again to obtain the desired particle size. Figure 4.4: Ball mill Consist of several parts which are charging, discharging, cyclone and rotation part, the ball mill is used in dry and wet material. Hollow axis is made of steel parts with lining replaceable. It rotates around a horizontal axis, which partially filled with the material to be ground plus the grinding medium, media. Different materials are used for media including ceramic balls, flint pebbles and stainless steel balls. In LMC Langkawi, the various sizes of stainless steel balls are used to grind the raw material.

Figure 4.5: Stainless Steel Used As Media

Figure 4.6: Intermediate Diaphragm

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4.3.2 MECHANISM

Figure 4.7: Inside the ball mill Materials shall be evenly charged through quill shaft in feeding device into the first chamber, which has step or waved lining with steel balls in different specifications. Steel balls are taken to a certain height by centrifugal force from drum rotation and then fall. Thus it will give a heavy blow to materials, playing a role of grinding. Materials after crushed in the first bin shall enter bin across single-layer diaphragm into the second, which is provided with flat lining with steel balls, to go through further grinding. Powder shall be discharged from discharging grating, ending the milling process.

Figure 4.8: Shell Liner (side view) Figure 4.9: Shell Liner (top view) 57

4.4

GRINDING AID

Figure 4.10: Grinding aid is pumped to the mill

Grinding aids are materials which facilitate grinding in ball or vertical mills by eliminating ball coating or by dispersing the ground material. When grinding cement, the additive must also have been shown not to be harmful to the finished cement. Grinding aids may be added in solution, as solids to the mill feed or directly to the mill itself. The addition of a fluid may be more readily controlled than the additional of a small amount of granular material. Grinding aids are metered in quantities from 0.006% to 0.08% of the clinker weight. The majority of grinding aids are substances which become strongly absorbed by the ground particles, so that surface energy requirements are satisfied and no bonds remain to attract other particles and cause agglomeration.

58

4.5

PREVENTIVE MAINTENANCE

4.5.1 OUTER SLOTTED PLATE RENEWED Procedures 1. Power is isolated and LOTOTO is applied. 2. The manhole mill inlet is opened. 3. The old slotted plate is cut out by cutting bolt. 4. By using a forklift, the new slotted plates are lifted to the floor mill. 5. A chain block is used to lift the plates into mill. 6. Steps 3 to 5 are repeated for each of the new plates. 7. Iching mill is done for the next slotted plate. 8. The housekeeping is done on the work area. 9. Power is connected back and test run is done.

Figure 4.11: Manhole mill inlet Figure 4.12: Liners are cut out

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4.5.2 FEED END LINER AND S HELL LINER RETIGHTEN

Problem There are loosening bolts and missing bolts at Cement Mill 4. Besides, the old shell liners also need to be replaced. Solution The loosening bolts are retightened and the missing bolts are replaced with the new one. Procedure 1. Power is isolated and LOTOTO is applied. 2. All the end liners are retightened. 3. If there is a missing bolt, a new bolt needs to be fixed. 4. If necessary, iching mill is conducted.

Figure 4.13: Locked out, Tagged Out, Try Out (LOTOTO)

5. Steps 2 to 4 are repeated. 6. Safety precautions; extra precautions need to be taken when lifting the bolt as it is heavy. 7. Use scaffolding is necessary. 8. Housekeeping the work area. 9. Power is turned ON and LOTOTO is removed. 10. Steps 2 to 9 are repeated for the shell liner.

Figure 4.14: Details are needed to be written at the tag 60

4.5.3 ALIGNMENT MOTOR FOR DRIVER RAW MILL 2

Problem The high vibration is detected at the driver for Raw Mill 2. Solution Motor alignment need to be done in order to prevent the motor from being damaged and the shaft may be broken. Other than that, the vibration of the motor also can be reduced.

Procedure 1. LOTOTO is applied. 2. Safety corner is unlocked and opened. 3. The coupling bolt is jacked by a Jacker. 4. Motor bolt is opened. 5. Do alignment for the motor. 6. Tighten back the motor bolt. 7. Fix back the coupling bolt. 8. Close the safety corner. 9. Tighten the bolt of the safety corner. Figure 4.15: Motor alignment is done by a qualified engineer

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4.5.4 TAKING MILL

FLOW RATE READING OF GRINDING AID FOR CEMENT

3 (CM3)

Problem During the inspection, it was found that some coatings occurred at the inlet pipe of the solution Solution In order to free the coatings, the pipe is knocked several times. After that, the flow rate is calibrated again. Procedure 1. Pipe transferring the grinding aid is knocked several times to release the coating. 2. Valve at the pipe transferring the grinding aid

Figure 4.16: Cement Mill is inspected by an engineer

from pump into the mill is opened. 3. By using a stopwatch, time taken for beaker to be filled with 1 Liter is recorded. 4.

Steps 2 and 3 are repeated till the required flow rate is achieved.

Figure 4.17: Time taken for grinding aid to achieve 1 Liter is taken 62

Figure 4.18: Measuring tube used to measure the volume of grinding aid

CHAPTER 5: DUST COLLECTOR

5.1

INTRODUCTION

Figure 5.1: Dust collection system in LMC Langkawi

Dust is the primary emission in the manufacture of cement. For the control of dust, Lafarge employs mechanical collectors, from cyclone collectors to a much smaller size like gravity settling chambers, fabric type dust collectors, gravel bed filters and finally electrostatic precipitators. To meet the emission standards, combinations of various collectors are employed, depending on the intensity and temperature of the effluents. Dust collectors are evaluated by their efficiencies. The efficiency of dust collector equipment is the ratio of the quantity of precipitated dust to the total quantity of dust introduced into the collection device expressed in percentage.

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5.2

TYPES OF DUST COLLECTORS USED IN LAFARGE LANGKAWI PLANT

5.2.1 GRAVITY SETTLING CHAMBERS

Gravity settling chamber is used for pre-cleaning of high dust laden gases. The chamber works on the principle of removing the dust by reducing the velocity of the gas or air stream. The gas is directed from the dust generating equipment into the large volume settling chamber where velocity drops low enough to let large dust particles drop out by gravity. Dust settling chambers are equipped with deflectors in order to change the direction of gas flow and so to shorten the settling path of the particles, improving collection efficiency. However, only relatively coarse particles are removed. For removing of fine dust particles for instance in the range of 20 microns, large settling chambers are required.

Technical Data Efficiency

: 30% – 70%

Gas Velocity : Not exceed 0.5 m/sec Pressure drop : 5 – 25 mm W.G

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5.2.2 CYCLONES

Cyclone

Cyclone consists essentially of two sections which are a cylindrical and a conical one. At the top of the cylindrical section the gas enters tangentially and spirals along the walls

Figure 5.2: A cyclone

downward into the conical section. Then, it starts to occupy the center space of the cyclone and spirals upward to the outlet thimble. Centrifugal forces push the dust particles towards the wall where they accumulate and descend down by gravity. Most of the particles fall down to the bottom into a hopper where the particles are removed by rotary valves or screw conveyors. In plant, cyclones are used for application with rotary kiln, clinker coolers, crushers, dryers, grinding mills, conveyor and others. It can be designed for high throughput and medium efficiency and medium pressure drop as well as for medium throughput, higher dust collection efficiency and a higher pressure drop.

Technical Data Diameters

: 300 – 2300 mm

Efficiencies

: 96.7 %, 92.6 %, 88.2 % and 57.5 %

Temperature

: Up to 975 °C

Pressure drop : 30 – 165 mm Gas throughput: 17 m3/min (1 cyclone) – 8500 m3/min (6 cyclones) 65

5.2.3 MULTIPLE CYCLONES

Multicyclones are enclosed units and arranged in banks for parallel flow with feed gas from a plenum chamber and with a common dust discharge hopper. Multicyclones units can operate up to 400 individual cyclones.

Figure 5.3: A multiple cyclone / multicyclone

In countries with less stringent air pollution regulations, the Multicyclones is in the cement industry a major component in collection of dust from kiln gases, grate clinker coolers, dryers and grinding mills. However, in countries with stricter dust control regulations, the Multicyclones serve mostly as a primary dust collector ahead of high efficiency dust collectors.

Technical Data Efficiency

: 85 % – 94 %

Diameter

: 15 – 20 micron diameter

Pressure drop : 130 mm – 180 mm

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5.2.4 FABRIC FILTERS

Fabric filters are woven or felted cloth made from natural or synthetic fibers. Fabric filters can handle small particles in the submicron range at high efficiency. Depending on the type of fabric, the filters can withstand temperature up to 285 °C. Figure 5.4: A fabric filter bag The dust laden gases flow through a porous medium of the filter fabrics and deposits particles in the voids. After filling the voids, a cake starts to build up on the fabric’s surface which does most of the filtering. During the precoating period which lasts only moments, the efficiency may drop. When the dust layer on the fabric becomes too thick, an increase in pressure drop results thus requires cleaning of the fabric. Cleaning is accomplished periodically mostly response to a timer. During cleaning action there is no air flow through the filter bag in the normal direction thus requires the particular dust collector compartment must be taken off-stream.

Air bag fabric filter

Cage of the fabric filter

Figure 5.5: A fabric filter bag with its cage 67

Cleaning Method a. Bag swinging This method imparts a gentle oscillating motion to the tops of the filter bags thus help to dislodge the dust cake. b. Reverse air This method collapses the filter tube by differential air pressure thus releasing the filter cake. c. Pulse pressure The plenum chamber of the isolated compartment is supplied with a burst of compressed air. This pulse of air expands rapidly and sets up a shock wave. d. Sonic cleaning This method employs sound generators which produce a low frequency sound, causing the filter bags to vibrate. These vibrations combined with reversed air loosen dust particles from the surface of the fabric.

Figure 5.6: A pulse pressure fabric filter 68

5.2.5 ELECTROSTATIC PRECIPITATORS

The principle of this type of dust collection is based on the utilization of the effect of gas ionization in a strong electric field which is formed by discharge electrodes and collecting electrodes. With a sufficiently high electrical voltage between two electrodes, the discharge electrode begins to emit electrons resulting in charging the gas molecules surrounding the electrode in positive and negative ions. Figure 5.7: An Electrostatic Precipitator Under the influence of the strong electric field, the negative ions migrate to the grounded positive or collecting electrode. If the gas is dust laden, the negative ions impose their charge onto the dust particles which then are attracted by the positive electrode. By rapping or vibration, the collected dust is removed from the collecting electrode, dropping into a dust bin. However, a small part of the dust particles will also be charged positively and precipitate on the discharge electrode. Therefore for cleaning, the discharge electrode must also be rapped.

Technical Data DC voltage

: 40 – 80,000 V

Efficiency

: 85 % - 90 %

Temperature : 200 °C – 250 °C Pressure drop : 15 mm – 20 mm 69

5.3

PREVENTIVE MAINTENANCE

5.3.1 CHANGE THE AIR BAG FILTER FOR CEMENT MILL 3 (CM3)

Fabric filtration has been applied for many years before. In essence, a dust bearing gas is intercepted by a permeable fabric in such manner that all the gas passes through the fabric whilst the dust impinges on the fibre of the fabric and is thereby retained.

Problem The increases of emission level are caused by broken filter bags. Besides, the increase of emissions also can be caused by leaks in the tubesheet or internal chambers. For this case, the air filter bags are broken thus the dust cannot be Figure 5.8: Damaged filter bags are gathered at one place

fully trapped. Solution

The broken filter bags need to be replaced with the new filter. Procedure 1. Power is isolated and LOTOTO is applied. 2. Check for the damaged air bag filter. 3. The broken filter bags are replaced with the new one. 4. Housekeeping the work area. 5. Turn back the power ON and test run the system.

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Figure 5.9: Dust collector at CM 3

5.3.2 INSPECTION AT COM2 DUST COLLECTOR SYSTEM PURGING AIR

In dust collector system, air is purged to filter bags at 6 mbar to make dust in the filter bags drop. However, low pressure will cause the dust does not drop and this will damage the filter bags.

Problem A weird sound is detected when air is purged in the dust collector system. Solution An inspection is done to find the source of the weird sound. The inspection needs Maintenance Department engineers and Process engineers to work together in order to run this inspection. Result It is found that the weird sound comes from the broken nuts of the dust collector. Besides, it also found that some leakages occur and purging air system is damaged.

Leakage

Figure 5.11: Inside the dust collector

Figure 5.10: A leakage is found

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CHAPTER 6: PREHEATER

6.1

INTRODUCTION

Figure 6.1: Preheater towers Preheater is a device used to heat air before the air is used for another process. With the primary objective to increase the thermal efficiency, preheater recovers the heat from the boiler flue gas by reducing the useful heat loss. As a result, the flue gas is also sent to the flue gas stack at low temperature thus allowing the simplified design of the ducting and the flue gas stack. It also allows control over the temperature of gases leaving the stack. There are six standard Dry-process kiln system configurations used in high industry especially for cement production. The all 6 kiln systems are as below; a.

Suspension Preheater Kiln

b.

In-Line Calciner using Excess air

c.

In-Line Calciner

d.

Separate Line Calciner-Downdraft

e.

Separate Line Calciner

f.

Separate Line Calciner with In-Line Calciner 72

6.2

MECHANISM

Figure 6.2: Temperature preheater LK2

Multi-Stage Cyclone Preheater Modern cement manufacturing plant like Lafarge preheats raw meal to calcination temperature in a multi-stage cyclone preheater. Most of the calcination process takes place in a separately fired, stationary calciner, while the remaining calcination and clinkerization process takes place in a rotary kiln. Raw meal is introduced at the inlet gas duct to the Cyclone I. It is subsequently preheated by hot, countercurrent gas flow as it is continuously collected and passed down the other cyclone stages in the preheater to the calciner. Fuel is burned in the calciner to achieve 92-95% of the total material calcination before collection in the bottom cyclone and entrance into the kiln.

73

Combustion air Combustion air for the calciner is taken from the kiln via the riser duct and through a separated tertiary air duct from the cooler. Compared with other conventional preheater, it’s a very uncomplicated and effective way for FL Smith’s preheater used by Lafarge to create low NOx emissions with only one firing location, one meal split and one tertiary air stream entering tangentially to the calciner as the preheater design is based on dividing the meal from the second-lowest stage cyclone to the kiln riser and the calciner. These feed points are separated by an expanded riser duct that forms a NOx reducing zone. That is, the calcining chamber is built into the kiln riser. All of the calciner fuel is introduced to the kiln riser duct with less oxygen than required for complete combustion, thereby forming a reducing atmosphere. Above the reduction zone is the main calciner vessel, which is divided into two or more sections separated by a notch. The changes in cross-sectional areas create turbulence that ensures effective mixing of fuel, raw meal and gas, improving heat transfer and combustion. The calciner outlet loop duct ensures optimum gas retention time, further mixing and complete fuel combustion section of the calciner. This creates a “hot zone” in the lower section of the calciner that is conducive to burning difficult fuels and further NOx reduction.

Combustible waste Used car tyres and wood chips are used as partial substitution for ordinary types of fuel as they contain no chemical compounds that might damage clinker quality or affect kiln operation. Such fuels are normally fed into the kiln riser for subsequent complete combustion at the kiln inlet.

74

Figure 6.3: Parts of preheater

75

6.3

PREVENTIVE MAINTENANCES

6.3.1 MEASURING TEMPERATURE AND PRESSURE READING In preheating process, the material will be fed on the top of the preheater and fell into the ground. In the process of material flows from the top to the bottom, the material will experience the increase of temperature from as low as 300°C to 1000°C. In order to maintains an efficient process, temperature, pressure, oxygen and carbon monoxide readings are taken. This will help engineers to detect if any problem occurs. Equipments that have been used are digital thermocouple, manometer and Flue Gas Analyzer. Besides, the tools are steel rod and Pitot tube.

Figure 6.4: The amount of oxygen is measured by a Fluid Gas Analyzer

Figure 6.5: Manometer used to measure pressure

Figure 6.6: Thermocouple

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6.3.2 COATING LEAKAGE AT SINGLE FLAP DAMPER , HOT MEAL DUCT

Problem There is a leakage identified at each of the flap damper, Hot Meal Duct in Preheater Line 2 (LK2). The leakages occur at the bearings of the damper. Implications The leakage allows fresh air flowing inside the preheater thus affecting the heating process. If this problem keep occur, it may cost lot to plant as more fuel is needed in keep maintaining the required heating temperature. Solution As the flap damper keep moving, normal glue cannot be used. Thus, silicon glue has been used to cover the leakages. The ductility of the silicon glue after it dries make it the most suitable glue to be used to encounter this problem.

Figure 5 A flap damper

Figure 6.7: Flap damper Silicon Glue

Figure 6.8: Leakage has been blocked

77

6.3.3 TAKE PRESSURE , TEMPERATURE AND AIR FLOWS OF KILN There are 3 types of flows that have been calculated which are axial, swirl and coal. All these flows have been measured its pressure. It is a need to measure the pressure, temperature and air flows as this helps engineers especially for Process Engineers in Figure 6.9: Temperature is measured by a thermoscan determining the exact shape of burning flame generated in kiln. The correct shape of burning flame produced will cause an efficient burning process in kiln thus high clinker

quality

and

optimum

power

consumption can be achieved. The desired flame for burning is the compact medium-

Figure 6.10: A rotating kiln

length flame. In order to obtain the shape, magnitude of swirl and axial flow need to be the same.

Figure 6.11: Type of flames in rotating kiln 78

6.3.4 MEASURING THE WET BULB TEMPERATURE

Wet bulb temperature indicates the humidity of air. This temperature indicated by a moistened thermometer bulb exposed to the air flow. The wet bulb temperature can be measured by using a thermometer with the bulb wrapped in wet muslin. The rate of evaporation from the wet muslin on the bulb, and the temperature difference between dry bulb and wet bulb depends on the humidity of air. Procedure 1. Coat the wet muslin at the sensor of thermocouple. 2. With half minute intervals, the temperature reading is noted. 3. As the temperature constant, the wet bulb temperature is obtained.

Figure 6.12: A muslin is tied up at thermocouple

Figure 6.13: Muslin is wet by water 79

CHAPTER 7: QUALITY CONTROL 7.1

INTRODUCTION

ISO 9000

ISO 14001

OHSAS 18001

Figure 7.1: Qualifications obtained by Lafarge Malayan Cement

In the manufacture of cement, proportioning of raw materials is strictly controlled at all stages to ensure the quality of product well exceeds the quality requirements stipulated in the relevant standard specification, ISO 9000. Besides, researches and various tests are keep doing by the Quality Control Team in order to keep and at the same time enhancing the quality products ordered by customers. Any complaints regarding to their products are taken serious and further inspections are done to find the main cause of the problem so that the same problem will not occur again.

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7.2

HARD GRAIN INDEX

Hard Grain Index Test is done to ensure the quality of product in term of fineness. Good quality of product has not too large nor too small. Good fineness product will provide cement that will be easily mixed and has great strength.

Step

Descriptions

Pictures

Clinker is filtered until 600 micron clinker is 1

obtained

The clinker then is weighed 2

By using Hard Grove, the clinker is crushed to 3

small

Disc Mill Grinding is used to crush the clinker till 45 micron 4

5

The index is calculated by using information obtained Table 7.1: List of procedures

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7.3

SIEVE TEST

Sieve test is done in order to determine the size of limestone that has been crushed by limestone crushers. The appropriate size of limestone is necessary so that the limestone can be crushed and mixed easily in millers. The most suitable size of limestone for milling is less than 25mm however limestone size up to 50mm is still acceptable.

Samples obtained is filtered by 100mm, 50mm and 25mm filters

For each of the size obtained, the weight of it is measured.

The percentage of the weight to the overal weight is calculated

Figure 7.2: List of procedures

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7.4

RESIDUE TEST

Residue test is done to ensure the fineness of product that has been produced. This test is done for both Normal Blaine product and High Blaine product. For Normal Blaine product, the 2.5g samples is needed while for High Blaine product the 5g samples is needed.

STEP 1 • Normal Blaine product is weighed to the respective weight needed

STEP 2 • The sample then is filtered to obtain 60 micron residue

STEP 3 • The residue is weighed back

STEP 4 • By using formula, the product residue is calculated Figure 7.3: List of procedures

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7.5

DROP TEST

Drop test is a test where the feed rate of each raw materials entering into machines is calculated. The feed rate is very important in achieving the desired product with optimum power consumption.

• Speed of belt conveyor is measured by a contact tachometer STEP 1

STEP 2

STEP 3

• Power of the belt conveyor is isolated

• A 1m long is marked on the belt conveyor

• Material in the 1m range is put onto the weigher STEP 4

STEP 5

• The weight of material is recorded

• By using a formula, the feed rate is calculated STEP 6

Figure 7.4: List of procedures 84

CHAPTER 8: PROJECTS

8.1

SEALING AIR FAN FOR CEMENT MILL 4

8.1.1 BACKGROUND This project covers the following scope of works: To purchase and install one unit air sealing fan complete with accessories (filter, ducting etc) to prevent dust from entering into Cement Mill 4 (CM4) combiflex system. LANGKAWI PLANT CM4 DATA Cement mill no. 4 (CM4) was commissioned by Krupp Polysius AG in 1997. The mill that has shell diameter 5200 mm and nominal length 15,000 mm is driven by 2 units of gear box supplied by Flender AG. In the combiflex system (consist of gear box, girth gear and supporting equipment) the lubrication oil is sharing between gear box and girth gear by means of one LO unit system. Since commissioned, the gear box had been overhauled a few times due to high vibration as follows: Year overhauled Nov 2007 May 2008 Aug 2009 May 2010 May 2011 Jan 2012

Reason High Vibration Output shaft bearing damage Input shaft crack – Total Overhauled (CAPEX) High vibration (Gear Misalignment) High vibration (CAPEX) Gear box replaced (CAPEX)

Table 8.1: Maintenance done for Cement Mill

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After some various brain storming sessions with Lafarge Malayan Cement engineers, dust ingression into gearbox oil circulation system was shortlisted as one of the main factors causing the failure. In addition to precautions of reducing suspended dust and improved lubrication filters, it was decided to incorporate positive pressure dust suppression systems in gear-gearbox guard sealing. On most occasions, the Combiflex arrangement is at the mill feed end making the Combiflex system highly vulnerable to dust contamination. The ingress dust through seal combines with oil to form clots at the lubrication nozzles for mesh lubrication and bearing lubrication resulting in lubrication and gearbox components failure. Due to dynamic application of seal, 100% theoretical sealing of dust ingress is not possible. Additionally, the abrasive nature of clinker dust in the inlet aggravates the situation further. The only way to effect 100% sealing from dust ingress in Combiflex system is by creating a positive air pressure inside the combined gear and gearbox guard. This can be achieved by installing low pressure high volume blower (forced draft) with discharge connections directly into the common guard seal areas. The blower inlet is mounted with suction filter which is regularly cleaned. The individual pipes branching off to the guard are to be mounted with flow adjustment dampers. This will help in ensuring uniform flow of air in all sealing areas. This main objective of this project is to sustain Cement Mill 4 operation and improve mill reliability by securing CM4 operation from major failure caused by gears damage due to oil contamination.

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8.1.2 OBJECTIVE This main objective of this project is to sustain Cement Mill 4 operation and improve mill reliability. 8.1.3 EXPECTED BENEFITS Main benefit is to secure CM4 operation from major failure caused by gears damage due oil contamination. 8.1.4 COST JUSTIFICATION The justification for installation of sealing air fan is Strict Sustaining Capital as this work is essential to sustain the operation of Cement Mill no 4 (CM4). The project cost can be justified based on loss of maintenance cost due to gearbox repaired as follows

No Equip 1 2 3 4

Year Overhaul

CM42008 May No 2 CM42007 No 1 November CM42009 No 1 August CM42010 May No 2

Cost (RM) Duration (day) Specialist Contractor Rental N/A

Spare part

Total

150000

500000

14

250000

100000

15

150000

100000

60000 150000

460000

23

250000

100000

85000 850000

1285000

14

150000

108000

25000 200000

483000

GRAND TOTAL

2,728,000

Table 8.2: Project cost justified based on loss of maintenance cost

For year 2011, CM4 mill inlet lubrication oil had been renewed 4 times due to oil badly contaminated which cost of RM 140 000.

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8.1.5 RESOURCE REQUIREMENTS

Budget Total estimated investment of RM 262,500.00 is required for this project to be implemented. The details breakdown of the budget is as follows:

No

Part Description

Cost (RM)

Remark

1

Sealing air fan (1 unit)

40,000

Quotation

2

Air filtering chamber

30,000

Estimation

3

Ducting and other accessories

80,000

Estimation

4

Electrical parts

20,000

Estimation

5

Contractor for installation

80,000

Estimation

6

Contingency cost (5%)

12,500

TOTAL

262,500 Table 8.3: Detail breakdown

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8.2

TRACING PRESSURE VESSEL TANK IN CEMENT MILL SECTION

8.2.1 INTRODUCTION

Figure 8.1: A pressure vessel In manufacture of cement, the usage of compressed air is very important. The compressed air is used by almost all parts available in plant especially machines. In Lafarge Malayan Cement Langkawi Plant, compressed air is generated by 6 units of compressor located in Silo 4 and Silo 5. From the Silos, the compressed air is flowed to each of the sections in plants and it then will be distributed to each of parts and machines needed by pressure vessel tank. Pressure vessel tank is a closed container designed to hold gases or liquids in transferring compressed air throughout the entire sections in plant. As pressure may drop when flowing throughout the system, the pressure vessel tank is important in keep maintaining the required pressure needed thus machines can keep operating with suitable pressure.

89

8.2.2 PROBLEM Damages and malfunction of pressure vessel tanks may cause disruption on operating machines like millers, grinders and dust collectors. Moreover, a long period taken to trace and repair the damage pressure vessels may cause the damages of machines plus unavoidable accidents like pressure vessel tank explosion to occur. This might seem to be a simple problem however if the problems occur, it might cost lot to plant.

8.2.3 SOLUTION In order to solve the problems, an initiative to trace each of the pressure vessels in Langkawi plant is started by Process Department and well supported by LMC Langkawi Safety and Health Department. Each of the pressure vessel tanks is traced and the condition of each tanks are remarked in a proper document for official reference later on. For more easily, a diagram indicates all tanks available in Cement Mill Sections are drawn. This helps engineers to know where a pressure vessel tank is located if problems occur. The official reference document and drawing are attached in Appendix.

90

Figure 8.2: Drawing of Pressure Vessel Tanks for Cement Mill 4 91

8.3

MEASURING THE ACTUAL FAN PERFORMANCE CURVE FOR LK1 AND LK2

8.3.1 INTRODUCTION Since each type and size of fan has different characteristics, fan performance curve must be developed by the fan manufacturers. A fan performance curve is a graphical presentation of the performance of a fan. Usually it covers the entire range from free delivery (no obstruction to flow) to no delivery (an air tight system with no air flowing). Generally, these curves are determined by laboratory tests, conducted according to an appropriate industry test standard, and obtained under ideal conditions. The fan curves used to predict the pressure-flow rate performance of each fan. With the curve also, engineers can determine which fan gives the volumetric flow rate needed for their system pressure drop. In additions, engineers also can choose fan that has its peak efficiency at or near to their operating point. For this special task, I was asked to calculate the actual fan performance curve for Raw Mill EP fan in Line 2 and Cooler Exhaust Fan. The produced curve will help engineers at Process Department in analyzing the actual performance at the existing fan thus can identify and overcome problems occur. Formula that has been used;

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8.3.2 LK2 – RAW MILL EP FAN

Figure 8.3: Raw Mill EP fan curve

Figure 8.4: Performance Curve plotted for RM EP Fan

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8.3.3 LK2 – COOLER E XHAUST FAN

Figure 8.5: Cooler Exhaust Fan curve

Figure 8.6: Performance Curve plotted for Cooler Exhaust Fan

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8.3.4 DOPOL WASTE GAS FAN

Figure 8.7: Dopol Waste Gas Fan curve

Figure 8.8: Performance Curve plotted for Dopol Waste Gas Fan

95

8.3.5 RAW MILL FAN

Figure 8.9: Raw Mill Fan curve

Figure 8.10: Performance Curve plotted for Raw Mill Fan 96

CHAPTER 9: DISCUSSIONS

9.1

SAFETY AT WORKPLACE

Figure 9.1: Signs of hazards Heavy industries may be a great place to work and earn big salaries however with the speeds in which events occur mixed with the sum of possible safety hazards, it might be our own grave. The Main Dangers at Work Place Dangers are elsewhere in the site of heavy industries. Dangers could come from our own negligence, others’ negligence or the condition of the site itself. It can be avoided if all site hazards are well avoided and safety precautions are seriously taken. The top hazards recorded in heavy industry are as follows: 1.

Trip and fall

This item always makes the top of the list for heavy industry site hazards. Falls from equipment, scaffolding, and other high places are dangerous and far too common to occur. 97

2.

Scaffolding

This also causes falls and if put together improperly can cause injuries and death. People seldom think about heavy industrial equipment safety with respect to equipment that moves but standstill equipment can be just as dangerous when not used properly. 3.

Electrical appliances

This hazard involves all the electrical appliances used seldom in site. Explosion, electrical shock or electrocution may occur on these appliances if it is not well maintenance. If this occurs, serious injury and fatality may occur. To prevent this from occur in their workplace, continuous inspection need to be executed to all electrical appliances used in their site. 4.

Over-exertion and stress

This repetitive use injury has been recorded as the fastest growing type of injury in the workplace. It is caused by repeating the same actions or maintaining the same position for a long time. The effects of this problem are unconscious and injuries at wrist hand or back.

5.

Excessive Noise

Most of heavy industries workers are exposed to excessive noise that comes from operating machines. The louder the noise, the more damage it can cause. The excessive noise may cause permanent injury like hearing loss either progressively, or by the exposures over a long period of time. To overcome this, workers need to wear ear buds when working in a noise site.

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9.1.1 PERSONAL PROTECTIVE EQUIPMENT (PPE) PPE which stands for Personal Protective Equipment is defined as equipment which is intended to be worn or held by a person at work and it protects him against one or more risks to his health or safety.

Figure 9.2: Basic Personal Protective Equipments

Employers have basic duties concerning the provision and use of personal protective equipment (PPE) at work and they have no right to ask for money from an employee for that equipment, whether it is returnable or not. If employment has been terminated and the employee keeps the PPE without any permission, as long as it has been made clear in the contract, employer may be able to deduct the cost of replacement from any wages owed. To allow the right type of PPE to be chosen, employer need to be carefully consider the different hazards in the workplace. This will enable them to access which type of PPE are suitable to protect them against hazard for the job need to be done. 99

9.1.2 SAFETY REPORTING SYSTEM (SRS) Safety Reporting System (SRS) is an online database which allows members of Lafarge to share and learn effective and efficiently and at the same time follow up the corrective actions. Analysis of accident is circulated on weekly basis to all employees throughout the organization worldwide. For this reporting system, each members of Lafarge Cement is needed to submit at least 2 reports on any near miss or faulty observed in plant. The report shall be based on members of Lafarge, contractors, or the plant condition itself which if it is continually ignored will cause accidents later on. The structure of the report will be picture of the situations, who involve, time taken, the location and lastly the estimated cause if it happens. The report then will be sent to the Safety and Health Department via Lafarge e-mail and it will be strictly checked and recorded by the department. To encourage members of Lafarge Cement to join this program and send more reports monthly, a reward system has been introduced. In this reward system designed by Safety and Health Department, members who recorded to send higher than 2 reports will be rewarded with a voucher. This RM50 voucher can be used by members to buy any items at Teow Soon Huat Shopping Mall located in Kuah, Langkawi. This reward system has encourages Lafarge members to submit more reports thus indirectly increases the awareness on the important of safety and hazards at the workplace amongst them. With the increasing number of report submitted by members compared to the last few years, the objective is totally achieved.

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9.2

ENVIRONMENTAL ISSUE

9.2.1 LAFARGE GROUP POLICIES For Lafarge Cement Group, they keep believe that they will only succeed in the long term if their actions respect the common interest. This means they must not comply with laws but also conduct business consistent with sustainable development principles. Thus, they are committed to the protection of the environment, human health and well-being, to the migration of climate change and the conservation of nature. With objective of to ensure the continued improvement of environmental performance, they aim to use energy and natural resources more efficiently, minimize the production of waste, harmful air emissions, and water discharge while seeking ways to preserve landscape and biological diversity. In order to implement these objectives, Lafarge commits to: 1. Operations 

Operate their facilities in a manner that meets local laws, standards and regulations and the environmental management systems requirements.



Minimize the use of non-renewable resources (feasible and safe) and replace them with substitute raw materials (alternative fuels or biomass).



Minimize the amount of hazardous and other wastes generated, reuse and recycle materials where practicable and dispose of wastes using safe and responsible methods.



Implement programs to prevent accidental releases like having emergency response action programs in place at all sites. 101

2. Resources, Training, Research 

Provide adequate financial and human resources, employee training and awareness rising to facilitate continuous improvement in environmental performance.



Take the necessary steps, including sponsoring research, to improve employee’s knowledge of the environmental impacts of their processes and products.

3. Procurement 

Evaluate the environmental values and policies of subcontractor and supplier candidates as part of the selection process.



Require subcontractors and suppliers to respect our environmental, health and safety values and comply with Lafarge policies and procedures when present at plant.

4. Stakeholder relations 

Provide stakeholders routinely with environmental information about Lafarge operations and products in an open manner.

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9.2.2 LAFARGE MALAYAN CEMENT INITIATIVES

Conserving natural resources – Biomass to energy

Figure 9.3: CO2 emissions from combustion of the biomass are considered to be “carbon neutral”.

Objective To reduce the cement plant’s consumption of fossil fuel and provide a disposal solution for the organic wastes generated by palm oil production. Context Malaysia is the world’s leading producer of palm oil. Waste from this production (mainly the palm kernel shells) poses a disposal problem for growers, and is commonly landfilled or burned with no energy recovery. At the same time, the Rawang and Kanthan cement plants use large quantities of coal which is imported and used as their primary fuel.

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Solution

Figure 9.4: Palm kernel shells are substituted for some of the coal. Lafarge Cement decided to use palm kernel shells as a secondary fuel in its cement kiln. The equipment needed to receive, sort and grind the palm kernel shells, as well as the necessary belt conveyors, was installed. The shells are now fed directly into the precalciner. Results This substitution is a means of reclaiming the biomass for energy at a rate of 10% of overall energy consumption. By reducing the amount of coal burned, the two plants have cut their aggregate CO2 emissions by 140,000 metric tons per year, given that emissions generated by combustion of the biomass are considered “carbon neutral”. Finally, the reduction in imports also means less transport-related pollution.

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Lafarge Roofing – CoolRoof insulating roof system

Figure 9.5: A conventional roofing system transmits heat from outside to inside. Objective To define a construction system appropriate for tropical climates which control heat transmission from the roof to the living areas of the house. Context In warm climates, construction features can make a significant contribution to efforts to control the indoor temperature of housing units. In conventional construction, the sun’s radiation on the roof tiles causes heat to be transmitted from the roof to the attic or loft area, and then down into the living areas. If the house is air conditioned, high temperatures also have an impact on energy consumption, since more energy is needed to counterbalance the higher heat load. Solution Lafarge developed the Monier CoolRoof, a roofing system that allows a significant reduction in the indoor temperature of houses. The light color of the roofing tiles limits

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the heat absorption. Heat is then blocked by a reflective aluminum radiant barrier foil installed below the roof tiles. The warm air around the radiant barrier is then evacuated by means of an arrangement consisting of a breathable ridge membrane, counter battens and ridge tiles. Finally, an insulating material limits the transmission of the remaining heat.

Figure 9.6: CoolRoof provides effective insulation and optimizes air circulation.

Result Compared to conventional roofing systems, Monier CoolRoof cuts heat transmission by more than 80%, lowering the building’s indoor temperature by up to 4°C.

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CONCLUSION

Internship program at Lafarge Malayan Cement Langkawi Plant was successfully done. Throughout the program, a lot of experiences, skills and knowledge had been obtained either related with engineering or not. While training there, I was exposed to the real working life in heavy industry. In industry like cement manufacturer, problems and challenges come in many ways. Executives like engineers need to think the new solutions for each of challenges come in a very short period. In order to work in this surrounding, they need to have a strong determination for them to overcome the working pressure. Moreover, training at Lafarge also gives me an opportunity to understand and applies all the things that I have learned at UNITEN. Strong foundation in theories needs to be obtained in order to understand the working principle of each machine operating in plant. However, it is not a big problem if our foundation is not too strong as each of Lafarge members stand on their organization’s principle which is learning is a continuously done. That is why Lafarge members keep learning by attending seminars and training done by the head quarter. Helps and explanations will be well delivered to trainees if they not understand in a particular thing. Finally, I would like to suggest UNITEN to prolong the industrial training period in the future as 3 months internship is not sufficient for students to well understand and adapt things occur in an organization. For Lafarge, it is better if each of trainees there is guided with a planned schedule so that they know what they will learn thus they can prepare themselves first. The internship program will be more successful if these recommendations are done in the future. 107

REFERENCES

Books

1. Standard Specification for Portland Cement. Published by the American Society for Testing Materials. Philadelphia. Pa. USA 2. Sobolewski. 1957. Crushers, Design and Applications. Katowice 3. Der Mechanismus, 1962. Size reduction by impact – Considerations about performance and sizing of impact crushers, Aufbereitungs-Technik ( p.437-447, 479-490 ) 4. 1938. Grinding in Cement Industry Rock Products 1, Rockwood 5. Sullivan. 1927. Passage of Solid Particle Through Rotary Cylindrical Kiln. Published by US-Bureau of Mines 6. Dersnah. 1956. Ball Coating and Grinding Aids. Published by Portland Cement Association. Chicago: Illinois 7. Bernutat. P. (1969). Design of Modern Tube Mills and Mechanical Air Separators. Published by Cement-Wapno-Gips, Warsaw 5 (p.131 – 134) 8. Kannewurf. (1956). Grindability Standard. Published by Portland Cement Association Report. Chicago 9. Pearson. 1952. Fine Grinding in Tube Mills. Published by Rock Products ( p.106 ) 10. Clarke. 1962. Process Engineering Calculations. Published by McGraw – Hill. New York 11. Tonry. 1961. Heat Transfer Systems for Dry Process Kilns in Cement Manufacturing. Published by Pit & Quarry. Chicago ( p.151 – 154 )

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12. 1972. The Development of F.L. Smidth and Co, Published by Cement Technology. London ( p.14 – 19 ) 13. 1983. Pulse Energization of Electrostatic Precipitator of Electrostatic Precipitators. Copenhagen: Denmark

Websites 1. United

States

Department

of

Labor.

Confined

Space.

taken

from

http://www.osha.gov/SLTC/confinedspaces/index.html 2. Canadian Centre for Occupational Health and Safety. Confined SpaceIntroduction.

taken

from

http://www.ccohs.ca/oshanswers/hsprograms/confinedspace_intro.html 3. Wikipedia.

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Space.

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2012.

taken

from

http://en.wikipedia.org/wiki/Confined_space 4. Binq

Inc.

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and

Calcining

System.

2012.

taken

from

http://www.miningequipments.org/faq/preheater-and-calcining-system/ 5. FLSmidth. October 2011. Preheating. Taken from http://www.flsmidth.com/enUS/Products/Product+Index/All+Products/Cement+Preheating/In Line+Calciner+Preheater+System/In-Line+Calciner+Preheater+System 6. Wikipedia.

Air

Preheater.

March

2012.

taken

from

2010.

taken

from

2012.

taken

from

http://en.wikipedia.org/wiki/Air_preheater 7. Magotteaux.

Pioneering

Solutions.

http://www.magotteaux.com/wiki-mag/ball-mill/ 8. Wikipedia.

Ball

Mill.

May

http://en.wikipedia.org/wiki/Ball_mill 9. Vipeak. Ball Mill. 2008. taken from http://www.crushingmill.com/ball.html 109

10. ThyssenKrupp Polysius. Raw Material Preparation Brochures. 2010. taken from http://www.polysius.com/en/publications/brochures/raw-material-preparation/ 11. Manufacturing-the

cement

kiln.

Taken

from

http://www.understanding-

cement.com/kiln.html 12. CIMA.

Production

Process.

2011.

taken

from

http://www.cima.com.my/cima/mainpage.php?menu=process 13. Wikipedia.

Portland

Cement.

May

2012.

taken

from

Process.

taken

from

http://en.wikipedia.org/wiki/Portland_cement 14. CEMBUREAU.

Cement

Manufacturing

http://www.cembureau.be/about-cement/cement-manufacturing-process 15. Essroc

Italcementi

Group.

Engineering

Graduates.

2012.

http://www.essroc.com/default.aspx?pageid=183 16. Lafarge

North

America.

About

Cement.

taken

from

http://www.lafargenorthamerica.com/wps/portal/na/en/2_2_1Manufacturing_process 17. Lafarge

United

Kingdom.

All

About

Cement.

2012.

taken

http://www.lafarge.co.uk/wps/portal/uk/2_2_1-Manufacturing_process

110

from

Appendix A – SRS RM50 Voucher

111

Appendix B – Worker Pass

(Front)

(Back)

112

Appendix C – Near Miss Report Form

113

Appendix D – Safety Observation Report Form

114

Appendix E – Risk Assessment Form

115

Appendix F – Measurement Overview Sheet for Preheater

116

Appendix G – Cement Mill Lubrication Piping Drawing

117

Appendix H – Shell Liners Arrangement in Cement Mill

118

Appendix I – Purge Air Seal Plan for Cement Mill

119

Appendix J – Type of Shell Liners and Its Arrangement in Cement Mill

120

Appendix K – Drawing Produced for Maintenance Department in Changing New Shell Liners

121

Appendix L – Traced Pressure Vessel Valve in Cement Mill Section

122