Plant Operations and Productivity Enhancement a Case Study

The most advanced cement manufacturing technology does not, on its own, guarantee profitable operations. The cement manufacturing operation for maximum cost efficiency not only requires the advanced technological design but also sound operational practices. Operational Audit is an effective way for enhancing the productivity and minimising energy consumption. The objectives of a comprehensive operational audit of a plant should include: • Optimisation of the output • Reduction in Specific Energy Consumption • Trouble shooting in electrical, mechanical and process systems • Dust abatement • Quality assurance This paper describes with the help of a case study, a typical methodology adopted for such an audit and the various measures suggested for optimising the operations and improving the productivity of a cement plant. The studies have identified the potentials for increasing production & reduction in energy consumption and in planning their investment priorities for their plants modernisation.