Cement, Energy and Environment

40 Project Engineering & Management Best Practices in Cement Industry Rajesh Kumar Gupta Technical Advisor, J K Cement Limited Abstract Project Engineering & Management is one of the most complex function with host of variables & multidiscipline activities in a Cement Industry coupled with various alternatives. Excellence in planning, organising, managing and executing resources is essential to meet the challenging environment and achieve project goals within the budget and time frame. A cement project basically could be either of the following categories:  Green field integrated cement plant (clinkerisation + cement grinding).  Green field split located cement plant (clinker & cement grinding at different locations).  Brown field expansion (additional clinker line and / or cement grinding) at existing unit.  Technology Up gradation at an existing operating unit.  Acquisition of an existing plant. Once Business Need is established responsibility is handed over to a Project Manager to conceptualise and execute the project. This paper is restricted to “Green Field Integrated Cement Plant” while some important features of other project categories is also touched upon. By an Integrated Cement Plant, we mean  Limestone mining & crushing.  Raw Material preparation, storage and pre blending.  Raw meal grinding, storage & homogenisation.  Pyro-processing & clinkerisation.  Waste Heat Recovery Power Generation.  Clinker Transport & storage.  Clinker evacuation & cement grinding.  Cement transport and storage.  Cement Packing, Loading & Dispatch. Best practices for a “Green Field Integrated Cement Plant” is enumerated in this paper based on experience gained through international exposure. Introduction Project Engineering & Management is an entity in itself and should be taken care in like manner. The multidisciplinary function starts with planning, organising, executing, managing and controlling activities related to civil engineering , process engineering , mechanical engineering , electrical & instrumentation engineering as well as computer engineering to achieve specific timelines within the budget and commission the plant satisfactorily. Objective of a best managed project are  Best Available proven Technology in terms of reliability, quality, energy consumption.  Commission the project within projected time schedule.  Commission the project within allocated budget. A project has both internal and external stakeholders and hence it’s meticulous execution is very important. The life cycle comprises of Feasibility Study, Defining Scope, Planning, Organising & Layout, Execution & Reporting, Monitoring & Control, Commissioning, Closure & Review.