Project Synopsis

For Vertical roller mill (VRM)

By

Shubham Tripathi

Roll No: MBA22504

A PROJECT SYNOPSIS

Submitted to the

University Of Mysore

For approval of project towards partial fulfillment for the award of the

degree of

Master of Business Administration

University Of Mysore

Year: 2022-2024
Background

I intend to choose a project from the domain of my work in UltraTech cement Ltd,

which would be enriched by the lessons and tools learnt from the University of Mysore

MBA curriculum.

Building Solutions Powerhouse

UltraTech Cement Limited is the cement flagship company of the Aditya Birla Group. A USD

8.4 billion building solutions powerhouse, UltraTech is the largest manufacturer of grey

cement and ready-mix concrete (RMC) and one of the largest manufacturers of white cement

in India. It is the third largest cement producer in the world, excluding China. UltraTech is the

only cement company globally (outside of China) to have 175+ MTPA of cement

manufacturing capacity in a single country. The Company’s business operations span UAE,

Bahrain, Sri Lanka and India.

UltraTech has a consolidated capacity of 190.46 million Tonnes Per Annum (MTPA) of grey

cement. UltraTech has 34 integrated manufacturing units, 34 grinding units, one

Clinkearization unit, and 9 Bulk Packaging Terminals. UltraTech has a network of over 1.3

lakh channel partners across the country and has a market reach of more than 80% across

India. In the white cement segment, UltraTech goes to market under the brand name of Birla

White. It has two White Cement units and three Wall Care putty units, with a current capacity

of 2.6 MTPA. With 395 Ready Mix Concrete (RMC) plants in 155 cities, UltraTech is the

largest manufacturer of concrete in India. It also has a slew of speciality concretes that meet

the specific needs of discerning customers. Our Building Products business is an innovation

hub that offers an array of scientifically engineered products to cater to new-age

constructions.
UltraTech is a founding member of the Global Cement and Concrete Association (GCCA). It

is a signatory to the GCCA Climate Ambition 2050 and has committed to the Net Zero

Concrete Roadmap announced by GCCA. UltraTech is focused on accelerating the

decarbonization of its operations. It has adopted new age tools like the Science Based Targets

Initiative (SBTi) and Internal Carbon Price as well as set ambitious environmental targets

through both EP100 and RE100.

UltraTech is the first company in India and the second company in Asia to issue dollar-based

sustainability linked bonds. UltraTech works to actively contribute to the social and economic

development of the communities in which it operates. The Company’s social initiatives focus

on education, healthcare, sustainable livelihoods, community infrastructure, and social causes.

UltraTech reaches out to more than 1.8 million beneficiaries in over 500 villages in 16 states

across India.
Market Needs

UltraTech Cement, a subsidiary of Aditya Birla Group, has shifted its marketing strategy from

hyperbolic advertising to focusing on consumer needs, especially targeting first-time home

builders with the campaign 'UltraTech Se Pucho', which leverages technology for

personalized assistance.

The brand has successfully engaged with rural markets highlighting its commitment to

empowering local community leaders.

UltraTech Cement's 'Banega Toh Badhega India' campaign, featuring collaborations with

popular influencers, has reached to millions of people and significantly increased the brand's

perception as a nation-builder, demonstrating the impact of infrastructure on societal progress.

UltraTech Cement Ltd (UltraTech) is a manufacturer of cement and ready-mix products. The

company’s product portfolio includes ordinary Portland cement, Portland blast furnace slag

cement, Portland pozzolana cement, Portland composite cement, white cement, wall care

putty and white cement-based products. It also manufactures ready mix concrete comprising

building products and specialty concrete such as autoclaved aerated concrete blocks, grouting

solutions, jointing mortars, plastering solutions and waterproofing solutions. The company’s

products find applications for the development of work for various construction projects. The

company has operations in India, the UAE, Bahrain, and Sri Lanka. UltraTech is

headquartered in Mumbai, Maharashtra, India.

Scope

Detailed information on UltraTech Cement Ltd required for business and competitor

intelligence needs

A study of the major internal and external factors affecting UltraTech Cement Ltd in the form

of a SWOT analysis

An in-depth view of the business model of UltraTech Cement Ltd including a breakdown and

examination of key business segments

Intelligence on UltraTech Cement Ltd.'s mergers and acquisitions (Manda), strategic

partnerships and alliances, capital raising, private equity transactions, and financial and legal

advisors

News about UltraTech Cement Ltd, such as business expansion, restructuring, and contract

wins

Large number of easy-to-grasp charts and graphs that present important data and key trends

Aim

Strategic Aim: UltraTech will focus on scaling production capabilities through new plant

setups and expanding existing facilities. The company has already outlined several key

investments across India to achieve this target, aiming to meet the rising demand from

infrastructure and construction sectors.

UltraTech current production capacity stands at over 130 MTPA. The expansion plan, once

completed, will significantly strengthen its footprint in the domestic and international

markets. The company also emphasizes sustainable practices, incorporating green energy

initiatives and reducing its carbon footprint.

This move is expected to not only bolster UltraTech’s market share but also contribute to

India’s ambitious infrastructure growth targets. With this capacity enhancement, the company
remains well positioned to address the demands of the future and sustain its leadership in the

cement industry.

Specific Aim: - UltraTech Cement, India’s leading cement manufacturer, is set to surpass the

200 million tons per annum (MTPA) production capacity.

 Large-Scale Production Capacity: With over 119 MTPA capacity, UltraTech benefits

from economies of scale, allowing it to meet growing demands efficiently.

Literature Review:

Innovations and Sustainability in the Cement Industry with a focus on UltraTech

Cement and Vertical Roller Mills

The cement industry is a cornerstone of global infrastructure development, continuously

evolving to meet rising demands while addressing critical environmental concerns. This

literature review synthesizes information on key advancements, operational efficiencies, and

sustainable practices, with a specific focus on UltraTech Cement's contributions and the

pivotal role of Vertical Roller Mills (VRMs).

1. Vertical Roller Mills (VRMs) in Cement Production

Vertical Roller Mills (VRMs) have revolutionized cement manufacturing, offering significant

advantages over conventional grinding systems, particularly in energy efficiency and

operational flexibility. VRMs integrate grinding, separation, drying, and conveying into a

single, compact unit, which is crucial for producing the fine powder required for cement.

Research indicates that VRMs can be 1.5 to 2 times more energy-efficient than traditional ball

mills, with a specific power consumption that is notably lower. The comminution in VRMs

primarily occurs through compression and shear forces, leading to a more consistent material

bed and narrower particle size distribution. Modern VRMs are designed to handle materials

with high moisture content and coarser feeds, further enhancing their efficiency. Studies have

also focused on optimizing VRM performance through computational fluid dynamics (CFD)

to analyze airflow and erosion patterns, and through advanced control systems that use real-

time data and predictive models to improve grinding energy efficiency and reduce energy

consumption.
 Vertical roller mill (VRM)

INTRODUCTION

Ultratech, the largest cement manufacturer in India, has ramped up its manufacturing

capabilities and set new benchmarks with the commissioning of Dhar cement Works (DCW)

in Madhya Pradesh on 8 March 2018.

Located in Tonkin, about 140km from Indore, Madhya Pradesh, the plant has an installed

capacity of 2.5 Mtpa and clinker production of per day 7200 TPD.

There is Raw mill Make- LOESCHE, 530 tph it’s capacity. There are 4 rollers in this mill.

There is calculated body vibration which can be 4 to 10 mm/sec at operation. There are four

hoppers one of them limestone hopper which capacity 550mt and other three additive hoppers

150mt per hoper capacity.

There are manufacturing 5 types of cement- PPC, OPC43, OPC53, Weather plus, and HSR as

per requirement.
Stacking and reclaiming: -The operation of building a pile is called “stacking,” and

removing and relocating operations are “reclaiming.’’ “The main objective of stacking and

reclaiming is to achieve homogeneity in the material. This process is called pre-

homogeneous.
Hoppers: -

There are four Hoppers – one limestone hopper and three hoppers for additives

(low/high grade, and iron ore) as per requirement of quality.

Vertical roller mill (VRM):- Vertical roller mill is a type of grinder used to grind

materials into extremely fine powder for used in cement making.

Details of Vertical roller mill:-

Functions of Roller Mill: -

•Grinding

•Separation

•Drying

•Conveying

Four functions in one machine makes VRM a compact grinding system.

Principle of Vertical roller mill: -

” It is working on compression and attrition forces.”

Details of VRM:-

SN Particular Calculation details

1 Area of nozzle 60 nozzle *per nozzle length 0.27 *per
nozzle width 0.27
2 Raw mill fan capacity 1080,000m3/hr
3 Water flow at mill As per requirement
4 Armour ring inclination It should be 5-15 as per material drying
requirement
5 Nozzle ring plate angle It should be 35 to 65 as per material
drying requirement
6 Scatter ring width 200mm (it helps in better spreading of
material)
7 Dam ring height It should be 3.5 to 5% of table diameter
8 Table diameter 5600mm
9 Roller diameter 2800mm
10 Weight of each rollers 24 tons
11 Air velocity 50-55 m/s
12 Residue 212μm- 1.5%
90μm- 15%
Model. - LM 56.4

MAKE. - LOESCHE

TPH. - 530 TPH

GB MODEL - KPBV-160

G/B MAKE. - Renk

Power. - 4100kw

TABLE DIA. - 5600

NOOT Roller - 4

GRB OIL - OMALA 600 XP 320

OIL QTY - 8300 LTR

Nozzle ring: -

 Nozzle ring is also called as louver ring.

 Better to design number of nozzles in such a way that the area of each Nozzle ring

blade could be either be Vertical in dry condition of material or at an angle of 35 -45

deg. when some moisture available in material.

 Optimum nozzle ring velocity creates the minimum pressure drop across mill

 Reduction of nozzle ring velocity to reduce Mill dip.

 Maintaining the optimum nozzle ring velocity in the range of 45-55 m/s

 Based on the roller's arrangement and table design, the material reaches in uneven

flows towards the louver ring.

 nozzle should be exactly same.

Dam ring: -

The purpose of dam ring is to control material bed thickness over table and allow smooth

discharge of ground material to nozzle ring and maintain stable bed. Its height is related to

the table diameter of the mill. The dam ring controls material flow leaving the grinding

zone and thereby allows an adjustment of the bed height. It is more important for mills

with flat tables to retain the material on the grinding table. As the wear at rollers and table
 segments proceed, the grinding bed height increases. To keep the bed height constant, the

dam ring height needs then to be lowered. When exchanging roller and table wear parts,

the dam ring is generally to be replaced. Too low dam ring height will cause higher

vibration and too high dam ring height will cause high motor amps and roller skidding

causing high vibration & lower recirculating loads.

 Too low dam ring height will cause higher vibration and too high dam ring height will

cause high motor amps and roller skidding causing high vibration & lower

recirculating loads.

 Dam ring height optimization is important part of mill operation

 Types of Dam Ring: -Inner and outer

 Inner-Constant; Outer: -Variable(segmented)

The purpose of dam ring is to control material bed thickness over table and allow smooth

discharge of ground material to nozzle ring and maintain stable bed.

 The purpose of dam ring is to control material bed thickness over table and allow

smooth discharge of ground material to nozzle ring and maintain stable bed.

 Height of dam ring mainly depends upon table diameter (2-4% of table diameter) but

in case of larger diameter of table this thumb rule is not applicable.

Armour ring:-
  The smooth velocity profile of gas inside the mill.

 It is necessary to determine on what angle the velocity profile will be smooth inside

the mill body.

 This will reduce the pressure drop across the mill and subsequently reduce

the power consumption.

 vertical wall inclination can be 5 to 15. Armour ring inclination varies from supplier

to supplier.

Rollers: - The roller in VRM are statically mounted and hydraulically tensioned to generate

grinding forces and impart it to the material bed on rotating table. These rollers vary in size,

design and material. For raw grinding the number of rollers varies from 4 rollers to 6 rollers

for higher capacity design. The maximum material feed size to mill also depends on the roller

size, typically 5-7 % of the roller diameter. The mechanism of grinding is by compression &

shear

. There are 4 master rollers, 24 ton per rollers weight. Rollers are used to grind the material in

powder form.

‘’Grinding force Rollers = roller weight+ (pressure) Force’’

Water injector: - It is used to spray water in the table for bed preparation and used to

maintain the outlet temperature of mill. It is used as per moisture content available in the feed.

Rotary tablet:- It is a rotating part of vrm connected to bearing and kept upon thrust pad.

Working of vertical roller mill: -

The raw materials are fed directly to the centre of the grinding plate, which, thanks to

centrifugal forces and the pushing effect of the incoming materials themselves (both fresh and

separator coarse material), are distributed evenly under the grinding rollers. The turning speed

of the grinding plate, together with the pressure of the grinding rollers, create the necessary
friction for grinding the materials. After being ground, the material is transported to the

dynamic separator by the (hot) gas flow, where the selection of the material takes place.

The gas flow, besides transporting the material, performs other important tasks: -

• First material selection; the coarse particles tend to fall back on the Grinding plate.

• Thermal exchange; more efficient compared to tubular ball mills, thanks to the complete mix

of gases and materials.

The grinding process starts with the preparation of the so-called grinding bed, where the

coarse material is crushed. Then the material in compressed and ground by the grinding

rollers. For a stable grinding procedure, the following parameters are important:

• The vibrations of the grinding plate.

• The ΔP of the grinding system.

• The height of the grinding bed (formed by a small border on the grinding plate).

• pressure of the grinding rollers.

Control to parameters: -

Vibration: -

Know the reason of vibration:

•The vibration limit and optimum grinding bed thickness for our mill.

•Avoid magnetic and non-magnetic objects entering Mill.

•Mill neither should be too much full nor too much empty, material should be available at mill

in sufficient quantity for smooth grinding.

•Material will be too much then load of main drive will be high and material will not grind

proper so vibration will increase.

•If material will not at mill, then in low bed height condition vibration will increase.

Δ pressure: -

• Mill ΔP will increase if mill will be full.

•If temperature will be high than ΔP also will be high.

•Flow will be low then material will not be lift so ΔP will increase and reject will also be

increase.

•If temperature will be higher than ΔP will be increase

Height of the grinding bed: -

•Height should be sufficient (70-80mm) for smooth grinding operation.

•If bed height will be less then vibration will be high.

Pressure of the rollers: -

[Link] Pressure:

Established by trials and experience

Seeing the ΔP and power of the mill main drive, we can down rollers.

It can be 66 bars to 100 bars.

Bladder cylinder uses for this type of pressure

It acts on downward direction.

[Link] Pressure:

Accumulator cylinder uses for counter Pressure, and it is filled to nitrogen gas.

It works on rollers upward direction.

Material Scraper: -

The Material scraper is fixed to table bottom and rotating with the table pushing material

which has fallen through the nozzle ring until it falls into the exit chute. This is situated just

below the mill table called gas chamber (mill gas duct) The materials removed from the gas

chamber is being conveyed as an external recirculation and feed to the mill.

Water Injection: -

The purpose of installation water spray is to maintain the stable material bed height over the

table. Indirectly it controls the mill vibration & mill exit temperature. Table water sprays

install on the leading side of the rollers. Injection nozzles should spray onto the material in

front of each roller. Normally it kept 0.75 meter (maximum) above the grinding table but can

be adjusted based on operational experience Higher quantity of water, better the stable bed

formation. However, power absorbed will also increases with higher moisture, so optimization

of water spray to get better grinding efficiency with lower power needs to be done. Water

injection should be kept at close to centre grinding track. Wrong position of water injection

leads to formation of coating over the lances. Quantity of water injection depends on the feed

moisture and granulometry. In any case water spray should not be on roller tire

Separation: -

A sharp separation improves the raw meal quality and avoids over grinding (saving of

energy). Coarse Tailings, fed through the tailings cone to the centre of the grinding table,

helps the formation of a more of the cage rotor speed.

Some major and minor raw materials and their percentage: -

Cao - 44.93

SiO2 - 11.56

Al2O3 - 3.16

Fe2O3 - 1.97

MgO - 0.63

K2O - 0.58

Na2O - 0.02

S03 - 0.06

LSF - 90 to 110 as per coal quality.

Action should be taken during problem-

Symptom Possible cause Corrective action

Low output Worn tires and grinding Replace worn tires and segments
segments
Air flow too low or Adjust air flow accordingly
extremely high
High system pressure drops Analyze pressure profile
Grinding pressure too low Increase the grinding pressure and reset
Grinding pressure too low accumulator
pressure.
Dam ring too low Increase dam ring height
Product too fine Decrease classifier speed.

Excessive Excessive feed Reduce feed rate.

vibration with Sudden change to high Control feed moisture

high bed height moisture feed material

Improper feed distribution Control feed distribution

Sudden change over size Check feed granulometry adjust and
feed correct
 High mill ΔP Low grinding pressure Increase grinding pressure and reset
accumulator pressure
Feed rate too high Decrease feed rate
High internal circulating Take ΔP reading across louver ring and
load classifier to determine problem
Dam ring height too low Increase the dam ring height
Product too fine Decrease classifier speed
Low gas temperature either Increase the inlet gas temperature or
at mill inlet or out let reduce the
fresh air damper.
Separator speed high Decreasing the separator speed up to
minimum permissible limit considering
residue
Low mill ΔP Feed rate too low Increase feed rate gradually
Product too coarse Increase classifier speed
Product too fine Classifier speed too high Decrease classifier speed
Mill air flow too low Increase mill fan air flow
(if rejects present)
Grinding pressure high Decrease the grinding pressure
Product too coarse Classifier speed too low Increase classifier speed
Air flow too high Decrease mill fan air flow
(coarse carryover)

Louver ring velocity too Verify louver ring area for given air
high with proper air flow flow
Grinding pressure low Increase the grinding pressure
Mill High rejects Mill air flow too low. Increase mill fan air flow
Sudden increase in feed Control feed rate
Sudden increase in feed Control feed moisture
moisture.
Low bed formation due to Increase the water flow rate
low water injection
Mill inlet gas temperature Increase mill inlet gas temperature and
low reduce fresh air damper (if required)
Grinding pressure too low. Increase grinding pressure and reset
accumulator
Low dam ring height Increase dam ring height
Louver ring velocity too Verify louver ring area for given air
low with proper air flow flow condition
Low nozzle ring velocity Nozzle ring covered to be adjusted
and material bypass
Mill Inlet In put gas temperature low Check the temperature of hot gas source
temperature low and increase as per requirement
Recirculation damper Decrease opening of recirculation
opening high. damper position as per requirement
Fresh air damper opened Decrease the fresh air damper as per
requirement
\
Data Analysis and Research Methods

The project on Vertical Roller Mills (VRM) at UltraTech Cement Ltd, aiming to provide

comprehensive business and competitor intelligence, would primarily employ a combination

of qualitative and quantitative research methods, relying heavily on secondary data analysis.

Given the nature of the project synopsis, which focuses on delivering detailed insights into the

company's operations, market position, and specific technological applications, the following

methodologies would be central:

 Roller Mill (VRM), including its design, operational parameters, and performance

data, as partially outlined in the project synopsis itself (e.g., VRM model, capacity,

component details, control parameters).

1. Qualitative Data Analysis

Qualitative analysis would be used to interpret non-numerical data and draw insights,

particularly for strategic aspects of the project. This would involve:

 Content Analysis: Systematically analyzing textual information from various sources

(company reports, news articles, interviews if applicable) to identify themes, patterns,

and trends related to UltraTech's business model, strategic initiatives, and market

positioning.

 SWOT Analysis: A structured qualitative method used to evaluate UltraTech Cement's

Strengths, Weaknesses, Opportunities, and Threats based on collected secondary data

and market intelligence.

 Case Study Approach: Given the deep dive into UltraTech Cement Ltd and its VRM

operations, the project essentially serves as a case study, analyzing a specific company

and technology within its industry context to derive broader lessons and insights.
2. Quantitative Data Analysis

Quantitative analysis would be applied to numerical data to identify trends, measure

performance, and support strategic conclusions. This would include:

 Operational Performance Metrics: Evaluating VRM parameters such as capacity

(TPH), power consumption (kW), material percentages, and operational control

parameters (e.g., vibration, pressure drop, grinding pressure) to understand efficiency

and areas for optimization. The project synopsis's inclusion of specific VRM details

and corrective actions for mill problems suggests an analytical approach to operational

data.

 Market Share and Capacity Analysis: Quantifying UltraTech's market share,

production capacity, and growth projections in comparison to competitors and industry

benchmarks.

 Trend Analysis: Using historical data to identify trends in production, sales, and

operational efficiency, often presented through charts and graphs, as explicitly

mentioned in the project aims.

 Conclusion and Recommendations

Conclusion

This project synopsis has provided a comprehensive overview of UltraTech Cement Ltd, its

strategic objectives, market dynamics, and the integral role of Vertical Roller Mills (VRMs) in

its manufacturing processes.

UltraTech Cement stands as a global leader in the cement industry, demonstrating robust

financial performance and an ambitious vision for capacity expansion, aiming to surpass 200

MTPA. The company's strategic focus extends beyond growth to encompass significant

commitments to sustainability, including aggressive decarbonization efforts, green energy

initiatives, and active participation in global climate goals. Its extensive distribution network,

strong brand recognition, and diversified product portfolio underpin its competitive advantage

in the Indian and international markets.

The Vertical Roller Mill (VRM) at UltraTech's Dhar Cement Works exemplifies modern,

efficient grinding technology. VRMs are critical for their energy efficiency, integrating

multiple functions (grinding, separation, drying, conveying) into a single unit, which

contributes to lower operational costs and enhanced productivity compared to traditional

grinding systems. The detailed operational parameters and corrective actions for mill

problems highlight the importance of precise control and continuous optimization for stable

and efficient grinding.

Recommendations

Based on the analysis, the following recommendations are proposed to further enhance

UltraTech Cement's operations and strategic objectives:

1. Continuous VRM Optimization through Advanced Analytics:

a. Recommendation: Implement advanced analytics and predictive maintenance

systems for VRMs to monitor parameters like vibration, pressure drop and

grinding bed height in real-time. This can proactively identify potential issues,

optimize grinding efficiency, and prevent costly downtime.

b. Rationale: While the project synopsis outlines corrective actions, a data-driven

approach can move from reactive problem-solving to predictive optimization,

leading to consistent performance and extended equipment life.

2. Enhanced Focus on Carbon Capture and Utilization (CCU) Technologies:

a. Recommendation: Accelerate investment and research into scalable CCU

technologies beyond pilot projects. Explore partnerships with technology

providers and academic institutions to develop commercially viable solutions

for CO2 capture and its utilization in new products or processes.

b. Rationale: Given UltraTech's commitment to Net Zero Concrete and its

participation in initiatives like the GCCA Climate Ambition 2050, pioneering

CCU will not only meet environmental targets but also create a competitive

differentiator and potentially new revenue streams.

3. Diversification of Energy Mix with Renewable Sources:

a. Recommendation: Continue to aggressively expand the portfolio of renewable

energy sources (e.g., solar, wind) for plant operations. Evaluate opportunities

for captive power generation from renewable sources to reduce reliance on grid

electricity and volatile fossil fuel prices.

b. Rationale: This will further reduce the carbon footprint, enhance energy

security, and contribute to long-term operational cost stability.

4. Strengthening Supply Chain Resilience through Digitalization:

 a. Recommendation: Leverage digital tools and platforms to enhance supply

chain visibility, optimize logistics for raw materials and finished products, and

mitigate risks associated with raw material price fluctuations and disruptions.

b. Rationale: A resilient supply chain is crucial for maintaining operational

efficiency and cost control, especially given the vulnerability to raw material

price volatility.

5. Knowledge Sharing and Best Practices:

a. Recommendation: Establish robust internal platforms for knowledge sharing

regarding VRM operational best practices, energy efficiency gains, and

sustainability initiatives across all UltraTech facilities.

b. Rationale: This will foster continuous improvement, standardize high-

performance operations, and ensure that innovations in one plant can be

rapidly adopted across the entire network.