11/28/2016

Industrial tour report on ASKARI CEMENT FACTORY Wah Cantt texila

Submitted to:

study report Askari cement factory wah cantt texila

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Engineer Mujtaba Ashraf

Submitted by: Group Members:

Hafiz Muhammad Amir 2K13-Che-18

Ehsan Elahi 2K13-Che-20

Ch. Sumail Kasana 2K13-Che-21

Nauman Tariq 2K13-che-05

Muhammad Raza 2k13-che-36

Class: Bsc Chemical Engineering

Section : (A)

Session: 2K13-2K17

Department :

Chemical Engineering

NFC Institute of Engineering And Technology, Multan

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ACKNOWLEDGEMENT

The accomplishment of this report was possible only due to the cooperation,

coordination and united efforts of different individuals, several sources of

material, knowledge and time. First of all we want to thank our kind teacher who

gave us an opportunity to groom ourselves. We want to thank the official member

who gave us all the required information.

We are very grateful to the officials of Askari Cement for their guidance,

encouragement and Kind Cooperation.

The moving spirit behind this tour was all of them, without their constant

encouragement and support this tour would not have been a successful outcome.

However, the team work of the members is another key point of the completion of

work.

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Executive Summary

This tour is arrange to us by Sir Mujtaba Ashraf. We start the work on the

project in group. This project has been done in spirit of team work in the group.

The tasks were assigned to each member and all have done their work very well up

to their maximum.

We learned the practical implementations of the topics we studied in the lecture.

As Askari Cement is an significant twig of Cement Industry of Pakistan. There

were very less data available for the selected company on the Web. To get the

information about this company we directly consulted the high officials of the

company. Going with this theme, really gave us good exposure.

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Methodology

Our theme guided us to go mostly for Brain storming. However, along with this we

got a lot of material from the internet. We studied different links and researches

from Web. We went through the reports and project slides of the other companies

working in same business.

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Table of Contents

Sr. No Contents Page No

1 INTRODUCTION 6

2 ASKARI CEMENT LTD., WAH 6

4 ASKARI CEMENT MARKETING 7

5 VISION ANS MISSION 8

6 MARKETING STRATEGY OF ASKARI CEMENT 8

7 PRODUCTS OF ASKARI CEMENT 9

8 QUALITY CERTIFICATES 9

9 PROMPT SERVICE 10

10 CUSTOMER OF MICROTECH ENGINEERING SERVICES 10

11 PRICING STRATEGY 10

12 PLACEMENT 10

13 EXPORT MARKET 12

14 AVAILABILTIY AREA WISE 11

15 PROMOTIONAL STRATEGIES 12

16 WHAT IS CEMENT, USES AND TYPES 13

17 MANUFACTURING PROCESS 14

18 RAW MATERIAL PREPARATTION 15

19 FINISHING,PACKAGING AND DISTRIBUTION 16

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INTRODUCTION

Askari Cement is product of AWT with two factories Askari Cement Ltd Wah and Askari Cement Nizampur. Askari Cement Ltd,Wahis successor of Associated Cement Company. It is the first cement plant in the area now constituting Pakistan. The first plant was set up by famous Bombay based Indian company (Associated Cement company) in 1921 with rated capacity of 120 tons per day. First major expansion was made in 1936 when a kiln of the capacity of 250 tons per day was added followed by enhancement by 300 tons per day in 1950. In 1970 another kiln of 600 tons daily was erected. In 1972 the company was nationalized and put under control of State Cement Corporation of Pakistan in 1974. In 1991 name of the plant was changed to Wah Cement Company. In 1994 the whole old structure and machinery was scrapped prior to start the latest state of the art - FLS Dry Process Plant which was privatized by the Govt. of Pakistan and acquired by Army Welfare trust (AWT) in 1996.

ASKARI CEMENT LTD., WAH

These plants have been designed by the world’s best global engineering companies like

FL Smidth of Denmark M/s Holder Bank Consultants of Switzerland M/s Tianjin Cement Design & Research institute, China M/s China Building Material Industrial Corporation (CBMC)

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After acquisition of the FLS Dry process Plant, AWT changed name of the brand to Askari Cement. The plant installed in 1994 is the latest 3000 tons per day single production line designed by FL Smidth of Denmark and M/s Holder Bank Consultants of Switzerland-two renowned names of the Cement world. The capacity of the plant has been enhanced by another 500 tons per day, by which the capacity comes to 3500 tons per day w.e.fjan 2006. Askari Cement has the credit of being the first in the cement industry to get ISO 9001, and now the first to get the ISO-14001 Environment Friendly Standards Certification in Pakistan.

ASKARI CEMENT MARKETING

It is a setup, established to manage the market of the Askari cement. The selling of the product of both the industrial units of Askari Cement is done through this organization.

All the orders are placed with this Askari Marketing to regulate the supply of the cement. It decides whether order is to be delivered from the Nizampur or from Wah factory. The option is also available with the clientele.

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VISION

To transform Askari Cement Marketing into model Cement Marketing Unit as part of worldwide construction activities. Strive hard for optimizing and expanding business in terms of “Brand Image, Business Growth and Increased Revenues”.

MISSION

Manage and operate Askari Cement Marketing in a manner that it achieves continuous growth and profitability, without any risk for customers or employees, with a view to achieving a status of “Best Marketing Unit” in the Cement Industry.

Marketing Strategy of Askari CementThe main focus of Askari cement is not mainly on the general public for sales, but they mainly focus the big projects (government and private sector) and exporting their product to other countries.

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Quality certificates

Products of Askari Cement

Askari Cement Wah

Askari Cement Nizampur

Concrete Cement

Faulad Cement

Askari Green

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Askari for Indi

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Strenght of the Cement:-

Gains highest strength of 9000 PSI and more against 5950 PSI required by British

Standards. The fineness around 2900-3000 cm sq/gm against 2250 cm sq/gm under

British Standards also contributes to the strength

Prompt Service:

They claim: Customer satisfaction through prompt professional response is our

hallmark.

Customer of MicroTech Engineering Services:

Askari cement is the worthy customer of the MicroTech Pakistan. This company tends

to provide value solutions by managing projects to ensure success, safety,

craftsmanship and value, while generating opportunities through long-term customer

relationships.

Pricing StrategyThe Askari Cement has made strategy to keep its cost in a way which is not standing equivalent to their manufacturing price. Instead they charge little more than their competitors. Currently, they are charging 445RS for 50 KG bag. However, the average price of the same quantity bag is almost 435RS. So we can regard it as a high price cement. This cost may increase or decrease accordingly.

PlacementBoth the industrial units of Askari cement are situated in the north area. Talking about their marketing strategy, they do not try to place their product in the southern area of Pakistan. They place their product only in the Northern Sector.

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The map of their target area is given as under.

Askari Cement is the largest exporting cement of pakistan. It export cement in bulk to the other countries every year.

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This cement is being exported in the following areas:

EXPORT MARKET

Afghanistan Sri Lanka

IraqUAE

India South Africa

Sudan Bangla Desh

The main focus of Askari Cement is to capture the Government and Private construction projects. They supply their product to following construction sites.

Promotional StrategiesFor the promotionof product in the general public, the Askari Cement does not perform any special activity, because general domestic consumers are not their main

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focus. However, they have an organization i.e., Askari Marketing, through which their promotional campaigns are lead.

Conversely, they do certain business tricks to not lose the contract of cement supply to the big government and private projects.

What is cement?

The word Cement has come from the Roman word ‘Opus Caementicium’

Cement is a binder, a substance that sets and hardens independently, and can bind other materials together.

The most important use of cement is the production of mortar and concrete—the bonding of natural or artificial aggregates to form a strong building material that is durable in the face of normal environmental effects.

Joseph Aspdin, a British stonemason, invented Portland cement way back in 1824. With this invention, Aspdin laid the foundation of today’s cement industry.

Uses of cements:

• Production of Concrete

• Construction Purpose

o Building (Floors, Beams, Columns, Roofing)

o Transport (Roads, Pathways, Crossings, Bridge)

o Water (Pipes, Drains, Canals)

o Agriculture (Irrigation, Housing)

The types of cements

• Ordinary Portland Cement (OPC)

• Portland Pozzolana Cement (PPC)

• Portland Blast Furnace Slag Cement (PBFS)

• Oil Well Cement

• Rapid Hardening

• Sulphate Resisting Portland Cement

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• White Cement etc.

Manufacturing process:

Cement is made out of limestone, shale, clay mined out of quarry close to the plant. The raw material is crushed, and then heated at temperature in excess of 1000 degree Celsius in rotating kiln to become clinker. Clinker is then mixed with gypsum and ground to a fine powder to produce final grade of cement.

The technology is a continuous process and is highly energy intensive.

Cement is a fine, soft, powdered substance, made from a mixture of elements that are

found in natural materials such as limestone, clay, iron ore and sand. When cement is

mixed with water, it can bind sand and turns into a hard, solid mass called concrete.

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Raw Material Preparation

The key element – Limestone and clay are mined through blasting from rock quarries

by setting off explosives. Limestone and clay contains calcium, silicon, aluminum and

iron, which are the essential elements for cement manufacturing. Latest technology is

used for blasting so as to ensuring vibration, dust, and noise emissions are kept at a

minimum level. Blasting produces materials in a wide range of sizes from

approximately 1.5 meters in diameter to smaller particles less than a few millimeters

in diameter. Quarried material is the loaded into trucks or belts for transportation to

the crushing plant. Through a series of crushers and screens, the Limestone is reduced

to a size less than 100 mm and is stored until required.

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Pre - Homogenization

In the dry process, each raw material is proportioned to meet a desired chemical

composition and fed to a vertical steel mill. The raw materials are dried with waste

process gases and grinded through the pressure exerted by three conical rollers in a

rotary kiln. The rotary kiln is fired with an intense flame produced by burning coal,

coke, oil, gas or waste fuels. The dry materials exiting the mill are called "kiln feed".

The kiln feed is pneumatically blended to ensure the chemical composition is well

homogenized and is then stored in separate silos until required.

Basic chemical reactions that take place in the kiln, at 1400 °C are: Evaporation of

moisture, calcinations of the Limestone to produce free calcium oxide and reaction of

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the calcium oxide with other materials (sand, shale, clay, and iron). This results in a

final, nodular, red-hot product known as "Clinker" which is 3 – 4 centimeters in

diameter and can be stored for several months.

Finishing, Packaging and Distribution

The clinker is cooled and grinded into a fine grey powder. The grinding is done

through different-size steel balls. A small amount of gypsum and other process are

also added during the final grinding. The amount of gypsum and process added during

the process varies in all of the final cement products. Each cement product is stored in

an individual silo from where it is transported to packaging facility for either sack –

packaging or bulk transportation. Bulk cement is distributed through bulkers or is

shipped; depending on the customer's needs.

Reference:www. askaricement .com.pk/Acl Wah .html

www.slideshare.net/shreenathbohra5/cement-manufacturing-process

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