rotary presentation february 23th, 2009. pueblo plant overview 89 employees 54 hourly @ $30.59/ hour...

Rotary presentation

February 23th, 2009

Pueblo Plant Overview

89 Employees 54 Hourly @ $30.59/ hour average 35 Salary @ $73,263/ year average 78% Hired Locally

Total Annual Payroll $6,524,422

Taxes $3,400,000 County $700,000 Sales Tax

Pueblo Plant Overview Royalties

$750,000 State Education Fund $32,800 State Education Fund

Purchase Locally $18,000,000 Annually Pueblo County and Colorado

Community Budget $38,950 Annually

GCC Competitive Advantage HP/CI Self Directed Work Teams

Plant Overview

Quarry

• Crushing capacity of 500 tph

• Product size 5” to fines

• Mobile crusher due the type of quarry

Limestone storage

• Continuous stacking and reclaiming

• Blending ratio 8 to 1

• Capacity 17,000 ton

Longitudinal storage

• One stacker for raw materials (Mill scale, Sandstone, kaolin, coal )

• 2 reclaimers (one for raw materials and one for coal)

Raw mill

• 4 materials ( limestone 88%, sandstone 5%, kaolin/clay 5%, mill scale 2% )

• 225tph

•Active vibration damping (AVD) system

Raw mill and Finish mill

Blending silo

• 7,500 ton capacity ( 1.5 days of kiln operation )

• Blending ratio 8 to 1

• 7 programmed outlets to blend the material

Pyro system• 2,900 tpd capacity

• 5 stages preheater with calciner

• Heat consumption 725 kcal/kg

•Friction drive•Tangensial tyre suspension•DeSOx•Low NOx calciner

Kiln Low NOx calciner

Reduction zone At high temperature

Kiln DeSOx system

Dry scrubber for sulfur Fix sulfur in the raw mix avoiding emissions

Kiln Tangential suspension

Free radial expansion of the shell to minimize ovality and maximize refractory life

Bracket are bolted onto the tyre “Dog bone” keep the tyre in position Welded blocks rest on elastic brackets bolted to sides of tire with spring-loaded

wedges in between Spring keeps wedge on position as dimension change with heat expansion

Kiln Friction drive

No lubrication needed usage Roller-tire friction Maintenance free

Clinker cooler• Cools clinker from 2600 F to 150 F

•Mechanical flow regulator system for air control

• Hydraulic drive

•Hydraulic roller breaker

Clinker cooler Mechanical Flow Regulator

( MFR ) system in the cooler Automatic control of cooling air Energy savings Transport separate from cooling

Clinker cooler Hydraulic Roller braker (HRB):

Uniform clinker size of clinker for the finish mill Less maintenance Smooth operation

Coal system

• Capacity 26 tph

• Prepare for high moisture coal grinding

•CO2 system for fire protection

• Coal tube/pipe conveyor

Clinker dome storage• 110,000 ton capacity

• 6 outlets

• Concrete wall design

Finish mill• 180 tph

• Type I/II low alkali cement

• 95% clinker 5% gypsum

•Active vibration damping (AVD) system

Raw mill and Finish mill Active vibration damping system (AVD)

Raise roller to stabilize operation Reduced vibration levels Maintain high mill runtime factor Minimize restarts that affects the main motor Better control of grinding pressure

Cement silos and shipping

• 4 silos 10,000 ton each

• 385 tph loading capacity

• Railcar and truck load spouts

• Certified scales for railcars and trucks

GCC Rio Grande

Pueblo Plant

Team Building

Vision Statement Key on Team Leaders Leadership team Weekly meetings Training No one better than anyone No lies Union defense Pay and Benefits Process Overview General Operations Methodology

VisionWe are a world class producer of quality cement.

We are highly productive and profitable because we are well trained, highly motivated employees who are dedicated to using state-of-the-art technology and continuously improving our processes in a safe and clean environment.

Our commitment to all employees is based on trust, mutual interest, respect and honesty.

We create opportunities that allow all to seek their level of excellence.

We reach our shared vision through a plant wide philosophy that empowers all employees through leadership and the practice of Continuous Improvement.

<<Each team created their own vision aligned to this one>>

Leadership

Key on Team Leaders Lead and understand

Leadership Team Every…is an apprentice

Communication

Weekly meetings Communicate expectations Listen!! Respond with business reasons Reinforce operations values

Safety Environment Equipment Quality Production High Performance and CI

Ownership

NO ONE IS BETTER THAN ANYONE ELSE! Through our actions Communicate all, everything Answer all, everything

ALL RESPONSES- BUSINESS BASED NO LIES!!

Training

Basic platform PCC In house

Specific OJT (L-0, L-1) and Process Operation Guideline (POG) PMR development Equipment parts catalog Sister operations visit/run Vendors

Skilled workforce

Pay and benefits Leader in community

$23.78/ hour average- hourly $73,650 annual average- salary

Expect more Involvement and participation

CI methodology Ideas for improvement JOBS-verification and versatility

Cement manufacturing process

Structure

Plant Leadership Team

S1(6)

S2 (6)

S3 (6)

S4 (6)

Quarry (7) Clin

ker

and

Cem

ent

BU

Maintenance Support

Qualit

y

Shipping RRU (10)

Maintenance Support• One electrician/instrumentation

on each area of responsibility team (3)

PCPACC

Plant MgrENV

HR

HP&ISO

Raw

Mat

eria

ls B

U

Ship

ping

BU

One electrician and one mechanic within each shift team

Adm

in Support

Procurement

Reliability

Raw Materials

Raw Mill-Kiln

Finish Mill-ShippingElectrical Engineer

System administrator

CI Methodology

SET OBJECTIVES IN KEY MEASURES & VISIBLY

MEASURE PERFORMANCE TOWARD THE OBJECTIVE

FOCUS IMPROVEMENT EFFORTS TO IDENTIFY

WHERE, WHAT, & WHEN PROBLEM PATTERNS OCCUR

ANALYZE & SOLVE PROBLEMS TO PREVENTION

RESOLVE PERFORMANCE

ISSUES CONSISTENTLY ORORGANIZE & IMPLEMENT

PROJECTS ON TIME

STEP ONE

STEP TWO

STEP THREE

SET OBJECTIVES IN KEY MEASURES & VISIBLY

MEASURE PERFORMANCE TOWARD THE OBJECTIVE

FOCUS IMPROVEMENT EFFORTS TO IDENTIFY

WHERE, WHAT, & WHEN PROBLEM PATTERNS OCCUR

ANALYZE & SOLVE PROBLEMS TO PREVENTIONRESOLVE PERFORMANCE ISSUES CONSISTENTLYOR

ORGANIZE & IMPLEMENT PROJECTS ON TIME

STEP ONE

STEP TWO

STEP THREE

A disciplined DATA driven process involving every team in the organization