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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

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  1. Rotary presentation February 23th, 2009

  2. 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

  3. 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

  4. Plant Overview

  5. Quarry • Crushing capacity of 500 tph • Product size 5” to fines • Mobile crusher due the type of quarry

  6. Limestone storage • Continuous stacking and reclaiming • Blending ratio 8 to 1 • Capacity 17,000 ton

  7. Longitudinal storage • One stacker for raw materials (Mill scale, Sandstone, kaolin, coal ) • 2 reclaimers (one for raw materials and one for coal)

  8. Raw mill • 4 materials ( limestone 88%, sandstone 5%, kaolin/clay 5%, mill scale 2% ) • 225tph • Active vibration damping (AVD) system

  9. Raw mill and Finish mill

  10. Blending silo • 7,500 ton capacity ( 1.5 days of kiln operation ) • Blending ratio 8 to 1 • 7 programmed outlets to blend the material

  11. 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

  12. Kiln • Low NOx calciner • Reduction zone • At high temperature

  13. Kiln • DeSOx system • Dry scrubber for sulfur • Fix sulfur in the raw mix avoiding emissions

  14. 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

  15. Kiln • Friction drive • No lubrication needed usage • Roller-tire friction • Maintenance free

  16. Clinker cooler • Cools clinker from 2600 F to 150 F • Mechanical flow regulator system for air control • Hydraulic drive • Hydraulic roller breaker

  17. Clinker cooler • Mechanical Flow Regulator ( MFR ) system in the cooler • Automatic control of cooling air • Energy savings • Transport separate from cooling

  18. Clinker cooler • Hydraulic Roller braker (HRB): • Uniform clinker size of clinker for the finish mill • Less maintenance • Smooth operation

  19. Coal system • Capacity 26 tph • Prepare for high moisture coal grinding • CO2 system for fire protection • Coal tube/pipe conveyor

  20. Clinker dome storage • 110,000 ton capacity • 6 outlets • Concrete wall design

  21. Finish mill • 180 tph • Type I/II low alkali cement • 95% clinker 5% gypsum • Active vibration damping (AVD) system

  22. 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

  23. 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

  24. GCC Rio Grande Pueblo Plant

  25. 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

  26. Vision We 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>>

  27. Leadership • Key on Team Leaders • Lead and understand • Leadership Team • Every…is an apprentice

  28. Communication • Weekly meetings • Communicate expectations • Listen!! • Respond with business reasons • Reinforce operations values • Safety • Environment • Equipment • Quality • Production • High Performance and CI

  29. Ownership • NO ONE IS BETTER THAN ANYONE ELSE! • Through our actions • Communicate all, everything • Answer all, everything • ALL RESPONSES- BUSINESS BASED • NO LIES!!

  30. 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

  31. 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

  32. Cement manufacturing process

  33. Structure Shipping BU Shipping RRU (10) Quality Admin Support HP&ISO Plant Leadership Team Procurement Plant Mgr Reliability ENV HR PC PACC Raw Materials Maintenance Support Raw Mill-Kiln Raw Materials BU S1(6) Clinker and Cement BU Electrical Engineer Finish Mill-Shipping S2 (6) Quarry (7) System administrator S3 (6) • Maintenance Support • One electrician/instrumentation on each area of responsibility team (3) One electrician and one mechanic within each shift team S4 (6)

  34. CI Methodology A disciplined DATA driven process involving every team in the organization

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