SUBMITTED BY
BINIL M.S
DERY ANTONY.T
DILIP .S
FREJIN .P. FRANCIS
GEORGE JOSEPH

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ABSTRACT
As leading companies continue to look for innovative ways to reduce costs and increase in production, and labour is one of the main constrain of present time, rail wagon unloading systems are generating more attention. Our project gives a brief overview of unloading coal by BOBRN (Bottom open broad gauge rail) type wagon using track hoppers instead of manual unloading.
INTRODUCTION
1.1 An overview of the company
Malabar Cements Ltd is the only Portland cement manufacturer in Kerala. The company was incorporated in April 1978 commenced commercial production in 1984, with a capital outlay of Rs.680 Million and paid-up equity capital of 260 Million is owned fully by the Govt. of Kerala.
The 1200 Tonnes per day plant at Walayar is continuously running in profit. Geological survey of India has identified a cement limestone in Walayar Reserve Forest way back in 1961-62.The Mineral Exploration Corporation Ltd confirmed its efficiency.
Despite its difficult terrain and perilous conditions at the deposit, Kerala State Industrial Development Corporation (KSIDC) obtained the Industrial License for setting up a unit in November 1976. The Malabar Cements Ltd thus comes into existence at Walayar, Palakkad District.
The company is well equipped to set precedence among public sector unit in the State. A 2.5MW multifold power plant was commissioned in June 1998 to complement 25% of the total power requirement for the Walayar plant operation. The company was updated by the plant with State Art Technology in time.
Belt bucket elevators, Kiln automation, modification to cement mill internals etc are few to mention. The 0.42 Million capacities less than 10% of the cement consumption in Kerala, the company harness the market beyond care segments.
CALCULATION FOR MANUAL COAL UNLOADING
3.1 Time study
• Time of arrival of wagons = 5.30 am
• Time of unloading start = 7.00 am
• Time of unloading finish = 2.40 am
• Time taken for unloading 5 wagons = 50 min
• Dozing time for 5 wagons = 30 min
• Time taken for shifting 5 wagons = 15 min
• Rest time for 5 wagons = 5 min
• Total time for 5 wagons =50+30+15+5
= 100 min
• Total time for 1 wagon = 100/5
= 20 min
• Effective time for unloading 1 wagon of coal
carrying 65T = 20 min
• Time for unloading 59 wagons = 20*59
= 1180 min
• Routine idle time for shunting of rake to
a safe track and detaching of railway
engine (5.30am to 7.00 am ) = 90 min
• Total time for unloading 59 wagons including
routine idle time = 1270 min
= 21 hrs 10 min
• Time allowed by railway without demurrage
for unloading = 9 hrs
• Demurrage time = 12 hrs 10 min
3.2 Cost study
• Rate of unloading charge = Rs 36 /TONNE
• Cost for unloading 1 wagon = 36*65
= Rs 2340
• Cost for unloading 59 wagons = 2340*59
= Rs 138060
• Time allowed without demurrage by railway = 9 hrs
• Extra time taken = 12 hrs
• Rate of demurrage charge = Rs 100 / wagon/hr
• Demurrage charge for 59 wagons for 12 hrs = 100* 59*12
= Rs 70800
• Total cost per rake = 70800+138060
= Rs 208860
• Cost of indigenous coal = Rs 3000/T
• Cost of imported coal = Rs 6300/T
• Yearly consumption of indigenous coal = 60000T/year
• Yearly consumption of imported coal = 40000T/year
• Total consumption of coal = 100000T/year
• Labour cost per Tonne for manual unloading = Rs 36/Tonne
• Labour cost per year for manual unloading
(Excluding demurrage charge) = Rs 36lakhs
• Cost of coal in one year (coal value per year) = Rs 4320lakhs
• Ratio of labour cost to coal value in
manual unloading = 0.83%