In this case study, we delve into a chronic problem of creeping that plagued one of the cement plants operated by a multinational company. The issue caused extensive damage to various areas, including the rotating kiln, cyclones, and disrupted cement supply, ultimately leading to a loss of customer confidence. The management enlisted the expertise of BiC, a promoter who possessed extensive experience in instrumentation. This article explores the identification, analysis, and resolution of the creeping problem, highlighting the importance of out-of-box thinking and collaborative problem-solving.

A multinational company established a cement plant along with a large chemical plant. The company faced the challenge of utilizing waste as an input to reduce costs and prevent the disposal of limestone into the sea, which was their primary product. The cement plant had a capacity of 1 MMTPA and was operating smoothly. However, over time, both the chemical plant and the cement plant faced a shortage of raw materials, compelling them to explore alternative solutions to avoid waste dumping. The government has put a restriction to dump the effluent into the sea which is triggered to find a solution.