A

Practical Training Report

On

“CEMENT MANUFACTURING”
At
“UltraTech Nathdwara Cement Limited, PINDWARA”
Submitted in Partial Fulfilment for the Award of degree of

Bachelor of technology
in
Electrical Engineering

(Session 2019-2020)

SUBMITTED TO: SUBMITTED BY:

Mr. Udit Mamodiya Shrawan Suthar
Mr. Rajendra Singh (PIET/16/EE/047)
(Coordinator- Industrial Training)

POORNIMA INSTITUTE OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF ELECTRICAL ENGINEERING
ISI 06, RIICO INSTITUTIONAL AREA
Jaipur-302022
 DECLARATION

I hereby declare that the work which is being presented in the Practical Training & Industrial
visit report titled Cement Manufacturing in partial fulfilment for the award of the Degree of
Bachelor of Engineering in Electrical Engineering and submitted to the Department of Electrical
Engineering, Poornima Institute of Engineering & Technology, Jaipur , Jaipur, is an authentic
record of my own work carried out at UltraTech Nathdwara Cement Ltd. during the session
2019- 20 (Even Semester).

I have not submitted the matter presented in this report anywhere for the award of any other
Degree.

Signature of the Student with Name & Reg.

No.: Place:

Date:

Enclosed: Training Certificate from Company

ii
iii
 DEPARTMENT OF ELECTRICAL ENGINEERING

CERTIFICATE

This is to certify that Practical Training & Industrial visit report titled has been
submitted by Shrawan Suthar (PIET/16/EE/047) in partial fulfilment for the award of
the Degree of Bachelor of Engineering in Electrical Engineering during the session
2019-20, Even Semester. The Practical Training & Industrial visit work is found
satisfactory and approved for submission.

Mrs Shuchi Shukla Dr. Dinesh Goyal

(HOD, EE Department) (Campus Director, PIET)

Date:-
Place: Jaipur

iv
 ACKNOWLEDGMENT

I feel profound happiness in forwarding this industrial training report as an image of

sincere effort. It is almost inevitable to ensure indebtedness to all who generously helped
by sharing their valuable experience and devoting their precious time with me, without
whom this seminar report would have never been accomplished.

First and foremost I extend my thanks and gratitude to the entire unit of “Cement
Manufacturing” along with “Mr. Vishnu Prakash Sharma”, whose guidance, teaching
and invaluable suggestions provided me a deep inside in my chosen field of technology,
enhanced my knowledge and support in widening my outlook towards the electrical
industry. I am also very thankful to all engineers of the department for their kind support
through the training.

I highly intend to Dr. Dinesh Goyal (Campus Director, PIET), Mrs. Shuchi Shukla
(HOD, Dept. of EE), Mr. Vishnu Prakash Sharma (Assistant Professor), Mr. Udit
Mamodiya (Assistant Professor), Mr. Rajendra Singh (Assistant Professor) for
providing me the desired platform and deliver the learning in an effective and efficient
manner.

Shrawan Suthar
IV Year EE
(PIET/16/EE/047)

v
 PREFACE
The industrial training is one of the necessities of engineering courses. It is aimed to
provide the students of an engineering professional course with some industrial exposure.
Students are expected to learn the technical aspects of the theoretical knowledge taught
in the courses applied in the industries.

I selected UltraTech Nathdwara Cement Limited for training purpose. It is relatively new
cement plant and hence uses some of the recent evolved technologies and is fully
automated, giving more exposure and knowledge of the modern technologies.

The training report consists of various sections. The first one being brief description of
the development of plant and details about the company. Second one gives brief
description of the process and working required for cement production and finally
description of the role of electronic instruments and applied electronics being used in
cement plants.

Shrawan Suthar
IV Year EE
(PIET/16/EE/047)

vi
 LIST OF CONTENT

CHAPTER TOPIC
PAGE
NO.
TITLE i

DECLARATION ii

COMPANY CERTIFICATE iii

COLLEGE CERTIFICATE iv

ACKNOWLEDGMENT v

PREFACE vi

LIST OF CONTENT vii-viii

LIST OF FIGURES ix-x

ABSTRACT 1

1. 1.1 COMPANY PROFILE 2

INTRODUCTION 1.1.1 Introduction 2
1.1.2 Company History 3
2. 2.1 CEMENT 5
TRAINING 2.1.1 Introduction 5
DISCRIPTION 2.1.2 Raw Materials Extraction 6
2.1.3 Raw Materials Preparation 6
2.1.4 Clinker Burning 6
2.1.5 Cement Milling 6
2.2 CRUSHING PLANT 7
2.2.1 Introduction 7
2.2.2 Equipment & Flow Diagram 8
2.2.3 Unloading Hopper 8
2.2.4 Apron Feeder 8
2.2.5 Jaw Crusher 9
2.2.6 Features of Jaw Crusher 9
2.2.7 Structure of Jaw Crusher 10
2.2.8 Working Principle of Jaw 10
Crusher
2.2.9 Hammer Crusher 11
2.2.10 Working Principle of 11
Hammer Crusher
vii
 2.2.11 Vibrating Screen & DSM 12
Screen
2.2.12 Raw Material Handling 12
Section
2.3 RAW MILL 13
2.3.1 Introduction 13
2.3.2 Decanter and DP Tank 15
2.3.3 Feeder 16
2.3.4 Layout of Raw Mill 16
2.3.5 DSM Screen 18
2.3.6 Slurry Mixer Tank 18
2.4 KILN SECTION 19
2.4.1 Introduction 19
2.4.2 Kiln Shell 19
2.4.3 Refractory Lining 20
2.4.4 Tyres & Rollers 20
2.4.5 Drive Gear 21
2.4.6 Internal Heat Exchangers 21
2.4.7 Other Equipment 22
2.4.8 Thermal Efficiency 22
2.4.9 Principle of Operation 22
2.5 ELECTROSTATIC 23
PRECIPITATOR
2.5.1 Introduction 23
2.5.2 Collection Efficiency 24
2.5.3 Advantages of ESP 25
2.6 CLINKER COOLER & COAL 25
SECTION
2.6.1 Introduction 25
2.6.2 VSI Crusher 26
2.6.3 Cement Silos 27
2.7 CEMENT MILL 28
2.7.1 Introduction 28
2.7.2 Materials Ground 28
2.7.3 Temperature Control 29
2.8 PACKAGING PLANT 29

2.9 QUALITY CONTROL 31

3. CONCLUSION 3.1 CONCLUSION 32

3.2 REFERENCES 33

viii
 LIST OF FIGURES

FIG.NO. TOPIC PAGE NO.

2.1 LAYOUT OF CEMENT MANUFACTURING 7
PLANT

2.2 FLOW DIAGRAM OF CRUSHING PLANT 8

2.3 APRON FEEDER 9

2.4 JAW CRUSHER 10

2.5 RING HAMMER CRUSHER 11

2.6 RECLAIMER AND STACKER 12

2.7 RAW MILL 13

2.8 LAYOUT OF RAW MILL 14

2.9 DP TANKS 15

2.10 DECANTER 15

2.11 LAYOUT OF MILL 17

2.12 DSM SCREEN 18

2.13 SLURRY MIXER TANK 18

2.14 KILN 19

2.15 TYRES AND ROLLERS 21

2.16 REFRACTORY LINING 21

2.17 WORKING OF ESP 24

2.18 VSI 26

2.19 SILO 28

2.20 PACKAGING MACHINE 30

ix
 ABSTRACT

Cement is a binding material that has a property to act as binder, sets and hardens to bind
material together. Cement is essentially a binding material used for making concrete,
which in turn the basic material for building dams, bridges and other construction works.
Cement has an exceptional strength under compressive loads and also it can take any
shape.

Grade of cement alters as the composition of additives varies and also on the excipients
used in milling. This report gives brief introduction to cement manufacturing process
which involves Mining of Limestone, Raw material preparation & storage, Fuel
preparation, Clinkering (Pyro section), Cement Grinding & Packing & Dispatching.

The manufacture of cement is a very carefully regulated process comprising the

following stages:

1. Quarrying - a mixture of limestone and clay.

2. Grinding - the limestone and clay with water to form slurry.

3. Burning - the slurry to a very high temperature in a kiln, to produce clinker.

4. Grinding - the clinker with about 5% gypsum to make cement.

1
 CHAPTER 1
1.1 COMPANY PROFILE: - UltraTech Nathdwara Cement Ltd.

1.1.1 Introduction: -
Ultratech cement limited was established in 1996. It has two units, 1 of which was
recently set up in 2007. The total capacity of the plant is 6.25 million tonnes per year. The
cement plant is situated near Pindwara in Sirohi district Rajasthan.

Ultratech Cement Limited is the flagship subsidiary of Ultratech Industries Limited

(BIL), representing the Aditya Ultratech Group. The cement business started operations
in 1997, in Sirohi District, Rajasthan with a 1.65 MTPA integrated cement facility and a
55 MW captive power plant with technological support from F. L. Smidth, Denmark and
Larsen & Toubro Ltd.

The capacity was raised to 2.25 MTPA in 2005 through advanced in-house R&D and de-
bottlenecking and the Company was also certified to ISO 9001, ISO 14001 and OHSAS
18001 within a short span from commencement of operation. This is an achievement that
clearly illustrates the management's commitment to quality, efficiency, environment,
health and safety. In 2008, a split-grinding unit at Neem Ka Thana was commissioned,
boosting the capacity in India to 6.25 MTPA.

The power consumption of the cement plant is around 80 units per ton of cement
produced. The turnover of the cement plant is around 1800 Cr per annum.

The cement plant produces 3 different grade cements differing on quality, namely

1. 43 grade
2. 53 grade
3. PPC
The Company has operations in India, China and Dubai where it has already scripte
d a success story. It has now set its sights on emerging markets in Africa. For the Ult
ratech Group, cement business is a means to transform imagination and vision into r
eality. Ultratech Cement has already set global benchmarks, in its existing operation
s and is poised to achieve the same stature worldwide.

2
1.1.2 Company History -
BCL is the flagship company of the Binani group which has diverse manufacturing
interests in cement, zinc and glass fibre. The Company was incorporated in Kolkata, West
Bengal on January 15, 1996 as Dynasty Dealer Private Limited. The name of the
Company was changed to Binani Cement Private Limited and a fresh certificate of
incorporation was issued to it by the RoC on April 23, 1998. Subsequently, the Company
was converted into a public company and the name was changed to Binani Cement
Limited vide a fresh certificate of incorporation dated October 6, 1998. The Company's
Registered Office is at 706, Om Tower, 32, Chowringhee Road, Kolkata - 700071. The
Company's Corporate Office is at Mercantile Chambers, 12 J.N Heredia Marg, Ballard
Estate, and Mumbai- 400001.

The Company's cement plant is in Pindwara, District Sirohi, Rajasthan. The main plant
and machinery has been supplied by M/s F L Smidth, Denmark along with their then
Indian Associates M/s. Larsen and Toubro Ltd. The Sirohi facility is located on the
Mumbai - Ahmedabad - New Delhi highway at a distance of 2.5 km from the New Delhi
- Ahmedabad rail line and approximately 435 km from Kandla Port. The Company
commenced commercial production at the plant on November 1, 1997.

The Company filed a scheme of amalgamation under Section 391 of the Companies Act
before the High Court of Calcutta for merger with Munga Holdings Limited ("MHL").
The High Court of Calcutta approved the scheme on January 16, 2001. However, due to
the delay in obtaining the approval from lenders of the Company, the scheme of
amalgamation became effective only in September 2003 pursuant to which MHL was
merged with the Company. The amalgamation was made effective from April 1, 2000.

In September 2005, the promoter BIL sold 50,775,318 Equity Shares held by it in the
Company (representing 25% of the equity share capital of the Company) to Silver Peak
Investments (Mauritius) Limited, subsequently renamed as JPMSSM for an aggregate
consideration of Rs. 1.2 billion. As a result of the purchase, JPMSSM has also been
granted certain rights in the Company such as the right to nominate one director on the
Board of Directors of the Company. For further details, please refer to the section "History
and Certain Corporate Matters - Acquisition of Shares by JPMSSM" on page 67 of this
Draft Red Herring Prospectus. JPMorgan Special Situations Asia Corporation has also

3
extended a Term Loan of Rs. 1.3 billion to the Company through its Indian affiliate, J.P.
Morgan Securities India Private Limited towards part financing the Company's expansion
project. On October 17, 2006, J.P. Morgan Securities India Private Limited has intimated
its intention to assign its rights with respect to the Term Loan to its affiliate, JPMorgan
Chase Bank, National Association, Mumbai branch. The Board of Directors of the
Company has taken note of the proposed assignment.

In August 2006, BIL sold 20,500,000 Equity Shares to GPHL for Rs. 1.4965 billion. For
further details, please refer to the section "History and Certain Corporate Matters -
Acquisition of Shares by GPHL" on page 68 of this Draft Red Herring Prospectus. The
Board of Directors of Binani Industries Limited ("BIL") has approved a swap of upto
50% equity shares of the issued share capital of BIL held by its members for the equity
shares of the Company and BZL held by BIL ("Scheme"). Consequent to such share swap,
shareholders of BIL will have an option to receive Equity Shares of the Company and
BZL while their shareholding in BIL will stand cancelled and they will cease to be
shareholders of BIL. The swap ratio has been fixed at 25 existing fully paid Equity Shares
of the Company and 25 existing fully paid equity shares of BZL of Rs. 10 each for every
20 existing fully paid equity shares of Rs. 10 each of BIL. The swap ratio has been arrived
at on the basis of the valuation report by N M Raiji and Co and fairness report of Kanu
Doshi and Associates. The Scheme under Section 391 and other applicable provisions of
the Companies Act has been approved by the Bombay Stock Exchange (BSE) and the
Calcutta Stock Exchange (CSE) and has been filed with the High Court of Calcutta for
its approval. The court convened meeting of shareholders of BIL was held on June 6,
2006 and the shareholders approved the scheme. The final court order is awaited. The
eligible number of equity shares of BIL available for swap is upto 14,798,212 (being 50%
of the total paid up equity shares of BIL). In the event that the High Court of Calcutta
grants its approval and upon the Scheme becoming effective in accordance with its terms,
upto 18,497,765 Equity Shares of the Company held by BIL may be offered to the
shareholders of BIL in exchange for upto 14,798,212 equity shares of BIL held by them.

4
 CHAPTER-2
2.1 CEMENT:-
2.1.1 Introduction
Cement is a binder, a substance that sets and hardens and can bind other materials
together. Cement is essentially a binding material used for making concrete, which in turn
the basic material for building dams, bridges and other construction works. Cement has
an exceptional strength under compressive loads and also it can take any shape.

Types of cement

 Ordinary Portland cement (OPC)

 Portland pozzolona cement (PPC)
 Sulphate resisting cement
 Rapid hardening cement
 Oil well cement
 Masonry cement
 Portland blast furnace slag cement
 Super Sulphate cement
 High alumina cement
 White grade cement
 Quick setting cement
 Hydrophobic cement
 Silver grade cement

There are three processes of manufacturing cement which are known as the wet, dry, and
semidry processes and are so termed when the raw materials are ground wet and fed to
the kiln as slurry, ground dry and fed as a dry powder, or ground dry and then moistened
to form manufacturing of cement.

In Ultratech cement limited cement is manufactured via wet process.

The manufacture of cement is a very carefully regulated process comprising the following
stages:

1. Quarrying - a mixture of limestone and clay.

5
2. Grinding - the limestone and clay with water to form slurry.

3. Burning - the slurry to a very high temperature in a kiln, to produce clinker.

4. Grinding - the clinker with about 5% gypsum to make cement.

2.1.2 Raw Materials Extraction

The limestone and clay occur together in quarries. It is necessary to drill and blast these
materials before they are loaded in trucks. The quarry trucks deliver the raw materials to
the crusher where the rock is crushed to smaller than 12mm. The raw materials are then
stored ready for us.

2.1.3 Raw Materials Preparation

About 80% moisture contained slurry comes from carbide plant and acetylene plant,
which is the by-product of those plants. Adjusting the relative amount of limestone and
clay being used very carefully controls the chemical composition of the slurry. The
slurry is stored in large basins ready for use known as decanter and DP tanks and then
further fined by raw mill.
2.1.4 Clinker Burning

The slurry is fed into the upper end of a rotary kiln, while at the lower end of the kiln; a
very intense flame is maintained by blowing in finely ground coal. The slurry slowly
moves down the kiln and is dried and heated until it reaches a temperature of almost 1500
degrees Celsius producing "clinker". This temperature completely changes the limestone
and clay to produce new minerals, which have the property of reacting with water to form
a cementations binder. The hot clinker is used to preheat the air for burning the coal, and
the cooled clinker is stored ready for use.

2.1.5 Cement Milling

The clinker is finely ground with about 5% gypsum in another mill, producing cement.
(The gypsum regulates the early setting characteristic of cement). The finished cement is
stored in silos then carted to our wharf or packing plant facilities.

6
 Figure 2.1: Process layout of cement manufacturing

2.2 Crushing Plant:-

2.2.1 Introduction

The crushing plant receives limestone from mines and in two stages operation crushes it
into size of 12mm. there are two crushers, primary crusher of L&T (double toggle jaw
crusher) and secondary crusher of Economic (Hammer crusher). Crushers have capacity
of 100 ton per hour and are driven by 132 KW motors. The crushed limestone is stored
in yard of 2 miles.

7
2.2.2 Equipment & Flow Diagram

Unloading Hopper

Apron feeder

Jaw Crusher

C-1 Conveyer

C-2 Conveyer

Intermideate hopper

vibro feeder

Hammer Mill

C-3 Conveyer

Vibrating screen

C-4 Conveyer

Stacker system

Figure 2.2: Flow Diagram of Crushing Plant

2.2.3 Unloading hopper

The limestone from Bundi and Ramganjmandi comes into plant in loaded trucks and is
unloaded here in the chambers having rectangular sections .The capacity of Unloading
Hopper is 60 Metric ton.

2.2.4 Apron feeder

Apron feeders were designed for uniform and regulated feed of loose and lump materials
from feed bin to crushing aggregates and transporters of different types. The transporting
cloth of apron feeders is a closed circuit, consisting of plates, which are connected
hingedly. The productivity of feeders is regulated at the expense of cloth speed changing
and size of bin outlet. The transporting cloth is activated with drive sprocket; direction
and chain supporting are implemented with the shaped rolls. To regulate the cloth tension
the screw mechanism of back sprocket movement is used.The capacity of Apron feeder
is 150 tons per hour.

8
 Figure 2.3: Apron feeder

2.2.5 Jaw Crusher:

Jaw crusher is also named jaw breakers, rock crusher, or rock breaker. Jaw crusher is
mainly used to primarily and secondarily crush many kinds of mining rocks, and the
highest anti-pressure strength of crushed material is 320Mpa.

2.2.6 Features of Jaw Crusher:

 Simple structure, reliable working condition, easy maintenance, low operating

costs;
 High crushing ratio, even final particle size products;
 Deep broken cavity, no dead zone, increased capacity;
 Safe and reliable lubrication system, convenient replacement parts;
 Stand-alone energy-saving 15% ~ 30%;
 The discharging size of jaw crusher can be adjusted to meet the users' different
requirements.

9
2.2.7 Structure of Jaw Crusher:
The structure of jaw crusher: main frame, eccentric shaft, a large belt pulley, fly wheel,
swing jaw, side guard plate, toggle plate, Rear bracket, adjust gap screw, reset spring,
and fixed jaw and swing jaw board etc., and the toggle plate also plays a role of
protection. The length of toggle is 898 mm (movable jaw) and 790 mm (fixed jaw).

Figure 2.4: Jaw crusher

2.2.8 Working Principle of Jaw Crusher:

 The motor drives the movable jaw plate to do periodic motion towards the fixed
jaw plate by the eccentric shaft.
 The angle between toggle plate and movable jaw plate increases when movable
jaw plate moves. So the movable jaw plate moves towards the fixed jaw plate.
 The material between the movable jaw plate and fixed jaw plate will be crushed
in this process. The angle between toggle plate and movable jaw plate decreases
when movable jaw plate moves down, the movable jaw plate move leaves fixed
jaw plate by pulling rod and spring, the final crushed material will be discharged
from the outlet. The capacity of Jaw Crusher is 130 tons per hour.

10
2.2.9 Hammer crusher:
Hammer crusher is a kind of machine widely used in crushing medium hardness materials
such as Limestone, slag, coke and coal in Cement, chemical industry, electric power,
metallurgy, etc. Hammer crusher broken materials mainly rely on impact. The crushing
process is roughly like this, materials into the hammer crusher, and broken by the impact
of high-speed rotary hammerhead. Then the broken materials obtained kinetic energy
from the hammerhead and rushed to frame and screen with high speed.

Figure 2.5: Hammer crusher

The materials collisions with each other at the same time, after repeatedly broken, the
materials less than sieve article education from the gap. Individual larger materials impact
by the hammerhead again, grinding, extrusion and broken. At last, deduction from the
gap. Thus obtaining products with required size. It is made by manganese steel.

2.2.10 Working principle of Hammer Crusher

The main working part of the Crusher is the rotor with hammer rings. The rotor is
consisted of hammer ring shaft and the ring hammer, etc. The rotor driven by motor
rotates at a high speed in the crushing chamber. The materials are conveyed into the
chamber from the top inlet, then impact by the high-speed rotating hammer ring, thus
crashed, squeezed ground among the materials and finally achieved the goal of crushing.
At the bottom of the rotor, there are grate plate equipped, the crushed materials which

11
smaller than the grate hole size can be discharged through the grate plate, while the larger
ones will be crushed by the hammer ring till the required size and be discharged. The
capacity of Hammer mill is 130 tons per hour.

2.2.11 Vibrating screen or DSM screen

The function of DSM (Dynamic screen manager) screen is to only pass the particles with
size of not more than 12mm. It consists of vibration damper of 6-12 mm. The rejected
particles are again feed into crusher and the remaining is sent to the yard via belts. Before
coming to screen the particles are moved below the magnetic separator so that all particles
with magnetic properties shall be kept aside from the process. After the screen there is
placed a dust collector.

2.2.12 Raw material handling section

The stored limestone is reclaimed is from yard by the help of reclaimed. This equipment
is supplied by space age limited. Its capacity is 100 ton per hour. The reclaimer shaves
one side of the pile in such manner that further blending of Limestone occurs. The
reclaimed limestone is conveyed to the raw mill through belts.

Figure 2.6: Reclaimer & Stacker

12
 2.3 Raw Mill:-
2.3.1 Introduction
A Raw mill section used to grind raw materials into " rawmix" during the manufacture of
cement. Rawmix is then fed to a cement kiln, which transforms it into

Clinker, which is then ground to make cement in the cement mill. The raw milling stage
of the process effectively defines the chemistry (and therefore physical properties) of the
finished cement, and has a large effect upon the efficiency of the whole manufacturing
process.

Figure 2.7: Raw Mill

13
 slurry from carbide
plant

decanter

DP Tank2
DP Tank1

crushed
Drum Filters limestone from
crushing plant

feeder

Raw mill

DSM Screen

Slurry mixer tank

Figure 2.8: process layout of Raw Mill

14
2.3.2 Decanter and DP Tank
Calcium hydroxide sludge available from acetylene plant is pumped into the decanter.
The decanter is a large tank with a diameter of 25 m .it is operated on recirculation till
sludge of 68% - 69% moisture is reached in the outlet. The decanter sludge is than pumped
into DP Tank (Daily precipitation tank). There are two such tanks having capacity of 600
m3/hour. Here, sludge is continuously agitated to that sludge doesn’t solidify. From
decanter, sludge is also sent to lagoons where it is naturally decanted over the years before
cement plant inception. Mechanical shovel and dumpers do this. The pumping capacity
of DP Tank is 65m3/hour .it pumps the sludge to the feeder on the top of the Raw mill
building.

Figure 2.9: DP Tanks

Figure 2.10: Decanter

15
2.3.3 Feeder
The feeder is a ferries wheel driven by a variable DC drive. There are three hoppers in a
raw mill building .one for the limestone received from the yard after proper blending,
second for high grade limestone used sometimes to improve the limestone content to the
burn ability or melting characteristics of raw mix the clinkerization section.

2.3.4 Layout of Raw mill

A Raw/Ball mill is a horizontal cylinder partly filled with steel balls (or occasionally other
shapes) that rotates on its axis, imparting a tumbling and cascading action to the balls.
Material fed through the mill is crushed by impact and ground by attrition between the
balls. The grinding media are usually made of high-chromium steel. The smaller grades
are occasionally cylindrical ("pebs") rather than spherical. There exists a speed of rotation
(the "critical speed") at which the contents of the mill would simply ride over the roof of
the mill due to centrifugal action. The critical speed (rpm) is given by: nC = 42.29/√d,
where d is the internal diameter in meters. Ball mills are normally operated at around 75%
of critical speed, so a mill with diameter 5 meters will turn at around 14 rpm.

The mill is usually divided into at least two chambers,(Depends upon feed input size
presently mill installed with Roller Press are mostly single chambered), allowing the use
of different sizes of grinding media. Large balls are used at the inlet, to crush clinker
nodules or limestone (which can be over 25 mm in diameter). Ball diameter here is in the
range 60–80 mm. In a two-chamber mill, the media in the second chamber are typically
in the range 15–40 mm, although media down to 5 mm are sometimes encountered. As a
general rule, the size of media has to match the size of material being ground: large media
can't produce the ultra-fine particles required in the finished cement, but small media can't
break large clinker particles.

A current of air is passed through the mill. This helps keep the mill cool, and sweeps out
evaporated moisture, which would otherwise cause hydration and disrupt material flow.
The dusty exhaust air is cleaned, usually with bag filters.

16
 Figure 2.11: Layout of Mill

 Specification

A Raw mill is driven by 750 KW motor that rotates the mill at 17 rpm. The length of mill
is 13 m and diameter is 2.25 m. Both the compartments of mill are filled with grinding
media apart from sludge and limestone.in first compartment high steel balls are put which
are responsible for coarse grinding.

First chamber is filled in accordance with following data:

Size of ball (in mm) % In tank

90 3
80 8
70 8
60 9
The second compartment contains balls of high chromium steel, which are responsible
for grinding limestone and iron. About 36 % of compartment is filled with these balls.

Second chamber is filled in accordance with following data:

Size of balls (in mm) % In tank

50 20

40 10
30 6

17
A circular section called diaphragm, which is having 12 small screens at different
periphery, separates both the compartments. Molasses is also added in raw mill .it is
required to increase the slow ability of the raw mix at low moisture.

2.3.5 DSM Screen

The raw mill outlet slurry goes to war man pump, which pumps the slurry to DSM Screen.
Here the fine particles passé through the drum filters and goes to slurry mixer. The coarse
particle goes back to the mill to further grinding.

2.3.6 Slurry mixer tank

The slurry mixer is 12.5 m diameter tanks having arms on which air nozzles are fixed.
Compressed air through these nozzles about 1.5 kg/cm3 agitates the slurry and prevents
it from becoming solid. From here the slurry is feed into kiln by slurry pumps

Figure 2.12: DSM Screen Figure 2.13: Slurry mixer tank

18
2.4 Kiln Section:-
2.4.1 Introduction
A Rotary kiln is a pyro processing device used to raise materials to a high temperature
(calcination) in a continuous process. The basic components of a rotary kiln are the shell,
the refractory lining, support Tyres and rollers, drive gear and internal heat exchangers.

Figure 2.14: Kiln

2.4.2 Kiln Shell

This is made from rolled mild steel plate, usually between 15 and 30 mm thick, welded
to form a cylinder, which may be up to 230 m in length and up to 6 m in diameter. This
will be usually situated on an east/west axis to prevent eddy currents. Upper limits on
diameter are set by the tendency of the shell to deform under its own weight to an oval
cross section, with consequent flexure during rotation. Length is not necessarily limited,
but it becomes difficult to cope with changes in length on heating and cooling (typically
around 0.1 to 0.5% of the length) if the kiln is very long.

19
2.4.3 Refractory Lining

The purpose of the refractory lining is to insulate the steel shell from the high
temperatures inside the kiln, and to protect it from the corrosive properties of the process
material. It may consist of refractory bricks or cast refractory concrete, or may be absent
in zones of the kiln that are below around 250°C. The refractory selected depends upon
the temperature inside the kiln and the chemical nature of the material being processed.
In cement, maintaining a coating of the processed material on the refractory surface
prolongs the refractory life. The thickness of the lining is generally in the range 80 to 300
mm. A typical refractory will be capable of maintaining a temperature drop of 1000°C or
more between its hot and cold faces. The shell temperature needs to be maintained below
around 350°C in order to protect the steel from damage, and continuous infrared scanners
are used to give early warning of "hot-spots" indicative of refractory failure.

2.4.4 Tyres and Rollers

Tyres, sometimes called riding rings, usually consist of a single annular steel casting,
machined to a smooth cylindrical surface, which attach loosely to the kiln shell through
a variety of "chair" arrangements. These require some ingenuity of design, since the Tyre
must fit the shell snugly, but also allow thermal movement. The Tyre rides on pairs of
steel rollers, also machined to a smooth cylindrical surface, and set about half a kiln-
diameter apart. The rollers must support the kiln, and allow rotation that is as nearly
frictionless as possible. A well-engineered kiln, when the power is cut off, will swing
pendulum-like many times before coming to rest. The mass of a typical 6 x 60 m kiln,
including refractories and feed, is around 1100 tonnes, and would be carried on three
Tyres and sets of rollers, spaced along the length of the kiln. The longest kilns may have
8 sets of rollers, while very short kilns may have only two. Kilns usually rotate at 0.5 to
2 rpm, but sometimes as fast as 5 rpm. The Kilns of most modern cement plants are
running at 4 to 5 rpm. The bearings of the rollers must be capable of withstanding the
large static and live loads involved, and must be carefully protected from the heat of the
kiln and the ingress of dust. In addition to support rollers, there are usually upper and
lower "retaining (or thrust) rollers" bearing against the side of Tyres, that prevent the kiln
from slipping off the support rollers.

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 Figure 2.15: Tyres & Rollers Figure 2.16: Refractory Lining

2.4.5 Drive Gear

The kiln is usually turned by means of a single Girth Gear surrounding a cooler part of
the kiln tube, but sometimes driven rollers turn it. The gear is connected through a gear
train to a variable-speed electric motor. This must have high starting torque in order to
start the kiln with a large eccentric load. A 6 x 60 m kiln requires around 800 kW to turn
at 3 rpm. The speed of material flow through the kiln is proportional to rotation speed,
and so a variable speed drive is needed in order to control this. When driving through
rollers, hydraulic drives may be used. These have the advantage of developing extremely
high torque. In many processes, it is dangerous to allow a hot kiln to stand still if the drive
power fails. Temperature differences between the top and bottom of the kiln may cause
the kiln to warp, and refractory is damaged. It is therefore normal to provide an auxiliary
drive for use during power cuts. This may be a small electric motor with an independent
power supply, or a diesel engine. This turns the kiln very slowly, but enough to prevent
damage.

2.4.6 Internal heat exchangers

Heat exchange in a rotary kiln may be by conduction, convection and radiation, in
descending order of efficiency. In low-temperature processes, and in the cooler parts of
long kilns lacking preheaters, the kiln is often furnished with internal heat exchangers to
encourage heat exchange between the gas and the feed. These may consist of scoops or
"lifters" that cascade the feed through the gas stream, or may be metallic inserts that heat
up in the upper part of the kiln, and impart the heat to the feed as they dip below the feed
surface as the kiln rotates. The latter are favoured where lifters would cause excessive

21
dust pick-up. The most common heat exchanger consists of chains hanging in curtains
across the gas stream.

2.4.7 Other equipment

The kiln connects with a material exit hood at the lower end and to ducts for waste gases.
This requires gas-tight seals at either end of the kiln. The exhaust gas may go to waste, or
may enter a preheater which further exchanges heat with the entering feed. The gases
must be drawn through the kiln, and the preheater if fitted, by a fan situated at the exhaust
end. In preheater installations, which may have a high pressure-drop, a lot of fan power
may be needed, and the fan is often then largest drive in the kiln system. Exhaust gases
contain dust and there may be undesirable constituents such as sulphur dioxide or
hydrogen chloride. Equipment is installed to scrub these out before the exhaust gases pass
to atmosphere, called ESP.

2.4.8 Thermal efficiency

The thermal efficiency of the rotary kiln is about 50-65%.

2.4.9 Principle of Operation

The kiln is a cylindrical vessel, inclined slightly to the horizontal, which is rotated slowly
about its axis. The material to be processed is fed into the upper end of the cylinder. As
the kiln rotates, material gradually moves down towards the lower end, and may undergo
a certain amount of stirring and mixing. Hot gases pass along the kiln, sometimes in the
same direction as the process material (co-current), but usually in the opposite direction
(counter-current). The hot gases may be generated in an external furnace, or may be
generated by a flame inside the kiln. Such a flame is projected from a burner-pipe (or
"firing pipe"), which acts like a large Bunsen burner. The fuel for this may be gas, oil,
pulverized petroleum coke or pulverized coal.

Here, at DCM SCW the kiln is 120 m long, it has a diameter of 3.75 m. it is longer than
usual because it’s a wet process and additional chain zone required to bring the moisture
down. The chain zone is about 23.75 m in length. The speed of kiln is varied by a D.C
drive. Kiln is coal fired and the flue gases travel up the kiln. These flue gases then passes
through the ESP (electrostatic precipitator) where dust is collected and cleaned flue gases
are pulled out of the system by an I.D fan which is again driven by a variable speed motor.

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The dust is again put into the decanter from where it goes again to the normal procedures
of raw preparation

As the raw mix travel down the kiln it follows the helical path from chain zone. After
chain zone comes the preheating zone where the raw mix components are heated up to
the calcination temperature. A calcination zone where the raw mix gets calculated follows
this. CO2 released .the calcination zone terminates into burning zone where heat released
through coal burning melt the oxide an bring them to react to clinker .the fine coal, which
is used to create the flame is provided by coal mill. The length and temperature of various
zones in kiln vary with the firing rate, feed rate and the I.D fan speed .the burning zone
temperature is 1250°C-1400°C

Different reactions at different temperatures are given below in table:

Temperatures Reactions
180c Evaporation of water
500c and above Evolution of combined gases
900c and above Clinkerization and dehydration
1200c Production of clay and production of CO2

1200c and above Reaction between clay and lime and thus forms the
cement compound

2.5 Electrostatic Precipitator:-

2.5.1 Introduction
An electrostatic precipitator (ESP) is a filtration device that removes fine particles, like
dust and smoke, from a flowing gas using the force of an induced electrostatic charge
minimally impeding the flow of gases through the unit. In contrast to wet scrubbers,
which apply energy directly to the flowing fluid medium, an ESP applies energy only to
the particulate matter being collected and therefore is very efficient in its consumption of
energy (in the form of electricity).

The most basic precipitator contains a row of thin vertical wires, and followed by a stack
of large flat metal plates oriented vertically, with the plates typically spaced about 1 cm
to 18 cm apart, depending on the application. The air or gas stream flows horizontally
through the spaces between the wires, and then passes through the stack of plates. A

23
negative voltage of several thousand volts is applied between wire and plate. If the applied
voltage is high enough, an electric corona discharge ionizes the gas around the electrodes.
Negative ions flow to the plates and charge the gas-flow particles. The ionized particles,
following the negative electric field created by the power supply, move to the grounded
plates. Particles build up on the collection plates and form a layer. The layer does not
collapse, thanks to electrostatic pressure (due to layer resistivity, electric field, and current
flowing in the collected layer).

Figure 2.17: Working of ESP

2.5.2 Collection efficiency

Precipitator performance is very sensitive to two particulate properties:

1) Electrical resistivity; and

2) Particle size distribution.

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These properties can be measured economically and accurately in the laboratory, using
standard tests. Resistivity can be determined as a function of temperature in accordance
with IEEE Standard 548. This test is conducted in an air environment containing a
specified moisture concentration. The test is run as a function of ascending or descending
temperature, or both. Data is acquired using an average ash layer [further explanation
needed] electric field of 4 kV/cm. Since relatively low applied voltage is used and no
sulphuric acid vapour is present in the test environment, the values obtained indicate the
maximum ash resistivity.

In an ESP, where particle charging and discharging are key functions, resistivity is an
important factor that significantly affects collection efficiency. While resistivity is an
important phenomenon in the inter-electrode region where most particle charging takes
place, it has a particularly important effect on the dust layer at the collection electrode
where discharging occurs. Particles that exhibit high resistivity are difficult to charge. But
once charged, they do not readily give up their acquired charge on arrival at the collection
electrode. On the other hand, particles with low resistivity easily become charged and
readily release their charge to the grounded collection plate. Both extremes in resistivity
impede the efficient functioning of ESPs. ESPs work best under normal resistivity
conditions.

2.5.3 Advantages of ESP

 High collection efficiency.

 Low resistance path for gas flow
 Treatment of large amount of gases and at high temperature
 Ability of coping with corrosive atmosphere

2.6 Clinker cooler and coal Section:-

2.6.1 Introduction
The clinker due to rotary of the kiln gets discharged into the grate cooler where clinker is
cooled. There are four sections of grate cooler. in first section ,moving clinker bed is
cooled with the fresh air is forced through the grate cooler fan no.1 . In second and third
section, the clinker is cooled with the help of circulation air through fan no. 2&3. Finally
the cooled clinker is about 100c. This is then feed into VSI crusher where it is broken into

25
small pieces. From here small pieces are fed into the drag chain, which fall onto the deep
where it is stored into the cement silos.

2.6.2 VSI (Vertical shaft impact) crusher:

VSI crushers use a different approach involving a high-speed rotor with wear resistant
tips and a crushing chamber designed to 'throw' the rock against. The VSI crushers utilize
velocity rather than surface force as the predominant force to break clinker. Applying
surface force (pressure) results in unpredictable and typically non-cubical resulting
particles. Utilizing velocity rather than surface force allows the breaking force to be
applied evenly both across the surface of the clinker.

VSI crushers generally utilize a high speed-spinning rotor at the centres of the crushing
chamber and an outer impact surface of either abrasive resistant metal anvils or crushed
rock. Utilizing cast metal surfaces 'anvils' is traditionally referred to as a "Shoe and Anvil
VSI".

Figure 2.18: VSI

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2.6.3 Cement Silos
Cement silos are on-site storage containers used for the storage and distribution of various
types of cement mixtures. A cement silo can be a permanent structure, or a portable model
that can be relocated when necessary. The cement silo usually is equipped with some type
of blower to help expel the stored contents into a truck or other receptacle.

A cement storage silo can be structured to hold no more than a few tons of dry cement
products, or be designed to efficiently hold several hundred tons. Generally, larger silos
are permanent structures that cannot be moved. It is used, where the finished product is
stored until it is time for shipment. Many building sites that utilize concrete in the
construction process opt for portable cement silos that can be moved around the site as
the need arises.

It is not unusual for construction companies to keep several portable cement silos
available for different building projects. These simple storage devices can usually be set
up in a matter of hours, and then dismantled once the project is complete. Storage of the
portable cement silo is relatively easy, since the components can be stored in a Warehouse
until the device is needed at another building site.

Both the permanent and the portable cement silo are usually equipped with some type of
blower. The blower makes it easier to expel the product from the silo. Blowers are often
driven by electricity, although there are models that rely on propane or even gasoline.
Blower equipment with the portable silos takes very little time to set up, and can also be
stored easily when not in use.

It is important to note that the materials and the design of a cement silo will vary,
depending on the type of cement product that is to be stored in the facility. Not all types
of building materials are conducive to keeping all of the various components that go into
cement blends from caking or absorbing moisture. For example, a silo that is structured
to protect the integrity of soda ash may not work as well with lime. Along with the
ingredients of the concrete, the configuration of the cement silo will be slightly different
for products that are identified as high performance concrete or self-compacting concrete.

There are two cement silos, one for POC and other one for PPC and one steel silo for steel
grade cement. The cement silos have a capacity of 3500 metric ton each and steel silo is
having 700 metric ton capacity.

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 Figure 2.19: Silo

2.7 Cement mill:-

2.7.1 Introduction
A cement mill is the equipment used to grind the hard, nodular clinker from the cement
kiln into the fine grey powder that is cement. Most cement is currently ground in ball
mills and also vertical roller mills, which are more effective than ball mills.

Clinker from the silos is extracted from the bottom through three vibrio feeders installed
in each silos. The clinker belt with a constant speed feed the clinker into cement mill.

For OPC, gypsum is added and for PPC, pozzolona is added. The feeding of cement mill
is done through weight feeder. Gypsum from yard is fed into a hopper through a conveyer
belt into pozzolona bins by diverting the material with the help of hydraulically operated
diverter. Here, the ball mill is filled with grinding media varying from 100mm-150mm
sizes in first chamber and in second compartment cylindrical pebbles clypeus of 20mm-
25mm.

2.7.2 Materials ground

Portland clinker is the main constituent of most cement. In Portland cement, a little
calcium sulphate (typically 3-10%) is added in order to retard the hydration of tricalcium
aluminate. The calcium sulphate may consist of natural gypsum, anhydrite, or synthetic
wastes such as flue-gas desulfurization gypsum. In addition, up to 5% calcium carbonate
and up to 1% of other minerals may be added.

It is normal to add a certain amount of water, and small quantities of organic grinding
aids and performance enhancers. "Blended cements" and Masonry cements may include
large additions (up to 40%) of natural pozzolans, fly ash, limestone, silica fume or met

28
kaolin. Blast furnace slag cement may include up to 70% ground granulated blast furnace
slag.

Gypsum and calcium carbonate are relatively soft minerals, and rapidly grind to ultra-
fine particles. Grinding aids are typically chemicals added at a rate of 0.01-0.03% that
coat the newly formed surfaces of broken mineral particles and prevent re-agglomeration.
They include1,2-propanediol, acetic acid, triethanolamine and lignosulfonates.

2.7.3 Temperature control

Heat generated in the grinding process causes gypsum (CaSO4 .2H 2O) to lose water,
forming bassanite (CaSO4 .0.2-0.7H 2 O) or γ-anhydrite (CaSO4. ~0.05H2O). The latter
minerals are rapidly soluble, and about 2% of these in cement is needed to control
tricalcium aluminate hydration. If more than this amount forms, crystallization of gypsum
on their re-hydration causes "false set" - a sudden thickening of the cement mix a few
minutes after mixing, which thins out on re-mixing.

High milling temperature causes this. On the other hand, if milling temperature is too
low, insufficient rapidly soluble sulfate is available and this causes "flash set" - an
irreversible stiffening of the mix. Obtaining the optimum amount of rapidly soluble
sulfate requires milling with a mill exit temperature within a few degrees of 115 °C.
Where the milling system is too hot, some manufacturers use 2.5% gypsum and the
remaining calcium sulfate as natural α-anhydrite (CaSO4).

Complete dehydration of this mixture yields the optimum 2% γ-anhydrite. In the case of
some efficient modern mills, insufficient heat is generated. This is corrected by
recirculating part of the hot exhaust air to the mill inlet.

2.8 Packaging plant

Packing of cement is done by L&T rotatory packing machine .the cement is extracted
from the selected silos and through slides; cement is taken into bucket elevator and
subsequently to the hopper just above the packer. There are two packing machines for the
emergency case.

Rotatory packing machine is packing machine developed against influence of cement

impurities in open circuit mill on packing. it has overcome the problems such as poor
measurement and serious ash leakage of shutter in mechanized kiln for controlling ash
discharge .it completes the procedures of ash discharge and stopping through using

29
electromagnetic valves and air cylinder to control the loosening and closing of rubber
hose, and thereby reduces the maintenance cost and thoroughly solve the problem of large
packing dust.

It is a impeller filling machine, with stable performance, easy operation, reasonable

structure and convenient maintenance .it can realize the packing of cement without need
of pneumatic components .it thoroughly solves the problem of ash leakage and extruding
gate plate. Its outstanding advantage are energy saving and environment protection.
Replacement rate of spare is remarkably reduced. Maintenance cost is also reduced.
Therefore, it is widely accepted by vast users.

Figure 20: Packaging Machine

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2.9 Quality control
There is a laboratory setup to continuously monitor the quality of cement, parameters of,
which are defined as under:

In addition to control of temperature (mentioned above), the main requirement is to obtain

a consistent fineness of the product. From the earliest times, fineness was measured by
sieving the cement. As cements have become finer, the use of sieves is less applicable,
but the amount retained on a 45-μm sieve is still measured, usually by air-jet sieving or
wet sieving. The amount passing this sieve (typically 95% in modern general-purpose
cements) is related to the overall strength-development potential of the cement, because
the larger particles are essentially unreactive.

The main measure of fineness today is specific surface. Because cement particles react
with water at their surface, the specific surface area is directly related to the cement's
initial reactivity. By adjusting the fineness of grind, the manufacture can produce a range
of products from a single clinker. Tight control of fineness is necessary in order to obtain
cement with the desired consistent day-to-day performance, so round-the-clock
measurements are made on the cement as it is produced, and mill feed-rates and separator
settings are adjusted to maintain constant specific surface.

A more comprehensive picture of fineness is given by particle size analysis, yielding a

measure of the amount of each size range present, from sub-micrometre upwards. This
used to be mainly a research tool, but with the advent of cheap, industrialized laser-
diffraction analysers, its use for routine control is becoming more frequent. This may take
the form of a desk-top analyser fed with automatically gathered samples in arobotized
laboratory, or, increasingly commonly, instruments attached directly to the output ducts
of the mill. In either case, the results can be fed directly into the mill control system,
allowing complete automation of fineness control.

In addition to fineness, added materials in the cement must be controlled. In the case of
gypsum addition, the material used is frequently of variable quality, and it is normal
practice to measure the sulfate content of the cement regularly, typically box-ray
fluorescence, using the results to adjust the gypsum feed rate. Again, this process is often
completely automated. Similar measurement and control protocols are applied to other
materials added, such as limestone, slag and fly ash.

31
 CHAPTER- 3
3.1 Conclusion
The practical training has provide to be quite fruitful .It provided me to encounter with
such huge machines and mechanisms. It has allowed me an opportunity to get an exposure
of practical aspects and their implementation to theoretical fundamentals.

I became Familiarize with the practical engineering work in various disciplines and
methods of engineering practice. This will help me improving my performance in theory
classes by introducing to the practical work. It helped me to know my strengths and
weaknesses so that I can improve my skills and overcome my limitations by taking
appropriate measures I was exposed to real work situations and I learned how to equip
them with the necessary skills so that I would be ready for the job when I’ll be graduated.

The architecture of the plant, the way various units are linked, the way of working in plant
and how everything is controlled make me realize that engineering is not just learning the
structured description and working of various machines but the greater part of planning
management.

32
3.2 References
1. Retrieved from ultratech Cement: http://www.ultratechcement.com/
2. Retrieved from Birla Cement Ltd.:
http://www.birlacorporation.com/cement_division.html
3. Retrieved from J. K. Cement: http://www.jkcement.com/
4. Retrieved from Ambuja Cement: http://www.ambujacement.com/ 5
5. Ajmera, B. C. (2005). A Study of Liquidity, Productivity Viz.-A-Viz. Financial
Efficiency of Birla Group of Companies. Saurashtra University. Retrieved from
http://etheses.saurashtrauniversity.edu/id/eprint/202
6. Angelides, D. C. (n.d.). Project Management and Govt Technical. Journal of
Management in Engineering, Vol 15.
7. Arora, R. R., & Sarkar, R. (2008). Detecting Cartels in the Indian cement industry: An
Analytical Framework.
8. Baily, P. J. (1973). Purchase Research and Cost Reduction. Purchasing and Supply
Management.
9. Chester, M., & Hendrickson, C. (2005). Journal of Construction Engineering and
Management.
10. Christian, J., Gillin, & Pandeya, A. (1997). Cost Predictions of Facilities. Journal of
management in Engineering Vol. 13, Issue

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