cement plant report

1. INTRODUCTION
1

2. INTRODUCTION
Cement industry is one of the important industries to country development in
the light of the main important basis for construction industry and also the
important indicator showing domestic economic growth.
In the past, the
domestic demand of cement used to be up to 36 million tons. But, the severely
negative effects from economic crisis in 1997 have caused real estate and
construction industry subdued; the domestic demand of cement has shrunk and
been in oversupply atmosphere.
Until 2001–2003, the government has launched many economic actuating
policies. This has made real estate and construction industry recovered and the
demand of cement has been increasing gradually from 21 million tons in 2001
to 25 million tons and 26.82 million tons in 2002 and 2003 respectively; and
the price level is higher in line with increased production cost.
Cement Industry originated in India when the first plant commenced
production in 1914 at Porbandar, Gujarat. The industry has since been
growing at a steady pace, but in the initial stage, particularly during the period
before Independence, the growth had been very slow. Since indigenous
production was not sufficient to meet the entire domestic demand, the
Government had to control its price and distribution statutorily. Large
quantities of cement had to be imported for meeting the deficit. The industry
was partially decontrolled in 1982 and this gave impetus to its pace of growth.
Installed capacity increased to more than double from 27 million tones in 198081 to 62 million tones in 1989-90.
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3. The cement industry responded positively to liberalization policy and the
Government decontrolled the industry fully on 1st March 1989. From 1991
onwards cement industry got the status of a priority industry in schedule III of
the industry policy statement, which made it eligible for automatic approval for
foreign investment up to 51% and also for technical collaboration on normal
terms of payment of royalty.
After the globalization and liberalization of Indian economy, the cement
industry has been growing rapidly at an average rate of 9 per cent. The country
is now the second largest producer of cement in the world next only to China
with a total capacity of 188.97 million tones. Additionally, in the last two
decades, the industry has undergone rapid technological up gradation
and growth, and now, some of the cement plants in India are
comparable to the world’s best operating plants in all respects.
Till a few years ago India was importing cement from other countries, as the
production could not meet the demand for the whole country. Now the tables
have turned as India has started exporting large quantities of cement and clinker
to Bangladesh, Nepal, Sri Lanka, Maldives, Mauritius, Africa, Seychelles,
Burma, UAE, and Singapore etc.
India is today the second largest producer of cement in world with an
installed capacity of close to 188.97 million tones per year. 95 % is
consumed domestically and only 5% is exported. Demand is growing at
more than 10 % per annum. More than 90 % of production comes from
large cement plants. There are a total of 130 large and more than 350
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4. small cement manufacturing units in the country. More than 80% of the
cement-manufacturing units use modern environment friendly “dry”
process.
Today total number of cement companies in Indian market are
47,having number of cement plants 139, the installed capacity of large
plants is 188.97 million tones and cement production during 2007-2008
was 168.31 million tones
The forms of cement produced:•
Ordinary Portland Cement ( OPC )
•
Portland Pozzolana Cement ( PPC )
•
Portland Slag Cement ( PSC )
Major players in Indian cement sector:•
ACC
•
BCL Cement
•
Gujarat Ambuja Cement
•
Ultratech Cement
•
India Cements
•
Century Cements
•
Jaypee Group
•
Madras Cements
•
Birla Corporation Limited
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5. 5

6. INTRODUCTION OF BIRLA CORPORATION LTD.
Overview
Founded in1919 by the visionary industrialist Shri G.D. Birla, at the
outskirts of the Kolkata, Birla jute manufacturing company Ltd. Was the first
company of the Birla Industrial Conglomerate. Under the stewardship of his
nephew Shri M.P. Birla, the company diversified and expand its business
interest beyond jute, to encompass cement PVC coated fabric, PVC floor
covering and auto trims.
After the demise of Late Mr. M.P. Birla in 1990, his wife, Mrs.
Priyamvada Birla took over as chairman of Birla Corporation and continued to
6

7. lead the company till her death on 3 July 2004. She was an entrepreneur of
distinction strong business acumen and, under her leadership, the company
crossed the Rs. 1,300-plus turnover mark.
The company, renamed Birla Corporation Limited, to reflect the wide
range of operation, is the flagship company of the M. P. Birla group. The
strategic focus of the company has been on steady growth by developing and
assimilating technologies of tomorrow to manufacturing an ever widening
range of value-added product, while striving for complete customer satisfaction
in India and abroad. Birla Corporation Limited is proud of safe work practice
followed at all its factories and godowns. As an enlightened corporate citizen,
Birla Corporation Limited is keenly aware of social responsibilities too, and
provide education and health care facilities for its employees, their families and
the community at large.
Its export in 2004-05 stood at Rs. 85.28crores. Over the year, BCL’s
business has grown from strength to strength.
1.1
Overview : Cement Industry
The cement division of Birla Corporation Limited has seven plants, two
each at Satna (M.P.) – Satna Cement Works & Birla Vikas Cement, Chanderia
(Rajasthan) – Birla Cement Works & Chanderia Cement Works, and Durgapur
(W.B.) – Durgapur Cement Works & Durga Works & Durga Hitech Cement
and one at Raebareli (U.P.) the total capacity of these plants is 57.80 lakh tones.
This plant manufacture varieties of Cement like Ordinary Portland Cement
(OPC),43 & 53 grade, Portland Pozolanna Cement (PPC), Fly Ash based PPC,
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8. Low Alkali Portland Cement, Portland Slag Cement, Low Heat Cement and
Sulphate resisting Portland cement.
The cement is marked under the brand name of Birla Cement
KHAJURAHO, Birla cement CHETAK, Birla cement and Birla premium
cement, bringing the product under a common brand of Birla cement while
retaining the niche identity of Khajuraho (for the OPC product of Satna),
Chetak (for OPC product of Chanderia) and Samrat of blended cement, i.e. PPC
& PSC, for all the units.
The division export large quantity of cement to Nepal and Bangladesh,
under the brand name of Khajuraho, Samrat, Camel, Royal tiger.
The special variety of SAMRAT cement, begun produced by the company is
ideal for mass concrete. RCC / pre-stressed – pre-cast structure (for reduced
thermal crack), increased water tightness of concrete, increase resistance to
Sulphate soils and aggressive water and increased resistance to alkali aggregate
reaction beside corrosion resistance properties.
SCW, BVC and DVC have received the ISO 9001-2000 quality system
certification, covering the entire range of production and marketing. SCW &
BVC have received the IS / ISO 14001 certificate, an international recognition
for “Implementation of Environmental Management System” BVC have got the
“Best productivity of Performance” award from NPC during 1986-88, NCCBM
recognized it for “best in energy performance” during 1986-87. It received
“National Safety Award” for outstanding performance in achieving the longest
accident free-period during 1994. In 1996, it received the runner cup under
8

9. scheme –1 of National Safety Award, for the lowest average frequency rate
accident. BVC has also received “Fuller Energy Conservation Award” as first
for “Lowest Thermal Energy Consumption” (for group B’ category plants) for
three consecutive years i.e. 1997-98, 1998-99, 1999-2000. SCW has been
adjudged by NCCBM the “Best In Energy Performance” during 1993-94, 199495, 1995-96, 1997-98. It was the second best for “Improvement in Energy
Performance” during 1996-97. SCW has also got “Fuller Energy Conservation
Award” as first prize for “Lowest Thermal Energy Consumption” (for group A
category plants) for three consecutive years i.e. 1997-98, 1998-99, & 19992000.
BCW & SCW have received the ISO 9001-2000 certification for Quality
Management system, covering the entire range of production and marketing
and also have received the IS / ISO: 14001 certification for BCW & CCW have
bagged various awards from NCCBM. CCW have received the “Best
Productivity” award during 1989-90 & 1993-94. NCCBM recognized it for
“Best Improvement in Thermal Energy Performance” during 1993-94. It has
won “Lal Bahadur Shastri Memorial National award for “Excellent Pollution
Control Implementation” for 2001-02 by International Greenland Society.
BCW was awarded “Best Improvement in Energy Performance” and “Best
Improvement in Thermal Energy Performance” during 1992-93.
The Rajasthan Government gave “Bhama Shah Samman” it during 1996.
VEC-IIT Madras chose Chanderia unit for excellence in “Improving Machinery
Health Condition” during 1997. VEC, Chennai chose Chanderia unit for
sustained implementation of condition monitoring and continued Machine
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10. Health Improvement Award during 2001-02. The Central Board awarded the
“Worker Education Trophy” for worker education, Udaipur Ministry of Labor,
Government of India for excellent contribution and Implementation of workers’
training during 1998-99 and again in 2001-02. BCW has received excellence
award in Cement Sector from the Rajasthan State Council, Jaipur, during 200203.
The DWC plant has received IS / ISO 9001-2000 license for Quality
Management system certification (accredited by road voor accredited
Netherlands). The capacity of the 6,00,000 tons plant increased by another
10,00,000 tons, making it the largest plant in West Bengal. The new grinding
unit, Durga Hitech Cement, has one ball mill of 165 TPH capacities. This
environment-friendly project, commissioned in 2005-06, utilized thermal power
station fly ash to produce PPC. DCW recorded 114% capacity utilization in
2004-05, emerging as the highest growing cement unit in the eastern region.
Cement plant were set up in MP and Rajasthan and Grinding units in West
Bengal and UP.
• Satna Cement Works
-
1959
• Birla Cement Works
-
1967
• Durgapur Cement Works
-
1974
• Birla Cement Works
-
1982
• Chittor Cement Works
-
1986
• SCW-Conversion Plant
-
1989
• Raebareli Unit
-
1998
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11. Late Shri M.P.Birla
Late Smt. Priyamvada Birla
Mr. P.S. Marwah
President of Satna Cement And Birla Vikash Cement Plant satna (m.p.)
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12. Birla Corporation Limited is a multi- product conglomerate.
• It plays significant roles in the Cement, Jute, PVC floor Covering,
Auto Trim and Steel casting industries.
• The concentric around the triangle represents this very multidimensional nature.
• The apex of the triangle is a visual representation of the force that
drives the entire corporation – the unifying force in search of
excellence.
The circle represents the inspiration to explore new frontiers of
growth.
MANAGEMENT
The day- to- day management of the company is being looked after by the Chief Executive
Officer, Shri B.R.Nahar who is assisted by a team of highly qualified professional persons.
Chairman
Late Shri R.S. Lodha
ED & CEO
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13. Shri B.R.Nahar
Board of Directors
Shri N.K. Kejriwal
Smt Nandini Nopany
Shri Harsh V. Lodha
Shri Pracheta Majumdar
Shri Vikram Swarup
Shri Anand Bordia
Shri B.B. Tandon
Shri D.N.Ghosh
CHIEF FINANCIAL OFFICER
Shri P.K. Chand
ACTING COMPANY SECRETARY
Shri Girish sharma
AUDITORS
H.P. Khandelwal & company charted Accountants
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14. Achievements
1.
SCW, BVC & DCW have got ISO 9002 quality certification, covering the entire
range of production & marketing.
2.
Best Energy performance award in 1995-96 & 1994-95.
3.
Second best improvement in energy performance award in 1995-96.
4.
Top export award in 1994-95.
5.
First prize in productivity to CCW in 1993-94.
6.
Special Export award in 1993-94.
7.
Best Energy performance award to SCW in 1993-94.
8.
Special export in 1992-93.
9.
Top export award for 1990-91 & 1991-92.
10. Second Best Performance in 1991-92.
11. Best Performance award in 1989-90.
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15. AWARD EARNED BY SCW AND BVC
S. NO.
1.
AWARDS
Best
Energy
AWARDED BY
YEAR
Performance NCB, New Delhi and 1986-87
Award
BVC
Power 1993-94
SCW
1994-95
SCW
1995-96
SCW
1996-97
SCW
1997-98
SCW
of 1997-98
SCW
Cement Manufactures 1998-99
SCW
Association.
1999-00
SCW
2001-02
SCW
1997-98
BVC
1998-99
BVC
National Productivity 1987-88
BVC
Fuller Energy Conservation M.P.
Award
3.
of
Govt. of India
2.
Ministry
UNIT
Best Productivity Award
Chamber
Council, New Delhi
4.
Export Award
CAPEXIL, Kolkata
BVC
1991-92
BVC
1993-94
SCW & BVC
1994-95
BVC
1996-97
BVC
1997-98
BVC
2001-02
15
1990-91
BVC

16. 5.
National Safety Award
Ministry Of Labour, 1994
BVC
Govt of India
6.
ISO-9001
for
quality RWTUV, Germany
Management
Since
July SCW & BVC
1994 Renewed
every year
7.
IS
/
ISO-14001
for BIS, New Delhi
Environment Management
Since
Sept. SCW & BVC
1999 Renewed
every 3 year
8.
Sagmania
Mines
Safety DGMS
1997-98
Award
9.
Mines Environment & Mineral ISM, Dhanbad
1997-98
conservation
2002-03
Overall
Performance
10.
Best Energy Conservation
Rajiv
Implementation Gold Award
Memorial
Award
16
Gandhi Oct 2004
National
SCW

17. Product Profile
At Satna Cement Works & Birla Vikas Cement the dry process of
Cement production followed which is termed as a modern technology. The
Entire Manufacturing process is controlled through a microprocessor based
programmable logic control system to maintain a constantly uniform quality of
Cement & high rate of production. The entire operation of plant is controlled in
a single control room. SCW plant, which was initially, a plant using a wet
technology for cement production was changed an to a dry one in the year
1989. These modern plant have also taken adequate core to prevent the
environment policy & dust nuisance to its surrounding areas. These cement
mills have electrostatic precipitator (ESP) installed to check dust emission & to
ensure health hazard free atmosphere.
Both the plant uses the global technology for the production of goods &
consistent quality cement. The Stacker Reclaimer Technology & the alkali by
pass system along with other sound technology make the manufacturing
process of Birla Cement Khajuraho a highly competitive & unique one.
The various varieties of cement produced at these plants are:
1)
Ordinary Portland Cement (33, 43, 53 grade)
2)
Portland Pozzolana Cement (PPC)
3)
Low alkali Cement.
4)
Sulphate resistant Cement.
5)
Special Cement for Indian Railway Sleeper (IRS-T-40)
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18. The benefits of using high quality cement manufactured by the company are :
1)
Ideal for mass concrete structure.
2)
Reduce thermal cracks.
3)
Increased water tightness of concrete.
4)
Higher fineness, ideal for plastering.
5)
Increased resistance for sulphate attack & aggressive water.
6)
Increased resistance to alkali aggregate reaction.
7)
Improved durability.
General Review
The year 2005-06 was the most successful year of the company since its
inception in terms of financial performance. The company, maintaining stable
growth, posted 7% increased in turnover to Rs. 1433.44 crores as compared to
Rs. 1342.64 crores in the pervious year. The interest cost further reduced during
the year Rs. 13.62 crores as compared to Rs. 21.69 crores in the previous year.
Profit before tax recorded at 54% jump when up to Rs. 144.09 crores from Rs.
93.70 crores in the previous year. The company recorded the highest ever
turnover, cash profit, profit before tax and profit after tax during the year. The
management continued its effort to control and reduce cost across all the
18

19. division at all levels. Profitability of the company improved due to increase in
volumes, sales price realization and better operating efficiencies.
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20. Corporate Matters
Thermal power plant of 27 MW each for captive use at the company’s
units at Chanderia and Satna were installed and put to use during the year.
These power plant are expected to reduce the power cost significantly and
increase the operational efficiencies.
The company’s new unit: Durga Hitech Cement, adjacent to the existing
plant at Durgapur, West Bengal was also commissioned for commercial
production on
24 December 2005.
The company has taken up steps to enhance the capacity of clinker
production at its plant in phases. The project once executed, will result in
saving in fixed running cost and existing infrastructure like railway siding and
power plant will also be used optionally.
Effort to shift Soorah Jute Mill’s to Birlapur from heart of Kolkata city
for economic viability, operational efficiencies and environmental issues are
continuing.
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21. Cement Manufacturing
process
1-Mining:
The cement manufacturing process starts from the
mining of lime stone , which is the main raw material for making
cement. Limestone is excavated from open cast mines after
drilling and blasting and loaded on to the dumpers which
transport the material and unloaded into the hoppers of limestone
crusher.
2-Crushing Stacking & Reclaiming of Limestone: The l/s crusher
crush the Limestone to minus 80mm size and discharge the material
onto a belt conveyer which take it to the stacker via the bulk material
analyser. The material is stacked in longitudinal stock piles .
Limestone is extract transversely from the stockpiles by the reclaimers and conveyed to the Raw Mill hoppers for grinding of raw
meal.
3-Raw Meal Drying/Grinding & Homogen-ization: Reclaimed l/s
along with some lat-rite stored in their respective hoppers is fed to the
raw mill for fine grinding. The hot gasses coming from the
clinkerisations section are used in raw mill for drying and transport of
the ground raw meal to the electrostatic precipitator /Bag house,
where it is collected and then stored and homogenized in the concrete
silo. Raw meal extracted from the silo(ne called kiln feed ) is feed to
the top of the pre-heater for pyro-processing.
4- cooling: Hot clinker discharged from the kiln drops on the cooler
and gets cooled.
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22. 5-Clinkerisation: Cement clinker is made by pyro processing of kiln
feed in the pre-heater and the rotary kiln. Fine coal is fires as fuel to
provided the necessary heat in the kiln and the pre-calciner located at
the bottom of the 5/6 stage pre-heater. Hot clinker discharged from
the kiln drops on the gate cooler and gets cooled. The cooler
discharged the clinker onto the pan / bucket conveyer and it is
transported to the
Conveyer Belt
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23. Mining
The major raw material for cement manufacturing is limestone.
Limestone is excavated from open cast mines after drilling and
blasting and loaded onto the dumper which is transported the material
and unloaded into hopper of the limestone crusher.
Equipment Used in mining:
1. Compressor drilling machine.
2. Shovels/Excavators-for lifting material onto dampers.
3. Dumper- for carrying material.
4. Built-dozers.
5. Pay-loaders.
Explosive:
1. Ammonium nitrate(Fuel oil)
2. Nitroglycerine.
3. Ammonium nitrate and slurry explosive.
Steps of Mining:
1. The first step of mining l/s the l/s has been located.
2. Limestone mining is to remove the mines.
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24. 3. The third step is to be taken as drilling.
4. After drilling blasting is done.
Drilling and Blasting:
1. The large hole blasting method is not pre-dominated in
quarrying in open pit.
2. The depth of the wholes are more then 12m and 100-150mm
dia.
Lime Stone Crusher
Lime stone crusher is the lead role playing equipment in this section.
The raw lime stone is carried out from the mines is introduced to the
lime stone hopper through whole pack dumper of capacity 32 tons.
The feed inside the impact crusher first enters to the crushing
chamber with help of apron feed encounters. The impact bars
mounted over the rotor &revolving with the circum-frencial velocity
of 30-40 m/sec. Material are blown bars and stick on a impact arm.
Here materials are initially install to hold these grinding bars. The
squire impact arm is install just behind the impact path and having 12
liners. When the material get crushed enough for transportation
towards stacker. A bag house is also installed to control the dust loss
and pollution control.
Equipment Used in Crushing:
1. Crusher.
2. Apron conveyer – for feeding l/s to crusher.
3. Bag filter – for collecting dust.
4. Belt conveyer- for transporting crushed material.
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25. This section is worked with following equipment:
1. Impact crusher.
2. Magnetic separator
3. Limestone stacker& re claimer
4. Bag filter
5. Apron feeder
6. Limestone hopper & late rite hopper
The important mode of transportation in this section is
belt conveyer.
Main component of impact crusher:
•
Housing: housing of impact crusher is of studly steel
fabricated and consists of three parts.
•
Rotor: The rotor in the impact crusher is of s-type construction
secured to the shaft by locking assembly. The blow bar placed
in to the rotor from the side and are secured against lateral
moment by a suitable locking device at the extreme end. The
rotor is dynamically arranged to avoid any undesirable stress on
the bearing.
•
Blow bar: Blow bar is made from high quality alloys steel.
After the certain period in operation the blow bar can be taken
out from the rotor and turned to other side or exchange.
•
Wear plates: housing is fitted with the resistance wear plates
which are secured in position by special fastners which can be
changed as and required.
25

26. •
Impact Arm: The impact crusher is fitted with the impact arm.
The impact arms are each suspended in the housing parts by
means of knock out spindle and can be adjusted the desire gap
setting from out side.
•
Hydraulic system: Impactors are depends on their size
normally supplied with a hydraulic arrangement for setting of
gap for grinding path lifting of the rear top housing.
Magnetic Separator: A magnetic separator is installed just above
belt conveyer between crusher and stacker. When the magnetic
material are comes along with lime stone .they get se-prated by
magnetic separator. In the magnetic separator a permanent magnet
and a continually moving belt being fin use. Magnetic materials are
attached by magnet due to cont. rotating of belt , material get seprated on removal of magnetic field.
Gamma Matrices: A gamma matrices analyzer being used for
analyze the chemical composition of lime stone. It is also known as
cross belt analyzer. In gamma metric analyzer we are using specially
gamma rays, the gamma rays are fall on material and return back,
according to absorption rays in to material we can determine the
chemical composition of lime stone .
LIME STONE STACKER:A limestone stockpile (closed stock pile) has been proposed at the
plant site with stacker re-claimer. The re-claimer will help in feeding
a homogenized limestone by mixing rich quality LS with low grade
mineral. By installing a re-claimer in the plant, the plant can achieve
not only quality raw material input but also the conservation of
natural resources by utilizing low-grade raw material.
26

27. There are two main methods being used for stacking of lime stone in
cement industry. They are……..
1. Chevron Method
2. Windrow Method
Pulverizer :-
27

28. LIME STONE RECLAIMER
28

29. Re-claimer which is used in our industry is bridge type scrapping reclaimer. The bridge on which the racking down device is mounted
accommodates a scraper chain conveyer whose blades shift the
dislodged material along to collecting belt conveyer that extent along
one edge of stack pile. Re-claimer having harrow assembly. Reclaimer moves on a track for fast travel a.c. Motor being used and for
slow traveling d.c. motor being used. Harrow is moves to and fro
motion on rack car which is driven by a motor. A limit sensor is
installed for reverse and forward motion of harrow assembly.
According to pile we can adjust the inclination of harrows. When
harrows are moves they are scrap the material of each layer of
stockpiles and material slides down due to gravity. A scraper chain
take out the material and fed to belt conveyor material now get
transported forwards limestone hoppers.
29

30. Raw mill:
Blending Of Raw Meal:
30

31. The meal from the mill need storage and blending become different
chemical composition of lime stone in different lot. They may vary
the quality of lime stone.
Silo: Silos are huge construction of concrete and iron with aeration
units to stone and blend the fine material such as raw material.
.Continuous Fluidize Silo: The raw meal is completely
fluidized by admission of compressed air through the suitable inlets
at the bottom of the silo. The air penetrates the mass of raw meal into
the silo and reduces the inter particle friction forces. A circulatory
motion is formed and thus homogenization is take place.
Operation of Raw Mill:
When the Limestone feed is started with la-trite rollers get
down & the grinding start.The grinded material is sucked up through
the classifier by the help of hot gases .The reject material from the
classifier is sent back to the grinding table by the help of reject group.
The remaining fine material is sent to ESP & ESP reject material to
silos. So total three types of material is falling on grinding table
during running:1)-Mill feed
2)-Classifier reject
3)-Mill reject
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32. SILO
It is the large storage of Raw mill which comes from the Raw Mill. It
is made of concrete & can store Raw mill for long time.
Purpose:It’s main purpose is to homogenize the raw mill. One
of it’s main purpose is to also store raw mill for long time.
Construction:It mainly a large structure made of concrete. It
contains following devices:1)-Air Compressor
2)-Large Air Ducts
3)-Pneumatic Valves
4)-Exhaust Fans on the top
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33. Preheater
Purpose:To increase the temperature of rawmill material
through the incoming hot air from kiln & transfer air duct.
Working Principle Of Preheater
As the name explains “Pre-heater Tower” is place to use for
preheating the raw material. The material which comes from c.f. silo
in other words pre-heater is a device in which heat transfer takes
place from hot gases which comes from kiln due to counter current
flow of material and hot gases. The raw mill is heated about 850 oc
before it enter it the kiln pre-heater with calcined system is most
economical and hence the length of kiln is reduce pre-heater in Unit-1
and five stage in unit-2 with separator line calciner. These suspension
pre-heaters are work in kiln string & pyro string with pre-calciner
string successfully.
Main part of suspension Pre-heater:
1. Cyclone: The cyclone is use for separation of raw meal from
gas flow. For improving the separating efficiency of cyclones of
top most pre-heater stage. We have designed as double
separator.
2.
Gas Duct:
The gas ducts is to join the individual cyclone
stages to each other. The raw meal coming from next higher
stage and in the gas duct underneath. The raw meal particles are
entering by the upward flowing gas stream and taken to the next
cyclone. The heal exchange is achieved by con-current flow.
The gas ducts b/w stage 1 and 2 consist of the cylindrical
suction.
33

34. 3.
4.
The Double Flow Box:
These are used for raw meal
pipes in pre-heater system the flaps are consists in such a
manner that a minimum flow of raw mill is always maintained.
The full material causes a upward and downward moment of the
pendulum flaps and thus and upward and downward rocking
motion of the lever arm with counter weight penetrating the
single flaps. The upward and downward forces of flaps is
remains constant.
Raw Material distributor:
It is integral part of raw meal
ducts and spits a downward flowing stream of raw meal in to
raw meal duct. Basically the distributor has a two fold function.
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35. Calciner:
The main purpose of the pre-calciner is to let the calcinations process
take place out side the rotary kiln. It causes in sufficient reduction of
thermal load of the kiln burning as approximately 60% of total fuel is
burn in to calciner. This has made possible to increase the production
in the given size to about double compared to a conventional dry
process kiln with suspension pre-heater.
The calciner consists of a vessel lined with heat resistance bricks.
Calciner has three inputs and one output.
Input1. Fuel as Pulverized coal.
35

36. 2. Preheated material to approx 800oc
3. Hot gases from kiln/coolers at 800oc
OutputHot gases including combustion products and co2 from the
calcinations process and material in form of dust carried with the hot
gases.
Lime Stone Tablet Maker :-
36

37. Rotary kiln:
37

38. Purpose:Kiln is cylindrical rotary equipment rotating on supporting rollers
at about 3.5 RPM. Discharge in its completing calcinations reaction.
Firing is done from kiln outlet with the help of burner pipe.
Construction: Kiln can be divided into :a. Kiln inlet (consist seal, grease pump, lines, cylinders etc)
b. Girth gear(Gear, pinion, spray system)
c. Thrust roller(Hydraulic cylinder, oil line)
d. Supporting roller& tyre (Consist of bearing, chair plate, bolts
etc)
e. Kiln outlet seal(S.S shims, crown shell, seal)
f. Burner pipe(consist of air pipe, coal pipe, diesel pipe etc)
Kiln inlet: Kiln
inlet is seated by sealing arrangement. Greasing
is done by pneumatic pump seal. It consist of 10-14 segment so it
can be mounted and disassembled from kiln inside. A conical section
forms an extension of the inlet ring. A brick retaining ring has been
mounted at the end of conical section.
Girth Gear: Kiln is rotating by Gear – pinion arrangement. Girth
gear is mounted on kiln with the help of spring plates.
Thrust Roller: The function of thrust roller is to control axial
moment of kiln in both upward & downward.
Supporting Roller & Tyre: Supporting roller are for support of
kiln. They are in contact with tyre which are fitted in kiln shell.
Kiln Outlet: There is a sealing arrangement in kiln outlet.
Burner Pipe: It is for firing of fine coal into the kiln. Air is
controlled by damper and fine coal by solid flow meter.
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39. Kiln cooler:
Clinker cooler has two main function to perform. They are:1. To cool the hot clinker quickly.
2. To provide necessary air for burning of coal in pre-calciner and
kiln.
After introducing of red hot clinker into the
cooler, mechanically driven gates moves it to the rear end of cooler.
Three pair of gates are installed inside the cooler. A single pair
consist of fixed gate and movable gate. Too and fro moment of
movable gate pressurized which cools it quickly.
Clinker cools down gradually as it moves, due to the air
blow by the fans which is taken from the atmosphere. Air falling over
clinker is highly pressurized which cools it quickly.
Clinker escaping out of the cooler is fed to a hammer crusher, since
lumpy material requires crushing. Crushed material is transported to
clinker silo through deep bucket conveyor. Temperature of clinker
escaping out of cooler is about 208oc.
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40. Grate Cooler operation:
The grate cooler operates with a cross current principle in which the
clinker is moved across the grate while cooling air blow in from
below through the grate and clinker layer. The hot clinker falls from
kiln and forms clinker bed on he grate and transported through the
cooler over alternatively fixed and reciprocating grates. At the inlet of
first great clinker is quenched and spread evently across the cooler
width by the increased cooling air. The grate is fabricated to be as
possible to obtained a thick clinker layer and a uniform distribution of
air through the clinker bed in the interest of heat recovery.
During the clinker transport from the cooler a part of dust
and small size clinker is falls from the grates and collected into
hoppers under the grates. The drag chain and rotary air lock system
fed these clinker and dust in clinker transport system. A dust
collection ESP is also installed beside the cooler known as cooler
ESP. Exhaust gases from collection is fed to the ESP for dust
collection.
Grate cooler consist of: Cooling grate Plates
 Standard Plates
 Cooling housing
 Drive unit
 Grate aeration system
 Clinker crusher
 Conveying unit(DBC)
 Cooling fan
40

41. Model of Lime Stone Crusher :-
41

42. Coal Mill:
The coal mill works for producing the pulverized coal for burning to
increase the temperature of kiln, pre-heater, raw mill .It works as
same as raw mill for lime-stone & latrite mixture {Raw mill}
grinding, & the coal mill grind & transfer the coal to the furnace for
burning. The raw mill is grounded dried swept away by fan
through the separator to bag filter or ESP. finally it is stored in to the
fine coal bin hot air for coal mill is supplied by cooler exhaust hot
42

43. gases or pre-heater outlet gases before GTC circulation. The
function of coal mill is to ground suitable grate coal and for feeding
the same in to the kiln and calciner in fluidized form. Coal from stock
yard is fed for stacking and reclaiming in to the stacker and reclaimer. Pre-homogenized raw coal is feed in to the coal mill hopper
with the help of belt conveyer. The raw is then fed to the coal mill
VRM via weigh feeder, drag chain and screw conveyer.
Important Parameters Of Coal:
• Residue on 90 micron=18-20%
• Residue on 212micron=0.4-1%
• Moisture
=1.5%
• Volatile Matter
=20-30%
• Ash content
=28-32%
Coal Mill:Coal Mill is an important integral part of cement plant.
Here large size of approx size 600mm, is ground fine to the size of 90
micron. Coal from coal mill is used to feed kiln and calciner. Outlet
tem of coal from coal mill is different in different seasons. It is 70750c in dry season and 80-840c in rainy season.
Coal from mines is initially
crushed at crusher site. Coal is then sent to stacking making mixture
homogenized. Reclaimer picks up the coal and coal is fed to
the coal mill hopper through belt conveyer. Coal taken out from
hopper is feed inside VRM with the help of a screw conveyer
which is mounted just below the hopper. Coal inside VRM is
grounded between roller and table.
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44. Hot air from cooler ESP fan is taken inside
VRM and is used for drying of coal. Fine coal from VRM
moves to the cyclone, where most of the coal is separated from
air and the coal which does not get collected due to ultra fine size is
separated with the help of ESP.
LV separator is for separating coarse and fine particles.
Now, coal is fed to screw conveyer through rotary lock, which
transport it to the FK pumps. Two FK pump delivers material to the
storage bins.
There are two Storage bins, They are:1. Kiln Bin
2. Pre-calciner Bin
Fine Coal is then transported to the kiln and pre-calciner by kiln
firing FK pump and pre-calciner FK pump respectively.
Classifier:
A classifier is the top most rotary part of the vertical
roller Mill . Here classification of materials occurs .Fine particles
pass through classifier and course particles are rejecter and recycled
for regrinding. According to the fineness required speed of the
classifier rotor can be adjusted.
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45. 45

46. Lime Stone Regrinder:-
QUALITY CONTROL IN CEMENT PRODUCTION
46

47. Quality Control
Efficiency quality control is error prevention rather than error
detection. Online reaction to special cause of variation will lead to
progressive improvement in the process, performance and cost.
Fundamental improvement in quality results from testing rational
prediction about special process using statistical method. The
effective pursuit of quality permanent commitment through out an
organization.
Pitfall of quality control
Pitfall of the successful implantation of the permanent quality
improvement culture are:-
1.
2.
3.
4.
5.
Lack of top management support.
Lack of middle management support.
Commitment to only department.
Haphazard approach a little of this and that with no
meaning change in the system.
Measurement of success and guidance program on the
basis of short-term profile.
47

48. Cement :-
Cement is a word given to a powder material which initially has
plastic flow when mixed with water but has the property of setting
hard solid structure in the several hours with varying degree of
strength and bonding properties.
Natural is a mixture of burnt silicate and lime. It was discovered by
Joseph Aspdin an English brick layer in 1924. This Cement is
called Portland Cement and now a day prepared artificially.
Properties of Cement
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49. It gives strength to the masonry.
It is an excellent binding material.
It is easily workable.
It harden early.
Types of Cement
A.
Ordinary Portland Cement (OPC)
It is of 3 types
1. 33G
2. 43G
49

50. 3. 53G
B.
Pozzolana Portland Cement (PPC)
Uses of Cement
At present the cement is widely used in the construction
of various engineering structure. It has proved to be one
of the leading engineering materials of modern time and
has no rival in production and application. Following are
possible uses of cement:1. Cement mortal for masonry work, plaster etc.
2. Concrete for layering floor, roof, construction
lanters, beams weather shed stairs pillars.
3. Construction of important engineering structure
such as bridges, culverts, dams, tunnels, storage
reservoir, light houses, dock etc.
4. Construction of water tanks, well, tennis court,
septic tank, lamp post, roads, telephone cabins etc .
5. Making joints for drain and pipes.
6. Manufacturing of present pipes, piles, garden seats,
artistically design urns, flower pots, dustbin fencing
post etc.
7. Preparation of foundation, watertight floor, footpaths
etc.
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