A brief information about the process of Cement Production.

1. By:-
Deepesh Kumar Mishra
11202732
Satna Cement Works
Birla Corp. Ltd.
Six Weeks Training Report

2. Satna Cement Plant

3. Counted amongst the larger plants of the Cement Division, Satna Cement Works
and Birla Vikas Cement at Satna (MP) along with Raebareli Cement Works (UP)
have an installed capacity of 2.36 million tones at present, which is projected to rise
to 2.84 million tones after the present expansion/modification.
Birla Cement Samrat and Birla Cement Khajuraho are already leading Brands and
frontrunners of company’s activities. Riding on the glory of very high standards of
quality, the company products are premierly priced in all the markets where it is
available.

4. 00. Limestone Quarry and Crushing plant 09. Cooler
01. Limestone Stockpile 10. Deep Bucket Conveyor
02. Additives Hopper 11/12. Clinker/Gypsum Storage
03. Additives Storage 13. Coal Mill Building
04. Raw Mill Building 14. Cement Mill and Bag House
05. Blending and Storage Silo 15. Cement Storage Silo
06. Preheater 16. Packing & Dispatch
07. Gas Conditioning Tower and ESP 17. Central Control Room
08. Kiln
Plant Layout

5. Process Flow Chart

6. 00. Limestone Quarry and Crushing plant
The major raw material for cement production is
limestone.
The limestone most suitable for cement production
must have some ingredients in specified quantities
i.e., calcium carbonates, silica, alumina, iron,etc
Belt Conveyors
The quarried raw material is transported to the
cement plant, using mechanical conveying
equipment such as ropeways or belt conveyors, or
by vehicles like wagons and trucks.
There are mainly two types of crushers available
- compression type or impact type crushers.
Imapct Crusher

7. 01 Limestone Stock Pile
Circular or longitudinal stock piles are used to store
the material.
A number of layers are stacked in circular or
longitudinal piles and are reclaimed in transverse,
cross-sectional slices.
02 & 03 Additives Storage Hopper
In order to get the required composition of raw
material, certain additives such as iron ore, bauxite,
laterite, quartzite and flourspar are added in required
quantities.
These additives are stored at the plant in separate
hoppers and are extracted using belt conveyors in
conjunction with belt-weighing equipment.

8. 04 Raw Mill Building
VRM
The raw material is finish-ground before being fed
into the kiln for clinkering. This grinding is done
using either ball mills or vertical roller mills (VRM).
VRM uses the compression principle to grind the raw
material.
The main advantage of VRM is higher grinding
efficiency and ability to accept material with higher
moisture content.
Normally the energy consumption level in VRM is
10 to 20 percent lower than in ball mills.

9. 05 Blending and Storage Silo
In order to blend and homogenize the raw materials
properly, continuous blending silos are used.
As there are various sources of raw materials, it becomes
necessary to blend and homogenize these different
materials efficiently to counteract fluctuation in the
chemical composition of the raw meal.
06 Preheater
Clinkering takes place in the kiln and the preheater
system.Preheater systems offer heat transfer from the
hot kiln gases.

10. 07 Gas Conditioning Tower and ESP
The conditioning tower is used to reduce the temperature and to increase the moisture level
of the dusty exhaust gas from the kiln, before it is passed through the bag house and ESPs.
The Electrostatic Precipitators are used in cement plants particularly for removal of dust
from the exit gases of cement kilns and from the exhaust air discharged by dryers,
combined grinding and drying plants, finishing mills and raw mills through water injection.
08 Kiln
A kiln is the heart of any cement plant.
It is basically a long cylindrical-shaped pipe, and
rotates in a horizontal position. Its internal surface is
lined by refractory bricks. Limestone and additives
are calcined in this. The output of the kiln is called
clinker.

11. 09 Cooler
The clinker coming out of the kiln is hot. It is cooled
in a set-up called a cooler. In the cooler, cold air is
blown to effect heat exchange between hot clinker
and cold air.
10 Deep Bucket Conveyor
The deep bucket conveyor is essentially an equipment to
lift material vertically.

12. 11 Clinker Storage
The output of the kiln is stored before it is fed to the
cement mill for conversion to cement.
12 Gypsum Storage
The storage space is used for gypsum storage.

13. 13 Coal Mill Building
The coal mill building houses the
mill for grinding lumpy coals. This
fine ground coal is used for burning
in the kiln.
14 Cement Mill and Bag House
Clinker, along with additives, is ground in a
cement mill. The output of a cement mill is the
final product viz. Cement.
The term bag house is applied to large filters
containing a number of tubular bags mounted in a
usually rectangular casing. The dust laden air is
drawn through them by suction.

14. 15 Cement Storage Silo
The cement storage silo is used for storing the finished
product – cement.
16 Packing and Dispatch
The cement is packed with the
help of a rotary packer and finally
dispatched to the market.

15. 17 Central Control Room
It is the nerve center of the cement plant since all equipment is controlled from this
place. It is the place from where all the process parameters are controlled.

16. Gantt Chart of 6 weeks Training