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4
INDEX
Sr.No TOPIC
Page No.
1 Introduction
4-6
2 Overview of cement manufacturing process3 Steps in cement manufacturing--a.
Quarryingb. Raw meal preparationc. Pyroprocessingd. Cement grinding
10-12
4 Various instruments used in field
13-33
5 PLC , Preheater
34-36
6 Clinker Cooling,bag filter
37-38
7 Cement packing, storage &dispatch
39-40
8

Conclusion
41

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PORTLAND CEMENT
DEFINITION:
Cement is finely ground hydraulic binding medium for mortar and
concrete,consisting substantially of compounds of CaO with SiO2, Al2o3 and ferric
oxide which have been formed by sintering or fusion. Sintering means
burning at a temperature which cause partial fusion of the material. Whenmixed
with water cement hardens, both in air and under water and retainsits strength
under water.ORPortland cement clinker is a hydraulic material which shall consist of
atleast two-thirds by mass of calcium silicates (3CaO.SiO
2
and 2CaO.SiO
2
), the remainder consisting of aluminum- and iron-containing clinker phasesand
other compounds. The ratio of CaO to SiO
2
shall not be less than 2.0.The magnesium content(MgO)shall not exceed 5.0% by
mass.Portland cement is manufactured by burning a calcareous material, suchas,
limestone, chalk, shells or marl and an argillaceous material such asclay, shale etc.
at a high temperature of 1450-1500c and grinding the
resultant product called Clinker with the addition of the small quantity of
the Gypsum.The ordinary Portland cement consists of four major components i.e.

Tricalcium Silicate (C3S)

Dicalcium Silicate (C2S)

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Tricalcium Aluminate (C3A)

Tetracalcium Alumino ferrite (C4AF).

OVERVIEW OF cemENT MANUFACTURINGPROCESS

Cement manufacturing consists of raw meal grinding, blending, pre-calcining,
clinker burning and cement grinding. In short, limestone andother materials
containing calcium, silicon, aluminium and iron oxides arecrushed and milled into
raw meal. This raw meal is blended and heated inthe preheated system to initiate
dissociation of carbonate to calcium oxideand carbon dioxide.The secondary fuel is
fed into the preheater to keep thetemperature sufficiently high.Then meal is fed into
the rotary kiln forreaction between caclcium oxide and other elements to form
calcium

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Tricalcium Aluminate (C3A)

Tetracalcium Alumino ferrite (C4AF).

OVERVIEW OF CEMENT MANUFACTURINGPROCESS

Cement manufacturing consists of raw meal grinding, blending, pre-calcining,
clinker burning and cement grinding. In short, limestone andother materials
containing calcium, silicon, aluminium and iron oxides arecrushed and milled into
raw meal. This raw meal is blended and heated inthe preheated system to initiate
dissociation of carbonate to calcium oxideand carbon dioxide.The secondary fuel is
fed into the preheater to keep thetemperature sufficiently high.Then meal is fed into
the rotary kiln forreaction between caclcium oxide and other elements to form
calcium

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The raw materials used are lime stone, shale, iron ore and gypsum.The lime stone
provided by nature and Iron-ore comes from BIHAR andRAJASTHAN. Firstly we get
the 70mm size limestone with the help ofcrusher and stock it with the help of
stacker through belt conveyor.In Raw mill / VRM section, limestone, shale, quartzite
& Iron ore arefed in measured quantity through weigh feeders. In the mill the
mixturefurther reduces the size to the desired fineness. The finer productseparated
by air separator is goes to the Electro-static precipitator & thento the blending silos
and coarse material is fed back into the mill Inlet. Rawmill / VRM s controlled by
central control room. The set point for chemicalcomposition of the raw meal and
fineness of the material is given by theLaboratory department.From raw mill the raw
meal is fed to the blending and the storagesilos .In the blending part of the silo,
further homogenization of raw mealtakes place so that a constant quality is
maintained. In storage part the rawmeal is stored so that it may be fed at the
desired rate. From there thematerial is fed to the low lift pumps (L.L.P.s) with the
help of bucketelevators. Low lift pumps feed the material or raw meal to the
preheatercyclone . To reduce the requirement of heavy coal injection in the kiln ,
95%of the calcination occurs in the M.F.C., D.D.F. vessels and cyclones ofpreheating
zone. About 60%of the coal firing is done at pre-calciner sectionitself . Raw meal
which is almost calcined enters from the one end of thekiln . From the other end of
the kiln the pulverised coal is fired . Variouschemical reactions occurs as the raw
meal progresses from feed end to theburning zone , where intermediate phases
consisting of CaO, Al
2
O
3
, Fe
2
O
3
become liquid and because of the rotation of kiln CaO and silica combinewith liquid
to form nodules called clinker.At the lower end of the kiln the temperature reaches
to about 1450degree centigrade . Due to such high temperature the physical and
thechemical characteristics of the raw meal changes . Clinker that comes outof the
kiln is at a very high temperature and has to be cooled to facilitate

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handling and grinding . Hence, the clinker is passed through the coolerwhere
cooling takes place by means of fans. Hot air is used for combustioninside the kiln
and calciner. In cooler circuit the ESP has also been installedto control the air
pollution. With the help of the drag chains and bucketelevators the clinker is fed to
the clinker silos. .
STEPS IN MANUFACTURING OF PORTLAND CEMENT
Portland cement is manufactured in four step process.STEP 1.
Quarrying
The raw material for cement manufacture is rock mixture which is about80%
limestone (which is rich in CaCO3)and 20% clay or shale (source ofslica,alumina and
ferrite ).These are quarried and stored separately.Thelime ind silica provide the
main strength to cement,while the iron reduce thereaction temperature and gives
the cement its characterstic grey colour.STEP 2.
Raw Meal Preparation
It involves mixing the extract raw material to obtaine the correct
chemicalcomposition,and grinding them to achieve proper particle size to
ensureoptimal fuel efficiency in the kiln and strength in final concrete product.If
thedry process is used then raw material is dried by using dryers,Airseparaters
before grinding.STEP.3
Pyroprocessing or Clinkering
In this raw mix is heated to produced cement clinker(which is grey incolour and in
spherical nodules with diameter ranging 0.3-5cm).It involvesthree steps
preheating,calcining(in which CaO is formed)and burning. Thepyroprocessing takes
place in kiln department.The raw mix is provided inform of powder.In the rotary kiln
temperature is ranging about 1400-1450c.STEP.4
Cement Milling

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handling and grinding . Hence, the clinker is passed through the coolerwhere
cooling takes place by means of fans. Hot air is used for combustioninside the kiln
and calciner. In cooler circuit the ESP has also been installedto control the air
pollution. With the help of the drag chains and bucketelevators the clinker is fed to
the clinker silos. .
STEPS IN MANUFACTURING OF PORTLAND CEMENT
Portland cement is manufactured in four step process.STEP 1.
Quarrying
The raw material for cement manufacture is rock mixture which is about80%
limestone (which is rich in CaCO3)and 20% clay or shale (source ofslica,alumina and
ferrite ).These are quarried and stored separately.Thelime ind silica provide the
main strength to cement,while the iron reduce thereaction temperature and gives
the cement its characterstic grey colour.STEP 2.
Raw Meal Preparation
It involves mixing the extract raw material to obtaine the correct
chemicalcomposition,and grinding them to achieve proper particle size to
ensureoptimal fuel efficiency in the kiln and strength in final concrete product.If
thedry process is used then raw material is dried by using dryers,Airseparaters
before grinding.STEP.3
Pyroprocessing or Clinkering
In this raw mix is heated to produced cement clinker(which is grey incolour and in
spherical nodules with diameter ranging 0.3-5cm).It involvesthree steps
preheating,calcining(in which CaO is formed)and burning. Thepyroprocessing takes
place in kiln department.The raw mix is provided inform of powder.In the rotary kiln
temperature is ranging about 1400-1450c.STEP.4
Cement Milling

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To produce the final product clinker is mixed with gypsum and otheradditive is
grinded in large tube mill.First grinding breaks up the materialand second grinds
into fine powder.The grinding process is controlled to obtain a powder with a broad
particlesize range
,in which typically 15% by mass consists of particles below 5 m
diameter.
QUARRYING
Quarry operation consists of drilling,blasting,loadingcrushing,hanhling,screening
and storing.The raw materials are usually quarried from local rock, which in
someplaces is already practically the desired composition and in other
placesrequires the addition of clay and limestone,as well as iron ore, bauxite

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HAMMER CRUSHER: .
Description
:These are used for the size reduction of hard to medium hardlimestone and for raw
marl crushing. Reduction ratios are as high as 1:40.Depending upon crusher feed
this can be reduced to 1:60. Generally twotypes of the hammer crushers are
manufactured:

Single shaft hammer crusher.

Double shaft hammer crusher.These work with the impact effect of the hammers
according to theformula, P=mv/2. Mass of hammers in hammer mill was reduced
tominimum while increasing the velocity as far as possible, resulting ingreater
impact force combined with reduced wear. Rim speed of thehammers is in the range
of 5000 to 7000 rpm. Power demand of singlehammer crusher is between 1.3 to 2.8
HP h/t

Pre - blending: stacking and reclaiming

The blending bed consists of two equal material stockpiles which arearranged in
line. These material stockpiles are used both for storing andalso for
prehomogeniation of the material to be stacked. The materialstockpile of one pile
can be reclaimed while the other stockpile is stacked.
Stacking of the blending bed:Stacking of the blending bed is carried out in the Chevron method by
means of a stacker with loop car. The stacker with loop car is moved into
its starting position in manual mode w
ith the boom raised its highestposition. The boom is lowered to its lowest position
after reaching thestarting position.The stacker starts the operating process after the
commands for automaticmode of stacking are given from a central control room.
The stacker nowthrows off the incoming material to the yard as it travels from one
end of thestockpile to the other, until a material probe which is mounted to the
boom
tip sends a singal material height reached. Then a command is given to
the luffing gear to lift the boom by one lifting step. This process is repeateduntil the
boom, after 20 lifting steps, has reached its maximum lifting height

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and the stockpile is stacked to its maximumvolume
.
The material is reclaimed from the stockpile by the forward movementof the scraper
travel gears in connection with the reversible rake car on thescraper bridge, the
rakes mounted to the car on the scraper bridge, therake mountRAW MEAL
PREPARATION
The raw materials are usually quarried from local rock, which in someplaces is
already practically the desired composition and in other placesrequires the addition
of clay and limestone,as well as iron ore, bauxite orrecycled materials. The
individual raw materials are first crushed, typicallyed to the rake car and the
material discharge by the scraperchain drive

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to below 50 mm. In many plants, some or all of the raw materials are thenroughly
blended in a "prehomogenization pile." The raw materials are nextground together
in a rawmill.Silos of individual raw materials are arrangedover the feed conveyor
belt. Accurately controlled proportions of eachmaterial are delivered onto the belt
by weigh-feeders. Passing into therawmill, the mixture is ground to rawmix. The
fineness of rawmix isspecified in terms of the size of the largest particles, and is
usuallycontrolled so that there are less than 5%-15% by mass of particles
exceeding 90 m in diameter. It is important that the rawmix contains no
large particles in order to complete the chemical reactions in the kiln, and toensure
the mix is chemically homogenous. In the case of a dry process, therawmill also
dries the raw materials, usually by passing hot exhaust gasesfrom the kiln through
the mill, so that the rawmix emerges as a fine powder.This is conveyed to the
blending system by conveyor belt or by a pump.
RAW MILL
Activity of Raw mill department start from feeding the raw materials(Limestone,
Shale, Quartzite and Iron ore) to the mills and ends at fillingthe raw meal to silos.

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19
RAW MILL CIRCUIT CONSISTS OF:1.Feed Hoppers(to feed lime stone &corrective
materials).2.Weight Feeders(to feed material in different rates).3.Bucket Elevator(to
carry raw material & product discharge from mill to airseparator).4.Air Separator(to
separate out coarse and fine particles).5. A multi bag dust collector (for
precipitating fine dust from mill draft)
1.
Function of Ball mill

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A
ball mill
is a type of grinder used to grind materials into extremely finepowder for use in
many industries. The ball mill allows grinding of theharder limestone that are more
common than chalk. A ball mill consists of ahorizontal cylinder that rotates on its
axis. It holds spherical, cylindrical orrod-like grinding media of size 15

100 mm that may be steel or a variety ofceramic materials, and occupy 20

30% of the mill volume. The shell of themill is lined with steel or rubber plates.
Grinding is effected by impact andattrition between the grinding media
.
The ball mills are two chamber tube mill lined with Mn steel liners,chambers are
separated by intermediate diaphragms and charged withHyper steel balls. The
compartments are separated by double diaphragmfor improving the retention time
and transfer of material in second chamberfor further grinding. Size reduction of the
mill feed is performed by motion ofthe grinding media. Rotation of the mill cylinder
raises the pile of mill feedand grinding media to an optimum height, necessary for
grinding operation

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A
ball mill
is a type of grinder used to grind materials into extremely finepowder for use in
many industries. The ball mill allows grinding of theharder limestone that are more
common than chalk. A ball mill consists of ahorizontal cylinder that rotates on its
axis. It holds spherical, cylindrical orrod-like grinding media of size 15

100 mm that may be steel or a variety ofceramic materials, and occupy 20

30% of the mill volume. The shell of themill is lined with steel or rubber plates.
Grinding is effected by impact andattrition between the grinding media
.
The ball mills are two chamber tube mill lined with Mn steel liners,chambers are
separated by intermediate diaphragms and charged withHyper steel balls. The
compartments are separated by double diaphragmfor improving the retention time
and transfer of material in second chamberfor further grinding. Size reduction of the
mill feed is performed by motion ofthe grinding media. Rotation of the mill cylinder
raises the pile of mill feedand grinding media to an optimum height, necessary for
grinding operation.
2
. TERTIARY CRUSHER (REVERSIBLE
IMPACTOR TYPE
)

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It is a impactor type crusher employing a high speed rotating disc towhich no. of
hammers are fixed whose swung towards with centrifugalforce. the hammers are
made up of mild steel. The material is fed at top ofthe crusher and it is thrown out
centrifugally and crushed by being betweenhammers and periphery of cylindrical

casing. Since the the hammer barsare hinged, in case of any hard material does not
cause damage toequipment. The bars are readily replaced when they are worn out.
Hammer crusher
3
.AIR SEPARATOR

Principle of operation
:
Action of air current of a certain velocity upon amass particle is prortional to surface
presented by this particle to the aircurrent. Materials leaving the distributing plate
are acted upon by variousforces. The action of force Fg &FcUpon a particle is
proportional to its volume since volume is function ofdiameter cube.It is an
industrial machine which sorts materials by a combination of size,shape, and
density.It works by injecting the material stream to be sorted

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into a chamber which contains a column ofrising air.Inside the separation chamber,
airdrag on the objects supplies an upward force which counteracts the force of
gravity and liftsthe material to be sorted up into the air.

VERTICAL ROLLER MILL

With the continual increasing demand for Portland cement and constantpressure for
reduced energy consumption, producers are exploring a wide

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variety of cost-saving manufacturing options. One option is vertical rollermill
technology for raw material grinding.VRM-CIRCUIT FLOW DIAGRAM :

DESCRIPTION:
It has same way of working as of raw mill, but it is moreeconomical then raw mill.
The raw material from hoppers goes to thevertical raw mill where material is
grinded and fines are through to CF silo

and to bag house. Fines from bag house go to the blending silo and stackto vent off.

RAW MEAL HOMOGENISATION

Ground raw meal is stored in large blending silos. These silos are airactivated to
promote homogenization of the raw meal, reducing chemicalvariation and
promoting a stable sintering process in the rotary kiln.. Thesemay work continuously
or batch-wise, in multi-stage systems, and incombination with air agitation. In
modern plants, the trend is large,continuously operating silos. It follows that the
silos, working as continuousblending systems, have to be full in order to have a
blending effect. If thesilos are only partially full, the variations in the raw mix
composition fromthe raw mill will go directly to the kiln. The efficiency of a blending
systemcan be characterized by the ratio, H, between variations in composition ofthe
incoming and the outgoing material. An example is the ratio betweenthe standard
deviation of CaO in the raw meal before and after the kiln feedsilos.

Homogenization is the final opportunity to affect the raw meal chemistryand quality
before introduction to the pyroprocessing phase.

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and to bag house. Fines from bag house go to the blending silo and stackto vent off.
VRMRAW MEAL HOMOGENISATION

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25
Ground raw meal is stored in large blending silos. These silos are airactivated to
promote homogenization of the raw meal, reducing chemicalvariation and
promoting a stable sintering process in the rotary kiln.. Thesemay work continuously
or batch-wise, in multi-stage systems, and incombination with air agitation. In
modern plants, the trend is large,continuously operating silos. It follows that the
silos, working as continuousblending systems, have to be full in order to have a
blending effect. If thesilos are only partially full, the variations in the raw mix
composition fromthe raw mill will go directly to the kiln. The efficiency of a blending
systemcan be characterized by the ratio, H, between variations in composition ofthe
incoming and the outgoing material. An example is the ratio betweenthe standard
deviation of CaO in the raw meal before and after the kiln feedsilos.

Homogenization is the final opportunity to affect the raw meal chemistryand quality
before introduction to the pyroprocessing phase.

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VARIOUS TYPE OF FIELD INSTRUMENT USED IN GAGALCEMENT WORKS

TEMPRATURE MEASUREMENT

Resistance temprature measurement (RTD)

Thermocouple

Optical pyrometer

FLOW MEASUREMENT

Head type flow meter like orifice,venturi,pitot tube.

Electromegnatic flow meter

Rotameter

PRESSURE MEASUREMENT

Diaphragm, bourdon tube

LVDT type transducer

VEL MEASUREMENT

Capacitor level measurement

RF type level measurement

Ultra sonic level measurement

Vibrating folk type level measurement

Float type level switch

Bin level measurement

Radar type level measurement

WIEGHING SECTION (STRAIN GAUSES

)

Solid flow meter

Weigh feeder

Rotor scale

Multi core

Belt weigher

Weigh bridge

Poldos system
GAS ANALYZER

CO analyzer

Oxygen analyzer

NOX analyzer

TEMPERATURE MEASUREMENTResistance Temperature Detectors (RTD)

RTDs commonly use Platinum, Nickel and Copper to form the sensors. Therelation
ship between the Resistance of these metals and Temperature is asshown below.
Platinum is used very widely in the Industry for measuring thetemperature of
moderate range between 0

300 Deg. C.
NickelCopperPlatinum
Resist

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30RTD Characteristics
Platinum RTDs are used widely in industries because it is resistant to corrosion
and oxidation, malleable, has a very high melting point. As shown in the graphplots
the relation ship between resistance and temperature is linear over a widerange of
temperature from 250

800 deg C.Metals are basically crystalline in structure comprising metal ions and
freeelectrons in equilibrium. The application of DC potential across the
metallicelements results in directional flow of these electrons. During their
movementthey collide with themselves and with the ions comprising the crystal
lattice, thusrestricting its flow, which results in an electrical resistance. As the metal
is heated,temperature rises and the mean free length between collision decreases
due tothe increase in amplitude of oscillation, resulting in an increase in
electricalresistance.The range of temperature over which this phenomenon is valid
is decided by thetemperature coefficient of resistance, chemical inertness, and its
crystal structurewhich should not undergo permanent changes within this range. In
general, theresistivity of metals increases with an increase in temperature (i.e.: The
Temp.coefficient is positive), where as in some semiconductors the resistance
decreaseswith the increase of temperature. (i.e.: Temp. coefficient is negative).
Suchvariation in the temperature can be measured with the suitable electrical
circuits
like Wheatstones bridge or Mullers bridge

R
esistance Temperature Detector (Four Wire)

Calendars interpolating equation for temperature above 0 deg C for Platinum

(PT100) sensor is as given below.Platinum resistance elements (PT100) fabricated
with high purity wires orfoils are excellent for high precision temperature
measurements. Coiled platinum
wire elements are used on board aircrafts for outside air temperature
measurements.Application: Measurement of bearing temperatures and motor
windingtemperatures. Apart from it RTDs are used in the Coal mill circuit and other
lowtemperature applications.Problems faced: Damage to element of RTD due to
vibration in bearings.

thermocouples
Thermocouples are perhaps the most widely and commonly used sensors for
temperature measurements of higher ranges in any industrial application.
Thesensing is based on the principle that current flows in a closed circuit made up
of two dissimilar metals if the junction of the two metals kept at different
temperature. In each lead, the concentration of the valence electron isproportional
to the temperature, and at the point of contact, the electrons diffusethrough the
boundary layer between the two leads, resulting in one leadbecoming positive and
the other becoming the negative. Thus the EMF generatedis proportional to the
temperature difference in a predictable manner. Thisphenomenon is known as
SEEBECK .

FLOW MEASUREMENTS
Electromagnetic Flow Meters
The Operation of this type of flow meters are based on the Faradays laws of
electromagnetic induction principal. The law states that the relative motion of
amedium flowing at right angles to a pair of electrodes and a magnetic field
willdevelop an emf across the electrodes.ElectrodeBFig : Principle of
electromagnetic flow meterIn this device the fluid passing through the pipe has to
be conductive. Theschematic arrangement of the Electromagnetic flow meter is as
shown in figure.The flow tube lies in the uniform magnetic density B

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The two electrodes are inserted in the tube, their surfaces being flushed with
theinner surface of the tube and in contact with the liquids. As the conductive
liquidpasses through the insulated tube with an velocity v, it may be considered as
flatconductor disks passing through the magnetic field, inducing an emf e across
theelectrodes. This is expressed as following equation.e = B X d X v X 10-8V Where,
e is the inducedvoltage,B is the flux density in tesla,d is the distance between the
two electrodes in meter,v is the average velocity in met/secV is the constant to care
of Units.The main advantage of this flow meter is, it does not obstruct the flowing
fluidand it do not have any moving part.
Application:
VRM internal water spray flow measurement.

Rotameters
A Rotameters consists of a vertical tube with a tapered cone in which a
floatassumes a vertical position corresponding to each flow rate through the tube.
Theconical tube is made of glass, stainless steel or Monel and the floats are made
upof brass, stainless steel, monel or special plastics. The Rotameters are
sometimesreferred as constant pressure drop, variable area or variable aperture
meters.Flow
PRESSURE MEASUREMENTS:
Pressure is defined as the force acting per unit area, measured at a givenpoint or
over a surface. This can be in absolute, gauge or differential units,depending on the
reference taken.

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Pressure Transducers can be classified into gravitational and elastic types.
Ingravitational type, the familiar Manometer is the simplest device. In
elastictransducer the pressure exerts a force over the area of an elastic device.
Theforce responsive member is in the form of diaphragm, capsule, bellows
orBourdon tube as shown in figure.MembranePP CorrugatedStretched
DiaphragmDiaphragmA Bpointer
Manometer Bourdon Gauge

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The resultant displacement or strain developed is measured with anappropriate
electrical sensor. The conversion of this mechanical phenomenonto an equivalent
electrical signal is achieved by a variety of linkagemechanisms. The transduction
principles used are deflection measurementswith resistive, inductive, and capacitive
principles or measurement of change innatural resonance frequency of a stretched
member.In all transducer energy from the measurand is converted to
energyproportional to the measurand. Conventional pressure transducers achieve
thisby converting the pressure to a mechanical displacement.The pressure
measuring transducers can be of two types. They are
Direct
and
Indirect
type of measurement.The direct types of measuring devices are, Manometer,
barometers etc. TheIndirect types of devices are, based on the elastic elements
which deflectsunder pressure, such as diaphragms, bellows and tubes. Instruments
of thisgroup can be coupled to the mechanical to electrical transducers of
suitabletype.

LOW MEASUREMENTS
Electromagnetic Flow Meters
The Operation of this type of flow meters are based on the Faradays laws of
electromagnetic induction principal. The law states that the relative motion of
amedium flowing at right angles to a pair of electrodes and a magnetic field
willdevelop an emf across the electrodes.ElectrodeBFig : Principle of
electromagnetic flow meterIn this device the fluid passing through the pipe has to
be conductive. Theschematic arrangement of the Electromagnetic flow meter is as
shown in figure.The flow tube lies in the uniform magnetic density B