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MR.
ASSIT. MGR.
ON
ASPECTS OF
MANUFACTURING
(2013-2017)
SUBMITTED BY:
SUBMITTED TO:
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H.O.D OF
Mechanical Engg.
+
INDEX
Sr. No
TOPIC
Introduction
Page No.
4-6
10-12
13-33
PLC , Preheater
34-36
37-38
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39-40
41
Conclusion
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. When
mixed with water cement hardens, both in air and under water and retains
its strength under water.
OR
Portland cement clinker is a hydraulic material which shall consist of at
least two-thirds by mass of calcium silicates (3CaO.SiO2 and 2CaO.SiO2),
the remainder consisting of aluminum- and iron-containing clinker phases
and other compounds. The ratio of CaO to SiO2 shall not be less than 2.0.
The magnesium content (MgO) shall not exceed 5.0% by mass.
Cement manufacturing consists of raw meal grinding, blending, precalcining, clinker burning and cement grinding. In short, limestone and
other materials containing calcium, silicon, aluminium and iron oxides are
crushed and milled into raw meal. This raw meal is blended and heated in
the preheated system to initiate dissociation of carbonate to calcium oxide
and carbon dioxide.The secondary fuel is fed into the preheater to keep the
temperature sufficiently high. Then meal is fed into the rotary kiln for
reaction between calcium 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 and
RAJASTHAN. Firstly we get the 70mm size limestone with the help of
crusher and stock it with the help of stacker through belt conveyor.
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In Raw mill / VRM section, limestone, shale, quartzite & Iron ore are
fed in measured quantity through weigh feeders. In the mill the mixture
further reduces the size to the desired fineness. The finer product
separated by air separator is goes to the Electro-static precipitator & then
to the blending silos and coarse material is fed back into the mill Inlet. Raw
mill / VRM s controlled by central control room. The set point for chemical
composition of the raw meal and fineness of the material is given by the
Laboratory department.
From raw mill the raw meal is fed to the blending and the storage
silos .In the blending part of the silo, further homogenization of raw meal
takes place so that a constant quality is maintained. In storage part the raw
meal is stored so that it may be fed at the desired rate. From there the
material is fed to the low lift pumps (L.L.P.s) with the help of bucket
elevators. Low lift pumps feed the material or raw meal to the preheater
cyclone. 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 of
preheating zone. About 60%of the coal firing is done at pre-calciner section
itself. Raw meal which is almost calcined enters from the one end of the
kiln. From the other end of the kiln the pulverised coal is fired . Various
chemical reactions occurs as the raw meal progresses from feed end to the
burning zone , where intermediate phases consisting of CaO, Al 2O3, Fe2O3
become liquid and because of the rotation of kiln CaO and silica combine
with liquid to form nodules called clinker.
At the lower end of the kiln the temperature reaches to about 1450
degree centigrade . Due to such high temperature the physical and the
chemical characteristics of the raw meal changes . Clinker that comes out
of the kiln is at a very high temperature and has to be cooled to facilitate
handling and grinding . Hence, the clinker is passed through the cooler
where cooling takes place by means of fans. Hot air is used for combustion
inside the kiln and calciner. In cooler circuit the ESP has also been installed
to control the air pollution. With the help of the drag chains and bucket
elevators the clinker is fed to the clinker silos. .
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QUARRYING
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BLASTING
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HAMMER
CRUSHER:
.
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Description:-
These are used for the size reduction of hard to medium hard
limestone 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 two
types 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 the
formula, P=mv/2. Mass of hammers in hammer mill was reduced to
minimum while increasing the velocity as far as possible, resulting in
greater impact force combined with reduced wear. Rim speed of the
hammers is in the range of 5000 to 7000 rpm. Power demand of single
hammer crusher is between 1.3 to 2.8 HP h/t.
The blending bed consists of two equal material stockpiles which are
arranged in line. These material stockpiles are used both for storing and
also for prehomogeniation of the material to be stacked. The material
stockpile 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 with the boom raised its highest position.
The boom is lowered to its lowest position after reaching the starting
position.
The stacker starts the operating process after the commands for automatic
mode of stacking are given from a central control room. The stacker now
throws off the incoming material to the yard as it travels from one end of the
stockpile to the other, until a material probe which is mounted to the boom
tip sends a signal material height reached. Then a command is given to
the luffing gear to lift the boom by one lifting step. This process is repeated
until the boom, after 20 lifting steps, has reached its maximum lifting height
and
the
stockpile
is
stacked
to
its
maximum
volume .
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The ball mills are two chamber tube mill lined with Mn steel liners,
chambers are separated by intermediate diaphragms and charged with
Hyper steel balls. The compartments are separated by double diaphragm
for improving the retention time and transfer of material in second chamber
for further grinding. Size reduction of the mill feed is performed by motion of
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the grinding media. Rotation of the mill cylinder raises the pile of mill feed
and grinding media to an optimum height, necessary for grinding operation.
crusher
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3.AIR SEPARATOR
Principle of operation: Action of air current of a certain
velocity upon a mass particle is prortional to surface
presented by this particle to the air current. Materials
leaving the distributing plate are acted upon by various
forces. The action of force Fg &Fc
Upon a particle is proportional to its volume since volume
is function of diameter cube.
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VRM-CIR
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FLOW MEASUREMENT
PRESSURE MEASUREMENT
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LEVEL MEASUREMENT
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TEMPERATURE MEASUREMENT
R
e
s
Nickel
i
s
t
a
Copper
Platinum
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RT D C h a r a c t e r i s t i c s
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R1
R2 R3 R4
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Thermocouples
Thermocouples are perhaps the most widely and commonly used
sensors for temperature measurements of higher ranges in any
industrial application. The sensing 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 is
proportional to the temperature, and at the point of contact, the
electrons diffuse through the boundary layer between the two
leads, resulting in one lead becoming positive and the other
becoming the negative. Thus the EMF generated is proportional to
the temperature difference in a predictable manner. This
phenomenon is known as SEEBECK Effect.
Copper
Measuring
Measuring
Junction
Instrument
Constantan
Reference Junction
FLOW MEASUREMENTS
Electrode
North
South
flow meter is as shown in figure. The flow tube lies in the uniform
magnetic density B.
The two electrodes are inserted in the tube, their surfaces being
flushed with the inner surface of the tube and in contact with the
liquids. As the conductive liquid passes through the insulated tube
with an velocity v, it may be considered as flat conductor disks
passing through the magnetic field, inducing an emf e across the
electrodes. This is expressed as following equation.
e = B X d X v X 10 -8 V Where, e is the
induced voltage,
B is the flux density in tesla,
d is the distance between the two electrodes in
meter,
v is the average velocity in met/sec
V is the constant to care of Units.
The main advantage of this flow meter is, it does not obstruct the
flowing fluid and it do not have any moving part.
Application: VRM internal water spray flow measurement.
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Rotameters
A Rotameters consists of a vertical tube with a tapered cone in
which a float assumes a vertical position corresponding to each
flow rate through the tube. The conical tube is made of glass,
stainless steel or Monel and the floats are made up of brass,
stainless steel, monel or special plastics. The Rotameters are
sometimes referred as constant pressure drop, variable area or
variable aperture meters.
Flow
W
W
PRESSURE MEASUREMENTS:
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Membrane
P
P
Corrugated
Stretched
Diaphragm
Diaphragm
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pointer
Manometer
Bourdon Gauge
Elastic Element
Mechanical
Pressure
to
Transducer
Electrical Transducer
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Fluid
Energy Input
Mechanical
Energy Output
Electrical
Energy
Fig : Basic Principle for Pressure Transduce
SERIAL OR
PARALLEL I/O
PROCESSOR
RACKS
The Output from PLC are given to the devices and final
control elements such as:
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Lamps
Indicators
Relays
Solenoids
Motor contactors
4-20 mA signals to operate control valves
PREHEATER
All the three processes drying,preheating and
calcinations are done in the preheater.
The key component of the gassuspension preheater is the cyclone.
A cyclone is a conical vessel into
which a dust-bearing gas-stream is
passed tangentially. This produces a
vortex within the vessel. The gas
leaves the vessel through a co-axial
"vortex-finder". The solids are thrown
to the outside edge of the vessel by
centrifugal action, and leave through a
valve in the vertex of the cone.
Cyclones were originally used to
clean up the dust-laden gases leaving
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simple dry process kilns. If, instead, the entire feed of rawmix is
encouraged to pass through the cyclone, it is found that a very efficient
heat exchange takes place: the gas is efficiently cooled, hence producing
less waste of heat to the atmosphere, and the rawmix is efficiently heated.
This efficiency is further increased if a number of cyclones are connected in
series
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take place due to which hot gase transfer the heat to the raw material and
heat it up in the preheater and gases cool down.
As we see in the graph between temperature and stages,temperature of
exhaust gas decrease as it flows from 5th stage 1st stage and on other sides
temp. of raw meal increases as it comes down from 1 st to 5th stage.
Precalciner ;
ROTARY KILN
A Rotary kiln is a pyroprocessing device used to raise materials to a high
temperature (calcination) in a continuous process. The rotary kiln consists
of a tube made from steel plate, and lined with firebrick. The tube slopes
slightly (14) and slowly rotates on its axis at between 30 and 250
revolutions per hour. Rawmix is fed in at the upper end, and the rotation of
the kiln causes it gradually to move downhill to the other end of the kiln.
The temperature of the burning zone is 1400-1500 0C.
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FUNCTIONAL DESCRIPTION :
The feed material enters the rotary kiln through the inlet housing. The
inclination and the rotation of the kiln cause the material to move in
counter-flow to the hot gases towards the outlet and from there into the
cooler.
In this process the feed material passes through the following
reaction zones :
1.
2.
3.
4.
clinker
CLINKER COOLING
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Cement
The reciprocating grate cooler serves for the cooling of the small sized or
granulated burned material. An excellent cooling effect is achieved in that.
The cold air is blown through the cooler grate and through the burned
material lying on the grate.
Cooling principle:
CEMENT GRINDING
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Cement clinker is usually ground using a ball mill. This is essentially a large
rotating drum containing grinding media - normally steel balls. As the drum
rotates, the motion of the balls crushes the clinker. The drum rotates
approximately once every couple of seconds.The drum is generally divided
into two or three chambers, with different size grinding media.
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As the clinker particles are ground down, smaller media are more efficient
at reducing the particle size still further. Grinding systems are either 'open
circuit' or 'closed circuit.' In an open circuit system, the feed rate of
incoming clinker is adjusted to achieve the desired fineness of the product.
In a closed circuit system, coarse particles are separated from the finer
product and returned for further grinding.
BALL MILL INTERNAL
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Ball mill
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DUST COLLECTORS
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1.Cyclone Separator:
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2.Bag Filter
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3.Electrostatic Precipitator:
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