FIVE WEEK INDUSTRIAL TRAINING

AT TAMBEE ERECTORS PVT.

LTD
RAIPUR

PREPARED BY:UNDER GUIDENCE OF:Aditya Kumar Yadav

AMIT SINGH
Branch :- Mechanical Engg.
INSTRUMENTATAION
Roll No:- 1349240005

@aditya_kumar_Yadav #1349240005

MR.
ASSIT. MGR.

SUMMER TRAINING PROJECT

REPORT
PROCESS
CEMENT

ON
ASPECTS OF
MANUFACTURING

KCC Institute on technology and

Management
(B.Tech in Mechanical Engg.)

(2013-2017)
SUBMITTED BY:
SUBMITTED TO:
@aditya_kumar_Yadav #1349240005

Aditya Kumar Yadav

H.O.D OF

Branch:- Mechanical Engg.

Roll No:- 1349240005

Mechanical Engg.
+

Mr. Keshav Jha

INDEX
Sr. No

TOPIC

Introduction

Page No.

4-6

Overview of cement manufacturing process

Steps in cement manufacturing-a. Quarrying

b. Raw meal preparation
c. Pyro processing
d. Cement grinding

10-12

Various instruments used in field

13-33

PLC , Preheater

34-36
37-38

Clinker Cooling, bag filter

@aditya_kumar_Yadav #1349240005

39-40

Cement packing, storage &dispatch

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.

Portland cement is manufactured by burning a calcareous material, such

as, limestone, chalk, shells or marl and an argillaceous material such as
clay, 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.
@aditya_kumar_Yadav #1349240005

Tricalcium Silicate (C3S)

Dicalcium Silicate (C2S)
Tricalcium Aluminate (C3A)
Tetracalcium Alumino ferrite (C4AF).

OVERVIEW OF CEMENT MANUFACTURING

PROCESS

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
@aditya_kumar_Yadav #1349240005

silicates and other aluminates at temperature upto 1450 degree calcius.

Primary fuel is used to keep temperature high enough in burning zone to
chemical reaction takes place.

PROCESS FLOW DIAGRAM OF CEMENT

MEANUFACTURING

@aditya_kumar_Yadav #1349240005

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.

@aditya_kumar_Yadav #1349240005

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. .

@aditya_kumar_Yadav #1349240005

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 about
80% limestone (which is rich in CaCO3)and 20% clay or shale (source of
silica, alumina and ferrite ).These are quarried and stored separately. The
liming silica provide the main strength to cement, while the iron reduce the
reaction temperature and gives the cement its characteristic grey color.
STEP 2. Raw Meal Preparation
It involves mixing the extract raw material to obtain the correct chemical
composition, and grinding them to achieve proper particle size to ensure
optimal fuel efficiency in the kiln and strength in final concrete product. If
the dry process is used then raw material is dried by using dryers, Air
separators before grinding.
STEP.3 Pyro processing or Clinkering
In this raw mix is heated to produced cement clinker (which is grey in color
and in spherical nodules with diameter ranging 0.3-5cm).It involves three
steps preheating, calcining (in which CaO is formed)and burning. The pyro
processing takes place in kiln department. The raw mix is provided in form
of powder. In the rotary kiln temperature is ranging about 1400-1450c.
STEP.4 Cement Milling
To produce the final product clinker is mixed with gypsum and other
additive is grinded in large tube mill. First grinding breaks up the material
and second grinds into fine powder.
The grinding process is controlled to obtain a powder with a broad particle
size range, in which typically 15% by mass consists of particles below 5 m
diameter.

QUARRYING
@aditya_kumar_Yadav #1349240005

Quarry operation consists of drilling, blasting, loading crushing, handling,

screening and storing.
The raw materials are usually quarried from local rock, which in some
places is already practically the desired composition and in other places
requires the addition of clay and limestone, as well as iron ore, bauxite or
recycled material.

BLASTING

LOADING & HAULAGE

@aditya_kumar_Yadav #1349240005

MINING, CRUSHING & HANDLING

Raw Material Crushing:

HAMMER
CRUSHER:
.

@aditya_kumar_Yadav #1349240005

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.

Pre - blending: stacking and reclaiming

@aditya_kumar_Yadav #1349240005

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 .

@aditya_kumar_Yadav #1349240005

The material is reclaimed from the stockpile by the forward movement

of the scraper travel gears in connection with the reversible rake car on the
scraper bridge, the rakes mounted to the car on the scraper bridge, the
rake mounted to the rake car and the material discharge by the scraper
chain drive.

@aditya_kumar_Yadav #1349240005

RAW MEAL PREPARATION

The raw materials are usually quarried from local rock, which in some
places is already practically the desired composition and in other places
requires the addition of clay and limestone, as well as iron ore, bauxite or
recycled materials. The individual raw materials are first crushed, typically
to below 50 mm. In many plants, some or all of the raw materials are then
roughly blended in a "prehomogenization pile." The raw materials are next
ground together in a rawmill. Silos of individual raw materials are arranged
over the feed conveyor belt. Accurately controlled proportions of each
material are delivered onto the belt by weigh-feeders. Passing into the
rawmill, the mixture is ground to rawmix. The fineness of rawmix is
specified in terms of the size of the largest particles, and is usually
controlled 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 to
ensure the mix is chemically homogenous. In the case of a dry process, the
rawmill also dries the raw materials, usually by passing hot exhaust gases
from 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 filling
the raw meal to silos.

@aditya_kumar_Yadav #1349240005

RAW MILL CIRCUIT FLOW DIAGRAM :

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 air
separator).
@aditya_kumar_Yadav #1349240005

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:

A ball mill is a type of grinder used to grind materials into extremely fine
powder for use in many industries. The ball mill allows grinding of the
harder limestone that are more common than chalk. A ball mill consists of a
horizontal cylinder that rotates on its axis. It holds spherical, cylindrical or
rod-like grinding media of size 15100 mm that may be steel or a variety of
ceramic materials, and occupy 2030% of the mill volume. The shell of the
mill is lined with steel or rubber plates. Grinding is effected by impact and
attrition 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 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

@aditya_kumar_Yadav #1349240005

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.

2. TERTIARY CRUSHER (REVERSIBLE IMPACTOR TYPE)

It is a impactor type crusher employing a high speed rotating disc to

which no. of hammers are fixed whose swung towards with centrifugal
force. the hammers are made up of mild steel. The material is fed at top of
the crusher and it is thrown out centrifugally and crushed by being between
hammers and periphery of cylindrical casing. Since the the hammer bars
are hinged, in case of any hard material does not cause damage to
equipment. The bars are readily replaced when they are worn out.
Hammer

crusher

@aditya_kumar_Yadav #1349240005

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.

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

Three forces acted upon particles are:

@aditya_kumar_Yadav #1349240005

VERTICAL ROLLER MILL

With the continual increasing demand for Portland cement and constant
pressure for reduced energy consumption, producers are exploring a wide
variety of cost-saving manufacturing options. One option is vertical roller
mill technology for raw material grinding.

@aditya_kumar_Yadav #1349240005

VRM-CIR

CUIT FLOW DIAGRAM :

DESCRIPTION: It has same way of working as of raw mill, but it is more

economical then raw mill. The raw material from hoppers goes to the
vertical 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 stack
to vent off.
VRM

@aditya_kumar_Yadav #1349240005

@aditya_kumar_Yadav #1349240005

RAW MEAL HOMOGENISATION

Ground raw meal is stored in large blending silos. These silos are air
activated to promote homogenization of the raw meal, reducing chemical
variation and promoting a stable sintering process in the rotary kiln.. These
may work continuously or batch-wise, in multi-stage systems, and in
combination with air agitation. In modern plants, the trend is large,
continuously operating silos. It follows that the silos, working as continuous
blending systems, have to be full in order to have a blending effect. If the
silos are only partially full, the variations in the raw mix composition from
the raw mill will go directly to the kiln. The efficiency of a blending system
can be characterized by the ratio, H, between variations in composition of
the incoming and the outgoing
material. An example is the
ratio between the standard
deviation of CaO in the raw
meal before and after the kiln
feed silos.
Homogenization is the final
opportunity to affect the raw
meal chemistry and quality
before introduction to the
pyroprocessing phase.

@aditya_kumar_Yadav #1349240005

VARIOUS TYPE OF FIELD INSTRUMENT USED

IN GAGAL CEMENT 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

@aditya_kumar_Yadav #1349240005

LEVEL 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

@aditya_kumar_Yadav #1349240005

OTHER MISCELENIOUS INSTRUMENT

Zero speed sensor and transmeter

VVVF drives (variable frequency variable speed drives)

Dc drive (10 nos ranging from 2.2 kw -1250kw)

Metal detector (10 nos)

CCTV kiln camera (4 nos)

Bag filter timer panel (100 n0s)

Electronic packer (7 nos)

Electronic ear (sound level)

Girth gear lubrication system ( nos)

Field bus control (10 nos)

@aditya_kumar_Yadav #1349240005

TEMPERATURE MEASUREMENT

Resistance Temperature Detectors (RTD)

RTDs commonly use Platinum, Nickel and Copper to form the

sensors. The relation ship between the Resistance of these metals
and Temperature is as shown below. Platinum is used very widely
in the Industry for measuring the temperature of moderate range
between 0300 Deg. C.

R
e
s

Nickel

i
s
t
a

Copper

Platinum

@aditya_kumar_Yadav #1349240005

RT D C h a r a c t e r i s t i c s

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 graph plots the relation ship
between resistance and temperature is linear over a wide range
of temperature from 250 800 deg C.

Metals are basically crystalline in structure comprising metal ions

and free electrons in equilibrium. The application of DC potential
across the metallic elements results in directional flow of these
electrons. During their movement they collide with themselves
and with the ions comprising the crystal lattice, thus restricting its
flow, which results in an electrical resistance. As the metal is
heated, temperature rises and the mean free length between
collision decreases due to the increase in amplitude of oscillation,
resulting in an increase in electrical resistance.
The range of temperature over which this phenomenon is valid is
decided by the temperature coefficient of resistance, chemical
inertness, and its crystal structure which should not undergo
permanent changes within this range. In general, the resistivity of
metals increases with an increase in temperature (i.e.: The Temp.
coefficient is positive), where as in some semiconductors the
resistance decreases with the increase of temperature. (i.e.:
Temp. coefficient is negative). Such variation in the temperature
can be measured with the suitable electrical circuits like
Wheatstones bridge or Mullers bridge.
Platinum wire
Mica

@aditya_kumar_Yadav #1349240005

R1

R2 R3 R4

Resistance 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 or foils 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
winding temperatures. Apart from it RTDs are used in the Coal mill
circuit and other low temperature applications.
Problems faced: Damage to element of RTD due to vibration in
bearings.

@aditya_kumar_Yadav #1349240005

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

Fig: Typical construction of Thermocouple Element

@aditya_kumar_Yadav #1349240005

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 a medium flowing at right
angles to a pair of electrodes and a magnetic field will develop an
emf across the electrodes.

Electrode

North

South

Fig : Principle of electromagnetic flow meter

In this device the fluid passing through the pipe has to be
conductive. The schematic arrangement of the Electromagnetic
@aditya_kumar_Yadav #1349240005

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.

@aditya_kumar_Yadav #1349240005

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:
@aditya_kumar_Yadav #1349240005

Pressure is defined as the force acting per unit area,

measured at a given point or over a surface. This can be in
absolute, gauge or differential units, depending on the
reference taken.
Pressure Transducers can be classified into gravitational and
elastic types. In gravitational type, the familiar Manometer is
the simplest device. In elastic transducer the pressure exerts a
force over the area of an elastic device. The force responsive
member is in the form of diaphragm, capsule, bellows or
Bourdon tube as shown in figure.

Membrane

P
P

Corrugated

Stretched
Diaphragm
Diaphragm

@aditya_kumar_Yadav #1349240005

pointer

Manometer

Bourdon Gauge

The resultant displacement or strain developed is measured

with an appropriate electrical sensor. The conversion of this
mechanical phenomenon to an equivalent electrical signal is
achieved by a variety of linkage mechanisms. The transduction
principles used are deflection measurements with resistive,
inductive, and capacitive principles or measurement of change
in natural resonance frequency of a stretched member.
In all transducer energy from the measurand is converted to
energy proportional to the measurand. Conventional pressure
transducers achieve this by 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. The Indirect types of devices are, based on the
elastic elements which deflects under pressure, such as
diaphragms, bellows and tubes. Instruments of this group can
be coupled to the mechanical to electrical transducers of
suitable type.

Elastic Element

Mechanical

Pressure

to

Transducer

Electrical Transducer

@aditya_kumar_Yadav #1349240005

Fluid
Energy Input
Mechanical
Energy Output

Electrical

Energy
Fig : Basic Principle for Pressure Transduce

PROGRAMMABLE LOGIC CONTROLLER

CONCEPTUAL DIAGRAM OF A PLC:
PROCESS OR
MACHINE TO BE
CONTROLLED BY
PLC

SERIAL OR
PARALLEL I/O
PROCESSOR
RACKS

The inputs to PLC come from the process connected

devices or sensors such as:

Limit Switches/Inductive proximity Switch

Push buttons
Thermocouple Couples
RTD
Transmitters like 4 to 20 mA current source
P to E converters

The Output from PLC are given to the devices and final
control elements such as:
@aditya_kumar_Yadav #1349240005

Lamps
Indicators
Relays
Solenoids
Motor contactors
4-20 mA signals to operate control valves

The processor part of the PLC contains a Central Processing Unit

(CPU), Program Memory, and Data Memory. The operation of the
PLC starts with execution the control program stores in the
program memory. This program reads the status of all input
devices connected to it and stores it in input status table of the
data memory. It then executes the instructions used for process or
machine control and calculates output conditions as per the
program logic. These output conditions are stored into the output
status table of the Data Memory. The output devices connected to
the I/O racks are updated as soon as the CPU calculates the
outputs. This operation of PLC; called as PLC Scan; is cyclic and
continues unless interrupted by an external command. The Time
taken by the processor to complete one PLC Scan is called Scan
Time .

Apart from the processor and I/O Racks, a programming device is

also required to enter the user program. The programming device
is a personal computer, which is connected to the processor only
while loading and testing the program.
TYPES OF PLC USED AT GAGAL CEMENT WORKS

Seimens S5 100U PLC in all Stacker Reclaimers Coal as well

as Limestone
@aditya_kumar_Yadav #1349240005

 Allen Bradley SLC500 PLC in Bag House of K2 and Packing

House of Gagal I
Tata Honeywell LCS 620 PLC in Gagal Packing House
Compton Greaves PLC in Gagal II Packing House, and for air
blasters.K1 and K2.
HONEYWELL LCS 620 PLC
The Honeywell LCS 620 programmable controller is a
modern state of the art PLC. The LCS (Logic Control
System) Series consists of 620-12, 620-16, 620-36 and
620-35 processors.

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
@aditya_kumar_Yadav #1349240005

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

Heat Transfer in preheater:

Raw meal is fed to the top of the preheater and it flows down in feed
pipe,while the hot gases coming from kiln flows in upward direction due to
upward force applied by Id fan.As the hot gase going up through riser duct
and raw meal coming down comes in intimate contact the heat transfer

@aditya_kumar_Yadav #1349240005

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.

@aditya_kumar_Yadav #1349240005

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.

Preheating zone (subject to kind of preheater )

Calcining zone (subject to the kind of preheater )
Clinkering zone
Cooling zone

The presence and the length of these zones is mainly

dependent on the composition of the material to be burnt ,
the preheater and the downstream cooling system
Diameter and the length of the rotary kiln depends upon the
desired output and are considerably influenced by the
chosen preheater and cooling. The quality of the refractory
lining of the rotary kiln pipe is adjusted to the length of the reaction and
temperature zone and is specifically determined for every individual plant.
The heat quantity required for different reaction stages is generated
by the rotary kiln burner at the rotary kiln outlet. The combination air is high
temperature secondary air coming from the cooler section. The hot gases
flow through the rotary kiln and reach the inlet housing via the rotary kiln
inlet. The heat is transmitted to the feed material by the contact between
the hot gases and the material and by its contact with the refractory brick
lining.
Successive chemical reactions take place in the kiln:
70 to 110 C - Free water is evaporated.
@aditya_kumar_Yadav #1349240005

 400 to 600 C - clay-like minerals are decomposed into their

constituent oxides; principally SiO2 and Al2O3. Dolomite (CaMg(CO3)2)
decomposes to calcium carbonate, MgO and CO2.
.650 to 900 C - calcium carbonate reacts with SiO2 to form belite
(Ca2SiO4).

clinker

CLINKER COOLING

@aditya_kumar_Yadav #1349240005

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:

The burned material discharged

from the kiln falls through the inlet
shaft of the cooler onto the entry to
the grate . Due to the special design
to the grate entry the material to be
cooled forms a uniform bed. Over the
stationary and movable grate plate rows, the burned material is transported
by the forward movement of the movable grate plate rows to the end of the
cooler.
The oscillating frame with the movable grate plate rows is driven on
both the sides; the number of the strokes per minute is infinitely variable.
The cooling air is generated by the several fans. Normally, one fan is
allocated to each air chamber, thereby providing the targeted aeration to
the grate and the material to be cooled.
The heated up cooling air is captured in the upper section of the
cooler and is available for the further use as secondary air for the kiln or as
the tertiary air.

CEMENT GRINDING
@aditya_kumar_Yadav #1349240005

Final processing step in the manufacture of the cement is cement

grinding.It is the grinding of mixture of clinker and additives into a finished
product Object is to create a particular fineness of the product to achieve
some predetermined physical characteristics in the cement. When in
concrete, Main ingredient used in cement is the clinker. Clinker is ground
with gypsum to produce Portland cement. Grinding mill is the main
component used in finish grinding system. A ball mill is horizontal cylindrical
drum with two compartments having steel balls of the different diameter. as
grinding media . Clinker is ground by a closed circuit grinding system where
mill product is routed through the dynamic air separator and the material
coarser than the required grain size is returned to the mill. Thus, separator
removes the coarser and the fine particles, which are fed back to the mill.
Cement mill

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.

@aditya_kumar_Yadav #1349240005

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

@aditya_kumar_Yadav #1349240005

Ball mill

@aditya_kumar_Yadav #1349240005

Function of gypsum in cement:

DUST COLLECTORS
@aditya_kumar_Yadav #1349240005

1.Cyclone Separator:

@aditya_kumar_Yadav #1349240005

2.Bag Filter

@aditya_kumar_Yadav #1349240005

3.Electrostatic Precipitator:

@aditya_kumar_Yadav #1349240005

CEMENT STORAGE,PACKAGING & DISPATCH

Packing Plant is the place where cement is stored, packed and

dispatched to various destinations.
Gagal Cement Works Packing Plant has seven cement silos.
All the packers have the truck loading facility because the cement
from Gagal is transported to different destinations by road only.
The different varieties of cement handled are :

33 Grade OPC (Ordinary Portland Cement) as per IS : 269

43 Grade OPC (Ordinary Portland Cement) as per IS : 8112
PPC (Portland Pozzolana Cement) as per IS : 1489(part II)
PPC (Portland Pozzolana Cement) super Separate bags Godown is
available in Gagal plant I and Gagal plant II, Where up to 40 lakhs and
80 lakhs can be stored respectively. Packing plant is close liason with
cement Dispatch section and Laboratory.

@aditya_kumar_Yadav #1349240005

Cement packing and dispatch is done through road transported by trucks

only.
Cement dispatch section receives order from RMO and accordingly
they place demand of trucks to the truck unions, destinations wise. Then
the trucks are placed in accordance to demand for loading of cement. The
silo from which the cement is to be extracted for loading depends upon the
type of cement and type of cement filled in the silos.

@aditya_kumar_Yadav #1349240005