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Internship Report
Submitted by
Shoaib Hassan Khan
Shoaibhassankhan51@gmail.com
Preface
Learning in practical side is somewhat that cannot be compared with books knowledge.
Moreover from engineering point of view learning experience matters a lot aside a
bachelor degree from a reputable institute.
The purpose of this report is to elaborate my experience and learning during my three
month internship period. In this three month I had visited every department and
analyzed different process involved in cement production. My main object was to view
the processes from Mechanical point of view i.e. Mechanical equipment, maintenance
work involve and troubleshooting of different problem faced in every department. In this
report I have tried my best to write everything I haves seen or learned during my three
month experience at Maple Leaf Cement. Process description and equipment involved
in every process is discussed in this report. Moreover step by step processes with
concise mass flow are also discussed in this report. In Maple Leaf Cement there are two
lines working in parallel, Line I capacity was 3800 TPD while line II capacity was 6700
TPD. Mostly data discussed in this report is of line II since it is newly developed and
efficient W.R.T to other lines. I hope that this report will cover a comprehensive view of
cement manufacturing plant from Mechanical point of view.
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Acknowledgement
Thanking Almighty Allah, who bestowed me the knowledge and the courage to write this
report. This internship provided me a golden opportunity to learn. In this report I have
tried to relate everything that I thought was necessary. Though, it’s a bit difficult to say
anything about the perfection of the effort that I have made but I hope that it finds its
place somewhere to meet the required and expected criterion. I would like to add a few
deepest words for the people who were part of this report in numerous ways… people
who gave unending support right from the stage the report was assigned. Particularly I
wish to thank the foreman’s of every Area who helped me to gain a lot of Practical
Experience regarding the company and cement industry and also thankful to Mr.Zeshan
( A.M. Crushing Area) who have through his professional demeanour made me able to
to learn & Mr.Khalid who provide me an opportunity to learn and understand the working
of organization as an internee. I am also thankful to Mr Amir (Senior Manager Cement
mill) who played a role of polar star for me in the organization and whose experience
taught me a lot about the industry and the organization.
I am especially thankful to Mr. Jawed (Senior Manager Raw mill & kiln Area) who
helped me a lot in getting the knowledge of cement industry.
My special thanks to the person who from the first day of my internship help me
understand the manufacturing process,Mr. Fareed(A.M Design section),his gentle
,courteous and cooperative behaviour motivated me a lot.
And finally deepest and warmest appreciation to the whole team of Maple Leaf Cement
factory who helped me a lot in getting knowledge about the office working and about the
cement plant.
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Contents
Preface ............................................................................................................................ 0
Acknowledgement ........................................................................................................... 2
Introduction ..................................................................................................................... 7
About: .......................................................................................................................... 7
CEMENT: ................................................................................................................. 7
Legacy of the Leaf:................................................................................................... 7
Vision: ...................................................................................................................... 8
Mission: .................................................................................................................... 8
Corporate Strategy: .................................................................................................. 8
Leading Edge Production Capabilities: ........................................................................ 8
Naturally Enriched: ...................................................................................................... 9
MLCF Basis for Uninterrupted Supply ...................................................................... 9
Core Values: ............................................................................................................ 9
Cross Functional: ................................................................................................... 10
Collective Wisdom:................................................................................................. 10
Creative Thought Process: ..................................................................................... 10
Empathy: ................................................................................................................ 10
Integrity: ................................................................................................................. 10
Cement.......................................................................................................................... 11
What is cement? ........................................................................................................ 11
Types: ........................................................................................................................ 11
1-Common or General purpose cement: ................................................................ 11
2-Sulphate resistance cement: ............................................................................... 12
3-Rapid hardening cement: .................................................................................... 12
4. Low heat of hydration cement: ........................................................................... 12
5. Sulphate resistance: ........................................................................................... 12
Methods of cement manufacturing:............................................................................ 13
1- Wet process: ...................................................................................................... 13
2- Dry process: ....................................................................................................... 13
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List of Figures:
Figure 1: Crusher working ............................................................................................. 21
Figure 2-Detailed labeled figure of Crusher................................................................... 22
Figure 3-Limestone Stacker .......................................................................................... 23
Figure 4-Reclaimer ....................................................................................................... 24
Figure 5-Stacker and Reclaimer .................................................................................... 24
Figure 6-Working of Bridge reclaimer ............................................................................ 25
Figure 7-Figure referring parts of Bridge Reclaimer and Clay stacker .......................... 26
Figure 8-Belt drive Mechanical system.......................................................................... 27
Figure 9-Labeled Figure of Raw Mill(Left) and inside of Raw mill(Right) ....................... 28
Figure 10-WPU two stage mill gear unit with lubrication system ................................... 30
Figure 11-Three component of the drive system ........................................................... 30
Figure 12-Cyclone working ............................................................................................ 31
Figure 13-A pictorial view of pyro processing and kiln burning ...................................... 32
Figure 14-Mechanical construction of a rotary kiln ........................................................ 33
Figure 15-Roller Drive for Rotary Kiln............................................................................ 33
Figure 16-Roller Construction ....................................................................................... 34
Figure 17-A view of FL Smidth Cross bar cooler ........................................................... 35
Figure 18-Labeled Diagram of Ball Mill ......................................................................... 36
Figure 19-Working of Ball Mill ....................................................................................... 38
Figure 20-Ok Mill ........................................................................................................... 38
Figure 21-Working of bag filter ...................................................................................... 43
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Chapter-1
Introduction
About:
The Kohinoor Maple Leaf Group was born from the trifurcation of the Saigol group of
companies and is a reputable and leading manufacturer of textiles and cement. KMLG
comprises of Kohinoor Textile Mills limited (KTML) and Maple Leaf Cement factory
limited (MLCF). Both companies are incorporated in Pakistan and are listed on three
stock exchanges of the country.
CEMENT:
Maple Leaf Cement is the third largest cement factory in Pakistan. It was set up in 1956
as a joint collaboration between the West Pakistan Industrial Development Corporation
and the government of Canada. It is strategically located at Daudkhel (District Mianwali)
in Northern Pakistan, which is an area rich in raw materials required for the production
of cement. Kohinoor acquired the ownership and management of Maple Leaf Cement
under the privatization policy of the government of Pakistan in 1992. At the time of
privatization in 1992, the capacity of Maple Leaf to produce Ordinary Portland Cement
(OPC) was 1000 tones per day (tpd). A second plant of 4000 tpd was commissioned in
1998 and a third plant of 6700 tpd came into production in 2006. It increased the total
capacity to 11,700 tpd. The capacity of White Cement has also increased from 100 tpd
to 500tpd with the addition of a new plant. This plant also has provisions for doubling
the capacity to 1000tpd. Presently Maple Leaf cement has 9% of the market share of
OPC and is a leading brand in Pakistan with a diverse customer base. It is also the
largest producer of White Cement in the country with 80% of market share. In order to
remain competitive in the market the management at Maple Leaf continuously
reevaluates its business strategies. With the increase of furnace oil prices the company
adopted coal as a more cost efficient and environmentally friendly fuel for kiln firing.
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Vision:
The Maple Leaf Cement Factory stated vision is to achieve and then remain as the most
progressive and profitable Company in Pakistan in terms of industry standards and
stakeholders interest.
Mission:
The Company shall achieve its vision through a continuous process of having sourced
and implemented the best leading edge technology, industry best practice, and human
resource and by conducting its business professionally and efficiently with the
responsibility to all its stakeholders and community.
Corporate Strategy:
At Maple Leaf Cement Factory manufacturing and marketing of different types of
consistently high quality cement, according to the demanding requirements of the
construction industry is done. The strategy of MLCF is to be competitive in the market
through quality and efficient operations. As a responsible member of the community,
MLCF is committed to serve the interest of their stakeholders and contribute towards
the prosperity of the Country.
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Naturally Enriched:
MLCF Basis for Uninterrupted Supply
With a covered area of more than 3,000 acres, MLCF factory is situated at Daud Khel,
Punjab. Located near the Salt Range, it is surrounded by the finest quality of raw
materials; limestone, clay and sand. These valuable resources are quarried from the
mineral rich mountain ranges located at our manufacturing site. To ensure uninterrupted
supply, Maple Leaf Cement has strategically built separate production plants for Grey
and White Cement in this area.
Core Values:
Maple Leaf Cement is committed to be an ethical and a responsible member of the
business communities in which it operates. The Company always endeavors to ensure
that highest standards of honesty, integrity and ethics are maintained.
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Cross Functional:
Cross functional teams often function as self-directed teams in order to achieve
common goals
Collective Wisdom:
For sharing knowledge, innovative ideas, experience & individual expertise with others
to attain common objectives
Empathy:
Ability to understand & share feelings of other. Put oneself in someone else’s shoes
Integrity:
Adherence to moral & ethical principles; soundness of moral character & honesty.
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Chapter-2
Cement
What is cement?
Cement is a material with adhesive and cohesive properties which make it capable of
bonding minerals fragments into a compact whole.
For constructional purposes, the meaning of the term "cement" is restricted to the
bonding materials used with stones, sand, bricks, building stones, etc.
The cements of interest in the making of concrete have the property of setting and
hardening under water by virtue of a chemical reaction with it and are, therefore, called
hydraulic cement.
The name "Portland cement" given originally due to the resemblance of the color and
quality of the hardened cement to Portland stone – Portland island in England.
The Basic Constituents of cement are
Lime stone
Clay
Iron Ore
Gypsum
First three constituents are mixed at early stage while gypsum is mixed at the later
stage .These all basic constituents have their own role to play in cement manufacturing
i.e. to give strength, to make it economical and making setting time optimum.
Types:
In 1824 English man Joseph Aspdin, patented artificial cement made by the calcinations
of an argillaceous lime stone. He called it “Portland” because concrete made from it
resembles with a famous building stone obtained from land near England.
There are five types of Portland cements with variations of the first three according to
ASTM( AMERICAN SOCITY OF TESTING MATERIAL ) C150.
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5. Sulphate resistance:
Type V is used where sulfate resistance is important. Its typical compound.composition
is:
38% (C3S), 43% (C2S), 4% (C3A), 9% (C4AF), 1.9% MgO, 1.8% (SO3), 0.9% Ignition
loss, and 0.8% free CaO.
This cement has a very low (C3A) composition which accounts for its high sulfate
resistance. The maximum content of (C3A) allowed is five percent.
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2- Dry process:
Grinding and mixing of the raw materials in their dry state.
The process to be chosen, depend on the nature of the used raw materials.
Wet process: the percentage of the moisture in the raw materials is high.
Dry process:
The raw materials is so hard (solid) that they do not disintegrate by water
Cold countries, because the water might freeze in the mixture
Shortage of the water needed for mixing process.
Wet process:
When chalk is used, it is finely broken up and dispersed in water in a washmill. The
clay is also broken up and mixed with water, usually in a similar washmill. The two
mixtures are now pumped so as to mix in predetermined proportions and pass through
a series of screens. The resulting – cement slurry – flows into storage tanks.
When limestone is used, it has to be blasted, then crushed, usually in two
progressively smaller crushers (initial and secondary crushers), and then fed into a ball
mill with the clay dispersed in water. The resultant slurry is pumped into storage tanks.
From here onwards, the process is the same regardless of the original nature of the raw
materials.
The slurry is a liquid of creamy consistency, with water content of between 35 and
50%, and only a small fraction of material – about 2% - larger than a 90 μm.
The slurry mix mechanically in the storage tanks, and the sedimentation of the
suspended solids being prevented by bubbling by compressed air pumped from bottom
of the tanks..
Finally, the slurry with the desired lime content passes into the rotary kiln. This is a
large, refractory-lined steel cylinder, up to 8 m in diameter, sometimes as long as 230
m, which is slightly inclined to the horizontal.
The slurry is fed in at the upper end while pulverized coal (oil or natural gas also might
be used as a fuel) is blown in by an air blast at the lower end of the kiln, where the
temperature reaches about 1450PoPC.
The slurry, in its movement down the kiln, encounters a progressively higher
temperature. At first, the water is driven off and COR2R is liberated; further on, the dry
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material undergoes a series of chemical reactions until finally, in the hottest part of the
kiln, some 20 to 30% of the material becomes liquid, and lime, silica and alumina
recombine. The mass then fuses into balls, 3 to 25 mm in diameter, known as clinker.
The clinker drops into coolers.
Dry process:
The raw materials are crushed and fed in the correct proportions into a grinding mill,
where they are dried and reduced in size to a fine powder. The dry powder, called raw
meal, is then pumped to a blending silo, and final adjustment is now made in the
proportions of the materials required for the manufacture of cement. To obtain a uniform
mixture, the raw meal is blended in the silo, usually by means of compressed air.
The blended meal is sieved and fed into a rotating dish called a granulator, water
weighing about 12% of the meal being added at the same time. In this manner, hard
pellets about 15 mm in diameter are formed.
The pellets are baked hard in a pre-heating grate by means of hot gases from the kiln.
The pellets then enter the kiln, and subsequence operations are the same as in the wet
process of manufacture.
cement, and to facilitate the grinding process. The grinding is done in a ball mill. The
cement discharged by the mill is passed through a separator, fine particles being
removed to the storage silo by an air current, while the coarser particles are passed
through the mill once again.
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Chapter-03
Manufacturing layout
General Process:
A general cement Manufacturing process consist of the following steps
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Chapter-04
Clay:
Roller crusher provide clay on average rate of 280 TPH while it can provide at max 400
TPH.Clay storage has the capacity of 13000 tones i.e. 1.3 tone/m3.From storage clay
can be transported to the weigh feeder at the rate of 16 to 160 TPH while the bin has
the mac the max capacity of 195 tones. From weigh feeder it can be transported at the
rate of 20-200 TPH.
Iron Ore:
Iron ore by wheel handler can be provided at the rate of 225-270 TPH according to
need since it is needed in fewer amounts. The feeder of iron has capacity of 625 tones.
From weigh feeder ore is provided at the rate of 2.5-25 TPH.
3-CF Silo:
CF Silo also called as control flow silo has the capacity of 25500t with volume of 17500
m3.It can provide the material at a control rate of 115tph to 554tph while providing the
material at average rate of 462 to 554 tph.
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5-Cement Mills:
There are two cement mills present at MLCF one is Ok Mill one is ball Mill. Both mills
can handle the clinker and gypsum mixture at the rate of 175/210tph.while gypsum is
added t the clinker at the rate of 100.120tph.so the output of cement from both mills are
350/420 tph.Where it is stored in cement silos. There are two cement silos with
individual capacity of 21000t.From cement silos it can ne transported with equal
capacity of 200.240 tph to six packers with total 600 tph dispatch capacity.
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Chapter-05
Process Description
Cement industries typically produce Portland cement, although they also produce
masonry cement (which is also manufactured at Portland cement plants). Portland
cement is a fine, typically gray powder comprised of di calcium silicate, tri calcium
silicate, tri calcium aluminate, and tetra calcium alumino ferrite, with the addition of
forms of calcium sulfate. Different types of Portland cements are created based on the
use and chemical and physical properties desired. Portland cement types I - V are the
most common. Portland cement plants can operate continuously for long time periods
(i.e., 6 months) with minimal shut down time for maintenance.
The air pollution problems related to the production, handling, and transportation of
Portland cement are caused by the very fine particles in the product.
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Major Equipment:
Major equipment of storage area include
Crushers
Belt conveyer with drives
Bag filters
Stacker
Bridge re claimer
Crusher:
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Parts:
1. Incoming belt conveyor
2. Jib
3. Conveyor belt on jib
4. Jib counterweight
5. Luffing unit
6. Operator cabin
7. Stacker bogie
8. Re claimer bogie
9. Hydraulic tensioning
unit
10. Scraper chain
11. Raking harrow
12. Raking car Figure 4-Reclaimer
13. Operator cabin
14. Outgoing belt conveyor
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SS – Longitudinal
Side Scraper store:
The longitudinal Side Scraper store, type SS, is used in a production line as a relatively
small bulk material buffer store. The store operates with stockpiles placed in line. While
building up one pile by Cone Shell or Chevron stacking another pile is reclaimed. The
material enters the store on a rubber belt conveyor along one side of the store. It is
discharged onto a stacker jib which is kept close to the pile crest to reduce dust
emission. Alternatively, stacking can take place by a tripper car supported by a frame
structure above the pile. The stacker and the side scraper travel on separate rails along
the store.The side scraper reclaims the material by means of a scraper chain system
which removes one slice at a time from the pile. The scraper chain fitted with blades or
buckets conveys the materials to the discharge point above the outgoing conveyor. The
system only requires an operator when shunting from one pile to another.
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Parts:
1. Hoist for raising
2. lowering chain
3. Operator cabin
4. Outgoing belt conveyor
5. Re claimer bogie
6. Scraper chain
7. Jib
8. Belt conveyor on jib
9. Stacker bogie
10. Operator cabin
11. Incoming belt conveyor
12. Hydraulic cylinder
13. Jib counterweight
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Belt Drive:
The types of conveyors used in cement industry are,
Belt conveyors
Roller conveyors
Cable conveyors
Pipeline conveyors
Screw conveyors
Elevating conveyors
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If the dry process is used, the raw materials are dried using impact dryers, drum dryers,
paddle-equipped rapid dryers, air separators, or autogenous mills, before grinding, or in
the grinding process itself. In the wet process, water is added during grinding. In the
semidry process the materials are formed into pellets with the addition of water in a
pelletizing device.
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The gas flow, besides transporting the material, performs other important tasks:
First material selection; the coarse particles tend to fall back on the grinding plate
Thermal exchange; more efficient compared to tubular ball mills,
Thanks to the complete mix of gases and materials. The coarse material coming from
the separator is directed back to the centre of the grinding plate in order to be ground
again. The grinding process starts with the preparation of the so- called bed, where the
coarse material is crushed. Then the material is compressed and grounded by the
grinding rollers. The material, which flows over the damn ring is caught by the vertical
gas flow from the nozzle ring and lifted up. Coarse particles fall back to the grinding
table and Finer ones are swept up to the separator for being classified. The internal
circulation Rate depends mainly on the grind ability of the ground material and can
amount up to 15 to 25 cycles. Reducing the gas speed in the nozzle ring adjustment of
the open Area leads ti falling through of larger particles. The fall through material has to
be extracted with scrapers and mechanically re circulated to the mill feed
Separation
The use of modern separators in roller mills is state of the art. A sharp separation
improves the raw meal quality and avoids over grinding (saving of energy). Coarse
Tailings, fed through the tailings cone to the center of the grinding table, helps the
Formation of a more stable grinding bed. The raw meal fineness is easily controlled by
the adjustment of the cage rotor speed.
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Figure 10-WPU two stage mill gear unit with lubrication system
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Cyclone:
It is used mainly for separating material from air. After grinding from the raw mill a
mixture of hot gases and material passes through the cyclone. Cyclone separates
material from the air.
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The supports for rotary kilns are based on the two-roller support principle.
Each roller is seated in two sliding bearings, which are self-adjusting journal bearings.
The spherical ball socket of the bearings constantly ensures totally even axial and radial
contact between the bearing liner and the journal, even if one bearing is displaced
relative to the other, and when shaft deflection occurs.
Retrofitting bearings and rollers onto a non-Valmet kiln can in some cases be done
without replacing the baseplate and thereby avoid civil work. In some cases, changes in
refractory configuration or cooler type overloads the support and a larger support
(baseplate, bearings, rollers) will be required to sustain the load.
Labeling:
1. Thrust ring
2. Oil distribution tray
3. Oil elevators
4. Shaft journal
5. Bearing liner
6. Oil level indication
7. Connection for water cooling
8. Spherical ball socket
9. Seal arrangement,
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5. Clinker Storage:
Although clinker storage capacity is based on the state of the market, a plant can
normally store 5 - 25% of its annual clinker production capacity. Equipment such as
conveyors and bucket elevators is used to transfer the clinkers from coolers to storage
areas and to the finish mill. Gravity drops and transfer points typically are vented to dust
collectors.
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6. Finish Milling:
During the final stage of Portland cement production known as finish milling, the clinker
is ground with other materials (which impart special characteristics to the finished
product) into a fine powder. Up to 5% gypsum and/or natural anhydrite is added to
regulate the setting time of the cement. Other chemicals, such as those which regulate
flow ability or air entrainment, may also be added. Many plants use a roll crusher to
achieve a preliminary size reduction of the clinker and gypsum. These materials are
then sent through ball or tube mills (rotating, horizontal steel cylinders containing steel
alloy balls) which perform the remaining grinding. The grinding process occurs in a
closed system with an air separator that divides the cement particles according to size.
Material that has not been completely ground is sent through the system again.
Ball Mill:
Ball or tube mills are rotating steel cylinders where size reduction of the mill feed is
Performed by motion of the grinding media. Rotation of the mill cylinder raises the pile
of mill feed and grinding media to an optimum high, necessary for grinding operation.
Grinding is performed by impact and friction between the grinding balls which hit one
against another, as well as between the grinding media and the mill lining itself. The
difference between ball mill and tube mill is the ratio of the tube length to the tube
diameter. Tube mills have a ratio of length to diameter of [3-6 : 1], for ball mill this
relation is[<2 : 1]. Two different processes occur inside the mill:
Crushing: Breaking up of the incoming particles from a size of about 30 mm to a
size of minus 2.5 mm diameter. This process takes place in the first
compartment of the mill.
Refining: Powdering of the particles until they reach the required fineness. This
process stakes place in the second or last compartment of the mill.
Figure 18-Labeled Diagram of Ball Mill
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Structure of Mill:
Shell:
The shell is welded structure and manufactured from steel sheets, or from fine-grained
Structure steel. Boiler plates are also frequently in use.
Thickness of the Mill Shell:
The thickness of the mill shell ranges between 1/100 and 1/75 of the mill diameter. It
should be mentioned that the shell thickness depends not only the diameter, but also on
the length of the mill cylinder. Besides, the shell thickness of long mills are graded, i.e.
the shell thickness increase from both ends toward the mill center. When calculating the
thickness of the mill shell, it should be considered that the bolt holes for the mill liners
reduce the strength of the shell by about 11%.
Shell Liners:
Clinker grinding is performed in two different stages: in the first stage where material
must be crushed, sufficient impacts are required to reduce coarser particles in to finer
ones, whereas in the second stage, an action of attrition should be take place. The first
compartment shell lining must assure an efficient lifting effect of grinding media charge
so that the grinding media give impacts strong enough to break large particles.
However, it shouldn't lift the grinding balls too high, since a part of them would then fall
on liners where no materials are found; this would accelerate the wear of liners and
media and cause a loss of energy. The first compartment ball charge must exerts a
maximum amount of impacts on the materials to be ground, and these impacts should
be strong enough to quickly reduce the clinker particle size. It is not advisable to use a
segregation lining in the first compartment. Segregation liners which allow an automatic
segregation of the grinding bodies are equipped in the second compartment more
recently. Large balls are directed towards the inlet end, with the ball dimension
decreasing regularly from the inlet towards the outlet where smaller balls are located.
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OK Mill:
Ok mill mostly work as the raw mill, which has been discussed before. The difference is
it has four rollers while the raw mill was having three rollers.
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Chapter-06
SOURCES OF POLLUTION
Although Portland cement plants generate the same final product using similar
processes, plant layouts vary according to fuels and raw materials used location,
climate, site topography, and the manufacturer of the equipment.
1. Air Pollutants
Air pollutants generated during the cement manufacturing process consist primarily of
particulates from the raw and finished materials, and fuel combustion by-products.
Controlling particulate emissions from sources other than the kiln usually entails
capturing the dust using a hood or other partial enclosure and transporting it through a
series of ducts to the collectors. The type of dust collector used is based on factors such
as particle size, dust loading, flow rate, moisture content, and gas temperature. The
best disposal method for collected dust is to send it through the kiln creating the clinker.
Additional air pollutants emitted include such materials as sulfur oxides and nitrogen
oxides generated from the kiln and drying processes. Sulfur dioxide is generated from
the sulfur compounds in the ores and the combusted fuel and varies in amount
produced from plant to plant. The efficiency of particulate control devices is inconclusive
as the result of variables such as feed sulfur content, temperature, moisture, and feed
chemical composition, in addition to alkali and sulfur content of the raw materials and
fuel. The combustion of fuel in rotary cement kilns generates nitrogen oxides from the
nitrogen in the fuel and incoming combustion air. The amount emitted depends on
several factors including fuel type, nitrogen content, and combustion temperature. Both
sulfur dioxide and some of the nitrogen oxide react with the alkaline cement and are
removed from the gas stream.
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The following methods are used to control particulate emissions generated from the
quarry and handling of purchased raw materials:
Dust that is collected by these means is restored to the process. For quarry operations,
newer plants typically use the pulse-jet fabric filters while older plants employ the
reverse-air or shaker-type fabric filters.
b. Raw Milling
Fugitive dust is emitted from raw material feeders, stackers, blenders, reclaimers,
conveyor belt transfer points, and bucket elevators used for transferring materials to the
mill department from storage. Particulate emissions from the dry raw mills and
subsequent equipment occur during temporary failure or from improperly designed or
maintained seals. The following devices are used to collect particulate matter in the raw
mill and raw mix storage areas:
Newer plants typically use the pulse-jet fabric filters while older plants employ the
reverse-air or shaker type fabric filters.
c. Pyro processing
The main pyro processing system emissions are nitrogen, carbon dioxide, water,
oxygen, nitrogen oxides, sulfur oxides, carbon monoxide, and hydrocarbons. Cement
kiln dust (CKD) is also produced. The cement kiln itself has been designated as best
available control technology (BACT) for the control of SO2. The highly alkaline
conditions of the kiln system enable it to capture up to 95% of the possible SO2
emissions. However, if sulfide sulfur (pyrites) is present in the kiln feed, this absorption
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rate can decline to as low as 50%. Therefore, sulfur emissions can be decreased
through careful selection of raw materials.
No device to control cement kiln NOx emissions has been developed, but there are
several prospects:
stable kiln operation (reduces long term NOx emissions);
burner configurations for the rotary kiln (efficiency varies);
staged combustion for precalciner kilns;
recirculation of the flue gas (oxygen deficient air in the rotary kiln); and
alternative/low-nitrogen fuels.
Cement kiln dust (CKD) is the powder retrieved from the exiting gases and is either all
or partly returned to the operation or removed entirely. The type of system, the chemical
makeup of the raw materials and fuel, and the condition of the system operations all
affect the chemical configuration of the CKD. Portland cement specifications usually
limit the amounts of sodium and potassium. Because bypass CKD contains a large
quantity of these minerals, CKD is usually removed from the process. The CKD from a
preheater tower is composed of the same general elements as the kiln feed and
therefore is returned to the process. The handling, storage, and deposition of CKD can
generate fugitive dust emissions.The following methods are used to control particulate
emissions from the kiln system:
reverse-air fabric filters
electrostatic precipitators (ESPs)
acoustic horns (sometimes used in conjunction with the two devices above)
d. Clinker Cooling
Reciprocating grate clinker coolers most often employ fabric filters, but ESPs and gravel
bed filters are also used with a mechanical cyclone or multiclone dust collector
sometimes placed infront. Newer plants typically use pulse-jet or pulsed-plenum fabric
filters and older plants use reverse-air type fabric filters which may simply be a smaller
form of a kiln fabric filter. Gravel bed filters, which are also used by the cement industry,
contain quartz granules; contaminated gas passes through this filter and the dust settles
to the bottom of the bed.
e. Clinker Storage
The devices used to control dust emissions from clinker storage areas are similar to
those used in the raw milling process. The particulate emissions generated by dropping
clinkers onto storage piles can be reduced by using a rock ladder or variable-height,
automatic, stacker belt conveyor systems. Fugitive dust generated from open storage
piles is tempered by rain and snow, wind breaks, and pile covers. Clinker in open piles
is moved using front-end loaders; in storage halls overhead bucket cranes are used.
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MLCF Internship Report
Fugitive clinker dust emitted from open storage piles is common and very difficult to
control.
f. Finish Milling
Particulate matter is emitted from mill vents, air separator vents, and material-handling
system vents. Newer plants usually use pulse-jet or pulsed-plenum fabric filters with
high-efficiency separators, while older plants use reverse-air/shaker fabric filters. The
cement dust collected by the fabric filter is restored to the system. In cold weather, a
plume may develop at the baghouse vent; this may be mistaken for particulate matter,
but actually is condensed water vapor from the cooling system.
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MLCF Internship Report
Bag Filter:
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MLCF Internship Report
Chapter-07
Power generation:
MLCF produces its own electricity by effectively recovering the heat utilized in the pyro
processing.
At Pre-Calciner
In the kiln
One is connected with the pre heater that utilized the gases of pre heater and kiln
Second is present at the cooler side
Steam created is effectively transported to power plant where impulse and reaction
turbines are installed and about 15 megawatts electricity is produced.so MLCF only
need a small amount to meet its power need.
More over steam is also produced from the exhaust of second power plant where diesl
engines are installed.
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