A

Report On Practical Training

Taken At

UDAIPUR CEMENT WORKS LIMITED

( Shripatinagar ) Dabok
Submitted in partial fulfillment for the award of Degree of Bachelor of
Technology in Mechanical Engineering

From 12/06/2019 To 26/07/2019

Session 2019-20
Submitted to : seminar incharge : submitted by:
Mr. Yogesh Tamboli Mr. Sushanto Mahato Kishan Singh kitawat
(HOD associate prof.) (assistant professor) (16ESHME004)

Department Of Mechanical Engineering

Shrinathji Institute Of Technology & Engineering

(Affiliated To RTU Kota,Rajasthan)

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 ACKNOWLEDGEMENT

First, I would like to express my sincere gratitude indebtedness to Mr. Naveen

Sharma (Director) allowing me to undergo the industrial training of 45 days at
UCWL (Raj.)
At the outset, I would like to thank UDAIPUR CEMENT WORKS LTD. for
giving me the approval to do this training in such a prestigious and professional
organization and also for their interactive contribution towards execution and
completion of this project, I am grateful to Mr. RANVIR SINGH and MR.
KAUSHAL JAIMAN for the moral support, encouragement and motivational
assistance
Here I obtained practical knowledge, for this travel of knowledge & training I
am grateful & thankful to UDAIPUR CEMENT WORKS LTD. for arising
my interest in training.

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 CONTENT

Title page no.

1. Contents
2. Preface
3. Abstract
4. Organisational info
Chapter 1 Safety 8
Chapter 2 Clinker production process chart 11
Chapter 3 Mines & crusher 12
Chapter 4 Stacker 16
Chapter 5 Reclaimer 18
Chapter 6 Vertical raw mill (VRM) 19
Chapter 7 Continuous flow silo 21
Chapter 8 Preheater 24
Chapter 9 Kiln & cooler 26
Chapter 10 Vertical coal mill (VCM) 31
Chapter 11 Cement process 33
11.1 Cement mill 33
11.2 Bucket elevator 38
11.3 Air slide 39
11.4 Separator / Classifier 40
11.5 Cyclone 41
11.6 Circulating air (CA) fan 41
11.7 Bag house 42
11.8 Fly ash silo 43
Chapter 12 Packing plant 45
12.1 Silo 47
12.2 Elevator 48
12.3 Vibrating screen 49
12.4 Roto packer 51
12.5 Bag filter 52
12.6. Truck loader 54
12.7 CCR 55
Chapter 13 Quality control & testing 56

Project 60

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 PREFACE

Practical training is a way to implement the theoretical knowledge to practical

use to become a successful engineer. Theoretical knowledge is only for
understanding the things but the practical knowledge improves this, and gives a
skilled development to us.

In books, the principle taken, are ideal or efficient to the particular but actual
condition is what? , it can only be understood by doing it practically. So only
bookish knowledge cannot give the success. The practical knowledge is also
important.

UDAIPUR CEMENT WORKS LIMITED is one of the best examples to

understand the production process & productivity in particular of cement.

This report is an overall attempt made to study the production system of cement
at UCWL, a unit of JK Lakshmi cement.

I have undergone my training in UDAIPUR CEMENT WORKS LIMITED,

Udaipur, from 12 june, 2019 to 26 july, 2019. Succeeding contents gives details
what I have learnt in this training.

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5
 ABSTRACT
During period I had made an attempt to understand the working procedure and
quality understand used in each department. It is very synthetic organization set
up and working on ethical principal, without compromising on quality. It
respects its employees and workers alike and this respect is reflected in pleasant
working environment of “UDAIPUR CEMENT WORKS LIMITED”.
Company has nine departments they are laboratory & process, Electrical &
Instrumentation, Mechanical Utility, Pyro-Project, Cement mill, Packing plant,
Safety, Mines, Drawing.
The management has maintained a good relationship with its employees and all
the employees are quite satisfied with the management between the two and
also with the customers. The knowledge and information I have obtained during
my in-plant training was enormous. My exposure to the industry through this
training enabled me to understand the subjects practically rather than studying
in books.
Every organization needs to have well trained and experienced people to
perform the activates that have to be done. If the current or potential job
occupation can meet this requirement. But this is not necessary to raise the
level.
The training changing society employee training & development or not only an
activity that organization resources or if it is to maintain a variable &
knowledge work force. Training is activity leading to skilled behaviour.
Training can either on the job or off the job in first case. The worker is trained
under the guidance of a supervisor where off the job training is usually through
lectures.

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 Organisational information

Udaipur cement works limited is formerly known as 'J.K. Udaipur

Udyog Limited'.

It was incorporated as a Public Limited Company on 15th March 1993.

The Company is presently engaged in the business of manufacture and

sale of cement.

JKUUL acquired UCW, as a going concern from BAJAJ

HINUSTHAN LTD. w.e.f. December 2, 1993, with an installed
capacity to manufacture 8 lack tonnes per annum (TPA) of Portland
cement.

The Equity Shares of the Company are listed on Bombay Stock

Exchange Limited, Delhi Stock Exchange Association Limited, Jaipur
Stock Exchange Limited and Ahmadabad Stock Exchange Limited.

Since the project is undergoing, the capacity of clinker production in

the cement plant will be 3750 TPD.

UCWL produces grey PPC and OPC cement of 43 and 53 grades.

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Company over view:-
Udaipur Cement Works Limited, (formerly known as `J.K.Udaipur Udyog
Limited’) was incorporated as a Public Limited Company on 15th March 1993
having registered office at Shripatinagar,CFA P.O Udaipur , Rajasthan.
The name of the Company was subsequently changed to its present name w.e.f.
19th May 2006. The Company is presently engaged in the business of
manufacture and sale of cement.
The Equity Shares of the Company are listed on BSE Limited

This incredible communion is the source of inspiration for JK Organisation,

which also embodies a perfect blend of rich legacy of over 135 years and
modern work culture. JK Organisation a very well respected name in the Indian
industry contributing in the various sectors important to the national growth. Its
major interests are in the field of production of Tyres, Paper, Cement,
Automotive transmission system, Agri-Genetics, Dairy Products, Education etc.
The group has been committed to “Make in India’ even in the pre-independence
era by manufacturing products of impeccable quality to substitute imported
goods. It has been in cement business for over three decades and distinguishes
itself based on its innovative practices and initiatives aimed at customer
satisfaction

Incorporated in the year 1993, J K Udaipur Udyog manufactures and markets

43-grade cement under the J K Shakti Cement brand. It has acquired the 8 lac-
tpa cement division of Bajaj Hindustan for Rs 147.5 cr. It is now modernising
and de-bottlenecking it to increase the capacity to 1 mtpa.

The entire exercise costing Rs 220 cr, was part-financed by equity and PCD
issues aggregating Rs 66 cr. The plant was taken over in Apr.'94. Since then, it
has shown good capacity utilisation, wherein lies the key to the company's
success. After acquisition, it was able to solve its technical problems. The 1-
mtpa plant costs Rs 220 cr, only half the regular cost of a greenfield project. As
a result, the company will be the first to benefit when the cement industry's
fortunes take a turn for the better in north India. The company has been
accredited with ISO 9002 Certificate.

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 Chapter 1 SAFETY

PERSONAL PROTECTIVE EQUIPMENT

Personal protective equipment, commonly referred to as “PPE”, is equipment

worn to minimize exposure to a variety of hazards. Examples of PPE include
such items as gloves, foot and eye protection, protective hearing devices
(earplugs, muffs) hard hats, respirators and full body suits.

PERSONAL PROTECTIVE EQUIPMENT IN CEMENT

PLANT
1. Eye protection
Safety glasses or face shield during welding, cutting, grinding and nailing.
Safety glasses for protection against intense light, UV rays, infra-rays (radiation
from hot objects) and flying objects, such as wood chips, dust particles and
metal pieces.
1.For eye

2. Foot protection
Safety shoes during working in cement plant.

9
Footwear must protect the ankle sole and toes. Safety footwear with a CSA
green triangle symbol meets these requirements.
For foot

3. Hand protection
Heavy duty rubber gloves for concrete work.
Welding gloves for welding.
Insulating gloves and sleeves for electric work.

4. Head protection
A chinstrap or ratchet may be required if your job involves constant bending
and your head is below the waistline.
Head protection (hard hats) for protection against falling objects.

10
5. Hearing protection
Earplugs or earmuffs in high noise work areas.
Ear protection devices inserted in the ear shall be fitted or determined
individually by component persons.

11
 Chapter 2
CLINKER PRODUCTION PROCESS CHART

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 Chapter 3 Minse & Crusher

DAROLI MINES:- Large sized lime stones are brought from the mines
which is situated far away from work place. With the help of transportation .
The Lime stone is directly dump into the receiving hopper which passes through
grizzly feeder.

Grizzly feeder:- helps in moving the lime stone towards primary jaw crusher
avoiding the accumulation of lime stone in hopper.

Grizzly feeder specification

Power (motor) - 37kw
Speed range - 550 to 1000 RPM

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Blasting
Blasting is an essential part of the mining cycle. In virtually all forms of mining,
rock is broken by drilling and blasting the rock. Blasting technology is the process
of fracturing material by the use of a calculated amount of explosive so that a
predetermined volume of material is broken. Common explosives used in
industry now are ANFO (ammonium nitrate/fuel oil), slurries, and emulsions.

UCWL obtain limestone from mines by blasting. After basting rock size vary
from 1m to 1.2 m. It is then crushed into 250mm size by using JAW CRUSHER.
It is fed into jaw crusher via grizzly feeder.

CRUSHER
A crusher is a device that is designed to reduce large solid chunks of raw material
into smaller chunks.

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In UCWL two crushers are used to reduce the size of the rocks obtained from
mines . These are –

• JAW CRUSHER

• CONE CRUSHER

Therefore the limestone are crushed in primary single toggle jaw crusher. The
size of jaw crusher is reduced to 150 to 180 mm.

Primary jaw crusher specification

Capacity – 700TPH
Size – 1300*1500 mm
Speed range – 200 RPM
Motor power – 200 kw

It works with help of motor and fly wheel. The crushed lime stone falls on
sacrificing conveyor belt (size 1400mm breadth). Then it passes to secondary

15
conveyor belt (1200mm). Bag filter is also attached to the jaw crusher ,which
collect fine particle of dust through suction.
Therefore 150 to 180 mm size limestone are dumped into secondary hopper by
belt conveyor 2. A vibro feeder is connected to secondary hopper in downward
direction. crusher There are two vibro feeder which supplies lime stone to two
cone crusher. It is also called secondary.

Specification of cone crusher

Capacity – 350 TPH (Each)

Power (motor) – 220 kw
No. of cone crusher – 2

Fig: cone crusher

It works on hydraulic system situated at the bottom. In cone crusher a

rotor is rotate eccentrically in the concave shape structure and helps in crushing.
The size of lime stone is reduced to 30-50 mm. Lubrication is also provide with
the help of motor. A heat exchanger is also used for cooling system. The
crushed lime stone passes through BC3 and BC3A of cone crusher first and
second respectively , after it passes BCH.

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 A diverter is connected to BCH which is used to divert the direction of
lime stone transportation in emergency situation. There are two ways through
which the crushed lime stone are dumped into OLBC hopper.
From BCH lime stones are transported to BC5 and then BC6 which accumulate
the lime stones at retaining valve (chutes) for again discharging the accumulated
lime stone to BC7 which is connected to OLBC hopper.
From BC4 the lime stone passes through BC5 and BC6 loading towards OLBC
hopper and dumped in it.

There is long conveyor belt connected from mines to cement plant which
helps in efficient transportation of crushed lime stone, it is 5.8 km long. The
breadth of belt is 800mm.

Chapter 4 Stacker

A stacker is a large machine used in bulk material handling. Its function is to

pile bulk material such as limestone, ores and cereals on to a stockpile. A
reclaimer can be used to recover the material.

Stackers are nominally rated for capacity in tonnes per hour (tph). They
normally travel on a rail between stockpiles in the stockyard. A stacker can
usually move in at least two directions: horizontally along the rail and vertically
by luffing (raising and lowering) its boom. Luffing of the boom minimises dust
by reducing the distance that material such as coal needs to fall to the top of the
stockpile. The boom is luffed upwards as the height of the stockpile increases.
Some stackers can rotate the boom. This allows a single stacker to form two
stockpiles, one on either side of the conveyor.

Stackers are used to stack in different patterns, such as cone stacking and
chevron stacking. Stacking in a single cone tends to cause size segregation, with
coarser material moving out towards the base. In raw cone ply stacking,
additional cones are added next to the first cone. In chevron stacking, the
stacker travels along the length of the stockpile adding layer upon layer of
material.

Stackers and reclaimers were originally manually controlled, with no

means of remote control. Modern machines are typically semi-automatic or
fully automated, with parameters remotely set. The control system used is

17
typically a programmable logic controller, with a human-machine interface for
display, connected to a central control system.
The conveyor belts used in stackers may be made of fabric or metal wire,
depending upon the material to be handled. They are driven by pulleys, which
in turn are driven by DC motors.
The motors and gear are coupled by fluid coupling.

Specification –
Capacity – 1100 TPH

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 Chapter 5 Reclaimer

A reclaimer is a large machine used in bulk material handling applications. A

reclaimer's function is to recover bulk material such as ores and cereals from a
stockpile. A stacker is used to stack the material.

Reclaimers are volumetric machines and are rated in m3/h (cubic meters
per hour) for capacity, which is often converted to t/h (tonnes per hour) based
on the average bulk density of the material being reclaimed. Reclaimers
normally travel on a rail between stockpiles in the stockyard. A bucket wheel
reclaimer can typically move in three directions: horizontally along the rail;
vertically by "luffing" its boom and rotationally by slewing its boom.
Reclaimers are generally electrically powered by means of a trailing cable.

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Specification –
Capacity – 550 TPH
Power (motor) – 90kw

Chapter 6 Vertical raw mill (VRM)

Vertical roller mill is a type of grinder use to grind materials into extremely fine
powder for use in process of cement.
After the process of reclaimer, lime stone is mix with some other material
in fix quantity they are following

Limestone -85%
China clay -8-10%
Copper ash or red hocker -25%
Boxite - 2.5%
After the mixing of material it passes to the vertical raw mill by the help
of belt conveyor. Before the vertical raw mill, a metal separator is placed which
find the unwanted metal and remove it from material.

Specification of vertical raw mill

MODEL NO. - LM 38.4
TABLE DIA - 3.8
NO.OF ROLLER - 4
MILL CAPACITY - 330 TPH

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 Fig: Vertical Raw Mill

Working of vertical raw mill:-

Material is entered into the VRM machine through belt, then it falls on
the table which rotates with the help of motor. So the material is completely
spread on the table. The spreaded material is form a bed. As the VRM machine
consist of 4 rollers, they start rotating cause of the contact between the bed
(spread on rotating table) and rollers. The rollers are attached to the suspension
system which works as the protection. By the movement of rollers on the bed of
spreaded material, the material is grinded then it is rises up in the form of a
cyclone which is generated by a circulated air fan. Finally the fine material is
exerted and the heavy material is again falls down from the cyclone and grinded
until they are fined. The fine material is then sent to CF silo by the help of
elevato

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 Chapter 7 CF SILO

The CF (controlled flow) silo is continuously operating system for blending and
storage of cement raw meal. Material is extracted simultaneously at different
flow rates from a number of outlets in the silo bottom.

Use of CF silo-
Controlled flow silo for continuous blending and storage.
Ensure stable kiln operation.
There are six nos extraction air slide which acts at the bottom of the CF silo to
exert the material to feel the kiln feed bin.

In each air slider there is 3 gates classified as

1. Manual gate
2. Pneumatic gate
3. Motorized gate

The material is stored in the kiln feed bin. Two air slide is attached to the kiln
feed bin for the purpose of material transportation to the preheater by the help
of elevator.

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Specification –

CF SILO
Capacity – 12000 Tone
Length – 78 M
Diameter – 18 M

Kiln feed bin

Capacity – 100 Tone
No. of air slides – 2
Capacity of each slide – 315 TPH

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24
 Chapter 8 Preheater

Multistage preheaters and pre-calciner make use of the waste heat from the kiln
to preheat and pre-process the kiln feed and thereby allow for considerable
energy saving. Kiln system with five cyclone preheater stages and precalciner
are considered standard technology for ordinary new plant.
Raw material coming from the CF silo is heated in preheater. It is heated in five
different stages of preheater. Temperature of raw material is increase
simultaneously stage by stage. Finally the out come of the preheater is heated
up to 800 degree Celsius. Total Height of preheater - 98 met

• Height - Civil : 85m

Mechanical : 98m

• Five stage cyclones

25
Fig: pre heater

26
 Chapter 9 KILN

The rotary kiln consist of the tube made from steel plate, and lined with
firebrick the tube slopes slightly ( 1- 4 degree ) and slowly rotated its axis and
between 30 and 250 revolutions per hour. Raw mix 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. At the other end fuel, in the form of coal is blown in through the “
burner pipe “ ,producing a large concentric flame in the lower part of kiln tube.
As material moves under the flame. it reaches its peak temperature ,before
dropping out of the kiln tube into the cooler. Air is drawn first through the
cooler the and then through the kiln for combustion of the fuel. In the cooler the
air is heated may be 400 to 800 degree Celsius before it enters the kiln, thus
causing intense and rapid combustion of the fuel.

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Specification
DIA of kiln – 4.3 m
Length of the kiln – 66 m
Kiln capacity – 3750 TPD

28
 Fig: internal view of kiln

A typical process of manufacture consists of three stage-

Grinding a mixture of limestone and clay to make a fine rawmix
Heating the rawmix to sintering the temperature ( up to 1450 degree c) in a
cement kiln.
Grinding the resulting clinker to make cement.
Lubrication in gear within a time interval 15 sec. RTD used in bearing
for temp. measurement . cooling in gear box water jacket is used . Heat
exchanger is used for oil cooling.
Chair plate used between the cell and tyre for distribute the load.
Scanner is used to measure the temperature of cell
Outlet of kiln graphite block is used for reduse the resistance
Counter weight is connected to graphite block so that kiln moves in stable
position

The clinkers are cooled by the cooling fan situated under the trays. these
trays transfer the clinker from kiln chamber to bucket elevator. there after
clinker stored in clinker silo

Specification of clinker silo

Capacity – 30000MT
DIA of clinker silo – 30M

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COOLER:-

In the production of cement, the raw meal is burned into clinker in long rotary
furnaces. The clinker has a temperature of over 1450 °C after leaving the rotary
furnace and must be cooled down to a temperature of about 125 °C for
intermediate storage. To accomplish this clinker bed is cooled with a continuous
stream of air. Thus cooler is used to cool clinker.

Fig: cooler side view

Img: cooler internal view

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Working
The essential characteristic of a cooler is a layer of clinker spread on a more-or-
less horizontal perforated grate, through which cool air is blown. The grate is
made of steel, and the cold air keeps it sufficiently cool to avoid melting or
burning. The clinker progresses through the cooler by moving more-or-less
horizontally along the grate, and so the direction of the cooling air is roughly at
right angles to the direction of movement of the clinker, and the cooler functions
as a cross-current heat exchanger. This mechanism is inherently less efficient
than a counter-current heat exchanger such as a rotary or planetary cooler, but
there are distinct advantages:

• The hot clinker at the inlet is treated with cold air rather than partially heated
air, so that a rapid quenching effect is possible, improving clinker quality by
preserving reactive high-temperature silicate polymorphs.

• By using air in excess of that needed for combustion, the clinker can readily
be cooled below 200°C.

• It is easy to tap off exhaust hot air streams in desired temperature ranges for
use in other processes - e.g. calciner tertiary air or drying air for fuel or raw
materials.

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 Chapter 10 Vertical coal mill

Working of VCM is same as the VRM .In vertical coal mill coal is feed
from the upper part or side of the mill onto the rotating table.It was crush by the
help of roller. Fine coal particles are dried and swept away into the separator by
high velocity of hot air flow from the bottom of the mill.

For production of cement the temperature of clinker should be around 1500 oC,
which can be achieved when flame temperature is maintained at 1700 oC. This is
achieved by providing preheat to the secondary air. If high moisture coal is used
in direct firing system, there may be an excess of moist primary air and required
temperature may not be obtained. However, in indirect firing system using dry
primary air a satisfactory flame temperature can be achieved even with low
energy coal.

During the production process of cement it is normal to have some buildup of

deposits in the clinkering zone of the kiln, but excessive deposits can hinder the
movement of solids through the kiln. The deposit formation is commonly
associated with the presence of chlorine, sodium, potassium and sulphur.

Specification of mill
Make – LOESCHE
Model – LM20.2D
Capacity – coal 29 TPH
Petcoke- 15 TPH
Table DIA - 2M
No. Of Roller – 2
Gear Box – 595 (LGK 80)
Gear Box Ratio – 39.916
Table RPM - 430

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Classifier:-
Model – LSKS 36D-r
Design volume – 88000m3/h
Rotor Speed – 186RPM
Geared Motor KW/RPM – 30/1500

FAN
Make – REITZ
Model – KBA-160-18005-251
Capacity – 115000m3/h
Motor kw/RPM – 430/1493

BAG HOUSE
Make – THERMAX
Model – 2TP-350-470
Capacity – 100000m3/h
No. Of Bags – 700

Two types of coal used in industry

 South African Coal
 Petcok Coal

33
 Chapter 11 CEMENT PROCESS

11.1 CEMENT MILL:-

The second chamber the size of grinding media is small as compared to the first
chamber. The materials are grind through a grinding media & it convert in
powder form. The spray water cooling system is provided through a liner which
reduces the temperature of the cement mill. The liners are provided inner wall
of the mill. The shell is rotates In the it's own axis through a girth gear. The
girth gear is placed at the outlet head of the mill and drive through a torsional
shaft, gearbox & motor.

There are two outlets at the end of mill, first is duct which go to the mill
vent filter, another one is to the air slide which feed directly bucket elevator.
There is mill vent bag filter provided for feeding the fine material It is a long
hollow cylindrical shell which made of steel. It is soul of cement industry
because without cement mill we cannot manufacturing cement. Generally the
shell is divided in two chambers with size of grinding media through a
diaphragm. First one is crushing chamber and other one is grinding chamber.
The grinding media are heal in shell about 25 to 30% of mill volume. The
materials are come through inlet head to the first chamber, in the first chamber
crushing is done through a grinding media. After completion crushing the
materials are fed into second chamber through a diaphragm.from the mill. A fan
is also connected from top of these mill vent bag filter and it is placed near the
mill vent bag filter and hence sucks the air from the mill vent bag filter and
transfer to the stack.
Rotary air locks are provided at the bottom of the mill vent bag feeder, to
separate the air and fine material. RAL stores the material and transfer it to the
product line with constant flow rate

Cement mill specification

Cement mill (ball mill) – 1
Make – ABL/LNVT
Dia – 3.8MTR
Length – 12.52MTR ( I chamber - 4.26M, II chamber – 7.21m)
Capacity – 75TPH (OPC)
RPM – 16.5 RPM
Motor Kw – 1492 (Twin Drive)
Motor Rpm - 985 rpm
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Cement Mill (ball mill)– 2

Make – LNVT
DIA -3.8 MTR
Length - 13.52M (I Chamber – 4.23M, II chamber – 8.73m)
Capacity – 85TPH (OPC)
RPM – 16.5 RPM
Motor Kw – 1500 (Twin Drive)
Motor rpm - 990 rpm

35
 GIRTH GEAR CEMENT MILL

Fig.- BALL MILL

A cement mill is the equipment used to grind the hard, nodular clinker obtained
from the cement kiln into the fine grey powder that is cement.

Process

• Clinker and gypsum are stored in respective hoppers.

• From these hoppers the clinker and gypsum are sent to grinding mill via
weigh feeder. These weigh feeders helps in controlling the amount of
clinkers and gypsum .

• In grinding mill, the clinker and gypsum are grind to very fine powder.

• From grinding mill very fine particles are sucked out with air by the help
of Fan and collected using bag filters.

• Rest of the grind material is carried through air slide to the bucket
elevator. For manufacturing PPC fly ash is added at this stage.

• Now from bucket elevator the material is carried through air slide to the
classifier. In classifier the fine particles are carried out with air and the
coarse particles are rejected and sent back for grinding.

36
 • Now these fine particles with air are sent to cyclone which has a rotary
air lock installed in it. Hence only fine cement is taken out of the cyclone
separator and the air is sucked out using a Fan.

• The air coming out of cyclone separator may contain some amount of
cement therefore it is sent through bag filter before it is released in
atmosphere.

• Cement coming out of cement mill is then sent to packing plant via belt
conveyer.

The cement mill circuit in UCWL consists of the following equipment’s:-

• Dump Hopper

• Push feeder

• Belt conveyor

• Three way diverter gate

• Gypsum and Clinker hopper

• Vibrating Screen

• Hammer Crusher

• Weigh Feeder

• Ball mill

• Mill elevator

• Classifier

• Cyclone

• Bag filter

• Air slide

37
Working:-
The materials feed through weigh feeder at the inlet head of mill to pass
in first chamber. In this chamber the material is crushed through a grinding
media.

In first chamber crushing is done. Grinding media of 50mm, 60mm, 70mm,

80mm and 90mm diameter are used. Usually 30% of chamber is filled with
grinding media. In this chamber cataract movement (grinding because of impact
and friction) occurs. Floating or lifting liners are used in this chamber to lift the
grinding media.

In second chamber rubbing is done. Grinding media of 40mm, 30mm, 25mm,

22mm and 17mm diameter are used. Usually 30% of chamber is filled with
grinding media. In this chamber cascade movement (grinding because of
friction) occurs. Classifying liners are used in this chamber for rubbing process.

38
Mill Rotation
The mill is having twin drive system for the rotation . Each drive having three
phase induction motor ( 1492KW, 985 rpm),Gear box, Torsion shaft and pinion
shaft. Pinions are rotating the mill through Girth gear installed on mill shell.

Now this material is passed through outlet head of mill for further
process, one is for mill vent bag filter and second one for bucket elevator.
The working mill is influence by the critical speed of mill. If the mill is rotates
above the critical speed the material is not grind and crushed, but the grinding
media freely rotates inside the shell. So the mill drives below the critical speed.
The critical speed of mill is calculated by the following formula.
42.5/d1/2
Where d is the inner diameter of shell.

10.2 BUCKET ELEVATOR:-

Bucket elevator is used in cement plant for transporting the material in vertical
direction. The typical elevator consist of a series of buckets mounted on a chain
which operating over a sprocket, a steel casing cover the bucket line. The head
section and boot section house integral transmission component. The bucket
feed the material from air slide and convey in upward direction over the head
sprocket then throw the material out through discharge throat.

Fig.- bucket elevator

39
11.3 AIR SLIDE:-
It is design to convey the powder form material it is connected from the bucket
elevator to the separator. The air slide carries the material from bucket elevator
to transfer the separator classifier. It is divided into two chambers by permeable
cloth whose thickness is 10mm. air slid is inclined at an angle of 8 0-110. First
chamber is for fine material other one is for air. It uses blower to fluidized the
material.

Fig.- Air slide

40
11.4 SEPERATOR/CLASSIFIER:-

It is the mostly used in cement plant for separating the material in fine and
coarse form. the duct of CAFAN is connected at the bottom end of separator
which gives this fresh air to separator for separating the material, which causes
the material stick to the rotor and cage. The rotor is rotates it's own axis around
a cage is provided. The material is stick to the rotor through a cage then coarse
materials are settles down at the bottom of the classier and transfer to the
cement mill for further grinding and crushing through a reject belt. The fine
materials from top of the separator are transferred through a duct to the cyclone.

Fig.- separator & classifier

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11.5 CYCLONE:-

Cyclone is a conical vessel mostly used in cement industry. A high speed

rotating (air) flow is established within a conical container called a cyclone. The
material flows in a helical pattern and "eddy" stream are created inside the
vessel, at the bottom (narrow) end before exiting the cyclone. The RAL is
provided to pass the material which is settles down due to vortex of air in the
cyclone.

Ca fan is connected at the top of the cyclone, which sucks the air with
superfine dust and transfer this to classifier went bag filter. RAL provided at the
bottom of the cyclone is connected with air slide which transfer this material to
the prioduct line

Fig.- cyclone

11.6 CIRCULATORY AIR FAN:-

CA FAN is mostly used in cement plant it has onl

y two main functions, first is suck air from cyclone send to the classifier bag
filter. Another work is to give fresh air to the separator.

42
CA FAN takes the air from environment give to the separator bottom its flow is
of 190000m3/hr gives is the material in classifier and hence classifier shows its
working.
UCWL use only one CA FAN in the cement plant.

FRESH
AIR
DAMPER

Fig.- CA FAN

11.7 BAG HOUSE:-

It is a dust collector system in this bag house many bags are used to collecting
the cement dust. These bag filters operated through a solenoid valve. The high
compressed air is used for purging the bags. Since fine materials are settle down
at the narrow end of the house and discharge through a rotary airlock to the
product line belt. The Fan is placed near the bag house and it is used for
removing the air from bag house, send to the stack.

43
 Fig:seperater bag house

11.8 FLY ASH SILO:-

A silo is provided for storing the fly ash. The bulker feed the fly ash through
duct into the silo. it uses compressed air 1.8 Kg/cm2 for purging the bulker
which causes increase the pressure inside the bulker Since easily flow of
material through a duct in upward direction to the silo.
There are 60 open air slides are provided inside the silo for continuously
blending which connected to the root blowers and alternative operating of air
slides. A bag filter is provided at the top of the silo for collecting the dust.
The material storage capacity of this silo is 500MT. The outlets from the silo is
in air slide transfer the material to the bin of capacity 30MT. Load cells are
provided for measuring the load in bin.
There is no effect on strength of cement while addition of fly ash (upto a limit)
takes place.

44
 Fig.- Fly ash silo

CEMENT CLINKER GYPSUM FLY ASH

Ordinary Portland 94% 6% 0%
cement
Pozzolana portland 64% 6% 25-30%
cement

ADVANTAGE OF FLYASH:

 It is clinker replacement reducer.

 It increases the product durability.
 It protects the steel, iron reinforcement from corrosion.
 It reduces environment hazards.
 It increases reaction with free lime.

45
Chapter 11 PACKING PLANT

46
Main elements of the packing plant

• Silos
• Bucket elevator
• Reject screen
• Storage bin
• Control gate
• Rotary packer machine
• Bag discharge belt
• Bag cleaning device
• Dust collecting hopper
• Bag filter
• Bag diverter
• Air slide
• Belt conveyor
• Truck loading machine

12.1 SILO:-

Used for cement storage which is coming from cement mill through product belt
& then from bucket elevator to silo.
At UCWL there are 4 no. silo's in packing plant for cement storage & they are
as follows:

1. SILO NO.01:
Capacity: 6000mt
Cement stored: ppc
Height: 40 meter
Airslide used: open airslide
Airation bin

2. SILO NO.02:
Capacity: 2000mt
Cement stored: opc
Height: 27meter
Open airslide is for blending

3. SILO NO.03:
Capacity: 2000mt

47
Cement stored: ppc
Height: 27meter
Open airslide is for blending

4. SILO NO.04:
Capacity: 2000mt
Cement stored: ppc
Height: 27meter

Fig.- SILO arrangement

48
12.2 BUCKET ELEVATOR:-
Bucket elevator is used in cement plant for transporting the material in vertical
direction. The typical elevator consist of a series of buckets mounted on a belt
which operating over a pulley, a steel casing cover the bucket line, The head
section and boot section house integral transmission component. The bucket
feed the material from air slide and convey in upward direction over the head
Silo 2 pulley then throw the material out through discharge throat.

Silo 4

Fig.:-product line elevator Fig.:- packer elevator

SPECIFICATION:
MAKE: Mahindra
CAPACITY: 250 TPH ,150TPH, 150TPH
GEAR BOX SPECIFICATION:
MAKE: ELECON
RATIO: 40/1
POWER: 18.5KW
COUPLING: FLUID COUPLING & PINBUSH COUPLINGS

49
TOTAL BUCKET: 257, 157, 157 BUCKETS respectively.
HEIGHT: 42, 24, 24 MTR respectively.
BUCKET BELT WIDTH: 400MM
12.3 VIBRATING / REJECT SCREEN:-
Vibrating Screen is one of the essential equipment used in packing plant, in
cement packing plant it is used for separating nibs, lumps and foreign materials
from cement so that only cement is passed on to the packer. Vibrating Screen
vibrates through the shaft with counter weight, which is driven through a ‘V’
pulley system and electric motor. Due to the inclination of screen and vibration
of its screen deck they travel and come out of the reject funnel where they get
collected. At UCWL design capacity of vibrating screen for material handling is
150 TPH.

Fig.- Vibrating screen

SPECIFICATION:
MAKE: Fls Midth Ventomatic
CAPACITY: 150 Tph
SCREEN SIZE: 1000x2500 Mm
SCREEN HOLE SIZE: 4x4 Mm

Advantages

50
• It increased product quantity.
• It reduced wear & tear at packing.
• It has higher packing machine availability.
• It has higher personal health & safety.

Features

• It has compact, solid, simple & dust proof design.

• It is maintenance friendly.
• Its capacities according to the respective packing machine.
• It is independent of the installed packing machine.

12.4 ROTO PACKER:-

PACKER: 8 RS-E SINGLE DISCHARGE PACKERS:

At UCWL Roto Packers with 8 nozzles (spout) of capacity 2400
bags/hour (120TPH) is used. Every Spout is equipped with individual filling
system consisting of impeller box assembly, bag chair assembly, filling spout
assembly, load cell assembly and electronic unit. The electronic unit is a sturdy,
user friendly, proven design unit and very reliable enabling to achieve good
accuracy for this kind of machines. Electronic units have been installed in
Packers, providing the superiority with regards to functions and accuracy.

SPECIFICATION :

MAKE: FLS midth VENTOMATIC

CAPACITY: 120 TPH
RPM: 5RPM (MAX)
COMPRESSED AIR: 5-7 BAR (64 NM3/HR)
MAIN DRIVE: 1.5 KW
IMPELLER DRIVE: 5.5 KW
CONTROL VOLTAGE: 230V. AC, 50HR
INVERTOR: 2-2 KW ACS 350 ABB
POWER SUPPLY: 415 AC +-10%, 3 PHASE , 50HZ

51
 Fig.- 8 Nozzle Discharge Roto Packer

BAG FILTERS:-
A dust collector is a system used to remove dust in air released from industrial
and commercial processes by collecting dust and other impurities from air.
Designed to handle high-volume dust loads, a dust collector system consists of a
blower, dust filter, a filter-cleaning system, and dust removal system. It is
distinguished from Aircleaners, which use disposable filters to remove dust. In
this bag house cleaning a high pressure blast of compressed air is used to
remove dust from the bag. The blast enters the top of the bag tube, temporarily
ceasing the flow of dirty air. The shock of air causes a wave of expansion to
travel down the fabric. The flexing of the bag shatters and discharges the dust
cake. Due to its rapid release, the blast of air does not interfere with
contaminated gas flow. Therefore, bag houses can operate continuously and are
52
not usually compartmentalized. The blast of compressed air must be powerful
enough to ensure that the shock wave will travel the entire length of the bag and
remove the dust cake.

UCWL uses three bag filters at packing plant one is above the packer floor of
capacity 18000m3/hr. Near the silo 1 there is a bag filter of 15000m3/hr. third
one is near the product belt end of capacity 12000m3/hr.

Fig.- Bag filter

53
SPECIFICATION:
CAPACITY: 18000 MTR3/Hour
BAGS & CAGE: 3 Meter (length).
DRIVE: BELT DRIVE
AIR PRESSURE: 3KG/CM2
TOTAL BAG: 96 (16X6)

TRUCK LOADER:
Loading of bags in the truck is carried out automatically by means of truck
loading machines, truck loading machine consists of two conveyors i.e. feeding
conveyor & loading conveyor.
Motor used for rotating the conveyor is drum motor. Loading conveyor, up &
down movement is through luffing Gearbox which is installed beneath the
loading conveyor. The whole truck loader is running on rail line with trolley
drive arrangement.

Fig.- Loader

SPECIFICATION:
MAKE: FL Smidth
CAPACITY:2000bags/hour
LENGTH: 15.3m

FEEDING CONVEYOR:
BELT WIDTH: 650MM
DRUM MOTOR: 2.2KW,
54
LOADING CONVEYOR:
BELT WIDTH: 750MM
DRUM MOTOR: 2.2KW

LUFFING GEARBOX:
MAKE: ELECON
RATIO: 10/1

CENTRAL CONTROL ROOM (CCR):-

Fig.- CCR SCREEN

CCR is the heart of the over all process in all plants. because it control
all the process including raw material feeding to product
discharging/manufacturing. it reducs human power, time, efforts and
most important, it act as a alarm before the breakdown. It saves the
file data for long time. It uses the sensors, actuators and electronic
devices to make automatic control on the process of the plant.

55
The chief chemical constituents of Portland cement are as follows:

LIME (CaO) 60 to 65 %
Silica (SiO2) 17 to 25 %
Alumina(Al2O3) 3 to 8 %
Iron Oxide (FE2O3) 0.5 to 6 %
Magnesia (MgO) 0.1 to 4 %
Sulphur trioxide (S03) 1 to 3 %
Soda and/or Potash (Na2o+K2O) 0.5 to 1.3 %

The above constituents forming the raw materials undergo chemical reactions
during burning and fusion, and combine to form the following compounds
called BOGUE COMPOUNDS.

Compound Abbreviated
designation
Tri calcium silicate (3CaO.SiO2) C3S
Di calcium silicate (2CaO.SiO2) C2S
Tricalcium aluminate (3CaO.Al2O3) C3A
Tetra calcium aluminoferrite (4CaO.Al2O3.Fe2O3) C4AF
Clinker Formula Ca2SiO4+CaO =
Ca3SiO5

56
 Chapter 13
QUALITY CONTROL AND TESTING

There are many ways and methods for the testing of cement. Some of them need
a proper laboratory setup while other can be conducted at field itself. For the sake
of convenience we will divide the methods under following two categories as (i)
Tests in Field and (ii) Tests in Laboratory.

Tests in Field

Field tests are convenient way of primary inspection of cement when it is used in
small scale works or when decision has to be made during purchase process.
These are some of the steps that can ensure you good quality cement while
inspection at site-
a) First cement bags should be open a little wide for visible inspection. There
should not be any lumps formation inside the bag.
b) Put your hand inside the bag and ensure additionally that there are not any
hidden lumps. Also this activity should give u a feel of cool sensation on your
hands.
c) Take a sample of cement in your hand and rub it in between your fingers.
It should be smooth in nature.
d) Take another handful sample of cement and throw it in the bucket full of
water. Particles of cement should float a while before sinking down.

57
Tests in Laboratory

Field tests only indicate that cement is not bad and can be used for small scale
works. Thus Laboratory tests are necessary to confirm that cement is good in
nature and can even be used for important works too. Following tests are
necessary to be conducted on cement in laboratory-
a) Fineness Test-The fineness of cement can be defined as the measure of size
of particles of cement or in simple form “Specific Surface of Cement”.
b) Setting Time Test- Cement when mixed with water triggers a process which
results in a hardened mass of mixture wherein hardness gradually increases with
time. There are two setting times for cement- Initial Setting Time (IST) or Final
Setting Time (FST).It is tested using Vicat’s Apparatus. Eg. For Portland Cement
IST is around 30 mins and FST is around 600 mins.
c) Strength Test- The strength of cement is defined in MPa or N/mm2. For
grade 53 Portland cement, strength should be around 53MPa in 28 days.
Compression test is carried out to check the strength of cement.
d) Heat of Hydration Test- The heat of hydration can be defined as heat from
cement paste liberated as a reaction of water with cement. This test is usually
carried out in thermos flask.
e) Chemical Composition Test- A test is carried out on cement that tests the
ratio of chemicals in the cement. Different standards and codes specify different
value of such ratios. A standard oxide and chemical composition of Portland
cement is as given below-

Chemical compound Percentage

Lime, Cao 60-66%

Silica, Sio2 17-25%

Alumina,Al2O3 3-8%

Iron Oxide, Fe2O3 0.5-6%

Magnesia, MgO 0.5-4%

Sulphur trioxide, SO3 1-2%

58
 Alkalis 0.5-1.3%

Grade OPC-43 OPC-53 PPC

Content Unit BIS UCWL BIS UCWL BIS UCWL

Sp.surface M2/kg 225 300+-10 225 300+-10 320 400+-10

Setting time

I ST Minut 30 120+-10 30 120+-10 30 125+-10

FST Minut 600 180+-10 600 180+-10 600 195+-10

Expansion

Auto clave % 0.8 0.08+- 0.8 0.08+- 0.8 0.08+-

0.02 0.02 0.02

Lechetiben Mm 10 .5+-.05 10 .5+-.05 10 .5+-.05

Compressive Mpa
strength

1day Min 23 21+-1 _ 23+-1 _ 18+-1

3 day Min 33 33+-2 27 37+-2 16 27+-2

7 day Min 43 45+-3 37 48+-3 22 39+-3

28 day Min 58 55+-3 53 62+-3 33 58+-3

59
 PROJECT

Bag Filter / Dust Collector:-

A dust collector is a system used to enhance the quality of air released from
industrial and commercial processes by collecting dust and other impurities from
air or gas.

Designed to handle high-volume dust loads, a dust collector system consists

of a blower, dust filter, a filter-cleaning system, and a dust receptacle or dust
removal system. It is distinguished from air cleaners, which use disposable filters
to remove dust.

Five main types of industrial dust collectors are:

1. Inertial separators
2. Fabric filters
3. Wet scrubber
4. Electrostatic precipitators
5. Unit collectors

At UCWL, fabric filters used as a baghouse dust collector.

Fabric collectors use filtration to separate dust particulates from dusty gases.
They are one of the most efficient and cost effective types of dust collectors
available and can achieve a collection efficiency of more than 99% for very fine
particulates.

60
Dust-laden gases enter the baghouse and pass through fabric bags that act as
filters. The bags can be of woven or felted cotton, synthetic, or glass-fiber
material in either a tube or envelope shape.

Working

At UCWL, pulse jet is used for the baghouse cleaning. This type of baghouse
cleaning (also known as pressure-jet cleaning) is the most common. A high
pressure blast of air is used to remove dust from the bag. The blast enters the top
of the bag tube, temporarily ceasing the flow of dirty air. The shock of air causes
a wave of expansion to travel down the fabric. The flexing of the bag shatters and
discharges the dust cake.

Conclusion :-

I got a opportunity to pursue my training in UDAIPUR CEMENT WORKS

LIMITED. It was really a learning experience for me to have a feel of different
industrial aspects.
In this period, I have learned those things which I could not get from books
which is the practical experience under the guidance of learned professionals.
Special thanks to UCWL team.

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