VIDYA VIKAS UNIVERSAL COLLEGE

Presentation on :

PRODUCTION AND MATERIAL MANAGEMENT

 ACKNOWLEDGEMENT
Thanking Ms. Manju Chakravarthy for believing in me and assigning such a interesting task. Her words of encouragement were really helpful in in fulfilling the project.

 DECLARATION
I, Shaikh Sameer Usman certifies that every information provided is true to my knowledge and doesnt plagiarize or infringe any individual / organization rights.

 UltraTech Cement Limited has 12 integrated plants, 1 white cement plant, 11 grinding units in India and 1 clinkerization plant in UAE, 15 grinding units( 11 in India, 2 in UAE, 1 each in Bahrain and Bangladesh)and 6 bulk terminals (5 in India and 1 in Sri Lanka). In Durgapur Plant, around nine thousand people are employed. This plant has been assigned the work of grinding the cements. The total output of this plant is around 1.9 million tonnes.

Durgapur Plant

Closed Circuit Grinding

 PRODUCTION
MINING
Limestone is extracted from own mines, which are situated approximately 4 from the plant. The mining is done in such a way so as to get 78% to 82% limestone. kms pure

CRUSHING
The extracted limestone is transported to crusher by dumpers. The limestones are crushed into small pieces of about 16-25 mm in size.

BLENDING
The raw materials are blended to make the mixture uniform. From here the raw materials are send to pre-heaters.

BURNING
In pre-heaters, the mixture is heated at several temperatures at various stages. The pre heated material is send to kiln where it is heated at temperature between 1400-1500 degree Celsius . Coal is used to maintain the temperature and finally clinker emerges out of it.

 DIAGRAMATIC REPRESENTATION

 RAW MATERIALS
Limestone: - Limestone is the main raw material for manufacture of cement. For manufacturing one tone of cement, a quantity of 1.5 tone of limestone is required. India is endowed with large deposits of limestone. The cement industry is the largest consumer accounting for about 75-80% of total limestone production. Gypsum: - Gypsum is another raw materials used mainly as a retarding agent along with clinker during the manufacture of cement. It is used during the grinding stage of clinker. Consumption of gypsum varies from 2% to 6%. Coal: - Coal is an important input in the manufacture of cement both as a fuel and as a feedstock. Coal is used twice mainly for the purpose of generating heat and also used as silica. For every tone of clinker, around 200-220 kg of coal is consumed, which accounts for 15-20% of total cement production cost.

 MACHINES USED IN PRODUCTION

Ball Mill
Ball mill is crucial equipment for grinding after materials are crushed. It is an efficient tool for grinding various materials into powder. There are two ways of grinding: the dry process and the wet process.

Vertical Grinder
Used in metallurgy, ie the heating process which eliminates the waste products.

 Other machines used in manufacturing cement are:

Coarse Powder Grinding Trapezium Mill

Ultra Fine Grinder

Raymond Mill

 Method of Cement Storage

All windows and doors are closed and weather and Moisture must not affect to the cement. Distance of stacking bags should be 1 feet from wall and 2 feet from ceiling. Placing maximum 15 bags in one stacking.
Storage Time Fresh 3 Month 6 Month 12 Month 24 Month Compressive Strength 100% 80% 72% 60% 46%