15 Days Inplant Training Presentation in ACC limited., Madukkarai Cement Factory.

1. Welcome
Done by
E.Gokul Nathan (16RBTCE006)
3rd Year Chemical Engineering

3. The ACC Ltd., [ACC]is the largest Producer of
cement in India with annual turnover of about
Rs.24,000 million. It has a large operation
with 11 marketing offices spread all over the
country with a network of 8000 dealers. In
addition to the domestic operations, ACC
extends its services to various parts of the
world including operations and management
of cement plants.

4.  The site consists of a semi-wet process
cement plant with a single kiln that has
clinker manufacturing. The plant also has an
on-site 15 MW power station and an on-site
colony that provides housing for over 2000
people (workers and families).

5.  Limestone and other raw materials for the
cement operations are transported by truck
from quarries located 4 km (Madukkarai
Mine) and 22 km (Walayar Mine) from the
plant site.

6. Cement is finely ground hydraulic binding
medium for mortar and concrete, consisting
substantially of compounds of CaO with SiO2,
Al2O3 and Fe2O3 which have been formed by
sintering or fusion.
 Sintering means burning at a temperature
which cause partial fusion of the material

7.  Calcium (Ca)
 Silicon (Si)
 Aluminum (Al)
 Iron (Fe)
 Typical Raw Materials:
 Limestone (CaCO3)
 Sand (SiO2)
 Clay (SiO2, Al2O3, Fe2O3)
 Iron Ore (Fe2O3)

8. Limestone +Clay + Heat = Clinker +CKD + Exit
Gas.
Clinker + Gypsum = Portland Cement

9.  The Semi wet process is generally used when
the raw materials are soft because complete
mixing is not possible unless water is Added.
 Actually the purpose of both dry and wet
process is to change the raw material into
fine powder.

10.  Quarry
 Crushing
 Raw material preparation state
 Kiln Feed stage
 Fuel preparation stage
 Pyro-processing
 Cement grinding stage
 Cement packing and dispatch stage.

11.  Raw materials are homogenized by crushing, grinding
and blending so that approximately 80% of the raw
material pass a No.200mm sieve.
 The mix will be turned into form of slurry by adding 30 -
40% of water.
 It is then heated to about 2750ºF (1510ºC) in horizontal
revolving kilns (76-153m length and 3.6-4.8m in diameter.
 Natural gas, petroluem or coal are used for burning. High
fuel requirement may make it uneconomical compared to
dry process.

13. In the kiln, water from the raw material is driven off and
limestone is decomposed into lime and Carbon
Dioxide.
Ca2O3 ------> CaO + CO2
In the burning zone, portion of the kiln, silica and
alumina from the clay undergo a solid state chemical
reaction with lime to produce calcium aluminate.
CaO + SiO2 + Al2O3 ----> CaAl2 O4.

14.  The rotation and shape of kiln allow the blend to flow
down the kiln, submitting it to gradually increasing
temperature.
 As the material moves through hotter regions in the
kiln, calcium silicates are formed
 These products, that are black or greenish black in
color are in the form of small pellets, called cement
clinkers
 Cement clinkers are hard, irregular and ball shaped
particles about 18mm in diameter

16.  The cement clinkers are cooled to about 150ºF (51ºC)
and stored in clinker silos.
 When needed, clinker are mixed with 2-5% gypsum
to retard the setting time of cement when it is mixed
with water.
 Then, it is grounded to a fine powder and then the
cement is stored in storage bins or cement silos or
bagged.
 Cement bags should be stored on pallets in a dry
place.

17.  Fineness
 SettingTime
 Expansion
 Compound strength
 Heat of Hydration
 Durability