The PPT shows cement manufacturing process from the mining of the raw material to the packing of powdered cement.

1. CEMENT MANUFACTURING
PROCESS
Presented by:-
SHUBHAM MALVIYA
Mechanical engineering
UECU

2. About JK Cements Nimbahera
• J.K Cement has three decades of experience in cement
manufacturing. From modest beginning in the year 1974
with a capacity of 0.3 million tonnes at Nimbahera in
Rajasthan, today J.K Cement has 6 kilns of different
capacities with a combined annual capacity of 7.5 million
tonnes. The three cement units having aggregate
capacity of 4.5 million tonnes are located in Rajasthan at
Nimbahera (capacity 3.25 million TPA).
• Unit head : Mr. S.K Rathore
• HR HEAD : Mr. M.S Shekhawat
• Training coordinator : Mr. Faraz Muhammad

3. RESOURCES
Raw materials
• Lime stone from mines
• Gypsum
• Laterite
• Bauxite
• Fly ash
• Coal
Electricity
Water

4. Objectives of training
The main objective of Industrial Training is
to expose the students to actual working
environment and enhance their knowledge and
skill from what they have learned in the college.
Another purpose of this program is to instill
the good qualities of integrity, responsibility and
self confidence. In cement manufacturing
industry our main goal is to learn the working
and maintenance of different manufacturing
machines involved.

5. PROCESS
• MINING
• CRUSHING
• PREHOMOZENISATION
• GRINDING
• HOMOGENIZATION or PYRO-PROCESSING
• CEMENT GRINDING
• PACKING AND LOADING

7. MINING
• Extraction process of raw materials
• Limestone(CaCO3) is the major raw material.
• Some more raw materials are :
gypsum
laterite
bauxite
flyash

8. CRUSHING
• IMPACT
• SHEAR
• COMPRESSION
• ATTRITION

9. CRUSHING OF BOULDERS IN JK
CEMENTS
In JK cements, they use two processes of crushing :
• Primary crushing : it is done by primary jaw crusher.
• Secondary crushing : it is done by single rotor impact
type crusher.

10. Primary crushing
SINGLE JAW CRUSHER

11. Secondary crushing
SINGLE ROTOR DOUBLE IMPACT CRUSHER

12. HOMOGINIZATION
• In this process crushed limestone of 45mm are
stored in the form of piles.
• Stacker is used in piling of crushed limestone.
• Reclaimer is used to reclaim limestone on
conveyor belt for further processing.

13. stacker
RECLAIMER

14. GRINDING
• Grinding can be done by either ball mill or
VRM(vertical rolling mill).
• In JK cements Nimahera, they use ball mill
method. But in other plants, they also use VRM.

15. Ball mill
• It needs secondary crusher, because it can only
grind pieces of limestone having size 25mm.
• It consists several metal balls in a cylindrical
shaped machine.

16. WORKING OF BALL MILL

17. VRM
• It is capable to grind the pieces of limestone
having size of 45mm.

18. PYRO-PROCESSING
• PRE HEATING STAGE
It is a vertical tower used to exchange heat
from flue gases into grinded powder. It reaches
the temperature up to 1300K.
• KILN
It is an inclined rotating drum of diameter
up to 5m and length 60-70m. Here the grinded
powder is heated up to 2500K and is converted
into Clinker.

19. GRINDING OF CLINKER
• After clinker has cooled in silos it is transferred
to a ball mill.
• In this stage gypsum/gypsum + fly ash is added
to clinker in order to give necessary properties.

20. PACKING AND LOADING
• Cement stored in silos after grinding process is
taken to packing plant where it is packed in bags
of 50kg each with the help of semi-automatic
machine.
• Packing capacity of each machine is
80bags/minute.
• Finally the cement bags are loaded in to rail
wagons or trucks with the help of semi-
automatic conveyor belt system.

21. SILOS
• A silo is a structure for storing bulk materials.
• In JK cements plant Silos are being used to store
1. Raw meal
2. Final product.

22. BAG HOUSE
• It is a device used to collect dust
particles in order to control air
pollution and also creates workable
environment.
• It is a high efficiency mechanical device
which contains fiber bags into which
high pressure air is being blown in the
form of pulse and dust is collected in to
hoppers and stored.
• It can collect dust up to 0.6microns.

23. SOME MORE SECTIONS
• Separators
• Compressor section
• Transformer section
• 20 MW Waste heat power plant

24. SUMMARY
• We have seen the process of cement
manufacturing. In the period of this training the
expert engineers from different sections of the
industry have shared their experience with us.
• We experienced the working environment in JK
cements.
• We interacted with the various kinds of
machines, which means a lot to a mechanical
engineering student.

25. COURTESY
• I would like to thank Mr. S.K Rathore sir(unit
head), Mr. M.S Shekhawat(Asst. vice president -
HR) ,Mr. Faraz muhammad(training
coordinator,RTC) and training staff of JK
cements,Nimbahera for their support and
guidance.

26. REFERENCES
• JK CEMENTS guide book.
• Wikipedia
• Animated gif files from google.