1. 1 | P a g e
INTERNSHIP REPORT
DG KHAN CEMENT
(Khairpur Plant, Kallar kahar, Distt. Chakwal)
Prepared For
Mr. Safdar Kamal
SDM Technical
DG CEMENT LTD Kallar Kahar
Prepared By
Mr. Syed Ali Ikram
Internee, Institute of Chemical Engineering & Technology,
University of the Punjab, Lahore.

2. 2 | P a g e
Personal Information
Sr. No: 5
Name: Syed Ali Ikram
Father’s Name: Syed Ikram Hussain
Discipline: Chemical Engineering
Roll No: M12- PG04
Contact Number: +92 335 0406323
Email Address: syedali.ikram999@gmail.com
Internship Duration: 1st
June, 2016 to 10th
June, 2016
Institute of Chemical Engineering and Technology,
University of the Punjab, Lahore.

3. 3 | P a g e
Acknowledgment
In doing this internship, first of all I would like to say thanks to Allah
Almighty who showered His blessings on me and blessed me with the
potential to complete the task in time.
The report presents the knowledge we have gained and a sort of purposeful
learning outcome under the supervision of Engineer Zahid Akram. No doubt
it is the outcome of our handful work on the plant site regarding the
understanding of various processes occurring there. We did our best to get
our understanding at the better level and make this opportunity fruitful.
I would like to thank the managerial staff at DG Cement especially Mr.
Safdar Kamal. They helped me to gain a lot of information regarding the
company and cement industry and also who provide me an opportunity to
learn and understand the working of organization as an internee. They gave
me a chance to improve my industrial skills that will surely help me in the
practical field. I’m also thankful to Mr. Engr. Zahid Akram who taught me a
lot about the industry and the organization.

4. 4 | P a g e
Executive Summary
The internship offered to us through university in DG CEMENT LTD Kallar
Kahar. During the internship our main objective was to get ourselves
familiarize with different processes occurring in the plant site and to get
knowledge of the equipments working in the whole process.
The report is mainly divided into two major portions. First portion include the
details about the function of equipments installed in the process of cement
manufacturing ranging from bag filters to major component of the process
that is Rotary Kiln and includes the process description of the cement
manufacturing in somewhat precise manner. Second portion includes utility
section which includes the cooling tower, water treatment plant, waste heat
recovery section.
Thereby concludes that it’s a valuable endeavor of learning at plant site and
gave me in hand the practical experience out there.

5. 5 | P a g e
Table of Contents
Chapter no. 1.................................................................................... 8
Introduction:.....................................................................................8
Block Diagram of Cement Production Process ........................................9
Chapter no. 2.................................................................................. 10
Cement Production Process ...............................................................10
2.1. Quarry and Raw Material..........................................................10
2.1.1. Drilling: ...........................................................................10
2.1.2. Blasting:..........................................................................10
Lime Stone................................................................................10
Clay .........................................................................................10
Additives...................................................................................10
2.2. Limestone/Clay Crusher...........................................................11
2.3. Storage Yard ..........................................................................13
2.4. Stackers ................................................................................13
2.4.1. Side Scraper ....................................................................13
2.4.2. Reclaimer ........................................................................13
2.4.3. Hoppers...........................................................................14
2.5. Raw Mill Area .........................................................................14
2.5.1. Raw Mill...........................................................................14
2.5.2. Cyclone Separators ...........................................................15
2.5.3. Bucket elevator ................................................................15
2.5.4. CF Silo.............................................................................15
2.6. Preheater...............................................................................16
2.7. Rotary Kiln.............................................................................16
2.8. Clinker Cooler.........................................................................17
2.9. Electrostatic Precipitator (EP) ...................................................17
2.10. Clinker Crusher & Storage ......................................................18
2.10.1. Clinker Crusher...............................................................18

6. 6 | P a g e
2.10.2. Clinker Storage...............................................................18
2.11. Cement Feed Mill Area ...........................................................19
2.11.1. Cement Mills...................................................................19
2.11.2. Storage Silos ..................................................................19
2.12. Packing Plant........................................................................20
Chapter No. 3 ................................................................................. 21
Instrumentation Devices ...................................................................21
3.1 Proximity Sensor .....................................................................21
3.2. Pt-100...................................................................................21
3.3. Vibration Measuring Instruments ..............................................21
3.4. Gas Analyzer ..........................................................................21
3.5. Programmable Logic Controller .................................................22
Chapter No. 4 ................................................................................. 23
Power Plant.....................................................................................23
Motors............................................................................................24
Safety and Fire Fighting....................................................................25
4.1. Safety ...................................................................................25
4.2 Fire Fighting ..............................................................................25
4.2.1 Hose Reek System .............................................................25
4.2.2. Sprinkler System ..............................................................25
Foaming System ..............................................................................25
Fire Tender System ..........................................................................26
Emergency Alerts & Precautions.........................................................26
Chapter No. 5 ................................................................................. 27
Utilities ...........................................................................................27
5.1. Cooling Tower ........................................................................27
5.2. Water Treatment Plant ............................................................27
5.3. Waste Heat Recovery Section ...................................................27
Feedback & Conclusion................................................................... 28

7. 7 | P a g e
List of Illustration
Figure 1 Block diagram of cement production process Pg. no 9
Figure 2 Raw material collection Pg. no 11
Figure 3 Lime stone Pg. no 11
Figure 4 Clay Pg. no 11
Figure 5 Raw Mill Pg. no 15
Figure 6 CF Silo Pg. no 16
Figure 7 Kiln Pg. no 17
Figure 8 Kiln Pg. no 17
Figure 9 Clinker Storage Pg. no 18
Figure 10 Cement Mills Pg. no 19
Figure 11 Cement Silos Pg. no 19
Figure 12 Packing Plant Pg. no 20
Figure 13 Power Station Pg. no 24
Table 1 Storage Yard Piles Pg. no 13
Table 2 Motor Power Pg. no 24

8. 8 | P a g e
Chapter no. 1
Introduction:
Dera Ghazi Khan Cement Company Limited Khairpur Plant is a business unit
of Nishat Group, which is the largest and most growing industrial group in
Pakistan. Nishat Group is one of the most renowned business groups in
Pakistan. It was founded by Mian Muhammad Mansha in 1951. It is
playing a significant role in the private sector by adding value to cotton.
Nishat Mills Limited started out as a weaving unit with 500 semi-automatic
looms, later on 10,000 spindles were added, laying the foundation of
nation’s biggest textile composite project. Today, Nishat Mills Limited is
largest vertically integrated unit of Pakistan and the cotton based economy.
D.G. Khan Cement Company Limited (DGKCC), a unit of Nishat
group, is the largest cement manufacturing unit in Pakistan with a
production capacity of 5,500 tons clinker per day . Its product is
relatively high priced yet it has highest market share because of
good quality. This is the reason why it is producing most of the
cement needed in the country as compared to other cement companies.
Its plants are situated in Dera Ghazi Khan and Khairpur and head office is
situated at Lahore. All the plants are situated in places where the raw
materials needed are all at one place. Two plants are located in DG Khan
while one in Khairpur near Kallar Kahar. This one is installed with the
collaboration of a Danish company called FLS. Much of its machinery is
imported from Germany.
This plant has a total production capacity of 6700 TPD. Currently the
company is also exporting the cement to various countries like Iraq, India,
Afghanistan and UAE. D.G Khan Cement has also contract with ELEPHANT
cement at Sri Lanka.
To energize the massive mechanical setup, power is needed .Total power
being provided to this plant is 32.2 MW.
There is also a Paper Mill running here for the purpose of producing plastic
bags for packaging of cement. These bags not only meets the packing
requirements in the plant itself but are also sold to the neighbor
contemporaries.

9. 9 | P a g e
Block Diagram of Cement Production Process
Figure 1 (Block Diagram of Cement Production Process)

10. 10 | P a g e
Chapter no. 2
Cement Production Process
The detail of production of cement process is given below:
2.1. Quarry and Raw Material
Quarry is the place from where Raw Material is extracted. Drilling and
Blasting is done to extract the material. There are two types of quarry:
Side
Pit
2.1.1. Drilling:
Drilling is done in the quarry with the help of drilling machine. A space of 10-
15m is created for the powder explosive.
2.1.2. Blasting:
The powder explosive is blasted under a controlled process to get the rocks
in the form of pieces of different small sizes. This extracted material is
loaded on dumper trucks and conveyed to the crusher. The Raw
Material used are:
Lime Stone (76%):
This raw material is owned by company and is extracted from nearby quarry
unit. Limestone has the highest composition in the cement production.
Clay (24%):
Clay is another nature resource used in cement production. It contains
Silicon in abundance. 25% contribution in cement is of Silicon.
Additives (<1%):
a) Iron Ore, Bauxite & Silica: Iron ore is not extracted from quarry unit
but it is bought from contractors. This is added in very small quantity to
strengthen the cement.
b) Gypsum (5%): Gypsum is retarding agent and is used to increase
setting time (to slow down hardening process).

11. 11 | P a g e
Figure 2(Raw Material
Collection)
Figure 3 (lime Stone) Figure 4 (Clay)
2.2. Limestone/Clay Crusher
Raw material such as limestone and clay are dumped into hoppers by
dumper trucks and entered into a hammer crusher through an apron feeder.
Inside hammer crusher there are hammers having a weight of 90-98 kg.
They rotate at a speed of 1200- 1300 rpm and is capable of crushing feed of
very large sizes. The motor responsible for grinding is of 1540kW.The
crushed material is sent to the suction bags where dust is sucked and re-
used while the other crushed material is conveyed by the conveyer
belts to the storage yard. To deal with the magnetic particles, iron
separator is used which is a magnet and thus separates the ferric material
out there.
Example code: 131 BC 200
131= area code
BC= belt conveyor
200= equipment number.
Side where motor is connected to drive the belt is known as driven drum.
Driven drum is connected to a motor through a gear assembly.
Other end is known as tail driven drum.
Speed of motor, n = 120f/p, f= 50 Hz, p= no. of poles.
Motors with the speed 3000, 1500, 1000, 750rpm etc. are designed by
changing the no. of poles.

12. 12 | P a g e
Most of the motors are designed with 4 poles to run at 4000rpm.
After slip canceling, such motors rotate at 1460-1480rpm.
Belt conveyors are run at speed of 0.8-1.5m/s.
A gearbox is used with the motor to run conveyor belt at such speed.
n1/n2 = d2 /d1, where n and d are speed and diameter of the gears
respectively.
Speed is reduced and torque is increased using gears
Rotational motion is converted into linear motion by taking the path covered
in one rotation as a circumference and then considering it as a linear
distance travelled by the belt.
Circumference c= pi*d.
Crusher Substation:
It has 6.3kV feeder coming from main substation.
From feeder, supply goes to crusher motor and a transformer that drives all
other motors of the area.
Substation panels contain relays SIPROTEC 75J62.
SF6 circuit breakers.
Crusher motor operates on fixed speed.
Frequency drives are present for the other motors of the crusher area.
UPS set up is present for back up of control supply in case of power
shutdown at any time.
The main transformer of the area is of 1600kVA.
It’s a 3 phase and output is 415V.
Has Delta-y connection topology.

13. 13 | P a g e
2.3. Storage Yard
6 piles are made in the storage yard:
Pile # Material Capacity
1 Bauxite 1500-3000t
2 Iron ore 2800-3000t
3 HG lime stone 3000t
4 HG lime stone 3000t
5 Mix 30,000t
6 Mix 30,000t
Table 1 (Storage Yard-Piles)
2.4. Stackers
Stacker is a device which forms conical piles of the crushed material. Pile#3
4, 5 and 6 are created by stackers and pile#1&2 are created by hoppers.
Feed is conveyed to the stacker through conveyor belts, called jibs. This
stacker then moves to and fro to make a pile.
2.4.1. Side Scraper
It operates on the pile #1, 2, 3 and 4 .It collects the material from piles and
throw it on the belt which further supply the material to the hopper.
2.4.2. Reclaimer
It works on pile #5 and 6. It collects the material and sends it to the
hopper.

14. 14 | P a g e
2.4.3. Hoppers
There are four hoppers or bin to feed four ingredients to the raw mill. Each
hopper provides feed with the help of rotary feeder that is controlled by
CCR. So CCR and QC lab controls the material ratio.
2.5. Raw Mill Area
The raw mill feed area consists of 4 feed hoppers:
1. Mixed feed hopper
2. Pure limestone hopper
3. Bauxite hopper
4. Iron ore hopper
The capacity of first two hoppers is 800 tons while the other two hoppers
have a capacity of 600 tons. The feed from each pile is conveyed to the
hoppers through conveyor belts in relevant hoppers. Each hopper has
four load cells.
Load Cells are sensing devices from which the feed in required proportions
is transferred by the belt conveyor to the Raw Mill. A lot of dust is produced
during the conveying of material, to avoid this problem Bag Filters are
installed.
Magnetic Separator is also installed to remove metal impurities.
2.5.1. Raw Mill
Raw Mill contains a huge rotating disk and 3 big grinding rollers 120 degree
apart tightly pressed on to the disk by hydraulic mechanism.
Disk moves with the help of motor and rollers move on it.
Material on the rotating disk moves away toward the rollers due to
centrifugal force and thus grinded. Raw mill has a mechanism of hot gases
passing through it which takes very fine particles to the cyclones through air
separator and the coarse particles back to the raw mill by breaking their
kinetic energy.

15. 15 | P a g e
Figure 5 (Raw Mill)
2.5.2. Cyclone Separators
These are funnel type structures. Strong vacuum is created in them through
dig tubes suspended in their centers. Air with the grinded particles from the
mill is allowed to come at very high velocity and move in circular manner
due to the designed shape of inlet. In this way kinetic energy of material
particles are broken down and they are collected through rotary locks.
2.5.3. Bucket elevator
It is a vertical belt conveyer.
Used to transport material straight upward or downward.
A belt runs in a straight vertical position.
Running belt has buckets attached to it.
Material is filled into the buckets and the belt takes it to the destination
point.
2.5.4. CF Silo
The fine particles from the conditioning tower and electrostatic precipitator
and the powdered feed from the raw mill are conveyed to the bucket
elevator. The bucket elevator picks this feed and takes it to the top of the CF
silo and then throws it in.

16. 16 | P a g e
Specifications of a CF Silo:
Length = 54 m
Diameter = 22.4 m
Capacity = 25,500 ton
Figure 6(CF Silo)
2.6. Preheater
The bucket elevator puts the material on the top of 2nd cyclone. The hot
gases from the kiln flow with very high velocity in countercurrent direction.
The hot gasses lift the particles from the particles from the top of 2nd
cyclone and put it on the top of the 1st cyclone. From there the material falls
on the top of the 3rd cyclone and sends it into the 2nd cyclone. Then the
material falls on the top of 4thcyclone and hot gases take it into the 3rd
cyclone. Then the material falls on the top of the 5thcyclone and hot gases
take it into the 4th cyclone and finally into the 5th cyclone pre heater. During
this complete cycle, the hot gases foe in the counter current direction. These
cyclones serve the purpose of preheating the feed material with hot gases of
kiln. There are total 10 cyclone pre heaters. 5 are on the right side of the
pre calciner and 5 on the left of the pre-calciner. The temperature of feed
increases as the feed flows downwards the pre heaters.
2.7. Rotary Kiln
It is the most important part of the cement manufacturing process, as
materials are baked here to produce cement. A Rotary Kiln is a pyro

17. 17 | P a g e
processing device used to raise materials to a high temperature into a
continuous process. It has a length of 66m and diameter of 5.5m. Its
calcination is 4%. Its rotating speed varies according to the quantity of feed
entered. Normally, revolution is kept 4rev/min. In addition to the inner
diameter of the Kiln, there is refractory lining to prevent the shell from
damage and to control the environment temperature. Outside the Kiln, there
are induced draft fans which turn on automatically when the shell
temperature increase more than a certain limit.
Figure 7 (Kiln) Figure 8 (Kiln)
2.8. Clinker Cooler
The clinker cooler is used to lower the clinker temperature. There are ID
fans which take fresh air from the atmosphere and send it to the cooler. At
the bottom of the cooler there are reciprocating rails which move with the
help of hydraulic motors. These rails convey the clinker forward to the
clinker crusher.
2.9. Electrostatic Precipitator (EP)
It removes air and dust by electrodes. Small hammer present it drop the
dust to hopper. It can collect 20 to 20 ton/hr. material. Its mechanism based
on corona effect. Very high voltages produced in EP.

18. 18 | P a g e
2.10. Clinker Crusher & Storage
2.10.1. Clinker Crusher
When the clinker cools and hardens then it is sent to the clinker crusher
installed after the cooler. Big stones of clinker are crushed to small pieces.
The crushed clinker is dropped on the deep pan conveyor at the bottom of
the conveyor which conveys it to the clinker storage.
2.10.2. Clinker Storage
The clinker from the deep pan conveyor is stored in the clinker storage. Its
capacity is 110,000 tons. Its length is 60 m and its width is 46 m. There
are 3 gates at the bottom of the clinker storage from where the clinker
is sent to cement mill through belt conveyor. Besides the main clinker
storage bin, there is a temporary clinker storage hopper with a
capacity of 1400 tons. If the temporary hopper is also full then the clinker
is removed from hopper and dumped into clinker storage yard.
Figure 9 (Clinker Storage)

19. 19 | P a g e
2.11. Cement Feed Mill Area
2.11.1. Cement Mills
There are two cement mills each of having specification
OK 36.4, Power of motor 3.6Mwatts and Capacity of 175t/hour.
The feed which is free from impurities falls on the table of cement mill
which contains three rollers. Each roller has weight of 35 tons and the
clearance between table and rollers is 0.5 mm. These rollers move
hydraulically using nitrogen gas as hydraulic fluid. The rollers crush the feed
to a very fine powder. The air slides convey the ground product to the
bucket elevator which lifts it to enter into the 1St storage silo.
2.11.2. Storage Silos
Specifications of Storage Silos:
Capacity: 21,000 tons; Length: 45 m; Diameter: 22.4 m
There are 3 cement storage silos in which crushed cement is stored up till
packing. To convey the cement to the other 2 silos air slides are used. From
these silos the cement enters air slides by air circulations through blowers.
Now these air slides take the cement to the packing plant.
Figure 10 (Cement Silos) Figure. 11 (Cement Mill)

20. 20 | P a g e
2.12. Packing Plant
The packing plant comprises of 6 packers and 12terminals. Each packer has
a capacity of 100 tons/hr. The cement bags are attached manually to the
rotating packer which fills the cement bag. When the bag is filled up to the
required weight, it automatically falls on the conveyor belt which takes the
bags to the roller conveyor. From these rollers the bags slide to different
channels and finally cement bags are loaded on the trucks foe dispatch.
Figure 12 (Packing Plant)

21. 21 | P a g e
Chapter No. 3
Instrumentation Devices
3.1 Proximity Sensor
Proximity sensor detects metallic objects without touching them. The
proximity sensor used in DGKCCL 2 gives about 6-150 pulses per minute.
These types of sensors can be used for speed sensing. The purpose of a
motor speed sensing is to take a signal representing the speed, and to check
a motor speed. Here we checked the speed of motor by pulses that are sent
by proximity sensor to electronic circuit, which has a comparator.
Comparator compares the pulses or time between the two pulses is noted, if
there is time delay in pulses, there is a possibility of fault due to reduction of
speed of motor. This feedback is sent to main plc.
3.2. Pt-100
It is a family of RTD. It is a transducer, which converts temperature signal
into an electrical signal. It is made of platinum wire. Its resistance changes
almost linearly within a specific range of temperature change .Pt-100 means,
100 Ω resistance at 0°C.Initially calibrated for values of m Amps against the
corresponding values of resistances. Rate of change is 0.385 Ω/°C.
Calibration is
0°C↔100 Ω↔4 mA
100°C↔138.5 Ω↔20 mA
3.3. Vibration Measuring Instruments
Piezoelectric material is used for vibration sensor which produces voltage
when pressure is applied on it. When surface vibrates voltage is induced in
the coil due to change in flux. Amplitude of the voltage gives vibration.
3.4. Gas Analyzer
Gas Analyzer is used to monitor O2 and CO level for proper combustion in
the kiln. Hot gases from the kiln along with the dust come into the filter to
remove dust particles. It is then moved to the condenser to cool down and
water is extracted as a waste from it. Pump is present after it, which sucks
the gas sample. After it analyzers are present to monitor the quantity of

22. 22 | P a g e
each gas separately. A magnet is present in the path of sample. O2 is
attracted towards the magnet placed in the path of gas, as it is
paramagnetic. Area around the magnet is maintained at a temperature of 60
degrees Celsius.O2 when comes near magnet, attains 60 degree Celsius
temperature, loses paramagnetic behavior and then pushed further by the
molecules coming. As the O2 molecules attains 60 degrees temperature,
temperature of the area drops. A temperature sensor presents senses the
fall in temperature and calibrated so to detect the amount of O2 by fall in
temperature. For the measurement of CO, an IR transmitter and receiver are
present in the path of gas at opposite ends.CO passing absorbs the IR
radiations. Difference in the amount of IR transmitted by the transmitter and
received by the receiver tells the amount of CO present through proper
calibration.
3.5. Programmable Logic Controller
It consists of a power supply, CPU and some digital and analog inputs and
outputs. Different DPs are available for controlling real I/O sub PLCs, MV
panels, VFDs, LV simocodes.
10 main units of PLCs are installed
Overall communication is done through Profibus, optical fiber and Ethernet
cable. Profibus can travel the signal up to 100m of length without using
repeaters. For more than 100m distance, optical fiber is used. Windows
based Expert Control Supervision (ECS) is also used. Machine Status Word
(MSW) links between ECS and PLC.

23. 23 | P a g e
Chapter No. 4
Power Plant
For continuous and smooth operations of the plant uninterrupted power
supply is very crucial. The power is supplied to the huge machinery with the
help of
Two grids from WAPDA of 132kW power.
Two transformers in the power station producing 632 kW power.
The company has its own power generation plant along with WAPDA supply.
The power provided by WAPDA is converted to 632 kW by the step down
transformer. The Company power plant consists of two Generators, these
are dual nature generators that can be run on GAS as well as on
Diesel depends upon availability of fuel. In case if any of supporting
engine fails to work the company has Turbine Engine of CATERPILLARS
so that there is no load shedding at all. The two generators combine
produce 32.2MV of energy one generator produce 16.1MVand other
one also of 16.1MV. Maintenance of generators is made by staff of
WARTSILLA. These transformers are then connected to all the panels in the
sub-stations. This connection is based on the bus topology that is a common
bus of wires is running from where more wires branch out and supply power
to panels of the required ratings. There are total of thirteen panels of
thirteen substations. Details of the transformers deployed to power up the
machinery are; PEL IEC-76

24. 24 | P a g e
Figure 13(Power Station)
Motors
Motors of the following power are being used mainly:
Name Power (kW)
Limestone Crusher 1540
Cement Mill 3400
Raw Mill Suction Fan 5100
Raw Mill Main Motor 3400
Cooling Fan Motors 237
Table 2 (Motors Power Consumption)

25. 25 | P a g e
Safety and Fire Fighting
4.1. Safety
The equipment used for personal safety is known as Personal Protective
Equipment (PPEs). The equipment provided for safety is as follow:
Helmet
Safety shoes
Spectacles
Earplugs
Safety vest
4.2 Fire Fighting
There is a fire-fighting department for any kind of emergency and to bring
back the conditions to normal.
The systems installed for this kind of operations are as under.
4.2.1 Hose Reek System
This system consists on a moving mechanism, having 100 feet long water
pipe. According to situations, with the help of this pipe we can make jet or
shower for controlling any emergency.
4.2.2. Sprinkler System
This system provide sprinkle of water at the time of emergency. This system
is made by US Company Glove. Whenever the temperature of the space
where the system is installed rises above 68 C, sprinkle automatically burst.
Foaming System
In this system foam is applied to the emergency area, which makes a layer
over it and cuts off the supply of oxygen. AFF chemical is used for this
purpose. This chemical is added to H2O by 3%.

26. 26 | P a g e
Fire Tender System
It is a fire-fighting vehicle and is loaded with multiple kinds of equipment for
extinguishing the fire. It is also called Fire Hydrant System.
Emergency Alerts & Precautions
In case of any kind of emergency a siren sound can be heard after intervals.
The power of this siren is 7 HP. whenever the siren is heard; everyone has
to get to the nearest assembly point. Whenever the clearance happens a
continuous siren is heard for 1.5 to 2 minutes.

27. 27 | P a g e
Chapter No. 5
Utilities
5.1. Cooling Tower
Induced Draft Counter Flow Cooling Tower is installed to meet the
requirement. Cooling tower cools the water by the transfer of heat from hot
water to air induced by fans. The water from waste heat recovery section is
transferred to cooling tower for lowering of temperature.
5.2. Water Treatment Plant
This plant makes the water suitable for industrial use. Following operations
are done in the water treatment plant Service, Backwash, Regeneration,
Slow Rinse and Fast Rinse. Brine solution is used for regeneration of Sodium
Zeolite used for removal of hardness in water.
5.3. Waste Heat Recovery Section
It is a complex piping section to generate approximately 5 to 8 MW of
electricity. Kalina Cycle is used for the energy generation in WHR Section in
which working fluid used is mixture of ammonia and water. Ammonia is 55
percent and water is 45 percent in the mixture. Kalina Cycle is the improved
form of Bryton Cycle and Rankine Cycle which generates the energy even at
low temperature because of low critical temperature of ammonia.

28. 28 | P a g e
Feedback & Conclusion
I would like to say thanks to every member of the industry I encountered
because of their assistance and cooperation. Every employee of the industry
is courteous and polite. It was my first ever industrial visit for a long time. I
gained a lot of experience in this tour. I have learned how to interact with
people and do team work in professional field. I have learned how to survive
in an industrial environment and to do work in efficient way. I learnt about
the criticalities of the processes being performed there and I’m happy to
gain experience in such a polite & wonderful environment that improved my
professional skills.
I’m happy to have done the internship at the DG Khan Cement
Company Limited –DGKCC, Kallar Kahar, Khairpur Plant.
.