A SUMMER TRAINING REPORT MADE BY VAIBHAV CHAUDHARY. A STUDENT OF ELECTICAL ENGG. AT JECRC COLLEGE.

1. A
SEMINAR REPORT
ON
60 DAYS INDUSTRIAL TRAINING
TAKEN AT
“JK LAKSHMI CEMENT LTD. (SIROHI)”
Submitted in partial fulfillment for the award of degree of
Bachelor of Technology of Rajasthan Technical University, Kota
Submitted to :- Submitted by :-
MR. MUKESH CHANDRA GAUTAM VAIBHAVCHAUDHARY
HR DEPARTMENT JECRC COLLEGE
JK LAKSHMI CEMENT LTD.

2. ACKNOWLEDGEMENT
I would like to thank all the people who directly or indirectly helped me in my
process of learning’s during two months. I would also find a great pleasure in
learning & working in such a great organization. From senior officers to
technicians including helper who made my learning’s for two month successful.
I would like to mention a special thanks to my Mr. NIKESH MITTAL
(Sr.Manager) without whose help I’ll never be able to complete my training at JK
LAKSHMI CEMENT.

3. ABSTRACT
This paper analyzes an existing processing management system in a cement factory in India.
During the last two decades (80's and 90's), major technological advancements took place in
design of cement plant equipment/systems. The analysis shows that there are Strong areas such
as opencast lime stone mining, lime Stone crushing & stacking, raw material handling &
Grinding, coal grinding, preheater kiln & cooler, Clinker grinding (cement mill), packing plant
& Loading plant, quality control. It also provides the brief description about the machinery
used in each stage and its working principles. Cement industry has come a long way in
technological up gradation, production and quality. India today is the second largest cement
producing country in the world with an installed capacity of 119 million metric tons per annum.
Cement: In the most general sense of the word, cement is a binder, a substance that sets and
hardens independently, and can bind other materials together. The word "cement" traces to the
Romans, who used the term opus caementicium to describe masonry resembling modern
concrete that was made from crushed rock with burnt lime as binder. The volcanic ash and
pulverized brick additives that were added to the burnt lime to obtain a hydraulic binder were
later referred to as cementum, cimentum, cäment, and cement.
Early uses: It is uncertain where it was first discovered that a combination of hydrated non-
hydraulic lime and a pozzolan produces a hydraulic mixture (see also: Pozzolanic reaction), but
concrete made from such mixtures was first used by the Ancient Macedonians and three
centuries later on a large scale by Roman engineers. They used both natural pozzolans (trass or
pumice) and artificial pozzolans (ground brick or pottery) in these concretes. Many excellent
examples of structures made from these concretes are still standing, notably the huge
monolithic dome of the Pantheon in Rome and the massive Baths of Caracalla. The vast system
of Roman aqueducts also made extensive use of hydraulic cement. Although any preservation
of this knowledge in literary sources from the middle Ages is unknown, medieval masons and
some military engineers maintained an active tradition of using hydraulic cement in structures
such as canals, fortresses, harbors, and shipbuilding facilities. The technical knowledge of
making hydraulic cement was later formalized by French and British engineers in the 18th
century.
.

4. INTRODUCTION
JK LAKSHMI CEMENT, a well known cement organization is a 24 hrs. process plant
installed in 1982 with 5.0 LTPA. With growing years this production had increased from 5.0
to 6.0 LTPA in 1988 & 30 LTPA in 2005. In 2006 this production is increased up to 33
LTPA. JK LAKSHMI CEMENT had been accredited with ISO 14001:1996 for environment
management system & OHSAS 18001:1999 for occupational, health & safety assessment
system in 2003. In 2006 JK Lakshmi cement has accredited by ISO 14001:2004 & OHSAS
18001:1999. It is also recognition of company’s sustained effort to maintain standards at
every level & also dedication & commitment of every employee as a team.
The company’s high quality & continuous effort to improve services have been
instrumental in high level of satisfaction. In company’s high profile, sale of blended cement
during the year has increased by nearly 50% from 8.11 lacs MT to 12.0 lacs MT.
The whole plant is divided into three sections
1. Mines
2. Processing area
3. Dispatch or Packing Plant
The lime stone which is the basic raw material for cement manufacturing is obtained from
mines. Then it will undergo processing at different stages at processing area and final product
i.e. cement is dispatch from packing plant. A brief explanation about each part will be
explained afterwards. An oral view about each section will be discussed as under.
 MINES
JK LAKSHMI CEMENT has wide area spread over 390.625 hectares including shovels,
dumpers and dozers. The raw material (limestone) is obtained by blasting over the required
place. Then the raw material is accumulated by dozers and shovels along with dumpers get
through crushers. Then the crushed material gets accumulated at limestone pile. From there
with the help of stack car and conveyor belts goes to the hopper building as per it’s grade.

5.  PROCESSING AREA
Process area includes VRM section, Kiln Section along with Cement mills. Process area is
divided into three phases which includes Unit1, Unit 2 Phase 1, Unit 2 Phase 2.
Unit 1 only includes only clinker producing part i.e. Kiln area only. The raw material for this
unit comes from Phase 1 and Phase 2.
Unit 2 Phase 1 and Unit 2 Phase 2 includes all the above mentioned section i.e. VRM, Kiln,
Cement mills. Going for particular section we found that VRM is comprised of hydraulic
rollers through which the material is grind. This material with the help of raw mill fan lift up
and with the help of conveyor goes to C.F. silo i.e. continuous flow silo. From there the
material is lifted to pre heater through two different methods, one is through air lift and
another with the help of bucket elevator. Mostly material is lifted with the help of bucket
elevator only. This material is then passed from pre heater and goes to kiln pro heating and
there only it will change its phase at temperature of 1300 deg C.
This material is then cooled down in grate cooler drive with the help of coolers. And with the
help of pan conveyor lifted to clinker silo.
From clinker silo the clinker with the help of belt conveyors goes to cement mill hopper
building at where clinker along with gypsum and fly ash for the required grade of cement
sent to ball mill drive with the help of weigh feeder and belt conveyors. The final product
from the cement mill with the help of air slides goes to cement silo. This section comes under
processing area.
 PACKING PLANT
From cement silo the material is sent to packer from where the material is packed in cement
bags and dispatched by the wagon loaders. There are two units in packing plant
(Unit 1 & Unit2)
Unit 1 has got 8 truck loaders and 4 diverters. Unit 2 has got 8 truck loaders and 4 wagon
loaders. There are 5 cement silos. The material in Unit1 can be taken from cement silo
1,2,3,4. And in Unit 2 material can be taken from silo no. 3,4,5 silo. The packers used in Unit
1 are of two types VENTOMATIC PACKER and another type is mechanical packers.
In unit 2 there are only VENTOMATIC PACKERS with 12 nozzels and double discharge.

6. STAGES OF CEMENT MANUFACTURING
Stage-1.Opencast lime stone mining
Opencast mining refers to a method of extracting rock or minerals from the earth by their
removal from an open pit or borrow. These mines are used when deposits of commercially
useful minerals or rock are found near the surface. Open-pit mines that produce building
materials and dimension stone are commonly referred to as quarries.
Process of lime stone extraction-
1. Area: To start extracting lime stone from ground we should require an area where the
limestone quantities are more with high carbonate and low sio2.
2. Drilling & blasting: Open-pit mines are dug on benches, which describe vertical levels of
the hole. These benches are usually on four meter to sixty meter intervals, depending on the
size of the machinery that is being used.
Most walls of the pit are generally dug on an angle less than vertical, to prevent and minimize
damage and danger from rock falls. This depends on how weathered the rocks are, and the type
of rock, and also how many structural weaknesses occur within the rocks, such as a fault,
shears, joints or foliations. After the drilling is done 2/3 holes are filled with slurry explosives
and ammonium nitrate fuel oil. 1/3 part is stemmed with sand and BC soil. After stemming
detonators are fixed above the hole with detonating fuse. And the blasting is done with the
battery charge.
During the blasting bulk rocks are crushed in to small pieces which are easier to transport. It is
a long process and should take more safety precautions like
a) Wet drilling should be done for preventing environmental pollution.
b) The person who is blasting should be in iron made shelter with blasting kit.
c) Working people should wear helmet and shoe during the work.
d) Stemming (filling of holes with hard material before the detonator is fitted) should be done
properly.
e) Siren should be given before and after blasting.
f) During the blasting working people should be 500mts away from blasting area.

7. Vertical drilling machine drilled hole
3. Loading & transport: The muck file (blasted material) is loaded in to dumpers with the
help of excavators to transport lime stone to the crusher.
Precautions to be taken in this stage
a) utilize maximum hours of men and machines in a shift with safe operation methods
b) do not over load, do not over speed, avoid spillages
c) Good haul road maintenance is required to increase dumper tyre life.
d) Dump break should be applied while loading and dumping time.
Loading the raw material transporting the raw materials
Stage-2. Lime stone crushing & stacking
Crusher is a new stone crusher machine that absorbs advanced technologies at home and
abroad. Dealing with the material with the side length 500mm, not more than 350Mpa anti-
pressure strength, Impact Crusher can be widely used in the primary and secondary crushing
process. This impact pressure is also used in lime stone crushing.
Process of crushing the raw material and transferring the crushed raw material to stock
pile
1. Dumping of raw material in to hopper: This stage continues after transportation of raw
materials from mining .The material loaded in dumper at mining is dumped in the crusher
hopper.
Dumping in to hopper crusher hopper

8. 2. Flow of raw material with Push feeder: The dumped raw material in the hopper moves in
to crusher with the help of push feeder which moves to and fro and sends the material with in a
limit.
3. Crushing of raw material with impact crusher: When the crushed materials get into the
impact crusher inner space where the hammers effect, under the impact function of the hammer
at a high speed, the materials are thrown to the impact device above the rotor continuously.
And then the materials are rebounded from the impact liner to the area where the hammers
effects for being recrushed. The materials from large to small all to be crushed at the impact
crusher chamber repeatedly. The process won't stop till the materials in the impact crusher are
crushed to the required size and then discharged from outlet.
4. Transfer of crushed raw material to stock pile: After the raw material is crushed to
required size in a crusher. The small size raw material is transferred to stock pile with the help
of belt conveyors. Bag filter collects the dust from the raw material at belt conveyor and filter
it. This bag filter works with one fan and compressor. This helps to control the dust pollution.
5. Tipper belt: At the end of the belt conveyor ther is tipper belt. This helps to drop the raw
material in the required area (low grade stock pile, high grade stock pile).
STAGE-3.RAW MATERIAL HANDLING & GRINDING
A raw mill is the equipment used to grind raw materials into “raw mix" during the manufacture
of cement. Dry raw mills are the normal technology installed today, allowing minimization of
energy consumption and CO2 emissions.
Process of raw mill in grinding of raw material and silo storage
1. Transporting crushed raw material to raw mill hoppers: This stage continues after
crusher lime stone stock pile. A belt conveyor collects the raw material from the stock pile with
the help of hoppers below the stock pile. So these belts are fixed under the stock pile to collect
the raw material.
Belt conveyor transfering the material to raw mill

9. 2. Weigh feeders: Weigh feeder is a machine which allows the material to the required
quantity from the hopper. These are three types High grade weigh feeder, Low grade weigh
feeder, Additives weigh feeder.
High/lograde feeder additives weigh feeder
3. Raw mill: The conveyors collect the raw material (low or high grade), additives and transfer
it to raw mill. This raw mill consists of 3 chambers (dry, 1st, and 2nd chamber).
Raw mill grinding media
Dry chamber
Dry raw mills are the normal technology installed today, allowing minimization of energy
consumption and CO2 emissions. Cement raw materials are mainly quarried, and so contain a
certain amount of natural moisture. Attempting to grind a wet material is unsuccessful because
an intractable "mud" forms. On the other hand, it is much easier to dry a fine material than a
coarse one, because large particles hold moisture deep in their structure. It is therefore usual to
simultaneously dry and grind the materials in the raw mill. A hot-air furnace may be used to
supply this heat, but usually hot waste gases from the kiln are used. For this reason, the raw
mill is usually placed close to the kiln preheater. Ball mill is used in cement industry. After the
dry chamber material enters the 1st grinding chamber.
1st grinding chamber: The chamber allows grinding of the harder limestone that is more
common than chalk. A ball mill consists of a horizontal cylinder that rotates on its axis. It holds
spherical, cylindrical or rod-like grinding media of size 15–100 mm that may be steel or a
variety of ceramic materials, and occupy 20–30% of the mill volume. The shell of the mill is
lined with steel or rubber plates. Grinding is effected by impact and attrition between the
grinding media and forms as a powder. This process will not continue to 2nd chamber directly.
there are several intermediate stages. This mill is a center discharge mill.

10. 2nd grinding chamber: This is similar to the process in 1stchamber but in this chamber coarse
material from DAS (dynamic air separator) is grinded.
4. Grit separator: Grit separator allows the grinded raw material (powder).this is placed above
the raw mill. It takes the powdered raw material from the center of the raw mill. it separates the
unwanted materials and sends useful material to cyclone.
5. Cyclone: This stage continues after grit separator. Cyclone is cone shaped equipment which
separates the fine material and unfine material. Unfine material is sent to bag house and fine
material is sent to P.G (pnumatic gravity) conveyor. This is above the grit separator.
6. DAS (dynamic air separator): The material which is not taken by grit separator above the
raw mill is discharged from the center of the raw mill to the P.G conveyor at the below of raw
mill. This P.G conveyor transfer the powdered raw material to the bucket elevator .this bucket
elevator drop the material into DAS .this DAS separates the material as fine and coarse
material. Fine material is send to P.G.conveyor (cyclone dropped P.G conveyor). Coarse
material is send to girtreturn belt conveyor and then to 2nd chamber in raw mill for grinding.
7. Transfer of fine material to silo: Fine material dropped from cyclone and DAS on P.G
conveyor is transferred to bucket elevator and then filled to silo.
Raw mill silo
Stage-4.COAL GRINDING
Air Swept Coal Mill is widely used in grinding coal operation of cement processing. It is a kind
of special equipment which crushes and grinds coal with the function of drying simultaneously.
Horizontal Coal mill

11. 1. Coal yard and raw coal hopper: Coal is stored in a big area under the shed. And then coal
is dumped in a hopper to supply the coal to the coal crusher. This hopper vibrates to send the
coal in a required quantity and drop coal on a belt conveyor
2. Coal crusher: crusher crushes the large coal to the required small size. Hammer Mills
operate on the principle that most materials will grind or crush upon impact with the hammers.
3. Raw coal hopper and table feeder: The raw coal material from Belt conveyor is dropped in
to raw coal hopper. This hopper stores the crushed raw coal material. Below the hopper ther is
table feeder which supplies the coal in a limited(required) quantity to the coal mill.
4. Coal grinding ball mill : Raw coal materials are fed into revolution cylinder through hollow
shaft neck to be milled in which grinding mediums with lots of diameters are loaded. As
cylinder rotating around the horizontal axis at a certain speed and under the help of centrifugal
force and friction, the medium and raw material loaded in the cylinder will reaches a certain
height. When their own gravity is greater than centrifugal force, they will fall or roll down from
breaking away the cylinder inner wall, and then the ore is crushed by impact force.The crushed
material is discharged from hollow shaft neck on the other side. In the cylinder, the raw
material is pushed to move from feeding side to discharging side due to feeding material
continuously. Induced draught fan is connected with discharging side to form negative pressure
so that the pulverized coal will be taken out with pumping air.
5. Classifier: The grinded coal from mill enters the classifier. This classifier separate the coal
material as fine and unfine material is send back to coal mill with the help of girt return belt
conveyor for grinding fine material is sent to cyclone.
6. Cyclone and dust collector: After the fine material enters the cyclone from classifier Some
fine coal is sending to dust collector. This dust collector brings the fine material closer and
store in it.
7. Screw conveyor: This screw conveyor collects the fine coal from cyclone, dust collector and
drop it in fine coal hopper.

12. 8. Fine coal hoppers: This fine coal from screw conveyor is collected in fine coal hopper and
sends to weigh feeders.
9. Weigh feeders: This feeder collects the required amount of coal.and send it to required area.
There are 2 weigh feeders one is to send coal to killen and another is to send coal to
precalciner. 65% coal is send to calciner and 35% coal is send to kiln.
Weigh feeder for sending the fine coal to preheater and kiln
Stage-5. Pre heater kiln & cooler
Pyro processing is a process in which materials are subjected to high temperatures at 1500C in
order to bring about a chemical change. The raw material mix is fed to a kiln where pyro
processing takes place.
Process of kiln feed, preheater, cooler and silo storage
1. Transfer of raw material to kiln weigh bin: Raw meal stored in a raw mill silo is
transfered to bucket elevators with the PG conveyor at the bottom of the silo. This bucket
elevator sends the raw meal to the weigh bin with the help of PG conveyor.
2. Transfer of raw meal from weigh bin to preheaters: This weigh bin sends the raw meal
material to the PG conveyor. This PG Conveyor transfrers the raw meal to the bucket elevator
and to preheater.

13. 3. Preheaters: The preheater tower supports a series of vertical cyclone chambers through
which the raw material pass on their way to the kiln. To save energy,modern cement plants
preheat the materials before they enters the kiln rising more than 200feet,hot exit gases from
the kiln heat the raw materials as they swirl through the cyclones.
i. Preheater -4A, 4B:
The raw meal from bucker elevator enters to preheater-4A, 4B.At that stage raw meal is heated
to 3700c or 3800c.and sends to preheater-3.
ii. Preheater -3:
The molten metal from preheater-4A, 4Benters to preheater-3.At that stage material is heated to
6400c and sends to preheater-2A, 2B.
iii. Preheater -2A,2B:
The molten metal from preheater-3 enters to preheater-2A, 2B.At that stage material is heated
to 8000c and sends to preheater-1 and calcinar.
iv. Preheater-1, calcinar:
The molten metal from preheater-2A, 2Benters to preheater-1 and Calcinar.At that stage
material is heated to 880 0c (PH-1), 950 0c (calcinar) and Send to kiln. Coal from coal mill is
used in heating of material at calcinar ( 65% of coal from coal mill).
4. Kiln: Kiln is the heart of the cement making process.a horizontal sloped steel cylinder lined
with fire brick turning from about one to three revolutions per minute.the kiln is the world’s
largest piece of moving industrial equipment. From the preheater, the raw material enters the
kiln at the upperend .it slides and tumbles down the kiln through progressively hot zones
toward the flame. At the lower end of the kiln, fuels such as powdered coal (35%) from coal
mill feed a flame that reaches 3400 0F (1870 0c) one third of the temperature of the sun’s
surface.here in the hottest part of the kiln, the raw materials reach about 2700 0F(1480 0C) and
become molten.This intense heat triggers chemical and physical changes expressed at its
simplest, the series of chemical reactions converts the calcium and silicon oxidesin to
calciumsilicates, cemen’s primary constituents. At the lower end of the kiln, the raw materials
emerge as a new substance: red hot particles called clinker.
5. Gate cooler: The clinker tumbles on to a grate cooled by forced air.there are several moving
plates which helps the clinker to move forward. Several fans are also used in cooling
process.these send the air from bottom of the plates.

14. Cooler fans for cooling the material from kiln
To save energy, heat recovered from this cooling process is recirculated back to the kiln or
preheater tower.
6. Clinker breaker & silo storage: The bulk clinker material is crushed into required size and
dumped on DBC. This DBC transfer the clincker to silo.
Clinker Crusher Transfering the clinker to silo
Stage-6.clinker grinding (cement mill)
A cement mill is the equipment used to grind the hard, nodular clinker from the kiln area into
the fine grey powder that is cement.
1. Transfer of clinker to cement mill hopper from kiln silo: After the clincker is stored in
the silo . To transport the clinker directly rejects silo is used to fill the lorry. The clinker in the
clinker storage tank is passed though a hopper at the bottem of tank to drop the clincker on the
belt conveyors.
From clinker silo to cement mill through belt conveyors

15. 2. Weigh feeders: There are 2 weigh feeders (clinker, gypsum) and one fly ash dosing system.
These weigh feeders send the required amount of clinker, gypsum in to the cement mill.
3. Cement mill: Clinker is grinded in a ball mill a horizontal steel tube filled with steel balls.
As the tube rotates the steel balls tumble and crush the clinker in to a super fine powder. It can
now be considered as Portland cement.the cement is so fine enough to hold water. A small
amount of gypsum is added during final grinding to control the setting time.quality depends on
mixing of fly ash. More fly ash mixed cement is called ppc.low fly ash mixed cement is called
opc.
4. Transfer of cement to silo: The cement from cement mill is passed through bag filter. The
heavy material is sent to seperator where the ungrinded material is again send to cement mill
for grinding. The fine grinded material is send to cyclone from seperator. The fine material
from bag filter & cyclone is send to PG conveyor.this PG conveyo dumps the cement in the
bucket elivator to fill the cement in the silo. There are 4 silos , 2 is for ppc and another 2 is for
opc.
Stage-7. Packing plant & loading plant
Finally processed cement enters in packaging unit from here it is packed in equal bags, loaded
on trucks and further transported to the customers. Process of packing and loading plant:
1. Transfer of cement from silo to packers: The required cement that is OPC or PPC from
silo is transfered to Bucket elevator with the PG conveyor at the bottom of the silo. Those
elivators Drop the cement in the rotary screen. This rotary screen rejects the unwanted material
from the cement and sends the pure cement material to the rotary packers (electronic packers).
Hear the packing of cement bags starts.
2. Packing of cement bags: The cement in the packers is packed in bags with the rotary
packers (electronic packers). For these packers there is Handles to hold the cement bag and for
filling the bags with cement. The manual work is done for fixing the bags to the handles. It is a
sensor operated for correct filling of bags. After filling of bags it automatically stiches the bag
and leaves it on a slider.

16. Electronic cement bag packers
3. Loading of cement bags and bulk loading:
After packing the cement bag slider is directly plased in to lorrys. The manual work is done to
place the bags in order. But in bulk loading cement is directly filled in tankers from the silo
with the help of PG conveyor.
Cement bags loading

17. EQUIPMENT USED IN CEMENT MANUFACTURING
1. MINES
As we know that limestone is the basic raw material for cement manufacturing. Thus it is
required in bulk quantity for production of cement. So therefore cement plants are thus
established near the place where there is abundance of limestone. As discuss earlier that
LAKSHMI CEMENT has got limestone mines spread over 390.625 hectares area. The area is
divided into 6 blocks. Open cast mines are there and mining operation is done in benches and
each block is divided into 11 benches of height 9 meter each. In these benches to obtained
raw material hole of 9 meter deep are drilled by drilling machine. These holes are then filled
with explosives & then they are blasted. The scattered material is then collected by dozers &
by the help of shovel they are loaded in dumpers. These dumpers transport raw material to
crusher.
CRUSHER
The limestone had been received in required size (1500 mm max) is passed through FLS make
EV crusher and crushed into product size less than 80 mm, crushed material is passed through
Bulk Material Analyzer (BMA) to find out the composition of material, only 25% of
material is analyzed by BMA, rest sample is taken manually and tested in laboratory for
composition identification. After finding out the composition we determine the following
factors:-
LSF
(Lime Saturation Factor)
= CaO/(2.8 SiO2+1.2 Al2O3+0.65 Fe2O3)
Silica Module
Aluminia Modulus
=
=
SiO2/(Al2O3+Fe2O3)
Al2O3/Fe2O3
For filtering out material less than 80 mm size we use vibrating screen from where the material
greater then 80mm size is rejected.

18. Technical Specifications:-
CRUSHER:-
1. DESIGN & SUPPLIED BY FULLER SMIDTH
2. MODEL NAME EV CRUSHER
3. TYPE HAMMER CRUSHER
4. CAPACITY 1100 TPH
5. NO. OF HAMMERS 54
6. WT. OF HAMMERS 91 KG
7. MOTOR RPM 990
8. MOTOR 1700 KW
9. LINNING MATERIAL MAGNESE STEEL
VIBRATING SCREEN:-
1. MAKE ALLIS MINERAL SYSTEM
2. TYPE DOUBLE CHECK
3. SIZE 10/20
4. FEED SIZE 150 mm
5. PRODUCT SIZE 80 mm TO 20 mm
STACKER AND RECLAIMER:-
The crushed limestone of less than 80 mm size is stacked & reclaimed in CIMMCO making
continuous stock pile of 6000 MT capacity with blending efficiency of 10:1. Using convey-
ors belts, raw material is transferred to hopper, in hopper building. We have four varieties of
hoppers in hopper building one is for low grade, other is for high grade, and one for blended
and last is for sand hopper.
The types of machines used in mining area are as under.
TYPE QTY. MAKE CAPACITY MODEL NO.
SHOVEL 8 a. L&T-6 4 cu m 300 CK
b. BEML-2 4.3 cu m PC 650
DUMPER 13 a.CATPILAR-8 50 TONNS 773 B
b. HINDU- 5 35 TONNS 1035
DOZZER 5 BEML-5 - D335(LARGE)
- D155(SMALL)
LOADER 5 HINDUSTAN 5 cu m – 2 2071
2 cu m -3 2021
DRILL MACHINE 5 IR-4 6 INCH DIA. 41BH 10

19. 2. PROCESS
VERTICAL RAW MILL
According to desired quality of cement, raw material (either of high grade, low grade) is
taken with the help of apron feeder, weigh feeder, and belt conveyors taken to vertical raw
mill. Vertical Raw Mill has got four hydraulic rollers and one horizontal circular disc. The
material coming from hopper building is grind between horizontal circular disc & hydraulic
rollers. The grinded material is sucked from top by raw mill fan and coarse material is
recycled back to main feed to VRM. Fine material as sucked by raw mill fan goes to cyclones
where the material is separated from air through these four cyclones and one bag house. Fine
material is now with the help of air slides goes to kiln feed silo or CF silo. Similarly the role
of bag house fan. Air from pre heater fan divided into three ways. One of the way is to bag
house where the material coming from pre heater stick to bags of bag house and emit out but
the material which stickled to bags gets accumulated by the purging. The material is
accumulated and with the help of screw conveyors feed back to CF silo. CF silo having the
capacity of 16000 MT and blending efficiency of 10:1. In blending silo the material is
blended with the help of compressed air and the material is discharged to kiln feed bin for
onward transportation to Kiln for clinker production with the help of bucket elevator. There
are two method through which the material is lifted to pre heater either with the help of
bucket elevator or through air lift. In case if bucket elevator fails because of any reason the
material is lifted through air lift.

20. PREHEATER & KILN SECTION
From Kiln feed bin the material is feed to 6 stage pre heater equipped with SLC-5 calciner.
Here the material is heated with the help of hot gas produced in Kiln and calciner to various
temperatures at various stages. Material from the pre heater top is divided into double string
pre heater i.e. new pre heater and old pre heater for better efficiency. So the material is
divided at the pre heater top and then it will pass through various cyclones and heated at
various temperatures at each cyclone. Adding to this some of the material is also heated in pre
calciner which is connected to cyclones no .5 for high efficiency so that pre calcinations is
done before entering into Kiln.
The various temperature ranges in cyclones in old and new pre heater are as discussed
under.
OLD PRE HEATER
CYCLONES GAS TEMPERATURE 0C MATERIAL TEMP.0C
1A 358 410
1B 421 402
1C 411 401
2 520 555
3 673 676
4 700 777
5 808 Thermocouple taken out
6 888 Thermocouple taken out
NEW PRE HEATER
CYCLONES GAS TEMPERATURE MATERIAL TEMP.
1 289 281
2 465 441
3 576 569
4 814 659
5 883 797
PC OUTLET TEMPERATURE 885-900 0
C
KILN INLET TEMPERTAURE 1079 0
C
KILN OUTLET SECTION 1330 0
C

21. 8
Heated material discharged from pre heater is then enters into Kiln area. The Kiln has a
diameter of 4.27 m and length is 61 meter with a slope or inclination of 4%. It has got two
sections, burning zone and heating zone. In heating zone the material is heated up to the
temperature of 1100 0
C. In burning zone the material is fused and it changes.
Hot material into fused state is discharged from Kiln at a temperature of 1330 0
C is then
cooled around 120 0
C in fuller make CIS/CFG/RFT 2 grate horizontal cooler. Here the
material is cooled down and transformed into another state i.e. now {clinker} is formed.
Hence the clinker produced is with the help of pan conveyors goes to clinker silo. There are
two pan conveyors one is for clinker or main silo another is for off spec silo. The capacity of
clinker silo is 40000 MT each. The facility of off spec silo is provided into both of two
phases, Phase 1 and 2. Likewise the material as discussed earlier transformed into Unit 1 silo
there the material is passes through various stages. Such that the material is taken to kiln feed
bucket elevator with the help of air slides. There are two kiln feed bucket elevator and this
material is then passed to pre heater and the material is then go to Kiln. The length of the kiln
is 91 meter.
COAL MILL
Another important circuitry is of coal, which is as important as any other circuitry. Here the
coal mill is used to grind coal into powder form. The coal used are of two types pet coke and
Chinese coal. The most important difference between two is that of sulphur which plays an
important role in jamming of cyclone. Pet coke had 7% of sulphur and in Chinese coal the
percentage will be reduced to 2%. The process of coal circuitry is as discussed below.
First the coal is emptied in coal gantry by the truck with the help of truck tippler. Now with
the use of belt conveyors it is taken to coal yard. Here with the help of EOT crane and belt
conveyors the coal is taken to coal stock pile. LAKSHMI CEMENT has got two EOT crane
with the use of what the coal is emptied in belt conveyors which take it to the coal stock pile.
From there the coal is taken to coal mill where the coal is grind in powder form up to its
maximum fineness. Now with the help of coal mill fan the powder coal is sucked from coal
mill and it will taken to separator then to bag house with the air. Now this air is emit out just
like in raw mill bag house and the remaining fine coal is accumulated with the help of
purging and with the use of screw conveyors the coal is transported to fine coal bin where it
is transferred to simplex bin from where it is taken for two purposes.
The first purpose of fine coal is in main firing which is required in Kiln main firing so it is
only used whenever we have to fire or light up the Kiln.

22. 9
The another purpose of fine coal is for PC firing operation for pre calcinations of raw material
so as to obtained the better efficiency. It is continuous operation and so in this coal has to be
continuously supplied. The separator of coal mill is just used to separate the fine coal from
the coarse material. The rejected material is then send again to coal mill, where it will again
crushed to its ultimate finesse the same procedure will be repeated again and again.
CEMENT MILL
Cement mill has got three sections
-Inlet section
-Intermediate Diaphragm
-Outlet Diaphragm
There is also classifier in cement mill to classify the fine and coarse material.
Intermediate Diaphragm consists of holes through which pipes are connected among
which fine cement passes to other segment.
Outlet Diaphragm inside which air passage screen is connected. The use of air passage screen
is to create negative suction so as to suck the cement from the inside of cement mill. In outlet
diaphragm like intermediate diaphragm pipes are connected among which some of the pipes
are make dummy. These pipes allow the cement to pass through it. The pipes are created
dummy so to limit the excess of the cement from outlet. From cement mill fine material is
suck to mill vent bag house and from which with the help of rotary air lock, screw conveyors,
air slides cement passes through cement silo. The coarse material is raised through bucket
elevator. With the bucket elevator the air slides are connected. This air slides takes material
to separator. Again in separator reject material with the help of belt conveyors goes to ball
mill drive inlet chute where the material is again grind. This fine material from separator goes
to cyclone by the suction created by CA fan. From there the material goes to separator bag
house which is again used to separate fine material and coarse material. Now under separator
bag house the rotary air lock, then screw conveyors and air slide the material is send to
cement silo.

23. 10
The comparison among Clinker Silo and Cement Silo is as under.
CLINKER SILO
S.NO. DESIGN CAPACITY HEIGHT DIAMETER
1 FULLER 40,000 MT 40 MTR 40 MTR
2 FULLER 40,000 MT 40 MTR 40 MTR.
CEMENT SILO
S.NO SPECIFICATION HEIGHT DIAMETER CAP./MT
1 CS1 30 MTR. 14 MTR. 6000
2 CS2 30 MTR. 14 MTR. 6000
3 CS3 29 MTR. 14 MTR. 6000
4 CS4 31.3 MTR. 14 MTR. 6000
5 CS5 30 MTR. 14 MTR. 6000
From cement silo the material goes to packer in packing plant for its packing and dispatch.
From air slide coming from cement mill the material with the help of bucket elevator goes to
cement silo. The material {cement} goes to packer.
3. PACKING PLANT
Packing plant, as already discussed the LAKSHMI CEMENT has got two units of packing
plant. Unit 1 has got two packers one is MECHANICAL packer and other is VENTOMATIC
packer. Similarly Unit 2 has got two VENTOMATIC packers. The specifications of both
types of packer are discussed as under.
S. NO. MAKE CAPACITY TYPE
1 L&T 90 TPH SINGLE DISCHARGE
2 VENTOMATIC 180 TPH DOUBLE DISCHARGE
3 VENTOMATIC 180 TPH DOUBLE DISCHARGE
4 VENTOMATIC 180 TPH DOUBLE DISCHARGE
Going to packing details in packing plant, the type of packing media used are of two types.
One is truck loader and other type of media used is wagon loader.

24. 11
Unit 1 of packing plant has got 8 truck loader, 4 old one and 4 new one and 4 diverter for
filling of wagons out there. Similarly the Unit 2 of packing plant has got 8 truck loader for
loading in truck and 4 wagon loaders for as usual loading in wagon. The another important
point to be discussed here is that the manual packer of L&T make has got rotating in one
direction that is clockwise but the electronic packer that is VENTOMATIC packer can be
rotated in both directions i.e. clockwise and anticlockwise. And each packer either Manual
packer or electronic packer had got 12 spout for discharge of cement.
So through this process the cement coming from limestone mines can be converted into
cement and dispatched from packing plant. Then material is passed to feed hopper whose
capacity is 35 MT for VENTOMATIC packer.

25. 12
STORAGE CAPACITIES,FEED RATES& PLANT LAYOUT
Now we see the various capacities involved in cement manufacturing start from the
beginning of raw material and up to the finish of dispatch. Some of them might be discussed
earlier but for the sake of convenience they also discussed again.
STORAGE CAPACITIES:-
LIME STONE STOCK PILE 60,000 MT
COAL STOCK PILE 16,000 MT
CF SILO 16,000 MT
CLINKER SILO 40,000 MT
CEMENT SILO 6000 MT
VARIOUS FEED RATES:-
VERTICAL RAW MILL-1&2 325 TPH
CEMENT MILL-1 100 TPH
CEMENT MILL-2 180 TPH
CEMENT MILL-3 65 TPH
CEMENT MILL-4&5 75 TPH
KILN-1 3500 MT/D
KILN-2&3 4500 MT/D

26. 13
PLANT LAYOUT

27. 14
ELECTRICAL DISTRIBUTION NETWORK
There are three own sources of power in JK LAKSHMI CEMENT.
They are: -
1. Diesel Generators
2. Thermal Power Plant
3. Waste Heat Recovery Power Project
There are three outer sources of power in JK LAKSHMI CEMENT.
They are: -
1. RSEB
2. VS Lignite Power Private Ltd.
3. Indian Energy Exchange
Our plant load is about 55 MW at the time of complete running this power is distributed in
following manner.
1. Lime Stone Crusher 1475 KW
2. Lime Stone Stacker and Reclaimer 340 KW
3. RM Unit-1 3500 KW
4. VRM-1 3150 KW
5. VRM-2 3250 KW
6. KILN - 1 3300 KW
7. KILN - 2 4560 KW
8. KILN – 3 4660 KW
9. Coal Mill Unit-1 850 KW
10. COAL MILL-1 1290 KW
11. COAL MILL-2 850 KW
12. CEMENT MILL- 1 3400 KW

28. 15
13. CEMENT MILL-2 5370 KW
14. CEMENT MILL-3 3370 KW
15. CEMENT MILL-4 2800 KW
16. CEMENT MILL-5 2800 KW
17. CEMENT MILL-6 2800 KW
18. PACKING PLANT -1 600 KW
19. PACKING PLANT- 2 400 KW
20. LIGHTING LOAD 500 KW
21. MISCELLENEOUS 500KW
POWER SOURCES:-
1. Diesel Power Plant: - DG’s generates power at 6.6 kV, which is our working HT
voltage in emergency like power failure, voltage fluctuation or Max Demand exceed. We
synchronize it with the above sources at 6.6 kV. Presently we have SIX DG’s which
capacities are given below.
DG 1 3.5 MW
DG 2 3.5 MW
DG 3 4.0 MW
DG 4 4.0 MW
DG 5 6.0 MW
DG 6 6.0 MW
Out of which DG-2 and DG-4 is out of order and DG-1 & 3 are manually operated
and DG 5 & 6 are PLC operated. Cost is more than RSEB so it is used for emergency purpose
only.

29. 16
2. Thermal Power Plant: - we had established our own thermal power plant of 18 × 3
MW capacity, made by THERMAX. We take 132 kV supply from power plant and it is
connected to the sub-station. Importing power is 32 MW from unit 1& 2 and unit- 3 is used
for exporting power to RSEB. Cost would be Rs 80 -90 paisa per unit.
3. WHRP: - It is a latest power plant of waste heat recovery. Total capacity of WHRP is
15 MW and including losses we import 10 MW from it. Cost would be 60 -70 paisa per unit.

30. 17
Now we take a look of three outer power sources:
1. RSEB: - We take 132 KV transmission line from PINDWARA grid substation upto our
plant. According to our plant demand and our captive power sources we time to time change
our contact demand from RSEB. Presently it is 35.5 MVA. Cost would be Rs 50-60 paise
per unit.
2. VSLPP: - This lignite power plant is 75 km from Bikaner. Capacity of power plant is
135 MW. We have a group partnership of 15-16% with VSLPP i.e 21 MW. We have a
contract demand of 17.87 MW from it. Cost would be 3 Rs 45-50 paise per unit.
3. IEX: -It is our last power source. For exchange we would require membership but if we
don’t have a membership we can become a member of professional and through it we can
buy and sale power. Suppose we want 5 MW Power tomorrow for 5 hour we have to
give a bit today before 12:00 pm to Tata Power. For giving a bit three conditions require :
I) Power quantum quotation
II) Rate quotation
III) Time
132 KV SWITCH YARD
The various switchgear equipments used at 132KV switchyard are as follows:
1. Lightning Arresters
2. Isolator with ear thing switch
3. Isolators
4. Current Transformers
5. Potential transformers
6. SF6 Circuit Breakers
7. M.O.C.B
8. OLTC Transformer 132/6.6 KV

31. 18
Taking individual equipments in details we have:
1. LIGHTNING ARRESTORS:- It is used for arresting the extra high voltage, which
may be due to any reason that might be Lightning, Thunder or any fault in the line; it
can ground the extra voltage. Rating of the Lightning arrestors is 132KV, 10KA Where
10KA is the fault current.
2. ISOLATOR:- Versatek make isolators with earthing & without earthing are used in
switchyard. For incoming 132 KV, 600 amps with earthing switch is used.132KV, 800
amps are used for transformer no. 1 & for the transformers no. 2 & 3 we have 600 amps.
3. CURRENT TRANSFORMER: ABB make CT is used in switchyard for metering &
protection purpose.
a.) Incoming: - 2 CORE C.T OF 400-250/1-1 Amp of burden 15 VA.
b.) For transformer no 1:
Primary side: - 3CORE C.T OF 100/1-1-1 Amp of burden 15 VA.
Secondary side: - 3CORE C.T OF /1-1-1 Amp of burden 15 VA
c.) For transformer no.2 & 3: -
Primary side: - 3 CORE C.T OF 160/1-1-1 amps of burden 15VA.
Secondary side: - 4 CORE C.T OF 2500/5-5-1-1 amps of burden 15VA.
4. POTENTIAL TRANSFORMER:- we are using P.T of rating 132kv/1.732/6.6/1.732
for the measurement of voltage across the line.
MAKE NAGPUR TRANFORMER LTD
INSULATION LIMIT 275/650 KV

32. 19
VOLTAGE FACTOR 1.5
NO. OF PHASE 1
FREQUENCY 50
PRIMARY A1, A2
SECONDARY 1a1, 1a2/2a1, 2a2
OUTPUT 100VA
RATIO 132/1.732/6.6/1.732 KV
OIL QTY/POLE 225
5. SF6 CIRCUIT BREAKER :- ABB make circuit breaker of SF6 types are used for
transformer no. 2 & 3. In normal operating conditions we have got the NC contact of
circuit breaker but due to occurrence of fault the circuit breaker got its contacts open
and break the circuit
VOLTAGE 145 KV
NORMAL CURRENT 3150 AMP
LIGHTING IMPULSE SWITCHING VOLTAGE 650 KV
SWITCHING IMPULSE WITHSTAND VOLTAGE -
SHORT CIRCUIT BREAKING CURRENT 31.5 KA
SHORT TIME WITHSTAND CURRENT 31.5KA, 3S
LINE CHARGING BREAKING CURRENT 50A
OPERATING SEQUENCE 0-0.3-CO-3MIN-CO

33. 20
FIRST POLE TO CLEAR FACTOR 1.5
GAS PRESSURE SF6 7 BAR
AIR PRESSURE 22 BAR
CLOSING & OPERATING DEVICE SUPPLY VOLTAGE 110V DC
AUX. CIRCUIT SUPPLY VOLTAGE 240 V DC
MAKE ABB
6. M.O.C.B BREAKER: M.O.C.B breaker is used for the old system i.e. to feed the
transformer no 1.
MAKE BHEL
TYPE HLD 145/1250B
CURRENT 1250 AMP
VOLTAGE 145 KV
INSULATION 650-275 KV
FREQUENCY 50
BREAKING CAPACITY 20 KA
MAKING CURRENT 50 KA
SHORT TIME CURRENT 20 KA-3S
FIRST POLE TO CLEAR FACTOR 1.5
MASS OF C.B INCL.OIL 2525 KG
OPERATING MECHANISM TYPE BLG 202

34. 21
CLOSING COIL 110 V DC
TRIPPING COIL 110 V DC
7. TRANSFORMERS: - we are using three OLTC transformers 1st of rating 18 MVA and 2nd & 3rd of rating
22.5/28 MVA. The other details of transformer are as follows:
TRANSFORMER NO.1
MAKE BHARAT BIJLEE LTD
KVA 15000/18000
VOLTS AT NO LOAD HV 132 KV
LV 6.6KV
AMPERE AT NO LOAD HV 65.5/78.75
LV 1312/1575
PHASE 3
FREQUENCY 50
TYPE OF COOLING ONAN/ONAF
%IMPEDANCE VOLS AT 750C 1. 10.67
2. 10.46
3. 10.04
UNTANKING MASS: 15800KG
MASS OF OIL: 9933 KG

35. 22
TOTAL MASS 36700 KG
GURANTEED MAXIMUM TEMP. RISE IN OIL/WDG 50/55C
SPECIFICATION IS 2026 1977
VECTOR GROUP YNynO
TRANSFORMER NO. 2 & 3
MAKE KIRLOSKAR
KVA 22500/28000
VOLT AT NO LOAD HV 132 KV
LV 6.6 KV
AMERE AT NO LOAD HV
LV 1968.2
FREQENCY 50
TYPE OF COOLING ONAN/ONAF
CORE AND WDGS 30000 KG
MASS OF OIL 14400 KG
TOTAL MASS 61720 Kg
TOTAL OIL 16800 LTR
GURANTEED MAXIMUM TEMP. RISE IN
OIL/WDG
45/50C

36. 23
INSULATION LEVEL LI650AC275-AC38/460 AC
CAPACITY OF COOLING FAN 10450 m3/hr
VECTOR GROUP: YNynO
TAP POSITION 1 11.19
9 10.62
25 9.56
PHASE 3
OLTC SPECIFICATIONS
SERVICE VOLTAGE 132 KV
RATED THROUGH CURRENT 153 AMPS
RATED STEP VOLTAGE 953 VOLTS
EFFECTIVE VALUE TRANSITION IMPE 3.33 OHMS
POWER FREQUENCY 140 KV
IMPULSE 350 KVp
N.G.R FOR TRANSFORMER 1
VOLTS 6600 VOLTS
AMPERE 1575
RESISTANCE 2.42
RATING 10 SEC

37. 24
MAKE STROM KRAFT CONTROLS
PROTECTIVE RELAYS ON 132 KV SUB STATION
1. 132 kv INCOMER
TRIPPING ALARM:-
 OVER CURRENT R, Y, B PHASE
 INCOMER BREAKER TRIPPED
 OVER VOLTAGE
EMERGENCY ALARM:-
 GAS PRESSURE LOW
 LOW AIR PRESSURE
 LOW OIL LEVEL (COMPRESSOR)
MASTER RELAY:-
TRIPPING RELAY TYPE VAJ LH VOLTS 110
OVER VOLTAGE RELAY:-
TYPE VDG VOLTS 121/187, 50 HZ
OVER CURRENT AND EARTH FAULT RELAY:-
OVER CURRENT (INVERSE) TYPE CDG -2 RELAYS
AMPERE = 5-2 A, 50 HZ
CT SEC 1 A

38. 25
EARTH FAULT (INVERSE) TYPE CDG – 1 RELAY
AMPERE = .1-4 A, 50 HZ
CT SEC 1 A
2. REALY AND CONTROL PANEL FOR TRANSFORMER NO. 1
TRIPPING AND EMERGENCY ALARM:-
A. RESTRICTED EARTH FAULT
B. OVERCURRENT EARTH FAULT
C. TRANSFORMER DIFERENTIAL
D. WINDING TEMPERATURE HIGH ALARM
E. OIL TEMP. HIGH ALARM
F. BUCCHOLZ ALARM
G. FAN FAILURE
H. BUCCHOLZ TRIP OLTC
I. BUCCHOLZ TRIP
J. LOW OIL LEVEL MAIN TRANSFORMER CONSERVATOR
K. LOW OIL LEVEL OLTC CONSERVATOR
L. CIRCUIT BREAKER TRIPPED
EARTH FAULT RELAY:-
EASUN REYROLLE TYPE
ER TYPR 4B3, RATING 15-170V, 50 Hz
SETTING CAN BE INCREASED OR DECREASED BY ADDING OR REMOVAL HAVE
LINKS

39. 26
HIGH SPEED TRIPPING REALY:-
EASUN REYROLLE INDIA TYPE B34
RATING 110V DC
WINDING TEMPERTURE TRIP/WINDING TEMP. ALARM/OIL SURGE:-
ER TYPE B12 RATING 110V DC/ ER TYPE B12 RATING 110V DC/ ER TYPE B12
RATING 110V DC
IDMT PHASE FAULT-2 REALYS:-
EASUN REYROLLE
TYPE TM 10 RELAY RATING 1A, 50 HZ
IDMT EARTH FAULT RELAY:-
EASUN REYROLLE
TYPE TJM 10 RELAY, RATING 1A, 50 Hz
OIL TEMPERATURE TRIP/BUCCHOLZ ALARM/BUCCHOLZ TRIP:-
EASUN REYROLLE
ER TYPE B12, RATING 110V DC
DIFFERENTIAL PROTECTION RELAY-3 RELAYS:-
EASUN REYROLLE
TYPE 4C21 RATING1A, 50 Hz
3. RELAY AND CONTROL PANEL FOR 132 KV TRANSFORMER2 & 3
TRIPPING AND EMERGENCY ALARM:-
A. OVERCURRENT

40. 27
B. EARTH FAULT
C. RESTICTED EARTH FAULT (PRIMARY)
D. RESTRICTED EATH FAULT (SECONDARY)
E. DIFFERENTIAL
F. WDG. TEMP. HIGH TRIP
G. BUCCHOLZ TRIP
H. PIT TEMP. TRIP
I. OVERFLUX
J. WDG. TEMP. ALARM
K. BUCCHOLZ ALARM
L. OIL TEMP. ALARM
M.LOW OIL LEVEL
N. GA PRESSURE LOW
O. LOW AIR PRESSURE
P. LOW OIL LEVEL (COMPRESSOR)
Q. OLTC OIL TEMP.
MASTER TRIP:-
ENGLISH ELECTRIC
TRIPPING RELAY TYPE VAJ
LH VOLTS 110-125 DC

41. 28
PCC , MCC & HT MOTOR PROTECTION
ELECTRICAL DISTRIBUTION NETWORK LOAD CENTRES
The supply from 132KV substation goes to various load centers. So there are out going
feeder for LC-4, LC-4A and LC-6 and incomers of EB and DG at the same so the 6.6KV
supply from 132 KV substation comes through these EB and DG incomers with whose help
the bus charges and with this we get the required 6.6KV supply for H.T. drives established at
various load centers, also along with these H.T. drives there are transformers which get
6.6KV supply at their primary side. So at their secondary side we get 433V supply, they are
step down transformers. There are such transformers located at each load centers means at
LC-4, LC-4A, and LC-6. Now from this step down transformers 433V supply goes to PCC
incomer, which had got Incomers of Various MCC panels. That means from PCC incomer
the 433V supply charges the MCC incomers and from these incomers of MCC the supply
charges the various LT drives. So this is how we get the required HT supply for HT drives
and LT supply for the required LT drives.
Now the thing is that from these load centers the supply also goes to various load centers.
First of all we decide the no. of load center in JK Lakshmi cement.
There are 10 load centers and they are as follows:
LC-1 E.V.CRUSHER
LC-1A OLD CRUSHER
LC-2 LIMESTONE STACKER AND RECLAIMER
LC-3 VRM1 & COAL GRINDING (PH-1)
LC-3A VRM2 & COAL GRINDING (PH-2)
LC-4 CCR & KILN 2 (PH-1)
LC-4A KILN 3 (PH-2)
LC-5 COAL SATCKER AND RECLAIMER
LC-6 CEMENT MILL
LC-7 PACKING PLANT

42. 29
The supply from LC-4, LC-4A, LC-6 goes to various load centers.
FROM TO
LC-4 LC-3, LC-2, LC-1
LC-4A LC-3A, LC-5
LC-6 LC-7 (PACKING PLANT)
LC-1 LC- 1A
Now moving on back to LC-4 we would like to discuss the types of HT drives and the types of
MCC section in the same load center i.e. LC-4
LC-4
HT PANELS
O SEPA VENT FAN DRIVE FRO CM-3
TRANSFROMER FOR CM-3
LIGHTNING TRANSFORMER
CV FAN
PH FAN
TRANSFROMER-3
TARNSFROMER-4
TRANSFROMER-5
TRANSFROMER-6
TRANSFORMER-7
TRANSFROMER-8
COAL MILL FAN
COAL MILL
BH FAN
RAW MILL FAN
RAW MILL
LIME STONE STORAGE
LIME STONER CRUSHER
CEMENT MILL-3
PCC SECTION CONTAINS
MCC-10A COAL FIRING SECTION

43. 30
MCC-10B COAL FIRING SECTION
MCC-11 KILN AUXILLARIES
MCC-12 COOLER AUXILLARIES
MCC-13 COOLER FAN PDB2
MCC-14 COOLER FAN PDB1
MCC-16 CLINKER TRANSFORMER
LC-4 ALSO CONTAINS LT CAPACITORS, RATING OF WHAT ARE AS FOLLOWS:
147X6=883 KVAR
LC-3
MCC-5 RAW GRINDING SECTION
MCC-6 RAW GRINDING SECTION
MCC-7 BAG HOUSE
MCC-8 SILO EXTRACTION AND KILN FEEDING
MCC-9 COAL MILL SECTION
LT CAPACITORS
111X6=670 KVAR
60X3=180 KVA
LC-4A
HT PANELS
RAW MILL MAIN DRIVE
RAW MILL FAN
BAG HOUSE FAN
COAL MILL MAIN DRIVE
PREHEATER FAN
CV FAN
TRANSFORMER-1
TRANSFORMER-2
TRANSFORMER-3

44. 31
TRANSFORMER-4
TRASNFORMER-5
TRANSFORMER-6
PCC SECTION CONTAINS
MCC-10A COAL FIRING SECTION
MCC-10B COAL FIRING SECTION
MCC-11 KILN AUXILLARIES
MCC-12 COOLER AUXILLARIES
MCC-13 COOLER FAN PDB-2
MCC-14 COOLER FAN PDB-1
MCC-16 CLINKER SECTION
LT CAPACITORS
90X6=540 KVAR
LC-3A
PCC SECTION
MCC-5 RAW GRINDING SECTION (520 KW)
MCC-6 RAW GRINDING SCETION (772 KW)
MCC-7 BAG HOUSE (270 KW)
MCC-8 SILO EXTARCTION KILN FEEDING (750 KW)
MCC-9 COAL MILL SCETION
LT CAPACITORS
150X6-919 KVAR
LC-6
HT DRIVES
TRANSFORMER FOR CM-5
CEMENT MILL-5 MOTOR FEEDER
O SEPA FAN FOR CM-2
TRASNFROMER FRO CM-2

45. 32
CEMENT MILL-2
TARNSFORMER-10
TRANSFORMER-11
TRANSFORMER-12
CEMENT MILL-4
TRANSFORMER FOR CM-4
PCC SECTION
MCC-16 CLINKER HANDLING SECTION
MCC-17 CEMENT GRINDING SECTION
MCC-18 CEMENT GRINDING AUXILLARIES
MCC-20 PACKING PLANT UNIT 1
MCC-21 PACKING PLANT UNIT 2

46. 33
LRS, GRR & POWER FACTOR MAINTAIN
LRS & GRR:-
A variant of the induction motor is the slip ring or wound rotor motor. The induction motor
has a "squirrel cage" rotor which is in effect a short circuited winding in the rotor. The start
and run characteristics are influenced by the resistance and inductance of the rotor circuit.
One of the problems of the induction motor, is that the start current is very high (600
- 900%) and the start torque is relatively low (120 - 200%) compared to the start current
drawn. The induction motor has a speed at which maximum torque is produced and this is
very close to full speed. By altering the resistance in the rotor design, we can alter the speed
at which maximum torque is produced. Below this speed, the current goes high and the
torque goes down. Above this speed, the current drops with the torque. The wound rotor mo-
tor, has a winding on the rotor that is not short circuited, but is brought out to slip rings. This
enables the effective rotor resistance to be altered. By varying the rotor resistance while the
motor starts, we can cause the speed of maximum torque to shift from zero speed up to very
close to full speed in a number of steps. The big advantage of this, is that the motor is able to
provide a high start torque (around 200%) and a low start current (around 200%) from zero
speed to full speed. This is very god for starting high inertia and difficult start loads on
relatively weak supplies. The rotor resistors can be cast resistors, wound resistors, or liquid
resistors. With standard resistors, the stages are switched in and out by contactors to alter the
resistance.
1. Smooth progressive acceleration
2. Wide range of applications
3. Rugged and reliable
4. Customised for each application
5. Reduced maintenance

47. 34
Maintain the Power Factor of Plant by Capacitors:-
Our aim is to maintain power factor at unity. If we can maintain the power factor above 0.99
then we got 4% deduction in our electricity bill charged by RSEB. In fact we got incentive in
electricity bill by maintaining the power factor above 0.95. There were penalty if power factor
is below 0.9 and between 0.9 to 0.95 there is neither penalty nor incentive Now question
arises that what is significance of power factor due to which we get other incentives and
penalty. As we know that power is given as:-
P = √ 3. V.I. Cos Ө
Now where,
P = load in MW
V = voltage in KV
MW = MVA * Cos Ө
For a constant power load as power factor decreses, current will increase. This will increase
extra load on transmission line and transformer at RSEB substation. So for reducing this
overload power factor should be maintained at our side.
As our plant comprises major electrical load which is inductive in nature and inductive load
have lagging power factor. So we are using capacitors to maintain the power factor, because
they have leading power factor. Capacitors having leading power factor neutralises the
inductive loads and thus will improve the power factor.
HT capacitors and LT capacitors are used to improve power factor, we are using 5th
, 7th
and
11th
harmonic capacitors for improvement of power factors.

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EARTHING SYSTEM
We have used double earthing system for the entire machinery, which means the electrical
equipment is connected to earth in twice manner. There are two type of earthing:
BODY EARTHING
NEUTRAL EARTHING
BODY EARTHING:
In body earthing, body of the equipment is connected with the earth pit. We have used latest
technology for the earthing system. Instead of charcoal, salt we have used “ASHLOK”
EARTHING SYSTEM. It comes with the Electrode & Back fill compound. The height of the
ELECTRODE is nearby 2-3 meter. Backfill compound has all the qualities of the ideal back-
fill material for an earthing system. It is easily compacted and when water is added to it, it
will absorb up to thirteen times its dry volume. These consistencies hold its own shape & ad-
here to any surface it touches. These capabilities resolve the issue of compatibility & soil/ rod
contact that are crucial to an earthing system.
NEUTRAL EARTHING:
In neutral earthing the neutral point of the motor circuit is connected to the earth. It is used
for neutralize the unbalance current in the circuit. For neutral earthing we had provided two-
earth pit and the neutral brought out from the transformer is been connected to it. Before
connecting the earth pit the resistance of the earth pit should be less than 1 ohm. If it is not
so, spray water over the pit and let it come under 1 ohm
BODY EARTHING:
In body earthing the transformer body is being connected to the earth. It is being used to
protect the human being from getting shocks when he come the contact of the faulty
equipment.

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CONCLUSION
I successfully accomplished my plant training program gaining lots of
information about the work culture in the organization, its various inventory
techniques being used in different departments for the better result oriented
procedures.
It was a great experience for me to get in to touch with each and every
person of the organization who is so helpful and ready to accept a member in their
group.
Thanking You

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