Udaipur Cement Industries Limited is a fully government-owned cement plant in Nepal established in 1987 with financing from the Japanese government. The plant produces 277,200 metric tons of ordinary Portland cement per year. Limestone is mined 30km from the plant and transported via a 13.8km ropeway. The limestone is crushed and stored, then milled along with other raw materials before being preheated and fired in a rotary kiln to produce clinker. The clinker is ground in a cement mill and stored in silos before being packed and dispatched.

1. INDUSTRIAL TRAINING
UDAIPUR CEMENT INDUSTRIES
LIMITED
Sijan Rai
110106267

2. INDUSTRY BACKGROUND
• Udaipur Cement Industries Ltd is a fully Government owned industry in
Nepal, established on 14th June, 1987.
• The source of financing of the project is Japanese government assistance
of 18 billion 77 crore Japanese yen and equity share of Nepal Government
of 45 crore .
• The construction of the project started in September 1989 and was
completed in Oct,1992.The commencement of commercial production
started from the January 1993.
• The Industry Produces 2,77,200 MT Cement per Year Ordinary Portland
Cement (OPC) .
• Consulting Engineer: Onoda Engineering Co.Ltd.Japan.
• Turnkey Contractor: Consortium of Kawasaki Heavy Industries Ltd and
Tomen Corporation –Japan.

3. Annual Requirement
• Lime Stone:3,30,000 MT. (Has its own mine )
• Iron Ore :4,000 MT.(Imported from India )
• Clay :57,000~82,500 MT.(own min)
• Gypsum :10,500 MT.(Imported From India )
• Silica Sand : up to 21,000MT.(Own Mine)
• Fuel requirement
(i) Coal 50,000MT/Year (ii) Furnace Oil :12,000 KL.
• Electricity: 8000KW.
• Water 1500 M3/ Day.

4. Organizational Structure:

6. 00. Limestone Quarry and Crushing
plant
09. Cooler
01. Limestone Stockpile 10. Deep Bucket Conveyor
02. Additives Hopper 11/12. Clinker/Gypsum Storage
03. Additives Storage 13. Coal Mill Building
04. Raw Mill Building 14. Cement Mill and Bag House
05. Blending and Storage Silo 15. Cement Storage Silo
06. Preheater 16. Packing & Dispatch
07. Gas Conditioning Tower and ESP 17. Central Control Room
08. Kiln

7. Limestone Mine
I. Udaipur Cement Industry had its
own mine .
II. Limestone mine is a 30 km away
from the main plant site .
III. The limestone mine is mined by
using opencast method where the
bench are made and blasted off
using explosives.
IV. Then with the help of Dump truck
it is placed on primary crusher
and through the help of ropeway
the limestone is brought to the
plant site .

8. Ropeway
I. Ropeway is used to
transport the limestone
from the quarry site to the
main plant which is almost
30 km away from the plant .
II. The total length of the
ropeway is around 13.8 km
long .
III. The ropeway was built by
German Company .The
ropeway moves at a speed
of around 10 km per hour .
IV. There are almost 50
supporting towers to
support the load of the
buckets .

9. Crusher
I. The crushing of big limestone is carried out in
two stages through primary crushing and
secondary crushing .
II. Once the limestone arrives at the plant it is put
into primary crusher where the large size of
limestone is crushed into smaller pieces .
III. Jaw crusher is used in primary crushing .
IV. The after primary crusher through the help of
conveyer belt the limestone is put into
secondary crusher .
V. In secondary crusher the limestone pieces are
broken down into less than 20 mm size . Impact
crusher is used in secondary crushing .

10. Limestone Storage
Scrabber And Reclaimer Stacker
Stacker :It contains Belt
conveyers .It is continuous
moving parts and collect the
stone coming from the crusher
by stacking motion .
Scrabber :It is a triangular arm
positioned one the two sides of
reclaimer .It consist of armature
with rod in perpendicular
direction which moves to and
fro motion
Reclaimer: A reclaimer is a
large machine used in bulk
material handling applications.
A reclaimer's function is to
recover the limestone from
storage to the belt .

11. Raw Mill:
I. The raw material is finish-ground
before being fed into the kiln for
clinkering.
II. This grinding is done using either
ball mills or vertical roller mills
(VRM).
III. . The choice between a ball mill and
VRM is governed by many factors
such as the moisture content of the
raw material, the size of the plant,
the abrasiveness of the material,
the energy consumption levels,
reliability, and finally financial
consideration
IV. VRM uses the compression
principle to grind the raw material.

12. Blending Silo
I. In order to blend and
homogenize the raw materials
properly, continuous blending
silos are used.
II. The blending silo can store
6000 tons of the powder
mixture.
III. It is highly insulated so that it
can maintain the appropriate
temperature of the powder
mixture.

13. Pre Heater Tower
I. The key component of the gas-suspension
preheater is the cyclone.
II. A cyclone is a conical vessel into which a
dust-bearing gas-stream is passed
tangentially.
III. A very efficient heat exchange takes
place the gas is efficiently cooled, hence
producing less waste of heat to the
atmosphere, and the raw mix is
efficiently heated.
IV. This efficiency is further increased if a
number of cyclones are connected in
sequence.

14. Rotatory Kiln
I. The kiln is a cylindrical vessel,
inclined at around 15 degree to
the horizontal, which is rotated
slowly about its axis.
II. The kiln feed is fed into the
upper end of the cylinder.
III. As the kiln rotates, material
gradually moves down towards
the lower end, and may undergo
a certain amount of stirring and
mixing.
IV. Hot gases passes along the kiln
in the opposite direction
(counter-current) to that of kiln
feed. The hot gases is generated
by a flame inside the kiln.
V. Such a flame is projected from
a burner-pipe (or "firing pipe")
which acts like a large Bunsen
burner.

15. Cement Mill
I. It is the equipment used to grind the
hard, nodular clinker from the cement
kiln and gypsum into the fine grey
powder that is cement. The iron ball
also known as grinding media of
different size are used for grinding.
II. The cement mill consists of two
compartment separated by the
diapharm .
III. The primary compartment consists of
iron ball of bigger size whereas the
secondary compartment consists of ball
of smaller size.
IV. The clinkers are grinded into primary
compartment and then sucked into the
secondary compartment through the
diapharm.
V. Now this clinker is further grinded into
powder form which is then sucked to
the separator,then cyclone and finally
stored into the cement silo.

16. Material Handling Devices :
Belt Conveyer Bucket Elevator
Screw Conveyer

17. Electrostatic Precipitator
I. It contains a row of thin vertical wires, and
followed by a stack of large flat metal
plates oriented vertically, with the plates
typically spaced about 1 cm to 18 cm
apart.
II. The air or gas stream flows horizontally
through the spaces between the wires,
and then passes through the stack of
plates.
III. A negative voltage of several
thousand volts is applied between wire
and plate. If the applied voltage is high
enough, an electron discharge ionizes the
gas around the electrodes.
IV. Negative ions flow to the plates and
charge the gas-flow particles.
V. The ionized particles, following the
negative electric field created by the
power supply, move to the grounded
plates.
VI. The particles are collected whereas the
gas is released to atmosphere .

18. Thank You