Ambuja Cement plant Industrial report

1 CIT/ME/SEMINAR/009
Chapter-1
INTRODUCTION
1.1 THE BEGINNING
The emergence of Ambuja Cement, way back in the middle of the 20 century, coincides
with the beginning of the industrial India. The consistent of Ambuja Cement since mid 20
century in setting up of dynamic Indian industry, in the process of building an
economically an socially strong India is a well known and recognized fact and the
countrymen consider Ambuja Organisation as a steadfast forerunner in the case of strong
self reliant India.
The phenomenal rise in the growth of companies falling in the eastern zone of Ambuja
Cement is an ample proof of Shri Hari Shanker Singhania’s wisdom and vision.
1.2 PRODUCTS OF AMBUJA CEMENT
It Produces three types of cements as follows:
Ordinary Portland Cement (OPC)-43 as per IS8112-43 GROPC
Ordinary Portland Cement (OPC)-53 as per IS12269-53 GROPC
Portland Pozzolana Cement (PPC) as per IS-1489
1.3 DEFINATION AND COMPOSITION OF CEMENT
Cement can be defined as any substance which can join or unite two or more pieces of
some other substance to form a unit mass, Cement as used in construction industries, is a
fine powder which when mixed with water and allow to set and harden can join different
components or members together to give a mechanically strong structure. Thus, cement
can be used as a bonding material for bricks or for bonding solid particles of different
sizes to form a monolith. Construction of houses for shelter is one of the oldest industries
in human civilization, and cement of one kind or the another has been used in pre-historic
times for construction purposes. Lime and/or lime mixed with clay matter, burnt or
otherwise, have been used for bonding of bricks and stone masonry for at least a

millennium, and various theories have been propounded from time to time to account for
the setting and hardening properties of lime mortars. It was just about 150 years ago that
“Cement” as we know it today was developed or invented.
The range of chemical composition of Portland Cement types is given:
SiO2 19 to 25%
Al2O3 2 to 8%
Fe2O3 0.3 to 6%
CaO 60 to 65%
MgO 1 to 6%
SO3 1 to 3%
Alkalies 0.5 to 1.5%

Chapter-2
CEMENT MANUFACTURING: THE PROCESS
2.1 CEMENT MANUFACTURING PROCESS
There are different process involved in manufacturing of cement. They are as fallow:
1. Raw Material
Limestone is the basic raw material used in the manufacturing of Ambuja Cement. Good
quality cement grade limestone is abundantly available in mines within the Ambuja
Cement factory premises , which is spread over of 400 hectares.
Fig 2.1 Raw Materials
2. Blasting
Limestone is obtained from mines through the process of heavy blasting conducted under
strict supervision and safety precautions. The limestone obtained from the Ambuja
Cement mines is of such superior quality that it removes the need to add clay or any other
additional raw material that is generally added during the process of cement
manufacturing.

Fig 2.2 Blasting
3.Curshing:
The limestone in the form of huge stones is loaded in dumper and transported to the
Crusher. This machine is used to crush the huge stones into smaller and manageable
chucks that are 20mm in size.
Fig 2.3 Crushing
4. Quality Check
Limestone obtained from the crusher undergoes a rigorous quality check using Gamma
Metrics and Cross Belt Analyser.

Fig 2.4 Quality Check
5. Grinding
Fig 2.5 Grinding

6. Blending Silo
Fig 2.6 Blending Silo
7. Pre-heating
Fig 2.7 Pre-heating

8. Calcination
Fig 2.8 Calcination
This is the most critical stage in the Ambuja cement manufacturing process. The raw
materials is fed into a kiln, which is a huge rotating furnace. Using coal / pet-coke as fuel,
the kiln at Ambuja cement factory heats the raw material to a temperature of 1400
degrees Celsius , which is almost one-fourth of the mean surface temperature of sun.
9. Cooling
Fig 2.9 Cooling

10. Clinker Storage
Fig 2.10 Clinker Storage
11. Cement Milling
Fig 2.11 Cement Milling

12. Packing and Transportation
Ambuja cement is packed into HDPE/PP bags with the heil of automatic electronic
packers supplied by Ventomatic, Italy .

Chapter-3
DESCRIPTION OF CEMENT MANUFACTURING PROCESS
3.1 MINES
Ambuja Cement having its own open cast mines and we are working in highly digged
mines. Now what we are digging in the mines, is the limestone, the basic raw material
used in cement manufacturing. Before digging the mines a geological survey should be
done by the geologist and geological scientist.
As we know that Limestone is the basic raw material for cement manufacturing. Thus, it
is required in bulk quantity for production of cement. Therefore cement plants are
established near the place where there is abundance of limestone. The colours of
limestone are bluish, which is of our interest.
Ambuja 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. To obtain lime stone, 9
meter deep holes are drilled into these benches by drilling machine & holes are then filled
with explosives & blasted.
The scattered material is then collected by dozers & by the help of shovel they are loaded
in dumpers. These dumpers transport limestone to crusher for further size reduction
Process.
The limestone received from mines are having size of 1500 mm max, is passed through
FLS make EV crusher and Compound Impact crusher, crushed into product size less than
80 mm then crushed material is passed through Cross Belt Analyzer (CBA) to find out the
composition of material as well as quality of material, only 25% of material is analyzed
by CBA, rest sample is taken manually and tested in laboratory for composition
identification.

After finding out the composition we determine the following factors:-
(I) LSF = CaO/ (2.8 SiO2+1.2 Al2O3+0.65 Fe2O3) (Lime Saturation Factor)
(II) Silica Module = SiO2/ (Al2O3+Fe2O3)
(III) Alumina Modulus = Al2O3/Fe2O3
Lime saturation factor is very important because if silica is present in the kiln in high
quantity then the burning of mixture will take place very slowly hence it will reduce
efficiency of kiln and thus clinkerization will be effected. If lime is present in high
quantity then it will generate free lime in clinker in kiln. Hence LSF plays a key role in
KILN operation.
3.2 EV CRUSHER
1. CRUSHING
The raw material as received from the mines are in lump form and have to be crushed
before fine grinding. The size of lump would depend upon the raw material and the
method of mining, so the size of the crushing equipment used would depend primarily
upon the size of the lumps received. In the modern cement factory, manufacturing 100 to
2000 tones of cement per day, the limestone is mined by mechanical means and hence the
size of individual pieces may be 1meter or so. In smaller factories, the mining of
limestone may be manual and the size of individual pieces may be 200mm or so.
Similarly, clay, shale, bauxite, laterite, sandstone, coal, gypsum etc may be received in
sizes not larger than 300mm.
2. SPECIFICATIONS
EV CRUSHER (1030)
Make Fuller- FLS
Size EV200*300
Capacity 1100TPH
Feed Size 1500mm (max)
Product Size 80mm (97%)
Rotor Size 2000mm dia. &3000mm long
Weight 160tons

3.3 HAMMER CRUSHER
Impact Hammer Crusher, Type EV 200*300 for crushing of limestone. The Hammer
Crusher is of single rotor type, with outlet grates and inlet roller, and is designed for
larger- size reduction in one stage. The feed fall upon two slowly rotating shocks-
absorbing roller transporting the material to be crushed in the crusher properly. Part of the
fines is separated off at this stage. In the crusher, the hammers break up the material and
hurl it against the lining of the upper part of the crusher for further fragmentation. Final
crushing takes place at the adjustable crushing plate and the outlet grates. The rotor shafts
runs in amply dimensional spherical roller bearing in split bearing house with oil bath
lubrication and grease- filled labyrinth seals. The bearing housings are placed on rigid
bottom frame of cast steel, bolted together. The bottom frame is provided with large,
hinged access doors and lined with wear resistant, bolted- on lining plate, at areas
exposed to wear from crushed material.
The heavy forged, square, rotor shaft is provided with cast steel hammer discs. The
chrome-alloy manganese steel hammer are suspended on through going hammer bolts of
induction- hardened chrome nickel steel, supported in replaceable, hardened bushing of
chrome nickel molybdenum steel placed in the hammer discs. The hammer bolts are
locked into position by discs at either end of the rotor. The hammer are symmetrically
shaped and can be turned so that the leading and trailing edges are reversed, thus
prolonging the useful life of the hammers.
Outlet grate assembly with study, replaceable, manganese steel grate bars, carried in
strong cast cheeks. The position of the grate assembly is adjustable from outside the
crusher casing to compensate for wear.
The two cast steel inlet roller is placed on shaft with shock absorbing rubber blocks
between roller and shafts. The shafts rotate in grease-lubricated spherical roller bearing in
a bearing house with labyrinth seals, placed on the bottom frame.
The other one connected through an enclosed chain drive drives one of the roller. Top
casing made of rigid, large, welded up, section bolted together for easy dismantling,
allowing removing and installation of rotor and inlet roller without dismantling the feeder
for the crusher. However, the top casing does not have to be removed when replacing the
hammer proper T casing is provided with bolted-on lining plates of manganese steel and
carbon steel, the latter for areas less exposed to wear.

A heavy, vertical chain curtain is suspended in the crusher inlet to prevent material from
being hurdled back onto feeder. The rotor shaft is provides with a flywheel placed on a
flanged bushing, the latter keyed to the rotor shaft and with two shear pins between
flywheel and bushing, cut off switch which stops the crusher, inlet roller and feeder
motion in case the shear pins break and fly wheel starts rotating on the bushing. Included
is membrane coupling with torsion shaft between the driver flange of the flywheel and the
slow-speed shaft of separate gear unit for it.
Included in the supply of the crusher is also over loaded protection equipment, which
stops the feeder in front of the crusher and the inlet roller, in case of over load conditions
has been occurred.
3.4 STACKER AND RECLAIMER
The crushed limestone of less than 80 mm size is stacked & reclaimed in CIMMCO
making continuous stock pile with blending efficiency of 10:1. Using conveyors belts,
raw material is transferred to hopper, in hopper building. The plant has four hoppers in
hopper building one is for low grade, other is for high grade, and one for blended and last
is for sand hopper.
Fig 3.1 Stacker

The above shown image is of a stacker. Material is transported to the top and is then
dropped from height. As it drops, stacks are formed. Different stacks are made for
different grades of material.
3.5 VERTICAL RAW MILL
SPECIFICATION:-
MAKE : FULLER LOESCHE MILL 34.40 M
CAPACITY : 350 TPH
NO. OF ROLLERS : 4
TABLE DIA : 3.4M
GEAR BOX OUTPUT : 31.41 RPM
MOTOR RATING : 1700 KW
MOTOR RPM : 990
Fig 3.2 Vertical Raw Mill

3.5.1 PRINCIPLES OF OPERATION
In the fuller Loesche mill, grinding is accomplished on a rotating grinding table by hydro-
pneumatic rollers, which are pressed against the bed of material. A gear reduction unit
powered by an electric motor rotates the horizontal grinding table. A dam ring around the
periphery of the table establishes the bed depth of material, which can accumulate. As the
material is grounded between the rotating table and rollers, centrifugal force moves it off
the table and a stream of air carries it upward through the mill body and into the classifier
section. The Classifier controls the size of particles in the product. Those larger than size
desired by the operator are returned to the table for further grinding.
An induced-draft fan located downstream from the mill usually creates the flow of air,
which conveys the ground material through and out of the mill.
Hot air will be supplied from preheater to dry the material.
A water spray arrangement is incorporated in the mill body for cooling the air if exit
temperature rises above than the specific level. Because the mill is under suction, feed
material is introduced through an airlock through a chute.
Generally iron pieces in the feed material will be separated in the feed belt itself by means
of magnetic separator and metal.
Large rocks, tramp iron, and other ungrindable objects, which may have entered the mill,
are also moved off the table by centrifugal force and drop through Louvre ring and to
reject.
3.6 BLENDING SILO/ C.F Silo
The Central Chamber Mixing Silo as a same time serves as a storage silo and is operated
as continuous flow silo. Feeding and discharging are preferably performed continuously
but may also be performed intermittently the silo may either be filled or discharged. The
type of operation mainly depends on the operating conditions of the plant and on the
number of central chamber mixing silos operated parallel.

The principle of the material mixing process consists in the fact that different material
layers differing in their chemical composition.
(For example their Cac03 content) are merged during the discharging process.
Thus the blending process already starts during the silo feeding operation.
The essential objective is to evenly build up as many layers of varying material as
possible. To achieve an optimum result, the material flow for feeding the silo, is
conducted via a parallel distributor . and is then further distributed by way of individual
flows via system of airsides evenly over the entire cross-aerated by a high pressure fan
The intention is to obtain many thin layers of varying material. During the silo feeding
process and due to varying material layers being built up, the silo is discharged through at
least six discharge ports arranged in the form of ring at the silo bottom, the desired
quantity of material is fed directly or via an intermediate transport.
The flow gates are operated in succession via a solenoid valve compressed air is, fed
sometime in the silo aeration section allocated to the flow control gate. The Rotary
blowers generate compressed air. The time intervals of the section aeration and the
discharge via the respective flow control. Gate may be adjusted and depend on the
material quantities to be discharged. The material layers built up within the silos are
merged and mixed during the discharging process due to so called funnels created in the
material flows. As already mentioned, many different thin layers result in a better
blending effect than few but thicker layers. To achieve a good mixing, result it is
necessary to keep the height of the material column at least equal to the silo diameter.
When the material level is further lower, as a consequence fewer layers are available for
blending the overall mixing capacity is therefore reduced. As already mentioned, the flow
control gates required for the discharging process are operated in succession. Thus, a
constant lowering of the material level within the silo is obtained, a predetermined
creation of the material funnels and just a controlled mixing process are guaranteed. The
central chamber mixing silo makes use of the gravity force to which the material flow in.
The maintenance for the central chamber mixing silo is remarkably simple, as all essential
unit are installed outside the silo space.

3.6.1 PRINCIPLE OF OPERATION
Material to be conveyed enters the hopper, the screw advances the material through the
barrel to the discharge body . In the discharge body, the material is compressed to form
the material seal. The material seal prevents a reverse flow of conveying air from the
mixing chamber . The screw has a reverse pitch flight , which repel the material thus
aiding the advancing screw flight in forcing the material into the mixing chamber. After
the material is discharge into the mixing chamber , compressed air-entering the mixing
chamber through nozzle - fluidizes it sufficiently to permit pumping through the transport
line connected to the end of mixing chamber. The free floating flapper valve , located in
the discharge area of the pump, is mechanical seal which assist in preventing the reverse
flow of air from the mixing chamber through the pump barrel.
The external flapper valve level serves as a visual indication that the free-floating flapper
valve is operating satisfactorily. This external layer should never be connected by any
means to the internal valves. A counterweight is attached to the flapper valve handle to
aid in maintaining a material seal. This counterweight position is adjustable along the
flapper.
Valve handle to increase or decrease flapper valve pressure. Each pump is supplied with
one spacer ring located behind the flapper valve assembly.
The proper combination of counterweight plus spacer ring should provide an adequate
material seal for proper.
In some cases, the spacer can be removed to achieve the desired balance between
material seal and motor load. The pump screw is coupled to a drive motor by either a
shaft coupling or a v-belt drive. Fuller Company determines the screw pitch and speed for
each application. The Fuller-Kinyon pump will operate most efficiently at the maximum
capacity for it was sized. However it is permissible to operate the type M pump at
reduced load conditions.
The main parts of pump are:
Hoper
Barrel
Bearing House
Screw
Flapper Valve Assembly

3.7 COAL GRINDING
SPECIFICATION:-
CAPACITY : 28 TPH
MOTOR RPM : 989
3.7.1 SYSTEM DESCRIPTION
The system consists of the following equipment:
Raw coal hopper
Chain feeder
Tirax ball mill with auxiliary equipment
Five (5) shut off damper
Two (2) Louvere damper for airflow and temperature control
Two (2) explosion events
One (1) bag house dust collector
One (1) mill I.D fan with inlet damper
One (1) booster fan with inlet damper
One (1) twin cyclone
One (1) fine coal bin
One (1) nitrogen inertisation system
One (1) grit separator
Series of screw conveyors
Two (2) bag filters with fans
The raw lump coal is fed from the raw coal hopper by means of a chain feeder. The chain
feeder discharges the lump coal through a gravity operated flap valve into the mill.
Hot gases from the preheater are used for drying the coal. The preheater exit
Gas is drawn through a twin cyclone to deduct the gas by a booster fan.
The pulverized coal laden mill exit gas is passed through a grit separator that drops out
the coarse particles, which are returned back to the ball mill via a screw conveyor. The
fine particles are deducted in a bag house. The cleaned gas is vented into atmosphere.
During normal operation part of the clean gas is re circulated to the mill to maintain

overflow. The pulverized coal is extracted in the bag house by a screw conveyor to the
fine coal bin.
During start up all the gas to the mill comes from the preheater to keep the system inert.
The system can also run with hot air generator that is shared with the raw grinding
system.

Chapter-4
PYRO PROCESSING
4.1 INTRODUCTION
The pyro processing system consists of an SLC-S six stage preheater/ calciner, a three
support rotary kiln and a controlled flow GRATE reciprocating grate cooler. The system
is designed for a guaranteed production of 4500 TPD of clinker.
4.2 SPECIFICATIONS
KILN DIA : 4.27M
KILN LENGTH : 61.126M
CAPACITY : 4500 TPD
4.3 SYSTEM DESCRIPTION
4.3.1 PREHEATER
The preheater transfers the heat from the kiln exhaust gases to the raw meal before being
fed into the kiln, thereby reducing both the size of the kiln and the amount of fuel
required to produce clinker. About 80-90% calcinations of the raw mill takes place in
calciner before it enters the rotary kiln, further reducing the size of the kiln, and reducing
the thermal load on the kiln resulting in increase life of kiln refractory. The preheater
consists of six stages. The stages are numbered from top of the structure downward. Stage
1 of the preheater consists of twin cyclones, while the remainder of the stages consists of
single cyclone. A flash calciner is located towards the bottom of preheater and is
connected to the tertiary air duct. The calciner exit gases mix with the kiln exit gases
before entering the stage cyclone.
The first five stages of the preheater feed the heat by mixing it with the hot gases. The
mixing takes place in the duct work leading to each cyclone. The cyclone then separate
the feed gases and the feed continues down to next stage. This process is repeated five
times. As the feed travels down through the tower, it is continually heated in preparation
for introduction the calciner. When extra heat is needed for drying in the raw mill system,
the preheater feed can be diverted to next Stage 2 cyclone so that the preheater operates in

the five stages instead of six. Tipping valves are located at the exit of each cyclone to
prevent short-circuiting of the gas stream through the material chutes.
4.3.2 CALCINER
The preheated feed enters in the calciner from the Stage 5 cyclone. The calcium carbonate
is converted to lime and carbon dioxide gas in the calciner. Combustion gas for the
calciner are drafted from the clinker cooler via the tertiary air duct. Burners located in the
cone of the furnace heat these gases. The furnace operating temperature is adjusted to
maintain approximately 90-92% calcinations of the raw feed.
Oxygen for combustion is provided both by clinker cooler and fuel firing system. In the
case of oil firing, a primary air fan is provided. A start up burner is provided in the cone
of the furnace to increase the temperature of the gas in the calciner during start up of the
pyro processing system. A second start up burner is also provided at the back end of the
tertiary air duct to dry out the refractory in the tertiary air duct.
4.4 ROTARY KILN
4.27m inside diameter 60.96 m long Rotary kiln is designed to produce 4500 metric ton
per day of cement clinker. Kiln support roller frames, riding rings, thrust assembly, driver
gear and pinion assembly and feed and discharge seals are all furnished as part of
equipment. An automatic spray lubrication system for Kiln Girth Gear is provided.
The calcined raw feed enters the kiln from Stage 6 cyclone. Inside the kiln, the raw
materials are sintered and clinker is produced. Approximately 40% of the total fuel is
produced in the kiln. The flame is maintained in order to heat to proper reaction
temperatures. The rate at which the feed passes through the kiln is set by the kiln’s
revolving speed.
Total Kiln Capacity is 12,000 TPD.
KILN-1 3000 MT/D
KILN-2 4500 MT/D
KILN-3 4500 MT/D

4.4.1 CLINKER COOLER
The hot clinker (approx 1450 deg. Centrigrade) exits the kiln and is cooled in
reciprocating grate cooler. Air is forced by fans into the cooler to cool the clinker o 100
deg.c. Prior to the clinker cooler discharge a clinker breaker reduces the size of any large
pieces. The air used to quench the clinker is ambient and reused in the kiln. The front
portion of the hot cooler exhaust air is taken through the firing hood and is used as the
kiln’s and calciner’s secondary combustion air.

Chapter-5
CEMENT GRINDING SYSTEM
5.1 INTRODUCTION
MAIN MOTOR RATING : 2700KW
MAIN MOTOR RPM : 990
SHELL DIA : 4M
SHELL LENGTH : 14M
CAPACITY : 75TPH
GEAR BOX RATIO : 8:1
Fig 5.1 Rotary kiln
These instructions cover operation of fuller KCP Grinding Mills. This system includes
grinding mill with HRC in hybrid mode. The primary purpose of HRC is to precrush the
mill feed to have an optimum feed size to mill. The feed size can be varied to some extent
by adjusting the grinding pressure of HRC. By precrushing clinker in HRC the grinding
load in the mill will be reduced considerably.

5.2 PRINCIPLES OF OPERATION
In a grinding mill, a horizontally mounted cylindrically shell partially filled with grinding
media, usually ball or rods, is rotated about its longitudinal center line. The material to be
grounded is fed into the shell through one end where it comes into contact with tumbling
media. Grinding is effected through the repeated impact of the media on the material. As
it is ground, the material moves through the length of mill and is discharged from the end
opposite the one it entered.
Most mills are divided into two compartments. Feed material enters the first compartment
where an initial size reduction is performed on it before it enters the second. A diaphragm
containing holes through which the material can pass separates the two compartments.
The second compartment is generally larger than first and contains the smaller sizes of
grinding media.
Some mills include a water spray system in which cooling water can be sprayed into
first/second compartment from the diaphragm. Its purpose is to cool the material to avoid
material quality degradation.
5.3 CEMENT MILLS AT AMBUJA CEMENT
 Cement mill-1 (100TPH )
 Cement mill-4 (75TPH)
 Cement mill-5 (75TPH)
 Cement mill -6 (75TPH)
a. All are same in process and design but in cement mill -2 used hybrid grinding.
b. Hybrid grinding is process in which clinker is crushed before fed in to the cement mill
and crushing done by hydraulic roller crusher (HRC).
c. HRC have now been used very successfully for more than 10 yrs for better utilization
of energy during grinding.

d. In this high compressive stressing in the particle bed between a fixed roller and a
hydraulically preloaded floating roller comminutes the material, which rotates in
opposite direction to produce a compacted cake of material.
Material is fed via a material column on top of the rollers so called choke feed, pulled
down between the rollers, and pressures is supplied from hydraulic cylinders to working
on the moveable rollers.
The pressure required for optimum condition range of 6500-9000KN/M^2
5.3.1 ADVANTAGE OF HRC
 It increases production capacity 40 to 50%
 It saves energy in grinding in cement mill 15 to 20%
 It saves grinding media materials
5.4 CEMENT MILL PROCESS
 To produce the final product clinker is mixed with gypsum (fly ash for ppc ) and
ground in large tube mills . the cement flows from Inlet to outlet of the mill which us
being first ground by 90mm to 60mm .HI-chrome balls and then 30mm to 70mm balls
in 2 chamber mills
 Role of first chamber is to break up the granulated materials
 Role of second chamber is to make a fine product
 The amount of grinding governed by the volume of material fed to the mill ( the
greater the volume , coarser the grind ).
 % filling of grinding media balls is 28-30% of the total volume of the chamber
 Breaking of materials in first chamber is by impact action of balls on materials
 Making of fine powder in second chamber is by attrition and rolling action of the
balls.
 Both the chambers are separated by the intermediate diaphragm
 Materials passes to diaphragm to second chamber
 Venting through mill is governed by center screen

Fig 5.2 Photograph of inside ball mill
5. 5 DESIGN PARAMETERS AFFECTED PRODUCTIVITY OF CEMENT
a. CRITICAL SPEED
b. MILL INTERNALS
c. CRITICAL SPEED (Nc)
It is very important design parameter in ball mill,formula –
Nc=42.3/D^0.5 (RPM)
5.6 MILL INTERNALS
The right selection of mill internals contribute to the mill efficiency to a great extent.It
covers mainly diaphragm ,mill liners &grinding media.
5.6.1 DIAPHRAGM
Function of diaphragm or partition mainly prevent passing of oversize particles to next
mill compartment, double diaphragm are better than single diaphragm due to it provide
better ventilation due to less chocking of slots.

5.6.2 MILL LINERS
Liners are installed inside the mill to serve mainly two purposes:
 to protect the shell of mill against wear.
 take care of the normal grinding process by lifting or segregating the ball charge
as per requirement.
Types of mill liners:-
 Stepped liners
 wave liners
 Classified liners
5.7 GRINDING MEDIA
Grinding is performed by impact of grinding balls on mill feed and friction between the
grinding balls, which hit one against another as well as between the grinding media and
the mill lining itself.
Grinding media shape ,size, hardness, density and its percent loading in mill chamber
affects the performance of ball mill to a considerable extent therefore selection of
appropriate quality of grinding media charge should be made as per the particular
requirements.

Chapter-6
PACKING PLANT
6.1 INTRODUCTION
Packing plant has got two units of packing plant. Unit 1 has got three packers one is
mechanical packer and other is Ventomatic packer. Similarly Unit 2 has got two
Ventomatic packers.
The material from cement silo is taken with the help of air slides taken to bucket elevator.
The material is taken to air slides through root blower. This material from bucket elevator
is taken to vibrating screen. At this point the material is also again classified between fine
and coarse material. At the vibrating screen there is counter weight which is rotated with
the help of motor and as counter weight rotates the screen vibrates. Then material is
passed to feed hopper whose capacity is 35 MT for Ventomatic packer. Through this feed
hopper the material with the help of feed valve or butterfly valve pass through packer
tank and then discharge through the packer in the cement bags and then as final product to
the loading media.
6.2 ROTORY PACKER
SPECIFICATIONS:-
CAPACITY : 3600 BAGS PER HOUR
MOTOR RPM : 1450
6.3 PACKING PROCESS
In contrast with the in line packer with its filling spouts mounted stationary side by side,
required the machine operator to move from spout to spout, the spout, the rotary packer
move one by one into position in front of the operator, who merely has to fit the valve
sack onto them as they successively pass him. There are rotary packer with 6,8,1,2 and 14
spouts. Packers are of electronic type so that consistent weight of cement filled bags are
maintained within ranges of 50 to 50.5 per bag.

6.4 MATERIAL HANDLING EQUIPMENTS
6.4.1 AIR LIFT SYSTEM
Air lift or pneumatic elevator is capable of conveying dry pulverized material through a
vertical pipe to the discharge into receiver or bins at a substantially higher level.
The cylindrical shaped feed bin has a fully aerated bottom to allow complete fluidization
of the material in the bin. The pressure head effect in the fluidized material acts to move
the material towards the air nozzle is conveyed upward through the air lift pipe.
The primary air supply furnishes air to lift nozzle through a pipe manifold with check
valve. The aeration air supply furnishes air to the bottom of the feed bin to fluidized the
material in the bin. With separated source of air, the degree of fluidization of the material
can be finely tuned to obtain the ultimate material density and feed rate to the airlift pipe.
6.4.2 BELT CONVEYORS
Belt conveyors have been used for a great many as handling devices for bulk material and
also for unit load.
Nylon fabric belt as traction element to be employed for buckets elevator of the self
loading type which scooped up the material by the digging action of bucket- for the
handling of light fine grained materials .The desire to achieve greater elevating heights
and to operate at higher temperature led to the development of belt incorporating
polyester and steel cable reinforcing elements. This has resulted in general change in high
capacity bucket elevator engineering. Whereas chain bucket elevators are normally built
for elevating height not more than 50-60m, with steel cable belts it is possible to attain
height upto 100m.
6.4.3 CHAIN BUCKET ELEVATOR
This is the only type of bucket elevator that can be used for the handling of materials.
Beside bushed chains, round- link chain are also used, their advantage being the smaller
chain pitch giving quieter running on passing round the sprocket or chain wheel. For
high-capacity bucket elevator it is necessary to use suitably heated-treated steel chains of
the round-link type in order to keep the amount of wear at the point of articulation within

acceptable limits. Another of this open type of chain, especially for the handling of dry
material consisting of angular particles, is that these will not attach themselves to the
round articulation surfaces of the links and thus cause heavy wear.
6.5 ELECTROSTATIC PRECIPITATOR
An electrostatic precipitator is electrical equipment where a DC voltage is imparted,
through emitting a electrode creating an electric field around it. Dust particles carried by
the gas, while passing through the field in charge to saturation and migrate towards the
collecting electrode, usually in the form of plate curtain, where they are deposited in
layers. By suitable rapping dust is lodged into hoper.
6.5.1 PRINCIPLES OF OPERATION
The dust laden gas enters the precipitator at A and the cleaned gas leaves at B. The
electrode E usually known as emitting electrode and C known as collecting electrode
forms a large number of gas passages. The C electrode are usually curtains of vertically
hung plates. The electrode are placed between the C electrode curtain. A rectifier
impresses suitable DC voltage between electrode depending on the particular process.
Due to the electrical field around the E electrode the gas around the E electrode is ionized
and the region is filled with positive and negative ions. This is called corona formation.
The dust particles carried by the gas between the electrode are charged to saturation
immediately after entering space. The charged particles are then pulled towards the
collecting electrodes. Movement of the particles are opposed by viscous drag and
resultant velocity, called migration or drift velocity is attained by the particles. The dust is
then precipitated on to the plate electrodes. Hence a deposit of dust is formed on the plate
when the layer is sufficiently thick and agglomerated it is dislodged from the plates.

6.6 BAG FILTER
BAG HOUSE STACK DETAIL:
MAKE :FULLER
BAG Diameter :11.5 INCH
BAG LENTH : 368 INCH
TOTAL NO. OF BAG IN ONE MODULE :120
TOTAL NO. OF MODULE : 20
TOTAL BAGS IN BAG HOUSE : 2400
STACK HEIGHT : 60M
STACK DIA : 3.48M
GAS TEMP : 90c TO 220C
MOTOR RATING : 1000KW
MOTOR RPM : 989
6.7 PRINCIPLES OF OPERATION
The Plenum- Pulse Dust Collector is a device that accepts a dust-laden atmosphere, filters
it collects the dust and discharges the cleaned air. It mounts above a material handling
device that serves as a hoper to receive the collected dust and as a point of connection for
the manifold which introduces the dust-laden atmosphere to the Plenum-Pulse Dust
Collector.
This dirty air enters the hoper and by reversing the direction of flow any entrained
material having a low velocity will drop directly into hoper. Continuing upward, the air
encounters and surrounds tubular bags supported internally by wire cages, passes through
the bags, and rises inside them to a common clean air plenum from which it is exhausted.
6.8 EQUIPEMENT USED IN PACKING SECTION
6.8.1 CEMENT SILO
In cement silo there are two centrifugal fans. 1st for air slider which takes the atmospheric
air then pass it to the air slider to transfer the cement powder to cement silo with the help
of gravity. 2nd fan is called B.F. fan. It firstly takes the atmospheric air & then converts

it into superheated air and then passes it to the cement silo. From bottom of the silo to
take the cement moisture free in cement silo.
The B.F. pipe is divided into 4 equal pipe. Which are placed in one by one in quarter part
of circle . when air goes from one side of pipe than other side pipe does not operate. It is
controlled by electronic system.
6.8.2 ROTARY PACKER
In contrast with in the line packer with its filling spouts mounted stationary side by side,
requires the machine to move from spout to spout. It moves one by one into the position
of the operator, who merely has to fit the valve sacks onto them as they are five packers.
Machines rotate half-section and bag is filled with 50 kg cement.
6.9 MAINTANCE SECTION
6.9.1 TYPES OF MAINTANCE
1) Preventive maintenance:
It comprises all the activities which are initiated to correct an unacceptable condition to
develop.
2) Corrective maintenance:
It comprises all the activities which are initiated to correct an unacceptable condition.
The main activities with in it are:
1. Cleaning
2. Libretto
3. Over haul
4. Replacement
5. Function test
3) Periodic maintenance:
It can be either time based or production based. Time based is carried out in accordance
with the planning calendar. Where activities are fixed for specific time .

4) Condition based maintenance:
Instead of over haul & replacement at present interval, measurement of actual condition
parameter for a machine can be performed at present intervals.
By comparing the reading it is possible with previous reading it is possible to follow the
development of, a wear pattern or the onset of a fault, and to carry out the maintenance
before breakdown occurs.
6.10 IMPORTANCE OF MAINTANCE
1. Equipment and machines are increasing its capacity, and consequently demand higher
availabilities.
2. The age of equipment is increasing, because of investment in new, or replacement,
facilities are made at longer interval.
3. The demand on reliability and safety have become more stringent it being the task of
maintenance to ensure that they are fulfilled.
4. Environment protection demands a number of new facilities which have to be
maintained.

CONCLUSION
To do my summer training in such an esteemed organization like AMBUJA CEMENT
was a phenomenal learning experience for me. This one month was a joy ride for me in
the mechanical field, and now on completion of my training I can say that I have gained
very sound knowledge in mechanical field.
The Mechanical department in the industry is well equipped with latest technologies and
equipments. All the working of various departments is completely computerized. The
company is following a firm base to adopt new technologies that are coming these days,
this ensures a healthy and prosperous future.
I am highly thankful to Mr. B B Vadhawan under whose expert guidance I did my
training, and came to learn about the various minor and major aspects of mechanical
equipments and all various processing units, which are available here.

SAFETY MEASURES
 Always wear helmet for protection of head.
 Always wear spectacles for protection of dust
 Always wear dust mask to protect dust from entering nose.
 Always wear gloves while doing oily work.
 Always wear shoes to protect our self from electric shock.

BIBLIOGRAPHY
List of web surfed:
 www.ambujacement.com
 www.wikipedia.com
 www.howstuffworks.com

Ambuja Cement plant Industrial report

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