Nuvoco Vistas Corp. Ltd., presented by Ankit Sharma, discusses the comprehensive process of cement manufacturing, highlighting the importance of cement in infrastructure and identifying India as the second-largest producer. The document details the various stages of production, including mining, crushing, grinding, and packing, along with an overview of different cement types and their compositions. Additionally, it emphasizes the role of modern technology in enhancing efficiency and environmental sustainability in cement production.

1. NUVOCO VISTAS CORP. LTD.
PRESENTED BY
ANKIT SHARMA
Btech (7th Sem)
Under The Guidence
Mr Naveen Kumar Vyas
Executive- HR

2. CERTIFICATE

3. CONTENTS
 Introduction
 Cement Manufacturing
 Types of cement
 Flow Chart
 Mining
 Crushing
 Stacker and Reclaimer
 Vertical Raw Mill
 Preheater
 Rotary Kiln
 Cooler
 Grinding
 Roller Press
 Ball Mill
 Package and dispatch

4. INTRODUCTION
 Cement is the glue that holds the concrete together,
and is therefore critical for meeting society's needs
of housing and basic infrastructure such as bridges,
roads, water treatment facilities, schools and
hospitals.
 India is the world's second largest producer of
cement after China with industry capacity of over
200 million tonnes (MT).

5. CEMENT MANUFACTURING
 Cement is made out of limestone, shale, clay mined out of quarry
close to the plant. The raw material is crushed, and then heated at
temperature in excess of 1000 degree Celsius in rotating kiln to
become clinker. Clinker is then mixed with gypsum and ground to a
fine powder to produce final grade of cement.
 The technology is a continuous process and is highlyenergy
intensive.
 At present 93% of cement production in India is based on modern
and environment-friendly dry process technology and only 7% of the
capacity is based on old wet and semi-dry process technology.

6. TYPES OF CEMENT
 Ordinary Portland Cement (OPC).
 Portland Pozzolana Cement (PPC).
 Portland Blast Furnace Slag Cement (PBFS).
 Oil Well Cement.
 Rapid Hardening.
 Sulphate Resisting Portland Cement.
 White Cement etc.

7. PERCENTAGE CONTENTS OF CEMENTS
1.Ordinarily Portland Cement
 Clinker - 90.50%
 Gypsum - 4.00%
 Fly ash - 5.50%
2.Portland Pozzolana Cement
 Clinker - 66%
 Gypsum- 4%
 Fly ash - 30%
3.Portland Blast Furnace Slug Cement
 Clinker - 70%
 Gypsum- 6%
 Slag - 24%

8. FLOW CHART OF CEMENT MANUFACTURING

10. Overview of Mining Operations
The first step of cement production is mining operation. The mining
operationsmay be broken down into three processes:
A. Prospecting: Based on the report submitted by the Geological Survey of
India, prospecting is done to verify the tonnage of limestone. This is
done by drilling holes and testing the samples.
B. Development: Once the limestone reserves have been proven,
development activity starts. Mine development work includes the
activity of removal of top soil and rock overburden. In order to expose
the limestone, top layer of block cotton soil/lateritic soil, ranging in
between 1 to 3 mtrs. is removed.
C. Mining: Mining activities: After the development mining activities may
be subdivided into
a) Drilling
b) Primary blasting
c) Secondary blasting

11. CRUSHING
After the mining operation limestones are feed into the crusher
 Principles of material breakage used in crusher –
• Crushing defined as “pressing between two hard bodies so as to break
into fragments”
• Rock particles striking a hard object
• Rock particles striking other rock particles within the crushing chamber.
 Selection of crusher Depends on:
 Maximum Feed size
 Product specification (size + shape characteristics)
 Throughput – (production rate)
 Location
 Plasticity and Moisture content
 “Stickiness” (clay content) Hardness
 Abrasively/wear costs
 Capital costs.

12.  Types Of Crusher:-
 Jaw Crusher
 Gyratory (Cone) Crusher
 Hammer Crusher
 Roller Crusher
Jaw crusher
Hammer Crusher

13. Cone Crusher

14. Roller Crusher

15. Crusher Benefits Capacity
Cone crusher High reduction ratio, heavy duty
chassis and track frame,
230tph
Hammer
crusher
It produced spacified top size
without the need for a closed
circuit crushing system
900tph
Roller crusher High capacity, low horsepower 10-50tph
Jaw crusher Economical to operate with via
clutchand highly fuel efficient
direct dry system
500tph

16. STAKER & RECLAIMER

17. STAKER & RECLAIMER
• Now a days stacker with fixed or movable booms (which can be raised
and lowered) are used for covered as well as foroutdoor blending
beds. A drawback associated with fixed boom stacker is that dust
nuisance may arise.
• Reclaimer is a machine which removes material from stockpiles. The
materials are dislodged from the pile by the action ofa raking down
device which sweeps across the cross-sectional face. Harrows are
triangular structures fitted renewable teeth and so inclined as to suit
the angle of repose of the stockpile material.
• Subtype
a. Bridge type scraping reclaimer.
b. Bridge type mounted bucket wheel reclaimer
c. Bucket wheel reclaimer with slewing boom

18. VERTICAL RAW MILL

19. RAW MILL
After the stacking & reclaiming, the limestones are feed to mill for
grinding. The most common equipment is VerticalRoller mill.
 The term “Vertical mill” denotes equipment with the following basic
characteristics:
 A rotating, circular grinding table that turns around a vertical shaft.
 Spherical, cylindrical, tapered rollers (the grinding elements) that are
pressed into (grooved) roller surface of thetable.
 A source of pressure on the rollers (weight, hydraulic pressure, springs,
etc.).
 A stream of gas flowing upwards around the table, entraining and
drying the material.
 A separator mounted directly on the mill housing.

20. VERTICAL RAW MILL
In Chittorgarh cement plant they are using VRM as raw mill to
grind raw material like limestone,Sweatner,red orcher,laterite
etc. It’s a Pfeiffer VRM.
Vertical Raw Mill
Capacity:
Grinding Fineness:
Product Moisture:
Main Drive System-
Motor Type:
Power:
Voltage:
Speed:
400 TPH
90 µm
≤ 0.5%
YRKK900-6TH
4600 KW
6.6 KV
995 RPM

21. PREHEATER
 Manufacturers CEMTEK GROUP LTD.
i. PURPOSE- used for 5000t/d cement production line to preheat and
decompose raw meal.
ii. The 5000t/d kiln preheater system with the tiff calciner.
iii. Its structure includes cyclone, air duct, discharge pipe, Calciner,
feeding pallet in feeding chamber etc.
 The preheater system consists of cyclone, air duct, discharge pipe,
feeding chamber etc.
 Raw meals feed into the system from the inlet of the C1-C2 air duct
With ascending gas flow,
 The raw meal enters into the C1 cyclone through the air ductin this
cyclone raw meal are collected by vortex, pass through the discharge
pipe of C1, and enter into the C2-C3 air duct.
 There is a spread box in the outlet of the discharging pipe in order to
make the material more disturbing in ascending gas flow. so the raw
meal and gas flow can get sufficient heat exchange. The process of the
other cyclones above for C4 is the same as stated above.

22. PREHEATER

23. ROTARY KILN

24. ROTARY KILN
TECHNICAL DATA
1) Diameter of kiln
2) Length of kiln
3) Slop
4) Number of supporting device
5) Capacity
6) Rotating Speed
7) Power of main drive
8) Power of auxiliary drive
4.8 m
72 m
3.5%
3
6000 t/d
• Driven by main drive - 0.4 to 4 rpm
• Driven by auxiliary drive – 9.52 r/h
720 KW with 1500 RPM
55 KW with 1480 RPM

25. PYRO PROCESSING
 During this process raw meal material is converted to clinker. This requires
a selected mixture of raw materials, at veryhigh temperature, in a
specialized kiln system. Fuel(coal, oil) is fired to sinter the raw material.
 Calcium(C), silicon (S), aluminum (A) & Iron (F) in raw materials react to
form main clinker minerals.
The phases in clinkers are-
 C3S-Alite or C3S contributes to early strength formation, Has a high heat of
hydration
 C2S-Belite hardens slowly & contributes to later strength. It has a low heat of
hydration compare to C3S.Thecontent of C2S in low heat cement used for the
castings of large foundations is high.
 C3A-It sets quickly and contributes to early strength but minimally to final
strength .
 C3A also has a high heat of hydration. Higher concentrations of C3A can react
with sulphate causing expansion and crack formation exposingmore C3A
leading to further penetration of sulphates.
 C4AF-imparts a dark colour to the cement

26. COOLING ZONE / COOLER
Type
Capacity
Aerated area
Stroke times
Temperature of inlet Clinker
Temperature of outlet Clinker
TC – 12102
6000 T/D
119.3 m3
15 ~ 18 /m
1450
65+ Ambient Temperature °c
The cooler will act as a source of hot air for the preheater and the
rotary kiln. It will boost the clinker production line's thermal efficiency.
At the same time, the clinker production line's energy consumption
levels decline. It warms up air to generate waste heat power.
Modern clinker coolers have an air flow perpendicular to the
clinker flow, absorbing thermal energy. This hot air is used almost
entirely as secondary air for combustion in the rotary kiln, or as
tertiary air to the tertiary air duc

27. COOLING ZONE / COOLER

28. GRINDING
GRINDING PRINCIPLE
Two types of motions of balls do finish grinding in ball mills. First clinker is
crushed by cascade motion of balls, which occurs in step liner zone then it is
finish ground by attrition due to cataract motion of balls in classifying liner
zone. Thismechanism is depicted below.
FINISHED GRINDING
Crushed Clinker is mixed with gypsum & fed into Cement Mill for fine size
reduction.Gypsum is added to control setting time of cement.
Circuit Types: Open circuit Ball Mill, Closed circuit Ball Mill, Roller Press with
Ball Mill, Vertical roller mil circuit. Horro millDepending on final Cement
requirements Fly ash or Slag is added along with Clinker. Mostly the finish
grinding of clinker is done by BALL MILLS. These are called ball mills because
they have manganese steel balls of different sizes inside them.

29. ROLLER PRESS
 Roller presses are mainly used as a pre-grinder for capacity increase.
 Specific energy for grinding is significantly reduced when used in
conjunction with ball mills.
 Integral grinding with a high recirculation rate.
 Applies the concept of high-pressure transfer through a bed of
material.
 Pressure across the bed has a compacting effect on material which is
crushed and gradually reduces size
 Stability ensured by uniform feed control
 Can be utilized in various configurations
 Specific energy for grinding is significantly reduced when used in
conjunction with ball mills.

30. ROLLER PRESS

31.  ROLLER PRESS PARAMETERS-
Output increases proportionally with:
 Diameter
 Length
 Speed of the press.
Of course, there is also an influence by the-
 Profile of the surface,
 Rejects to RP and fresh feed,
 Moisture of feed to RP
 Material type

32. BALL MILL
A ball mill is a type of grinder used to grind or blend materials
for use in mineral dressing processes, paints, pyrotechnics,
ceramics, and selective laser sintering. It works on the principle
of impact and attrition: size reduction is done by impact as the
balls drop from near the top of the shell.
 Specification
1) Capacity
2) Power of main motor
3) Rotating speed of mill
4) Weight of grinding media
5) Effective length
6) Effective inner diameter
7) Total weight
420 t/h
3550 KW
15.6 RPM
230 t
12.5 m
4.05
235 t

33. BALL MILL

34. PACKING AND DISPATCH
Cement packing machine is a kind of cement equipment which is necessary for
the production of bagged cement. It is mainly used to complete the automatic
packing of cement and other powder materials with good fluidity, such as fly
ash,gypsum powder, cement additives, etc.
Most of the cement plants are using roto pakers these days for packing. After
the packing in bags, it is sent to differentarea by trucks/railway transport.

35. PACKING AND DISPATCH

36. THANK YOU….