This document provides an overview of cement manufacturing processes and equipment. It discusses ball mills which are used to grind clinker into fine powder. It also describes rotary kilns which produce clinker by heating limestone and clay at high temperatures. The document notes that temperature control is important during grinding to regulate the hydration process. It also discusses roller mills and their more efficient grinding compared to ball mills. Finally, it covers gas tungsten arc welding which is used to join metal components through heating with an electric arc under inert gas protection.

1. 1
CHAPTER– 1
INTRODUCTION
1.1 INTRODUCTION TO ORGANISATION
With roots that date back to more than 43 years, we introduce ourselves as a
company that offers high quality turnkey project services. We are committed to
providing the highest level of service and expertise, producing superior results for
our clients.
We offer turnkey solution for cement plants, sugar plants, paper plants, fertiliser
plants, mineral processing unit and major engineering industries like Demag,
Loesche & KHD Humboldt wedag of Germany, Voestalpine of Austria, and Fuller
of India. With systematic approach and a strong client base, we have maintained
our front runner position in the Industry. [1]
Table 1.1 Company Profile [1]
Nature of business Manufacturer
Additional business Exporter, Trader
Company CEO Mr. Sudhir Chandra
Year of establishment 1962
Number of employees 300 to 400
Annual turnover 50 Lakh – 1 Crore approx.
Size of premises 10,000 square feet
Website www.chanderpur.com
Products Manufacturing and Trading are Ball mills, Biomass gasifiers, Rotary
kilns, Pressure vessels, Heat exchangers, Belt conveyors, Elevators, Lime
processing machinery, Material handling equipment, Cranes, Granulators,
Clarifiers, Screens, Dryer and Coolers.
1.2 IN PURSUIT OF EXCELLENCE
We are pouring our best in research, production and quality control to widely
expand its wings into vast Indian and overseas market. We are an ISO-9001
certified company. Our shop is approved for manufacturing by Chief Inspector of
Boilers, Chief Controller of Explosives India. All the equipment are manufactured

2. 2
to International Standards of ASME, ASTM, TEMA, DIN, BIS specifications and
are cleared by International inspection agencies like SGS, Lloyds Register,
Inspectorate Griffith and Tata Projects Ltd.[1]
1.3 OUR PRODUCTS
Apart from providing turnkey plants, we are also involved in offering multiple
products with increase area of operations. The product range consists of ball mills,
rotary kilns, material handling systems and many more. These products are
manufactured in compliance with set industrial standards using advanced
technological standards. We use quality material while manufacturing these
products and also consider client’s requirement for customization. [1]
1.4 OUR VISIONS
Keeping the spirit of “Racing ahead of times”, we strive to move ahead with
never-ending zeal, technological up-gradations, rapid expansion & user-friendly
innovations to be the trendsetter in Integrated Engineering Business. [1]
1.5 OUR PATRONS
Our clients have appreciated our quest for excellence by establishing a long lasting
relationship, which speaks volumes about our commitment in providing complete
customer satisfaction. Our list of clients includes majority of customers who gave
us repeat orders, which certifies our quality, customer satisfaction and good
relations with the customers. [1]

3. 3
CHAPTER – 2
PROJECT WORK
2.1 BALL MILL
2.1.1 DESCRIPTION
A ball mill is a horizontal cylinder partly filled with steel balls that rotates on its
axis, imparting a tumbling and cascading action to the balls. Material fed through
the mill is crushed by impact and ground by attrition between the balls. The
grinding media are usually made of high-chromium steel. The smaller grades are
occasionally cylindrical rather than spherical. There exists a speed of rotation
("critical speed") at which the contents of the mill would simply ride over the roof
of the mill due to centrifugal action.
The critical speed (rpm) is given by,
N = 42.29/√d
Where, d is the internal diameter in metres.
Ball mills are normally operated at around 75% of critical speed, so a mill with
diameter 5 metres will turn at around 14 rpm.
Figure 2.1.1 Ball Mill [12]

4. 4
The mill is usually divided into at least two chambers allowing the use of different
sizes of grinding media. Large balls are used at the inlet, to crush clinker nodules
(which can be over 25 mm in diameter). Ball diameter here is in the range 60–
80 mm. In a two-chamber mill, the media in the second chamber are typically in
the range 15–40 mm, although media down to 5 mm are sometimes encountered.
As a general rule, the size of media has to match the size of material being ground:
large media can't produce the ultra-fine particles required in the finished cement,
but small media can't break large clinker particles.
A current of air is passed through the mill. This helps keep the mill cool, and
sweeps out evaporated moisture which would otherwise cause hydration and
disrupt material flow. The dusty exhaust air is cleaned, usually with bag filters. [3]
Figure 2.1.2 Ball Mill Layout [3]
2.1.2 WORKING
In case of continuously operated ball mill, the material to be ground is fed from the
left through a 60° cone and the product is discharged through a 30° cone to the
right. As the shell rotates, the balls are lifted up on the rising side of the shell and
then they cascade down (or drop down on to the feed) from near the top of the
shell. In doing so, the solid particles in between the balls are ground and reduced in
size by impact. [2]
2.1.3 APPLICATIONS
The ball mill is used for grinding materials such as coal, grains and feldspar for
pottery. Grinding can be carried out either wet or dry but the former is performed

5. 5
at low speed. Blending of explosives is an example of an application for rubber
balls. For systems with multiple components, ball milling has been shown to be
effective in increasing solid state chemical reactivity. Additionally, ball milling has
been shown effective for production of amorphous materials. [2]

6. 2.2 ROLLER MILL
2.2.1 DESCRIPTION
Roller mills are those mills that use cylindrical rollers, either in opposing pairs or
against flat plates, to crush or grind various materials, such
as grains, ores, gravels, plastics and others. Recently roller mills in combination
with high efficiency separators have been used for cement grinding. The grinding
action employs much greater stress on the material than in a ball and is therefore
more efficient. Energy consumption is typically half that of a ball mill and the
process has yet to receive wide acceptance. [4]
Figure 2.2.1 Roller Mill [13]
2.2.2 WORKING PRINCIPLE
While working, motor drives the hanger of the grinding roller to rotate through V
pulley and centre bearing. The roller, which is hung by bearing and pendulum
shaft, will roll along the inner circle of the roll ring while the hanger is rotating. A
dust removal blower will generate negative pressure at the inlet and outlet of the
grinder to prevent dust and radiating the heat in the machine. [4]
2.2.3 APPLICATIONS
 Specialized for the high production of superfine powder making in glass
fibre industry.
 Specialized for the high production of gangue powder making in coal industry.
 Specialized for the high production of various of chemical raw material powder
making in the chemical industry.[4]
Roller 3
Roller 2Roller 1

7. 7
2.3 ROTARY KILN
2.3.1 DESCRIPTION
A rotary kiln is a pyro-processing device used to raise materials to a high
temperature in a continuous process. Materials produced using rotary kilns include
Cement, Lime, Alumina, Iron ore pellets etc. [5]
Figure 2.3.1 Rotary Kiln [5]
2.3.2 CONSTRUCTION
The basic components of a rotary kiln are the shell, the refractory lining, support
tyres (riding rings) and rollers, drive gear and internal heat exchangers. [5]
2.3.3 WORKING
The kiln is a cylindrical vessel, inclined slightly to the horizontal, which is rotated
slowly about its longitudinal axis. The process feedstock is fed into the upper end
of the cylinder. As the kiln rotates, material gradually moves down toward the
lower end, and may undergo a certain amount of stirring and mixing. Hot gases
pass along the kiln, sometimes in the same direction as the process material (co-
current), but usually in the opposite direction (counter-current). The hot gases may
be generated in an external furnace, or may be generated by a flame inside the kiln.
Such a flame is projected from a burner-pipe (or "firing pipe") which acts like a
large Bunsen burner. The fuel for this may be gas, oil, pulverized petroleum coke
or pulverized coal. [5]

8. 8
Figure 2.3.2 Rotary Kiln Layout [5]
2.3.4 OTHER EQUIPMENTS
The kiln connects with a material exit hood at the lower end and ducts for waste
gases. This requires gas-tight seals at either end of the kiln. The exhaust gas may
go to waste, or may enter a preheater which further exchanges heat with the
entering feed. The gases must be drawn through the kiln, and the preheater if fitted,
by a fan situated at the exhaust end. In preheater installations which may have a
high pressure-drop, a lot of fan power may be needed, and the fan is often the
largest drive in the kiln system. Exhaust gases contain dust and there may be
undesirable constituents such as sulphur dioxide or hydrogen chloride. Equipment
is installed to scrub these from the gas stream before passing to the atmosphere. [5]

9. 9
2.4 SYSTEM REQUIREMENTS
Portland cement gets its strength from chemical reactions between the cement and
water. The process is known as hydration. This is a complex process that is best
understood by first understanding the chemical composition of cement. [6]
2.4.1 MANUFACTURE OF CEMENT
Portland cement is manufactured by crushing, milling and proportioning the
following materials:
 Lime or calcium oxide, CaO: from limestone, chalk, shells, shale or calcareous
rock.
 Silica, SiO2: from sand, old bottles, clay or argillaceous rock.
 Alumina, Al2O3: from bauxite, recycled aluminium, clay.
 Iron, Fe2O3: from clay, iron ore, scrap iron and fly ash.
 Gypsum, CaSO4.2H20.
The materials, without the gypsum, are proportioned to produce a mixture with the
desired chemical composition and then ground and blended by one of two
processes - dry process or wet process. The materials are then fed through a kiln at
2,600º F to produce greyish-black pellets known as clinker. The alumina and iron
act as fluxing agents which lower the melting point of silica from 3,000 to 2600º F.
After this stage, the clinker is cooled, pulverized and gypsum added to regulate
setting time. It is then ground extremely fine to produce cement. [6]
2.4.2 PROPERTES OF CEMENT
These compounds contribute to the properties of cement in different ways:
 Tricalcium aluminate (Ca3Al2O6)
It liberates a lot of heat during the early stages of hydration, but has little strength
contribution. Gypsum slows down the hydration rate of C3A. Cement low in C3A
is sulphate resistant. [6]
 Tricalcium silicate (Ca3SiO5)
This compound hydrates and hardens rapidly. It is largely responsible for Portland
cement’s initial set and early strength gain. [6]
 Dicalcium silicate(Ca2SiO4)
C2S hydrates and hardens slowly. It is largely responsible for strength gain after
one week.
[6]

10. 10
 Ferrite (Fe2O3)
This is a fluxing agent which reduces the melting temperature of the raw materials
in the kiln (from 3,000o
F to 2,600o
F). It hydrates rapidly, but does not contribute
much to strength of the cement paste. [6]
2.4.3 TEMPERATURE CONTROL
Heat generated in the grinding process causes gypsum (CaSO4.2H2O) to lose water,
forming bassanite (CaSO4.0.2-0.7H2O) or γ-anhydrite (CaSO4~0.05H2O). The latter
minerals are rapidly soluble, and about 2% of these in cement is needed to
control tricalcium aluminate hydration. If more than this amount forms,
crystallization of gypsum on their re-hydration causes "false set" - a sudden
thickening of the cement mix a few minutes after mixing, which thins out on re-
mixing. High milling temperature causes this. On the other hand, if milling
temperature is too low, insufficient rapidly soluble sulphate is available and this
causes "flash set" - an irreversible stiffening of the mix. Obtaining the optimum
amount of rapidly soluble sulphate requires milling with a mill exit temperature
within a few degrees of 115 °C. [3]
2.4.4 CLINKER HARDNESS
The hardness of clinker is important for the energy cost of the grinding process. It
depends both on the clinker's mineral composition and its thermal history. The
easiest-ground clinker mineral is “alite”, so high alite clinkers reduce grinding
costs, although they are more expensive to make in the kiln. The toughest mineral
is “belite”, because it is harder, and is somewhat plastic, so that crystals tend to
flatten rather than shatter when impacted in the mill. The mode of burning of the
clinker is also important. Clinker rapidly burned at the minimum temperature for
combination, then rapidly cooled, contains small, defective crystals that grind
easily. These crystals are usually also optimal for reactivity. On the other hand,
long burning at excess temperature, and slow cooling, lead to large, well-formed
crystals that are hard to grind and un-reactive. The effect of such a clinker can be
to double milling costs. [3]

11. 11
Figure 2.4.1 Cement Clinkers [14]
2.4.5 KEY PROPERTIES OF GRINDING MEDIA
 Size: The smaller the media particles, the smaller the particle size of the final
product. At the same time, the grinding media particles should be substantially
larger than the largest pieces of material to be ground.
 Density: The media should be denser than the material being ground. It becomes a
problem if the grinding media floats on top of the material to be ground.
 Hardness: The grinding media needs to be durable enough to grind the material,
but where possible should not be so tough that it also wears down the tumbler at a
fast pace.
 Composition: Various grinding applications have special requirements. Some of
these requirements are based on the fact that some of the grinding media will be in
the finished product. Others are based in how the media will react with the material
being ground.[2]

12. 12
2.5 WELDING TECHNIQUES
Welding is a fabrication or sculpture process that joins materials, usually metals or
thermoplastics, by using high heat to melt the parts together and allowing them to
cool causing fusion. Welding is distinct from lower temperature metal-joining
techniques such as brazing and soldering, which do not melt the base metal. [8]
2.5.1 GAS TUNGSTEN ARC WELDING (GTAW)
TIG stands for tungsten inert gas and is technically called gas tungsten arc welding
(GTAW). The process uses a non-consumable tungsten electrode that delivers the
current to the welding arc. The tungsten and weld puddle are protected and cooled
with an inert gas, typically argon. [9]
2.5.1.1 TIG WELDING PRINCIPLE
In the Gas Tungsten Arc Welding (GTAW) metals are fused together by heating
them by an electric arc established between a non-consumable (does not melt)
tungsten electrode and the work piece. A filler metal may be used depending on the
design of the joint. The molten metal, tungsten electrode and the welding zone are
shielded from the atmosphere (the air around it) by a stream of inert gas through
the welding torch.
Figure 2.5.1 Gas Tungsten Arc Welding [15]

13. 13
The melting temperature necessary to weld materials in the Gas Tungsten Arc
Welding (GTAW) process is obtained by maintaining an arc between a tungsten
alloy electrode and the work piece. Weld pool temperatures can approach 2500 °C.
An inert gas sustains the arc and protects the molten metal from atmospheric
contamination. The inert gas is normally argon, helium, or a mixture of helium and
argon. [10]
2.5.1.2 APPLICATIONS
It is a particularly effective and economic way for welding light metals (under
3mm thickness) and for welding metals difficult to weld with the conventional
welding process. Such metals include the following:
 Aluminium and Aluminium alloys
 Copper and copper alloys
 Nickel and nickel alloys
 Magnesium and magnesium alloys
 Low alloy steel and carbon steels
 Reactive materials (for example, titanium and tantalum)
 Joining carbon and alloy steels
Gas Tungsten Arc Welding (GTAW) finds application in industries such as
aerospace industry is one of the primary users of gas tungsten arc welding, the
manufacturing of metal furniture, sheet metal works and in automotive body
works.[10]

14. 14
2.5.2 SUBMERGED ARC WELDING (SAW)
This process requires a continuously fed consumable solid or tubular (metal cored)
electrode. The molten weld and the arc zone are protected from atmospheric
contamination by being "submerged" under a blanket of granular fusible flux
consisting of lime, silica, manganese oxide, calcium fluoride and other compounds.
When molten, the flux becomes conductive, and provides a current path between
the electrode and the work. This thick layer of flux completely covers the molten
metal thus preventing spatter and sparks as well as suppressing the intense
ultraviolet radiation and fumes. [11]
2.5.2.1 FEATURES
It feeds flux and filler metal to the welding joint. Electrode (filler metal) gets
energized here. [11]
 Flux hopper
It stores the flux and controls the rate of flux deposition on the welding joint. [11]
 Flux
The granulated flux shields and thus protects molten weld from atmospheric
contamination. The flux cleans weld metal and can also modify its chemical
composition. The flux is granulated to a definite size. It may be of fused, bonded or
mechanically mixed type. The flux may consist of fluorides of calcium and oxides
of calcium, magnesium, silicon, aluminium and manganese. Alloying elements
may be added as per requirements. Substances evolving large amount of gases
during welding are never mixed with the flux. [11]
 Electrode The electrode composition depends upon the material being welded.
Alloying elements may be added in the electrodes. Electrodes are available to weld
mild steels, high carbon steels, low and special alloy steels, stainless steel and
some of the nonferrous of copper and nickel. Electrodes are generally copper
coated to prevent rusting and to increase their electrical conductivity. Electrodes
are available in straight lengths and coils. Their diameters may be 1.6, 2.0, 2.4, 3,
4.0, 4.8, and 6.4 mm. The approximate value of currents to weld with 1.6, 3.2 and
6.4 mm diameter electrodes are 150–350, 250–800 and 650–1350 Amps
respectively. [11]

15. 15
Figure 2.5.2 Submerged Arc Welding [11]
2.5.2.2 WELDING OPERATION
The flux starts depositing on the joint to be welded. Since the flux when cold is
non-conductor of electricity, the arc may be struck either by touching the electrode
with the work piece or by placing steel wool between electrode and job before
switching on the welding current or by using a high frequency unit. In all cases the
arc is struck under a cover of flux. Flux otherwise is an insulator but once it melts
due to heat of the arc, it becomes highly conductive and hence the current flow is
maintained between the electrode and the work piece through the molten flux. The
upper portion of the flux, in contact with atmosphere, which is visible remains

16. 16
granular (unchanged) and can be reused. The lower, melted flux becomes slag,
which is waste material and must be removed after welding.
A backing plate of steel or copper may be used to control penetration and to
support large amounts of molten metal associated with the process. [11]

17. 17
CHAPTER – 3
RESULT AND DISCUSSION
3.1 RESULT
The basic function is to maintain the product quality and provide efficient after
sales service at a single alert, continuously improving the efficiency and providing
solutions endlessly and to exceed customer expectation by innovating new product
and optimising ongoing product performance.
3.2 DISCUSSION
Supervisors involved in maintenance of the product should be familiar with areas
prone to corrosion.
Supervisors should educate their technicians about areas prone to corrosion.
Supervisors should educate their cleaning staff so that they follow cleaning
techniques.

18. 18
CHAPTER – 4
CONCLUSION
4.1 CONCLUSION
It can be concluded that Chanderpur Works is a modernised and well-equipped
industry form every aspect whether it is manufacturing process. During this project
period, I got valuable knowledge regarding the most modern techniques used by
Chanderpur Works Pvt. Ltd.
This project also made me familiar with many machines & instruments used in
workshop. The management & employees are very helpful. I hope that the valuable
knowledge I have gain here will help me in future.

19. 19
REFERENCES
1) http://m.chanderpur.com/about-us.html
2) https://en.m.wikipedia.org/wiki/Ball_mill
3) https://en.m.wikipedia.org/wiki/Cement_mill
4) https://en.m.wikipedia.org/wiki/Roller_mill
5) https://en.m.wikipedia.org/wiki/Rotary_kiln
6) https://www.engr.psu.edu/ce/courses/ce584/concrete/library/construction/curing/co
mposition%20of%20cement.htm
7) http://www.wballoys.co.uk/TIG/what-is-tig-welding.html
8) https://en.m.wikipedia.org/wiki/Welding
9) https://www.millerwelds.com/resources/article-library/tig-it-how-a-tig-welder-
works-and-when-to-tig-weld
10) http://www.wballoys.co.uk/TIG/what-is-tig-welding.html
11) https://en.m.wikipedia.org/wiki/Submerged_arc_welding
12) http://www.mech4study.com/2017/10/difference-between-sag-mill-vs-ball-
mill.html
13) https://thewholetruth.org/res_oat.asp
14) https://www.exportersindia.com/grandcanyon-infracon-private-limited/cement-
clinker-2581832.html
15) https://en.m.wikipedia.org/wiki/Gas_tungsten_arc_welding