This document provides information about DG Khan Cement Company Limited, which is a major cement producer in Pakistan. It discusses the company's operations, including its plants, production capacity, quality standards, and expansion projects. The document also provides background on the cement production process and details about the company's awards and achievements, such as setting new production records.

1. Preface
Learning in practical
side is somewhat that
cannot be compared
with books
knowledge. Bs
Chemical Engineering
and Technology
program is designed
in such a way that
Internship Report
DG Khan Cement Company Limited
Adeel Arif
Syed Faizan Haider Shah
Nabeel Ahmed
Department Of Chemical Engineering
UET, Lahore

2. Executive Summary
Dera Ghazi Khan Cement Company Limited is a strategic business unit of Nishat
Group, which is the largest industrial group in Pakistan. D.G. Khan Cement
Company is market leader with respect to market share with about 11.4% market
share. Apart from its competitors; its product is high priced yet it has highest market
share because of good quality. Its plant is situated in Dera Ghazi Khan and Khair Pur
and head office is situated at Lahore.
Factory site Unit 1and 2 that is situated in very remote area of Punjab, yet it proved a
blessing for the company. Because it has all three basic raw materials i.e. Lime stone,
Shale, and Gypsum at one place. It has three plants working two in D.G. khan and
one in Khair Pur. First plant is old one and it is Japanese plant. The other two plants
are of F.L.Smiths, Denmark. Presently it has a total Installed capacity of 13000
tpd(tons per day). Presently the company is also exporting the cement to
Afghanistan, Iraq, UAE and Russia. The team of the D.G. Cement is story of success
of D.G. Cement. The whole team is self-motivated and had played a vital role in the
success of the company.
D.G. Khan Cement Company Ltd
Introduction
D.G. Khan Cement Company Limited (DGKCC), a unit of Nishat group, is the
second largest cement-manufacturing unit in Pakistan with a production capacity of
6700 tons clinker per day. It has a countrywide distribution network and its products
are preferred on projects of national repute both locally and internationally due to the
unparallel and consistent quality. It is list on all the Stock Exchanges of Pakistan.
DGKCC was established under the management control of State Cement Corporation
of Pakistan Limited (SCCP) in 1978. DGKCC started its commercial production in
April 1986 with 2000 tons per day (TPD) clinker based on dry process technology.
Plant & Machinery was supplied by UBE Industries of Japan.
Nishat Group
Nishat Group is one of the leading and most diversified business groups in South
East Asia. With assets over PRs.300 billion 0r $3.5 billion, it ranks amongst the top
five business houses of Pakistan. The group has strong presence in three most
important business sectors of the region namely Textiles, Cement and Financial
Services. In addition, the Group has also interest in Insurance, Power Generation,
Paper products and Aviation. It also has the distinction of being one of the largest
players in each sector. The Group is considered at par with multinationals operating
locally in terms of its quality of products & services and management skills.
Mian Mohammad Mansha:
The chairman of Nishat Group continues the spirit of Entrepreneurship and has led
the Group successfully to make it the premier business group of the region. The
group has become a multidimensional corporation and has played an important role
in the industrial development of the country. In recognition of his unparallel
contribution, the Government of Pakistan has also conferred him with “Sitara-e-

3. Imtiaz”, one of the most prestigious civil awards of the country. Expansion -
Khairpur Project:
The Group has also set up a new cement production line of 6,700 TPD clinker near
Kalar Kahar, Distt, Chakwal, the single largest production line in the country. First of
its kind in cement industry of Pakistan, the new plant have two strings of pre-heater
towers, the advantage of twin strings lies in the operational flexibility whereby
production may be adjusted according to market conditions. The project equipped
with two vertical cement grinding mills. The cement grinding mills are first vertical
Mills in Pakistan. The new plant is not only increasing the capacity but also
providing proximity to the untapped market of Northern Punjab and NWFP besides
making it more convenient to export to Afghanistan from northern borders.
Power Generation:
For continuous and smooth operations of the plant uninterrupted power supply is
very crucial. The company has its own power generation plant along with WAPDA
supply. The installed generation capacity is 23.84 MW.
Environmental Management:
DG Khan Cement Co. Ltd., production processes are environment friendly and
comply with the World Bank’s environmental standards. It has been certified for
“Environment Management System” ISO 14001 by Quality Assurance Services,
Australia. The company was also certified for ISO-9002 (Quality Management
System) in 1998. By achieving this landmark, DG Khan Cement became the first and
only cement factory in Pakistan certified for both ISO 9002 & ISO 14001...
Acquisition of DGKCC by Nishat Group
Nishat Group acquired DGKCC in 1992 under the privatization initiative of the
government. Starting from the privatization, the focus of the management has been
on increasing capacity as well as utilization level of the plant. The company
undertook the optimization by raising the capacity immediately after the privatization
by 200tpd to 2200tpd in 1993. Now a day the export demand of D.G cement is 2000
TPD. Presently D.G.K.C.C export cement to Afghanistan, Iraq AND UAE.
(Pakistan Cement Industry)
Vision Statement
To transform the Company into modern and dynamic cement manufacturing
company with qualified professional and fully equipped to play a meaningful role on
sustainable basis in the economy of Pakistan.
Mission Statement
To provide quality products to customers and explore new markets Promote/expand
sales of the Company through good governance and foster a sound and dynamic
team, so as to achieve optimum prices of products of the company for sustainable and
equitable growth and prosperity of the Company.

4. Company Awards and Achievements
DG Khan Cement Company Limited (DGKCC) has broken a world record in
operational excellence. This outstanding achievement was marked by the Danish
world leading company FLSMIDT awarding DG Khan Cement Company Limited
(DGKCC) with its global outstanding achievement award 2011.
The award was presented to the CEO of DGKC, Mr. Raza Mansha by the Danish
Ambassador, During financial year 2009-10, DG Khan Cement Company Limited
(DGKCC), Khairpur Plant has made new global records by achievement ever highest
clinker production of over 2.281 million tons with a kiln capacity utilization of 104%
and plant operational days of 346.5.
In recognition of this success, the Board of Management of FLSmidth A/s, Denmark
has given an Outstanding Achievement Award to DG Khan Cement Company
Limited (DGKCC), on a global basis for outperforming the World standard run factor
criterion for rotary cement kilns of 330 days per year at its Khairpur Plant during the
financial year 2009-10 by running it for 346.5 days at 104% of the rated capacity.
The award was presented, to Mr. Raza Mansha Chief Executive of DG Khan Cement
Company Limited (DGKCC), by the Ambassador of Denmark, H.E. Mr.Uffe
Wolffhechel and FLSmidth Vice President Mr. Kristian A. Gregersen in a ceremony
held at a prestigious local hotel in Lahore.
Mr. Raza Mansha congratulated General Manager Works Dr. Arif Bashir and his
team members for their outstanding performance. Concluding his speech, Mr. Raza
Mansha emphasized the need to work jointly for reducing the cost of production
through new technologies and by using alternate fuels. Mr. Raza Mansha highlighted
in particular the contributions of DG Khan Cement Company Limited (DGKCC) to
control pollution by incorporating latest environment friendly technologies and their
role to uplift the socio economic status of populations living both in DG Khan and
Chakwal Districts. All this has enabled DG Khan Cement Company Limited
(DGKCC) to produce the outstanding results and enabled DG Khan Cement
Company Limited (DGKCC) to efficiently outperform the best of the best in the
world and made them eligible to receive the F.L.Smiths Outstanding Achievement
Award.
Business Process
1. Cement acts as a binding agent, holding particles of aggregate together form
concrete.
2. Cement production is highly energy-intensive process and involves the
chemical combination of calcium carbonate (limestone), silica, alumina and
small amounts of other materials.
3. Burning limestone to make clinker produces cement, and the clinker is blended
with additives and then finely ground to produce different cement types.

5. Key Steps:
The raw materials needed to produce cement are:
1) Shale 2) Limestone 3) Bauxite (Aluminium) 4) Gypsum 5) Iron ore
Short cement Production Process
D. G. Khan Cement factory adopt true dry production process for the manufacturing
of cement. This process consists of following steps.
Drilling:
Drilling is done in the quarry with the help of drilling machine.
They create a space for the powder explosive.
Blasting
The powder explosive is blasted under a controlled process to get different small
segments of limestone. The large segments are also converted into small segments
which is called crushing process.
Transportation
The small fragments are loaded on the 7-Km long 3 belts conveyor system running
over rough terrain. This conveyor takes the new material from quarry to the factory
site. The limestone and shale to stored in the open space.
Grinding
After storage, the stored limestone and shale are fed to the raw mill with the help of
two hoppers according to predetermined mixed proportion. The roughly crushed
material passed through 3 rollers. The mixture is dehydrated, sized, and fine
particulars are separated.
Packing
In the packing unit, there are 4 rotary packers and each packer has 8 nozzles. The
whole packing process is automatic. Cement bags are loaded on the trucks.
Each cement bag has 50 Kg weight. Sometimes heavy users ask for bulk quantity of
cement without packing. It is loaded into the truck.
Loading
The final sample is taken when the packed cement is loaded on the truck. The some
four tests are performed as it is performed in cement mill. If the cement is not up to
the mark dispatch is stopped otherwise no problem.

6. Distribution
For the efficient distribution, the company open its four sales offices in four different
cities.
 Multan
 D. G. Khan
 Lahore
 Karachi

7. History of Cement:
Portland cement was developed from natural cements made in Britain in the early
part of the nineteenth century, and its name is derived from its similarity to Portland
stone, a type of building stone that was quarried on the Isle of Portland in Dorset,
England.
Joseph Aspdin, a British bricklayer from Leeds, in 1824 was granted a patent for a
process of making cement which he called Portland cement. His cement was artificial
cement similar in properties to the material known as "Roman cement" (patented in
1796 by James Parker) and his process was similar to that patented in 1822 and used
since 1811 by James Frost who called his cement "British Cement".
The name "Portland cement" is also recorded in a directory published in 1823 being
associated with a William Lockwood, Dave Stewart, and possibly others. Aspdin's
son William, in 1843, made an improved version of this cement and he initially
called it "Patent Portland cement" although he had no patent.
In 1848 William Aspdin further improved his cement and in 1853 he moved to
Germany where he was involved in cement making. Many people have claimed to
have made the first Portland cement in the modern sense, but it is generally accepted
that it was first manufactured by William Aspdin at North fleet, England in about
1842. The German Government issued a standard on Portland cement in 1878
What is a Cement
Cements are adhesive materials, which are capable of bonding together fragments or
particles of solid matter into a compact hole. Cements may be classified into two
groups: i.e., Non-Hydraulic and Hydraulic Cement.
I) Non-Hydraulic Cements are those which are either not able to set and harden in
water (e.g., Non-hydraulic lime) or which are not stable in water (e.g., Plaster of
Paris), Gypsum mortar and lime mortars.
GYPSUM MORTARS: Calcined gypsum when mixed with small quantity of water,
the setting and hardening of the material is due to the recombination of calcined
gypsum with the water of crystallization that had been driven off during the burning
process:
2CaSO4.2H2O Heat 2CaSO4.1/2H2O + 3H2O
Gypsum based matters are non-hydraulic, i.e., hardening will not take place under
water because gypsum is quite soluble.
LIME MORTARS: Lime mortars are prepared by calcining limestone.
CaCO3 Heat CaO + CO2
Lime mortar is sometimes known as AIR MORTAR, since it hardens in air. The
hardening is due essentially to the evaporation of the mixing water. A secondary
reaction is then the subsequent carbonation:

8. CaO + H2O Ca(OH)2 CaCO3 CO2 + H2O
Although the hardened matter is quite impervious to water, the hardening will not
take place under water.
II) HYDRUALIC CEMENT: Hydraulic cements are able to set and harden under
water. Portland cement is the most important and widely used hydraulic cement. It is
made by heating a mixture of limestone and clay/shale, to a temperature at which
partial fusion occurs. The product, which is called clinker, is ground and mixed with
a few percent of gypsum.
COMPOSITION OF PORTLAND CEMENT:
COMPOUND COMPOSITION
The chemical composition of ordinary Portland cement is given as under: calcium
silicates account for three fourths of Portland cement and are responsible for its
cementing qualities.
Typical composition of Ordinary Portland Cement:
Chemical Name Chemical Formulae Shorthand Notation Weight Percent
Tricalcium silicate 3CaO.SiO2 C3S 50
Dicalcium Silicate 2CaO.SiO2 C2S 25
Tricalcium Aluminate 3CaO.Al2O3 C3A 12
Tetracalcium
AluminoferriteFerrie
4CaOAl2O3. Fe2O3 C4AF 8
Calcium Sulphate
(Gypsum)
CaSO4.2H2O CSH2 3.5
Chemical analysis of Portland cement is routinely done using standard methods. A
typical oxides analysis of Portland cement is given as under:
Oxide Shorthand
Notation
Common Name Weight Percent
CaO C Lime 63
SiO2 S Silica 20
Al2O3 A Alumina 6
Fe2O3 F Ferric Oxide 2.5

9. MgO M Magnesia 2.6
K2O,
Na2O
K
N
Alkalies 0.6
SO3 S Sulphur Trioxide 2.8
Using these oxides analyses and compound stoichiometries, it is a sample matter to
calculate a compound composition. This is known as Bogue-Calculation.
Setting and Hardening of Cement
Setting Process :The process of losing plasticity with time and becoming dense,
which is formed by mixing the cement and water. It happened in two stage
initial setting and final setting.
Hardening Process: The process of forming hardening cement paste, which loses
plasticity and its strength increases with time. Factors such as fineness and types of
cement, blend of gypsum, age, water content, temperature and humidity which
influence setting and hardening of Portland cement. Setting is important in concrete
work to keep fresh concrete plastic for enough time which helps the processes of
transporting, casting, and compaction. There are four stage occurs during setting of
cement, First: when mixing cement with water, a rapid heat evolution, lasting a few
minutes, This heat evolution is probably due to the reaction of cement compounds
then, heat evolution ceases quickly. Second: this stage called “dormant period” and
last (1-4) hours. Also cement particles start to form initial layer of hydration product.
Bleeding and sedimentation appear in this stage. Third: Next heat evolution is on
account of dissolution of weak gel which formed first on surfaces of C3S crystals so
water will reach these surfaces and starts to form new gel. This stage last about 6
hours. Forth: in this stage cement begin to harden and gain strength.

10. Quarry: Quarry is the place from where raw material in extracted. Drilling and
blasting is done to extract the material. A hole of about 18 m is drilled and
ammonium nitrate in filled as an explosive in these holes. When this explosive is
ignited the rocks are broken into pieces of different sizes. These pieces sure then
loaded on the dumper trucks to the crusher. It is located about 7 Km from the plant.
Quarry and raw materials: The following raw material is required in the
production process:
1. Lime stone: This raw material is company owned and is extracted from the nearby
quarry Unit. Limestone has the highest composition in the cement
product. 75% of the cement constitutes of limestone.
2. Clay: Clay is another natural resource. This raw material is also
company owned. 15% of cement composition comprises of clay
3. Iron Ore, Bauxites and silica sand: Iron Ore is the only resource that
is bought from contractors. Iron Ore, Bauxites and silica sand are added
in small quantities less then one percent and it helps to strengthen the
cement.
4. Gypsum: Gypsum acts as a retarding agent. It slows down the
hardening process which in turn gives the constructor enough time to use it.
Proportions of different Raw Materials:There are basically three main raw
materials that are used for the production of cement. In addition to that, a small
proportion of other additives such as silica and Bauxites are also added.
1. Limestone 75%
2. Clay 15%
3. Iron ore (less than 5%)
4. Silica sand (less than 5%)

11. 5. Gypsum (less than 5%)
Lime stone and clay are extracted from the same place. Iron ore is bought from a
contractor.
Mining:
The major raw material for cement manufacturing is limestone. Limestone is
excavated from open cast mines after drilling and blasting and loaded onto the
dumper which is transported the material and unloaded into hopper of the limestone
crusher.
Equipment Used in mining:
1. Compressor drilling machine.
2. Shovels/Excavators-for lifting material onto dampers.
3. Dumper- for carrying material.
4. Built-dozers.
5. Pay-loaders.
Explosive:
1. Ammonium nitrate(Fuel oil)
2. Ammonium nitrate and slurry explosive.
Steps of Mining:
1. The first step of mining the bench located.
2. Limestone mining is to remove the mines.
3. The third step is to be taken as drilling.
4. After drilling blasting is done.
Limestone Mining and Processing Operations
Limestone
Limestone is a sedimentary rock composed primarily of calcium carbonate with the
occasional presence of magnesium. Most limestone is biochemical in origin
meaning the calcium carbonate in the stone originated from shelled oceanic
creatures. Limestone can also be chemical in origin as is the case with travertine.
Chemical limestone forms when calcium and carbonate ions suspended in water
chemically bond and precipitate from their aquatic sources.
Because of its high calcium content, limestone is usually light in color, although
many variations exist. Commercially, the term limestone includes dolomite,
dolomite limestone, and a porous calcite rock that is commonly formed near hot
springs.

12. Limestone Mining Operations: Limestone mining operations mainly
consists.
Drilling
Blasting (Primary and Secondary)
Loading/Transporting
Crushing (Hammer Crusher)
Drilling:
Drilling is done in the quarry with the help of drilling machine. A space of 15-18m is
created for the powder explosive.
Blasting:
The powder explosive is blasted under a controlled process to get the rocks in the
form of pieces of different small sizes.
Drilling machine
In rotary drilling crawler mounted machines are used to for the drilling of blast
holes. This method is unsuitable for deposits consisting of loose or soil type
deposits. Crawler mounted machines used for the drilling of large diameter holes
for blasting.
The drill bit, operating by rotary action, shatters the rock, and the cuttings are
removed from the hole by air issuing from the bit. The dust carried out of the hole
with this flushing air can be trapped in a dust collector, which is mounts on the
drilling machine. It comprises a cyclone in which the coarser particles are
precipitated, while the finer ones are retained in special fitters.
The suction extractor is connected to a flexible tube which terminates in a plastic
sleeve forming an airtight closure over the mouth of the borehole, so that alt the
dust can be collected.
Modern rotary drilling machines are operated by just one man. They mostly have
fully hydraulic drive systems, are reliable in operation and attain drilling rates of up
to 30 m/hour, depending on the nature of the rock and the diameter of the hole.
The power pack compressor, hydraulic units, drilling mast, rod magazine, operator's
platform and dust suppression system are mounted on a traction unit usually
equipped with crawler tracks, The prime mover is generally a diesel engine,
Although it is more expensive in energy consumption than an electric motor, it is
nevertheless preferred because It provides better mobility of the drilling machine
and make it independent of power feed cables. On some machine a slewing ring
enable the superstructure to swivel on the crawler chassis.

13. The use of increasingly long drill rods likewise aims at Increasing the efficiency
of the machine, a trend which has led to the development of the '"single-pass"
machine which drills the hole to its full depth with just one long rod, i.e., without
having to couple successive rods as drilling proceeds.
There are some drilling machines and air compressors are listed below
used in QUARRY;
No Description Engine Model/Machine
Model
Capacity
1. Crawler drill Furukawa no.1
PCR-200 75 mm dia hole
2. Crawler drill Furukawa no.2
PCR-200 75 mm dia hole
3. Crawler drill Atlas no. 3 ROC-460 110 mm dia hole
Blasting
When the blast holes have been drilled, they are charged with explosive
and the charges are fired. The object of blasting is to loosen and fragment the
rock so as to obtain rock pile suitable for loading.
The amount of explosive to be used in any given case will depend on the
specific explosive consumption, i.e., the amount needed for producing a tone of
rock pile or for loosening and fragmenting a cubic meter of solid rock. It is an

14. empirical value which varies from one set of quarrying conditions to another
and should be known in any quarry where production is in progress.
The smaller the spacing and the burden, with correspondingly smaller blast
hole diameter the better will be the fragmentation obtained, because the
explosive will be more uniformly distributed along the face. A finer location
grid is more particularly advantageous in dealing with thick-bedded rock
tending to produce a coarsely fragmented rock pile.
With increasing blast hole diameter, spacing and burden there is an
Increase both in the Proportion of very finely fragmented material (due to
shattering of the rock in the immediate vicinity of the charge) arid in that of
Large lumps (dislodged from the Darts of the rock farthest from the charge) A
coarse grid of this kind will as a rule be economically advantageous only in
rock which is fractured finely fissured and brittle Blasting by the tunneling
method, now seldom used represents an extreme case of fining large
concentrated charges.
Explosives Material
Powder explosives
ANFO
ANFO is a low density explosive of relative high weight strength well suited
mainly as a column charge in all types of rocks where conditions are
moderately dry. It is non cap sensitive explosive and require premier for
initiation. ANFO has excellent storage properties and offer maximum safety in
handling and transportation.
Composition
Ammonium nitrate 95.5 % Fuel oil
4.5%
LOADING
The machines used for loading in open-pit quarrying in solid rock. Including
limestone and shale are: Wheel loaders

15. Transporting:
DUMPER
:
A dumper is a vehicle designed for carrying bulk material, often on building
sites. Dumpers are distinguished from dump trucks by configuration: a dumper
is usually an open 4-wheeled vehicle with the load skip in front of the driver,
while a dump truck has its cab in front of the load. The skip can tip to dump
the load; this is where the name "dumper" comes from. They are normally
diesel powered. A towing eye is fitted for secondary use as a site tractor.
Dumpers with rubber tracks are used in special circumstances and are popular
in some countries. Early dumpers had a payload of about a ton and were 2-
wheel drive, driving on the front axle and steered at the back wheels. The
single cylinder diesel engine (sometimes made by Lister) was started by hand
cranking. The steering wheel turned the back wheels, not front. Having neither
electrics nor hydraulics there was not much to go wrong. The skip was secured
by a catch by the driver's feet. When the catch is released, the skip tips under
the weight of its contents at pivot points below, and after being emptied is
raised by hand.
No
Description Capacity
1. CAT dump truck no (1-6)
(52.3 tone)
2. CAT dump truck no 7,8 (63.5 tone)

16. Impact Hammer Crusher (limestone
Crusher)
A crusher is a device that is designed to reduce large solid chunks of raw
material into smaller Chunks. Here the material is held within a cage, with
openings of the desired size at the bottom, end or at sides to allow crushed
material to escape through them. Here the breakage can take place in a much
shorter scale compared to fragmentation process used in cone or jaw crushers.
Technical specification
No Description Crusher I Crusher II
1 Material Limeston
e
Limesto
ne2 Company UBE JAPAN FLS DENMARK
3 TYPE Impact hammer crusher Impact hammer crusher
4 Capacity 400 T/Hr. 800 T/Hr.
5 Feed size 1200 mm 1800 mm
6 Product size 90% <50mm 95% <50mm
7 Main motor 450 KW 1250 KW
8 Power consumption 2-3.10 KWH/T 1.5 KWH/T
9 FRAME Steel plate, cast steel Steel plate, cast steel
10 Hammer steel Steel
Clay Crusher: (Roller Crusher)
The Roller Crusher consists of two rollers with cast bosses. One of the roller
shafts is adjustable while the other has a fixed position and is provided with a
flywheel. The gap between the two rollers can be varied according to the
degree of crushing required. The motor power is transmitted through a gear
drive and two cards a shaft to permit the adjustment of the space between the
rollers. Both rollers have scrapers to remove any material sticking to the
surface.
The clay is drawn into the gap between the rolls by their rotating motion and a
friction angle formed between the rolls and the particle, called the nip angle.
The two rolls force the particle between their rotating surface into the ever
smaller gap area, and it fractures from the compressive forces presented by the
rotating rolls. Some major advantages of roll crushers are they give a very fine
product size distribution and they produce very little dust or fines.

17. Technical Specification
No Description Unit II (FLS, Denmark)
1. Type Roller crusher
2. Capacity 350 T/Hr.
3. Feed size 500 mm
4. Product size 100% <50mm
5. Main motor 250 KW
6. Power consumption 0.6 KWH/T
Belt
conveyors
A conveyor belt is the carrying medium of a belt conveyor system. A belt
conveyor system is one of many types of conveyor systems. A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums).One
or both of the pulleys are powered, moving the belt and the material on the
belt forward.
There are two main industrial classes of belt conveyors. Those in general
material handling such as those moving boxes along inside a factory and bulk
material handling such as those used to transport large volumes of resources
limestone, clay, coal, iron ore, silica sand, and more.
Today there are different types of conveyor belts that have been created for
conveying different kinds of material available in PVC and rubber materials.
The most common materials are used polyester, nylon and cotton. The cover is
often various rubber or plastic compounds specified by use of the belt.
Material flowing over the belt may be weight in transit using belt scale.

18. Keeping the belt conveyor in good operational order some devices is used.
Technical classifications
No. Description LBC C3 LBC C4 LBC C5
1. Capacity 800 T/Hr. 800 T/Hr. 800 T/Hr.
2. Horizontal 2346 m 2088 m 1777 m
3. Vertical 13.5 m 29.93 m 2.53 m
4. Width 800 mm 750 mm 750 mm

20. Bag Filter :
It separate dust from air. It consists of a
box with 2 chambers, with a separation
between them, the lower chamber has inlet
of dust laden air, from upper chamber
multiple fabric bags with metal structure
inside them hangs into lower chamber, in
upper chamber there is a purging
mechanism. A suction fan suck air from
upper chamber, the air enter from lower
chamber and after passing through bags it
enter upper chamber and then to suction
fan, The air when pass through the bags
get filtered the dust stick to the bag, after a
particular time purging is done which is
reversing the flow of air with the help of
high pressure air, this lead to falling down of dust, at bottom of lower chamber. The
lower chamber have a hopper type bottom into which a screw conveyor is present
which move the settled dust to one corner where a downward opening exist from
where it is dropped back to the conveyor line. The purpose of bag filter is to avoid
pollution plus recovery of material, leading to efficiency.
Magnetic separator :
A magnetic separator is installed on the feed
belt. It attracts and removes metal objects from
the feed which are collected in the bin.
Storage Yard:
The crushed material is stored in the form of
piles in the storage yard. There are 6 piles in
the storage yard. Mixed piles are used in larger quantity where as high grade and
additive piles are used in small quantity.
 2 Mixed piles (limestone & clay)
 2 High grade (pure Coal)
 Iron ore (additive)
 Gypsum (additive)
Stacker:
A stacker is a large machine used in bulk material handling applications. A stacker's
function is to pile bulk material such as limestone, clay, and coal. It operates on a

21. rail-like structure with movable wheels, stacking of material can be performed in
stationary or moveable mode. A stacker is a device which form conical piles of the
crushed material. Feed is conveyor to the stacker through conveyor belts. This
stacker then moves too an fro to make a pile. The stacker belt is called “Jib” in
engineering terms. Now, for conveying this material from piles to the conveyor
following equipment is used:
 Side scrapper
 Reclaimer
Side scrapper:
Side scrapper is a device which picks the crushed feed from the piles through its feed
belt called “Hoist”. This belt has a number of small buckets of low capacity. When
this belt moves, the buckets picks feed from the pile and put it on the belt conveyor.
Side scrapper in used for those piles which are required in low quantity like bauxite
and iron ore.
Reclaimer:
A re-claimer is a large machine used in bulk material handling. Its function is to
recover bulk material from a stockpile, which has been stacked by the stacker. Re
claimer travel on a rail between stockpiles in the stockyard. It’s electrically powered
by means of a trailing cable.
Scrapper types reclaimer:It has two arms called “Harrows” These harrows are
inserted into the pile, when they move sideward, the feed drops down the pile. This
feed in then collected by high capacity buckets installed in the bottom of the
reclaimer. These buckets pick the feed and put it on the belt conveyor. It is a large
capacity equipment and for those piles which are required in high quantity like
Mixed Pile.
Types of Reclaimers :
1)Bridge type:
This type of reclaimer lies across the pile and run on the tracks laid on both sides of
pile shed. . Bridge type reclaimers blend the stacked product as it is reclaimed. This
is used to reclaim chevron piles which are actually made of layers of material
2) Boom type:
The rail track is only on one side of the pile and the scrapper move on one side of
pile scrapping the material and loading it onto the conveyor belt running on the sides
of pile
Load Cells: These are sensing devices which tells the load being put on the hopper
by the feed. From these hoppers, the feed in required proportions is transferred by the
belt conveyor to the Raw Mill. A lot of dust is produced during the conveying of
material, to avoid this problem Bag Filters are installed. A Magnetic separator is also
installed to remove metal impurities.

22. Raw Mill Section
Raw Mill Feed Area:
The raw mill feed area consists of 4 feed hoppers:
limestone hopper.
silica hopper.
shale hopper.
Iron ore hopper.
The capacity of first two hoppers is 450-500 tons while the other two hoppers
have a capacity of 150-200 tons. The feed from each pile is conveyed to the
hoppers through conveyor belts in relevant hoppers. Each hopper has 4 load
cells. This section is one of most important section of plant where the crushed
material in form of piles is transferred to bins through belts and then to Raw
Mill through rotary feeder (28rpm) which permits only raw material to fall
inside the raw mill and air is not allowed to fall.
Mechanism:
The raw feed from the belt conveyer directly falls on the rotating table of the
raw mill. The table contains on 3 crushing rollers. The raw feed is crushed into
fine powder with these rollers. At the top of raw mill there is a separator section.
Hot gases come from pre heater at the bottom of raw mill. A suction fan with a
motor of 5500kw.Here the dusty air rotates and air is separated from dust nearly
80% dust from air is separated in four cyclones. These four cyclones sent the
crushed material into CF silo with the help of air slides and bucket elevators.
Sections of Raw Mill:
There are 3 sections of a raw mill.
Three Rollers
Bottom Scrapper
Seperator
Three Roller:
The raw feed from the belt conveyor directly falls on the rotating t able of the
raw mill. The table contains 3 crushing rollers. The raw fed is crushed to fine
powder with these rollers. The coarse particles are collected at the bottom of
raw mill and are sent to the vibrator from where they are sent to the raw feed

23. belt conveyor and again recycled to the ram mill for re crushing. The vibrator
is use to handle the quantity of the material being put on the belt.

24. Separator:
At the top of the raw mill, there is separator section. Hot gases from the kiln comes
from the bottom of the raw mill and lift very fine particles with it. A suction fan with
motor power of 1500-2027 KWH/T produces suction and sends dusty air into the
cyclones at the top. Here the dusty air rotates and particles are separated from the air.
These particles are collected at the bottom of the cyclone and sent to the CF silo with
the help of air slides. The air which still contains dust particles are separated in
Conditioning tower and Electrostatic precipitator. Two input ducts are coming inside
the raw mill which provide hot air having temp 108’C almost and there in single
outlet duct which takes material and exhaust air in form of cyclones. Id fan is
attached which is used for rapid movement of air b/w inlet and outlet ducts. Material
transfer in form of cyclones prevents the raw material from reaching Id fan.
This material is then transferred to silo’s four in number and the dusty air is
transferred to conditioning tower where foggy drops are sprayed from 30 nozzles
each having 3mm dia to decrease dusty air temp to a lower limit (80-100’C) before it
reaches EP (Electrostatic Precipitators) In this section cooled dusty air is passed
between electrical plates where ionization of dust take place, they are ionized into
positive and negative plates and then stick to respective plates.
After this process hammering or shock is produced in plates which removes dust
from plates and this dust is then transferred through bucket elevators to the CF-silo.
The same process occurs with grinded material, they are conveyed through duct to
bucket elevators and then transferred to CF-Silo through bucket elevators. Air from
EP and exhaust air from raw mill is exhausted to the atmosphere using chimneys so
that fresh air cycle can be started again.

25. Electrostatic precipitator :
The clean air from the conditioning tower still contains some particles which have to
be removed. These particles are separated from air by passing it through the
Electrostatic precipitator.
In Electrostatic precipitator there are 2 corona wires which are mesh like. These
wires are negatively charged. There is a positively charged electrode in the centre
which is equidistant from both corona wires. Dusty air passes through these corona
wires and the particles get negatively charged. The negatively charged particles in air
are then attracted by the positively charged electrode and the particles stick with it
and clean air is exhausted from the chimney.
Working of the electrostatic precipitator:
Based on the application of electrostatic charge to a particle and then subjecting it to
oppositely charged surface, it works on the phenomena of attraction between
opposite charges. the dust laden gases flows through a chamber in which it passes
through high voltage electric fields formed by alternate discharged electrodes and
plate type collecting electrodes. Subjected to electric field the dust particles get
charged and fly to collecting electrodes and get deposited there. The dust is dislodged
by hammering and drops down in the collecting hopper. High temperature and

26. moisture effect the resistively of dust making it less favourable for collection.
Conditioning tower reduces resistively of dust.
It works well at t<130c and 15% moisture. Electrostatic precipitator uses the
phenomena of attraction between + - to separate fines from air. The air along with
dust is charged at anode and then is subjected to – terminal, the particles being solid
stick to the –plates, which are hammered after an interval to separate the dust and it
settle down and are conveyed by screw conveyor and air slides to steel silo from
where it is directly sent to cement Mill
Cleaning of the electrostatic precipitator:
In order to remove particles from the electrode. A “Wrapping” device is used. This
device hits the electrode as a hammer and particles fall down from it. These particles
are collected and conveyor to the CF silo via screw conveyor.
Coal yard:
Coal yard is the area where coal is stored which is used for burning purposes. There
are different piles for the storage of local and imported coal. The coal is imported
from South Arica, and Indonesia. The coal is handled by a loader, the loader picks up
the coal and throws on a sieved net which separates bigger pieces of coal and stones
form it, before it goes to the tunnel.
From the tunnels the coal is placed on the belt conveyor which takes it to the coal
mill feed area. Pet coke which is hard is also used in the coal feed.
Coal mill feed area:
After the impurities are removed from the coal, it is chutes on the belt conveyor .A
bag filter is employed which sucks the coal dust and thus prevents the coal from
being wasted. The coal is then shifted to the coal storage hoppers.
Coal storage hoppers :
There are 2 hoppers for the storage of coal. One hoppers are for the storage of local
coal and the other is for the imported coal. All the two hoppers have a capacity of
250 tons. The coal required in different proportions are chute on the belt conveyor
from the hoppers. A bag filter is employed to remove coal dust. A magnetic separator
is employed to remove metal impurities. This belt conveys the raw coal to the raw
coal mill.
Coal mill: ATOX mil
Specifications of coal mill:
Capacity: 50 ton/hr (coal) than use in36ton/hr
Supplier: FLSmidth
Sections of a coal mill: There are 3 sections of a coal mill similar to the raw mill.
(1) Table (2) Rollers (3) Bottom scrappers, The coal on the belt conveyor falls
on the table of the mill where rollers grind it to a fine powder. A blower of very high
power pushes very fine particles towards the two fine storage bins. From the 1st

27. storage bin the coal is sent to the kiln for its use in the burner and from 2nd
storage
bin it is sent to the precalciner for calcinations.
CF Silo (continuous flow):
The fine particles from the conditioning tower and electrostatic precipitator and the
powdered feed from the raw mill are conveyed to the bucket elevator. The bucket
elevator picks this feed and take it to the top of the CF silo and then throws it in.
Specifications of a CF silo:
Capacity = unit 1 unit2
7000 tons 7500ton
SILO
It is the large storage of Raw mill which comes from the Raw Mill. It is made of
concrete & can store Raw mill for long time.
Purpose:-
It’s main purpose is to homogenize the raw mill. One of it’s main purpose
is to also store raw mill for long time.
Construction:-
It mainly a large structure made of concrete. It contains following devices:-
1)-Air Compressor
2)-Large Air Ducts
3)-Pneumatic Valves
4)-Exhaust Fans on the top
Air circulations:
After the feed is stored in the silo bin. Now for the movement of feed in the bin, air is
blown from the bottom through different points in CF silo. These points are located
at the base of the CF silo.
Due to air circulations, fine particles are sent to air slides from where they are
transferred to Low bin (Loss of weight bin). The capacity of low bin is 118 tons. The
feed from the low bin is sent to a bucket elevator which lifts it to the preheated.
Pre-heaters
The bucket elevator puts the material on the top of 2nd
cyclone. The hot gases from
the kiln flow with very high velocity in countercurrent direction. The hot gasses lift
the particles from the particles from the top of 2nd
cyclone and put it on the top of the
1sr cyclone. From there the material falls on the top of the 3rd
cyclone and send it into

28. the 2nd
cyclone. Then the material falls on the top of 4th
cyclone and hot gases take it
into the 3rd
cyclone.
Then the material falls on the top of the 5th
cyclone and hot gases take it into the 4th
cyclone and finally into the 5th
cyclone preheated. During this complete cycle, the hot
gases foe in the countercurrent direction. These cyclones serve the purpose of
preheating the feed material with hot gases of kiln.
There are total 9 cyclone preheaters. 5 are on the unit 2 side of the precalciner and 4
on the unit 1 side of the precalciner. The temperature of feed increases as the feed
flows downwards the preheaters.
Pre-calciner:
The feed from the 5th
cyclone preheated falls into the
precalciner which has burner with a supply of coal and
furnace oil. Here the calcinations of feed material takes
place due to burning. Exchange of heat also takes place in
the pre-calciner. CO2 is evolved and exhausted in the
atmosphere and the feed is entered into the kiln riser at
high temperature. Some of the feed directly goes to the
kiln without going to the pre-calciner through separate
pipes.
Kiln:
The preheated feed from the kin and the preheaters enter into the kiln riser. From the
kiln riser the feed enters into the kiln.

29. A Rotary kiln is a pyroprocessing device used to raise materials to a high temp
(calcinations) in a continuous process. Materials produced using rotary kilns
Principle of Operation:
The kiln is a cylindrical vessel, inclined slightly to the horizontal, which is rotated
slowly about its axis. The material to be processed is fed into the upper end of the
cylinder. As the kiln rotates, material gradually moves down towards 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 or pulverized coal.
Specifications of the rotary kiln:
The rotary kiln has a length of 78 m and diameter of 4.7m.Its rotating speed varies
according to the quantity of feed entered. Around
the inner diameter of the kiln there is refractory lining to prevent the shell from
damage and to control the environment temperature. Outside the kiln there are
induced shell fans which turn on automatically when the temperature increase more
than a certain limit.

30. Kiln Motors:
There are two kiln bases on which motors are installed which impart rotary motion to
the kiln.
Kiln burner:
On the other end of the kiln , there is huge burner
having a supply of coal, furnace oil and air. The burner
emits a flame which is prolonged with high pressure air.
The flame burn the material and the product is formed.
Kiln zones:
there are four zone of the kiln.
1) Calcinations zone
2) Transition zone
3) Burning zone
4) Cooling zone
1) Calcination zone
This is the first zone of the kiln in which feed enters from the pre-heater.
Temperature of this zone is about 600-1000co.In this zone, low alumina bricks are
installed. In this zone, decomposition of calcium carbonate and magnesium carbonate
occurs which are present in limestone.
CaCO3 CaO + CO2
MgcCO3 MgO +CO2
2) Transition zone
After calcination, the next zone is the transition zone in which high alumina bricks
are used. In this zone material liquifycation starts. It is the peak point of calcination
fallowed by clinkerization. Temperature of this zone is about 1200-1300C.
3) Burning zone
After transition, burning zone is starts and the liquid enters from the transition zone
changes into clinker. Temperature of this zone is about 1350-1450 C. Here megnasite
bricks are used for the insulation purpose.
4) Cooling zone
This zone is located below the burner of the kiln for the cooling of clinker. The
temperature in this zone is about 1400-1450c0.
A clinker with 25-30% liquid in raw mix is considered an ideal raw meal for kiln
lining, fuel saving and rapid C3S formation.
Kiln Reactions:
Following are the sequences of chemical reactions which occur in kiln.
(I)Decomposition of raw materials up to 1300 o
C
Up to 500 c dehydration of water occurs.
From 600-800 C dissociation of CACO3 and MgCO3 occurs.

31. From 800-900 C formation of C2S occurs.
From 1100-1200 formation of C3A and C4AF occurs.
Liquid formation at 1250-1280 C.
(ii) Alite (C3S) formation in the burning zone (1280-1450co).
(iii)Cooling of clinker.
Kiln hood:
The hot material form the kiln falls into the kiln hood at the end which has an angular
sieve. When material passes through it attains the shape of clinker. Now this clinker
is sent to the cooler.
Refractory Lining:
The purpose of the refractory lining is to insulate the steel shell from the high
temperatures inside the kiln, and to protect it from the corrosive properties of the
process material. It may consist of refractory bricks. The refractory selected depends
upon the temperature inside the kiln and the chemical nature of the material being
processed. The refractory life is prolonged by maintaining a coating of the processed
material on the refractory surface. . A typical refractory will be capable of
maintaining a temperature drop of 1000°C or more between its hot and cold faces.
The shell temperature needs to be maintained below around 350°C in order to protect
the steel from damage, and continuous infrared scanners are used to give early
warning of "hot-spots" indicative of refractory failure
Type and properties of bricks used in rotary kiln:
There are many types of bricks but in two type of bricks are used
1) High alumina bricks
2)Magnetite bricks
1) High alumina bricks
They are high refractory whose refractiveness increases with increase of alumina
content, having high mechanical strength at high temperature. They are resistant to
spalling. From the kiln feed inlet, high alumina bricks are lined from 2m to 37m.
They are being imported from Germany.
2) Magnetite bricks
They are extremely high refractory and high thermal resistance. They are chemical
bonded to the kiln surface and are resistant to sapling. From the kiln feed inlet,
magnetite bricks are lined from 38m to 63m.
3) Cast tables:
It is an unshaped refractory. It is composed of refractory aggregate with high
temperature resistance binder i.e. high alumina, which upon addition of water
produces concrete. The binders used are calcium aluminates having about 45%
alumina content. Such binders are suitable for making insulation cast tables. Good
refractory concrete with rapid hardening, high strength and abrasion resistance is
achieved.

32. Clinker cooler:
The clinker cooler is used to lower the clinker temperature. There are ID fans which
take fresh air from the atmosphere and send it to the cooler. At the bottom of the
cooler there are reciprocating rails which move with the help of hydraulic motors.
These rails convey the clinker forward to the clinker crusher.
Dust collection:
A suction fan is installed which sucks the product dust from the cooler and send it to
the electrostatic precipitator. In EP dust is removed and clean air is exhausted to the
atmosphere through a chimney. The dust particles are to the deep pan conveyor by a
screw conveyor.
Clinker crusher:
When the clinker cools and hardens then it is sent to the clinker crusher installed after
the cooler. Big stones of clinker are crushed to small pieces. The crushed clinker is
dropped on the deep pan conveyor at the bottom of the conveyor which conveys it to
the clinker storage.
Clinker storage:
The clinker from the deep pan conveyor is stored in the clinker storage. Its capacity
is 35000-40000 tons. There are 3 gates at the bottom of the clinker storage from
where the clinker is sent to cement mill through belt conveyor. If the clinker yard is
also full then the clinker is removed from the dumped into clinker storage yard.
Cement mill feed area:
There are 3 cement mills and 3 hoppers in the cement mill feed area. First hopper is
clinker second is gypsum third is limestone. Clinker 95% use gypsum 3-5% and
limestone is 1-3% use. The 1st
hopper contains the clinker which is major constituent
of the cement. The cement contains 95 % clinker which is conveyed through weigh
feeder to the main belt conveyor which takes it to the cement mill.
Gypsum addition:
The crushed gypsum from a separate crusher is conveyed by belt conveyor to the
cement mill. It is mixed in the clinker while crushing. Gypsum is added to about 3 –
5 %. Its purpose is to increase the settling time of the cement.

33. Mixing of additive:
The additive which is pure limestone is also added in the cement mill. Its added to
about 2 %. Its function is to increase strength of cement. A bag filter collects dust
from the main belt and a magnetic separator remove metallic impurities from
entering into the cement mill.
Metal detector;
To protect the cement mills from damage, a metal detector
is installed which analyzes the feed and if a metal object is
found it opens the dividend gate automatically and sends
the feed containing metal objects to the rejected surface,
which is again recycled to the main belt and magnetic
separator removes it.

34. Cement Mills :
Cement mills specifications OK Mill:
 Capacity : 230 ton/hr
 Motor power : 3400 kw
 Supplier : FLSmidth
The feed which is free from impurities falls on the table of cement mill which
contains three rollers. Each roller has weight of 35 tons and the clearance between
table and rollers is 0.5 mm. These rollers move hydraulically using nitrogen gas as
hydraulic fluid.
The rollers crush the feed to a very fine powder. The air slides convey the ground
product to the bucket elevator which lifts it to enter into the 1st
storage silo.
Storage silos:
Specifications of storage silos:
 Capacity : 36,000 tons
There are 5 cement storage silos in which crushed cement is stored up till packing..
To convey the cement to the all silos air slides and bucket elevator are used. From
these silos the cement enters air slides by air circulations through blowers. Now these
air slides take the cement to the packing plant.
Air slide: It a rectangular tube with two sections, the partition between them is of a
fabric layer, pressurized air is injected in the lower section, in the upper chamber fine
powder is dropped, due to pressure difference the air penetrate through the fabric, the
position of this slide is sloped downwards, this air entrainment lead to powder
movement.
Air lift:
This operates by fluidizing the powder and elevates it to desired height, the air from
compressors flow through the pipes in which
powder is dropped into the pipe thus air act as a
carrier.

35. Packing Plant:
The packing plant comprises of unit 1is 4 packers and unit 2 4 packers total 8 packer
used only one packer is 12 packing terminals and other is 8 packing terminals. Each
packer has a capacity of 100 tons/hr. The cement bags are attached manually to the
rotating packer which fills the cement bag. When the bag is filled up to the required
weight 50kg, it automatically falls on the conveyor belt which takes the bags to the
roller conveyor. From these rollers the bags slide to different channels and finally
cement bags are loaded on the trucks from dispatch.
Dispatch
In dispatch department the main work is to
dispatch the cement according the orders of
sales offices. After taking the authorities the
dispatch department makes truck loading
advice according to which cement bags are
loaded on truck. It basically shows the
quantity, location of unit, truck driver name,
truck number and destination of loaded
cements bags.
Dispatch department also make many report
daily some are

36. Truck Loading Advice
Truck Loading Advice (Inventory Transfer)
Truck Loading Check Report
Unit Wise Dispatch Detail
Gate Pass
Gate Pass (Inventory Transfer)
Office Wise Dispatches
District Wise Status Report
Brands (Product)
Two different products are produced at DGKCC namely Ordinary Portland Cement
and Sulphate Resistant Cement. These products are marketed through two different
brands:
• DG brand & Elephant brand Ordinary Portland Cement (It is also called the OPC
and its demand is about 92% because of commonly used).
•DG brand Sulphate Resistant Cement (It is also called the SRC and its demand is
about only 8% because it is only used in standing the foundations its main work is to
finish the pours produced while standing the foundations and made the foundations
much strong). In addition to following two brands they are also offering four
different packaging which are as following:
o OPC
o SRC
o ELEPHANT BRAND DG PLASTIC BAG
Safety Section
It is the second last portion of internship in which we have learned about safety
precautions in DG-Cement. In DG Khan cement company limited all equipment of
firefighting is available at every place and every person is equipped with safety
helmets and jackets. Internee is also provided with security helmet to prevent any
damage. Fire alarms are attached and one main security alarm which indicates any
emergency. In case of major emergency when the alarm rings, all the workers are
advised to come out of plant and stop working till that security team covers the
danger. There is a red line spread all around the plant which also covers tunnel area
so that in case of any damage workers can even pull a single wire and emergency can
be felt. AFF is added in 3% with water which produces foam and used in firefighting.

37. The company has firefighting Van which is of about 10Million cost. Very costly
equipment is present and the entire environment is safe and sound. There is no such
danger while working at DG. Pipes are present which sprays the water on fire during
working in form of mist and thus prevent the fire fighter also they have different kind
of nozzles which exhaust water at 7Bar pressure and covers an area of 100ft. Security
buzzers are present and also they are connected through cell phones with each other.
Main firefighting or danger area is of Kiln because in this region the temp is almost
around 1000-1350’C so there is a chance of fire spreading. After visiting the plant we
can say that it has best equipment of safety and has full.