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INTERNSHIP REPORT
PRPARED BY: MOHAMMAD AMMAD UDDIN
DAWOOD UNIVERSITY OF ENGINEERING & TECHNOLOGY
SUBMITED TO: MR. RAO MUBARAK (ISO)
DATE: 05-07-2016

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ACKNOWLEDGEMENT
First and foremost I would like to express my thanks to God because of His love
and strength that He has given to me to finish this logbook as my internship
report. I do thank for His blessings to my daily life, good health, healthy mind
and good ideas.
I perceive as this opportunity as a big milestone in my career development. I
will strive to use gained skills and knowledge in the best possible way, and I will
continue to work on their improvement, in order to attain desired career
objectives.
I am also gratitude to staff of Attock Cement Pakistan Limited Especially,
Mr. Muhammad Yousuf
Mr. Shabbir
Who provides me useful information during the internship program. I am
thankful to all those people, who provide me valuable information.
Finally, I should like to extend heartfelt thanks to my adoring PARENTS, for their
day and night prayers, sacrifices, encouragement, moral and financial support
throughout the course of my study.

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Table of Contents
S.No. Topics Page No.
01 Introduction to ACPL 04
02 Attock Cement Production 05
03 ISO (International Standard Organization) 06
04 Raw Material for Cement 07 – 08
05 Cement Manufacturing Process 08-09
06 Crushing 10-11
07 Stacker 12
08 Reclaimer 13-14
09 Ball Mill 14-15
10 Vertical Roller Mill 15 – 17
11 Bin Storage 18
12 Pyro-Processing 19 – 21
13 Cement Mill 21 – 22
14 Packing 23
15 Calculations 24-26
16 Conclusion 27-28

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Attock Cement Pakistan Limited (ACPL)
INTRODUCTION:
The journey of Attock Cement started from the year 1981 and the company started its
commercial production in 1988 in 25 years, company has shown steady growth. ACPL has
attained new peaks every year through strong team work, continuous modernization of
plant to improve efficiency and with utmost hard work. ACPL has cemented its place not
only in the local market but also in the regional markets through selling quality products.
VISION:
To be the leading organization continuously providing high quality cement, excelling in every
aspect of its business and to remain market leader in cement industry.
ACPL MISSION:
To be a premier and reputable cement manufacturing company dedicated to become an
industry leader by producing quality products, providing excellent services, enhancing
customer satisfaction and maximizing shareholders' value through professionalismand
dedicated team work.

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ATTOCK CEMENT PRODUCTION:
OPC (Ordinary PortlandCement):
OPC being the most popular product under the Falcon Brand is used in all types of general
construction. It is manufactured from Portland Cement Clinker and Gypsum and not only
conforms but also surpasses to the standards.
SRC (Sulfate Resistant Cement):
SRC, another popular product under the Falcon brand, is a cement with additional special
features. Generally used in coastal and saline areas, It is manufactured with SR Clinker and
Gypsum, as it main constituents. SRC is an active resistant against the attack of sulphate salt and
alkali aggregate reaction, in addition to being cost effective and offering greater area coverage.
The Product meets the followingrecognized standards.
FBC (Falcon BlockCement):
Another popular product of the company is Block Cement. This product has been developed
exclusively for block & precast slab makers.
The product due to its unique specifications give quick setting time and is very popular
among the block & precast slabs makers. The product due to its quality commands premium
in price over the similar products of competitors.

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ISO (International Standards
Organisation ):
Organization’s Supply products intended to satisfy customer’s needs. Increase global
competition has led to increasingly more stringent customer expectations with regard to
quality. To competitive and to maintain good economic performances organizations need to
employ increasingly effective and efficient system which should result continual
improvements in quality and increased satisfaction of the customers.
Quality Policy of ACPL:

We are committed to produce high quality, which not only meets but exceeds the
international quality standards.
We aim to maintain leadership of our cement industry by providing best quality of
Products and excellent services to our consumers.
We work as a team of dedicated professionals, who achieve excellence through training,
development and continuous technology up gradation.
We aim to implement and continually improve the effectiveness of our quality
management system.
We provide safe and conductive work environment and the inhabitants of the
surrounding areas.
Environmental Policy Of ACPL: 
By adoption of ISO 14001 standards our organization committed to produce high quality
cement while maintaining minimal environment impacts.
Our organization will be made to effectively maintain and continuously improve the
activities with respect to environment maintain greenery within and around the factory
area.
As a responsible organization ACPL will fulfill all the social and moral obligations
related to environmental control.
ACPL aims at contributing generously towards pollutions effects and thus save this
world for future generations.

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Raw Material for Cement:
The raw materials needed to produce cement (calciumcarbonate, silica, alumina and iron
ore) are generally extracted from limestone rock, chalk, clayey schist or clay. Suitable
reserves can be found in most countries. These raw materials are extracted from the quarry
by blasting.
Major raw material for cement manufacturing is limestone which is almost required 85%.
LIMESTONE:
It 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.
MININGOF LIMESTONE FROM QUARRY:
Extraction (more commonly referred to as quarrying) consists of removing blocks or pieces
of stone from an identified and unearthed geologic deposit. Differences in the particular
quarrying techniques used often stems from variations in the physical properties of the
deposit itself—such as density, fracturing/bedding planes, and depth—financial
considerations, and the site owner’s preference. Nevertheless, the process is relatively
simple: locate or create (minimal) breaks in the stone, remove the stone using heavy
machinery, secure the stone on a vehicle for transport, and move the material to storage.
LATERITE:
It is a soil and rock type rich in iron and aluminum, and is commonly considered to have formed
in hot and wet tropical areas. Nearly all literates are of rusty-red coloration, because of high iron
oxide content.

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HIGH SILICA:
Felsic igneous rocks containing a high silica content, greater than 63% SiO2 (examples granite
and rhyolite) intermediate igneous rocks containing between 52 – 63% SiO2 (example landsite
and deceit) mafic igneous rocks have low silica 45 – 52% and typically high iron – magnesium
content (example gabbro’s and basalt)
Clay is a fine-grained natural rock or soil material that combines one or more clay minerals with
traces of metal oxidesand organic matter. Clays are plastic due to their water content and
become hard, brittle and non–plastic upon drying or firing.
CLAY:
It is a fine-grained natural rock or soil material that combines one or more clay minerals with
traces of metal oxidesand organic matter. Clays are plastic due to their water content and
become hard, brittle and non–plastic upon drying or firing. The quarry is the starting point.
CEMENT MANUFACTURING
PROCESSES:
There are twomethodsof cementmanufacturing:
WET PROCESS:
Cementmanufacturingprocessinwhichfeedisprovidedinwetslurryform.
DRY PROCESS:
Cementmanufacturingprocessinwhichfeedisconsistof ultra-fine homogenousmixture of raw
materials.

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S.NO DRY PROCESS WET PROCESS
1 Moisture content of the
pellets is 12%.
Moisture content of the slurry
is 35-50%.
2 Size of the kiln needed to
manufacture the cement is
smaller.
Size of the kiln needed to
manufacture the cement is
bigger.
3 The amount of heat required
is lower, so the required fuel
amount is lower.
The amount of heat required is
higher, so the required fuel
amount is higher
4 More economically Less economically
5
Difficult to control the
mixing of raw materials
process, so it is difficult to
obtain homogeneous
material.
The raw materials can be mix
easily, so a better
homogeneous material can be
obtained.
6 The machinery and
equipments need more
maintenance.
The machinery and equipments
do not need much maintenance.

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CRUSHING:
Crushingisthe firstunitof cementindustry.Thisprocessisusedtoresize the size of raw material.In
cementindustrywe use hammercrushertoreduce the size material
OPEN CIRCUITCRUSHING:
In open circuit material the crushed material passes the crusher only once and the material do
not recycle back to the crusher.
CLOSE CIRCUITCRUSHING:
In closed circuit crushing the oversize material after passing to the crusher is return back to the
crusher for further reduction in size up to the desired level.
HAMMER CRUSHER:
The material crushed by the Hammer Crusher (Hammer Mill) through the collisions between
high-speed hammer and materials. The PC Hammer Crusher(Hammer Mill) were developed
for both dry and wet crushing of brittle, medium-hard materials for the mining, cement,
coal, metallurgic, construction material, road building, and petroleum & chemical industries.
Material feed size 1m-6m the final size 25mm for Line I and 75mm for Line II material Of
Crushing tools manganese steel alloy durability depending on feed material.

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WORKINGPRINCIPLE:
The motor drives the rotor rotates of the Hammer Crusher at a high speed through the belt,
and on the rotor there are series hammers. When the materials get into the working area of
hammers, they are crushed by the rotating hammers of the Hammer Crusher with high
rotation speed The material is crushed or shattered by a combination of repeated hammer
impacts, the products which are crushed to meet the required size can be discharged by the
outlet and become the final products, the large size products are brought back to the
crushed area by the hammers of the Hammer Crusher for being re-crushed until they
reached the required size.
SPECIFICATIONS OFCRUSHER:
Capacity at line 1 600 ton per hour
Capacity at line 2 800 ton per hour
Number of hammers 50
Number of shafts 05
Hammers per shaft 10
Weight of Hammer 75kg @line I, 105kg @ line II
Roller size 2018 x 2227 mm
Roller weight 35875 kg
Roller speed 1m-6m
Inlet size 400rpm
Main motor 1000KW, 985 rpm

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STACKER:
The stacker is a specialized machine as part of bulk material pre-homogenization facility
within the raw material storage. The machine is used for stacking limestone or homogenous
mixed crushed materials in prismatic shape stockpiles.
The most commonly used stacking methods are:
 Windrow
 Chevron
Specifications:
Capacity 800 tons per hour
Moving Mechanism Track distance = 4m
Moving Speed 18m/min
Truck size 50kg/m
Total Size 75KW
Belt Conveyer B1000

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RECLAIMER:
It is a device belongs to pre-homogenization station, which is used for reclaiming the raw
material by removing transverse slices on the faces of stacked material. The reclaimer is
usually equipped with constant speed motors. The reclaimed material is carried by belts.
In Attock Cement Pakistan Limited (ACPL), Bridge type reclaimer with scrapper is used.
Specifications:
Capacity 450 tons per hour
Type Bridge Type Scrapper
Speed (Beam) 10.7m/min
Speed (Rakes) 10.5m/min
COMPONENT POWER(KW) SPEED(RPM)
Scrapper Chain Motor 7.5kw 1480prm
Transition Drive
Motor
5.5kw 1000rpm
Power Cable motor 3.0kw 960rpm
Control Cable Motor 1.5kw 960rpm
The raw material that is obtained from crusher is not still suitable to be burnt in the kiln
therefore we grind the material through the mills to make it super fine.
Air Slides
Bucket Elevator
Dynamic Separator
Static Separator
Cyclones
DE dusting Fans
Electrostatic Precipitator Fan
Chimney

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In Attock Cement Pakistan Limited (ACPL), Ball Mill is used for grinding the material for Line I
and Vertical Roller Mill for Line II.
BALL MILL:
A Ball Mill grinds material by rotating a cylinder with steel grinding balls causing the balls to
fall back into the cylinder and onto the material to be ground. The rotation is usually
between 4 to 20 revolutions per minute, depending upon the diameter of the mill. The
larger the diameter, the slower the rotation. If the peripheral speed of the mill is too great,
it begins to act like a centrifuge and the balls do not fall back, but stay on the perimeter of
the mill. The point where the mill becomes a centrifuge is called the "Critical Speed", and
ball mills usually operate at 65% of 75% of the critical speed.
NC = 1/2π √ [g/(R-r)]
Ball Mills are generally used to grind material 1/4 inch and finer, down to the particle size of
20 to 75 microns. To achieve a reasonable efficiency with ball mills, they must be operated
in a closed system, with oversize material continuously being re-circulated back into the mill
to be reduced. Various classifiers, such as screens, spiral classifiers, cyclones and air
classifiers are used for classifying the discharge from ball mills.

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WORKINGPRINCIPLE OFBALL MILL:
When the ball mill works, motor and speed reducer transmit torque force to big and small
gears of ball mill, so the barrel rotates. When the barrel rotates, Steel balls or other grinding
media in the barrel are lifted to a certain height and fall down freely, so materials in the
barrel are impacted. Grinding media mixing with materials impact and grind materials
continuously. The grinding media and materials impact and grind each other when the ball
mill rotates continuously. The final product will be discharged from outlet when it meets the
request, so the grinding process is finished application range, simple structure and
convenient maintenance.
VERTICAL ROLLER MILL:
The differences between raw and cement grinding have been well documented in numerous
publications and presentations over the recent past. Specifically, as compared to limestone,
clinker and cement raw materials are finer and harder to grind. This, coupled with the finer
and more stringent product particle size distribution requirements, entails design
considerations to allow for continuous and stable operation of the grinding system.
The patented geometry of the mill’s grinding parts has demonstrated its suitability for this
application at the Arizona cement plant. As shown, the rollers are spherical in shape with a
groove in the middle. The table is also curved forming a wedge-shaped compression and
grinding zone between the rollers and the table.

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The dual-lobed design is optimal for clinker grinding because it supplies two distinct grinding
zones, a low pressure zone and a high pressure zone, at each roller.
The low pressure area under the inner lobe de-aerates and consolidates the material to be
ground. This ensures a compact well established grinding bed for maximum stability. The
proper grinding then takes place in the high pressure zone under the outer lobe. The groove
in the middle of the roller facilitates de-aeration of the material without fluidizing it.
Due to its design of grinding parts and integral high efficiency separator, the vertical cement
mill, as shown, addresses all the difficult grinding conditions associated with the fine
grinding of cement clinker and related products. The result is a high grinding efficiency and
extremely stable mill operation.
WORKINGPRINCIPLE OF(VRM):
Material through the feed tube fell on the center of vertical roller mill grinding plate,
centrifugal force generated from the rotation of grinding plate uniformly scatters and
flattens the materials outwards the surrounding area of vertical roller mill grinding plate, to
forms a certain thick layer of materials bed, the material was crushed by number of rollers
at the same time. Driven by the continuous centrifugal force to keep the materials moving
to the outer edge of the grinding plate, the materials off the grinding plate rising with the
hot air which enter from wind ring into the vertical roller mill, through the vertical roller mill
shell into the middle of the separator, in this course materials and hot gas do a fully heat
exchange, and the water quickly evaporates. Separator controls the output size of finished
product, greater than the specified size are separated and fall back to the plate, while meet
the fineness requirements are brought through the separator into the finished product
warehouse.
SPECIFICATIONS:
Capacity 260 tons per hour
Table diameter 3700mm
Grinding roller diameter 1900mm
Number of Grinding roller 04
Feed Size 75mm
Hydraulic Pressure 16MPa

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Min Motor 2.5 MW
Separator Motor 110KW
Rotation of Grinding table 25.63 rev/min
Inlet air temperature <150°C
Outlet air temperature 80-90°C
HT Motor specifications, installed at vertical raw mill area:
MOTOR POWER(KW) SPEED(RPM)
VRM Main drive 2500 993
VRM Bag House 650 1000
VRM System FAN 1800 992
Separator Motor 110 994

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BIN Storage:
Fine material cannot be stored outside because of environmental pollution so they are
stored in :
 Hopper
 Bin
 Silo
They are either cylindrical or rectangular vassal. A silo is relatively tall and bin are not so tall
and usually fairly wide. A hopper is the small vassal with sloppy bottom, for temporary
storage before feeding in the process all these containers are loaded from top by a kind of
elevator and discharge material from bottom.
In order to blend and homogenize the raw materials properly, continuous blending silos are
used.
The blending silo can store 6000 tons of the powder mixture.
It is highly insulated so that it can maintain the appropriate temperature of the powder
mixture.

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PYRO-PROCESSING:
Pyro-processing is a very energy intensive operation and has a major impact on the
economics of the entire plant. Many technological developments have been adopted so as
to make the pyro-processing systemmore fuel and energy efficient.
Pyro processing involve following equipment:
 PRE-HEATER
 PRE-CALCINER
 KILN
 CLINKER COOLING
Pre-heater Tower:
The suspension pre heater is the basis of all modern systems. Raw mix in dry powder form is
injected into hot kiln exhaust gas in a vertical duct. The upward gas velocity is sufficient for
the powder to be picked up and lifted up the duct "in suspension" in the gas. Because heat
exchange occurs over the vast surface area of the individual mineral particles, the gas and
raw mix reach a common equilibrium temperature in a fraction of a second. The solids and
gas are then separated in a cyclone. This process is repeated a number of times - typically
three to six - by stacking "riser" ducts and cyclones on top of one another in a tower. By
repeated heat exchange, most of the heat in the kiln exhaust gas can be captured, while
heating the raw mix to calcinations temperature. Such heat as escapes the pre heater is
used to heat the raw mill.
The concept of the suspension pre heater gradually emerged when, from the 1920s onward,
some kilns started to be fitted with cyclones to remove most of the dust from kiln exhausts.
BENEFITS:
The top stage can reach 97% settling efficiency:
 Pressure drop of the line, including a 5 stage pre heater, is less than 50 mbar
 Heat and energy consumption is reduced 19
 Reduction of dust load to filter
 Technical advantages
 Overall design to achieve a very low pressure drop
 High heat exchange efficiency
 Large cone to avoid build-up
 Fan power reduction

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Pre-calcinationSystem:
When cement clinker is burnt in a suspension pre-heater kiln a main proportion of the heat
consumed is required for the dissociation of𝐶𝑎𝐶𝑂3.
Instead of supplying the total heat required through the kiln main firing, it is advantages to
introduce part of the fuel (up to the 65%) before the meal enters the rotary kiln. From all
reaction involved during clinker burning, the calcination, also called de carbonation requires
the highest amount of energy.
𝐶𝑎𝐶𝑂3-----------------------------> 𝐶𝑎𝑂+ 𝐶𝑂2
Rotary Kiln:
Most Portland cement is made in a rotary kiln. Basically, this is a long cylinder rotating about
its axis once every minute or two. The axis is inclined at a slight angle, the end with the
burner being lower. The rotation causes the raw meal to gradually pass along from where it
enters at the cool end, to the hot end where it eventually drops out and cools. They were
introduced in the 1890s and became widespread in the early part of the 20th century and
were a great improvement on the earlier shaft kilns, giving continuous production and a
more uniform product in larger quantities.
Construction Of Rotary Kiln:
This is made from rolled mild steel plate, usually between 15 and 30 mm thick, welded to
form a cylinder which may be up to 230 m in length in wet process but in dry process, the
length is up to 45m and up to 6 m in diameter. This will be usually situated on an east/west
axis to prevent eddy currents.
Fuels that have been used for primary firing include coal, petroleum coke, heavy fuel oil,
natural gas, and landfill off-gas and oil refinery flare gas. High carbon fuels such as coal are
preferred for kiln firing.
Working Principle:
Rotary kiln is made of steel plate, and inside the kiln body inserts refractory lining, which
keeps specified inclination with horizontal line. Three tires are supported by each
supporting device, around the tire at feed end uses tangential spring plate to fix big gear,
under which a pinion is meshing with. During normal operation, the rotary kiln is driven by
main motor through main reducer to transmit power to open gear.

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Material is fed into kiln from kiln tail. Due to the slope and rotation of the cylinder, the
material make a composite motion—it rolls in circumferential direction and at the same
time moves in axial direction. After sintering process, the material is calcined in cement
clinker and discharged into cooler machine through kiln head hood.
Sprayed into the kiln from the kiln head, the fuel burns in the kiln, after exchanging with the
material, the generated waste is discharged from kiln tail. The burner in this design is
excluding fuel.
Clinker Cooling:
The essential characteristic of a grea cooler is a layer of clinker spread on a more-or-less
horizontal perforated grate, through which cold air is blown. The grate is made of steel, and
the cold air keeps it sufficiently cool to avoid melting or burning. The clinker progresses
through the cooler by moving more-or-less horizontally along the grate, and so the direction
of the cooling air is roughly at right angles to the direction of movement of the clinker, and
the cooler functions as a cross-current heat exchanger.
The hot clinker at the inlet is treated with cold air rather than partially heated air, so that a
rapid quenching effect is possible, improving clinker quality by preserving reactive high-
temperature silicate polymorphs.
By using air in excess of that needed for combustion, the clinker can readily be cooled below
200°C.It is easy to tap off exhaust hot air streams in desired temperature ranges for use in
other processes.
Cement Mill:
Clinker formed as a result of pyro-processing has to be mixed with specific amount of
gypsum to form the final product. Gypsum is used to increase the setting time of cement.
In cement mill the clinker size is reduced through ball mills long with gypsum mixing i.e. the
two main purposes of cement mill are size reduction and mixing.
Working:
A ball mill is a horizontal cylinder partly filled with steel balls (or occasionally other shapes)
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 chrome steel. The smaller grades are occasionally
cylindrical (“pebs”) 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 𝑛𝑐=42.29/√𝑑, where d is the internal
diameter in meters. Ball mills are normally operated at around 75% of critical speed, so a
mill with diameter 5 meters will turn at around 14 rpm.

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NAME Cement Mill # 3 Cement Mill # 4
Length 13 m 13 m
Diameter 3.8 m 3.8 m
Capacity 100 tons per hour 100 tons per hour
Revolution 16rpm 16RPM
Motor 2500KW 2500KW
Media Charge 174 tons 174 tons
Mixing of Additives in Clinker:
 Gypsum is added to clinker primarily as an additive preventing the flash setting of
cement, but it is also very effective to facilitate the grinding of clinker by preventing
agglomeration and coating of the powder at the surface of grinding media and mill wall.
 Ethylene glycol is also commonly added at 0.1 wt. % as grinding aid to avoid powder
agglomeration and is proved to be very effective.

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PACKING:
The material is now ready to be packed and get dispatched. The equipment and their
specification used in packing plant are as follows:
EQUIPMENT CAPACITY POWER
Compressor air pump 44 cubic meter per
hour
185 KW
Silo 9000 tons -------
Elevator 165 tons/hr 37 KW
F K Pump 40-60 cubic meter per
hour
55 KW
Air lift 130 tons/hr 160 KW
Packer 120 tons/hr -------
Silo Bag Filter 115000 cubic meter
per hour
37KW
Root Blower 29.9 cubic meter per
hour
55KW
Working:
Final product from the silo reaches to the packing plant through bucket elevator and air lift.
From there it is shifted to vibrating screen where any leftover metal piece is separated out.
Now material is ready for packing and transported to a packer where the packing of material
is carried out in cement bags. The bags then fitted by eight nozzle packing machine, then
bags are sealed automatically. These bags then discharged from the packer after exact
weight of bag is achieved.
The trucks then moves on to the dispatch office where they are weighed and then they
leave for specific cement outlets.

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CALCULATIONS:
KILN FEED RETENTION TIME:
T = 11.2 * L/NDS,
L = 64 m
N = 4 revolutions
D = 3.66 m
S = 2.29 °
T = (11.2)(64 )/ (4)(3.66)(2.29)
T = 21.38 mins
FILLING DEGREE (KILN) :
FILLING DEGREE = 3.2T/D³SR
T = 3200 TPD
D = 3.66 m
S = 4 %
R = 4 rev/min
FILLING DEGREE = (3.2)(3200)/(3.66)³ (4)(4)
FILLING DEGREE = 13.05 °
Line I Power Consumption
Clinker factor = 1.60
Gypsum factor = 1.05
Crusher:
Total production = 4102.76 tons / day
Total unit consumed = 5591.00 KWH
Unit consumed / Total production =5591.00 / 4102.76
=1.36 KWH / TPD
= (1.36 x 1.60) / 1.05
= 2.0765 KWH/ tons of cement

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Raw meal:
Total production = 3653.00 tons / day
Total unit consumed = 78870.00 KWH
Unit consumed / Total production = 78870.00 / 3653.00
=21.59 KWH / TPD
= (21.59 x 1.60) / 1.05
= 32.89 KWH / tons of cement
Pyro processing:
Total production = 2507.00 tons / day
Total unit consumed = 89030.00 KWH
Unit consumed / Total production = 89030.00 / 2507.00
= 35.51 KWH / TPD
= 35.51 / 1.05
= 33.82 KWH / tons of cement 28
Cement mill:
Production of cement mill 1 =2202.00 tons / day
Production of cement mill 2 = 934.00 tons / day
Total production = 3136.00 tons / day
Unit consumed by mill 1 = 96405.00 Kwh
Unit consumed by mill 2 = 40676.00 Kwh
Total unit consumed = 137081 Kwh
Unit consumed / total production = 137081 / 3136.00
= 43.71Kwh/ tons of cement 29
Line II Power Consumption
Clinker factor = 1.60
Gypsum factor = 1.05
Crusher:
Total production = 6437.00 tons / day
Total unit consumed = 6052.00 KWH
Unit consumed / Total production = 6052.00 / 6437.00
= 0.940 KWH / TPD
= (0.940 x 1.60) / 1.05
= 1.4326 KWH/ tons of cement

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Vertical Roller Mill (VRM):
Total production = 5640.00 tons / day
Total unit consumed = 92044.00 KWH
Unit consumed / Total production = 92044.00 / 5640.00
=16.31 KWH / TPD
= (16.31 x 1.60) / 1.05
= 24.86 KWH / tons of cement
Pyro processing:
Total production = 3205.00 tons / day
Total unit consumed = 116262.00 KWH
Unit consumed / Total production = 116262.00 / 3205.00
= 36.27 KWH / TPD
= 36.27 / 1.05
= 34.54 KWH / tons of cement 30
Cement mill:
Production of cement mill 3 =2080.00 tons / day
Production of cement mill 4 = 2160.00 tons / day
Total production = 4240.00 tons / day
Total dispatched = 4236 tons / day
Total = 8476 tons / day
Total unit consumed = 148415.00 Kwh
By mills and dispatch
Unit consumed / total production = 148415.00 / 8476.00
= 17.51Kwh/tons of cement

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CONCLUSION:
In review this internship has been an excellent and rewarding experience. I have been able
to meet and network with so many people that I am sure will be able to help me with
opportunities in the future.
The internship was also good to find out what my strengths and weaknesses are. This
helped me to define what skills and knowledge I have to improve in the coming time. It
would be better that the knowledge level of the language is sufficient to contribute fully to
projects.
Resource management:
 Raw material
 Machinery (Plant/Technology)
 Man Power
Cost Economy:
 Capacity utilization
 Reduction in input cost
 Economical use of fuel and power
 AFP, WHRS
Analytical Skills:
 Material & Mass Balance
 Stoichiometry
 Plant specification
 Operational techniques
Leadership qualities:
 Enhanced knowledge
 Role model
 Conceiving ideas for lasting modification n development
 Taking responsibilities
Inventory management:
 Stores n spares
 Maintaining balance in stock 26

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Staff management:
 Selecting right person for job
 Educating and grooming staff
 Timely appreciation and punishment
Communication skills:
 Communication with higher management
 Communication with supplier, plant and plant designer
Safety awareness:
 Man and machinery safeties