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LafargeHolcim
Bangladesh Ltd.
Group Presentation A 21-day long Industrial Training
Surma Plant Overview
1,17,590 MT of Clinker.
Monthly Production Rate
Internal employees 192
External employees 380.
No. of Employees
The only fully
integrated cement plant
in Bangladesh.
Specialty
Longest troughed
conveyor belt (17 KM)
in the world.
Specialty
Zero compromise in the
case of Health and
Safety concerns.
H&S Concerns
1,25,462.48 MT of Cement.
Health and Safety Rules
1
5
2
3
4
5
I assess and control risks before starting any task.
I only perform activities for which I am authorized.
I never override or misuse health & safety devices,
and I always use the required PPE.
I do not work under the influence of alcohol or drugs.
I report all incidents.
Personal Protective Equipment (PPE)
Helmet Goggles Vest Shoes Earplug GlovesMask
The ESSENTIALS The SPECIALIZED
(Job Specific, Site Specific)
Maintenance Department Overview
Preventive
Maintenance
Electrical Maintenance Mechanical Maintenance Instrumentation
& Control
Preventive Maintenance Department Overview
First Level (Walk By)
Inspection Planning &
Scheduling
Modifies the existing
design according
to the requirement.
Drawing &
Design Carries out the routined
lubrication
of the machinery parts.
Lubrication
Second Level (Specific)
Temperature Gun
Strobo-light
Dial Gauge
Ultrasonic Thickness
Gauge etc.
Checks availability, logistic support,
manpower, required time and creates
a work order.
If not available
Generates a PR.
Hierarchy observes and modifies if needed.
PR is sent to the purchaser.
Purchaser analyses & generates a PO.
The supplier then supplies.
Inspection
Vibro Pen
1st Level 2nd Level
Bearing Check:
- Pitting Check (Mainly occurs due to the electricity flow through the bearing)
- Clearance Check (Filler Gauges are used to check the clearance)
- Grease Color Check (Checks if the temperature is okay or not)
- Adapter Sleeve, Dust Seal, Location Ring Check
- Housing Condition Check
- Bearing Alignment Check (Toe in toe out)
Gearbox Check:
- Oil Flowing Condition Check
- Gear Teeth Profile Check
- Bearing Check
Checking Misalignment of Shaft/Coupling:
- Offset Misalignment
- Angular Misalignment
Dial Gauges are used to check whether the
misalignment in range of the coupling’s
tolerable limit.
(Is placed in the horizontal, vertical and axial
position to measure vibration along these
directions)
- Horizontal (Impeller Coating or Imbalance.)
- Vertical (Bearing Housing Loose)
- Axial (Shaft Misalignment)
Lubrication
Kiln: Main Gearbox: Mobilgear 632 ISOVG – 320
Solid
(Carbon, Graphite etc.)
Semi Solid
(Grease etc.)
Liquid
(Oil)
LBC: Main Gearbox – Mobilgear 634 ISOVG – 460
Hydraulic Capstain Brake: ISOVG – 46
VRM: Main Gearbox MAAG: Mobilgear 623 ISOVG – 320
Roller: Mobilgear 639 ISOVG – 1000
Hydraulic System : ISOVG – 46
Cement Production Process
LBC LSS
Hopper
Building
VRM Preheater
Kiln
Clinker
Cooler
Clinker
Silo
Hopper
Building
Cement
Mill
Packing
Plant
LBC (Long Belt Conveyor)
Conveys limestone to the plant which is an essential ingredient in cement production.
VS30 Drive Pulley
VS20 Drive Pulley
1st Bend Pulley
2nd Bend Pulley
Take Up Pulley
1st Snub
Pulley
1st Pressure
Pulley
2nd Pressure
Pulley
2nd Snub
Pulley
Fig: Long Belt Conveyor
Idlers
LBC (Long Belt Conveyor)
1 2 3
4 5 6
10 KM of the belt is in Bangladesh
region and 7 KM is in India region,
a total of 17 KM in length.
The belt is of 800 TPH capacity.
All three drives (630 KW each, 2 in
Bangladesh & 1 in India)
are synchronized together.
Chords are used as they can take up a
lot more tension in comparison to the
fabric type belts.
To strengthen the belt, 50x20
mm chords are used
inside the rubber belt.
Moves at a speed of 4 meters
per second.
7
As it’s a long belt, it’s essential
to keep the belt in tension and
that’s why counter weight is used. 8
Snub Pulley and Pressure Pulley
are used to give the belt a stronger
grip. 9
To prevent the idlers from damaging,
The carrying part and the return part
are altered at a point.
LBC (Long Belt Conveyor)
Fig. Limestone coming through the Long belt conveyorFig. Long Belt Conveyor
LBC (Long Belt Conveyor)
Fig. Limestone coming through the Long belt conveyorFig. Long Belt Conveyor
LBC (Long Belt Conveyor)
Mechanism of ‘How the motion is transferred from Motor to Pulley’
Motor Gearbox Pulley
Coupling Coupling
Different types of Coupling
Pin Bush Coupling Fluid Coupling Geared Coupling
LSS (Limestone Storage Shed)
A storage space for limestone and clay.
Fig: Bridge Reclaimer Fig: Bridge Reclaimer
VRM (Vertical Roller Mill)
Grinds the proportionate mixture of raw materials to a certain level of fineness.
Fig: VRM Flowchart
VRM (Vertical Roller Mill)
Fig: Inside of a VRM Fig: Working parts of a VRM
VRM (Vertical Roller Mill)
Accumulator: Acts as a shock absorber
Hydraulic Cylinder: Presses the rollers onto the table and provides the
grinding pressure.
Hopper Building
Fig: Clay Fig: Iron ore
VRM (Vertical Roller Mill)
Fig: Hot gas going into the VRM
Kiln
Turns the fine mixture of raw materials to Clinker through a series of chemical reactions.
Preheater: Increases the efficiency of the Kiln.
Rotary Kiln: Provides sufficient temperature and environment for necessary chemical
reactions required for clinker production.
Clinker Cooler: Hot clinker coming out of the Kiln is cooled using blown air.
Clinker Silo: Storage Space for Clinker.
Kiln
Turns the fine mixture of raw materials to Clinker through a series of chemical reactions.
Fig: Clinkerization process
Kiln Roller Drive Components
Fig: Hydraulic Thrust Devices for Proper Kiln Operations
The kiln is inclined at an angle to the horizontal so at it rotates, it possesses a threat to slip downwards.
In order to prevent this from happening, guide roller is used.
Kiln Roller Drive Components
Fig: Hydraulic Thrust Devices for Proper Kiln Operations
The tires provide support to the Kiln and keep the Kiln in rotation.
Kiln
Fig: Preheater Fig: Rotary Kiln Fig: Rotary kiln from underneath
Kiln
Fig: Pan conveyor in the clinker cooler Fig: Clinker Silo
Cement Mill
Grinds the mixture of Clinker, Gypsum and limestone to produce the final product.
Fig: Ball Mill Overview
Ball Mill
Fig: Grinding Mechanism of a Ball Mill
Fig: Inside of a Ball Mill
Ball Mill
Fig: Grinding Mechanism of a Ball Mill
Cement Mill Components
Slide Shoe Bearing: Helps to reduce the friction and provides a support to
the ball mill.
Planetary Gearbox: Are used because a huge magnification in torque is needed
in a compact space.
Each ball mill contains two slide rings and they’re placed on two slide shoe bearings and each bearing contains two
slide shoes which are made of babbitt materials.
In the center of the slide shoes, there is a HP line.
High Pressure (HP) Pump forces oil through this line to lift the ball mill up.
Low Pressure Pump maintains a film of lubricant in between the slide shoes and the slide ring.
There is another pump which recirculates the lube oil and makes it cooler and cleaner.
Slide shoes are cooled using water which flows through the tubes placed inside it.
Cement Mill Lubrication System
Packing Plant
x x
High High
High
Low
Silo
Mechanical Gate
Pneumatic Gate
Proxy
Fan
Central Hopper
Packer Machine
Barge Loading
Truck Loading
Fig: Packing Plant Flowchart
x8
Vibrating Screen
Hopper
Packing Plant
Packs the final product according to the requirement.
Cement Mill
Cement Silo 1
Cement Silo 2
Hopper
Hopper
Packer Machine 1
Packer Machine 2 (Future)
Packer Machine 3
Packer Machine 4
Fig: Packing Plant Overview
Packing Plant
Fig: Packer Machine Fig: Belt Conveyor
Packer Machine
Fig: Packer Machine
Capacity and Specifications
VRM 270 t/h @ 12% R on 90 Microns
Kiln 276 t/h
3.3 rpm
Cement Mill 100 TPH OPC @ 3200 blaine
990 RPM
Motor Rating – 3800 KW
Gearbox Reduction Ratio – 64.12
Shell RPM – 15.43
Barring Motor Ratio – 90 KW
Reduction Radio – 74.35
Shaft Speed – 1480 RPM
Packer Machine 100 t/h
Some Inspection &
Execution Jobs
Bearing Replacement in Cement Mill
Fig: Bearing replacement Fig: Bearing Replacement Fig: Clearance checking
Yearly Inspection of LBC
Fig: Fan to cool down the motor
Fig: Bearing Fig: Geared Coupling
Roller Overhauling in VRM
Fig: Heating the seal ring Fig: Seal Ring Removal Fig: placing the roller
horizontally
Fig: Hydraulic Jack
placement
Roller Overhauling in VRM (Cont.)
Fig: NU roller bearing Fig: Outer race cutting using oxy-acetylene flame Fig: Double roller
Spherical bearing
“Every ending is a new beginning.”
For all your relentless assistance and cordiality, all we can say is,
Latiful Kabir | Md. Mohaiminul Islam Sakib | Faiyaz Bin Naser
Md. Anamul Haque | Jewel Chakma
Dept. of MEE | SUST

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Plant Overview - LafargeHolcim Bangladesh Ltd.

  • 1. LafargeHolcim Bangladesh Ltd. Group Presentation A 21-day long Industrial Training
  • 2. Surma Plant Overview 1,17,590 MT of Clinker. Monthly Production Rate Internal employees 192 External employees 380. No. of Employees The only fully integrated cement plant in Bangladesh. Specialty Longest troughed conveyor belt (17 KM) in the world. Specialty Zero compromise in the case of Health and Safety concerns. H&S Concerns 1,25,462.48 MT of Cement.
  • 3. Health and Safety Rules 1 5 2 3 4 5 I assess and control risks before starting any task. I only perform activities for which I am authorized. I never override or misuse health & safety devices, and I always use the required PPE. I do not work under the influence of alcohol or drugs. I report all incidents.
  • 4. Personal Protective Equipment (PPE) Helmet Goggles Vest Shoes Earplug GlovesMask The ESSENTIALS The SPECIALIZED (Job Specific, Site Specific)
  • 5. Maintenance Department Overview Preventive Maintenance Electrical Maintenance Mechanical Maintenance Instrumentation & Control
  • 6. Preventive Maintenance Department Overview First Level (Walk By) Inspection Planning & Scheduling Modifies the existing design according to the requirement. Drawing & Design Carries out the routined lubrication of the machinery parts. Lubrication Second Level (Specific) Temperature Gun Strobo-light Dial Gauge Ultrasonic Thickness Gauge etc. Checks availability, logistic support, manpower, required time and creates a work order. If not available Generates a PR. Hierarchy observes and modifies if needed. PR is sent to the purchaser. Purchaser analyses & generates a PO. The supplier then supplies.
  • 7. Inspection Vibro Pen 1st Level 2nd Level Bearing Check: - Pitting Check (Mainly occurs due to the electricity flow through the bearing) - Clearance Check (Filler Gauges are used to check the clearance) - Grease Color Check (Checks if the temperature is okay or not) - Adapter Sleeve, Dust Seal, Location Ring Check - Housing Condition Check - Bearing Alignment Check (Toe in toe out) Gearbox Check: - Oil Flowing Condition Check - Gear Teeth Profile Check - Bearing Check Checking Misalignment of Shaft/Coupling: - Offset Misalignment - Angular Misalignment Dial Gauges are used to check whether the misalignment in range of the coupling’s tolerable limit. (Is placed in the horizontal, vertical and axial position to measure vibration along these directions) - Horizontal (Impeller Coating or Imbalance.) - Vertical (Bearing Housing Loose) - Axial (Shaft Misalignment)
  • 8. Lubrication Kiln: Main Gearbox: Mobilgear 632 ISOVG – 320 Solid (Carbon, Graphite etc.) Semi Solid (Grease etc.) Liquid (Oil) LBC: Main Gearbox – Mobilgear 634 ISOVG – 460 Hydraulic Capstain Brake: ISOVG – 46 VRM: Main Gearbox MAAG: Mobilgear 623 ISOVG – 320 Roller: Mobilgear 639 ISOVG – 1000 Hydraulic System : ISOVG – 46
  • 9. Cement Production Process LBC LSS Hopper Building VRM Preheater Kiln Clinker Cooler Clinker Silo Hopper Building Cement Mill Packing Plant
  • 10. LBC (Long Belt Conveyor) Conveys limestone to the plant which is an essential ingredient in cement production. VS30 Drive Pulley VS20 Drive Pulley 1st Bend Pulley 2nd Bend Pulley Take Up Pulley 1st Snub Pulley 1st Pressure Pulley 2nd Pressure Pulley 2nd Snub Pulley Fig: Long Belt Conveyor Idlers
  • 11. LBC (Long Belt Conveyor) 1 2 3 4 5 6 10 KM of the belt is in Bangladesh region and 7 KM is in India region, a total of 17 KM in length. The belt is of 800 TPH capacity. All three drives (630 KW each, 2 in Bangladesh & 1 in India) are synchronized together. Chords are used as they can take up a lot more tension in comparison to the fabric type belts. To strengthen the belt, 50x20 mm chords are used inside the rubber belt. Moves at a speed of 4 meters per second. 7 As it’s a long belt, it’s essential to keep the belt in tension and that’s why counter weight is used. 8 Snub Pulley and Pressure Pulley are used to give the belt a stronger grip. 9 To prevent the idlers from damaging, The carrying part and the return part are altered at a point.
  • 12. LBC (Long Belt Conveyor) Fig. Limestone coming through the Long belt conveyorFig. Long Belt Conveyor
  • 13. LBC (Long Belt Conveyor) Fig. Limestone coming through the Long belt conveyorFig. Long Belt Conveyor
  • 14. LBC (Long Belt Conveyor) Mechanism of ‘How the motion is transferred from Motor to Pulley’ Motor Gearbox Pulley Coupling Coupling Different types of Coupling Pin Bush Coupling Fluid Coupling Geared Coupling
  • 15. LSS (Limestone Storage Shed) A storage space for limestone and clay. Fig: Bridge Reclaimer Fig: Bridge Reclaimer
  • 16. VRM (Vertical Roller Mill) Grinds the proportionate mixture of raw materials to a certain level of fineness. Fig: VRM Flowchart
  • 17. VRM (Vertical Roller Mill) Fig: Inside of a VRM Fig: Working parts of a VRM
  • 18. VRM (Vertical Roller Mill) Accumulator: Acts as a shock absorber Hydraulic Cylinder: Presses the rollers onto the table and provides the grinding pressure.
  • 19. Hopper Building Fig: Clay Fig: Iron ore
  • 20. VRM (Vertical Roller Mill) Fig: Hot gas going into the VRM
  • 21. Kiln Turns the fine mixture of raw materials to Clinker through a series of chemical reactions. Preheater: Increases the efficiency of the Kiln. Rotary Kiln: Provides sufficient temperature and environment for necessary chemical reactions required for clinker production. Clinker Cooler: Hot clinker coming out of the Kiln is cooled using blown air. Clinker Silo: Storage Space for Clinker.
  • 22. Kiln Turns the fine mixture of raw materials to Clinker through a series of chemical reactions. Fig: Clinkerization process
  • 23. Kiln Roller Drive Components Fig: Hydraulic Thrust Devices for Proper Kiln Operations The kiln is inclined at an angle to the horizontal so at it rotates, it possesses a threat to slip downwards. In order to prevent this from happening, guide roller is used.
  • 24. Kiln Roller Drive Components Fig: Hydraulic Thrust Devices for Proper Kiln Operations The tires provide support to the Kiln and keep the Kiln in rotation.
  • 25. Kiln Fig: Preheater Fig: Rotary Kiln Fig: Rotary kiln from underneath
  • 26. Kiln Fig: Pan conveyor in the clinker cooler Fig: Clinker Silo
  • 27. Cement Mill Grinds the mixture of Clinker, Gypsum and limestone to produce the final product. Fig: Ball Mill Overview
  • 28. Ball Mill Fig: Grinding Mechanism of a Ball Mill Fig: Inside of a Ball Mill
  • 29. Ball Mill Fig: Grinding Mechanism of a Ball Mill
  • 30. Cement Mill Components Slide Shoe Bearing: Helps to reduce the friction and provides a support to the ball mill. Planetary Gearbox: Are used because a huge magnification in torque is needed in a compact space.
  • 31. Each ball mill contains two slide rings and they’re placed on two slide shoe bearings and each bearing contains two slide shoes which are made of babbitt materials. In the center of the slide shoes, there is a HP line. High Pressure (HP) Pump forces oil through this line to lift the ball mill up. Low Pressure Pump maintains a film of lubricant in between the slide shoes and the slide ring. There is another pump which recirculates the lube oil and makes it cooler and cleaner. Slide shoes are cooled using water which flows through the tubes placed inside it. Cement Mill Lubrication System
  • 32. Packing Plant x x High High High Low Silo Mechanical Gate Pneumatic Gate Proxy Fan Central Hopper Packer Machine Barge Loading Truck Loading Fig: Packing Plant Flowchart x8 Vibrating Screen Hopper
  • 33. Packing Plant Packs the final product according to the requirement. Cement Mill Cement Silo 1 Cement Silo 2 Hopper Hopper Packer Machine 1 Packer Machine 2 (Future) Packer Machine 3 Packer Machine 4 Fig: Packing Plant Overview
  • 34. Packing Plant Fig: Packer Machine Fig: Belt Conveyor
  • 36. Capacity and Specifications VRM 270 t/h @ 12% R on 90 Microns Kiln 276 t/h 3.3 rpm Cement Mill 100 TPH OPC @ 3200 blaine 990 RPM Motor Rating – 3800 KW Gearbox Reduction Ratio – 64.12 Shell RPM – 15.43 Barring Motor Ratio – 90 KW Reduction Radio – 74.35 Shaft Speed – 1480 RPM Packer Machine 100 t/h
  • 38. Bearing Replacement in Cement Mill Fig: Bearing replacement Fig: Bearing Replacement Fig: Clearance checking
  • 39. Yearly Inspection of LBC Fig: Fan to cool down the motor Fig: Bearing Fig: Geared Coupling
  • 40. Roller Overhauling in VRM Fig: Heating the seal ring Fig: Seal Ring Removal Fig: placing the roller horizontally Fig: Hydraulic Jack placement
  • 41. Roller Overhauling in VRM (Cont.) Fig: NU roller bearing Fig: Outer race cutting using oxy-acetylene flame Fig: Double roller Spherical bearing
  • 42. “Every ending is a new beginning.” For all your relentless assistance and cordiality, all we can say is, Latiful Kabir | Md. Mohaiminul Islam Sakib | Faiyaz Bin Naser Md. Anamul Haque | Jewel Chakma Dept. of MEE | SUST