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)
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)
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
18. VRM (Vertical Roller Mill)
Accumulator: Acts as a shock absorber
Hydraulic Cylinder: Presses the rollers onto the table and provides the
grinding pressure.
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.
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
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