This document provides a summary of Piyush Mondal's winter training report on his internship at the Cement Corporation of India Ltd. (CCI) Rajban cement factory. It discusses the different phases of cement manufacturing including raw material extraction and crushing, blending and storage, clinker formation in the kiln, and cement manufacturing and packing. It also describes the various material handling equipment and power transmission systems used at the plant as well as an overview of the company's history and operations.

1. A
WINTER TRAINING REPORT
ON
DIFFERENT PHASES OF CEMENT MANUFACTURING, MATERIAL
HANDLING AND POWER TRANSMISSION SYSTEM
SUBMITTED BY
PIYUSH MONDAL
B.TECH (3RD
YEAR), MECH. ENGG.
INDIAN INSTITUTE OF TECHNOLOGY,
(INDIAN SCHOOL OF MINES), DHANBAD
PERIOD (19 DEC 2016 – 19 JAN 2017)

2. ACKNOWLEDGEMENT
The training opportunity I had with CCI Ltd. (Rajban) was a great chance for learning and professional
development. Therefore, I consider myself as a very lucky individual as I was provided with an
opportunity to be a part of it. I am also grateful for having a chance to meet so many wonderful people and
professionals who led me though this training period.
Bearing in mind previous I am using this opportunity to express my deepest gratitude and special thanks to
the GM of CCI RAJBAN Sh. S. K. Sahu who in spite of being extraordinarily busy with her/his duties,
took time out to hear, guide and keep me on the correct path and allowing me to carry out my project at
their esteemed organization and extending during the training.
I express my deepest thanks to Sh. R. C. Sood (Assit. Engr. Mech) for mentoring me and taking part in
useful decision & giving necessary advices and guidance and arranged all facilities to make life easier. I
choose this moment to acknowledge his/her contribution gratefully.
It is my radiant sentiment to place on record my best regards, deepest sense of gratitude to Sh. R. Sinha,
DGM (P&A), Sh. Diwakar (Sr. M. (Inst.)), Sh. Kishan Lal (Sr. M. (Mech)) and all the other staff
members and plant workers for their careful and precious guidance which were extremely valuable for my
study both theoretically and practically.
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. Hope to continue cooperation with all of you in the future,
Sincerely,
[Piyush Mondal]

3. INDEX
CONTENTS
1. INTRODUCTION
I. History & background……………………………………………………………(5)
II. Cement plants of CCI…………………………………………………………….(6)
III. Rajban cement factory………………………………………………………….(7)
2. PHASES OF CEMENT MANUFACTURING PROCESS
I. Raw material (limestone) extraction and crushing atquarry……………(11)
II. Quarry to Blending/Storage Silos………………………………………………………(12)
III. Pre-heater & Clinker formation in kiln………………………………………………(13)
IV. Cement manufacturing, Packing & Shipping………………………………………(14)
3. POLLUTION CONTROL & RECYCLING……………………………………………..(15)
4. MATERIAL HANDLING EQUIPMENTS
I. Apron feeder……………………………………………………………………….(16)
II. Ropeway………………………………………………………………………………(16)
III. Conveyor belts…………………………………………………………………….(17)
IV. Airslide………………………………………………………………………………..(18)
V. Bucket elevator……………………………………………………………………(18)
5. POWER TRANSMISSION SYSTEM
I. Couplings……………………………………………………………………………..(19)
II. Belt drive……………………………………………………………………………..(22)
III. Chain drive……………………………………………………………………………(23)
6. MACHINE TOOLS……………………………………………………………………………(24)
7. BIBLIOGRAPHY…………………………………………………………………………….…(25)

5. INTRODUCTION
 HISTORY & BACKGROUND:
Cement Corporation of India Limited (CCI) is a Public-sector undertaking of the government
of India. The company was incorporated as a wholly government-owned corporation on January 18,
1965, with the objective of setting up cement units in public sector to help achieve self-sufficiency
in cement production in the country.
CCI is based in New Delhi. The corporation manufactures various types of cements, such as
Portland pozzolana cement (PPC), Portland slag cement (PSC), and Ordinary Portland cement (OPC) of
varying grades - 33, 43,53 and 53S (special grade cement for manufacture of sleepers for Indian
Railways).
CCI 10 units spread over seven Indian states and union territories, with a total annual installed capacity of
38.48 lakh MT.
 Vision
To emerge as an sustainable cement company committed to contribute to the economy and to enhance
value for the stakeholders.
 Mission
To improve the net worth of the company, inspiring employees in delivering an improved product and to
aim for diversification in related fields.
CCI with a strong & skilled work-force has always encouraged balanced regional growth with most of its
factories located in underdeveloped/backward areas. CCI has also been contributing to the development of
areas around factories by adopting nearby villages and providing the basic facilities like school, health
center, drinking water etc. For maintaining the ecological balance CCI is launching massive tree
plantation drives from time to time at all units and in surrounding areas.

6.  CEMENT PLANTS OF CCI:
The units are spread throughout the country from East (Bokajan in Assam) to West (Akaltara, Mandhar
in Chhattisgarh and Nayagaon in Madhya Pradesh) and from North (Rajban in Himachal Pradesh and
Charkhi Dadri in Haryana) to South (Kurkunta in Karnataka and Adilabad, Tandur in Telangana), with
one cement grinding unit in Delhi.
The performance of CCI was adversely affected due to severe liquidity crunch[1] and infrastructural
constraints particularly related to power shortage. 7 units out of 10 are non-operational due to various
reasons, especially after Mrs Indira Gandhi, the Prime Minister was no more. The company became sick
and was referred to BIFR. BIFR had directed the OA to appoint a merchant banker to explore the sale of
CCI as a whole as a going concern basis or its units individually or collectively.[2] (The above para is to be
updated as per the status on 2015 as CCI is earning profit year by year after 2007 with its 3 running plants:
Rajban, Bokajan & Tandur)
Cement Plant
Location
State Capacity
Lakh (MT)
Process Date of
Commisioning
Mandhar Chattisgarh 3.80 Wet 19-07-70
Kurkunta Karnataka 1.98 Wet 01-10-72
*Bokajan Assam 1.98 Dry 01-04-77
*Rajban Himachal Pradesh 2.48 Dry 01-04-80
Nayagaon Madhya Pradesh 4.00 Dry 01-03-82
Nayagaon Expn. Madhya Pradesh Clinkarisation Unit Dry 01-05-90
Akaltara Chattisgarh 4.00 Dry 01-04-81
Charkhi-Dadri Haryana 1.74 Semi-Dry 10-05-82
Adilabad Haryana 4.00 Dry 01-04-84
*Tandur Telangana 10.00 Dry 01-07-87
Delhi-Grinding
Unit
Delhi 5.00 --- 01-05-90

7.  RAJBAN CEMENT FACTORY:
LOCATION: Cement Corporation of India Ltd. (Rajban) Cement Factory Unit is situated along the road
side, 10 km away from place called Paonta Sahib (a famous tourist & industrial area). It is also surrounded
by some major cities like 60 km from Dehradun railway station, 75 km from Yamuna Nagar railway
station and 135 km from Chandigarh on National Highway No.72.
This unit was built in villages and in backward area because of its aim of development and employment
among the rural people. Not only this, availabity of raw material (lime stone) from Quarry just 12 km
from Rajban plant is one of the major reasons of its establishment here.
TYPES OF CEMENT: Mainly there are two types of cement being produced here-
1. OPC (Ordinary Portland Cement), 33 Grade as per IS 269.
2. PPC (Portland Pozzolana Cemant as per IS 1489.
Because of huge availability of the raw material required for production of Ordinary Portland Cement or
OPC, it is available in market at highly cost effective prices. Being a low cost yet optimum quality
material, OPC is used for the construction of dams, roads, houses etc. throughout the world.
PPC or Portland Pozzolana Cement is formed when pozzuolans are added in the above mentioned
mixture. The term Pozzuolana means a type of volcanic ash. When Pozzuolana is added in the OPC,
pozzuolanic reaction takes place which forms a cementitious material that requires less amount of cement
but possess greater durability than OPC. In comparison to OPC, PPC takes longer time to settle b ut
produces same result. Portland pozzolana cement contains spherical shaped cement particles which move
freely and allow more finesses than Ordinary Portland Cement. They provide better cohesiveness to the
concrete and decrease its rate of slump loss. The concrete produced using this type of cement possesses
higher strength gain which keeps on increasing with time spent.
RAW MATERIALS: In order in produce Clinker there are mainly three raw materials being used-
a. Limestone [calcium] (84%)
b. Shale [silicon, iron, aluminium] (14%)
c. Iron Dust (2%)
Whereas, composition of two different types of cements are as follows-
1. OPC- Clinker (94%), Gypsum (16%)
2. PPC- Climker (79%), Brickbats (10%), Gypsum (6%), Fly ash (5%)

8. CAPACITY & PROCESS : This plant has the Production Capacity 2.48 lakhs M.T. per year.
The production for the financial year (2015-16) = 191300 M.T.
The total sales for the same year = 167691.11 M.T.
There are several processes of Cement production such as-
 No index entries found.Dry process
 Wet process
 Semi-Dry process
The process used in Rajban Cement Plant is the Dry process of manufacturing
The both calcareous and argillaceous raw materials are firstly crushed in the gyratory crushers to get 2-
5cm size pieces separately. The crushed materials are again grinded to get fine particles into ball or tube
mill. Each finely grinded material is stored in hopper after screening. Now these powdered minerals are
mixed in required proportion to get dry raw mix which is then stored in silos and kept ready to be sent into
rotary kiln. Now the raw materials are mixed in specific proportions so that the average composition of the
final product is maintained properly.
.
Manufacture of Cement by Dry Process

9. Comparison of dry process and wet process of Cement Manufacture
Criteria Dry process Wet process
Hardness of raw material Quite hard Any type of raw material
Fuel consumption Low High
Time of process Lesser Higher
Quality Inferior quality Superior quality
Cost of production High Low
Overall cost Costly Cheaper
Physical state Raw mix (solid) Slurry (liquid)

10. Basic Process of Cement Manufacturing
Quarry
Crushing
Raw Mill
Blending &
Storage Silos
Preheater,
Kiln & Cooler
Clinker
Storage
Grinding
Packing

11. PHASES OF CEMENT MANUFACTURING PROCESS
Production of cement completes after passing of raw materials from the following six phases. These are:
1. Raw material (limestone) extractionand crushing at quarry.
The major raw material for cement production is limestone. The limestone most suitable for cement
production must have some ingredients in specified quantities i.e., calcium carbonates, silica, alumina,
iron, etc. Typically, cement plants locations are based upon the availability of good quality limestone in
the vicinity which is about 10 km (Hill Top) away from the Rajban plant. This saves the extra fuel cost
and makes cement somehow economical.
The quarrying operations are done by the cement producer using the open cast mining process. Quarrying
is done through controlled blasting, drilling and subsequently, using heavy earth moving equipment such
as bulldozers, payloaders and dumpers. The quarried raw material is then transported to the cement plant,
using mechanical conveying equipment such as ropeways or belt conveyors, or by vehicles like wagons
and trucks. The quarried limestone is normally in the form of big boulders, ranging from a few inches to
meters in size. These varying sizes of limestone need to be crushed to a size of about 10 mm in order to be
prepared for finish-grinding. The dumper collects the quarried limestone and dumps it onto the apron
feeder which guides the big sized particles to the crusher. The fine particles falls on the drag chain and
reaches the load hoppers through RB conveyor belts. There are mainly two types of crushers available
for this purpose-compression type or impact type crushers. The impact technology is used in hammer
crusher/impact crusher. The crushed particles are carried to the vibrating screen which detects the fine
particles and separates it from the bigger ones which are again directed towards the crusher for necessary
crushing. Finally the raw material collected in the load hoppers are fed into containers and transported to
the cement plant through bi-way aerial ropeways.
Separation
using Apron
feeder
Crushing
in Impact
Hammer
Crusher
Screening
in Vibrating
screen
Loaded
in hopper

12. 2. From Quarry to Blending/Storage Silos through Raw mill
The crushed raw material (limestone) from the ropeways are dumped into the Raw Mill Hoppers. In
order to get the required composition of raw material, shale and certain additives such as iron ore, bauxite,
laterite, quartzite and fluorspar are added in required quantities. These additives are stored at the plant in
separate hoppers and are extracted using belt conveyors in conjunction with belt-weighing
equipment(weigh feeder). This ensures that only the required quantities are extracted and added to the raw
material. These are then again allowed to pass through Hammer Mill and then carried to the Raw Mill
[(3.5*6.2M), 50 T/N] for further grinding.
The raw material is finish-ground before being fed into the kiln for clinkering. This grinding is done using
either ball mills or vertical roller mills (VRM). The raw material is simultaneously dried. Ball mills use
impact with attrition principles for grinding the raw material. Inside the ball mills, various sizes of balls
are used and classifying liners are used to maintain the position of different sizes of balls. The larger sized
balls are utilized for impact grinding and the smaller balls for attrition. Ball mills are suitable for low and
medium moisture content in the range of five to six per cent and are preferred for abrasive material.
The raw mix is then passed through airslide into the vertical bucket elevator which is then carried upto a
certain height and again after being through the airslide, the raw mix is poured into the air separator.
From the air separator the raw mix is finally transferred to the silos through FK pumps and the raw mix
with relatively bigger size are again send back to the raw mill and treated again. As there are various
sources of raw materials, it becomes necessary to blend and homogenize these different materials
efficiently to counteract fluctuation in the chemical composition of the raw meal. The variations in the
composition of kiln feed have very adverse impacts on the efficiency of the kiln. It results in undesired
coating and ring formation inside the kiln. In order to blend and homogenize the raw materials properly,
continuous blending silos [(10M*18M), 800 T cap.] are used.
Proportional
extraction
of raw
materials
Grinding
in the
Raw Mill
Passes
through Air
Separator
Stored
up in
Blending
Silos

13. 3. Raw Mealthrough Pre-heater& entering Kiln for Clinker formation
After being stored in the storage silos from the blending silos, raw meal supply is controlled by pneumatic
valves and carried through screw conveyors towards the passage hoppers from where it is conveyed once
again using bucket elevators and screw conveyors through the weigh feeders entering into the airslides and
finally into the FK pumps. The excess amount of meal is allowed to get stored in the load cell which is
again shifted to the passage hoppers. The FK pumps pneumatically conveys the raw meal at the top
rapidly from where it enters into the preheating chambers.
Pre-heater chamber consists of series of vertical cyclone from where the raw material passes before
facing the kiln. Pre-heating chamber utilizes the emitting hot gases from kiln. Pre-heating of the material
saves the energy and make plant environmental friendly.
Kiln is a huge rotating furnace also called as the heart of cement making process. Here, raw material is
heated up to 1450 ⁰C. This temperature begins a chemical reaction so called decarbonation. In this
reaction material (like limestone) releases the carbon dioxide. High temperature of kiln makes slurry of
the material.
Rotary kiln
The series of chemical reactions between calcium and silicon dioxide compounds form the primary
constituents of cement i.e., calcium silicate. Kiln is heating up from the exit side by the use of natural gas
and coal. When material reaches the lower part of the kiln, it forms the shape of clinker. After passing out
from the kiln, clinkers are cooled by mean of forced air. Clinker released the absorb heat and cool down to
lower temperature. Released heat by clinker is reused by recirculating it back to the kiln. This too saves
energy.
Storage silos to
Preheater
Enters into the kiln Clinker formation Cooling of Clinker
Size- 3.6 M * 49 M
Capacity- 600 T/Day
Speed- ~(3-4) rpm

14. 4. Cement manufacturing process,Packing & Shipping
The output of the kiln is collected and moved using drag chains for storing before it is fed to the cement
mill for conversion to cement. This storage is called clinker storage, if it is used for clinker storage
purpose. If the storage space is used for gypsum storage, it is called gypsum storage. The storage may be
of silo type or covered stacker reclaimer type or simply a gantry type. Silo type clinker storage has the
advantage that there is no dust pollution and spillage of clinker. Same advantage can be achieved through
stacker reclaimer type as well. However, there is a little bit of dust generated. Gantry type is not used in
modern cement plants because of its environmental unfriendly nature.
Clinker, along with additives, is ground in a cement mill [33 tons/hr Cap.]. The output of a cement mill is
the final product viz. Cement. In a cement mill, there is a cylindrical shell lying horizontal which contains
metallic balls and as it rotates, the crushing action of the balls helps in grinding the clinker to fine
powder. During grinding, gypsum is also added to the mix in small percentage that controls the setting of
cement. The term bag house is applied to large filters containing a number of tubular bags mounted in a
usually rectangular casing. The dust laden air is drawn through them by suction. The bag house is used to
remove dusty particles from discharge of different equipment such as cement mill, coal mill and kiln. In a
bag house system discharge gas containing dusty particles is passed through a series of bags made of
strong fabrics.
The readily manufactured cement is then extracted from the mill and after proper screening of the product,
it is conveyed to the Cement Silos.[(12M∅*25M), 5160 T/day Cap.] Suitable aeration equipments are
installed inside the silos in order to avoid the accumulation of cement. The cement is now ready to be
moved to the packing section where a packer machine[60 ton/hr cap.] is installed which fills up the
cement into the sack, sends them through the roller path and the divider finally gets them loaded in the
cargo vehicle for shipping. Around 12 tons(240 bags) of cement is loaded in a single truck which gets
transported to the customer.
Cement formation
in Cement mill
Stored in Cement
silos
Packing Shipping

15. POLLUTION CONTROL & RECYCLING
Gas Conditioning Tower and ESP
The conditioning tower is used to reduce the temperature and to increase the moisture level of the dusty
exhaust gas from the kiln, before it is passed through the bag house and ESPs. It is called a conditioning
tower because it conditions the hot gas, thus making it more suitable for the ESP and bag house to extract
dust from it. The Electrostatic
Precipitators are used in cement plants
particularly for removal of dust from the
exit gases of cement kilns and from the
exhaust air discharged by dryers,
combined grinding and drying plants,
finishing mills and raw mills through
water injection. Through ESPs, the dust-
laden gas is made to flow through a
chamber usually horizontally, during
which it passes through one or more high
voltage electric fields formed by alternate
discharge electrodes and plate type
collecting electrodes. By the action of
electric field, the dust particles, which
have become electrically charged by
negative gas ions which are formed at the discharge electrodes and attach themselves to the particles, fly
to the collecting electrodes and are deposited there. The dust is dislodged from these electrodes by
rapping and thus falls into the receiving hopper at the base of the precipitator casing.
Cyclone Dust Collectors
Mechanical separator using centrifugal force
to remove large and high-volume dust from
industrial applications.
 An economical solution to a wide range of
dust collection problems.
 Excellent for high dust load, high
temperature, and product recovery
applications.
 Can be used alone, with optional bag filter
assembly, or as a pre-cleaner.
 Applications from 300 to 13,000 cfm.
 Heavy-duty construction for long life and
low maintenance.
 Meets seismic zone 4 and 100 mph wind
load ratings.
 Removable cone section for easy
replacement.

16.  MATERIAL HANDLING EQUIPMENTS

 APRON FEEDER
An apron feeder is a mechanical feeder used to extract raw material typically from dump hoppers, bins
and stockpiles. Apron feeders are used to extract or feed materials :
♦ At a short distance.
♦ At a controlled rate of speed. The purpose of a slow
controlled rate of speed (feed) is
1. to prevent choking of material feeding
crushers and other equipment.
2. to reclaim material at a uniform rate from
hoppers, bins & stockpiles.
Apron Feeders are used in applications when:
♦ the need to feed large lumps of raw ore under
severe impact conditions.
♦ when material is wet, sticky / clayish or lumpy and can not be handled by other equipment or feeders.
♦ as a buffer to protect down stream equipment such as conveyors, crushers, wobbler feeders &
vibrating grizzlies.
 ROPEWAY
In a cement factory a ropeway can be used to bring
limestone from the quarry to the processing plant, which
is one of the central activities in cement production. The
cost of transporting limestone determines the cost of the
cement produced, and, as a result, the commercial
viability of a plant. Transport by trucks is expensive
because they run on imported fuel. Shortages of fuels,
which occur from time to time due to local, national and
international causes, jeopardize their smooth operation.
Though a ropeway runs on expensive equipment
requiring high initial capital investment, its maintenance
and operational costs are less compared to those of
trucks. Another advantage of a ropeway is that, except
for high winds—which last for a short time anyway—
unfavourable weather conditions, in particular the
monsoon rains, do not affect its operation. Its effective
operation is, however, critically dependent upon regular
maintenance and immediate repair. Continuity is
essential as even a brief stoppage in the provision of
limestone can completely disrupt cement production.

17.  CONVEYOR BELTS
1. BELT CONVEYORS
Its used to transport bulk raw / finished material. The
versatility, dependability and economy of the belt conveyor are
demonstrated in transporting a wide variety of material. The
adaptation of belt conveyor for special purpose and the
integration of belt conveyor with other equipment has
increased their usefulness.
The complete unit consists of all types of Idlers/Roller, Idlers
Frames, Pulleys, Conveyor Belts, Gear Boxes & Motors, Input
& Output Coupling, Internal & External Scrappers, Skirt
Boards, Deck Plates, Stringers, Short Support, Hood, VGTU,
Safety Switches etc.
2. DRAG CHAIN CONVEYOR:
A Drag Chain Conveyor is a conveyor in which the open links
of chain drag material along the bottom of a hard faced MS or
SS trough. It generally have a low bed height and are open
type. The flights are fixed between two strands of chain, drags
the material from feeding end to the discharge end in open or
closed trough. These are available in difference widths and
lengths as per the site requirements and are also used for
handling slightly sluggish, loose or lumpy hot
material(Clinkers).
Generally these conveyors are easy to install and have very
minimum maintenance for the clients. These are available in
different widths and lengths as per the clients/site
requirements. These conveyors are dust proof, low noise and
sealed design.
3. SCREW TYPE CONVEYORS
Screw conveyors possess the capability to handle various
types of bulk materials that range from free-flowing to
sluggish. This conveyor is designed with multiple
discharge points and inlets. It can convey and distribute
bulk materials to any desired location. The flow can be
controlled by adding slide valves or gates to screw
conveyor. Screw conveyor can also be used as metering
device in the name of screw feeder.

18.  AIRSLIDE
Cement Plant requires Slide gates to control the flow of materials
from storage silos, bins, conveyors and any other discharge points
handling dry bulk materials. These are widely used in different
sectors and acknowledged for the smooth functionality and long
service life features. The Air Slide is designed to convey bulk
powders from silos or storage compartments into a processing
system. They provide a convenient and easily controllable method
of conveying – they can incorporate bends and multiple discharge
points if necessary.
 BUCKET ELEVATOR
Bucket elevators are ideal for elevating a variety of bulk materials economically, efficiently and reliably.
The two main type of Bucket Elevators are: Centrifugal
type and Continuous type. These are usually centrifugal
chain type bucket elevators with buckets mounted on a
single strand of chain The buckets are normally a
special combination of AA and continuous type bucket.
Centrifugal type bucket elevators are extremely suitable
for handling fine, free flowing materials. Lover feed
point, simpler loading and lesser no. of buckets
compared to continuous. Buckets are on chain or belt
and travel at high speeds to effect discharge by
centrifugal forces as they pass around the head pulley.
The buckets are mounted at intervals on a chain belt.

19.  POWER TRANSMISSION SYSTEM
 COUPLINGS
Couplings are mechanical elements that ‘couples’ two drive elements which enables motion to be
transferred from one element to another. The drive elements are normally shafts. We tend to see lot of
applications of the couplings mainly in the automobile sector and industrial plants like cement plant, for
example the drive shaft which connects the engine and the rear axle in a bus or any automobile is
connected by means of a universal joint.
In order to transmit torque between two shafts that either tend to lie in the same line or slightly
misaligned, a coupling is used. Based on the area of applications there are various types of coupling
available. But they are generally categorized in the following varieties
1. Rigid Couplings
2. Flexible or Compensating Couplings
3. Clutches to are a type of Coupling
power
supply
motor
couplings
gear/chain
drive
couplings
bearings
Motor
Coupling
Pump

20.  RIGID COUPLINGS
Rigid Couplings are mainly used in areas where the two shafts are coaxial to each other. There are many
types of couplings that fall under the rigid couplings category. They are
· Rigid Sleeve or Muff Couplings- This is the basic type of coupling. This consists of a pipe whose bore is
finished to the required tolerance based on the shaft size. Based on the usage of the coupling a keyway in
made in the bore in order to transmit the torque by means of the key. Two threaded holes are provided in
order to lock the coupling in position. The photo shows a type of the rigid sleeve or muff coupling.
· Flanged Coupling – The coupling basically consists of two flanged end pieces as shown in the figure. A
spigot and recess is provided in the flanges to provide location between them. The flanges are connected
firmly by means of fitted bolts which are tightened accordingly to the torque to be transmitted.
 FLEXIBLE OR COMPENSATING COUPLINGS
Flexible couplings are normally used in areas where the coaxiallity between the connecting shafts is not
always assured and in areas where there is a possibility of occurrence of shocks in the transmission is
applicable. They are also called as Elastic Couplings. By
construction these couplings tend to have an elastic
member in between the two connecting entities. The
different types of flexible couplings are:
1. Flanged Pin Bush Couplings
2. Gear Tooth Coupling
3. Tyre couplings
4. Oldhams Coupling
5. Universal Coupling or Hooke’s Coupling
In Rajban cement plant mostly pin bush type, gear coupling, Hi-torque resilient coupling and jaw/claw
coupling are being in use.
Flange
Driven Shaft
Driving shaft
Key Hub
FlangeFlange
Driving
Shaft
Driven Shaft
Pin
Bush

21. Tyre coupling Gear coupling
Uses of coupling:
• To provide connection of shafts of units made separately
• To allow misalignment of the shafts or to introduce
mechanical flexibility.
• To reduce the transmission of shock loads
• To introduce protection against overloads.
• To alter the vibration characteristics
Advantages
• Torsionally stiff
• No lubrication or maintenance Hi-torque resilient coupling
• Good vibration damping and shock absorbing qualities
• Less expensive than metallic couplings
• More misalignment allowable than most metallic couplings
Limitations
• Sensitive to chemicals and high temperatures
• Usually not torsionally stiff enough for positive displacement
• Larger in outside diameter than metallic coupling
• Difficult to balance as an assembly Jaw coupling

22.  BELT DRIVE
A belt is a looped strip of flexible material, used to mechanically link two or more rotating shafts. They
may be used as a source of motion, to efficiently transmit power, or to track relative movement. Belts are
looped over pulleys. In a two pulley system, the belt can either drive the pulleys in the same direction, or
the belt may be crossed, so that the direction of the shafts is opposite.
Advantages of belt drive
• They are simple. They are economical.
• Parallel shafts are not required.
• Overload and jam protection are provided.
• Noise and vibration are damped out. Machinery life is prolonged because load fluctuations are
cushioned (shock-absorbed).
• They are lubrication-free. They require only low maintenance.
• They are highly efficient (90–98%, usually 95%). Some misalignment is tolerable.
 They are very economical when shafts are separated by large distances.
Disadvantages of belt drive
• The angular-velocity ratio is not necessarily constant or equal to the ratio of pulley diameters,
because of belt slip and stretch.
• Heat buildup occurs. Speed is limited to usually 7000 feet per minute (35 meters per second).
Power transmission is limited to 370 kilowatts (500 horsepower).
• Operating temperatures are usually restricted to –31 to 185°F (–35 to 85°C).
• Some adjustment of center distance or use of an idler pulley is necessary for wear and stretch
compensation.
• A means of disassembly must be provided to install endless belts.
flat belt v-belt timing belt

23.  CHAIN DRIVE
Chain drive is a way of transmitting mechanical power from one place to another. It is often used to
convey power to the wheels of a vehicle, particularly bicycles and motorcycles. It is also used in a wide
variety of machines besides vehicles. Most often, the power is conveyed by a roller chain known as the
drive chain or transmission chain, passing over a sprocket gear, with the teeth of the gear meshing with the
holes in the links of the chain.
Advantages of chain drive:
• As no slip takes place during chain drive,
hence perfect velocity ratio is obtained.
• Since the chains are made of metal, therefore
they occupy less space in width than a belt or
rope drive.
• It may be used for both long as well as short
distances.
• It gives a high transmission efficiency (upto
98 percent).
• It gives less load on the shafts.
• It has the ability to transmit motion to several
shafts by one chain only.
• It transmits more power than belts.
• It permits high speed ratio of 8 to 10 in one step.
• It can be operated under adverse temperature and atmospheric conditions.
Limitations of chain drive:
• The production cost of chains is relatively high.
• The chain drive needs accurate mounting and careful
maintenance, particularly lubrication
and slack adjustment.
• The chain drive has velocity fluctuations especially when
unduly stretched.

24.  MACHINE TOOLS (WORKSHOP)
LATHE MACHINE

25. BIBLIOGRAPHY
 Internet (Google)
 Staff members (Mechanical section)
 Workers (plant & machining workshop)
 Books (Machine Design, Production Technology)…. etc
THANK YOU…