From the limestone quarry to the delivery of the end product, follow every step in the cement manufacturing process. Step 1: Mining. ... Step 2: Crushing, stacking, and reclaiming of raw materials. ... Step 3: Raw meal drying, grinding, and homogenization. ... Step 4: Clinkerization. ... Step 5: Cement grinding and storage. ... Step 6: Packing. 14 Different types of cement :- Ordinary Portland Cement (OPC): This is the most common type of cement which is extensively used. ... Rapid Hardening cement: ... Low heat portland cement: – ... Sulphate Resisting Portland Cement:- ... High alumina Cement:- ... Blast furnace slag cement:- ... Coloured Cement:- ... Pozzolana cement :-

1. Internship Report
Internship Duration (15 days, 14-29th
Dec 2018)
Noman Zia
Batch-17 Chemical Engineering
D-17-CH-05

2. Introduction:
Lucky Cement is a part of one of the largest business groups in
Pakistan, the Yunus Brothers Group. Lucky Cement Limited
was founded in 1993 by Abdur Razzak Tabba. The company
started with factories in the Pezu located in Lakki Marwat
District, district of the Khyber PakhtoonKhwa (KPK). It now,
also, owns a factory in Karachi. Lucky Cement Limited (LCL) is
one of the largest producers and leading exporter of quality
cement in Pakistan with the production capacity of 7.75
million tons per annum. The company is listed on Karachi,
Lahore, Islamabad, and London Stock Exchanges.

3. Table of Contents
Quarry
Crusher
Stacker & Reclaimer
VRM (Vertical Raw Mill)
Pyro-Process (Pre-heater, Kiln & WHR section)
Mixing of Gypsum & Final Grinding
Packaging

4. Quarry
Total Area: 11KM2
Number of Phases: 7
Most limestone enriched phase: #5
Factors affecting the composition of raw material w.r.t area is regarded as Budge
Formation.
Quarry operation consist of 2 parts,
• Blasting
• Mining
Blasting:
For blasting bores are drilled in the desired place using a diamond rotary driller
deeper than the bench height in order to avoid TOW, this is called sub-drilling, once
the holes are drilled explosives are dosed into the bores. Bores are drilled with
spacing of 4.5m and burden of 4m.
The following types of explosives are used,
1. Blaster
2. Super Blaster
Both consist of a set of proportions of these 2
materials,
• Aculite (High Explosives)
• Ammonium Nitrate (Low Explosives)
Most commonly for blaster 20% Low
Explosives and 80% high explosives and vise
versa for Super blaster.
3 types of cords are used to control the
explosions
• Explosive cord: Burning rate 4000m/h
approx. Is attached with the explosives.
• Black Cord or ignition cord: Burning rate
110sec/m. used for ignition.
• Delay Relay: used to make delay between the explosions of about 50-80ms.
Connected between explosive cord connecting two bores of explosives.
Mining:
After blasting the material is transported to crushing section using Loader and
Dumper trucks.

5. Crusher:
Type of crushers: Hammer Crusher
Number of Crushers: 5
• 2 Limestone Crushers
• 2 Coal & Clay Crusher
• 1 Gypsum crusher
Working:
Dumper feeds the large rocks into the feed hopper which transfers the feed to the
apron conveyer, which dumps the feed into the crusher, first the feed falls on the
feed roller which decreases the size of any bulk having a greater size to
approximately 1m2, which then passes the feed to the hammer crusher, material is
crushed by the hammer roller rotating consisting of 45 total hammers in 5 shafts
(each hammer weighing about 120KG) into size of about 70-80mm, which then falls
into a chute connecting to delivery tunnel consisting of a delivery conveyer, this
conveyer transport the crushed material to long belt. Any material (relatively fine
particles) falling off the apron is collected by a discharge belt is dropped into a
chute also connecting to delivery tunnel, this dust in delivery tunnel is then picked up
by bag filter which is again mixed with the crushed material in delivery belt. There is
also a magnet separator to remove any metal fillings present in the crushed feed.
All the crushers work generally on the same
method and 3 principle laws of crushing
(Rittinger’s Law, Bond’s Law and Kick’s Law)
Whole Crushing operation is consisting of the
following:
• Feed Roller
• Rotary Hammer (1000KW Motor)
• Apron Conveyer (37 KW Motor)
• Discharge conveyer (45 KW Motor)
• Magnet Separator
• Bag Filter

6. Stacker & Reclaimer:
Delivery tunnel transports the crushed material to long belt, this belt transports the
material to piling area, the stacker takes feed from long belt and make piles of the
material ready to be transported by the reclaimer, reclaimer consists of a bucket
conveyer which picks up material from the piles and transports as per requested
amount to the way feeder,
Vertical Raw Mill (VRM):
Each plant has 2 VRMS one for raw crushed material grinding and one for Clinker
and Gypsum grinding, each plant also has a pair of ball mills for optional use.
As the 3 Way-feeders drops raw material (Limestone, Clay and Laterite) on long belt
in a fixed proportion, it is transported to the feed hopper of the VRM, this then falls
onto a rotary feeder which acts as an airlock for the VRM system, as the material
enters the VRM it falls through a duct onto a rotating table, grinding is done by 4 220
tons rollers supported and controlled by hydraulic shafts which grinds the material as
the material forces its way from under the bottom of roller, fine grinded particles are
then fluidized by the hot Flue Gas (around 320 degC) coming from Kiln which
increases the temperature of material in VRM and also fluidizes and carries the fine
material to classifier connected on the top of VRM, any large particles are declined
by the classifier and falls on the rotating table, any uncrushed particles are fallen
though damper ring and is called rejected material which is then then picked up by
rejected elevator buckets and mixed with hopper feed.
The fine material accepted by the classifier is then transported to a set of 4 High
efficiency Cyclone separators which separates about 90-95% of fine particles from
flue gas, the fine material is then fallen into an air slide which transfer the material to
silo elevator and is stored in Raw material Silo, while the flue gas leaving cyclone
enters the bag house where 5% of the remaining ultra-fine material is separated and
is mixed with the air slide material going to the Raw material Silo while the flue gas is
removed to the atmosphere from stack.

7. VRM is comprised of the followings:
• Damper ring
• Rotating table
• Center Doming plate
• Clamping rings
• Table liners
• Dam ring
• Scatter Ring (Curved ring)
• Louvre Ring (Flue Gas Intake)
• Armored Ring
• 4 Rollers (220 Tons Each) with hydraulic arms
• Reject bucket elevator
• 4 high eff. separator cyclones
• Air slide (with blowers)
• Bag house filter
• Raw material storage silo

8. Pyro-Process:
Following process takes place in Pre-heater, kiln & cooling
section,
• @100 degC free moisture evaporates.
• @500 degC chemically combined water decomposes &
evaporates.
• @900 degC Calcination of CaCO3 starts
• @950-1400 degC material starts to melt and causes
formation of Alite (Tri-calcium Silicate), Balite (Bi-Calcium
Silicate), Tri Calcium Aluminate & Tetra Calcium Alumino
ferrate.
• Quenching of product to avoid reverse reaction of Tri-
Calcium Silicate to Bi-Calcium Silicate.
• Hot flue gas is passed to Pre-heater section and heat
exchanger, after heat exchanger to WHR plant and bag
house.

9. Preheater & Pre-Calciner
Section:
Material from Raw material silo is taken to preheater section in a delivery elevator,
the preheater section is composed of 4 single preheater cyclones named (C2-C5)
and a two-in-one pre-heater cyclone named (C1), the raw feed enters C1A and
C1B mixing with flue gas leaving C2 which then passes on to VRM section. The
product from C1A and C1B is then taken to C2 by flue gas leaving form C3, product
from C2 is taken to C3 by flue gas from C4 and product from C3 is then transferred
to C4 by flue gas leaving C5, product from C4 then enters Pre-Calciner @ about 700-
800 degC while the cyclone C5 only traps any Kiln dust and returns it to Kiln. 90% of
process of making clinker completes in pre-heater rest is carried in Kiln at over 1400
degC. Feed from C4 enters pre-Calciner which heats up the feed using TDF and RDF
fuels to about 900 degC and then transfers the material to Kiln

10. Kiln & Cooling Section:
Coal from coal VRM is stored in a fin bin and mixed with the feed in Pre-Calciner and
then enters the Kiln which is then heated to around 1400 degC which makes a melt
of the feed in which all the desired reaction takes place and following compounds
are formed with the emission of CO2
• Alite (Tri-calcium Silicate)
• Balite (Bi-Calcium Silicate)
• Tri Calcium Aluminate
• Tetra Calcium Alumino ferrate.
Kiln is supported by 2 hoods, feeding end is connected to pre-calciner and the
product end is connected with a cooler & burner, The inclined kiln as it rotates drags
the clinker melt to the product end, there the clinker is quenched using fresh air in
order to avoid any reverse reaction of product in cooler consisting of perforated
plates, fresh air is taken into the system using 5 blowers. The clinker is then taken to
clinker silo, while the hot gas is passed in 2 parts one to pre-heater and other to WHR
heat-exchanger which is then taken to bag house to remove any dust and then
removed to atmosphere using stack.
Mixing of Gypsum & Grinding:
Gypsum is a very important additive as it controls the setting time of cement,
Gypsum is mixed with clinker and then grinded in the final VRM which is then
transferred to final storage silo.
Products:
Following are the products of Lucky Cement Industries:
• OPC (Ordinary Portland Cement)
• SRC (Sulphate Resistant Cement)

11. Suggestion & Margin of
Improvements:
Overall the process is well optimized but following are the margin of
improvement that can be performed
• Providing of PPEs to all the workers: Workers weren’t provided with the
required personal protection equipment like helmets and we saw many
workers working barehand and without any helmet or facemask dosing
the explosives in mining area & under conveyer transporting large rocks.
Even we weren’t provided with a helmet for about 10 days in our 15 days
internship.
• Mining & explosion procedure is pretty dangerous as the methods for
detonating is very unreliable, as we noticed the engineer fires the
detonation cord and rans away on the dumper with worker squad. This
can pose harmful results as there’s only time limit of around 110sec for
them to get away from the explosion site, and any margin of error can
cause casualty, so this procedure can be made safer and better by
providing mining engineers with Remote/Wireless detonators.
• In crusher one the bag filter inlet should be placed with the discharge belt
as majority of the fine dust falling is collected there, this can cause less
dust to enter the delivery tunnel.
• In VRM cyclone sections there were several spots from where gas was
leaking.
• In Pre-heater section the elevators were very insecure and on top there
were no railing and the base was very frightening just to set footings on.
• The Clinker silo was way too open to allow clinker dust to fly-off to the
atmosphere which can cause both environmental health and economical
losses.