summer tranning report jk cement works ltd nimbahera rajasthan or mangroll or cement plant report ...cament manufacturing process report...mlv textile and engineering college formet....jk cement report...

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A REPORT
On
INDUSTRIAL TRANNING
At
J.K. CEMENT WORKS PVT.LTD, NIMBAHERA
SUBMITTED IN PARTIAL FULFILMENT OF THE REQUIREMENT FOR THE AWARD
OF THE DEGREE OF
BACHELOR OF TECGNOLOGY
(Mechanical Engineering)
2018-2019
SUBMITTED BY:
NAME: NARENDRA SINGH
UNIVERSITY ROLL NO: 15EMBME035
SUBMITTED TO:
MR.AJAY KUMAWAT
MR.SURAJ KUMAR GUPTA
DEPARETMENT OF MEHANICAL ENGINEERING
M.L.V TEXTILE & ENGINEERING COLLEGE, BHILWARA
(An Autonomous Engineering College of Government of Rajasthan)

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CANDIDATE’S DECLAIRATION
I AM NARENDRA SINGH hereby declare that I have undertaken six weeks industrial training
at J.K. WORKS PVT.LTD during a period from MAY 15 TO JULY 15, 2018 in partial
fulfilment of requirements for the award of degree of B.Tech (Mechanical Engineering ) at
M.L.V TEXTILE & ENGINEERIING COLLEGE, BHILWARA the work which is being
presented in the training report submitted to department of mechanical engineering at M.L.V
TEXTILE &ENGINNERING COLLEGE , BHILWARA is an authentic record of training work.
SIGNATURE OF THE STUDENT
The six weeks industrial training viva- voice examination of ………………………….has been
held on………………………and accepted.
Signature of Internal Examiner Signature of External Examiner

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CERTIFICATE OF INDUSTRIAL TRANING

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ACKNOWLEDGEMENT
It was highly educative and interactive to take training at JK CEMENT WORKS,
NIMBHAHERA as technical knowledge is incomplete without the practical knowledge, I
couldn’t find any place better than this to update myself.
I am highly grateful to our Head of Department MR. AJIT KUMAR JOSHI and MR.ARUN
GOYAL to grant me permission to take training at such a coveted institute. Apart from him, there
was always a friendly guidance from Mr M.S SEKHAWAT for the betterment of this Training
Report.
I am also thankful to all those engineers and technicians without whom it was not possible form
to clear my doubts and difficulties.
After coming to this institute and knowing State of Art Technology available with learned
Training staff, I would like to come again to this coveted institute if got a chance.
NARENDRA SINGH
FINAL YEAR (ME)

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ABSTRACT
This report has been given by the author to convey the information about different sections and
departments of JK cement limited. Different specifications, prospective and processing in each
section while producing cement, is being discussed in the most convenient manner for the
readers. We have tried to enhance history, literature, survey and importance of the manufacturing
process. Also schematic figures are shown in each section to discover a better understanding.
Proper statistics and parameters of all the major equipment are also presented to make a better
analysis of the project in comparison to other major cement manufacturing plants and also briefly
learn about foundation of pre-heater, clinker silo, raw mill and construction of clinker silo at the
unit.

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TABLE OF CONTENT
S.NO. TOPIC PAGE NO.
1 INTRODUCTION TO COMPANY 8-10
2 CEMENT AND ITS TYPES 11-16
3 CEMENT MANUFACTURING PROCESS 17-40
3.1 GENERAL MANUFACTURING PROCESS 17-20
3.1.1 MINING 20-21
3.1.2 CRUSHING 22-23
3.1.3 STACKER 23-24
3.1.4 RECLAIMER 24-25
3.1.5 RAW MILL 25-36
3.2 PYRO-PROCESSING 30
3.2.1 PRE-HETER 31-32
3.2.2 ROTARY KILN 32-35
3.2.3 CEMENT MILL 35-36
3.2.4 STORAGE SILO 36-37
3.3 PACKING PLANT 37-38
4 POLLUTION CONTROL EQIPMENT 39-41
5 HEALTH & SAFETY 41-43
6 CONCLUSION 44

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LIST OF FIGURE
FIG.NO. DIAGRAM PAGE NO.
3.1 CEMENT PROCESS FLOW CHART 18
3.2 MINES 20
3.3 BELT CONVEYER 22
3.4 CRUSHER MACHINE 23
3.5 STACKER 24
3.6 RECLAIMER 25
3.7 VERTICAL RAW MILL 26
3.8 WORKING PRINCIPLE OF RAW MILL 28
3.9 PREHEAT FLOW DIAGRAM 31
3.10 ZONES ON ROTARY KILN 33
3.11 ROTARY KILN 33
3.12 CEMENT PACKING MACHINE 38

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CHAPTER 1
INTRODUCTION OF COMPANY
1.1 INTRODUCTION
The initial "J.K." stands for a father- son team, namely “Juggilal Kamlapath Singhania”.
J.K. organization started in the year 1884 at Calcutta. J.K. started their business as a Financier,
Investor, Trading Supplier of cotton belts and manufacturer of small machinery parts like ‘V'
belts, etc. They established few small cotton textile industries also.
In the year 1914 they shifted their business from Calcutta to Kanpur where they established many
big industries like J.K. cotton Mills, Straw product Co, Lohia Mach, J.K. Pulp and Raymond’s
Woollen, etc.
In the year 1934 J.K. organization started one more division, as J.K. Synthetics Ltd. They
established various big plants of Nylon, Acrylic fibre, etc. at Kota and Tyre Cord, Chemical and
Pesticides at Jhalawar.
In the year 1974 under the same division one more unit was started for manufacturing of Grey
Cement at Nimbahera.
The present cement factory was commissioned in the year 1974. The plant started its production
from 27th Dec 1974.
Ist plant / kiln was commissioned in 1974 and the capacity of this plant was 900 tonne per day
and 3 lakh tonne per year. After modification in Preheater, its present capacity is 1200 TPD.
Expansion of this plant took place in the year 1979, when 2nd kiln was commissioned with a
capacity of 1200 tonne per day and 7 lakh tonne per year. After modification in Preheater its
present capacity is 1800 TPD.

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Again in the third phase, a kiln was erected in the year 1982 and production of this kiln was 1350
tonne per day.
In the year 1988 a new technology was introduced in this 3rd Kiln that consisted of precalcination
process, which raised the capacity of this plant to 3400 tonne per day, which was earlier 1350
tonne per day. In Aug.-2003 after again some modification in Preheater and Folex cooler its
capacity is increased to 5000 TPD.
Besides, J.K. cement plant is having its own diesel generator sets, producing power to meet the
power energy requirements.
Main raw material for cement is LIMESTONE, for limestone we have our own open cast mines
adjoining to the plant. Besides we have developed few more mines at Maliakhera, Karoonda and
Tilakhera for producing 10,000 tonnes limestone per day as needed.
J .K. Cement erected one more plant from Jan. 2001 with the capacity of 1400 tonne per day at
village Mangrol. In Nov.-2003 after modification in Preheater and installation of Mechanical
elevator its capacity increased to 2200 TPD.
Due to power shortage as imposed by Ajmer electricity supply board J.K. established its own
Thermal Power Plant at village Bamania, near Shambhupura, which is generating 15 M.W.
power every day, which is consumed by J.K. Cement Plant.
J K Cement also has a plant of 400TPD installed capacity of White Cement at Gotan, Nagour
(Raj).
Cement Plant at Karnataka of over 5500 TPD and Thermal Power Plant of capacity 30 MW.
Thermal Power Plant at Nimbahera of 22 MW.
Waste Heat Recovery Plant at Nimbahera of 15 MW capacity.

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REGIONALTRAINING CENTRE(RTC NORTH): NIMBAHERA
The Regional Training Centre - North is a premier training centre of North India promoted by J
K Cement with assistance from World Bank, DANIDA and Govt. of India as a unique HRD
project in Cement Industry. It is equipped with modern training aids and caters to the skill
enhancement and competency developmental needs of more than 25 cement plants of northern
India. It has trained over 12000 technical and managerial personnel since its inception in June,
1994. The Centre has also conducted many tailor-made in-house programs for cement and other
industries in India and abroad including for Oman Cement, Oman and Star Cement, Dubai and
Hama Cement, Syria / EHDASSE Sanat Corp. Iran and National Cement Company, Yemen
besides many cement plants in India.
RTC, Nimbahera has specialized packages / modules in areas like Mining, Cement Process,
Mechanical and Electrical & Instrumentation designed and developed by renowned International
/ National agencies like FLS Denmark, NCCBM, TATA Interactive Systems, VEC, NITTTR,
etc. More than 150 senior line managers from 10 cement plants have been trained at Denmark,
NITTTR, Bhopal and Chennai, who act as resource persons for these programs. Besides, OEMs
and management experts of national repute are invited for various technical and management
programs to make them effective and gainful experience for the participants

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CHAPTER 2
INTRODUCTION TO CEMENT
2.1 CEMENT
Cement can be defined as any substance, which can join or unite or more pieces of sum other
substance together to form a unit mass. Cement, as used in construction industries, is a fine
powder which when mixed with water and allowed to set and harden can join different
components or members to give a mechanically strong structure. Thus, cement can be used as a
bonding material for bricks or for bonding solid particles of different sizes (rubble masonry) to
form a monolith.
Cement can be defined as an adhesive material consisting essentially of CaO, SiO2, Al2O3,
Fe2O3, etc. & which sets & hardens when mixed with water under controlled conditions.
Upon the addition of water and/or additives the cement mixture is referred to as concrete,
especially if aggregates have been added.
Cement refers only to the dry powder substance used to bind the aggregate materials of concrete.
2.2 History of cement
The history of cement is the story of civilization from primitive caves of pre historic times to the
sky scraper of the modern age. It is said that the use of cement is from the period of use of fire.
Egyptians utilized gypsum plaster as cementing material as early as 3000 blains, building there
monuments.
However, it was in 1824, 60-80 yrs. after the discovery of hydraulic
properties of lime joseph aspdin patented his product, which was called “Portland cement”.

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The plant manufacturing Portland cement outside England were commissioned in Belgium and
Germany in 1855. The interest that is evoked in the technology of cement resulted in the
development of rotary kilns in 1886.
Modern cement is the outcome of the combined research and development effort of chemist,
technologist and architects. the cement technology is an offshoot of the overall in the
development in other industries, technologies constructional activities and knowledge and the
availability of raw material.
2.3 TYPES OF CEMENT
2.3.1 ORDINARY PORTLAND CEMENT
Portland cement (often referred to as OPC, from Ordinary Portland Cement) is the most common
type of cement in general use around the world, used as a basic ingredient
of concrete, mortar, stucco, and most non-specialty grout. It usually originates from limestone.
Portland cement clinker is made by heating, in a kiln, a homogeneous mixture of raw materials
to a calcining temperature, which is about 1450°C for modern cements. The aluminium oxide
and iron oxide are present as a flux and contribute little to the strength. For special cements, such
as Low Heat (LH) and Sulphate Resistant (SR) types, it is necessary to limit the amount
of tricalciumaluminates (3 CaO·Al2O3) formed. The major raw material for the clinker-making
is usually limestone (CaCO3) mixed with a second material containing clay as source of alumina-
silicate. Normally, an impure limestone which contains clay or SiO2 is used. The CaCO3content
of these lime stones can be as low as 80%. Secondary raw materials (materials in the raw mix
other than limestone) depend on the purity of the limestone. Some of the materials used are clay,
shale, sand, iron ore, bauxite, fly ash, and slag. When a cement kiln is fired by coal, the ash of
the coal act as a secondary raw material.

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2.3.2 PORTLAND POZZOLONA CEMENT
The Portland Pozzolana Cement is a kind of Blended Cement which is produced by either
intergrading of OPC clinker along with gypsum and pozzolanic materials in certain proportions
or grinding the OPC clinker, gypsum and Pozzolanic materials separately and thoroughly
blending them in certain proportions.
Pozzolana is a natural or artificial material containing silica in a reactive form. It may be further
discussed as siliceous or siliceous and aluminous s material which in itself possesses little, or
no cementations properties but will in finely divided form and in the presence of moisture,
chemically react with calcium hydroxide at ordinary temperature to form compounds possessing
cementations properties. It is essential that Pozzolana be in a finely divided state as it is only then
that silica can combine with calcium hydroxide (liberated by the hydrating Portland cement) in
the presence of water to form stable calcium silicates which have cementations properties.

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2.4 TYPES AND USES OF CEMENT
Types of cement Applications
Ordinary Portland cement(opc) General construction
Portland slag cement General construction and marine work
Portland puzzolona cement (ppc) General const.and hydraulic const,marine
White Portland cement
Architectural purpose,decorative work and in manufacturing
of tiles.
Oil well cement
Connecting the steel casing to the walls of gas oil well at high
temp. and to seal porous formation in petroleum industry
Low heat Portland cement Where low heat on hydration is required in mass concrete for
dams.
Super sulphated cement In a Varity of aggressive conditions like marine works
concrete sewers carrying industrial effluents.
High alumina cement Mainly as refractory cement and as structural materials giving
high early strength development in cold regions.

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2.5 THE FOUR MAIN WHOLE PLANT CONCEPTS
Historically, the development of the clinker manufacturing process was characterized by the
change from “wet” to “dry” systems with the intermediate steps of the “semi-wet” and “semi-
dry” process routes. The first rotary kilns – introduced around 1895 – were long wet kilns.
“Wet” kilns allowed for an easier handling and homogenization of the raw materials, especially
in cases when the raw materials are wet and sticky or exhibit large fluctuations in the chemical
composition of the individual raw mix components. With more advanced modern technology
however, it is possible to prepare a homogeneous raw meal using the “dry” process, i.e. without
addition of water to prepare a raw slurry. The main advantage of a modern dry process over a
traditional wet system is the far lower fuel consumption and thus, lower fuel cost.
Today, the selection of the wet process is only feasible under very specific raw material and
process conditions. The four different basic processes (or “whole plant concepts”) can be shortly
characterized as follows:
Dry process:
Dry raw meal is fed to a cyclone preheater or proclaimer kiln or, in some cases, to a long dry
kiln with internal chain preheater.
Semi-dry process:
Dry raw meal is pelletized with water and fed to a travelling grate preheater prior to the rotary
kiln or in some cases, to a long kiln equipped with internal cross preheaters.

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Semi-wet process:
Raw slurry is first dewatered in filter presses. The resulting filter cake is either extruded into
pellets and fed to a travelling grate preheater or fed directly to a filter cake drier for (dry) raw
meal production prior to preheater /proclaimer kiln.
Wet process:
The raw slurry is fed either directly to a long rotary kiln equipped with an internal
drying/preheating system (conventional wet process) or to a slurry drier prior to a
preheater/proclaimer kiln (modern wet process).

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CHAPTER 3
CEMENT MANUFACTURING PROCESS
3.1 GENERALMANUFACTURING PROCESS
The manufacturing process of cement is carried out in a number of steps. Following are the
processes which are carried out in all type of cement. The change is occurred only by raw
material and cement mill content.
Here given some basic steps which are universally accepts.
 Mines
 Crusher Stacker &Recamier
 Raw mill
 Storage (silo)
 Preheater
 Kiln
 Cement mill
 Packing plant

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The Brief Introduction of Cement Manufacturing:
 Identified captive lime stones after assessing the required quality are drilled, blasted and
transported to single impact crusher hopper, where 1m3 LS boulder is crushed by impact
crusher and converted to 70-100 mm sizes. The crushed lime stones are transported to lime
stone yard through a series of belt conveyors and store in a pile through an automatic stacker
machine up. Once the known quantity & quality of piles achieved than reclaimer is used to
reclaim stockpile material. By using stacker and Recamier machines, pre-blending takes
Figure:-3.1 Cement Manufacturing Process Flow Chart

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place to minimize fluctuation in crusher limestone quality. Reclaimed pile LS stack is
continuously reclaimed, when raw mill in operation and store in hopper at raw mill section.
Magnet separators are installed over the belt conveyors to remove any foreign materials if
reported.
 Additive materials like china-clay purchased high-grade limestone and iron dust is also
used as a corrective material. The additives materials are stored in separate identified yard
and fed to feeding hopper through pay loader and then materials are transported in hoppers
via a series of belt conveyors. All additives are stored in separate hoppers.
 The proportionate ratio of LS and other additive materials after electronically weighing are
conveyed to a vertical raw mill , where 70-100mm size LS materials are ground to very
fine powder and residue of 90 µ & 212 µ is maintain at 14% and 2% respectively with the
help of high efficient dynamic separator. Pre-conditioned hot gases from kiln-Preheater are
utilized to dry up the material and swept the material to next conveying system. Cyclones,
air slide and bucket elevators are deployed to transport the powder into CF silo. Around
4% water of total feed rate to mill is being sprayed on feed table to maintain require material
bed layer.
 Controlled Flow silo can store 20,000 MT fine powders, which is also known as kiln feed.
In CF silo feeding, blending and extraction process took place simultaneously. Due to good
halogenations in CF silo, fluctuations in inputs are minimized. The required feed to kiln for
burning is being measured by an electronic weighing system (Solid Flow Meter) and fed to
kiln PH cyclones. Half of the kiln feed is fed in one string and remaining in other string.
Each sting is having 6 nos. of cyclones thus made total 12 nos. of cyclones in pre-heater.
Materials that are fed from top cyclone (cyclone 1) finally entered in cyclone 5 and then
from both string cyclone 5 it entered in inline- calciner and after achieving degree of

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calcinations (de-association of CaO from CaCO3) it again fed to cyclone 6, from where it
entered in kiln for next process. Feed also fed in separate line calciner having six stage
cyclones.
3.1.1 MINES
The major quantity of limestone is obtained from the captive limestone mines of the plant.
However, depending upon the proportions of different cement clinker phase forming
components, the additive materials including high grade / low grade limestone are purchased
from outside parties in required quantities in order to obtain the desired quality of cement grade
raw meal. Raw material (limestone) required for the manufacturing of cement is extracted from
captive mines. JK Cement have four mines:
1. Ahirpura Mines
2. Malikhera Mines
3. Tilakhera Mines
4. Karoonda Mines
Fig 3.2 Mines of JK Cement

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3.1.1.1 Composition
Portland cement consists essentially of compounds of lime (calcium oxide, CaO) mixed
with silica (silicon dioxide, SiO2) and alumina (aluminium oxide, Al2O3). The lime is obtained
from a calcareous (lime-containing) raw material, and the other oxides are derived from an
argillaceous (clayey) material. Additional raw materials such as silica sand, iron oxide (Fe2O3),
and bauxite (containing hydrated aluminium, Al [OH]3) may be used in smaller quantities to get
the desired composition.
The commonest calcareous raw materials are limestone and chalk, but others, such as coral or
shell deposits, also are used. Clays, shale, slates, and estuarine mud are the common argillaceous
raw materials. Marl, a compact calcareous clay, and cement rock contain both the calcareous and
argillaceous components in proportions that sometimes approximate cement compositions.
Another raw material is blast-furnace slag, which consists mainly of lime, silica, and alumina
and is mixed with a calcareous material of high lime content. Kaolin, white clay that contains
little iron oxide, is used as the argillaceous component for white Portland cement. Industrial
wastes, such as fly ash and calcium carbonate from chemical manufacture, are other possible raw
materials, but their use is small compared with that of the natural materials.
The magnesia (magnesium oxide, MgO) content of raw materials must be low because the
permissible limit in Portland cement is 4 to 5 percent. Other impurities in raw materials that must
be strictly limited are fluorine compounds, phosphates, metal oxides and sulphides, and excessive
alkalis.
Another essential raw material is gypsum, some 5 percent of which is added to the burned cement
clinker during grinding to control the setting time of the cement. Portland cement also can be
made in a combined process with sulphuric acid using calcium sulphate or anhydrite in place of
calcium carbonate. Flue gases on burning are converted to sulphuric acid by normal processes.

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3.1.2 CRUSHER
The big boulders produced during drilling and blasting methods of limestone mining are crushed
in suitable type of crushers. The crushing is carried out either in single or double stages by using
Primary crusher and Secondary crusher, or in a single stage crushing machine depending upon
the size of the boulder produced while mining. This also depends on the type of grinding mills
used for grinding of raw materials for preparation of finally pulverized raw meal. Jaw crushers
as well as impact crushers / hammer crushers of different capacities are employed in India
Cements Ltd., for reduction of size of limestone boulders to a suitable feed size acceptable to the
different types of grinding machines installed in plants. The crushers are mainly installed at the
plant site. The limestone produced in the mine is transported to crusher site with the help of
dumpers and tippers of different capacities. In some mines the crushers are installed at mine site
and crushed limestone is transported to plant
Stack pile with the help of Belt Conveyer / Ropeway.
Figure 3.3 Belt Conveyer

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Figure: - 3.4 Crusher Machine
3.1.3 STACKER
A stacker is a large machine used in bulk material handling. Its function is to pile bulk material
such as limestone, ores and cereals on to a stockpile.
Stackers are nominally rated for capacity in tonnes per hour (tph). They normally travel on a rail
between stockpiles in the stockyard. A stacker can usually move in at least two directions:
horizontally along the rail and vertically by luffing (raising and lowering) its boom. Luffing of
the boom minimises dust by reducing the distance that material such as lime stone needs to fall
to the top of the stockpile. Stackers are used to stack in different patterns, such as cone stacking
and chevron stacking. Stacking in a single cone tends to cause size segregation, with coarser
material moving out towards the base. In raw cone ply stacking, additional cones are added next
to the first cone. In chevron stacking, the stacker travels along the length of the stockpile adding
layer upon layer of material.

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Figure: 3.5 Stacker
3.1.4 RECLAIMER
A reclaimer is a large machine used in bulk material handling applications. A reclaimer's
function is to recover bulk material such as ores and cereals from a stockpile. A stacker is used
to stack the material.
Reclaimers are volumetric machines and are rated in m3/h (cubic meters per hour) for capacity,
which is often converted to t/h (tones per hour) based on the average bulk density of the
material being reclaimed. Reclaimers normally travel on a rail between stockpiles in the
stockyard. A bucket wheel reclaimer can typically move in three directions: horizontally along
the rail; vertically by "luffing" its boom and rotationally by slewing its boom. Reclaimers are
generally electrically powered by means of a trailing cable.

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Figure:-3.6 Reclaimer
3.1.5 RAW MILL
The pre-blended limestone from stack pile is transported to raw mill . Presently Raw mill hoppers
are provided with continuous weighing machines known as weigh feeders in order to produce a
suitable raw meal proportioned appropriately for production of desired good quality of cement
clinker.
There are following parts of raw mill:-
1. Mill motor
2. Gear box
3. Grinding table Grinding parts in wear resistant high chromium
4. White cast iron
5. Scrapers for external circulation Wear protected with Hardox 400 plate

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Figure:-3.7 Raw Mill

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6. Bottom plate for mill Repairable Density Wear flex 2000lining
7. Outlet for external material circulation
8. Rotary feed sluice
9. Feed chute Equipped with low friction stainless steel plates
10. Mill house Weld able mild steel lining
11. Nozzle ring
12. Air guide cone Chromium carbide composite plate
13. Segmented grinding roller assembly Grinding parts in wear resistant high chromium
white cast iron
14. Roller body Protection in chromium carbide composite plate
15. Joint head Protection in chromium carbide composite plate
16. Torque rod Protected with mild steel plate
17. Buffer house for torque rod
18. Air and material seal for tension rod
19. Tension rod
20. Hydraulic cylinder with accumulators
21. Variable speed drive for separator
22. Cage rotor
23. Guide vanes Chromium carbide composite plate
24. Reject cone
25. Area in cone below separation zone protected with Chromium carbide composite plate
26. Mill and separator outlet
Vertical roller mills are widely accepted as the most efficient means of preparing kiln feed for
the production of cement clinker. They are capable of preparing a wide range of feed materials
to the required fineness in an energy efficient process. Although cement raw materials vary

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considerably in grind ability, drying requirement and abrasion, the roller mill has the flexibility
to be adapted to these variations, as well as other specific requirements.
Figure 3.8 Working Principle of Raw Mill
3.1.5.1 Working Principal
The ATOX mill uses pressure and shear generated between the rollers and the rotating table to
crush and grind raw materials. Feed material is directed onto the grinding table by the feed chute.
The rotation of the grinding table accelerates the material towards the grinding track and passes
it under the rollers. Partially ground passes it under the rollers. Partially ground material passes
over the dam ring encircling the grinding table and into the hot gas stream coming from the
nozzle ring.

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The moisture in the materials is evaporated almost immediately while the finer portion of
material is carried by the gas stream to the separator and the coarser portion is deflected directly
back to the table. The separator allows material that has reached the required fineness to leave
the mill, while it rejects oversized material and sends it back to the table for further grinding. The
coarsest fraction of the material that spills over the dam ring may fall through the nozzle ring and
be conveyed back to the feed material inlet by a mechanical recirculation system.
3.1.5.2 Applications and Adaptability
The ATOX raw mill has demonstrated to be suitable for grinding virtually all types of raw
materials.
 Grind ability varying from very easy to grind to very hard to grind, say from less than 3
kWh/t to more than 11 kWh/t for the mill drive
 Moisture in feed material varying from less than 1 % to more than 20 %
 Materials varying from being non- abrasive to very abrasive
Feed materials varying from being non sticky to very sticky Raw materials that are easy to grind,
i.e. high capacity for the specific mill size, or with high moisture content may require an increased
air flow through the mill. The ATOX mill is simply adapted to this situation being provided with
an oversize nozzle ring and an oversize separator.
3.1.5.3 Basic Design Concept
The grinding table of the ATOX raw mill has a flat horizontal grinding track encircled by an
adjustable dam ring and an adjustable nozzle ring equipped with an air guide cone. The dam ring
is made of stacked bolted on segmented rings and is simply adjusted by adding or removing one

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or more segmented rings. The height of the dam ring determines the depth of the grinding bed
on the table.
The roller assembly is kept cantered on the grinding table and prevented from rotating by three
torque rods attached to the mill housing.
The grinding pressure is exerted hydraulically through three pull rods attached to the outer ends
of each roller shaft. By this unique ATOX roller suspension the grinding forces are transmitted
by the tension rods directly into the foundation.
3.2 PYRO SECTION
3.2.1 PYRO PROCESSING
In pyro-processing, the raw mix is heated to produce Portland cement clinkers. Clinkers are hard,
gray, spherical nodules with diameters ranging from 0.32 - 5.0 cm (1/8 - 2") created from the
chemical reactions between the raw materials. The pyro-processing system involves three steps:
drying or preheating, calcining (a heating process in which calcium oxide is formed), and burning
(sintering). The pyro-processing takes place in the burning/kiln department. The raw mix is
supplied to the system as a slurry (wet process), a powder (dry process), or as moist pellets
(semidry process). All systems use a rotary kiln and contain the burning stage and all or part of
the calcining stage. For the wet and dry processes, all pyro-processing operations take place in
the rotary kiln, while drying and preheating and some of the calcination are performed outside
the kiln on moving grates supplied with hot kiln gases.
The pyro section is the most vital part of any cement plant. It mainly consists of following parts:-
1 Pre-Heater
2 Rotary Kiln
3.Cement Mill
4 Clinker Silo

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3.2.1.1 Pre-Heater
Suspension preheater is a kind of heat exchange equipment in the system of dry-process rotary
kiln. Under the conditions of suspension, the dry raw meal would exchange heat and separate
with the hot air flow from the kiln. The preheating and partial decomposition of raw materials
shall be completed in the preheater which can replace partial function of rotary kiln so as to
shorten length of rotary kiln.
The suspension preheater has many advantages such as good preheating effect, strong
adaptability to raw materials, low pressure loss of system, blocking resistance and good tightness.
Material and flue gases flow system is in such a way that the hoe material is come down inside
cyclone and hot gases goes to the higher side preheated cyclone .in the last of preheated cyclone
stage plant modified means plant capacity is increased to Performa precalcinar in which direct
coal firing is done except of kiln. Material and flue gases flow system is in such a way that the
hoe material is come down inside cyclone and hot gases goes to the higher side preheated cyclone
.in the last of preheated cyclone stage plant modified means plant capacity is increased to
Performa precalcinar in which direct c direct coal firing is done except of kiln. In such a way
the plant capacity is double.
Figure 3.9 Pre-Heat Flow Diagram

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The main function of the pre-heater cyclone is preheating of the raw meal, from outlet hot gases
of the kiln. 6-stage double string in the line calciner system is used for this purpose. Initially raw
meal entering the kiln from last stage of the pre-heater is fed between 6th and 5th stage then it
goes to 6th cyclone by hot air. There the material is being separated and it goes to 5th cyclone
through 4thriser duct and the process continues adjacently. After 2nd cyclone the material goes
to pre-calciner duct. Here calcination of the material is completed upto 90%. The material then
reaches the kiln after passing through 1st cyclone.
3.2.1.2 Rotary Kiln
Cement kilns are used for the pyro-processing stage of manufacture of cement in which calcium
carbonate reacts with silica-bearing minerals to form a mixture of calcium silicates. Over a billion
tonnes of cement are made per year, and cement kilns are the heart of this production process:
their capacity usually define the capacity of the cement plant. As the main energy-consuming
and greenhouse-gas–emitting stage of cement manufacture, improvement of their efficiency has
been the central concern of cement manufacturing technology. The Bricks are made by Alumni
Magnesia.

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Fig 3.10 Direction of Hot Air Flow
Figure 3.11 Rotary Kiln

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3.2.1.2.1 Working of Kiln:
 The calcined raw feed enters the kiln from the calciner string stage VI cyclone.
 Inside the kiln raw materials are sintered and clinker is produced.
 Approximately 39- 40 % of fuel is used in the kiln.
 The flame is maintained in order to heat the feed to the proper reaction temperature.
 The rate at which the feed passage through the kiln is set by the kiln revolving speed.
 Gases are drafted through the kiln and through the kiln string by the Preheater I.D. fan.
 BROKK330 (1475rpm) use for dismenling of old Bricks.
SPECIFICATION OF KILN
Design - FL Smiths
Length & Diameter of kiln - 68m & 4.10m
Inclination of kiln - 4 Degree
Speed - 5 RPM (max)
Production capacity - 6000 TPD
Main drive - DC Drive 950 KW

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CHEMISTRY INVOLVED:-
 Calcination reaction (between 800-900 degree C)
 Endothermic reactions and the formation of silicate phases (between 1100-1300 degree C)
 Sintering and the reaction within the melt to form tertiary silicates and tetra calcium alumina
ferrates (between 1300 – 1450 degree C)
 Cooling and crystallization of various mineral phases formed in the kiln (between 1000 –
1300 degree C)
3.2.1.3 Cement Mill
A cement mill (or finish mill in North American usage) is the equipment used to grind the hard,
nodular clinker from the cement kiln into the fine grey powder that is cement. Most cement is
currently ground in ball mills and also vertical roller mills which are more effective than ball mill
. Cement clinker is usually ground using a ball mill. This is essentially a large rotating drum

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containing grinding media - normally steel balls. As the drum rotates, the motion of the balls
crushes the clinker. The drum rotates approximately once every couple of seconds.
The drum is generally divided into two chambers, with different size grinding media. As the
clinker particles are ground down, smaller media are more efficient at reducing the particle size
still further.
Grinding systems are either 'open circuit' or 'closed circuit.' In an open circuit system, the feed
rate of incoming clinker is adjusted to achieve the desired fineness of the product. In a closed
circuit system, coarse particles are separated from the finer product and returned for further
grinding.
Gypsum is inter-ground with the clinker in order to control the setting properties of the cement.
Clinker grinding uses a lot of energy and the cement become hot - this can result in the gypsum
becoming dehydrated, with potentially undesirable results.
The clinker and the required amount of gypsum are ground to a fine powder in horizontal mills
similar to those used for grinding the raw materials. The material may pass straight through the
mill (open-circuit grinding), or coarser material may be separated from the ground product and
returned to the mill for further grinding (closed-circuit grinding). Sometimes a small amount of
a grinding aid is added to the feed material. For air-entraining cements (discussed in the following
section) the addition of an air-entraining agent is similarly made.
3.2.1.4 Storage (Silo)
On sites of construction and industries, cement silos are used to store large amounts of cement
or cement mixtures. Such silos come in a number of shapes and sizes which makes cement silos
all the more accessible and suiting to the needs of the construction site or the industry. Cement
silos can either be permanent structures, strong and rigid, or even they can be made on temporary

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basis making it more flexible and portable. Like a host of other silos, even cement silo is equipped
with a kind of blower which helps to expel the stored contents into the truck or any other
receptacle. This allows any quantity of cement or powder discharged to be controlled and also
provides an accurate indication of what remains inside the Silo. These are a low-maintenance,
value for money option for the storage of cement or other powders.
3.3 Packing Plant
The pulverized different types of cements are stored in different silos installed with different
capacities. Depending upon the market requirements the cement is loaded in bulk or packed in
50KG bags with the help of conventional rotary packers or electronic packers, loaded on to trucks
and finally dispatched to the required destinations.
Cement Packing Machine is fully automatic sensor machine in which it sense 50 kg weight of
cement fill into bags and send to the dispatch department.
Cement is carried forward to an elevator and is collected in cement bin. Bin is connected to
vibrating screen through which cement is passed down to cement tank. There is a valve attached
between vibrating screen and cement tank which regulates the flow of cement, level sensor senses
the level of hopper attached to cement tank. The gate valve is connected to solenoid valve. To
measure the temperature of cement, a RTD is connected to cement tank. There is also a direct
pathway (optional) from vibrating screen bin to loader if there is no requirement for packing the
cement.
Dust suppression system has been installed to collect the dust at various locations. Collected dust
through dust suppression system is sent back to elevator and vibrating screen bin.From cement
tank, cement is fed to packers. The packer itself has in house tank of capacity of 5 tons.Packer
plant consists of two types of packers based on their feature, capacity and working style.

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The packer rotates on its axis. When an office in-charge inserts a bag in nozzle, the latter
automatically hold the bag until the bag weighs 50 kg. Load cell is mounted and attached with
rotors for weighing the quantity of cement in bag. As soon as the load cell sense 50 kg, the nozzle
releases the bag and bag moves on the belt conveyor towards to loading point to be loaded in
trucks / wagons.
Figure 3.12 Cement Packing
Since the packer makes rotation so a person has got to keep inserting bags one by one in each
nozzle. After one complete revolution, the nozzle releases the bag. The whole process goes on
this way
Finally packed cement is made to reach on loaders through conveyor belts. There is interlocking
system also in between.

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CHAPTER 4
POLLUTION CONTROL EQUIPMENT
A dust collector is a system used to enhance the quality of air released from industrial and
commercial processes by collecting dust and other impurities from air or gas. Designed to handle
high-volume dust loads, a dust collector system consists of a blower, dust filter, a filter-cleaning
system, and a dust receptacle or dust removal system. It is distinguished from air cleaners, which
use disposable filters to remove dust.
A high speed rotating (air) flow is established within a cylindrical or conical container called
a cyclone. Air flows in a helical pattern, beginning at the top (wide end) of the cyclone and ending
at the bottom (narrow) end before exiting the cyclone in a straight stream through the centre of
the cyclone and out the top. Larger (denser) particles in the rotating stream have too much inertia
to follow the tight curve of the stream, and strike the outside wall, then falling to the bottom of
the cyclone where they can be removed. The cyclone geometry, together with flow rate, defines
the cut point of the cyclone. This is the size of particle that will be removed from the stream with
50% efficiency. Particles larger than the cut point will be removed with a greater efficiency and
smaller particles with a lower efficiency.
Every plant have bond to government that it maintain environment accepts for running their
plant. Cement plant mainly issues dust particles which collect and control by cyclone.
4.1 CEMENT INDUSTRYSAFETY
Cement is a fine powder used to make binding materials -- concrete and mortar -- for the
construction industry. To produce cement, limestone, clay, sand, iron ore and sometimes
industrial waste such as oil shale and coal fly ash are ground in a rotary kiln, heated to 2,462

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degrees Fahrenheit and cooled. The final product, clinker, is mixed with gypsum and silica
powder to produce cement powder.
4.1.1 SKIN CONTACT
Contact dermatitis is a frequent hazard to construction site employees who work with wet cement.
Wet cement has a pH of 12.5; a pH of 7 is neutral, so wet cement is highly alkaline and
comparable in pH to domestic caustic soda cleaning agents. The alkaline strength of cement
derives from the calcium, potassium, sodium and chromium ions in the compounds that make up
the cement mixture. The dermatitis risk is reduced with the use of alkali-resistant gloves and
protective clothing. But constant exposure to wet cement will always be harmful to construction
workers.
4.1.2 DUST
Dust emitted during the grinding and heating stages of cement manufacturing irritates the eyes,
throats, skin and respiratory systems of those who are exposed to it. It will also cause burns on
exposed skin. The silica additive produces a particular danger because extended exposure to this
compound may cause silicosis and lung cancer. Construction workers should wear protective
respirators and avoid eating in any areas exposed to the dust. Accidental dust emissions from a
cement plant pose a danger to residents in surrounding neighbourhoods.
4.1.3 MERCURY
Mercury is a trace element that occurs as a sulphate or silicate compound in the raw materials
used in cement manufacture. Exposure to mercury can damage the kidneys and nervous system,
sometimes leading to brain damage. It is a highly volatile material that can escape in flue gasses
during the kiln heating process and collect in dust around the kiln area. Artificial gypsum,
aggregates and oil shale have a very high concentration of mercury, according to an April 2010

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U.N. Environmental Program study. But the mercury content of the natural raw materials varies
according to their original quarrying location.
4.1.4 OPERATING CONDITIONS
Cement plants operate at high temperatures -- up to 2,462 degrees F -- with high loads of raw
material. They frequently use coke and pulverized coal as a fuel to power kilns. Clouds of dust
from this fuel can ignite and explode. Coal can sometimes combust spontaneously and continue
burning on its own. Dust permeates all parts of the operating plant and can cause machinery
breakdown. Plant employees who try to clear away the dust risk exposure to high temperature
contact with machinery and collapsing loads of raw materials.

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CHAPTER 5
HEALTH AND SAFETY
DEFINATION
The cement production process can be divided into the two aspects of manufacturing processes
and quarrying activities. As outlined in Section, the two aspects have different profiles with
respect to the health and safety performance of the cement industry.
The cement manufacturing industry is labor intensive. This combined with the large scale and
potentially hazardous nature of the manufacturing process, means that the industry experiences
accident rates that are high compared with many other manufacturing industries.
It is also interesting to note the relatively high accident rates associated with quarrying. Quarrying
is a major activity associated with cement manufacture. If the cement industry as a whole is to
improve, considerable effort is needed to tackle safety in its quarry operations as well as in
cement production plants. The different hazards and types of activities in quarrying as compared
to cement production may mean that different management system priorities and approaches may
be needed to improve safety and health performance in these two areas.
5.2 KEY RISKS AND CONTROL MEASURES
Further analysis of the accident statistics reveals where the main risks arise. An analysis of recent
accidents by a UK company indicates the types of events that present most risk. A recent review
of worldwide fatal accident statistics by the Cement Safety Taskforce identified vehicle impacts,
falls from heights falling objects, and contractors working on unfamiliar plant or unfamiliar with
safe working practices as key issues. Plant cleaning and maintenance activities frequently involve
working at height or in awkward locations (for example confined spaces) presenting access and

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egress difficulties and the handling of unusual or unfamiliar equipment, tools or situations. This
is reflected in the percentage of incidents associated with manual handling and falls from height.
Contractors are frequently used for cleaning and maintenance activities, especially during major
planned plant shutdowns, where additional workforce is required to meet tight schedules. As a
result, contractors can be exposed to some of the higher risk activities, leading to a higher rate of
accidents if the contractors are not fully trained and familiar with the plant and its hazards.
Contractor safety awareness is improved through induction training addressing the specific
hazards and control measures related to cement manufacturing facilities.

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CONCLUSION
By doing this internship training at J.K cement I came to know much a cement firm and how the
production of cement is done. Each and every department of the company has its own duties and
responsibilities which should be followed by each staff members of the firm. The marketing
department plays a very important role in sales activities and by increasing the market of the
firm. The marketing mix such as product, place, price, promotion is maintained well effective.
Due to the good quality. J.K. cement has got good brand name and demand.
According to demand and supply theory – as the demand of the product increase the supply
remains constant due to the decreased production. Besides learning, it is one of the wonderful
experience for me.

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REFERENCES
Books andAuthors
• K E Peray, The Rotary Cement Kiln, CHS Press (1998), ISBN 978-0-
8206-0367-4
• R H Perry, C H Chilton, C W Green (Ed), Perry's Chemical Engineers'
Handbook(7th Ed), McGraw-Hill (1997), sections 12.56-12.60, 23.60, ISBN
978-0-07-049841-9
Web Site
• www.jkcement.com
• www.rtcnorthindia.org