ACKNOWLEDGMENT:

I wish to pay my sincerest regards to the following personnel’s for their wholehearted

guidance and cooperation, which enabled to me to gain valuable knowledge about

technologies and their application, during my in plant Training.

Mr. Rakesh Sinha(Plant Head)

Mr Rajender Thakur(HR Head)

Mr. P.K. Chauhan(Engineer)

Mr. Sanjeev Gautm(Supervisior)

I also wish to thank, Mr. Ajay Sharma (Training Head) for his whole hearted support

enabling me to prepare a training report in the most efficient manner.

I also wish to thank whole H&R Department members to give their support during the

training.

I wish to pay my word of thanks to each and every individual of plant helping me to

finish my training successfully.

Aman Sharma

Mechanical Engg

i

DECLARATION

I hereby declare that the Industrial Training Report entitled “Six Months Industrial

Training at ACC, Barmana” is an authentic report of my own work as a requirement of

6-months Industrial Training during the period from 1st July,2014 to 31st Dec 2014 for

the award of the Degree of B.Tech (Mechanical Engineering),BAHRA

U NIVERSITY, SHIMLA HILLS (Waknaghat Distt. Solan) under the guidance of

Aman Sharma

2013UGME012

Date :

Certified that the above statement made by the student is correct upto the best of my

knowledge and belief.

Signatures

Examined by:

1. 2. 3. 4.

HOD/DEAN

(Signature and Seal)

ii

CONTENTS:

Introduction 2.

Gagal Cement Works – An Overview 3.

Organization Chart 5.

Raw material 6.

Specification of the Product 8.

Cement manufacturing Process (In brief) 11.

Detail of different departments : 13.

1. Quarry 14.

2. Stacker & Reclaimer 19.

3. Raw mill 23.

4. Homogenisation system 31.

5. Preheater 33.

6. Kiln 38.

7. Cement mill 44.

8. Packing House Workshop. 47.

9. Workshop 49.

10. MIPS 51.

Material handling equipment (Mechanical & Pneumatic) 52.

MIPS Department 63.

Quality control technique 65.

Research & Development 68.

Inventory management 69.

ISO 71.

Gagal Cement Works a unit of the Associated Cement Companies Limited, has two

unites Gagal I and Gagal II. Gagal I was set up in the year 1984 and Gagal II was set up

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in the year 1994. Clinker production of Gagal I is 2800 TPD and of Gagal II is 3300

TPD. The total annual capacity of the plant is around 2.2 million tonnes. Both units are

located at BARMANA in District BILASPUR of H.P.

KIND OF PRODUCT :

Ordinary Portland Cement (OPC) in different grades i.e. 33GR, 43GR, 53GR and

Portland Pozzolona Cement (PPC).

The quality of the cement is in accordance with specification as per BIS (Bureau of

Indian Standard). The company has registration to ISO 9002 & ISO 14001.

CEMENT:

The present definition of cement as given in DIN 1164 is as follows:

Cement is finely ground hydraulic binding medium for mortar and concrete, consisting

substantially of compounds of CaO with SiO2, Al2o3 and ferric oxide which have been

formed by sintering or fusion. ‘Sintering’ means burning at a temperature which cause

partial fusion of the material. When mixed with water cement hardens both in air and

under water and retains its strength under water; it has to possess constancy of volume

(soundness) and attain a compressive strength of at least 25N/mm2 at 28 days.

Portland cement is manufactured by burning a calcareous material, such as,

limestone, chalk, shells or marl and an argillaceous material such as clay, shale etc. at a

high temperature of 1450-1500ºc and grinding the resultant product called ‘Clinker’ with

the addition of the small quantity of the Gypsum.

The ordinary portland cement consists of four major components i.e.

Tricalcium Aluminate (C3A)

Tricalcium Silicate (C3S)

Dicalcium Silicate (C2S) and

Tetracalcium Alumino ferrite (C4AF).

ORGANIZATION STRUCTURE:

PLANT HEAD

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GM TECH -- MGR. MINES MGR COMM SR.MGR HR MGR FIN MGR HS MGR W HRS

DY MGR DY.MGR DY MGR DY MGR DY MGR

ASST. MGR ASST .MGR ASST. MGR ASST.MGR

MGR MAINT. MGR.PRODN MGR. E& I

DY MGR DY MGR DY MGR

ASST.MGR ASST.MGR ASST.MGR

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RAW MATERIAL:

Minerals of natural origin as well as Industrial products can be used for the

production of cement.

The main component of cement: Lime, Silica, Alumina and Iron oxide.

Lime stone:

Calcium Carbonate (CaCo3) is wide spread in nature. The purest grades of

limestone are calcspar (calcite) and aragonite. Calcite crystallizes hexagonally (specific

gravity 2.7) and aragonite is rhombic (specific gravity 2.95). The hardness of the lime-

stone is between 1.8 & 3 of the Mohr`s of hardness. Only the purest varieties of

limestone are white. The total carbonate in limestone is minimum 80%. The limestone

provided to ACC is of grade 86 to 89 by nature. Chalk and Marl are other lime

component but not used by ACC plant.

Clay:

Clay is formed by the weathering of alkali and alkaline earth containing aluminium

silicate and their chemical conversion products.

Corrective Ingredients:

If an essential chemical component needed in the cement raw mixture is not present

in the required amount, corrective ingredients are used as additives i.e. Iron oxide.

Auxiliary Components:

Magnesium oxide (Mg2O) up to 2% by weight, K2O and Na2O up to 0.6% should

present in the Portland cement. Sulfur appears predominantly as sulfide in all cement raw

material. The alkali sulfate combined by the clinker is of advantage for the early strength

of the cement.

To control the setting time, cement needs a minimum amount of calcium sulfate,

mostly in the form of gypsum added to the clinker.

Proportioning of raw material per unit clinker (dry base):

Limestone: 1359 kg per 1000 kg of clinker

Shale : 105 kg per 1000 kg of clinker

Iron Ore : 12 kg per 1000 kg of clinker

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Total : 1476 kg per 1000 kg of clinker

Gypsum : 30-40kg per 1000 kg of cement

FUEL: Kind of fuel: coal

Total moisture content: less than 3%

Volatile matter : not less than 27%

Ash : 32%

Calorific value : 4200 kcal/kg (net on wet).

SPECIFICATION OF THE PRODUCTS:

[1]-P.P.C. (Fly ash based):

SCOPE: This standard controls the manufacture, physical and chemical requirements of

Portland Pozzolona Cement using only fly-ash pozzolona.

TERMINOLOGY: Pozzolona is a silicious material which in itself possesses little or no

cementitious properties, it will be in finally divided form in prerence of water, It reach

with calcium hydroxide at ambient temperature to form compounds possessing

cementitious properties. Term includes natural volcanic material having pozzolana

properties and also other natural and artificial material.

Setting time: P.P.C when tested by vicat`s apparatus method shell be as follows-

Initial setting time (minimum): 30 minutes

Fineness: When tested by air permeability method specific surface of ppc shall not less

than 300 m2/kg.

Drying shrinkage: In accordance with IS4031:1998, shall not be more than 0.15%

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Soundness: When tested by Le Chatelier method and autoclave test described in IS4031,

and a rated ppc shall not have an expansion of more than 10 mm and 0.8% respectively.

Compressive strength:

1- At 12 +/- 1h : 16 Mpa, minimum

2- At 168+/- 2h : 22 Mpa, minimum

3- At 672+/- 4h : 53 Mpa, minimum

Chemical requirements:

Loss of ignition % fineness (maximum) – 5.0

Magnesia % by mass (maximum) – 6.0

Sulphuric anhydride %by mass (maximum) – 3.0

[II]-O.P.C. (43 Grades):

1)-Chemical Requirement:

a)-Lime saturation factor CaO 0.7SO3 : Not greater than 1.02

2.8SiO2+1.2Al2O3+0.65Fe2o3 & not less than 0.66

b)-Ratio of percentage of Alumina : Not less than 0.66

to that of Iron oxide

c)-Insoluble residue, percentage by mass : Not more than 2.0

d)-Magnesia percentage by mass : Not more than 6.0

e)-Sulfuric anhydride percentage by mass : Not more than 2.5

f)-Total loss on ignition percentage by mass: Not more than 5%

g)-Total chloride content : max 0.05%

h)-C3A percentage by mass : Not more than 5%

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C3A=2.65(Al2O3)-1.69(K2O3)

2)-Physical Requirements:

a)-Fineness-

Specific surface (Blaine) : Not less than 2250 m2/gm

b)-Soundness-

Le-Hotelier expansion : Not more than 10 minutes

Autoclave expansion : Not more than 0.8%

c)-Setting time- Initial : Not less than 30 minutes

Final : Not more than 600 minutes

d)-Compressive strength- 3Days : Not less than 230 kg/cm2

7Days : Not less than 330 kg/cm2

28Days : Not less than 430 kg/cm2

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CEMENT MANUFACTURING PROCESS [IN BRIEF]:

The raw materials used are lime stone, shale, iron ore and gypsum. The lime stone

provided by nature and Iron-ore comes from BIHAR and RAJASTHAN. Firstly we get

the 70mm size limestone with the help of crusher and stock it with the help of stacker

through belt conveyor. Reclaiming of the blending bed stockpiles is carried out by means

of a movable Reclaimer system. The limestone goes to the hopper connected to weigh

feeder, within proportionate quantity through belt conveyor. Clay and Iron ore are also

goes to the weigh feeders with the help of belt conveyors.

In Raw mill / VRM section, limestone, shale, quartzite & Iron ore are fed in

measured quantity through weigh feeders. In the mill the mixture further reduces the size

to the desired fineness. The finer product separated by air separator is goes to the

Electro-static precipitator & then to the blending silos and coarse material is fed back

into the mill Inlet. Raw mill / VRM s controlled by central control room. The set point

for chemical composition of the raw meal and fineness of the material is given by the

Laboratory department.

From raw mill the raw meal is fed to the blending and the storage silos .In the

blending part of the silo, further homogenization of raw meal takes place so that a

constant quality is maintained. In storage part the raw meal is stored so that it may be fed

at the desired rate. From there the material is fed to the low lift pumps (L.L.P.s) with the

help of bucket elevators. Low lift pumps feed the material or raw meal to the preheated

cyclone. To reduce the requirement of heavy coal injection in the kiln, 95% of the

calcination occurs in the M.F.C., D.D.F. vessels and cyclones of preheating zone. About

60%of the coal firing is done at pre-calciner section itself. Raw meal which is almost

calcined enters from the one end of the kiln. From the other end of the kiln the

pulverized coal is fired. Various chemical reactions occurs as the raw meal progresses

from feed end to the burning zone , where intermediate phases consisting of CaO, Al2O3,

Fe2O3 become liquid and because of the rotation of kiln CaO and silica combine with

liquid to form nodules called clinker.

At the lower end of the kiln the temperature reaches to about 1450 degree

centigrade. Due to such high temperature the physical and the chemical characteristics of

the raw meal changes. Clinker that comes out of the kiln is at a very high temperature

and has to be cooled to facilitate handling and grinding. Hence, the clinker is passed

through the cooler where cooling takes place by means of fans. Hot air is used for

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combustion inside the kiln and calciner. In cooler circuit the ESP has also been installed

to control the air pollution. With the help of the drag chains and bucket elevators the

clinker is fed to the clinker silos. There a pneumatic based roller press installed next in

the circuit to decrease the size of clinker and increases the efficiency of the cement mills.

Clinker and the necessary additives like – gypsum, Pozzolona, slag etc. are fed to the

cement mill in proper proportion. Grinding is done to desired fineness as in the raw mill.

Then, the final product cement is conveyed to cement storage silo. Cement is then sent to

packing machines for final packing and then dispatched.

DETAIL OF DIFFERENT DEPARTMENT:

01-Quarry

02-Stacker and Reclaimer

03-Raw Mill [Ball Mill / Vertical Roller Mill]

04-Homogenisation system

05- Preheater

06-Killn

07-Cement Mill

08-Packing House

09-Workshop

10-MIPS

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[01]-QUARRY:

We can divide in three divisions –

I-Mining –a) Drilling

b) Blasting

c) Loading

d) Transportation

II-Garage—[Maintenance of heavy earth material machine and provided them to mining]

III-Crusher [Reduce the size of material up to required size]

[I]-Mining:-

Mining department provide the limestone to the plant. This department follows the

rules of DGMS (Director General of Minning Safety). There are limestone as well as

dolomite but no use of dolomite in cement plant so its throw. For blasting, the hole depth

maintained up to 9, 10 or 11m with 6inch diameter. The blasting materials are NH4NO3

& Accuadoine (as booster). In 10m hole, 6m depth is fill up by NH4NO3 & Accuadoine

in which Accuadoine is 18-20% and then above the blasting material, rest 4m fill by soil.

To fire the booster use detonator, It is AL tube (high explosive) detonator attached to the

DTH wire. TLD use to interconnect the holes and then safety fuse wire used to fire the

hole. In 10m hole 100 kg NH4NO3 & 15-20kg Accuadoine required.

Loading and Transportation-The blasting material is of very big size stones. To

load them and transport to the crusher, equipment used as follows-

1-SHOVEL: Shovel used to load the Dumper. It is hydraulically operated and can

rotated at 360º. There are four shovels, their specification are as follows-

Make : Telco Tata Make : BEML

Model : EX700 Model : PC650

Capacity: 4.5m3 Capacities: 3m3

Total No. : 2 Total No. : 2

2-DUMPER: Dumper used to transport the big size stone from blasting place to the

crusher. It total hydraulically operated. There are total 9 dumpers in which 7 dumper of

773B and 2 dumpers of 210M which are of latest technology. Their specification are as

follows-

Make : BEML Make : Hindustan motors

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Model : 210M Model : 773B

Capacity : 44tonnes Capacity: 50tonnes

6- Cylinder engine, V-type 12-Cylinder engine, V-type

3-POCLAIN,

4-DOZARS,

5-PAYLODERS.

[II]-GARAGE:

Garage is related to automobile, there are only maintenance of the heavy earth

material machine (i.e. shovel, poclain, dumper, dozers and payloders) and provided them

to the Mining. Only regular maintenance of these machines carried out there.

[III]-CRUSHER: There are two crushers-

1-L &T Impactor (capacity 1000 TPH)

2-Hammer Crusher (capacity 400 TPH)

1]-L & T Impactor: General information-

Make : Larson & Tubro Limited

Type : Single rotor impactor

Size : APPM2022

Feed material : Limestone

Feed size : 0-1600mm×1300mm×1100mm maximum

End product size: 90-95 % min, 75mm

Capacity : 1000 TPH

Motor rating : Slip ring Induction motor

1200kw, 100 rpm

Description of the machine:

The single Rotor Impactor, also known as primary Impactor is designed to achieve

maximum reduction ratio in a single pass-particular features of the machine are its

cubical product, largely free of tension and cracks, and the ease with which the servicing

can be carried out.

Design and Operating Principle –

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The housing of the impactor is of welded plate construction, within this housing the

rotors is installed on rigid bottom housing.

The cross sectional view shows the rotor working in conjuction with impact arms

and a grinding path in the rear side. The impact arm are adjustable and they are

supported material enters or over feeding takes place. The easy adjustment of impact

arms & grinding path allows for constant product control and limitation of over size.

Main component of the impactor are as follows –

HOUSING: Housing of the impactor is of sturdy steel fabricated construction and

consists of three parts: bottom housing, front top housing and rear top housing. The rotor

and grinding path assembly is housed in bottom housing. The rear top housing can be

opened and closed with the help of hydraulic cylinders.

ROTOR: The rotor in the impactor is of S type construction, secured to the shaft by

locking assemblies.

BLOW BARS: The blow bars mounted in the rotor are made of high alloy steels. Their

shape is symmetrical and are secured against lateral movement.

DRIVE ARRANGEMENT: Power to the rotor is given through jack shaft arrangement.

The driven V-belt pulley is fixed on to the rotor shaft by means of ring feeder locking

assembly. The drive pulley is secured on the jack shaft by a pair of ring feeder. The jack

shaft assembly is supported on two bearing blocks (spherical roller bearing with adapter

sleeve-SKF23036CKC3+H3036) and it is coupled to motor shaft through a Resilient

coupling (Bibby size H556 or GBM size 125 type S). Impactor rotor bearing is spherical

roller bearing with adapter sleeve – FAG23264 BKMBC3+H3264HG.

2]-HAMMER CRUSHER: - Unit : 1 No.

Make : Hammer Mill Co.

Size : 7272

Capacity : 400 TPH.

Total hammers : 18; 6 on each shaft.

Material of hammers: Maganess steel.

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Description:-

These are used for the size reduction of hard to medium hard limestone and for raw

marl crushing. Reduction ratios are as high as 1:40. Depending upon crusher feed this

can be reduced to 1:60. Generally two types of the hammer crushers are manufactured:

Single shaft hammer crusher.

Double shaft hammer crusher.

These work with the impact effect of the hammers according to the formula,

P=mv²/2. Mass of hammers in hammer mill was reduced to minimum while increasing

the velocity as far as possible, resulting in greater impact force combined with reduced

wear. Rim speed of the hammers is in the range of 5000 to 7000 rpm. Power demand of

single hammer crusher is between 1.3 to 2.8 HP h/t.

Weight of the replaceable is between 155 to 440 lb, depending on the crusher.

Throughout capacity (Q) = (30/40)*D*L

Where, D =Rotor diameter, L =Useful length of rotor in meters.

[02]- STACKER & RECLAIMER:

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Gagal I –

Type: Portal

Make: TRF

Span: 42M

Gagal II--

Type of storage : Open Longitudinal

Make : CIMMCO.

Stacking capacity : 1000 TPH, designed for 1300

Width of stockpile : 32250mm

Height of stockpile : 12245mm

Total length of stockpile: 300000mm

Storage capacity : 2×25000M.T.

Reclaiming capacity : 600 TPH

The blending bed consist of two equal material stockpile which are arranged in

line. These material stockpile are used both for storing and also for prehomogeniation of

the material to be stacked. The material stockpile of one pile can be reclaimed while the

other stockpile is stacked.

Stacking of the blending bed:

Stacking of the blending bed is carried out in the ‘Chevron method’ by means of a

stacker with loop car. The stacker with loop car is moved into its starting position in

‘manual mode’ with the boom raised its highest position. The boom is lowered to its

lowest position after reaching the starting position.

The stacker starts the operating process after the commands for automatic mode of

stacking are given from a central control room. The stacker now throws off the incoming

material to the yard as it travels from one end of the stockpile to the other, until a

material probe which is mounted to the boom tip sends a single material height reached’.

Then a command is given to the luffing gear to lift the boom by one lifting step. This

process is repeated until the boom, after 20 lifting steps, has reached its maximum lifting

height and the stockpile is stacked to its maximum volume.

Stacker consist of the following units:

a)-Travel gear – fixed side:

with built in bogie wheels, complete with travel drive and pressure rollers.

xvi

b)-Travel gear – pendulium side

c)-Bogie car: for supporting the two travels gears and the linking of the loop car.

d)-Luffing gear: for stepwise adjustment of the stacker boom. The hydraulic lifting gear

consists of the hydraulic cylinder with electro hydraulic pump unit.

e)-Stacker boom: mechanical construction, comprising belt drive and standard parts.

Technical data- Conveying capacity: 1000 TPH

Centre distance : 23500mm

Belt width : 1200mm

Belt speed : 2.5m/s

Power : 55kw

Boom ascent : +18º

Boom descent : -15º

f)-Loop car: has the function to feed the conveying material arriving from the stacking

belt to the boom belt. Mechanical parts of the loop car are-

Pulley : Ø630×1400

Reverse pulley : Ø500×1400

Transition idler : Ø139.7×465×10º

Throughing idler: Ø139.7×465×30º

g)-Electrical Accessories: Electrical house, control panel, cable reels, cable duct

covering, limit switch support and speed control support.

h)-Lubricants: Oil lubrication and Grease lubrication.

Reclaiming of the blending bed stockpile:

The material is reclaimed from the stockpile by the forward movement of the

scraper travel gears in connection with the reversible rake car on the scraper bridge, the

rakes mounted to the car on the scraper bridge, the rake mounted to the rake car and the

material discharge by the scraper chain drive.

Reclaimer consists of the following units-

a)-Travel gear – fixed side

b)-Travel gear – pendulum side

c)-Scraper bridge

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d)-Rake car: The two rake car-side section are bolted on to the slide of the rake car-

upper section.

e)-Scraper chain: Technical data –

Power : 90kw

Chain speed : 0.51m/s

Bucket width : 1800mm

Centre distance: 32000mm

The scraper chain runs in the chain guide which is bolted to the scraper bridge from

beneath. The scraper buckets are bolted to the scraper chain with a spacing of 670mm.

The scraper chain is laterally guided by guide rollers. Every second scraper bucket is

equipped with a guide roller.

f)-Rails: Complete with plats, rail fastenings and buffers.

For trouble free operation of the machine, it is necessary that the laying of the rails

is carried out skillfully and within the tolerances stated below –

1-The maximum height tolerance must not exceed ±10mm on length of 25m.

2-The maximum permissible rail cant must not exceed 1:150.

3-The gauge of the rails in parallel must not exceed ±10mm.

g)-Electrical Accessories.

[3]- RAW MILL [BALL MILL / VRM]:

xviii

THE DEPARTMENT:

Activity of Raw mill department start from feeding the raw materials (Limestone,

Shale, Quartzite and Iron ore) to the mills and ends at filling the raw meal to silos.

Limestone feeding: Limestone feeding to Raw mill / VRM is through sequence of belt

conveyers of different hoppers. Feed size of limestone is up to 90mm.

Additive feeding: Iron ore and shale feeding is from the gantry to the respective hoppers

through sequence of belt conveyors. Shale feeding is through reclaimer or payloder and

Iron ore / quartzite feeding is by payloder.

GAGAL I: RAW MILL [BALL MILL]:

To close circuit two chambers ball mills are performing the grinding of raw mix.

Raw mill is a tube construction of thick mild steel plate with steel liners and the

compartments are separated by double diaphragm for improving the retention time and

transfer of material in second chamber for further grinding. Mill is charged with hyper

steel balls. Mill product and teritiary crusher output is fed to the elevator. Ball mill is air

swept mill.

In Ball mill section limestone, shale, quartzite and iron ore are first fed to the

tertiary crusher in measured quantity through weigh feeders. Tertiary crusher is single

rotor reversible impact crusher which is further reduces the size of mix. The finer

product separated by air separator is fed to the blending silos and coarse material is fed

back in to the mill inlet. The raw mill are operated through control room operators by

miller.

Detail of major component installed in Gagal I Raw Mill:

a] Type of Raw Mill : Ball Mill

Make : ABL

Size : 3.8 M dia x 9.5 M Length.

Motor details : 1875 kw, 2500 HP, 1420 RPM.

Gear box : Elecon, ratio 1500/24

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No. Of Units : 2 Nos.

Both the raw mills are two chamber tube mill lined with Mn steel liners, chambers

are separated by intermediate diaphragms and charged with Hyper steel balls. Size

reduction of the mill feed is performed by motion of the grinding media. Rotation of the

mill cylinder raises the pile of mill feed and grinding media to an optimum height,

necessary for grinding operation. Grinding is performed by impact and friction between

the grinding balls which hit one against another, as well as between the grinding media

and the mill lining itself.

Detail of Internal is given below:

First chamber Second chamber

Liners : Mn steel Liners Mn steel segregation Liners

Diaphragm : Mn steel Intermediate Mn steel single Diaphragm

GR.media : Hyper steel Hyper steel

Grinding media pattern : 90mm-10TS 60mm-17TS

75mm-34TS 50mm-15TS

60mm-20TS 40mm-26TS

b] Tertiary crusher : ABL Make

Type : Reversible Impact Hammer

Size : 1200 x 1200

Motor details : 225 Kw, 750 RPM.

c] Turbo Separator : ABL make

Type : ‘U’ type mechanical separator

Motor details : 350 HP, 750 RPM.

This separator is furnished with an auxiliary fan driven by a separate drive

arrangement. Hollow shaft and core shaft are attached to a common motor, totally

enclosed spur gear drive.

Rotating parts are not freely floating but are held by a flexible two point support

arrangement, one on the top in gear casing and down on the shafts end. This is

accomplished by a structure inside the separator. Special arrangement has been

xx

developed to improve the separation process by uniform distribution of separator feed

from the distribution plate into the circular separating space area.

The effect of the droplet size is related to the surface area of the volume ratio. This

means that a droplet of twice the diameter will have four times the evaporation time.

Regarding the temperature driving force relationship the rate of evaporation is increased

by a high inlet temperature, decreased by lower outlet temperature and also decreased by

a higher initial gas moisture content. The critical aspects of the evaporation gas cooler

design are as follows:-

1. ATOMISER:-

The higher performance atomizer is required. It should give fine atomization over

the whole of its flow range and should good turn down ratio. It should be capable of

withstanding the process conditions of temperature, corrosion and abrasion.

2. CONTROL SYSTEM:-

It must maintain a constant outlet gas temperature with an acceptable tolerance and

cope up with reasonable fluctuations in the process and gas conditions. It must ensure

that the atomizers are always operating at the optimum pressure whatever the water flow

rate.

d] Mill Vent Fan : Make Andrew Yule

Flow Rate : 1500 m3/minute.

Fan diameter : 2195 mm

Motor details : 225 Kw, 1000 RPM.

e] Mill Vent Dust Collector: Make Andrew Yule

Type : Pulse Jet 264 - 4 –10.

Total Filtering area : 644 m²

f] Weigh-feeders : Limestone Additives

Make : J&N make J&N make

Size : 1200x8m 800x7.46m

Hopper capacity : 212 M.T. 155 M.T.

xxi

g] Desired Product : 2% reside max. (on 212 micron sieve)

Particle size : Micron sleeve.

GAGAL II: RAW MILL [VRM] –

In VRM section raw material are directly fed to the mill through feed belt and

ground to the desired fineness. The ground material is stored in continuous flow silo

from where it is fed to the kiln. These mill utilize the hot air from the kiln exhaust to dry

the raw mix.

Detail of major components installed in Gagal II Raw Mill:

Type of Mill : RM 46/26 Vertical Roller Mill [VRM]

No. of Unit : 1 No.

Output capacity : 280 TPH

Make : Krupp Polysius

Feed material size : 80% Passing 75mm and 90mm max.

Moisture content : 1-2% normal, 5%max

Product size : 12-14% on 90micron

Power : 2500Kw.

Grinding Bowl dimension : 4750mm dia. X 1580mm height.

External diameter of Roller: 2600mm.

Raw mill fan : Type – Backward curve

Volume rating : 600000m³/hr.

Fan speed : 600-990 RPM

DESCRIPTION:-

A vertical roller mill has two vertical rollers, which are provided with roller tyres

and are mounted on the axle. The axle is mounted on the roller support. Each roller has a

bearing inside it. One side of one bearing is provided with oil/grease for lubrication

while the other side has the air seal to prevent the dust from entering the roller body. The

body has R.T.D. and an oil probe to detect the unusual increase in temperature of the oil

and also the amount of oil present. The rollers are placed in the grinding bowl. The

grinding bowl is rotated by a drive present below it. When the grinding bowl rotates the

xxii

roller rotates along with it. The material entering from the side of the housing will get

grounded when in between the rollers and the bowl. The nozzle rings are provided along

the side for the gas entry. The cross-section of the nozzles and the velocity of hot gases

can be adjusted. These gases will carry the grinding solid to the top in he separator,

which will feed the coarse particle back to the grinding bowl and will carry the fines in

the exit side

b]-: SEPOL SEPARATER (DYNAMIC SEPARATER):

Gas volume : 4, 60,000-5, 40,000 m³/hr.

Rotor diameter : 4000mm

Housing diameter : 7500mm

Speed : 7-70 RPM

Description:

The material that has been ground & entrained by the air flow is fed into the

separator through the outer adjustable guide vanes. The rotating rotor separates the

finished material from the portion of material, which is still too coarse– which are

centrally returned to the mill through the tailing return cone.

The external mill circulation material is fed into the separator from above and

scattered by the distributing disc rotating with the rotor. The circumferential zone of this

distributing disc is provided with a number of evenly distributed openings. These

openings in the form oblong holes bordered outside by guide elements. The fed in

material falls through the openings and is uniformly spread outward into the ring shaped

space between the tailing cone and the external housing. The material is flushed by

vertical directed gas flow, so that the fines contained in external circulation material are

also separated.

Fineness can be regulated by varying the rotational speed of the rotor. More the

speed more will be the fineness.

Hydrostatic drive for VRM Sepol:

It consists of the hydraulic drive station, Hydrostatic motor, electric motor and

accessories. Drive work in closed circuit which is designed for one direction of the

rotation of the radial piston motor only. The axial piston pump is driven by the electric

motor via a flexible coupling. Oil returning from the radial piston motor is fed into the

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axial piston pump again. In the hydraulic drive station a heat exchanger or a radiator

serve to help the hydraulic oil at operating temperature.

c] - BUCKET ELEVATOR:

Feed partical size : up to 50mm

Capacity : 540 TPH

Bucket width : 1400mm

Elevating speed : 1.4m/sec

Shaft centers : 31m.

d] - RAW MILL / KILN ELECTROSTATIC PRECIPITATER:

Size : M400 LC4F 3.45 x 12-19-36+PC.

No. of Unit : 1 No.

Make : Orient Engineering

Gas before ESP : 247500Nm³/hr.

Gas temperature : 90-100ºc

The Precipitator system is configured to achieve the following process for solid-gas

separation:

Corona Generation,

Particle Charging,

Particle Collection &Removal.

The basic configuration consists of collection plates and discharge electrodes

forming flue gas ducts through which the gas is passed for treatment. High voltage DC

power is applied to the discharge electrode while the collecting plates are grounded. The

presence of strong electric field in the vicinity of the discharge electrode and the free

electrons available in the gas generates corona. Also an electrostatic field is established

between discharge electrode and collecting plates. Particles which travel between the

discharge electrode and collecting plate get charged and collected on collecting plates.

The rapper mechanism provided for the collecting plates shear away the collected dust

into the dust hoppers for onward disposal. Rapper mechanism provided for discharge

electrode dislodges the dust gathered on these electrodes.

E] - AEROPOL:

Diameter of conveying vessel: 2500mm

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Height of vessel : 5500mm

Capacity : 380 TPH

Conveying height : 80m

Conveying pipe size : 600NB

f] - RAW MATERIAL HOPPERS:

Hopper capacity; Limestone: 1 No. 900T.

Shale : 2 No. 300T.

Iron ore : 1 No. 300T.

Weigh-feeder capacity; Limestone: 35 to 350 TPH

Shale : 4 to 40 TPH

Iron ore : 1 to 10 TPH.

Critical Operating Parameters:

Except raw meal composition and fineness, following are the control parameters-

Mill feed is kept in auto mode w.r.t. bucket elevator drive Amps,

Vibration level at gear box,

Roller bearing temperature,& Mill outlet temperature,

Differential pressure across mill,

Mill hydraulic pressure.

[04]- HOMOGENISATION SYSTEM:

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Gagal – I

a] Blending Silo : No. of Units 2.

Size : 13m dia.x 24m height.

Capacity : 1500 M.T. each.

b] Storage Silo : No. of units 2.

Size : 13m dia.x 40m height.

Capacity : 3100 M.T. each.

Gagal – II

Blending-cum-storage silo: Type – Multi-flow silo [C.F. silo]

Make : Krupp Polysius

Size : 22m dia.x 52m height.

Filling height : 50m

Effective Volume : 16500m³.

Capacity : 18000 M.T.

Air quantity : 10m³/min.

Air pressure : 1.6 M.bar.

BLENDING SIL0:-

In continuous blending system the feeding and the discharging of the material to

and from the silo is done simultaneously and continuously. Homogenization is achieved

either by pneumatic means inside the silo or mechanically as in cascading and recycling

system. Two or more silos are used in series and the overflow from one silo is fed into

the next silo and the material discharged from the silo is discharged into the inlet stream.

In the mixing chamber the material is fed from the top and distributed over the top of the

silo at the several points across the cross – section to ensure the uniform layer deposition

in the silo. Both the mixing chamber bottom and the outer ring bottom are aerated. Low

pressure air is admitted to the section of peripheral silo ring. This partial aeration creates

the fluidized material layer that passes below the un-aerated material through the

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peripheral opening into the mixing chamber where it freely expands. Alternated sectional

aeration initiates the gravity pre-blending inside the main silo compartment. The pre-

blending material entering into the mixing chamber is subjected to the intensive cycle

quadrant blending. The material is then discharged through one lateral discharge socket.

[05]- PREHEATER:-

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Gagal –I

No. of Streams –3

a] Four-stage, twin string type MF Calciner Make: ABL

Size – CY1 - Ø2925mm

-- CY2 - Ø5m

-- CY3 - Ø5m

-- CY4 - Ø5m

MFC size - Ø5.1m x 16.5m length.

Make - Mitsubishi

b] Five stage preheater, single string with DD Furnace

Size – CY1 – Ø3.244m x 8.65m height.

-- CY2 – Ø4.45m x 8.57m height

– CY1 – Ø4.45m x 8.57m height.

--CY1 – Ø4.45m x 8.57m height

DD Furnace size – Ø 4.20m x 8.41m.

Make- Nihon

c] Kiln ESP MFC Stream;

Make -- ABL

Nos of ESP – 2 Nos.

Design – Dry Horizontal.

Height of Electrostatic field – 10.5m

Length of Electrostatic field – 8.64m

d] Kiln ESP DDF Stream;

Make – Voltas

Nos of ESP – 1 No.

Size – IP, IC, 17 G.P. [16”x29”x29.2”]

2F [2x14.6”]

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Gagal – II

Nos of Stream – Round two string.

a] Five stage preheater with PREPOL –AS precalciner.

Make – Dopol, Krupp Polysium AG, Beckum.

Volume of calciner - 660 m³

Cross section of calciner – 14m²

DESCRIPTION:-

Basic function performed by a cyclone are:-

1-It heats up the raw meal in the gas stream,

2-It separates the raw meal and discharges it via the meal chute.

PREHEATER & IT’S COMPONENTS:-

A TYPE CYCLONE:-

It is arranged between the calciner and the B type cyclone. It is fed from above.

The exit gas containing the raw meal when leaving the calciner flows via the calciner

bend to the cyclone. Here the cyclone meal is separated and passed in via the meal chute

to the kiln inlet .The exit gas flows through the dip pipe and intermediate piece into the

next higher gas duct .

B TYPE CYCLONE:-

One or more of the B type cyclone stages are installed in the preheater between A

and C type cyclone stage. B type cyclone is fed from below.

The raw meal which fed into the gas duct is conveyed into the cyclone by the

exhaust gas. In the cyclone the raw meal is separated passes through the meal chute and

the dispersing box to the gas duct of the next lower cyclone stage. The dispersing box

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hereby effects the uniform distribution if the raw meal in the gas duct. Exhaust gas flows

into the dip pipe and the intermediate piece into the next higher gas duct.

C TYPE CYCLONES:-

It is the last cyclone in the DOPOL 90 Preheater. It may consist of one or more cyclones

per string. It is designed for high degree of raw meal separation.

The raw meal fed into the gas duct is conveyed into the cyclone by the exhaust gas.

In this cyclone the raw meal is separated and passes through the meal chutes and the

dispersing box to the gas duct of the next lower cyclone stage. The dispersing box hereby

effects the distribution of raw meal in the gas duct. Exhaust gas flows through the dip

pipe into the exhaust gas duct.

CALCINER:-

It is mounted between the kiln inlet and the lowest cyclone stage of the pre-heater.

The raw meal, fed into the transition piece, The fuel and the tertiary air are conveyed into

the exhaust gas through the calciner to the cyclone of the lowest stage of the preheater.

Combustion of the fuel takes place in the calciner. Raw meal is heated up by the heat

exchanger.

M.F.C. VESSEL:-

Mitsubishi Fluidized Calciner suspension preheater consists of a regular raw mix

suspension preheater working in conjugation with fluid bed calciner. The calcining of the

raw meal is performed in a separating fluid bed reactor which is located in between the

suspension pre-heater and the rotary kiln.

D.D.F. VESSEL:-

Dual combustion and de-nitration calciner was developed by the Nihon Cement

Company in 1973 to cope up with the soaring prices of heavy oil.

MECHANISM:

Coal firing capacity of the D.D.F. kiln is 3600tpd. D.D.F furnace is divided into four

zones:-

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Reducing zone:-

This is the inverted conical shaped part at the lower side of the D.D.F furnace

whose main function is to reduce NOX the kiln exit gas.

Fuel cracking and burning zone:-

This is the cylindrical part of the central lower side of D.D.F., whose main function

is to vaporize, crack and partially burn the fuel injected into this oxygen rich zone.

Main burning zone:-

This is that part of the orifice in the central part of D.D.F. where Main function is

to burn the fuel and to transfer the heat generated to the raw material.

Complete burning zone:-

This is the top cylindrical part of D.D.F. whose main function is to burn the

remaining fuel gas and to accelerate the calcining of the raw material.

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[06]- ROTARY KILN:

Gagal – I

a] Kiln Make : ABL

Size : Ø 4.11m x 64.0m length.

Capacity : 2800 TPD

Inclination angle : 3.5%

Motor : 475 HP

Feeding device : Sank weigh feeder

b] Grate Cooler, Make : ABL

Size : 829 H/ 1050 H

No. of fans : 8Nos.

Cooler ESP : Make Flakt

Size : FAA 2 X 45 M 152110 A2

Nominal Flow : 8000 m³ / minute.

c] Coal Mill : 1 No.

Type : 8.5 E Type

Coal Mill ESP Make : ABL

ESP Design : Dry Horizontal

Height of Electrostatic field: 4.5m

Length of Electrostatic field: 8.64m.

d] Type of Clinker storage : 2 No. Silos

Capacity : 10000 M.T. each.

Gagal –II

a] Kiln Make : KRUPP POLYSIUS

Size : Ø4.4m x 65m length

Capacity : 3300 TPD

Inclination angle : 3.5%

Motor : 600Kw, 1500 RPM

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Feeding device : POLDOS-SR,

capacity – 300tn/hr

b] Grate cooler make : Krupp- Polysius.

Type of grate cooler : Repol,

Size : SR3130 / III,

grate width-3044mm&

grate length- 30350mm,

grate surface- 92.4m²

No. of fan installed : 10

Cooler ESP Size : M.400 LCS 3 F 4, 6 x 12.19-34.

ESP Make : Orient Engg.

c] Coal Mill : 2 nos.

Type of mill : 8.5 e 9 coal mill.

Make : ABL

Capacity : 20 TPH

Coal mill ESP Nos. : 2, size- 15/6/2 x 9/0.3

d] Type of Clinker storage : Circular clinker stockpile

Storage capacity : 60000Tonnes.

The rotary is designed for the burning of the pulverulent, small size or sludge feed

material. For this purpose the kiln hood at the outlet of the rotary kiln accommodates a

special rotary kiln burner. The hot secondary air coming from the downstream cooler and

entering the rotary kiln via the kiln hood is mixed with primary air of the rotary kiln

burner and passed through the rotary kiln in the counter-flow to the feed material.

The inclination and the rotation of the rotary kiln make the feed material in the

rotary kiln inlet to flow towards the outlet. The downstream kiln hood serves as an air

seal and as a connection to the cooler.

For the protection of the rotary kiln shell and the attached parts as well as for the

preventation of the excessive heat losses, the rotary kiln is provided with a special

refractory lining which is adjusted to the requirements of the individual zones.

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The rotary kiln pipe consists of the individual pipe sections which can be welded

together depending upon their size and transport possibility, either in workshop or at the

site and the pipe is provided with a refractory lining. The plate thickness fulfil the

requirement of the calculated stresses in the respective zones.

The material quality has to be chosen according to the temperature stresses in the

respective zones.

The rotary kiln rests on the tyres or the supporting rollers the axial guidance is

effected via a hydraulically longitudinal guides or thrasher blocks. The driving torque is

transmitted via the rotary kiln drive and the rack and pinion drive to the rotary kiln pipe.

The rack and pinion drive is protected against influences by a guard and provided with a

lubrication device.

A transition piece is to the downstream cooler the outlet end is equipped with kiln

hood provided with the manholes for entering the rotary kiln and for introducing the

rotary kiln burner.

Seals at rotary kiln inlet and outlet serve as to prevent any entry of any infiltrated

gases.

FUNCTIONAL DESCRIPTION:

The feed material enters the rotary kiln through the inlet housing. The inclination

and the rotation of the kiln cause the material to move in counter-flow to the hot gases

towards the outlet and from there into the cooler.

In this process the feed material passes through the following reaction zones:

1. Preheating zone (subject to kind of preheater )

2. Calcining zone (subject to the kind of preheater )

3. Clinkering zone

4. Cooling zone

The presence and the length of these zones is mainly dependent on the composition

of the material to be burnt, the preheater and the downstream cooling system.

Diameter and the length of the rotary kiln depends upon the desired output and are

considerably influenced by the chosen preheater and cooling system.

The quality of the refractory lining of the rotary kiln pipe is adjusted to the length

of the reaction and temperature zone and is specifically determined for every individual

plant.

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The heat quantity required for different reaction stages is generated by the rotary

kiln burner at the rotary kiln outlet. The combination air is high temperature secondary

air coming from the cooler section. The hot gases flow through the rotary kiln and reach

the inlet housing via the rotary kiln inlet. The heat is transmitted to the feed material by

the contact between the hot gases and the material and by its contact with the refractory

brick lining.

RECIPROCATING GRATE COOLER:

SPECIFICATIONS:-

1. Type of the grate cooler : REPOL

2. Grate width (nominal) : 3040 mm

3. Grate length : 30350 mm

4. Grate surface : 92.4 m2

5. Number of single grates : 3

6. Grate inclination : 3 degree

7. Type of drive : Mechanical

8. Type of crusher : Hammer

9. Number of fans : 9

DESCRIPTION:-

The reciprocating grate cooler serves for the cooling of the small sized or

granulated burned material. An excellent cooling effect is achieved in that. The cold air

is blown through the cooler grate and through the burned material lying on the grate.

FUNCTIONAL CHARACTERISTICS OF THE COOLER:

The burned material discharged from the kiln falls through the inlet shaft of the

cooler onto the entry to the grate. Due to the special design to the grate entry the material

to be cooled forms a uniform bed. Over the stationary and movable grate plate rows, the

burned material is transported by the forward movement of the movable grate plate rows

to the end of the cooler.

The oscillating frame with the movable grate plate rows is driven on both the sides;

the number of the strokes per minute is infinitely variable. The cooling air is generated

xxxv

by the several fans. Normally, one fan is allocated to each air chamber, thereby providing

the targeted aeration to the grate and the material to be cooled.

The heated up cooling air is captured in the upper section of the cooler and is

available for the further use as secondary air for the kiln or as the tertiary air .The grate

riddlings are reclaimed from the collecting hoppers installed under the air chambers,

which are equipped with the dust tight discharge elements.

On leaving the reciprocating plate the cooled material is screened and the oversize

particles are fed into the crusher using a grate bar chute. The crusher throws the crushed

material partially back into the reciprocating grate.

The bearing and the lubrication points of the cooler are supplied with grease by

automatically working central lubrication systems.

The outlet opening of the running axle in the lower housing walls are encased with

sealing air housings. These have an over pressure towards the inside cooler area and

protect the bearing arrangements of the axles against dust and over-heating.

The reciprocating grate cooler is equipped with an automatic control system.

Proceeding from the pressure of the first and the second air chamber of the first grate, the

reciprocating speed of the cooling grates is controlled.

The reciprocating grate consists of -

The upper housing with the inlet shaft,

The lower housing,

The cooling grate,

The clinker crusher,

The cooling air fans,

The compartments with collecting hopper for the grate riddlings,

The discharge elements,

The material conveying system.

[07]- CEMENT GRINDING MILL:

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SPECIFICATIONS:

Capacity

Gagal 1 : 75 to 90 tph

Gagal 2 : 140 tph

Shell inside diameter : 4.4 mm

Shell length : 15.15 mm

Compartments : 2

Length of first compartment : 4.76 m

Length of second compartment : 9.41 m

Rated output : 115 tph

Operating mill speed : 14.11 rpm

Ball charge

First chamber : 28 %

Second chamber : 28 %

Recommended number of motors : 2

Power : 2200 kW

Speed : 990 rpm

DESCRIPTION:

Final processing step in the manufacture of the cement of the cement is grinding a

mixture of clinker and additives into a finished product Object is to create a particular

fineness of the product to achieve some predetermined physical characteristics in the

cement. When in concrete, Main ingredient used in cement is the clinker. Clinker is

ground with gypsum to produce Portland cement. Grinding mill is the main component

used in finish grinding system. A ball mill is horizontal cylindrical drum with two

compartments having steel balls of the different diameter. as grinding media. Clinker is

ground by a closed circuit grinding system where mill product is routed through the

dynamic air separator and the material coarser than the required grain size is returned to

the mill. Thus, separator removes the coarser and the fine particles, which are fed back to

the mill.

xxxvii

Sufficient new feed is added to the mill as required to maintain the charge within

the mill capacity. Heat generated in the mill is always present since the majority of the

energy imparted to the mill is converted into heat. Although nothing happens to the

clinker at 220 degree farenhite, but raw gypsum at that temperature begins to degenerate

loosing retarding effect on the setting of cement and thus rendering the cement for false

setting. Mill product temperature is maintained by water injection system, which

improves the grinding efficiency also and eliminates the problem of cement setting.

Further air vented through the mill is used to remove some of the heat generated during

mill grinding. Dust laden air vented through the mill is passed through the grit separator,

bag filters and ESP where fine dust is collected and clean air is vented to the atmosphere.

FLY- ASH HANDLING:

DESCRIPTION:

For higher production rate of fly-ash based cement, it was necessary to develop

silos with higher capacity and lower operating cost for both fly-ash and cement. Flat

bottom system is the result of Research and Development in American cement industry.

Several discharge gates placed at the bottom of silo, opened one or two make the fly-ash

flow downwards near the central aeration pad.

Silent features of fly-ash silo:-

Vertical silos wall avoidance of material, bridging by proper silo internal

construction, nearly total discharge.

Controlled discharge of the material flow, several aeration sections are fluidized

alternatively by motorized six ways distributor appertaining valves in the air supply

lines.

Minimum amount of the air is supplied which is necessary to locally fluidize and

discharge the required amount of the fly-ash.

Lowering the material level in the silo is controlled by dozing valve.

Easy availability for maintenance of all the components in the bottom.

High availability because there are four discharge spouts used on specific

requirement.

xxxviii

[08]- PACKING HOUSE:

xxxix

Packing Plant is the place where cement is stored, packed and dispatched to various

destinations.

Gagal Cement Works Packing Plant has six cement silos with a total storage

capacity of 35200tonnes. There are one mechanical and two electronic Rotary Packers at

Gagal I Packing plant of capacity 60 TPH (for mechanical packer) and 100 TPH (for

each electronic packers) and two electronic rotary packers at Gagal II Packing plant of

capacity 180 TPH each.

All the packers have the truck loading facility because the cement from Gagal is

transported to different destinations by road only.

33 Grade OPC (Ordinary Portland Cement) as per IS : 269

43 Grade OPC (Ordinary Portland Cement) as per IS : 8112

PPC (Portland Pozzolana Cement) as per IS : 1489(part II)

PPC (Portland Pozzolana Cement) super

Separate bags Godown is available in Gagal plant I and Gagal plant II, Where up to

40 lakhs and 80 lakhs can be stored respectively. Packing plant is close liason with

cement Dispatch section and Laboratory.

Function of the Department:

Cement packing and dispatch is done through road transported by trucks only.

Cement dispatch section receives order from CMD Chandigarh and accordingly

they place demand of trucks to the truck unions, destinations wise. Then the trucks are

placed in accordance to demand for loading of cement. The silo from which the cement

is to be extracted for loading depends upon the type of cement and type of cement filled

in the silos.

Rated Capacity of the packers are as follows:

Packer-1 : 60 TPH

Packer-2 : 100 TPH

Packer-3 : 100 TPH

Packer-4 : 180 TPH

Packer-5 : 180 TPH

The main parts in the packing plant:

Compressor for packer and dust collector,

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Dust collector fan,

Rotary screen,

Elevator,

Spillage screw conveyor of packer hopper,

P.G. Blower,

P.D. Blower of respective cement silo,

Loading machine,

Belt.

[09]- WORKSHOP:

Workshop department deals in repairing of the jobs inside the plant as per the

requirement of different departments, for the performance of their function at optimum

xli

return on investment in machinery. Whenever some job (i.e. fabrication or machining –

smaller in nature) is required by any department, he sends a job order to the workshop

and the job is completed by workshop maintenance gangs.

Workshop has three major sections:

Machine shop,

Welding shop,

Maintenance of Positive Displacement Blowers, Reciprocating compressors and

High horse power gearboxes of whole plant (Gearboxes of more than 150hp or

100kw).

The following machines & machine tools are available in the workshop –

Lathe: Make: VICO; unit nos. : 6

Make: HML; unit nos. : 2

Column Drilling machine:

Make: HMT; unit nos. : 2

Type: CD

Table size: 630 x 500mm.

Table travel (vertical): 200mm.

Milling machine:

Make: HMT; unit nos. : 1

Type: KNEE

Feeds: 18 nos. (16 – 1800mm/min).

Table clamping area: 1350 x 310mm

Planer machine:

Make: Punj steel. Batala

Bed : 3000 x 1000mm.

Boring machine:

Unit nos. : 1

Shaper machine:

Unit nos. : 2

Power hexa:

xlii

Unit nos. : 1

Grinder:

Unit nos. : 2

There are no special purpose machine or extraordinary machine in workshop

because no newly production, only maintenance and repairing are there. All new parts of

machine are purchased from other companies.

Routine maintenance is done by the department-gangs individually by their own

maintenance gangs.

MATERIAL HANDLING EQUIPMENTS:

There are two categories: Mechanical conveying equipments and Pneumatic

conveying equipments. Mechanical equipments consumed less power in comparison of

Pneumatic equipments, but maintenance is higher. Pneumatic conveyer conveyed only

Pulverized material.

Mechanical Conveying Equipments Installed in Gagal I & II:

1. Belt conveyer,

2. Screw conveyer,

3. Bucket Elevator,

4. Deep Bucket conveyer,

5. Drag Link Chain conveyer.

Pneumatic Conveying Equipment Installed in Gagal I & II:

1. Aeropol vertical conveyer,

2. Fluidor Pneumatic Trough Conveyer (P. G. Conveyer),

3. Poldos S-R Proportioning Feeder,

4. Fuller-Kinyon Pump (FK Pump),

5. Low Lift Pump (LLP).

DESCRIPTION OF THE MECHANICAL CONVEYORS:

[1]- BELT CONVEYORS:

xliii

CONVEYING OF A VERITY OF MATERIAL:

The size of materials that can be conveyed is limited only by the width of the belt.

Materials can range from very fine, dusty chemicals to large, lumpy ore, stone, coal or

pulpwood logs. Because rubber belts are highly resistant to corrosion and abrasion,

maintenance cost are comparatively low when handling highly corrosive materials or

those that are extremely abrasive, such as alumina and sinter.

ADVANTAGES:

Belt conveyors operate automatically and continuously without loss of time.

Without loss of time for loading, unloading or empty return of trips.

Low labour cost, low power cost, Low maintenance cost.

Belt conveyors provide a continuous flow of material while avoiding the confusion,

delays, and safety hazards of rail and motor traffic in plants and other congested areas.

For these reasons, belt conveyors are capable of handling tonnage of bulk materials that

would be more costly and often impractical to transport by other means.

They neither pollute the air nor deafen the ears. They operate quietly and do not

contaminants the air with dust or hydrocarbons. At transfers, dust can be contained

within transfer chutes or collected with suitable equipment, if necessary.

The conveyor equipment itself can be protected from overload and malfunction by built-

in-mechanical and electrical safety devices.

Long-distance transportation.

Conveyor component are – troughed conveyor belt, tail pulley, head pulley & drive,

closely spaced idlers at loading point (impact idlers, if required), return idlers, vertical

gravity take-up, loading skirts, discharge chute.

After the conveyor belt tension requirement in pounds per inch of width, the conveyor

belting must be selected on the basis of the tension rating of multiple-ply belts & their

trough ability. The maximum allowable inclination of the belt conveyor is 14º.

Specification of the belt used in the plant –

800/4 (Capacity-800kg/cm², 4-ply rating)

1800/5 (Capacity-1800kg/cm², 5-ply rating)

Belt width: 1000mm

Belt length: as per requirement.

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[2]- SCREW CONVEYOR:

Specification:

Diameter of screw: 70mm

Geared motor : BAUER Type-DO54SZ2-212/170

Motor rating : 0.25kw

Motor speed : 23RPM

Container capacity: 5 litres.

Consisting of:

The conveying screw in semi-open tube,

the reversible geared motor driving the screw conveyor,

the chute at the outlet end of the screw conveyor,

the sample collecting device,

the sample container with level indicator,

the control system for the screw conveyor.

No sample being taken, the screw conveyor is reversed, in order to always convey fresh

sample material. The scope of supply includes the welded pipe socket accommodating

the sampler.

[3]- BUCKET ELEVATOR:

DESCRIPTION:

The Bucket Elevator is used for the continuous vertical handling of bulk materials having

a peak temperature of approximate 300ºc and a grazing range from 0-50mm.

The Bucket Elevator consists of:

The boot with return sprockets,

The casing,

The head with drive sprocket,

The chain with round steel links,

The buckets,

The casing doors.

The Bucket Elevator boot is placed on the supporting structure. Adequate clearance must

be left on one side of the boot, to allow for the dismantling of the return sprockets. Its

casing consisting of individual sections are erected. All casing joints must be sealed with

the sealing cord, the cord being placed between the row of holes and the inside edge of

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the connecting flange. Spacer plates must be inserted between the two casings spaced

about 6m apart. The Bucket Elevator head may now be placed on the erected casings,

aligned and fastened.

The buckets are fixed onto the U-links of the chain. When making the two chains

endless, make sure that the return sprockets are in their highest possible position. In the

outlet of the bucket elevator head, an adjustable tongue is provided to guide the material

flow.

Generally speaking, the drive unit consists of:

a flexible coupling between machine and gear unit,

the speed reducer with backstop,

a hydraulic starting and overload protection coupling or a flexible coupling between gear

unit and motor,

and the motor.

[4]- DEEP BUCKET CONVEYOR:

The Deep Bucket Conveyor is a unit for continuous handling of bulk materials with a

lump-size not exceeding 150mm and a peak temperature of 500ºc.

The Deep Bucket conveyor works horizontally as well as on an incline up to an angle of

60º. In principle, the bulk material must be proportioned according to the maximum

quantity conveyed.

The machine consists of:

the drive station,

the frame with running track,

the supporting frame,

the take up station,

the two-strand bushed chain,

the deep bucket,

the bucket guide shoes and feed guides and the inlet chute.

The drive unit normally consists of:

- a flexible coupling between drive shaft and gear box, the speed reducer with anti-

run-back device,

- a hydraulic starting and overload coupling between gearbox and motor,

and the motor.

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[5]- DRAGLINK CHAIN CONVEYOR:

DESCRIPTION:

This conveyor is used for the continuous handling or distribution of bulk material at peak

temperature of 280ºc with chain links of manganese alloy steel, and up to 500ºc using

chain links of chrome – nickel alloy steel. This conveyor works horizontally as well as

on an incline. The material to be handled is fed onto the lower strand, i.e. the conveying

strand, if possible from both sides.

The conveyor consists of:

the drive station,

the return station,

the conveying chain,

the slide rails,

the guide shoes,

the support rollers,

the stripper plate, and

the trough of concrete or steel, as required.

Drive Unit: A chain drive with shear pin sprocket between machine and gear unit, slide,

rails, speed reducer with motor bracket, V-belt drive between gearbox and motor, and

electric motor. The gearbox is filled with the prescribed quality and quantity of oil.

DESCRIPTION OF PNEUMATIC CONVEYORS:

[1]- AEROPOL VERTICAL CONVEYOR:

DESCRIPTION:-

The AEROPOL vertical conveyor is a device for the continuous vertical transportation of

finely granular bulk materials. The conveyance is performed Pneumatically and is based

on the principle of lean-phase conveyance. The conveying medium is oil-free and

waterless compressed air of maximal 1 bar over pressure. The standard design conveyer

is suitable for non-combustible pulverulent to granular bulk materials with temperatures

of up to 120ºc.

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DESIGN:-

The AEROPOL vertical conveyer consist:

- The conveying vessel with bracket or supports as well as air supply ducts and

control

lines;

The conveying pipe with expansion tube as well as sliding and fixed anchorages;

The pipe branching or the separator.

The conveying vessel consists of the pressure vessel with material inlet connection piece,

riser pipe socket, and deducting pipe-socket, manhole with manhole closure and brackets

or supports. The air supply ducts and control lines including pressure gauges are

mounted according to the local conditions.

The expansion of the conveying pipe owing to thermal stresses is compensated by

expansion tubes. The separator serves for the separation of carrier gas and material.

FUNCTIONAL DESCRIPTION:

The material to be conveyed is continuously fed to the AEROPAL vertical conveyor

through the material inlet connection piece. For conveyance and aeration purposes the

conveying vessel must be charged with compressed air which is free from dust, oil and

water.

The aeration flows through the textile fabric belt in the aeration floor and fluidizes the

material conveyed. Tanks to the pressure of the material column the fluidized material

flows as dense phase to the riser pipe inlet where it is diluted by the conveying air and

carried away. The quantity conveyed is proportional to the intensity of pressure

generated by the material column in the conveying vessel and thus also proportional to

the conveying air pressure and the pressure on the bottom.

It is possible to mount a measuring diaphragm on to the pressure-measuring flange in

order to control the material feed and thus the throughput quantity by means of the

pressure on the bottom (POLDOS system).

The air quantity required for aeration of the material conveyed depends on the kind of

material conveyed and is adjusted by the throttle valve. The shut-off flap serves as safety

valve. If the conveying air supply is switched off or fails, the flap will shut immediately

in order to prevent material returning into the conveying air duct.

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[2]- FLUIDOR PNEUMATIC TROUGH CONVEYOR (P.G. CONVEYOR):

DESCRIPTION:

It is also named as Pneumatic Gravity Conveyor. It is a conveying unit of dust free

operation and low-wear design; its purpose is to transport all kinds of bulk material-from

dry, Pulverulent to fine grained or granular material.

DESIGN:

The FLUIDOR Pneumatic trough conveyor of the following components:

trough section

support

flexible joint

trough flow bow

fan

aeration piping

Fluidor shut off slide valve

Fluidor semi rotory isolating valve.

Trough upper section & through lower section are permanently screwed up with the

fabric floor insert-usually a textile fabric or polyster fabric-situated between the

longitudinal flanges. If required, the fabric may be protected by a laid-on wise cloth in

order to prevent the wear of the intermediate bottom.

The trough inlet can be flange-mounted to the trough section or welded in the trough

section. Flexible joints at the trough inlet and at the trough outlet compensate the

horizontal and vertical trough expansions.

The aeration air is supplied via aeration sockets welded in the trough lower section and is

removed via dedusting sockets in upper section or in the trough outlet. Fan is connected

to the aeration via the aeration piping consisting of hose line, pipe and throttle valve.

FUNCTIONAL DESCRIPTION:

The functional operation of the P.G. Conveyor is such that aeration is supplied from the

trough lower section via the fabric floor insert ventilates the material to be conveyed thus

producing its free-flowing condition. Thanks to gravitational force the inclination of the

trough has the fluidized material in the trough upper section flow to the outlet.

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The aeration air is supplied to the conveyor via the aeration socket at the trough lower

section. The quantity of air is adjustable by means of an upstream, mainly operated

throttle valve. The air to be used must be dry and clean. This air may be produced by

fans or taken from compressed-air mains. For exhausting the aeration air each conveyor

must be connected via dedusting pipe socket to a dust collector.

[3]- POLDOS S-R PROPORTIONATING FEEDER:

Material to be conveyed : Raw meal

Bulk density : 900 kg/m².

Temperature : 80ºC

Diameter of conveying pipe : 4954mm.

Vertical length of conveying pipe : 100mm.

DESCRIPTION:

The POLDOS S-R Proportionating feeder is a device for proportional and continuous

conveying of the fine grained bulk materials through horizontal and vertical piping.

Inclined piping either upwards or downwards is not allowed. Flow bows are not

permitted, as they cause different pressure drops and pulsations to those of pipe bends.

Conveying occurs pneumatically and is based upon the principal of lean-phase

conveying. It is suitable for non-inflammable; dusty to granular bulk materials at the

temperature up to 80ºC.The conveying rate can be varied within wide limits.

Consists of:

the pressure vessel which consists of the conveying vessel and the storage vessel;

the riser pipe which is fitted centrally in the pressure vessel;

the anchorage frame, a welded construction made of steel section;

three suspension fittings which contain the load cells;

the necessary control fitting and piping.

Functional Description: For conveying and aeration, the pressure vessel must be fed

separately with compressed air which is free of dust, oil and water. The aeration air flows

through the fabric in aeration floor and fluidness the material to be conveyed. The

fluidized material flows to the riser pipe inlet as a dense phase by means of pressure of

the material column and, there, is diluted and conveyed away by conveying air.

The through rate of material being conveyed is proportional to the pressure of the

material column in the conveying vessel and, consequently, also proportional to the floor

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pressure. The control valve in breather pipe of storage vessel regulates the top pressure in

the storage vessel. When the control value is fully open, there is same pressure in both

conveying and the storage vessels. The material columns automatically adjust themselves

to the same height. When control valve is throttled, aeration air serves to build up a top

pressure in storage vessel, which presses the fluidized material to be conveyed out of the

storage vessel and into the conveying vessel. In this condition maximum material column

height in the conveying vessel corresponds to the maximum output.

[4]- FULLER-KINYON PUMP:

PRINCIPLE OF OPERATION:

Material to be conveyed enters the hopper; the screw advances the material through the

barrel to the discharge body. In the discharge body, the material is compressed to form a

material seal. The material seal prevents a reverse flow of conveying air from the mixing

chamber. After the material is discharged into the mixing chamber, compressed air-

entering the mixing chamber through the nozzles-fluidizes it sufficiently to permit

pumping through the transport line connected to the end of the mixing chamber.

The free-floating flapper valve, located in the discharge area of the pump, is a

mechanical seal which assists in preventing the reverse flow of air from the mixing

chamber through the pump Barrel. The external flapper valve lever serves as a visual

indication that the free-floating valve is operating satisfactorily. A counter-weight is

attached to the flapper valve handle to aid in maintaining a material seal. Each pump is

supplied with one spacer ring located behind the flapper valve assembly.

The pump screw consists of a solid steel shaft and flight made from rolled mild steel

welded in position. All screws are dynamically balanced in two planes to improve

bearing life and ensure vibration-free pump operation. The pump screw is coupled to a

drive motor by either a shaft coupling or a V-belt drive. This pump uses angular contact

bearings. The bearing located at the discharge end of the pump screw is fixed to absorb

both radial and thrust loads. The bearing located at the drive end is not fixed to the screw

shaft and absorbs radial load only.

MIPS:

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MIPS is abbreviated form for Maintenance Inspection Planning System. As the name

suggests, the prime-function of the department is to prepare planning and scheduling of

carrying out various inspections, maintenance job and to record and update the

inspection result, maintenance remark for corrective action. Equipment inspection /

maintenance planning is the result of visual inspection / running hours or upon the result

of condition monitoring equipments etc.

The various techniques used for condition monitoring equipments are based upon the

diagnosis of the change in behavior pattern of sound, temperatures, heat, vibration,

viscosity etc.

MIPS department also coordinates in planning the maintenance activities of various

departments so as to get optimum utilization of stoppage duration of main equipments.

Whenever the equipment is remarked on unhealthy condition by the condition

monitoring equipments, analysis is carried out. MIPS department prepares the downtime

analysis of the main equipments such as mills, kiln etc.

Function of MIPS department:

Vibration measurement

Girth gear / Pinion profile & teeth impression

Wear measurement (mainly of E-mill grinding rings & balls, VRM table & roller liners,

wear of Roller press rollers).

Creep measurement – The live ring migrations or creep is the relative measurement

between the live ring and the kiln and it is measured in mm/revolution.

Shell thickness measurement – Shell thickness of kiln, mills are measured by ultrasonic

thickness gauge D-meter.

Kiln alignment reading.

Dynamic balancing.

Breakdown analysis.

Compact schedule – Compact stands for computerized maintenance planning and control

system.

Down time analysis.

QUALITY CONTROL:

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Daily outputs and intermediates of different departments at different stages and final

product are analyzed on a regular basis by the laboratory to achieve the set target. This

department provides the feedback for the relative departments. To maintain the quality as

per BIS Norms.

1-Limestone from quarry: Some samples are analyzed at works Laboratory, to get the

advanced information of the quality of the limestone proposed for mining.

The fresh limestone is carried out at stacker and Reclaimer, to control the carbonate

percentage. The desired characteristic normal operating range are-

Particle size: 3"

Total carbonate: 82% minimum.

CaO : 44.5% minimum.

Coal sample from coal stacker is analyzed to produce clinker of consistent quality.

2-Raw meal: Periodic samples of raw mill are collected for total carbonate and residue

and checked at Laboratory. The total carbonate and residue is conveyed to central control

room operator who according to the deviation if beyond to tolerance limit, take the

necessary action to obtain the targeted values as per BIS Norms and ACC’s Internal

norms. Periodic samples are also collected from discharge of blending silo and checked

for homogenization.

3-Final coal for Kiln: coal received from reclaimer is fed to raw coal hoppers. The final

coal sample from fine coal hoppers are collected in desired frequencies for residue, ash

and moisture. M.F.C. & D.D.F. coal sample are collected and checked for moisture,

residue and ash content.

Moisture : 6.0% maximum : To control flame temperature.

Residue on 90 micron,

Kiln : 25% maximum : To monitor the proper combustion

Pre calciner : 40% maximum and fineness control.

4-Clinker:

a) - Liter weight (gms) To control the quality of clinker.

1000 to 1350

b) - Free lime % maximum 2.5

Chemical analysis

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% CaO 63.0 to 66.0

% SiO2 20.0 to 23.5

% Fe2O3 3.5 to 4.5

% MgO 1.0 to 4.0

% LiO 0.2 to 1.5

5-Cement Grinding: According to the parameters of clinker, the gypsum and pozzolona

material are adjusted. Samples of cement at the cement mill out let is collected every

hour and check for different characteristic as required as chemical composition, strength,

fineness etc.

OPC PPC

Specific surface (m2/kg) : 240 to 350 min. 320 To maintain the quality

% So3 : 1.8 to 2.7 2 to 2.9 as per BIS Norms.

Setting time (minutes) :

Initial : 60 to 150 60 to 150

Final : 140 to 225 140 to 225

6-Packing House: Sample are drawn at every packing stage from all the running packers

and tested for key quality parameters for to access the quality of cement. In case, any

deviation is observed corrective action are taken.

ACC`s Internal norms on quality of cement manufactured at Gagal Cement Works-

Physical Parameters 33GR 43GR 53GR PPC

Seeting time (minutes) -

Initial (minimum) : 60 60 60 60

Final (maximum) : 225 225 225 225

Compressive strength (minimum) in MPa-

03 Days : 24 26 30 24

07 Days : 34 36 41 34

28 Days : 44 46 57 45

Specific surface (minimum) –

(m2/kg) 250 270 290

RESEARCH AND DEVELOPMENT:

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In all the dynamic and versatile companies Research and Development forms the hub of

new activities and is a constant partner, innovator, and evaluator. In 1964, the central

research station was established in Thane, MAHARASTRA. The Research station spread

over an area of 8000sq.m has modern Laboratory, with the latest technique equipment

and manned by highly qualified scientists and technologists, who carry out research in

cement and other fields. The thrust is on the process of optimization in cement plants,

utilization of low grade coal, development of special purpose cements, and special

varieties of dense and insulating bricks for rotary kiln lining; computer modeling and

simulation unit operation in cement manufacture; and watching brief on the plant quality

control and innovation aimed at its further improvement. The facilities at CRS are used

as the reference laboratory in terms of continual evaluation and monitoring of operations

and assistance to the factories in specific trouble shooting assignments.

INVENTORY MANAGEMENT:

There are three types of inventories: Raw material, Work in progress and Finished goods.

Raw materials are materials that are inputs in making the final product. Work in progress

refers to goods in intermediate stage of production and finished goods consists of final

products ready for sale. Manufacturing firms gradually hold all the three types of

inventories.

The goal of offertory inventory management is to minimize the total cost. Thus,

management is constantly confronted with the taste of attempting simultaneously.

To meet an ever-increasing demand for prompt customer services.

To maintain smooth flow of production operation.

The effective management of Inventory involves a trade off between having too much or

too little inventory. ACC’S Inventory consists of raw material, work in progress, finished

goods, stores and supplier.

Detail of Inventory in ACC:

Limestone, Gypsum and other raw material,

Coal, bags, stones, spares etc.

Loose plant and tools,

Stock in trade,

Work in progress

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Raw material, stock in trade and work in progressed is valued, whichever is lower coal,

packing materials, stones and spares are valued at cost, cost is determined on a weighed

average basis.

The ACC stores are classified as-

Regular: For items which are used regularly.

Sporadic: For items which are used once or twice in a year.

ESP (Emergency Stock Pool): For items having high value and are used in more than one

plant.

Discounted: For items not in use.

A class: For items which are very costly.

Generally in stores Inventory are broken in two parts-

a- General Items: Items which are common for different departments like electric

bulbs, paint etc.

Machinery parts: Spare parts as per drawing no. / part no. used for various

Machinery in plant.

ISO:

ISO is a specialized international organization whose members are the national standards

bodies of 111 countries. ISO was founded in 1946 to develop manufacturing, trade and

communication standards. The goals of ISO standards to facilitate the efficient exchange

of goods and services.

ISO develops standards in all industries except those related to electrical and electronic

engineering. Standard in these areas is developed by the Geneva – based International

Electro technical Commission (IEC).

ISO 9000:

The ISO 9000 series are generic standards for quality management and quality assurance.

The Standard in the series that are used for registration purposes include ISO 9001, ISO

9002 and ISO 9003. ISO 9001is the most comprehensive and covers all elements, from

design and development, through production, installation and servicing. Other standards,

such as ISO 9000 and ISO 9004, provide guidance for using the standard and for

implementing their element internally.

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More than 70,000 company facilitates worldwide have achieved registration to one of the

three standards in the series ISO 9001, ISO 9002, or ISO 9003.

For some companies, registration to ISO 9000 is a legal requirement to enter regulated

market. Companies have, implemented ISO 9000 to maintain market share, keep up

with, or get ahead of their competition. In addition, ISO9000 registered companies have

realized internal benefits, better operating efficiency, higher quality, reduced cost and

greater productivity.

ISO 14001:

The ISO 14001standard describes the basic requirements of an environmental

management system. ISO 14001 contains only those requirements that may be

objectively audited against for registration purposes and / or for self-declaration

purposes.

An ISO 14001 registration will not guarantee that a particular facility has achieved the

best possible environmental performance. Only that it has the basic elements of an EMS

in place and the continual improvement.

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