GONDWANA UNIVERSITY,GADCHIROLI – 442 605

BACHELOR OF ENGINEERINGIN

ELECTRICAL ENGINEERING

DEPARTMENT OF ELECTRICAL ENGINEERINGBALLARPUR INSTITUTE OF TECHNOLOGY – 442701

MAHARASHTRA

BALLARPUR INSTITUTE OF TECHNOLOGY

An Industrial Training seminar on

“MANIKGARH CEMENT”

Seminar Associates :-Mr. Praful L. Parsutkar

Mr. Rakesh I. Zingare

Mr. Atul R. Kude

Mr. Vivek V. Sawarkar

DEPARTMENT OF ELECTRICAL ENGINEERINGBALLARPUR INSTITUTE OF TECHNOLOGY – 442701

MAHARASHTRA

WHAT IS CEMENT ?

Cement is a fine powder which sets after a few hours when mixed with water, and then hardens into a solid,

strong material.

Joseph Aspdin, a Leeds Builder and bricklayer had invented the Portland cement in 1824. In this process,

Aspdin mixed and ground hard limestone and finely divided clay into the form of slurry and calcined it in a

furnace similar to a lime kiln ,till carbon dioxide was expelled. The mixture so calcined was then ground to a

fine powder & was used as Portland cement. The name Portland was given owing to the resemblance of this

hardened cement paste to the natural stone available at a place called Portland in England.

In India Portland cement was first manufactured in 1904 near Madras,(Chennai) by South India Industries

Limited and later developed by The Indian Cement company limited in 1914.

RAW MATERIAL FOR CEMENT PLANT

Materials transport associated with dry raw milling systems can be accomplished by a variety of mechanisms,

including pipe conveyors (across 9km from mines), belt conveyors, drag conveyors, bucket elevators, air slide

conveyors, and pneumatic conveying systems.

Raw materials are extracted from the quarry, then crushed and ground as necessary to provide a fine material

for blending silo. Once the raw materials are ground fine enough, they are blended in the proportions required

to produce clinker of the desired composition. The blended raw materials are stored in a silo before being fed

into the kiln. The silo stores several days' supply of material to provide a buffer against any glitches in the

supply of raw material from the quarry.

RAW MILLFeed material is directed onto the grinding table by the feed. The rotation of the grinding table

accelerates the material towards the grinding track and passes it under the rollers. Coarser material and bigger

lumps drops through the nozzle ring – and is eventually recirculated into the feed material inlet.

Moisture evaporates almost immediately as the gas stream carries the finer portion of material to the

separator. The separator allows material that has reached the required fineness to leave the grinding mill and

sends oversized material back for further grinding.

BAG HOUSE

Reclaimed along with some lat-rite stored in their respective hoppers is fed to the raw mill for fine

grinding. The hot gasses coming from the clinkerisations section are used in raw mill for drying and transport

of the ground raw meal to the electrostatic precipitator /Bag house, where it is collected and then stored and

homogenized in the concrete silo. Raw meal extracted from the silo (called kiln feed) is feed to the top of the

pre-heater for pyro-processing.

Unlike electrostatic precipitators, where performance may vary significantly depending on process

and electrical conditions, functioning baghouses typically have a particulate collection efficiency of 99%

or better, even when particle size is very small.

In reverse-air baghouses, (RABH FAN)the bags are fastened onto a cell plate at the bottom of the

baghouse and suspended from an adjustable hanger frame at the top. Dirty gas flow normally enters the

baghouse and passes through the bag from the inside, and the dust collects on the inside of the bags.

PREHEATER

Purpose:-

To increase the temperature of raw mill material through the incoming hot air from kiln & transfer air

duct.

Multistage preheaters and pre-calciners make use of the waste heat from the kiln and clinker

cooler to pre-heat and pre-process the kiln feed, and thereby allow for considerable energy

savings.

KILNPurpose:-

Kiln is cylindrical rotary equipment rotating on supporting rollers at about 3.5 RPM. Discharge in its

completing calcinations reaction. Firing is done from kiln outlet with the help of burner pipe.

The rotary kiln consists of a tube made from steel plate, and lined with firebrick. The tube slopes

slightly (1–4°) and slowly rotates on its axis at between 30 and 250 revolutions per hour.

The coal mill works for producing the pulverized coal for burning to increase the temperature of kiln, pre-heater, raw mill .It works as same as raw mill for lime-stone & latrite mixture {Raw mill} grinding, & the coal mill grind & transfer the coal to the furnace for burning. The raw mill is grounded dried swept away by fan through the separator to bag filter or ESP.

COAL MILL FOR FIRING KILN

CLINKERThe raw materials are delivered in bulk, crushed into a mixture which is fed into a rotary kiln. This is an

enormous rotating pipe of 60 to 90 m long and up to 6 m in diameter. This huge kiln is heated by a 2000°C

flame inside of it. The kiln is slightly inclined to allow for the materials to slowly reach the other end, where it

is quickly cooled to 100-200°C. 

Decomposition of raw materials - reactions at temperatures up to about 1300 °CThis includes:•Water evaporation in the raw feed, if any.•Loss of carbon dioxide from the limestone (i.e.: calcining).•Decomposition of the siliceous and aluminosilicate fractions of the feed.•Formation of a sulfate melt phase.

COOLING OF THE CLINKER

•As the clinker cools, the main liquid phase crystallizes to form aluminate phase, ferrite and a little belite.

Fast cooling of clinker is advantageous - it makes for more hydraulically-reactive silicates and lots of small,

intergrown, aluminate and ferrite crystals.

Slow cooling gives less hydraulically-reactive silicates and produces coarse crystals of aluminate and ferrite.

Over-large aluminate crystals can lead to erratic cement setting characteristics. Very slow cooling allows alite

to decompose to belite and free lime.

CEMENT MILL

Cement clinker is usually ground using a ball mill. This is essentially a large rotating drum containing grinding media - normally steel balls. As the drum rotates, the motion of the balls crushes the clinker.

The drum is generally divided into two or three 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.

PACKING PLANT•Cement from the cement silo comes into automatic rotary packer. There are four packer, three are 12 spouts & one 16 spouts.

•Worker put empty bags to the hook of packers 50 kg cement is automatically filled in this packs as the packer pack .The weight of cement is continuously displayed and a weigh becomes 50kg.the pack get sealed & transferred to conveyor belt. These packs are loaded automatically in trucks & in wagon (PLC programming over there.)

Distributed control system (DCS) is widely used for automation in modern industry since a process industry is usually installed in wide area and has a large number of machine and process sections, hence to operate and control all the machinery suitable from one place i.e. CCR ,one may install DCS. It has the capability to interface with external party software.

DCS(Distributed control system)

GENERATOR & TRANSFORMER SPECIFICATON (Unit 1 & Unit 2 )

SKODA GENERATOR(5MW)(SYNCHRONOUS TURBO ALTERNATOR)

P – 5000KWKVA- 6250

OUTPUT – STATOR - 11KV CURRENT – 328AEXCITATION OWN ROTOR – 73V

CURRENT – 350A

10MW TURBO GENERATORBHEL,INDIA Ltd.

KVA- 12500KW – 10000

EXCITATION - B.L.EXCITERRPM – 1500

CONNECTION – STATOR – STARVOLTAGE - STATOR – 6600V CURRENT – 1093A

ROTOR – 123V CURRENT – 406A

SKODA TRANSFORMERVOLTAS LTD. PUNE

HV – 11KV CURRENT – 341.12ALV – 6.9KV CURRENT – 543.83A

COOLING – ONANVECTOR GROUP – Dyn11

GENERATOR SPECIFICATON (60MW For Unit 2)BHEL, INDIA Ltd.

TURBO GENERATOR – 60MWKVA – 60000

STATOR -Voltage – 11kv Current – 3936AROTOR – Voltage – 237v Current – 678A

60MW TRANSFORMER(UNIT 2)

Schneider ElectricType of Cooling – ONAN & ONAF

Rated Power HV/LV in MVA – 75 & 82.5Rated Voltage at NO LOAD -PRIMARY – 11KV

SECONDARY – 12.1KVRated Line CURRENT -PRIMARY – 3936.5A & 4330.1A

SECONDARY – 3578.6A & 3936.5A

MANIKGARH CEMENT having Two Captive Power Plant(CPP), 15MW & 60MW

66KV SUBSTATION• 66kv (28 MW Capacity) Transmission line incoming form MSEB supply to the yard of substation.• This supply synchronies with CPP power plant (15MW & 60MW).

• The Total Three Transformer used in a Substation.• 30MVA,66/11KV (UNIT 2)• 20MVA,66/6.6KV(UNIT 1)• 20MVA,66/6.6KV(UNIT 1)

60MW GENERATOR TRANSFORMER11KV SUPPLY DISTRIBUTION

(UNIT 2)

TO PMCC PANEL

415V & 690V SUPPLY DISTRIBUTIONTO MCC PANEL

Thank You

Any Queries ?