(From 09th july 2012 to 24 sept 2012)

AT

DIAMOND CEMENTS (Prop: Heidelberg Cement India Limited)

Birlapur, P.O. Narsingarh 470 675, Dist. Damoh (M.P)

Guided By: Mr. Arbind Singh

(DGM Mechanical)

Submitted By:Saurabh Mishra Mechanical Engineering O.I.M.T. Damoh

ACKNOWLEDGEMENT
Every successful training requires a healthy atmosphere, good presence of mind, co-ordination and several other resources like energy and time through which a successful project can be made. The credit of all these things that I had got partially in completing my project approaches. I must admit that I cannot take credit for all ideas and information that this training comprises off. It is merely a collection of ideas from various books and people. I am very much thankful to Mr. Arbind Singh Sir and all other who directly or indirectly supported me to bring my training to a success.

PROFILE OF THE COMPANY

Heidelberg Cement India Limited is a subsidiary of Cement rum I.B.V. (a Company incorporated under the laws of The Netherlands, which is 100% controlled by Heidelberg Cement AG). Heidelberg Cement India Limited, with its core products being cement, ready mixed concrete, aggregates and related activities, is one of the leading producers of building materials worldwide, and it employs around 46,000 people in more than 50 Countries. Heidelberg Cement India Limited is committed to supply high quality products and provide best possible services to its customers. Its emphasis is to continuously upgrade plant efficiency by employing modern and latest technologies, reduce costs and improve production.

Heidelberg Cement India Limited (MCL), a Heidelberg Cement Group Company, was promoted in 1958 by a Karnataka based industrialist in technical and financial collaboration with Kaisers of USA as a Public Limited Company. The first one lac ton per annum dry process cement plant with an investment of Rs.220 lacs at Ammasandra Dist. Tumkur, Karnataka was commissioned in 1962. Immediately thereafter, an expansion was planned which doubled MCL's capacity to 2 lac tpa in 1966 at an investment of Rs.170 lacs Kaisers subsequently took control of the Company. Late Shri.G.D. Birla became the Chairman of the Company in 1966 and under his stewardship, the Company again doubled its capacity from 2 lac tpa to 4 lac tpa in 1968 at an investment of Rs.390 lacs MCL made steady progress and increased the capacity at Ammasandra to 6 Lac tpa with an investment of another Rs.230 lacs in 1978.

MCL, to expand, looked for a location in the North which, was then facing acute cement shortage. Damoh in Madhya Pradesh was selected and a 5 lac tpa green-field cement plant was set up at an investment of Rs.2950 lacs, which commenced production in 1983. This was a state of art first 5 stage preheater based technology plant in the Country which helped in maximising thermal efficiency. Encouraged with its success MCL also modernised its Ammasandra unit at an investment of Rs.3600 lacs, which was successfully completed in January, 1989, and helped not only in increasing the efficiency but also reduced cost of production on account of savings in power and fuel consumption. The Clinkerisation capacity at Damoh was further increased to 10 lac tpa by installing another state of art 6 stage preheater Kiln at an investment of Rs.8000 lacs, which was commissioned in 1989,and becomes 5cr.per.month\60cr.per.annum which helped not only in improving the operational efficiency but also in reducing the coal consumption and enhanced productivity.

A green field 5 lac tpa grinding unit was set up at Jhansi in Uttar Pradesh at an investment of Rs.5900 lacs, which commenced production in July 1989 to take advantage of the available fly ash from the nearby located Paricha Thermal Power Plant. Jhansi was considered an ideal location in view of the fact that Uttar Pradesh is one of the biggest cement consuming state with very little production capacity and even the available capacity then was only from the State Govt. owned cement plants. With this MCL achieved a total capacity of over 20 lac in 1989-90, with a presence both in Southern and Northern markets, which at that time only ACC enjoyed. Subsequently with upgradation and balancing at Damoh, the capacity increased to 23 lac tpa in 2004-05. Pursuant to the Share Subscription and Share Purchase Agreement and Escrow Agreement Cementrum I B.V.(subsidiary of HeidelbergCement AG) acquired Equity Shares from the S.K. Birla Group and its affiliates. In addition, further Equity Shares were acquired under the Open Offer giving Cementrum I B.V. 54.89% shareholding in HeidelbergCement India Limited.

MANUFACTURING PROCESS OF CEMENTS

The Plant incorporates the latest sophisticated dry process technology from KHD, Germany. The main raw material for the cement manufacturer is limestone. Limestone from the mines is carried to the main primary crusher by ropeway/dumpers after properly scrutinizing the limestone quality. The crushed limestone is brought to the pile by stacker through conveyor belts. The stacked material is extracted from the pile by reclaimer so as to get the uniform quality and brought to the roller press by conveyors where the material is pressed to form cokes with a size reduction upto 2-3% on 6.3 mm and 35% below 1mm. The pressed material is fed into the ball mill along with the appropriate quality of additives (fluxes) i.e. iron ore, bauxite and laterite etc. to produce a fine raw meal (2% on 210 micron sieve). Raw meal is transported by means of air slide and pumped to the blending silos by the air lift. The material is again blended to form uniform quality in silos.

The raw mill is further extracted from the silos and conveyed by pneumatic transport to first stage of suspension preheater. Material attains a temperature of 850o C by the heat exchange between the hot gases and material.With this temperature material attains about 30% calcination.This materials then enters a puroclone where because of the more retention of this material in the hot gases stream and pulverized coal firing it attains 85-90% calcination at the end and then the calcined material enters the last cyclone for further separation of material from the gases. Here the material attains a temperature 900-950 C.The meal from the last cyclone enters the kiln burning zone where temperature of about 1400 C is maintained by pulverized coal firing, here the chain of chemical reactions between the constituents of calcined raw meal i.e.SiO2, Al2O3, Fe2O3, CaO and MgO takes place. In this phase formation of nodules called clinker takes place. The hot air attains a temperature of 1000-2000 Celsius with enters the kiln as secondary air for coal combustion and balanced by cooler exhaust fan and ph fan. The cooled clinker is transported by means of bucket conveyor to the clinker yard or ropeway silos. The` clinker is transported by ropeway to clinker yard/cement mill hopper. The fine coal used for the firing purpose is ground in a ball mill to a fineness of 10-12% on 90 micron sieve and stored in fine coal silo.

MANUFACTURING PROCESS FOR 33, 43 & 53 GRADE

33Grade ordinary Portland Cement is manufactured by grinding clinker with about 2.0-4.0gypum to a fineness of 28003000 cm2/gm in terms of Blaine 33 Grade OPC is manufactured as per IS : 269 1989. 43Grade ordinary Portland cement is manufactured by grinding clinker with about 3.0 5.00% gypsum to a fineness of 3000 3200 cm2/gm in terms of Blaine 33 Grade OPC is manufactured as per IS : 8112 1989. 53Grade Ordinary Portland cement is manufactured by grinding clinker with about 3.0 5.00 % gypsum to a fineness of 3300 3500 cm2/gm in terms of Blaine. 53 Grade OPC is manufactured as per IS: 12269 1987. PPC is produced by inter grinding clinker with about 20 24 % fly ash (pozzolana material) and 2.00 4.00 % gypsum to a finess of 3500 - 3700 cm2/hr.PSC is produced as per IS : 455 1989 . Cement produced is conveyed by pneumatic pumps to the storage silos where from it is extracted and conveyed to the rotary packer where it is packed is bags and dispatched.

INTERMEDIATE CONTROLS
1. During cement manufacture, very stringent control is exercised on quality of incoming raw materials and at every stage of process products. 2. 100% consignments of raw materials are checked for their quality. 3. Crushed limestone is tested every hour (with continuous sampling at an interval of 5 minutes). Similarly raw mix, kiln feed and fine coal samples are tested on hourly basis for their composition.
4.

Clinkerisation is done at a temperature of more than 1400 oC and clinker is checked every hour for its quality and burning characteristics. Cement produced is checked every hour for various parameters like blains, setting time and So3 contents etc.

5.

6. The quality control lab is equipped with sophisticated equipments like X-ray and other testing equipments.

SPECIAL EFFORTS MADE FOR MANUFACTURE 53 GRADES

To cape up with the requirements of 53 grade OPC as per IS: 12269 1987, we have specially imported coal of low ash (13 15%) from Indonesia. with this coal of higher calorific value ash absorption in clinker is very low thus even normal lime in raw mix. The LSF and C3S of clinker is on higher side i.e., 0.92 0.94 and 52.0 - 55.80 respectively. The mineralogy of clinker has also improved. We ensure free lime of less than 1 % by maintaining higher temperature in kiln burning zone. High purity gypsum is used so that insoluble residue remains within limits. We have increased fineness of cement and maintaining blains of 3500 3800 cm2/gm. This helps in achieving higher strengths. The entire operation of the kiln and mills is automatic and controlled by sophisticated maintenance instruments through programmable logic control (PLC).

PLANT MAINTANANCE SYSTEM

The entire maintenance system is based on preventive maintenance, planned repairs and conditioned monitoring. Each section or stage will have maintenance plan indicating area, responsibilities, frequencies and associated documents etc. Broadly each sectional in charge will be responsible to carry out preventive maintenance activities per the maintenance plan. The section in charge will be responsible for arranging the resources like man power, tools and tackles, spares and planes shut down of the equipments for the maintenance. As and when required he will also obtain necessary guide lines from his higher authorities

CRUSHER
INTRODUCTION:DOUBLE SHAFT HAMMER CRUSHER HDS are successfully used for the reduction of limestone, marl, gypsum, bauxite, chalk as well as similar materials with compression strength of up to 2000 dn/cm2 mixing moistures in the feed of up to 20% H2O does not necessitate heating of the crusher housing. For the double shaft hammer crusher HDS the power spectrum of throughout is in the range of 260 TPH to 2100 TPH related to the crushing of medium hard limestone in one operation down to a final grain size of 0-25mm. Lumps sporadically occurring in the feed with a weight of up to 8000 kg/s are reduced to the desired final grain size with in few seconds, dependent on the size of crusher and motor output installed.

MODE OF OPERATION:The material fed to the HDS crusher is caught by the free swinging hammers of the rotors running in opposite direction and reduced by the resulting impact effect. Crushing mainly done above the rotors. Fine crushing proper takes place on the anvil and crushing grates which are adjustable so as to be at optimum height relative to the striking circle of rotors. The above average energy storing capacity reduces the speed drop of the rotors to a minimum even in case of large feed lumps and largely diminished current peaks. An overload protection circuit which depends on the rotor speed protects the crusher and control the speed of the steel-plate APRON FEEDER. This ensures optimum utilization of the HDS crusher.

SPECIFICATIONS:TYPE: HDS 1600 * 2200 CAPACITY: 700 TPH MAX. FEED SIZE: 1.3 m3 FINAL GRAIN SIZE: 0-50mm ROTOR DIA.: 1600mm MOTOR: 2 * 500KW No. Of HAMMER: 2 * 36 WEIGHT OF HAMMER: 90 Kg

WORKING OPERATION OF CRUSHER SECTION:

The raw materials are coming in from quarry which are of size (80mm-1.3mm) and are dumped into the crusher hopper (V=150m3) by means of dumper.

From the crusher hopper, raw material comes to apron conveyor (which is a belt) whose width is 2000 mm and capacity 1650 TPH. It acts as a media for raw material from hopper to H and B screen. Now in H and B SCREEN, the material coming from apron conveyor is separated out from foreign materials like clay etc. with this some small size raw materials (5-10mm) goes to the washer where raw materials with clay washed out such that limestone is recycled to crusher hopper.

SPECIFICATIONS OF H & B SCREEN:TYPE: DSS 2100 * 1600 CAPACITY: 1100 TPH MAX. : 1650 TPH MOTOR: 55 KW, 1500 RPM

From H and B SCREEN, the material coming to crusher

where they are crushed to a size of 0-50mm. From crusher, the limestone is coming to stacker through Vbelts. In between, we use two packet filters. First pocket filter, blows away the dust which sticks to the small sized limestone and second is to attract the small natural iron pieces from belts, if any (it works as magnet).

SPECIFICATIONS OF FIRST POCKET FILTER:TYPE: LGAB 23 CAPACITY: 3240 m3/hr FILTER AREA: 22.5 m2 FAN TYPE: HCCB 025-47 FAN MOTOR: 5.5 KW

SPECIFICATIONS OF SECOND POCKET FILTER:TYPE: LGAB 23 CAPACITY: 4320 m3/hr FILTER AREA: 22.5 m2

 Now, with the help of stacker we stock the limestone pieces on form of heaps for future use if there come any problem in crusher. After reclaiming the limestone goes to the roller press hopper through belts (W = 1000 mm, capacity= 500 TPH). Now in roller press, there are two rollers one is fixed and other is movable. When the limestone of -50mm goes in between the roller, then due to movable roller the coming limestone presses in between them, and then we get the burn-cake type of limestone which is brittle in nature and due to we get the limestone of size of about 0-20mm.

SPECIFICATIONS OF ROLLER PRESS

TYPE: RPB 115 100 ROLLER DIA & WIDTH: 1150 mm X 1000 mm MOTOR: 2 X 500 KW MOTOR SPEED: 1000 RPM V-BELT PULLY DIA.: 710 mm MOTOR V-BELT PULLY DIA.: 600,670 BELT: SPC X 13

From the roller press, the pressed lime moves to raw mill by V belts. WEIGHT SPEED = = 1000 mm 500 TPH 1.5 m/sec.

CAPACITY =

The similar process also takes place for bauxite and iron which are mixed limestone to improve the quality of cement.

RAW MILL
INTRODUCTION:
I.

The tandems grading plant is a combined drying and grinding mill system with IMPACT HAMMER MILL preceding for grinding cement raw mill material.

SPECIFICATION OF RAW MILL:

AREA: 4.2* 6.75m CAPACITY: 200TPH SPEED: 15.24/min MOTOR: 1700 KW

IMPACT HAMMER MILL

INTRODUCTION:
The HUMBOLT IMPACT HAMMER MILL is used as primary reducing unit in tandem grinding plants. It shall further open up the raw material discharge by the primary crusher thus relieving the following raw mill. Not gas is fed in to the impact hammer mill along with the raw material which means that material is dried during and after comminuting procedure.

MODE OF OPERATION
Depending on the characteristic of the discharge products, the IMPACT HAMMER MILL may be classified as medium or fine comminuting machine continuous flow of material with an adequate amount of air required for discharging the product will be the precondition for an optimum throughout of the machine.

FIGURE OF OPERATING PRINCIPLE

It represents the impact hammer mill in which the moist raw material is fed by a mechanically lock. Which sets as air seal ,over stepped deflecting and distributing plates The moist raw material comes into the contact with drying gasses Already before entering the impact hammer mill .The length of pre drying section has matched to the maximum moisture contact of the raw material. The pre dried raw material and the drying gasses jointly enter the impact hammer mill which operates at a circumferentially speed of approx 40m/min The raw material which has a size up to 5.mm approx is reduced between the rotor, the arm one plates of inlet and the mill bottom.

The fraction 10mm approx. Is entertained with the gas stream in the riser pipe.

The portion of minus 0.09mm amount to much smaller dimensions.

Fairly large volume of at this stage already but its quantity is determned exclusively by the type of fed material. And then else also discharge pneumatically .To large particles that have not been crushed at the adjustable impact plate. Either is recirculated through the hammer mill.

SPECIFICATIONS OF IMPACT HAMMER MILL

TYPE: PHM 2200* 2200 CAPACITY: 200TPH FEED SIZE: 0- 50 MM PRODUCT SIZE: 10MM ROTOR DIA: 2200MM ROTOR SPEED: 355RPM WEIGHT OF HAMMER: 29KGS NO. OF HAMMER: 108 MOTOR: 300KW, 1000RPM

PROCESS DESCRIPTION OF RAW MILL:-

The cement raw materials is discharged by proportioning divides from the mill storage bins .via a conveyor belt and a double flap box preventing air from being entertained into the grinding system, the raw materials fed into the impact hammer mill. The gases required for drying the raw materials will be sucked by the circulating air fan either from the pre heater or from the gas generator via impact hammer mill tube mill. If the moisture content of the materials will be found too high waste gas from the pre heater and hot gas generator may be used. Distribution of the gases volume rates is regulated by flaps. The materials are dis will be combined in the riser pipe and conveyed by gas stream to the separator. In the separator the finished product and rejects are separated from each other.

The rejects are passed through respected separator materials are recycled to impact hammer mill. The residual rejects are passed through a belt conveyor with rejects weight device on to the mill for reground. The finished products are conveyed with the gas stream to the cyclone collectors. Here, the finished product is separated from the gas stream. The finished raw mill is withdrawn from the separator by pressure and by subsequent conveyor unit passed on to the silo. Gas stream carrying the dust residual load is divided behind the circulating air part of it is conveyed to the grinding (to the inlet and outlet of the tube mill and to the impact hammer mill) the other part of the gas stream is conveyed to the E.S.P (ELECTRO STATIC PRECIPITATOR) for being deducted. The collected dust is conveyed by pressure worms to the subsequent conveyed unit and transported to the silos.

COAL MILL:INTRODUCTION:The air swept coal grinding plant is a grinding and drying plant for grinding the materials being conveyed through the system by the gas flow. The grinding plant mainly plant mainly consists of a chamber tube mill with drying chamber, a air separator, a cyclone dust separator , a circulating air fan , a motor controlled down flap valve , as well as two shut off slide valves , an electrical circular dust collector with rotary lock and a hot gases from the . In the cases of feed rises up to maximum approx. 30mm the shell lining of the mill may be designed as a lifter lining. The special design of the drying chamber permits to grind material with high contents the trunnion and slide shoe bearings are sized so that the gas velocity in the bearing journal are kept with normal ranges .The mill is drawn by a single pinion driver

PROCESS DISCRIPTION:The coal is discharged from the entire mill feed bin with the aid of a propertionating system and fed to the mill by a double flap valve which serves as a air seal and the inter bland. In the mill the coal is ground and dried at the same time. The heat which is required to drying the most coal is supplied to the mill in the form of hot waste gas by separating cyclone and the hot gas fans. The hot gases are distributed in the system by the adequate flap positioning. The ground coal is discharged from the mill with the gas flow and conveyed to the separator through the rising pipe.In the separator the pulverized coal is separated which the fineness set at the separator by the reects outlet which is sealed with flap valve, the rejects are recycled to the mill by the throughout screw conveyor. The pulverized carrier gas. al is transported to the C.D.S (CYCLONE

DUST SEPARATOR) with gas flow and separated from the

The carrier gas which is still laden with residual amount of dust is sucked by the mill inlet as a circulating gas flow the other portion which is composed of the hot gases supplied to the plant, the water stream driven out of the run-of -mine coal and false air is passed through the filter and largely discharged into the atmosphere after deducting. The pulverized coal separated into the filters is also conveyed to the final coal pin via a rotary lock and a throughout screw conveyor.

SPECIFICATION OF COAL MILL:AREA: 3.4m * 4.5m DRYING CHAMBER: 2M CAPACITY: 23TPH SPEED: 5RPM MOTOR: 580 KW, 986RPM.

ROTARY KILN:INTRODUCTION:The most essential data for production operation starting and stopping, locating and eliminating operational defects and servicing of the plant exactly observing the instruction given shall avoid production interruption. The special operating instruction for a individual machinery shall be observed. Following completion of commissioning revised operating instruction will be prepared by us who will consider the experienced gained during commissioning.

NORMAL OPERATION
Switch on the dust transporting system of E.S.P including mill air lift Switch raw material transporting. Switch cooler fan

It is taken for granted that the shock blowers in the pre heater

Start the E.S.P fan and regulating the draught to-10mm we down stream the pre heater fan Start the pre heater fan and opening the flap in front of the pre heater fan while observing the down stream the pre heater fan.Closing the fresh air socket raising the draught in front of the pre heater fan to 500mmwc. Increasing the quantity of the pulverized coal for the klin burner lance to 4-4.5tph. The raw mill branch in the raw meal line underneath cyclone has been set such that no raw mill will penetrate to the production The kiln speed has been kept at 1.51min this ensuring that the kiln is not choking fed with raw mill. After first raw mill feeding the pre heater inlet chamber, fresh air socket and kiln head assembly shall again be checked if necessary immediately be carried out during operation ingress of false air should be reduced to a minimum checking the kiln inlet and outlet seal at regular

intervals shall be implied. The cooler grates are operated at mean number of strokes. The kiln head pressure, the total cooler control as well as the number of strokes and air volume control systems are manually adjusted during the plant starting phase. Up an correct draught condition , inside the kiln and pre heater fan will adjust to 2.5 - 3.5 % after a certain period and the 02 content of the kiln inlet some what later to 1 -2%. The tertiary air flap is gradually opened as soon as a clinker belt has built up and hot secondary air is available as soon as the hot gas down stream of the pryoclon section has reached a temperature of more than 760 degree Celsius., the pulverized coal firing system can be stared upon simultaneous feeding of raw meal to the pyroclon section. With the tertiary air reaching higher temp. An increased raw meal feed rate, the control ekt for keeping the temperature down stream of the pyroclon section and downstream of the gas riser pipe between the inlet chamber and cyclone is set to automatic operation. Nom possible to run kiln up to rated capacity with in a short period the time of 4 - 6 hrs is been

taken for first raw meal feeding for the rated output. Subject to proper heating of the kiln and pre heater system , clinker will be found inside the sintering zone after a short period on observing the KW recorder for the main kiln drive, the kiln speed must be raised by 25/min each as soon as the KW requirement shows an upward tendency. Upon increasing the temperature inside the pre heater, the raw meal feed rate is increased by 10 TPH. Rapid heating of the plant due a excessive addition of pulverized coal in to the system in the danger of excessive clinkers burning and agglomerating in the coolers.

SPECIFICATION OF ROTARY KILN

AREA: 4.0 m *54.0 m FLOW: 3.5% CAPACITY: 100 TPH MOTOR: 340 kW; 1500-2500 RPM

WORKSHOP
DIFFERENT TYPES WORKSHOP:

OF

MACHINE

IN

Planner Machine Lathe Machine Drilling Machine Shearing Machine Hydraulic Machine Rolling Machine or Plate bending roller press Shaper Machine Grinder Machine Milling Machine Hack saw

Planner Machine
This Machine is used for machining the big job.

Lathe Machine
This Machine is used for machining the job drilling, boring, threading and making of shaft and bush.