INTRODUCTION

COMPANY PROFILE
Introduction

Maihar Cement is a division of Century Textiles and Industries Ltd, a flagship company of BK Birla Group. The company is well diversified having interest in cement, textiles, rayon, chemicals, pulp and paper. Maihar Cement is situated at Sarlanagar (Maihar) Dist. Satna in the State of Madhya Pradesh with an installed capacity of 4.20 Million TPA. Maihar is 45 Kms South - East of Satna on Howrah Mumbai Central Railway Main Line. Maihar is well known for Sharda Devi Temple and Maihar Gharana Music whose proponent was renowned Musician Padma Vibhushan Baba Allaudin Khan.

Apart from this, company has cement plants namely Century Cement at Baikunth, Dist. Raipur in the State of Chhattisgarh with an installed capacity of 2.10 Million TPA and Manikgarh Cement at Gadchandur, Dist. Chandrapur, Maharashtra with an installed capacity of 2.20 Million TPA. The combined Capacity of all cement plants taken altogether is 8.50 Million TPA

Century Textiles and Industries Ltd. was incorporated in 1897 as a Public Limited Company with its Registered Office at Mumbai. Till 1951, the Company operated only one Cotton Textile Mill in Mumbai. Thereafter, the Company has made rapid progress in expanding and diversifying its activities and today it is a well diversified conglomerate. The details of activities presently being carried on by the Company are as under:-

Business Segment - Cement

In 1974, the Company diversified into production of Cement by establishing its first cement plant at Baikunth, near Raipur (Chhattisgarh) to produce 0.60 million Tones Per Annum (TPA) of Portland cement. The present capacity is 2.10 million TPA. In 1980, the Company established its second Portland cement plant at Maihar (Madhya Pradesh) with a capacity of 0.80 million TPA. The present capacity is 1.80 million TPA. In 1985, the Company established its third Portland cement plant at Gadchandur, Dist. Chandrapur (Maharashtra) with a capacity of 1 million TPA. The present capacity is 1.90 million TPA. In 1995-96, the Company's fourth Portland Cement Plant with a capacity of 1 million TPA adjacent to the existing plant at Maihar started commercial production. The present capacity is 2.00 million TPA. Thus, the total present cement manufacturing capacity is 7.80 million TPA (of all 4 plants).

Century Cement Cement -

Maihar Cement -

Manikgarh

INDIAN CEMENT INDUSTRY

Cement is the preferred building material in India. It is used extensively in household and industrial construction. Earlier, government sector used to consume over 50% of the total cement sold in India, but in the last decade, its share has come down to 35%. Rural areas consume less than 23% of the total cement. Availability of cheaper building materials for nonpermanent structures affects the rural demand. The Indian Cement industry is the second largest cement producer in the world. The industry has undergone rapid technological upgradation and vibrant growth during the last two decades, and some of the plants can be compared in every respect with the best operating plants in the world. Although the newer plants are equipped with the latest state-of-the-art equipment, there exists substantial scope for reduction in energy consumption in many of the older plants adopting various energy conservation measures. There are around 11 different types of cement that are being produced in India. The production of all these cement varieties is according to the specifications of the BIS (Bureau of Indian Standards). Some of the various types of cement produced in India are: Clinker Cement Ordinary Portland Cement Blast Furnace Slag Cement Portland Pozzolana Cement Rapid Hardening Portland Cement Oil Well Cement

Type of Cements
Types of Cements based on Indian Standards 1. Ordinary Portland Cement -It is further classified into three types-33 Grade pertaining to IS 269:1989, 43Grade pertaining to IS 8112:1989, 53Grade pertaining to IS 12269:1987.Commonly referred as OPC, it is the most important type of cement.33Grade signifies that 28 days strength of the cement will not be less than 33N/mm2 and similarly for other grades as well. It is not in much use by masses today and had been replaced by other cement called PPC (Portland Pozzolana Cement). Still, it is used in construction activities of large scale.

2. Rapid Hardening Cement-It is pertaining to IS 8041:1990.The name is itself an explanation of the nature of the cement i.e. it gets hardened at a very rapid pace. Apart from rapid hardening it also develops high strength at an early stage than OPC. Used in prefabricated concrete construction works or at places where formwork has to be removed for reuse at fast rate or sometimes in road repair works too.

3. Sulphate Resisting Cement - It is pertaining to IS 12330:1988.OPC is vulnerable to the attack of sulphates, so as the name indicates it resist easily to sulphate attacks. Thus it find its use in concreting done in marine conditions or in concrete foundation beneath which soil contain sulphates compounds or sometimes in sewage treatment works too. 4. Portland Slag Cement-It is pertaining to IS 455:1989.This type of cement is manufactured by mixing Portland cement and Ground Granulated Blast Slag in suitable proportions. The resultant cement is more resistant to chemical attacks. It is thus generally used in water retaining structures or where structure is vulnerable to any form of chemical attack. 5. Super Sulphated Cement -It is pertaining to IS 6909:1990.This cement is like sulphate resistance cement but with higher percentage of granulated slag, higher sulphate resistance and fineness higher than that of OPC. It is mostly used in Belgium and recommended for used in foundation works (or sea works) where very high degree of sulphate resistance is required. 7

6. Low Heat Cement -It is pertaining to IS 12600-1989.It has low heat of hydration. High Heat of hydration is responsible for building cracks in the structure. Thus it finds its use in massive construction work. 7. Portland Pozzolana Cement - It is pertaining to IS 1489 (Part I) 1991 (fly ash based) and IS 1489 (Part II) (calcined clay based). PPC is obtained by mixing OPC with suitable Pozzolans at a certain temperature to produce PPC. Pozzolans are materials that are said to show similar properties as that of cement when they comes in contact with water. It is very popular now days and used by masses for all general construction activities. 8. Coloured Cement -It is pertaining to IS 8042:1989. As per IS code it is white but can be turned to any colour by adding suitable coloured pigments in OPC or PPC. It is manufactured from limestone that is available only near Jodhpur in India. It is use to aesthetically enhance the structure appearance and finish .9. Hydrophobic Cement -It is pertaining to IS 8043-1991.It is manufactured by grinding together OPC clinker with substances such as oleic acid or stearic acid that are famous for their film forming nature. It reduces the rate of deterioration of cement and thus gives long storage life to cement. 10. Masonry Cement -It is pertaining to IS 3466:1988. As the name suggest, it is used for masonry works in and have properties resembling to lime mortar instead of cement mortar. It is manufactured using certain admixtures. 11. Oil Well Cement -It is pertaining to IS 8229-1986. It is used in the oil wells. This cement is so manufactured using special set of admixtures so as to withstand high temperature and pressure inside the oil wells while maintaining its mobility.

12. Concrete Sleeper Grade Cement -It is pertaining to IRS-T 40:1985. It is special cement and is manufactured as specifications formulated by Indian Railways. Particularly used in concrete sleepers but can also be put forth use in prestressed concrete elements or high rise building where high early strength is required.

13. High Alumina Cement -It is pertaining to IS 6452:1989.It is the cement with very high content of alumina and having a unique property of extensively high rate of strength development.

Prop. Century Textiles and Industries limited

Chairman Century Textiles & Ind. Ltd.

B.K. Birla

Chairmans Message
I believe that the Fortunes of Century Textiles & Industries Limited rest solely on its continuing ability to evolve and successfully implement new techniques and systems to anticipate future trends and zero in on to them, to be in short, a company that is plugged into tomorrow.. Complete Customer Satisfaction and fulfilling the expectations of society is the key to success of any business enterprise in Global Economy.

The City of the Goddess and Music Maihars fame emanates from the Sharda Devi Temple, located at a distance of about 6 km. from the town. Thousands of pilgrims from all over the country , coverage at this temple, climb hundreds of its steps
9

and pass through the narrow passage leading to Devis idol for her audience and blessings, admit and chanting of the mantras and changing of the bells. Maihar has also been the auction centre of one of greatest
musicians of modern, Late Ustad Allauddin khan fondly remembered as Baba.

Sarlanagar the Cementing Community

Maihar Cement, A division of century Textiles & Industries ltd. Located at Sarlanagar Maihar-dhanwahi road in Satna district of Madhya Pradesh on northeastern slope of Rewa Kymore Range. Its towering silos, silent chimneys, serpentine conveyor belts multistoried preheaters, concrete roadways, provide avisual extra vaganza. A modern industrial temple carved out of what was previously a sprawling, barren and bare rock information.

10

MAIHAR CEMENT

CENTURY CEMENT

MANIKGARH CEMENT Century Cement - Chhattisgarh Maihar Cement Madhya Pradesh Manikgarh Cement Maharashtra

Units Century Cement Maihar Cement Manikgarh Cement Total

Figures in Million TPA 2009-10 2.1 4.2 1.9 8.2

11

Maihar Cement is pioneer in producing Blended Cement i.e. Portland Pozzolana Cement . The motivation for the production of blended cement has been primarily with the aim of preserving limestone reserves and environment.
low Heat of hydration resulting in resistance to cracking. Resistance to corrosive water and chemical attacks and thereby longer life to steel/iron structure underneath. High degree of impermeability and workability for the concrete mix. Higher ultimate strength at longer duration Higher degree of fineness, resulting in - Complete chemical reaction Easy workability Increased plasticity Reduced Alkali aggregate reaction as also free lime expansion and thereby resistance to cracking. Lower drying shrinkage and low leaching value.

Advantages

12

Maihar Cement has been bestowed upon several awards both at the National as well as Regional Levels

Some of the Important Awards won till date..

NATIONAL AWARD FOR ENERGY EFFICIENCY FROM NCCBM

Best Improvement in Energy Performance 1991-92 Best Improvement in Thermal Energy Performance 199192 Best Improvement in Electrical Energy Performance 200001 & 2003-04 Best Improvement in Energy Performance in manufacture of Blended Cement 2003-04

OTHER NATIONAL AWARD

Abheraj Baldota Environment Award for 1995-1996 from FIMI National Safety Award for outstanding performance in Industrial Safety Lowest average frequency rate as runner up for the award year 1998 Longest accident free period as runner up for the award year 2001 Longest accident free period as runner up for the award year 2003 Accident free year as runner up for the award year 2005 Accident free year - Best for the performance year 2005
13

National Energy Conservation Award for 2001 from Govt of India Social Awareness Award for 2002-03 from FIMI

FL SMIDTH AWARDS

First Prize for lowest electrical energy consumption per tonne of cement & clinker produced amongst modern plants using VRM Technology situated in Chhattisgarh & Madhya Pradesh for the year from 1998-99 to 2005-06. First prize for the lowest electrical energy consumption per tonne of cement production for the year 2006-2007 amongst modern cement plants using VRM technology situated in the State of Madhya Pradesh and Chhatisgarh. First Prize for Minium Auxiliary Power Consumption with respect to Captive Thermal Power Generation for the year 2005-06.

ISO CERTIFICATIONS

IS/ISO 9002:1994 IS/ISO 9001: 2000 IS/ISO 14001:1996 IS/ISO 14001:2004 Where there is Quality, there is Productivity

14

MANAGEMENT
Maihar Cement is managed by board of directors comprising of: 1. Shri B.K.Birla 2. Shri Kumar Managalam Birla 3. Shri P.K.Daga 4. Shri E.B.Desai. 5. Shri Arvindp C. Dalal 6. Shri Amal Ganguli. 7. Shri B.L. Jain (whole time director) STRUCTURE Unit 1 Shri Kamal Kishore President (co-ordination) Shri R.S.Doshi Executive President (Finance) Shri R.K. Vaishnavi Executive President (plant) Shri P.M. Intodia Joint President (Marketing) Shri Vijay Kumar Sr. Vice President (Process and Quality Control) Shri Ajay Kumar Jain Vice President (Production) Shri M.P. Joshi Vice President (Electrical) Shri. O.P. Moondra Vice President (Instrumental) Shri A.S. Thakkur Vice President (Store) Shri P.K. Agrawal Vice President (Purchase)

Unit 2 Shri B.P.Jain President (Technical) Shri V.K.Bhandari Executive President (Commercial) Shri Rakesh Sharma Joint President (Personnel and Administration) Shri S.K.Tiwari Sr Vice President (Mines) Shri Arvind Kumar Jain Vice President (Mechanical)

15

Cement Manufacturing process

The basic raw material in the production of cement is Limestone. The Limestone ore as obtained from the Mines is fed to the Raw Mills after first crushing it to acceptable size. Certain additives such as Laterite, Bauxite, High Grade Limestone(Sweetener) etc. are also introduced along with Limestone into the Raw Mills as applicable. In the Raw Mills, the above inputs are reduced to a particular fineness. The output of the Raw Mills, called 'Raw Meal' is then burnt in the Kiln and then cooled to produce Clinker. The fuel used for burning of limestone is powdered coal produced from the coal Mill. The Clinker is thereupon fed into Cement Mill & pulverized along with Gypsum to yield the basic cement. A certain proportion of Clinker in the production of cement is replaced by fly ash to produce PPC.

16

Mining
The major raw material for cement manufacturing is limestone. Limestone is excavated from open cast mines after drilling and blasting and loaded onto the dumper which is transported the material and unloaded into hopper of the limestone crusher.

Equipment Used in mining: 1. Compressor drilling machine. 2. Shovels/Excavators-for lifting material onto dampers. 3. Dumper- for carrying material. 4. Built-dozers. 5. Pay-loaders. Explosive: 1. Ammonium nitrate(Fuel oil) 2. Nitroglycerine. 3. Ammonium nitrate and slurry explosive. Steps of Mining: 1. The first step of mining l/s the l/s has been located. 2. Limestone mining is to remove the mines. 3. The third step is to be taken as drilling. 4. After drilling blasting is done. Drilling and Blasting: 1. The large hole blasting method is not pre-dominated in quarrying
in open pit.

2. The depth of
dia.

the wholes are more then 12m and 100-150mm

17

Conveyer Belt

18

Lime Stone Crusher

Lime stone crusher is the lead role playing equipment in this section. The raw lime stone is carried out from the mines is introduced to the lime stone hopper through whole pack dumper of capacity 32 tons. The feed inside the impact crusher first enters to the crushing chamber with help of apron feed encounters. The impact bars mounted over the rotor &revolving with the circum-frencial velocity of 30-40 m/sec. Material are blown bars and stick on a impact arm. Here materials are initially install to hold these grinding bars. The squire impact arm is install just behind the impact path and having 12 liners. When the material get crushed enough for transportation towards stacker. A bag house is also installed to control the dust loss and pollution control.

Equipment Used in Crushing: 1. Crusher. 2. Apron conveyer for feeding l/s to crusher. 3. Bag filter for collecting dust. 4. Belt conveyer- for transporting crushed material. This section is worked with following equipment: 1. Impact crusher. 2. Magnetic separator 3. Limestone stacker& re claimer 4. Bag filter 5. Apron feeder 6. Limestone hopper & late rite hopper The important mode of transportation in this section is belt conveyer. Main component of impact crusher:
19

 Housing: housing of impact crusher is of studly steel fabricated

and consists of three parts.

Rotor: The rotor in the impact crusher is of s-type construction

secured to the shaft by locking assembly. The blow bar placed in to the rotor from the side and are secured against lateral moment by a suitable locking device at the extreme end. The rotor is dynamically arranged to avoid any undesirable stress on the bearing.

Blow bar:

Blow bar is made from high quality alloys steel. After the certain period in operation the blow bar can be taken out from the rotor and turned to other side or exchange. housing is fitted with the resistance wear plates which are secured in position by special fastners which can be changed as and required. The impact arms are each suspended in the housing parts by means of knock out spindle and can be adjusted the desire gap setting from out side.

Wear plates:

Impact Arm: The impact crusher is fitted with the impact arm.

Hydraulic system:

Impactors are depends on their size normally supplied with a hydraulic arrangement for setting of gap for grinding path lifting of the rear top housing.

Magnetic Separator:

A magnetic separator is installed just above belt conveyer between crusher and stacker. When the magnetic material are comes along with lime stone .they get se-prated by magnetic separator. In the magnetic separator a permanent magnet and a continually moving belt being fin use. Magnetic materials are attached by magnet due to cont. rotating of belt , material get se-prated on removal of magnetic field.
20

Gamma Matrices:

A gamma matrices analyzer being used for analyze the chemical composition of lime stone. It is also known as cross belt analyzer. In gamma metric analyzer we are using specially gamma rays, the gamma rays are fall on material and return back, according to absorption rays in to material we can determine the chemical composition of lime stone .

21

LIME STONE STACKER:A limestone stockpile (closed stock pile) has been proposed at the plant site with stacker re-claimer. The re-claimer will help in feeding a homogenized limestone by mixing rich quality LS with low grade mineral. By installing a re-claimer in the plant, the plant can achieve not only quality raw material input but also the conservation of natural resources by utilizing low-grade raw material.

There are two main methods being used for stacking of lime stone in cement industry. They are.. 1. Chevron Method 2. Windrow Method

22

LIME STONE RECLAIMER

Re-claimer which is used in our industry is bridge type scrapping reclaimer. The bridge on which the racking down device is mounted accommodates a scraper chain conveyer whose blades shift the dislodged material along to collecting belt conveyer that extent along one edge of stack pile. Re-claimer having harrow assembly. Reclaimer moves on a track for fast travel a.c. Motor being used and for slow traveling d.c. motor being used. Harrow is moves to and fro motion on rack car which is driven by a motor. A limit sensor is installed for reverse and forward motion of harrow assembly. According to pile we can adjust the inclination of harrows. When harrows are moves they are scrap the material of each layer of stockpiles and material slides down due to gravity. A scraper chain take out the material and fed to belt conveyor material now get transported forwards limestone hoppers.

23

Blending Of Raw Meal:

The meal from the mill need storage and blending become different chemical composition of lime stone in different lot. They may vary the quality of lime stone. Silo: Silos are huge construction of concrete and iron with aeration units to stone and blend the fine material such as raw material. .Continuous Fluidize Silo: The raw meal is completely fluidized by admission of compressed air through the suitable inlets at the bottom of the silo. The air penetrates the mass of raw meal into the silo and reduces the inter particle friction forces. A circulatory motion is formed and thus homogenization is take place.

24

Operation of Raw Mill:

When the Limestone feed is started with la-trite rollers get down & the grinding start.The grinded material is sucked up through the classifier by the help of hot gases .The reject material from the classifier is sent back to the grinding table by the help of reject group. The remaining fine material is sent to ESP & ESP reject material to silos. So total three types of material is falling on grinding table during running:1)-Mill feed 2)-Classifier reject 3)-Mill reject

25

SILO
It is the large storage of Raw mill which comes from the Raw Mill. It is made of concrete & can store Raw mill for long time.

Purpose:Its main purpose is to homogenize the raw mill. One of its main purpose is to also store raw mill for long time.

Construction:It mainly a large structure made of concrete. It contains following devices:1)-Air Compressor 2)-Large Air Ducts 3)-Pneumatic Valves 4)-Exhaust Fans on the top

26

Preheater Purpose:To increase the temperature of rawmill material through the incoming hot air from kiln & transfer air duct.

Working Principle Of Preheater

As the name explains Pre-heater Tower is place to use for preheating the raw material. The material which comes from c.f. silo in other words pre-heater is a device in which heat transfer takes place from hot gases which comes from kiln due to counter current flow of material and hot gases. The raw mill is heated about 850 oc before it enter it the kiln pre-heater with calcined system is most economical and hence the length of kiln is reduce pre-heater in Unit-1 and five stage in unit-2 with separator line calciner. These suspension preheaters are work in kiln string & pyro string with pre-calciner string successfully.

Main part of suspension Pre-heater: 1. Cyclone: The cyclone is use for separation of raw meal from
gas flow. For improving the separating efficiency of cyclones of top most pre-heater stage. We have designed as double separator.

2. Gas Duct:

The gas ducts is to join the individual cyclone stages to each other. The raw meal coming from next higher stage and in the gas duct underneath. The raw meal particles are entering by the upward flowing gas stream and taken to the next cyclone. The heal exchange is achieved by con-current flow. The gas ducts b/w stage 1 and 2 consist of the cylindrical suction. in pre-heater system the flaps are consists in such a manner that
27

3. The Double Flow Box: These are used for raw meal pipes

a minimum flow of raw mill is always maintained. The full material causes a upward and downward moment of the pendulum flaps and thus and upward and downward rocking motion of the lever arm with counter weight penetrating the single flaps. The upward and downward forces of flaps is remains constant.

4. Raw Material distributor:

It is integral part of raw meal ducts and spits a downward flowing stream of raw meal in to raw meal duct. Basically the distributor has a two fold function.

28

Calciner:
The main purpose of the pre-calciner is to let the calcinations process take place out side the rotary kiln. It causes in sufficient reduction of thermal load of the kiln burning as approximately 60% of total fuel is burn in to calciner. This has made possible to increase the production in the given size to about double compared to a conventional dry process kiln with suspension pre-heater. The calciner consists of a vessel lined with heat resistance bricks. Calciner has three inputs and one output.

Input1. Fuel as Pulverized coal. 2. Preheated material to approx 800oc 3. Hot gases from kiln/coolers at 800oc

OutputHot gases including combustion products and co 2 from the calcinations process and material in form of dust carried with the hot gases.

29

Rotary kiln:
Purpose: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.

Construction: Kiln can be divided into :a. Kiln inlet (consist seal, grease pump, lines, cylinders etc) b. Girth gear(Gear, pinion, spray system) c. Thrust roller(Hydraulic cylinder, oil line) d. Supporting roller& tyre (Consist of bearing, chair plate,
etc)

bolts

e. Kiln outlet seal(S.S shims, crown shell, seal) f. Burner pipe(consist of air pipe, coal pipe, diesel pipe etc) Kiln inlet: Kiln
inlet is seated by sealing arrangement. Greasing is done by pneumatic pump seal. It consist of 10-14 segment so it can be mounted and disassembled from kiln inside. A conical section forms an extension of the inlet ring. A brick retaining ring has been mounted at the end of conical section. Girth Gear: Kiln is rotating by Gear pinion arrangement. Girth gear is mounted on kiln with the help of spring plates. Thrust Roller: The function of thrust roller is to control axial moment of kiln in both upward & downward. Supporting Roller & Tyre: Supporting roller are for support of kiln. They are in contact with tyre which are fitted in kiln shell. Kiln Outlet: There is a sealing arrangement in kiln outlet. Burner Pipe: It is for firing of fine coal into the kiln. Air is controlled by damper and fine coal by solid flow meter.
30

31

Grate cooler:
Clinker cooler has two main function to perform. They are:1. To cool the hot clinker quickly. 2. To provide necessary air for burning of coal in pre-calciner and kiln. After introducing of red hot clinker into the cooler, mechanically driven gates moves it to the rear end of cooler. Three pair of gates are installed inside the cooler. A single pair consist of fixed gate and movable gate. Too and fro moment of movable gate pressurized which cools it quickly. Clinker cools down gradually as it moves, due to the air blow by the fans which is taken from the atmosphere. Air falling over clinker is highly pressurized which cools it quickly. Clinker escaping out of the cooler is fed to a hammer crusher, since lumpy material requires crushing. Crushed material is transported to clinker silo through deep bucket conveyor. Temperature of clinker escaping out of cooler is about 208oc.

32

Grate Cooler operation:

The grate cooler operates with a cross current principle in which the clinker is moved across the grate while cooling air blow in from below through the grate and clinker layer. The hot clinker falls from kiln and forms clinker bed on he grate and transported through the cooler over alternatively fixed and reciprocating grates. At the inlet of first great clinker is quenched and spread evently across the cooler width by the increased cooling air. The grate is fabricated to be as possible to obtained a thick clinker layer and a uniform distribution of air through the clinker bed in the interest of heat recovery. During the clinker transport from the cooler a part of dust and small size clinker is falls from the grates and collected into hoppers under the grates. The drag chain and rotary air lock system fed these clinker and dust in clinker transport system. A dust collection ESP is also installed beside the cooler known as cooler ESP. Exhaust gases from collection is fed to the ESP for dust collection.

Grate cooler consist of: Cooling grate Plates Standard Plates Cooling housing Drive unit Grate aeration system Clinker crusher Conveying unit(DBC) Cooling fan

33

Coal Mill:

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. finally it is stored in to the fine coal bin hot air for coal mill is supplied by cooler exhaust hot gases or preheater outlet gases before GTC circulation. The function of coal mill is to ground suitable grate coal and for feeding the same in to the kiln and calciner in fluidized form. Coal from stock yard is fed for stacking and reclaiming in to the stacker and re-claimer. Prehomogenized raw coal is feed in to the coal mill hopper with the help

34

of belt conveyer. The raw is then fed to the coal mill VRM via weigh feeder, drag chain and screw conveyer.

Important Parameters Of Coal:

Residue on 90 micron=18-20% Residue on 212micron=0.4-1% Moisture =1.5% Volatile Matter =20-30% Ash content =28-32%

Coal Mill:Coal Mill is an important integral part of cement plant. Here large size of approx size 600mm, is ground fine to the size of 90 micron. Coal from coal mill is used to feed kiln and calciner. Outlet tem of coal from coal mill is different in different seasons. It is 70750c in dry season and 80-840c in rainy season. Coal from mines is initially crushed at crusher site. Coal is then sent to stacking making mixture homogenized. Reclaimer picks up the coal and coal is fed to the coal mill hopper through belt conveyer. Coal taken out from hopper is feed inside VRM with the help of a screw conveyer which is mounted just below the hopper. Coal inside VRM is grounded between roller and table. Hot air from cooler ESP fan is taken inside VRM and is used for drying of coal. Fine coal from VRM moves to the cyclone, where most of the coal is separated from air and the coal which does not get collected due to ultra fine size is separated with the help of ESP. LV separator is for separating coarse and fine particles. Now, coal is fed to screw conveyer through rotary lock, which transport it to the FK pumps. Two FK pump delivers material to the storage bins.
35

There are two Storage bins, They are:1. Kiln Bin 2. Pre-calciner Bin Fine Coal is then transported to the kiln and pre-calciner by kiln firing FK pump and pre-calciner FK pump respectively.

Classifier:
A classifier is the top most rotary part of the vertical roller Mill . Here classification of materials occurs .Fine particles pass through classifier and course particles are rejecter and recycled for regrinding. According to the fineness required speed of the classifier rotor can be adjusted.

36

Cement :Cement is a word given to a powder material which initially has plastic flow when mixed with water but has the property of setting hard solid structure in the several hours with varying degree of strength and bonding properties.

Natural is a mixture of burnt silicate and lime. It was discovered by Joseph Aspdin an English brick layer in 1924. This Cement is called Portland Cement and now a day prepared artificially.

Properties of Cement

37

It gives strength to the masonry. It is an excellent binding material. It is easily workable. It harden early.

Types of Cement
A. Ordinary Portland Cement (OPC) It is of 3 type 1. 33G 2. 43G 3. 53G

B.

Pozzolana Portland Cement (PPC)

Testing of Raw Material Iron ore

Loss of Ignition (LOI)
38

Take 1.0 gm of sample in a weighted crucible. Heat it in a constant weight at 900 to 1000C. Coal weight. %Loss of ignition = Loss weight x 100

Silica (SiO2)
Take a 0.2 gm of sample in dry beaker and add 400 ml Aquaregia &digest with slow heat. Evaporate the solution at a low heat to dryness. Cool it add 15 ml conc. H 2So4 and put the beaker at slow heat for 24 hours for digestion.

After 24 hours add 1:1 HCL 20 ml & just boil it in a 250 ml volumetric flask. Wash it chloride free the filtrate. Char & ignite the residue in a weight crucible (400 to 1200 C) treat the ignited residue thus obtained which contain small amount of impurities with 1 or 2 ml of distilled water + 10 ml HF and 2 drops of H 2So4 and evaporate to dryness. Finally treat the small residue at 1050 to 1100 C for minute or two. Cool in desicater & weight of ignited sample represented the amount of silica. (keep it).

Silica % = (W1-W2) x 100

Where, W1 = weight of silica + soluble impurities. W2 = weight of impurities. 39

Now add 2.5 gm of sodium and potassium per sulphate to the crucible heat in the Bunsen burner continuously till the small residue of impurities is dissolved in the melt. Cool dissolved the fused mass with 1:1 HCL and add into the filtrate. Make up volume upto 250 ml mark.

Ferric Oxide and Alumina

Take 100ml sol. From 250 ml volumetric flask (Mother sol.). add 1 gm NH 4CL and 2 drop of methyl indicator. Then boil and neutralize with NH4OH (1:1) using drop wise till just yellow. Add on drop excess NH 4OH. Put this ppt. To settle and filter using 41 no. filter paper. Wash with 2% hot ammonium nitrate sol. Till chloride free. Char and ignite the residue at 1050 to 1100C. keep the filtrate (A) R2O3 % = Weight of Residue x 250

Iron Oxide (Fe2O3)

40

Take 100 ml sol. From 250 ml. volumetric flask. Boil and add few drop of SnCl 4 dropwise till sol. Decolorise. Add few drop of SnCl 4 in excess. Cool it to room temperature. Rinse the beaker with H2O add 15 ml of HgCl4 sol., stir and add 25 ml of manganese sulphate sol. And titrate with standard KMnO 4 (0.05N) till permanent pink color is obtained. Calculate iron and ferric Oxide

R x 100 x 2.5 x N x 0.7985 (Fe 2O3 Eq) Al2O3 : Fe2O3 % = Weight of iron ore sample R = Burette reading N = Normality of KMnO4 AgO3 % = R2O3 Fe2O3

Calcium Oxide

Take the filtrate add 2 3 ml. Of acetic acid & boil mix 25-30 ml. of ammonium oxalate sol. with NH4OH (1:1) Allow to settle ppt. Filter using 40 no. filter paper and wash the residue free of oxalate with hot water. Keep the filtrate feo MgO (B).

41

In the sample previous beaker take 10 % H 2SO4 100 ml and boil it. Transfer filter paper with residue in the beaker and stir till the residue is dissolved.

Titrate against 0.12N KMnO4 sol. Keeping the filter paper at the side of the beaker. At the end point pink color is obtained after taking in filter paper.

R x 100 x 2.5 x N x 0.0285 (CaO Eq) CaO% =

Weight of iron ore sample Where, R = Burette Reading

N = Normality of KMnO4 MgO

Acidify the above filtrate (B) (CaO free) with HCl till red color appear. Reduce the volume to 200 cc by evaporating the sol. Add 25 ml of 5% diammonium hydrogen orthophosphate and add NH4OH (1:1) Scratch the side of the beaker till the ppt appears. Add 50 ml NH4OH (1:1) in excess and keep it 24 hours for settlement. Filter through 42 no. filter paper and wash the ppt with NH4OH (1:1) and finally wash with cold distilled water.

Take it in the crucible. Slowly char the paper and carefully burn the resulting carbon. Ignite it at 1100C to 1200C calculate the ppt as MgO. MgO % = W x 72.4 Where,
42

W 72.4

= gm of residue Mg2P2O7 = Molecular ratio of 2 MgO to Mg2P2O7 (0.362)

Gypsum

Loss of ignition (LOI)

Take 1.0 gm of sample in a weighted crucible. Heat it in a constant weight at 900 to 1000C. Coal weight.

%Loss of ignition = Loss weight x 100

Insoluble Residue (IR)

Take 1gm sample in a beaker add 50 ml water and stir it now add 5 ml HCL and stir. Crush the lump with flattened end of the glass rod. Boil it for 2 min. . Now filter it with whatman filter paper no. 40 wash the residue with hot distilled water. Keep the filtrate for SO3 (A). Residue is washed again with hot distilled water. Take out the filter paper with 30 ml. Hot distill water and 30 ml 2N Na2CO3 . For 15 min. at temperature just below boiling point filter it b through whatman filter paper no. 40. After transferring the sol. Treat the residue with 10 ml (1:1) HCl and transfer the whole in previous filter paper.

Wash it with hot distilled water till it is chloride free. Take the filter paper with residue in weighted crucible. Dry char and ignite at 100 C to 1100C for one hour. Cool and weight. 43

% of I.R. = Weight of residue x 100

Sulphuric Anhydride
Take 1 gm sample in a beaker. Add 50 ml water and stir it. Now add 5ml conc. HCl and stir . crush the lump with flattened end of glass rod. Boil it for 2 min. now filtered through whatman filter paper no. 40. wash the residue with hot distilled water. Boil the filtrate and add 50 ml hot BaCl 2 sol. With stirring rod for another 1 min. digest it for 4-5 hours at 60C. Now filter it with whatman filter paper no. 40 wash the residue with hot distilled water. Take the filter paper in weighted crucible. Dry and ignite at 900-1000C. Cool in desicator and weight.

%SO3 = Wt. Of BaSO4 x 0.343 x 100

Where, Molecular ratio of SO3 to BaSO4 = 0.343 CaSO4.2H2O = SO3 % x 2.15

Potassium Oxide (K2O)

Take 20 ml sol. From 250 ml measuring flask and transfer the solution in a 100 measuring flask. Make up the volume upto the mark by distilled water and see the reading for K2O by flame photometer.

Sodium Oxide (Na2O)

44

In another case 50 ml solution from 250 ml flask and transfer the solution to 100 ml measuring flask. Make up the volume upto the mark by distilled water and see the reading for Na2O by flame photometer. z x 250 x 100 {a}. Na2O % = 10 x 50 x 0.5 x 1000 z = 10

y x 250 x 100 {b}. K2O % = 10 x 20 x 0.5 x 1000

y = 10

LIMESTONE
Loss of ignition (LOI)

Take 1.0 gm of sample in a weighted crucible. Heat it in a constant weight at 900 to 1000C. Coal weight.

%Loss of ignition = Loss weight x 100

Sulphuric Anhydride
Take 1 gm sample in a beaker. Add 50 ml water and stir it. Now add 5ml conc. HCl and stir . crush the lump with flattened end of glass rod. Boil it for 2 min. now filtered through whatman filter paper no. 40. wash the residue with hot distilled water. 45

Boil the filtrate and add 50 ml hot BaCl 2 sol. With stirring rod for another 1 min. digest it for 4-5 hours at 60C. Now filter it with whatman filter paper no. 40 wash the residue with hot distilled water. Take the filter paper in weighted crucible. Dry and ignite at 900-1000C. cool in desicator and weight.

%SO3 = Wt. Of BaSO4 x 0.343 x 100

Where,

Molecular ratio of SO3 to BaSO4 = 0.343

Testing of Cement & clinker

A- Chemical analysis of Cement and clinker

1. Clinker
Loss of ignition (LOI)
Take 1.0 gm of sample in a weighted crucible. Heat it in a constant weight at 900 to 1000C. Coal weight.

%Loss of ignition = Loss weight x 100

Insoluable residue (IR & SO3)

46

Take 1 gm sample in a beaker. Add 50 ml water and stir it. Now add 5 ml conc. HCl and stir. Crush the lump with flattened end of glass rod. Boil it for 2 min. Now filter it with whatman filter paper no. 40 wash the residue with hot distilled water. Keep the filtrate for SO3 (A). Residue is washed again with hot distilled water. Take out the filter paper with 30 ml. Hot distill water and 30 ml 2N Na2CO3 . For 15 min. at temperature just below boiling point filter it b through whatman filter paper no. 40. After transferring the sol. Treat the residue with 10 ml (1:1) HCl and transfer the whole in previous filter paper. Wash it with hot distilled water till it is chloride free. Take the filter paper with residue in weighted crucible. Dry char and ignite at 100 C to 1100C for one hour. Cool and weight. % of I.R. = Weight of residue x 100 Boil the filtrate and add 50 ml hot BaCl 2 sol. With stirring rod for another 1 min. digest it for 4-5 hours at 60C. Now filter it with whatman filter paper no. 40 wash the residue with hot distilled water. Take the filter paper in weighted crucible. Dry and ignite at 900-1000C. Cool in desicator and weight.

%SO3 = Wt. Of BaSO4 x 0.343 x 100

Where, Molecular ratio of SO3 to BaSO4 = 0.343

Chloride (Cl -)

47

Take 20 gm of sample in 250 cc conical flask. Add 30 cc distilled water & 10 cc conc. HNO3. boil for 5 min. filter through whatman filter paper no. 41. Wash with hot distilled water 4 times. The filtrate adds 5 ml of silver nitrate sol. of 0.05N cool it. Add 5ml nitrobenzene sol. Then filtrate against 0.025N NH4SCN sol. Using ferric Alum (Ferric Ammonium Sulphate) as a indicator.

% of Cl = A-

RxN x 0.3546 x 100 Strength of AgNO3

Where

A R N

= Amount of AgNO3 = Burette Reading = Strength of NH4SCN

OPC Grinding

48

S. No. 1. 2.

Characteristics to be tested 33 G Fineness (in m2/kg) Setting time min. 225 60 300

Specified Requirement 43 G 240 60 300 320 60 300

53 G

3.

Soundness (a) Le-Chat After Areation (b) Auto Clave 10 mm 5 mm 0.8 mm % 0.6 mm % 10 mm 5 mm 0.8 mm % 0.6 mm % 10 mm 5 mm 0.8 mm % 0.6 mm %

After Areation
4. Compressive Strength (Mpa) 3 Days 7 Days 28 days 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. LOI IR SO3 MgO LSF AM (Al2O3/Fe2O3) CaO SiO2 Al2O3 Fe2O3

16 22 33 5 % 4 % 3 % 6 % 0.66-1.02 > 0.66 > 0.66 > 0.66 > 0.66 > 0.66

23 33 43 5 % 3 % 3 % 6 % 0.66-1.02 > 0.66 > 0.66 > 0.66 > 0.66 > 0.66

27 37 53 4 % 3 % 3 % 6 % 0.88-1.02 > 0.66 > 0.66 > 0.66 > 0.66 > 0.66

Uses of Cement

49

At present the cement is widely used in the construction of various engineering structure. It has proved to be one of the leading engineering materials of modern time and has no rival in production and application. Following are possible uses of cement:1. Cement mortal for masonry work, plaster etc. 2. Concrete for layering floor, roof, construction lanters, beams weather shed stairs pillars. 3. Construction of important engineering structure such as bridges, culverts, dams, tunnels, storage reservoir, light houses, dock etc. 4. Construction of water tanks, well, tennis court, septic tank, lamp post, roads, telephone cabins etc . 5. Making joints for drain and pipes. 6. Manufacturing of present pipes, piles, garden seats, artistically design urns, flower pots, dustbin fencing post etc. 7. Preparation of foundation, watertight floor, footpaths etc.

50