Conveyor Belt

A conveyor belt is the carrying medium of a belt

conveyor system (often shortened to belt conveyor). A
belt conveyor system is one of many types of
conveyor systems. A belt conveyor system consists of
two or more pulleys (sometimes referred to as drums),
with an endless loop of carrying mediumthe
conveyor beltthat rotates about them. One or both
of the pulleys are powered, moving the belt and the
material on the belt forward. The powered pulley is
called the drive pulley while the unpowered pulley is
called the idler pulley. There are two main industrial
classes of belt conveyors; Those in general material
handling such as those moving boxes along inside a
factory and bulk material handling such as those used
to transport large volumes of resources and
agricultural materials, such as grain, salt, coal, ore,
sand, overburden and more.
Today there are different types of conveyor belts that
have been created for conveying different kinds of
material available in PVC and rubber materials.
The belt consists of one or more layers of material.
Many belts in general material handling have two
layers. An under layer of material to provide linear
strength and shape called a carcass and an over layer
called the cover. The carcass is often a woven fabric
having a warp & weft. The most common carcass

materials are polyester, nylon and cotton. The cover is

often various rubber or plastic compounds specified by
use of the belt. Covers can be made from more exotic
materials for unusual applications such as silicone for
heat or gum rubber when traction is essential.
A conveyer belt can be a slide and be controlled by
the force of gravity.
Material flowing over the belt may be weighed in
transit using a beltweigher. Belts with regularly spaced
partitions, known as elevator belts, are used for
transporting loose materials up steep inclines. Belt
Conveyors are used in self-unloading bulk freighters
and in live bottom trucks. Belt conveyor technology is
also used in conveyor transport such as moving
sidewalks or escalators, as well as on many
manufacturing assembly lines. Stores often have
conveyor belts at the check-out counter to move
shopping items. Ski areas also use conveyor belts to
transport skiers up the hill.

Belt conveyor systems

Conveyors are durable and reliable components used in
automated distribution and warehousing. In combination with
computer controlled pallet handling equipment this allows for more
efficient retail, wholesale, and manufacturing distribution. It is
considered a labor saving system that allows large volumes to
move rapidly through a process, allowing companies to ship or
receive higher volumes with smaller storage space and with less
labor expense.
Rubber conveyor belts are commonly used to convey items with
irregular bottom surfaces, small items that would fall in between
rollers (e.g. a sushi conveyor bar), or bags of product that would
sag between rollers. Belt conveyors are generally fairly similar in
construction consisting of a metal frame with rollers at either end
of a flat metal bed. The belt is looped around each of the rollers

and when one of the rollers is powered (by an electrical motor) the
belting slides across the solid metal frame bed, moving the
product. In heavy use applications the beds which the belting is
pulled over are replaced with rollers. The rollers allow weight to be
conveyed as they reduce the amount of friction generated from the
heavier loading on the belting. Belt conveyors can now be
manufactured with curved sections which use tapered rollers and
curved belting to convey products around a corner.
These conveyor systems are commonly used in postal sorting
offices and airport baggage handling systems. A sandwich belt
conveyor uses two conveyor belts, face-to-face, to firmly contain
the item being carried, making steep incline and even vertical-lift
runs achievable.
Belt conveyors are the most commonly used powered conveyors
because they are the most versatile and the least expensive.
Product is conveyed directly on the belt so both regular and
irregular shaped objects, large or small, light and heavy, can be
transported successfully. These conveyors should use only the
highest quality premium belting products, which reduces belt
stretch and results in less maintenance for tension adjustments.
Belt conveyors can be used to transport product in a straight line
or through changes in elevation or direction. In certain applications
they can also be used for static accumulation or cartons.

Cement Manufacturing
process
1-Mining: The cement manufacturing process starts
from the mining of limestone , which is the main
raw material
for making
cement. Limestone is
exacavatedfrom open cast mines afterdrilling and
blasting and loaded on to the dumpers which
transport
the
material
and unloaded into the
hoppers of limestone crusher.
2-Crushing Stacking & Reclaiming of Limestone:
The l/s crusher crush theLimestone to minus 80mm
size and discharge the material onto a belt conveyer
which take it to the stacker via the bulk material

analyser. The material is stacked in longitudinal

stockpiles . Limestone is extract transversely from the
stockpiles by the reclaimers and conveyed to the Raw
Mill hoppers for grinding of raw meal.
3-Crushing Stacking& Reclaiming of coal: The
process of making cement clinker requires heat . coal
is used as the fuel for providing heat. Raw coal
receive from the collieries is stored in a coal yard. Raw
coal is dropon a belt conveyer from a hopper and is
taken to and crushed in a crusher. Crushed coal
discharge is stored in a longitudinal stockpiles from
where it is reclaimed by a reclaimer and taken to the
coal mill hopper grinding of fine coal.

4-Raw Meal Drying/Grinding &Homogenisation:

Reclaimed l/s along with some laterite stored in their
respective hoppers is fed to the Raw mill for fine
grinding. The hot gasses coming from the
clinkerisation 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(ne
called kiln feed ) is feed to the top of the preheater for
pyroprocessing.
5-Clinkerisation:
Cement clinker is made by
pyroprocessing of kiln feed in the preheater and the
rotary kiln. Fine coal is fires as fuel to provided the

necessary heat in the kiln and the precalciner located

at the bottom of the 5/6 stage preheater. Hot clinker
discharged from the kiln drops on the gate cooler and
gets cooled. The cooler discharged the clinker onto the
pan / bucket conveyer and it is transported to the
clinker stockpiles/silp. The clinker is taken from the
stockpiles/silo to the ball mill hoppers for cement
grinding.
6-Cement Grinding & Storage:
Clinker and
Gypsum(for OPC) and also Pozzolana(for PPC) are
extracted from their respected hoppers and feed to
the cement mill. These ball mills ground the feed to a
fine powder and the mill discharge is feed to an
elevator, which takes the material to a separator,
which separates fine product and the coarse the latter
is sent to the mill inlet for regrinding and the fine
product is stored in concrete silo.
7-Packing: Cement extracted from silos is conveyed
to the automatic electronic packers where it is packed
in 50 Kgs polythene bags and dispatched in trucks.

Mining

The major raw material for cement manufacturing is

limestone. Limestone is excavated from open cast
mines after drilling and blastin and loaded onto the
dumper which is transported the material and
unloaded into hopper of the limestone crusher.

Equipment Used in mining:

1.
2.

Compressor drilling machine.

Shovels/Excavators-for lifting material onto
dampers.
3.
Dumper- for carrying material.
4.
Buildozers.
5.
Payloaders.

Explosive:
1.
2.
3.

Amonium nitrate(Fuel oil)

Nitroglycerine.
Amonium 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 predominated in quarrying in open pit.

2.

The depth of the holes are more then 12m

and 100-150mm dia.

Lime Stone Crusher

Lime stone crusher is the lead role playing equipment

in this section. The raw lime stoe is carried out from
the mines is introduced to the lime stone hopper
through hole 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 circumfrencial 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.
2.
3.
4.

Crusher.
Apron conveyer for feeding l/s to crusher.
Bag filter for collecting dust.
Belt conveyer- for transporting crushed
material.

Material Inlet size =1-1.5m

Material outlet size=75-80mm
Technical Specification of limestone crusher:
Capacity
Type
Motor(KW)

Unit-1
650TPH
APPM/1822
780

Unit-2
900TPH
APPM/1822
1200

Rpm
Make

1000
L&T

1000
L&T

This section is worked with Following

equipment:
1.
2.
3.
4.
5.
6.

Impact crusher.
Magnetic separator
Limestone stacker&reclaimer
Bag filtor
Apron feeded
Limestone hopper & laterite hopper

The important mode of transportation in

this section is belt conveyer.
Main component of impact crusher:
Housing:

housing of impact crusher is of studly

steel fabricated and consist of three part.
Rotor: The rotor in the impact crusher is of s-type
construction secured to the shaft by locking
assembly. The blow bar are 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
avoide any undesireable stress on the bearing.
Blow bar:Blowbar is made from high quality
alloyes steel. After the certain period in operation
the blow bar can be taken out from the rotor and
turned to other side or exchange.

 Wear plates:housing

is fitted with the resistance

wear plates which are secured in position by
special fastners which can be changed as and
required.
Impact Arm: The impact crusher is fitted with
the impact arm. 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.
Hydraulic system:Impactors are depend on their
size normally
supplied
with a hydraulic
arrangement for setting of gap for grinding path
lifting of the rear top housing.

Magnaetic Separator:

A magenatic separator is
installed just above belt conveyer between crusher
and stacker. When the magenatic material are comes
along with limestone ,they get seprated by magnetic
separator. In the magnetic separator a permanent
magnet
and
a
continually
moving
belt
beinfinuse.magnetic materials are attached by
magnet due to cont. rotating of belt , material get
seprated on removal of magnetic field.

Gamma Matrics:

A gamma matric analyzer being

used for analyze the chemical composition of lime
stone. It also known as cross belt analyzer. In gamma
metric analyzer we are using specily 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 .

Stacking Of Lime stone:There

are two main

method being used for stacking of lime stone in
cement industry. They are..
1. Chevron Method
2. Windrow Method

Technical
Stacker:

Specification
Make

of

Lime

Stone

=MANTAKRAF

Capacity=1400TPH
Reclaimer:
Reclaimer 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 dis lodged
material along to collacting belt conveyer that extent
along one edge of stackpile. Reclaimer having harrow
assembly.Reclaimer moves on a track for fast travel
A.c. Motor being used and for slow traveling d.c.moter
being used. Harrow are moves to and fro motion on an
rack car which is driven by a motor. A limit sensor is
installed for reverse and forword motion of harroe
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 forwords limestone
hoppers.

Technical Specification of Reclaimer:

Unit-1
Capacity
Make

=400TPH

=Bulkauwalf(India)

Unit-2
Capacity =550TPH
Make

=Cimmco(India)

Raw mill:

This section is working with the fine grinding of raw

material upto 90 microne for proper burning & proper
calcinations of raw material. JaypeeRewa Plant have
two raw mill. In Unit-1 krupppolusius mill has the
capacity of 320TPH and unit-2 loesche mill has
capacity of 440TPH installed for grinding of raw
material. The mill are designed in a modular fashion
and can be equipped as required with four rollers.
Each roller together with rocker arm which is rigigly
clamped the pedestal in whch the rocker arm is
mounted and a hydro-pneumatic spring system
represent a power unit.

Technical Specification of VRN unit-1:

Make
Type
Capacity
Classifire
Gearbox
Speed Ratio
Motor
Feed Size
Product Size
Number of
Rollers
Storage Silo

Krupp polysius
LM K 54/27
320 TPH
LNV
RENK AG(2003)
990/23.53 RPM
3600KW(BHEL)
90mm+2%
90micron -12%
2,In pair
C.B. Silo

Working principle of crupppolysius Mill:

The material to be grounded is feed to the roller via an
air lock. It drops the material in to the rotating
grinding table thus transport under the grindingrollers.
The double groove grinding rand and the adjustable
height dam rings cause formation of material bed. The
crushed material is transported out words over the
edge of table, caught in to gas stream escaping from
nozzle ring and conveyed to classifier locating directly

above the grinding chamber. Classifier is classifies the

finished product ,taling falls back in to middle of
grinding table. Where as finished material is conveyed
to esp by gas flow.
Grounded material falling through the nozzle ring is
transported from discharge ringvia an air lock in to
recalculating bucket elevator. After passing through
trap iron separator these return are passed back to
grinding table via mill feed chute. Materisl of table is
cast steel and interchanging grindingrings are made of
wear resistance material. Grinding on material bed of
grinding table which is rotate by motor and gear box.
Each grinding roller is mounted on anty friction
bearing on excel firmly clamped in to roller supports.
The roller pair are guided bypins in corresponding
guides on housing in such a way that they can move
vertically and tilt about horizontal axis. This allows
good adaptation to any changes in grinding bed height
and means that the entire grinding area remains
effective all time.

Raw Mill unit-2:Raw

mill is one of the most

important section of cement plant. In raw mill raw
material is grounded enough to increase sufficient
reactive surface area. So that,material can burn fasily.
The roller grinding mill can be delivered in various
sizes. The characterization is described in smart form.
For example:-LM50.40
In JRP vertical roller mill is used to grind the raw
material. VRMconsist of four roller, which on
functioning rolls over a circular table. This table is
rotated with the help of a shaft attached to

motor.material is introduced from the top of the VRM.

Material falls down on table,and on coming in b/w
roller and table get crushed. Roller and table have
some specified minimum clearance b/w them, any
material of large size than that clearance gets crushed
inside VRM. Rollers are hydraulically supported to
exert specified force on material. Crushed material
gets lifted with the highly pressurized air and is taken
out through an outlet to ESP.

Technical Specification of VRM unit-2:

Make
Type
Capacity
Classifier
Gear box
Speed ratio
Motor
Feed size
Residue
No of roller
Storage silo

Loeshe
LM 50.4
450TPH
LNV
MAAG
990/26RPM
5000Kw/BHEL
100mm+2%
18%on 90 micron
4
C.F. silo

Working of loesche Mill:

Raw material comes into raw mill from hopper through
a belt conveyer via triple gate. The main function of
triple gate is to prevent the entrance of falls air and to
give air seales material flow. When material comes

b/w rotor and roller they are crushed in to fine powder

due to action of compression and alteration. Roller are
hydraulically activated, a 65 bar pressure exerted by
oil being used to operate the rollers. Hydraulic system
is connected with rollers through connecting rod and
rocker arm. Due to rotating of table, the material
which is not crushed enough is rejected from mill and
feed to reject bucket elevator through vibro feeder.
Exit gasses from preheater and pre-calciners fed to
raw mill via setting chamber to dry the raw material
and to lift the fines the nuzzling velocity of air is 40-50
m/sec.
A classifier is installed just above the mill it
classifies fines and course. Fineness of materials can
be increased by increasing the speed of the classifier.

VRM is divided into three parts, they are:

1.
2.
3.

Gas chamber.
Grinding chamber
Classifier

Gas Chamber
In gas chamber, hot air from PC fan and PH fan enters
lifts the material upward due to the counter flow.
Material is taken to the cyclones by the air.

Grinding chamber
In grinding chamber, grinding of material takes place
b/w four rollers and the rotating table. Material in
grinding chamber is introduced from hopper by belt
conveyer through triple gate.

Classifier

A classifier is the top most rotary part of the vertical

roller mill. Here classification of material occurs. Fine
particles pass through classifier and coarse particles
are rejected and recycled for regrinding. According to
the fineness required speed of the classifier rotor can
be adjusted.

Electrostatic
precipitator:
Electrostaticprecipitator the dust loaded gas to flow
through the chamber usally the horizontal direction in
which it passes throughone or more high voltage
electric from by alternate discharge electrodes and
plate type collective electrodes.

Under action of the electric fields the dust particle

whichhave become electrically change by the
negative gas ion which are formed the discharge
electrodes and attached them to the particle fly to the
collecting electrodes and are deposited there the dust
is rust from this electrodes by rapping and thus fall
into the receive hopper at the base of the precipitator
the electric charge acquired by the dust particle
depend
sustainability
on
their specific electric
resistance in the lower range of opting temperature
the specific resistance increase with rising temp as a
result of diminishing surface couductivity.

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 Blending Silo(C.B. Silo):

It is

suitable where sufficient degree of pre

homogenization has takeplace.The raw meal is
deposited in silo through several opening the actual
blending take place during emptying of raw meal
through the silo feed bins.

Continous 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.

Preheater Tower:

As the name explains Preheater Tower is place to

use for preheating the raw material. The material
which comes from cf or cb silo. In other words

preheater is a device in which heat transfer takes

placefron hot gases which comes from kiln due to
counter current flow of material and hot gases. The
raw mill is heated about 850oc before it enter it the
kiln preheater with calcined system is most
economical and hence the length of kiln is reduce
preheater 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.

Reaction occurs in pre-heater:Temperature

range
100-300oc
400-600oc
500-600oc
600-850oc

Type of Reaction
Loss of water
Removal of inherent gases
Structural change in silicate
phase
Dissociation of carbonate

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
preheater stage. We have designed as double
separator.
2.
Gas Duct: The gas duct are to join the
individual cyclone stages to each other. The raw
meal coming from next higher stage end 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.
3.
The Double Flow Box: These are used
for raw meal pipes in preheater system the flaps
are consist in such a manner that a minimum flow
of raw mill is always maintain. 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.

Calciner:
The main purpose of the precalciner 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
preheater.

The calciner consist of a vessel lined with heat

resistance bricks.Calcine 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 co2 from

the calcinations process and material in form of dust
carried with the hot gases.

Technical specification of Precalciner:

Coal firing
Temperature
Calcination
Burner
Burner capacity
Amount of coal fire

60%
1000oc
95%
2 nos
20TPH
18TPH

Rotary kiln:
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.

Technical specification of Rotary kiln:

Make
Precalciner
Diameter
Length

Unit-1

Unit-2

Krupp Polysius
SLC
4.4M
65M

FLS
SLC
4.75M
75M

Capacity
Rpm
Burner pipe
Slope
Fuel Used
Thrust roller
Thermal Load
Supporting
Roller

4500TPH
4.0
Duflex
3.5oc
Coal/pet coke
Hydraulic
14.07
6nos

5500TPH
3.8
Swirlex
4.ooc
Coal
Hydraulic
14.44
6nos

Construction:
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, bolts etc)
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 inletis 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. Duplex type of burner is used in kiln unit-1 and
swirlex type burner is used in kiln burner unit-2.

Kiln cooler:

Technical Specification of Grate cooler:

Type
Make
Capacity
Size
No. of gates
No. of cooling Air
fan

Folax
FLS(Germany)
5500 TPD
37.8m length*5.1m width
4 nos
11 nos

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
precalciner 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.

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 collcted 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

Hammer Crusher:
In discharge of cooler hammer crusher is provided
consisting of a rotor with shaft. Hammer are mounted
on each row. Hammer are casted made of high chrome
or manganese steel. Clinker is crushed to size 1525mm by hammer crusher.

Coal Mill:

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

Technical Specification of Coal Mill:

Make
Type
Capacity
Gear box
Motor(Kw)
No. of roller

Unit-1

Unit-2

Krupp Polysius
RM K 25/12
35TPH
MAAG
700
2 in pair

Loesche
26.3
55TPH
MAAG
750
3

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 Classifier:

Make
Gear Box
Input rpm
Motor(Kw)
Coal Mill:-

Unit-1

Unt-2

LNV
Sew
1480
37

LNV
MAAG
1500
50

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 70-75 0c 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.

There are two Storage bins, They are:1. Kiln Bin

2. Precalciner Bin
Fine Coal is then transported to the kiln and
precalciner by kiln firing FK pump and precalciner FK
pump respectively.

Coal Mill(Unit-1):The material to be grounded is fed to the roller mill

viaweigh feeder and drag chain. It drops the material
in to rotating grinding table thus transport under the
grinding roller. The double groove grinding rand and
the adjustable height dam rings cause formation of
material bed. The crushed material is transport out
ward over the edge of table, caught in to gas stream
escaping from nozzle ring and conveyed to classifier
locating directly above the grinding chamber.
Classifier is classified the finished product and tailing.
Tailing falls back in to middle of grounding table.
Whereas finished material is conveyed to bag filter by
gas flow. The reject of mill is fed towards the reject
side and removed manually.
Grinding is performed by
total of two rollers, combined into two roller pair and
rolling on material bed of grinding table which is
rotating by motor and gear box. Each grinding roller is
mounted on anti friction bearing on an excel firmly
clamped in to the roller support. The roller pair are
guided by pins in corresponding guides on housing in
such a way that they can move vertically and tilt
about horizontal axis. This allows good adaptation to
any changes in grinding bed height and means that
the entire grinding area remains effective at all time.

Coal Mill(Unit-2):Raw coal comes in to coal mill from hopper through a

drag chain and screw conveyor the entrance of fails

air is avoid to give air sealed material flow .when

material comes between rotor and roller they are
crushed in to fine powder due to action of
compression and alteration .Roller are hydraulically
activated ,hydraulic system is connected with rollers
through connecting rod and rocker arm .Due to
rotation of table ,the material which is not crushed
enough is reject
and remove manually .Exhaust
gasses from cooler is fed to the mill for the drying and
lifting of fine coal.
Fine material is then classified by classifier located
directly above the table oh mill .Fines are then fed to
the cyclone separator for separation of fines from
contaminant gases ,and tailings are fall back on the
table for further grinding ,Maximum separation takes
place in the cyclone and the ultra fine material is get
separated by ESP ,Now, coal is fed to screw conveyor
through rotary lock ,which transport it to the FK
pumps .Two FK pump delivers material to the storage
bins.
1. Kiln bin
2. Precalciner bin

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

Cement Mill:
In this section the
clinker exerted from clinker silo through belt conveyer
fed to the ball mill along with fly ash and gypsum to
grind in powder form. For making OPC clinker grind
along with gypsum and for PPC clinker is grounded
along wiyh gypsum and fly ash. The homogenized
product of cement mill is stored in to the specified
cement storage silo.

Technical specification of Cement Mill:

Type

Cement mill1
Compound
two chamber
ball mill

Cement mill2
Compound
two chamber
ball mill

Speed

15.85RPM

15.85RPM

Cement
mill-3
Compound
two
chamber
ball mill
14.8RPM

Cement
mill-4
Compound
two
chamber
ball mill
15.0RPM

Capacit
y
Motor

110TPH

110TPH

150TPH

120TPH

2400Kw

2400Kw

3000Kw

5000Kw

Separat
or
Type
o-sepa

o-sepa

o-sepa

o-sepa

Drive

225kw

300kw

250kw

225kw

Process:The material to ground is extracted in

certain portion from storage hopper, this mixture is
uniformly fed to the mill by means of feeding device.
Feed material enters the first grinding chamber of ball
mill through the inlet device.In this chamber the
material is pre-crushed due to catering action of
grinding media, the pre-crushed material flow through
a slotted lifter wall in to a fine grinding chamber where
it is ground in to end fineness. The material flow
through the slot of lifter wall in to discharge device.
The air sucked through the mill
by the fan serve for material transportaeration and
hence for cooling of grinding chamber. It contains a
considerable amount of fines therefore, the dust
laden gases is handle to the dedusting plant (bag
house of ESP) via a pre separator called multi
cyclone. Pre separator material is led together with

the lifter dust to the finished mill product. It is mixed

and handled as end product to the finished cement
storage silo.

Cement Mill:

Cement Mill(Ball Mill) consist of

mainly:-

A rotating Steel cyclone shell cylindrical shell

supported at both ends on turn-on/slide shoe
bearing.
Liners for protecting the inside surface of the
shell.
Diaphragrms for driving the mill into two or more
compartments.
Grinding balls.

Mill cooling system.

Details of Liners:
The line which protect the shell from wearing
action of clinker and additives, also help in the
grinding process.
In the second compartment classifying liners
are used which help to segregate the grinding
media according to its size larger balls towards
the compartment. Small balls towards the
discharge end.

Diapharagms:

Mill diaphargms are provided with

slots through which material and venting air pass
from 1st compartment to 2nd compartment.

Grinding Media:

The mill chambers are partially

filled with steel ball having diameter ranging from
90mm to 60mm in 1st compartment and from 50mm
ball to 17mm ball in 2nd compartment.

Heat Generation:
During grinding heat is generated in the mill
which if not controlled would raise the
temperature and effect cement quality.
The grinding heat is dissipated by injecting
atomized water in the mill chamber which on
evaporation cools down the mill to acceptable.

Dynamic Separator:

Material is fed in separating

disc in the separating chamber inside dynamic
separator. The spread material is divided into grift
lines by a recirculating air current built by a fan fall
on inner core. Fine particles get separated from
reconciliatory air. Counter vanes with adjustable
length are fitted above the separator plate to control
the fineness of particles. The fan separator disc and
counter vanes can be driven by single drive. The
separator is preferred for coarse separation due to
the lower specific consumption.

Size of Ball charges In Chambers:

Ball Size in 1st
Chamber

Ball Size In 2nd

Chamber

90mm
80mm
70mm
60mm

50mm
40mm
30mm
25mm

20mm
17mm

Amount of Ball chargers in Compound Mill:First Chamber:

90mm=17.5 Tons
80mm=21.0 Tons
70mm=17.5 Tons
60mm=13.0TonS
Total=69.0 Tons

Second Chamber:
50mm=13.0 Tons
40mm=15.0 Tons
30mm=16.5 Tons
25-17mm=120.5Ton
Total=165 Tons

o-Sepa Air Separator:

It gives sharp classification and save energy in
grinding process. The material is introduced to the osepa air separator which is then directed on the
dispersion plate. The plate is located on the top of
rotor by feed clutch. The material is then distributed
by centrifugal force in the angular gap b/w rotor and
guide vanes it is then followed by buffer plate which
is directed the material into the center or rotor. It exit
the separator through outlet duct located on the top.

The reject are collected in bottom and are discharge

through a wall locating at the bottom.
There are three location for air flow to the separator,
the primary air comprises mill bent and ambient air,
inters through the inlet path in to the separator,
secondary air comprised of bent air from equipment
in guiding unit and ambient air inters the
separator through the
separator opening. Both
primary and secondary air create a
vertex in
separating of the separator. Fine particles which
are discharge in to the hopper are also classified
by tertiary air. Rotor speed can be adjusted by the
variable speed drive motor. O-sepa air separators are
highly efficient they classifies a higher proportion of
feed particle in to product and reject.

Sepol Air separator:

This type of separator is of single rotor type and was
developed by F.L. Smidth. Its design is simple,
compacting and highly efficient. The material is fed
in to the separator from the mill in to an upward flow
of air duct below the separator this results through
dispersion of material. Proper dispersion of material
is very important for obtaining the high separating
efficiency. Suspended material flows into the
separator via vertical guide vanes which maintain the
uniform velocity and distributing of material.
Guide vanes are also serves as collecting plates
from coarse material reject from the rotor coarse
fraction falls back into the reject cone from
where it is discharge through the opening. The

fine or finished material leaves the separator

with the flow of air and is collected in cyclone or
in bag filter.
Air entering at the bottom of sepol air separator can
either fresh or dustloading and it permits any degree
of recirculation. When fresh air isused. Fines
and
tailings are cooled down to 70-75 deg. There by
reducing mill cooling requirement, the complete
dispersion of material is riser duct combined with
uniform distribution of air not only
gives
high
efficiency but also produces low degree wear on the
separator internal liner.

Packing Plant:
In this section the cement is extracted from several
cement silos and fed to the rotary packer for packing
in to the bags. The weight of each bag is 50kg.

Process:
There are six silos in JAYPEE REWA PLANT. Each silos
heaving specified type of cement. Cement is extracted
from silo at eight aeration fluidized points, there are
2-3 air slides are installed below each silo for
transportation of cement in to packet bucket elevator.
The cement from silo through air slides fed to the
bucket elevator. Cement is then passes through the

vibratory screen, these screens are used for retaining

the over size material and reject it because the
over sizematerial is harm full for roto packer cement
which passes through the screen comes into storage
hopper above each packer.
This hopper having minimum and maximum level
indicator. A rotary feed valve is used to control the
material level in packing machine. Cement is now fed
to packer hopper and then to packing machine and
spillage hopper is installed to collect the return of
cement below the rotopacker.

Technical specification of Rotary Packers:

Old Packing Plant:-

RPM
Capaci
ty
Spout
Make

Packer-1 Packer-2 Packer4

Packer-3

4.5-5
80-90TPH

4.5-5
80-90TPH

4.5-5
80-90TPH

4.5-5
80-90TPH

6
EEPL_HAV
ER

6
EEPL_HAV
ER

6
6
EEPL_HAV EEPL_HAV
ER
ER

New Packing Plant:Packer-5

Packer-6

Packer-7

RPM
Capacity

4.5-5
100-120TPH

Spout
Make

8
EEPL_HAVER

4.5-5
100120TPH
8
EEPL_HAVE
R

4.5-5
100-120TPH
8
EEPL_HAVER

Major System in ARoto Packer:

Bag Holding and Release System:a) Bag chair cylinder-After releasing

of a
bag from spout as spout advances, towards
the operator the bag chain cylinder
operators and the bag chair cylinder
operates and bring the bags in position.
When targeted 50kg weight is reached this
cylinder causes tilting of bag chair and bag
discharge on belt conveyer.
b) Bag Holding cylinder-When a bag is
applied on spout bag holding cylinder
,cylinder holds the bag in position. It holds
the bags till target weight is being achieved.
c) Limit Switches:-Each spout has two limit
switches one for sensing the position of
spout before discharge on belt and other for
sensing the position of spout after the bag
are discharge.
Electronic
Weighing
System:-The
electronic weighing system is provided is to
measure the weight on bag chair with the help of

load cell and also perform various logic control.

This can give various facilities like counting of
bags and totaling of weight etc.

Working Of Roto Packer:

The cement is discharge by the impeller through the
filling spout in to the bags standing on saddle, which
is guided parallel by theroad. The loadis transmitted
from the saddle through the tension rod to the equal
arm weight beam comprising two levers inter
connecting by cross piece. The weight box is
suspended from weight-beam. The dampers function
only when the left arm of weigh beam is descends.
For quickly cutting of feed flow when specified filling
weight has beenachieved. The upper flange of the
cross piece causes the small weight to tilt the
spring on the damper assist this action. On
removal of load the right arm of weight beam is
rises, this action is done again and again to fill the
cement in to the 50kg bags.