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Report
On
Practical Training and Industrial Visit
At
“J.K. CEMENT LTD., NIMBAHERA”
Submitted in partial fulfillment for the award of degree of
BACHELOR OF TECHNOLOGY
In
MECHANICAL ENGINEERING
Submitted To Submitted By
Mr. ANIL KU. CHOUDHARY MANOJ SHARMA
MR. DEEPAK GUPTA 15EGJME106
I
ACKNOWLEDGEMENT
I wish to acknowledge my profound gratitude towards Dr. M S SHEKHAWAT, Asst. Vice President
– HR, ER & RTC for giving me opportunity in this field.
I also wish to acknowledge my profound gratitude towards Mr. N K Vaishnav, Manager – RTC and
Mr. Faraz Mohammed, Sr. Officer - RTC for incessantly guiding me in-depth training on “Cement
Manufacturing Process and Use of Kiln in Cement Industry” they support me in every aspect of
my report and encouraging me at every step.
I would be a thankless child if I don’t mention the name of my continuous source of energy and
inspiration i.e. that is my Teacher’s & parents who always encourage and support me at every right
step in my life.
II
ABSTRACT
This paper analyzes an existing working management system in a cement factory in the city of
cement Nimbahera, chittaurgarh using a modified questionnaire. The analysis shows that there are
strong areas such as predictive maintenance and maintenance automation. This analyzes shows that
how a cement industry is execute their plans in field. It describes how J.k. plants are growing them
self in market and making most productive and recognize cement. Energy cost and environmental
standards encourage cement manufacturing.
The goal is to optimize process control and alternative fuel consumption while maintaining product
quality. Working with kiln and with safety is a big task but them doing exceptionally well. This paper is
an assessment initiative for maintenance and productivity continuous improvement and can be
integrated as a part of a decision support system for manufacturing management.
III
An Introduction to
HR Department
JK Cement Works
Kailash Nagar, Nimbahera
District: Chittaurgarh-312617
(Rajasthan)
IV
ACKNOWLEDGEMENT ...................................................................................................I
ABSTRACT......................................................................................................................II
3. ORGANISATIONAL CHART……………………………………………………………11
V
5.5 Sports services..................................................................................................... 15
7.2.3 Clinkering………………………………………………………………………….22
9. ENVIRONMENTAL IMPLICATIONS……………………………………………...…….33
9.2 CO2………………………………………………………………………………………34
VI
9.4 Chrome bricks…………………………………………………………………………..35
REFRENCE ……………………………………………………………………………………38
VII
List of figures
Figure 7.4: Cyclone preheater using for preheating clinker before kiln process……….26
Figure 9.1: shows the limestone stacker operation without and with water spraying…34
Figure 9.2: Typical Gypsum storage area and open stock pile of Clinkeran…………..36
VIII
List of tables
IX
1. OVERVIEW OF J K CEMENT LTD.
1
The Company is the second largest manufacturer of white cement in India, with an
annual capacity of 600,000 tonnes in India. We are also the second largest producer of
Wall putty in the country with an annual installed capacity of 5,00,000 tonnes.
J.K. Cement was the first Company to install a captive power plant in the year 1987 at
Bamania, Rajasthan. J.K Cement is also the first cement Company to install a waste
heat recovery power plant to take care of the need of green power. Today at its different
locations, the Company has captive power generation capacity of over 140.MWs which
include 23 MW of waste heat recovery power plants.
The Company has made its first international foray with the setting up of a green-field
dual process white cement-cum-grey cement plant in the free trade zone at Fujairah,
U.A.E to cater to the GCC and African markets. The plant at Fujairah has a capacity of
0.6 million tonnes per annum for White Cement with a flexibility to change over its
operation to produce upto 1 million tonnes per annum of Grey Cement.The commercial
production from Fujairah Plant started from Sep'2014.With this, J.K Cement Ltd has
become the second largest White Cement Producer in the World.
As a part of its new initiatives, the Company plans to increase the production capacity of
Wall Putty to keep pace with the rising demand .In this direction, the company plans to
put up 6 lac tonnes capacity at Katni in M.P.The first phase of 2 lacs tonnes will be
taken up by the end of Fiscal 16.
Backed by state-of-the-art technology, access to the best quality raw materials and
highly skilled manpower against the backdrop of India's infrastructural growth in an
overdrive, we are upbeat about the future. Superior products and a strong Brand name,
an extensive marketing and distribution network and the technical know-how represent
the Company's abiding strengths.
2
1.2 About J K Cement
J.K Cement has three decades of experience in cement manufacturing. From modest
beginning in the year 1974 with a capacity of 0.3 million tonnes at Nimbahera in
Rajasthan, today J.K Cement has 6 kilns of different capacities with a combined annual
capacity of 7.5 million tonnes. The three cement units having aggregate capacity of 4.5
million tonnes are located in Rajasthan at Nimbahera (capacity 3.25 million TPA),
Mangrol (capacity 0.75 million TPA) and Gotan (capacity 0.47 million TPA) and one unit
in Karnataka at Muddapur with capacity of 3 million TPA. The Company is the second
largest manufacturer of White Cement in India, with an annual capacity of 400,000 ton
nes and value-added building products such as Wall Putty.
The Company also has a fully automated plant of White Cement based Wall Putty
having a production capacity of 3 lac tonnes per annum. J.K. White Cement's plants are
accredited with ISO - 9001 and 14001 Certified Company by LRQA. Further, the plant is
also OHSAS 18001 (For safety and environmental upkeep) accredited.
3
1,3 Grey Cement Plants and Production Capacity
We manufacture grey cement in two facilities located at Nimbahera and Mangrol in the
state of Rajasthan in Northern India. Our plants have obtained many accolades and
recognition, the most noteworthy being IMS Comprising of : ISO-9001:2008 for QMS
and ISO-14001:2004 for EMS for the grey cement facility at Nimbahera and Mangrol.
J K Plant, Nimbahera
7550
I. Kiln 1200 II. Kiln 1650 III. Kiln 4700 TPD
4
Table1.3: FINANCIAL ANALYSIS IN Million – J K Cement Ltd.
5
J.K. Cement Works, Mangrol
Our pioneering foray into white cement 25 years ago created a new chapter in the
history of J.K. Cement and the J.K. White Cement Plant is an integral part of the same.
6
We were the first White Cement facility in India, which was limestone based, and
manufactured Cement through the dry process. The White Cement plant was
commissioned in 1984 at Gotan, Rajasthan, with an initial production capacity of 50,000
tons. The White Cement plant uses technical expertise from F.L. Smidth & Co. from
Denmark and state of the art technology with continuous on-line quality control by micro
processors and X-rays ensure that only the purest White Cement is produced. Over the
years, continuous process improvements & modifications have increased the plant's
production capacity to 400,000 tons per annum.
Foundation Stone Laying Ceremony of J.K. Cement Works, Fujairah - The Foundation
Stone being laid by H.H. Sheikh Mohammed Bin Hamad Al Sharqi - Crown Prince of
Fujairah along with Shri Yadupati Singhania - MD & CEO, J.K. Cement Ltd. and Shri
Raghavpat Singhania - Special Executive.
J.K. Cement Ltd. has added yet another feather to its cap with the announcement of its
maiden overseas plant at Fujairah, UAE which has a capital outlay of US $ 150 million.
The plant's foundation stone laying ceremony was held on November 14th, 2011in the
presence of His Highness H.H. Sheikh Mohammed Bin Hamad Al Sharqi - Crown
Prince of Fujairah. Also gracing the occasion were Shri Yadupati Singhania – MD &
7
CEO, J.K. Cement Ltd., Shri Raghavpat Singhania – Special Executive, Mr. A.K.
Saraogi – CFO & President (CA), Mr. N. Gowrishankar – Unit Head (J.K. Cement
Works, Fujairah) and Mr. D. Ravisankar – President, J.K. Cement Works, Nimbahera.
The capacity of the Grey cum White cement plant is slated to be at 1,750 tonnes per
day (tpd) for White Cement clinker and 2,800 tonnes per day (tpd) Grey cement clinker.
The plant at Fujairah has a capacity of 0.6 million tonnes per annum for White Cement
with a flexibility to change over its operation to produce upto 1 million tonnes per annum
of Grey Cement. The plant shall have the flexibility to have 100% white cement, a mix
both of white cement and grey cement or 100% grey cement, depending upon the
market demand. Thus, the Company plans to cater to the demand in the region as well
as to the neighbouring countries through this manufacturing facility.
As has been a ritual with J.K. Cement Ltd., in this venture as well, we will continually
strive to uphold the quality consciousness, customer experience and best ethical
practices that J.K. Cement Ltd. is known for.
All our plants have captive power facilities except grinding unit at Jhajjar. Infact, J.K.
Cement was the first Company to install captive power plant in the year 1987. J.K
Cement is also the first cement Company to install a waste heat recovery power plant to
take care of the need of green power. Today at its different locations, the Company has
captive power generation facilities of over 140.7 MWs including Waste Heat Recovery
of 23.2 M.W.
8
Figure1.4: J.K. Cement plants in INDIA
9
2. MANAGEMENT SET- UP
2.2 Heads:
Project
President Project Shri D Ravishankar
Units
J K Cement, Nimbahera and
Unit Head Shri S K Rathore Mangrol, Distt: Chittaurgarh,
Rajasthan
JK Cement Works, Muddapur,Distt:
Unit Head Shri A K Jain
Bagalkot, Karnataka
J K Cement- White and Grey Plants
President - Works Shri B K Arora
at Gotan, Distt: Nagaur, Rajasthan
10
3. ORGANISATIONAL CHART
J K Organization
J K Cement Ltd.
Production &
Location
CPP– 50 CPP –
CPP –
11 MW 7.5MW
22MW
4. Regional Training Centre : Nimbahera
The Regional Training Centre - North is a premier training centre of India promoted with
assistance from World Bank, DANIDA and Govt. of India as a unique HRD project in
Cement Industry. It is equipped with modern training aids and caters to the skill
enhancement and competency developmental needs of more than 20 cement and other
plants. It has trained over 13000 technical and managerial personnel during the last 21
years.
The centre has conducted many tailor-made in-house programs for cement and other
industries in India and abroad including for Oman Cement, Oman and Star Cement,
Dubai and Hama Cement, Syria / EHDASSE Sanat Corp.Iran and NCC Yemen.RTC
has specialized packages / modules in Mining, Process, Maintenance disciplines like
Operation & Maintenance of HEMM / Gear-boxes / Pumps / Compressors / Electrical &
Electronics Equipments / Energy Conservation /Environment Management and
Machinery Alignment, etc. designed and developed by renowned International / National
agencies like FLS Denmark, NCCBM, TATA Interactive Systems, VEC, NITTTR, etc.
More than 100 senior line mangers from ten plants have been trained at Denmark,
NITTTR, Bhopal and Chennai, who act as resource persons. Besides OEM's and
management experts of national repute are invited to make these programs effective
and gainful experience for the participants.
12
RTC OBJECTIVE To prepare the employees of Cement and other industries by
developing desired competencies for meeting the
requirements of present and future roles.
13
Figure 5.1: J.K, Cement Institute of Techonoligy & J.K.School of Education ,Nimbahera.
14
Financial contribution for construction of dispensary & health centre in nearby
villages.
Free Homeopathic consultancy/medicines for the patients of nearby area.
Sports infrastructure like wooden badminton court, table tennis court, billiard
room, and cricket ground, volleyball ground in colony campus.
Sponsoring all India youth football, volley ball and badminton tournaments.
Sponsoring inter-district tournaments.
Arranging summer camps for various sports.
15
Financial aid to organize religious festivals by municipal board.
At J.K. White Cement Works, Gotan we use technical expertise from F.L. Smidth & Co.
from Denmark and state of the art technology with continuous on-line quality control by
micro processors and X-rays to ensure that only the purest White Cement is produced.
We manufacture White Portland Cement through these 5 significant stages - Crushing,
raw meal grinding, clinkerisation, cement grinding and packing for dispatch.
16
Step 1 (Mining) Step 2 (Crushing) Step 3 (Grinding) Step 4 (Fuel
Preparation)
KILN
CEMENT
17
7. Manufacturing Process - Grey Cement
All J.K. Cement plants are dry process plants. Limestone is crushed to a uniform and
usable size, blended with certain additives (such as iron ore and bauxite) and
discharged to a vertical roller mill/Ball Mill, where the raw materials are ground to fine
powder. An electrostatic precipitator dedusts the raw mill gases and collects the raw
meal for a series of further stages of blending. The homogenized raw meal thus
extracted is pumped to the top of a preheater by mechanical transport /FK pumps. In
the preheaters the material is heated to 750ºC. Subsequently, the raw meal undergoes
a process of calcination in a precalcinator (in which the carbonates present are reduced
to oxides) and is then fed to the kiln. The remaining calcination and clinkerization
reactions are completed in the kiln where the temperature is raised to between 1,450ºC
and 1,500ºC. The clinker formed is cooled and conveyed to the clinker silo from where it
is extracted and transported to the cement mills for producing cement. For producing
OPC, clinker and gypsum are used , for producing Portland [Pozzolana] Cement
18
("PPC"), clinker, gypsum and fly ash are used and for producing Portland Slag Cement
(PSC), cement uses clinker , gypsum and slag.
The JK Cement has adopted the latest technology of manufacture of cement by dry
process with suspension pre heater and pre calcination. The unit has selected the dry
process for the manufacturing of cement because the fuel consumption in dry process
of cement manufacture is less; compared to wet process, The coal consumption ratio of
wet and dry process is about 1.3: 1. However, in the case of dry process power
consumption is higher. The present worldwide trend in cement industry is to put up all
plants with dry process mainly because of the overall economy and lesser need of water
resources.
a) Lime Stone
b) Gypsum
c) Laterite
d) Alumina
e) Coal
f) Fly Ash
19
Cement is a fine grey powder which when reacted with water hardens to form a rigid
chemical mineral structure which gives concrete its high strengths. Cement is in effect
the glue that holds concrete together. The credit for its discovery is given to the
Romans, who mixed lime (CaCO3) with volcanic ash, producing a cement mortar which
was used during IX-Materials-B-Cement-2 construction of such impressive structures as
the Colosseum. When the Roman empire fell, the information on how to make cement
was lost and was not rediscovered until the 16th century.
ferrate
The cement manufacturing process involves four distinct stages, and these are
outlined below.
7.2.1 Quarrying
The raw material for cement manufacture is a rock mixture which is about 80%
lime stone(which is rich in CaCO3) and 20% clay or shale (a source of silica,
alumina and Fe2O3). These are quarried and stored separately. The lime and
20
silica provide the main strength of the cement, while the iron reduces the reaction
temperature and gives the cement its characteristic grey colour.
Maliakhera, Karoonda and Tilakhera are the mines feeding the plants. Open cast
mining technique is used. The limestone is transported to the crusher hopper
through conveyor belts and dumpers.
The steps involved here depend on the process used. There are two main cement
manufacturing processes currently used in New Zealand: the dry process (used by
Golden Bay) and the wet process (used by Milburn). The dry process uses more
energy in grinding but less in the kiln, and the wet process has lower overheads
than the dry process. The two processes are discussed separately below.
21
The dry process
The quarried clay and limestone are crushed separately until nothing bigger than a
tennis ball remains. Samples of both rocks are then sent off to the laboratory for
mineral analysis. If necessary, minerals are then added to either the clay or the
limestone to ensure that the correct amounts of aluminium, iron etc. are present.
The clay and limestone are then fed together into a mill where the rock is ground
until more than 85% of the material is less than 90μm in diameter.
The clay is mixed to a paste in a washmill - a tank in which the clay is pulverised in
the presence of water. Crushed lime is then added and the whole mixture further
ground. Any material which is too coarse is extracted and reground. The slurry is
then tested to ensure that it contains the correct balance of minerals, and any extra
ingredients blended in as necessary.
7.2.3 Clinkering
This is the step which is characteristic of Portland cement. The finely ground
material is dried, heated (to enable the sintering reactions to take place) and then
cooled down again. While it is being heated various chemical reactions take place
to form the major mineral constituents of Portland cement.
The powder from the dry process doesn't contain much moisture, so can be dried
in a preheater tower. As it falls through the tower (which takes 30 seconds) it is
heated from 70 to 800oC. The moisture evaporates, up to 20% of the
decarbonation (loss of CO2) occurs and some intermediate phases such as
CaO•Al2O3 begin to appear. The mixture is then fed into the kiln.
The slurry from the wet process contains too much moisture to be successfully
dried in a preheater tower. Instead, the slurry is fed directly into the kiln where it is
22
formed into dry balls by the heat and rotation of the kiln. Because of this extra role
of the kiln, wet process kilns are generally longer than dry process kilns: e.g.
Milburn's kiln is more than 100 m in length, whereas that used by Golden Bay is
only 60 m long. The kilns used in both processes are inclined on a shallow angle
and lined with heat-resistant bricks.
The kiln shell is steel, 60m long and inclined at an angle of 1 in 30. The shell is
supported on 3 roller trunions and weighs in at over 1100 T. The kiln is heated by
injecting pulverized coal dust into the discharge end where it spontaneously ignites
due to the very high temperatures. Coal is injected with air into the kiln at a rate of
9 - 12 T hr-1.
The reaction processes occuring within the kiln are not easily understood due to
the wide variations in raw-mix chemistry, raw-mix physical properties and kiln
operating conditions, and the physical difficulties of extracting hot materials from
the process for investigation before they cool.
Breaking the reaction processes into a number of simple zones means we can
make someapproximations about the cement formation process.
heat
23
Zone 2: 35 - 40 min, 1100 - 1300oC
heat
Sintering and reaction within the melt to form ternary silicates and tetracalcium
aluminoferrates:
heat + time
heat + time
•Fe2O3
Cooling and crystallisation of the various mineral phases formed in the kiln.
24
Kiln System Chemistry
The chemical reactions that occur in the kiln are described in detail in (3). The
temperature is increased when going from the meal feed to the rotary kiln. The most
important oxides that participate in the reactions are CaCO3, SiO2, Al2O3 and Fe2O3. Up
to about 700C water is removed from the meal. In the preheating section (700-900C)
calcination as well as an initial combination of alumina, ferric oxide and silica with lime
takes place. Between 900C and 1200C belite, C2S (= 2CaO*SiO2), forms. Above 1250C a
liquid phase appears and this promotes the reaction between belite and free lime to form
alite, C3S (= 3CaO*SiO2). During the cooling stage the molten phase forms C3A, tri calcium
aluminate, (= 3CaO* Al2O3) and if the cooling is slow alite may dissolve back into the
liquid phase and appear as secondary belite.
Usually the production of clinker is done so that one type of clinker allows the plant to
manufacture several well-defined types of cement that comply with the physical demands
as specified by cement standards.
25
Cyclone preheater
Figure 7.4: Cyclone preheater using for preating of clinkers before KILN PROCESS.
Alternative fuels
The range of fuels is extremely wide. Traditional kiln fuels are gas, oil or coal. Materials
like waste oils, plastics, auto shredded residues, waste tyres and sewage sludge are often
26
proposed as alternative fuels for the cement industry. Also all kinds of slaughterhouse
residues are offered as fuel nowadays.
In Table several fuels of interest to the cement industry and their properties are
listed. Some of these were used in model calculations reported here. The
27
calculations were made to test the influence of a fuel change on the kiln process,
specially the demand of combustion air in the burning zone
28
The cooler
Immediately following the kiln is a large cooler designed to drop the temperature of
the clinker (as the fused material is now called) from 1000oC to 150oC. This is
achieved by forcing air through a bed of clinker via perforated plates in the base of
the cooler. The plates within the cooler slide back and forth, shuffling the clinker
down the cooler to the discharge point and transport to a storage area.
At this point in the process the materials have been formed into all the required
minerals to make cement. Like cement, the clinker will react with water and
harden, but because it is composed of 1-3 cm diameter fragments it is too coarse
to be used.
To produce the final product the clinker is mixed with gypsum (CaSO4 •2H2O),
which is added as a set retarder, and ground for approximately 30 minutes in large
tube mills. The cement flows from the inlet to the outlet of the mill (a rotating
chamber), being first ground with 60 mm then 30 mm diameter steel balls. The first
grinding breaks up the material and the second grinds it to a fine powder. The
amount of grinding is governed by the volume of cement fed into the mill: the
greater the volume the coarser the grind. This has practical limits, with too much
cement clogging up the mill and not enough actually increasing the particle size.
The particle size is measured by laser diffraction analysis, and the quantity of
material entering the mill adjusted accordingly. Over time the charge (steel grinding
29
balls) wear out, so when they reach a certain size they fall through a seive and
then are replaced.
The cement grinding process is highly energy intensive. The largest mill at Golden
Bay Cement is some 11 m in length, weighs over 230 T, is driven by a 2100 kW
motor and can produce over 60 T hr-1. The rotating mill generates significant
quantities of energy and water is added to both the inlet and outlet ends of the mill
to cool the product and the mill itself.
The cement from the cement mill is pneumatically fed into cement storage silos
from where it is packed in HDPE bags by rotary packing machine and then directly
loaded into wagons or trucks. The complete process is controlled by a most
modern process control instrumentation system. There is a well-equipped
laboratory for controlling the quality of the product at various stages in its
manufacturing process.
30
Figure 7.6: Paking of cement bages in 50 kg each one in packing plant.
31
8. THE ROLE OF THE LABORATORY
The laboratory forms an integral part of the control systems on site with testing from raw
materials to finished product. The laboratory operates a 24 hour facility in line with a
continuous manufacturing facility responsible for the following aspects:
Testing raw materials prior to blasting in the quarry and assisting with
development of quarrying strategies forms the first step in the process.
Analysing rock samples from the raw mill at regular intervals during the day and
night and fine tuning the process to ensure chemical control is maintained.
Analysing clinker at the end of the cooler (before grinding) to ensure that the
manufactured process meets specification.
Checking that cement mills are undertaking grinding correctly and that customers
receive the right product.
Checkings despatched materials for quality and compliance with NZ Standards
requirements. Certificates of conformance are issued to customers based on
these analyses.
Testing work within the laboratory ranges from simple air permeability measurements to
high technology X-ray fluoresence analysis (see air pollution article). Qualifications
within the laboratory relect this wide range of testing and skills requirement with
university qualified staff working alongside others with minimal formal qualifications.
32
Figure 8.1 : Product development knowledge at throw training program.
9. ENVIRONMENTAL IMPLICATIONS
Many of the aspects of the cement making process are potentially environmentally
damaging, although these risks can be minimised. The areas of potential concern are
listed below.
33
earthed collection plate. The electrostatic discharge between the electrode and the plate
forces the dust onto the plates, from which it is removed.
The current emission limit from the main stack at Nimbahera is 250 mg m-3 and at
Mangrol is 150 mg m-3, while in Indian emission limits of down to 50 mg m-3 are
becoming common.
This poses a significant challenge to the manufacturing operation both in capital cost to
reduce emissions and monitoring of emissions to ensure compliance with existing
resource consents.
Figure 9.1 :shows the limestone stacker operation without and with water spraying.
9.2 CO2
34
9.3 Quarry and plant water runoff
Runoff of storm water and treatment of waste water from quarries is a problem for
almost all quarry operations. Usually this is trapped in wetland areas where the water is
treated in a controlled manner. Within the factory runoff can be contaminated by oils
and lubricants, but the runoff is monitored and training programmes are reguarly
undertaken to ensure this does not happen.
Kiln bricks used to be made of hexavalent chrome, which is a carcinogen and causes
dermititus in some people. Since the problems associated with its use were identified
both along with almost all cement manufacturers internationally. Replaced these bricks
with environmentally-sound magnesium-spinal bricks.
35
Figure 9.2 :Typical Gypsum storage area and open stock pile of Clinkeran.
36
10. A Passion for Quality – Characteristics of Cement
At J.K. Cement, quality is not just a product centric vision but an Omni-organisational
vision. With a firm belief that quality begins and ends with people, the management has
inculcated a quality culture in the very thought process of the organisation.
Our plants are also ISO 9001:2008 & ISO 14001:2004 certified and are in the process
of getting our laboratory accredited with the NABL-National Accreditation Board for
Testing and Calibration Laboratories.
37
REFRENCE
38
Locate The Plants
NIMBAHERA MANGROL
MUDHOL GOTAN
Muddapur
P.O.Gotan - 342902,
Taluk Mudhol -
587122 Dist - Nagaur,
Rajasthan
Dist - Bagalkot,
Karnataka Phone - 01591 -
230201
Phone - 08350-
289000 Fax - 01591 -
230206
Fax - 08350 -
280710
JHARLI (GRINDING
UNIT)
P.O - Jharli
Dist - Jhajjar
39
Haryana – 124106
GOTAN
Gotan - 342902,
Dist -
Nagaur,(Rajasthan)
Phone - 01591 -
230201
40