Internship Report

DG KHAN Cement
(Khairpur Plant, Kallar Kahar, District Chakwal)

Reported to:
Mr. Safdar Kamal
SDM Technical
DG Khan Cement LTD Kallar Kahar

Submitted by:
Atif Ali
2015-CH-229

Department of Chemical Engineering

University of Engineering & Technology

New Campus, Lahore
 Personal Information:

Name: Atif Ali

Father’s name: Muhammad Anees
Discipline: Chemical Engineering
Registration no: 2015-CH-229
Email: aatif8304@gmail.com
Contact no: 03484568505
Internship Duration: 8th October, 2019 to 18th October, 2019

University of Engineering & Technology

New Campus, Lahore
 Acknowledgement

First of all I would like to thank Almighty Allah who showered his blessings on me
and blessed me the potential to do the task in time.
This report presents all the knowledge I have gained as a sort of purposeful
learning outcome under the supervision of Sir Zahid Akram. It is the outcome of
my handful work on plant site regarding the understandings of various processes
occurring there. I did my best to get my understanding at better level to make this
opportunity fruitful.
I would like to thank the managerial staff at DG Cement especially Mr. Safdar
Kamal. They helped me a lot to get information regarding company, plant and
other cement industries. They also helped me by providing me the opportunity to
work as an Internee in this plant. I am also thankful to Mr. Zahid Akram whose
kind supervision led me to get new interventions to my industrial concepts.
Executive Summary
Contents
Chapter 1................................................................................................................................................................................. 7
Introduction ........................................................................................................................................................................ 7
Block Diagram of Cement Production Process ................................................................................................................... 8
Chapter 2................................................................................................................................................................................. 9
Cement Production Process ................................................................................................................................................ 9
Quarry and Raw Material: ............................................................................................................................................... 9
Drilling: ............................................................................................................................................................................ 9
Blasting: ........................................................................................................................................................................... 9
Limestone Crusher: ........................................................................................................................................................... 10
Storage Yard: ..................................................................................................................................................................... 11
Stackers: ............................................................................................................................................................................ 11
Side Scrapper: ............................................................................................................................................................... 11
Hoppers: ........................................................................................................................................................................ 11
Raw Mill Area: ................................................................................................................................................................... 12
Raw Mill: ....................................................................................................................................................................... 12
Cyclone Separator: ........................................................................................................................................................ 13
Bucket Elevator: ............................................................................................................................................................ 13
CF Silo: ............................................................................................................................................................................... 14
Pre-Heater: ........................................................................................................................................................................ 14
Kiln: ................................................................................................................................................................................... 15
Clinker Cooler:................................................................................................................................................................... 15
Clinker Crusher and Storage: ............................................................................................................................................ 16
Clinker Crusher .............................................................................................................................................................. 16
Clinker Storage .............................................................................................................................................................. 16
Cement Feed Mill Area: .................................................................................................................................................... 17
Cement Mills ................................................................................................................................................................. 17
Storage Silos .................................................................................................................................................................. 17
Packing Plant: .................................................................................................................................................................... 18
Chapter 3............................................................................................................................................................................... 19
Proximity Sensor ............................................................................................................................................................... 19
Pt-100 ................................................................................................................................................................................ 19
Vibration Control Devices ................................................................................................................................................. 19
Programmable Logic Controller ........................................................................................................................................ 20
Chapter 4............................................................................................................................................................................... 21
 Power Plant ....................................................................................................................................................................... 21
Motors............................................................................................................................................................................... 22
Safety and Fire Fighting..................................................................................................................................................... 22
Safety ............................................................................................................................................................................ 22
Fire Fighting................................................................................................................................................................... 23
Hose Reek System ......................................................................................................................................................... 23
Sprinkler System............................................................................................................................................................ 23
Fire Tender System ....................................................................................................................................................... 23
Emergency Alerts and Precautions ............................................................................................................................... 23
Chapter 5............................................................................................................................................................................... 24
Utilities: ............................................................................................................................................................................. 24
Cooling Tower ............................................................................................................................................................... 24
Water Treatment Plant ................................................................................................................................................. 24
Waste Heat Recovery Section ....................................................................................................................................... 24
 Chapter 1
Introduction
Block Diagram of Cement Production Process
 Chapter 2

Cement Production Process

The detail of cement production is given below:
Quarry and Raw Material:

Drilling:

Blasting:
Additives (<1%):
 Bauxite
 Silica

Lime Stone Clay

Limestone Crusher:
Storage Yard:

Stackers:

Side Scrapper:

Hoppers:
Raw Mill Area:

Raw Mill:
 Raw Mill

Cyclone Separator:

Bucket Elevator:
CF Silo:

CF Silo

Pre-Heater:
Kiln:

Kiln

Clinker Cooler:
Clinker Crusher and Storage:
Clinker Crusher

Clinker Storage

Clinker Storage
Cement Feed Mill Area:
Cement Mills

Storage Silos

Storage Silos Cement Mills

Packing Plant:

Packing Plant
 Chapter 3
Instrumentation Devices
Proximity Sensor

Pt-100

Vibration Control Devices

Programmable Logic Controller
 Chapter 4
Power Plant
 Power Plant

Motors

Safety and Fire Fighting

Safety
Fire Fighting

Hose Reek System

Sprinkler System

Fire Tender System

Emergency Alerts and Precautions

 Chapter 5
Utilities:
Cooling Tower

Water Treatment Plant

Waste Heat Recovery Section

Conclusion and Feedback