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TOPIC:- INDUSTRIAL TRAINING REPORT

SUBMITTED TO :- SUBMITTED BY :-

MR. V.S. GAHARWAR (TECH. HEAD) SUNIL KUMAR PATEL (D111030)


MR. SAMEER GULERIA (PROD. HEAD) TULSIRAM LODHA (D111031)
UJJAWAL LODHA (D111032)
VIKASH KUMAR SHARMA(D111033)
ACKNOWLEDGEMENT
No significant achievement can be solo performance especially.
It took many very special people to enable it and support it. Here I would like to acknowledge their
precious co-operation and express my sincere gratitude to them.

I greatly thanks to my guide Mr. SAMEER GULERIA [(Production Dept.)]


Has been very supportive and helping. It was his support that helped to complete the project, he always
made that we were provided everything we needed.

My sincere thanks to Mr.V.S. GAHARWAR [(Technical Dept.)]


And Prof.P.K.Singh[HOD of Cement Tech.] who are always available for their kind help. Finally I
thank to all the Production, Chemical & mechanical Engg. Dept. who also help me in completing my
project within the time given for project work.

Prof.P.K.Singh M.R.SAMEER GULERIA Mr.V.S.GAHARWAR


(H.O.D. of Cement Tech.) [(Production head)] [(technical head)]
JUET Guna (M.P.) PANIPAT PANIPAT
manufacturing process

. .
v - separator

PRINCIPLE :- Air is forced in a cross current through the shifting

zone, between the deflector and towards a second outlet, for fine

material at the top of the housing. When material enters the

housing through the inlet it tumbles down the shifting zone under

force of gravity.

THE FOLLOWING FACTOR

1. Combination of cross flow and counter flow material and air

2. Fineness control by air flow

3. Cut size from 100µ to 1.5 mm and moisture remove from fress air

4. V-separator installation cost and capital cost is low because of no

moving part
V-SEPARATOR SPECIFICATION

PARTICULARS VALUE

Concept Static pressure


Machine type VS-96-26
Length 8400 mm
Width 3800 mm
Height 10650 mm
Weight 39480 kg
Inlet pressure 11 mmwc
Outlet pressure 20 mmwc
TRUCK TRIPPLER
Equipment NO. 512 T1, T2, T3
Make carter hydraulic
Capacity 60 ton
Modal 60 ton-55°
ROLLER PRESS

PRINCIPLE :- Roller Presses, the grinding pressure is transferred


from the hydraulic system via the movable roll to the material bed
and absorbed in a stable, closed machine frame. A key feature is the
mounting of the rollers in oil lubricated cylindrical roller bearings.
The oil is both, lubricant and cooling agent. Alternatively, grease
lubrication is possible

ADVANTAGE
1. Adjustable to vary output size and less than 50 mm
2. Low operational and maintenance costs
3. Especially beneficial for dry material and No use of water
4. Welded surface is stable and simple
5. Low noises, high production efficiency, even material crushing
and low powder rate
6. Hydraulic loaded relief mechanism provides tramp iron protection

DISADVANTAGE
1. Roller crusher is that it is limited by the roller rotation rate, So
its production capacity is relatively small,
ROLLER PRESS TECHNICAL SPEC.
PARTICULARS VALUE
Machine type RPZ-20-170/180E
RP Speed 1.7 RPM
RP Motor rating 1700*2 Kw
PR Motor speed 991 RPM
RP Motor voltage 6600 volt V
RP Throughput 1120 TPH
RP Roller length 1800 mm
RP Roller dia 1700 mm
Motor Gear Rating 1380 Kw
Auxiliary Drive Speed .3 RPM
BALL MILL (CEMENT MILL)

PRINCIPLE:- Ball mill is horizontally rotating steel cylinder where


grinding is alone due to the humbling action of the grinding media
over the feed material.
ADVANTAGE
1. Can be used dry or wet
2. Operating condition, and grinding in a closed machine, with No
dust flying
3. Reliable operation, grinding cheap, and easy to replace
4. Can be intermittent operation, but also continuous operation
5. Smash explosive materials, the mill can be filled with inert gas
instead of air
DISADVANTAGE
1. Bulky size
2. Running a strong vibrating and noise, there must be a solid
foundation
3. Low efficiency, energy consumption is relatively large
4. Grinding the friction loss and a great body, and will stain
product. Crush the hard materials are widely used materials.
BALL MILL TECHNICAL SPECIFICATION
PARTICULARS VALUE

Machine type BU-MILL 3.4m D *11.5 m L


Mill throughput 215 t/h (OPC),225 t/h (PPC),35% Fly ash
Mill speed 17.5 RPM
Mill motor rating 1700 Kw
Mill motor speed 991 RPM
Mill motor voltage 6600 volt V
Motor Gear rating 1380 Kw
Auxiliary drive speed 0.3 RPM
Make KHD
Mill feeding inlet 350mm*380mm
Main drive type planetary Gear
Movable Bearing size 560 mm(W)*800 mm(L) METAL
Fixed bearing size 560 mm(W)*800 mm(L)METAL
Max. water pressure 6 bar
Water injection volume flow 2.4 m³/h
GEAR BOX TECHNICAL SPECIFICATION

PARTICULARS VALUE

TYPE P25A
Size 35
Design 512/514
Installed power 1700 Kw
Effective power 1425 Kw
Input speed 990 RPM
Output speed 19.22 RPM
Ambient temperature 2-50 °C
Output torque 850000 Nm
Oil quantity 645 L
Oil Viscosity 50 VG 460 PAO-OL (synthetic oil)
SKS separator

SKS:-
Material is fed side ways an a separator disc in the separating chamber.
The spread material is divided into grits fines by a re-circulating a
air current created by in build fan faille on the inner cone and fines get
separated from recirculating air by cyclone action counter fanes with
adjustable length are filter above the separator plate to control fineness
of the fine .The fan separator disc and the counter vanes can be driven
by as ingle drive .

This separator is still preferred for coarse separation


(90µ) due to lower specific power consumption and can be used for
raw material grinding application
STAB KORBE STICHER(SKS) SEPARATOR
PARTICULAS VALUES

Machine type SKS V3750/350 (DYNAMIC SEPARATOR)


Make KHD
Input speed 1500-375 RPM
Output speed 187.65-41.91 RPM
Gear box B2SV12
Motor power 355 KW
Length 8985 mm
Width 7532 mm
Height h1,h2,h3 914 mm, 4430 mm, 7505 mm approx.
Angle of air entry at fan 30°
Lubrication pump 2/5, 7 LPM
BAG HOUSE

PRINCIPLE:-Bag house of a bag filter separates the gas and solid


by means of fabric bags and no. of fabric bags in series as well as
parallel may be used as per the required.

ADVANTAGES:-
1. Very high collection efficiency for particle smaller than10 µm in
diameter.
2. Low pressure drop and simple construction & operation
3. Dry disposal of collection particles
4. Air obtained is very clean & can be reused

DISADVANTAGES:-
1. High maintenance and fabric replace cost
2. High construction costs involved
3. Should be temperature less than 285 °C
4. Problem in handling dust which can corrode or blind the cloth
5. High construction costs involved and Large size of equipment
BAG HOUSE TECHNICAL SPECICATION
PARTICULARS VALUE

Design capacity 480,000 M³/h


Dust load inlet 625 gm./m³
Dust load outlet (wet basis) 30 mg/Nm³
Pressure at inlet BAG (-) 40 mbar
Pressure at inlet fan (-) 60 mbar
Inlet temperature 90-100°C
Gas density 1.293 kg/Nm³
Barometric Pressure 985 mbar
No. of total bags 3440
Bag size(dia*length) 130 mm OD*6040 mm long
Filtration area/Bag 2.4 M³
NO. of Bags in a row 21/22 staggered arrangement
ROTO-PACKER

PRINCIPLE :-Rotary packer machine design rotary fluxo packer


in 1930. The spouts are mounted on the bottom of a cylinder container
rotating on a vertical shaft.
The empty bags are placed manually on
the spouts as they pass in front of the operator fluidized cement flow
into the rotary container, At the bottom of the rotary container,
fluidizing air is added to cement to increased its flow through the
filling spouts into the bags.
“Cement is then transport to packing plant
for packing and dispatch. Automatic Rotary packing machine are
used to pack the cement”
ADVANTAGE :-
1. High weight accuracy by exact material flow dosing
2. Continuous high speed filling with great cleanliness
3. Changeovers between 25 and 50 kg bags
4. Maintenance and operation-friendly
5. Reduced energy consumption and Clean packing process
6. Compact modular construction
ROTO PACKER SPECIFICATION

PARTICULARS VALUES

Make EEL
Direction of rotation clock wise
Type RS-E,55V,R-150
Capacity 120
No. of spout 8
Discharge type Double
Control voltage 220 VAC
Connected load 45.5 KW
Compressed air requirement 64 Nm³/h
Packer inlet air flow 1000 m³/h
De-dusting device 6000 m³/h
Motor drove geared motor,1.5 KW,73 RPM, frame
R47DT90L4,SI Duty, Sew Make
BALL MILL (COAL MILL)

PRINCIPLE OF COAL :- Coal is a black or brown rock that can be


ignited and burned to produce energy in the form of heat. Coal's
chemical makeup is a complex mix of elements that include sulphur,
COAL
carbon, oxygen, hydrogen and nitrogen, as well as small quantities Of
aluminium,
COAL TYPES :- 1. Anthracite,2. Bituminous,3. Sub-Bituminous,4.
Lignite
ADVANTAGE OF BALL MILL
1. Can be used dry or wet
2. Operating condition, and grinding in a closed machine, with
No dust flying
3. Reliable operation, grinding cheap, and easy to replace
4. Smash explosive materials, the mill can be filled with inert gas
instead of air
DISADVANTAGE OF BALL MILL
1. Bulky size and Crush the hard materials are widely used materials
2. Running a strong vibrating and noise, there must be a solid
foundation
3. Low efficiency, energy consumption is relatively large
4. Grinding the friction loss and a great body,
COAL MILL SPECIFICATION
PARTICULARS VALUE
Size 1.75m. dia*7.75m. long
Capacity 4 TPH
Feed size 85% minus 25mm
Product size not more than 16% residue
On Indian sieve no.9
Initial moisture less than 7%
Final moisture not more than 1%
No. of grinding chambers 2
Length of grinding chambers (1) 2354mm, (2) 2354mm,
Length of Drying chambers 2344mm
Size of trunnion 900mm die, *300MM long,
Mill speed 26 RPM
Drive 200HP, 750 RPM, 160 KW
HAG TECHNICAL SPECIFICATION
PARTICULARS VALUE

Heat release 17.5 Mkal/h outlet


0utlet temperature 350-400°C
Ambient temperature 30°C (Min 0°c &Max 50°c)
Main fuel Coal
Calorific value 3800 kcal/kg
Type of burner multichannel
Fuel consumption 4605 kg/h
Initial ignition by pilot burner
Pilot fuel LPG Pressure ignition + oil for
start up firing
Dilution air required 129,712 m³/h
Combustion air required 33,600 m³/h
Total hot air Quantity 163,312 m³/h @400°C
Dry instrument air 5 m³/h
AIR FAN SPECIFICATION

FAN COMBUSTION FAN DILUTION FAN

PARTICULARS VALUES VALUES


Flow 42,000 m³/h 162,140 m³/h
Outlet pressure 480 mmwc 150 mmwc
Operating temperature 45°C 45 °C
Design temperature 70°C 70 °C
Density 1.293 kg/m³ 1.293 kg/m³
Fan speed 1485 RPM 960 RPM
Absorbed power 99 KW 158 KW
Total efficiency 86 % 63%
Fan weight (without motor) 1250 kg 1450 kg
Motor weight 905 kg 1800 kg
Impeller die 1413 mm 1585mm
lab testing

chemical testing Physical testing


1. Cao 1. N .C.
2. SiO2 2. Setting time
3. Al2O3 (a) initial setting time
4. Fe2O3 (b) final setting time
5. MgO 3. soundness
6. Free Cao (a) le – chatelier (b) autoclave
7. IR 4. compressive strength
8. K2O+Na2O (a) 3 days (b) 7 days (c) 28 days
9. Cl 5. Specific gravity
10. SO3 6. Specific surface
11. LOI 7. lime reactivity
8. Drying shrinkage
quality control equipment

FLAME
EQUIPMENT :- PHOTOMETER
1. XRF
2. XRD
3. SPECTRO PHOTOMETER
4. FLAME PHOTOMETER
5. BOMB CALORY METER
6. TURBIDI METERY
7. HEAT OF HYDRATION APPARATUS XRF
8. PARTICAL SIZE ANALYSER
9. CROSS BELT ANALYSER
10. OPTICAL MICRO SCOPE
chemical composition
physical composition
fly ash composition(SILICEOUS)

ORIGIN:-Coal ash swept by flue gases from coal fire boiler in


thermal power plants and collected in ESPs.

Fly ash is rich in silica and alumina and can replace clay or shale in raw
feed largely. Typically the chemical composition of fly ash is similar to
that of clay and shale with more alumina
Fly ash may also be used as an additive to produced PPC up
to 35%.
1. Lime reactivity :- not less than 4.5 Mpa
2. Specific surface area :-not less than 320 m²/kg (for intra-grinding)
gypsum

GYPSUM :- Gypsum is a mineral found in sedimentary rock


formations in a crystalline form known as calcium sulphate
dehydrate and gypsum is decreased the rate of reaction.

FORMULA :- CaSO4.2H2O CaSO4.1½.H2O

TYPE OF GYPSUM:-
1. Mineral gypsum
2. Marine gypsum
3. Chemical gypsum
type of chemical gypsum

(a) PhArmaco chemical gypsum


(b) Phosphatic chemical gypsum
(c) Boro chemical gypsum
(d) Fluro chemical gypsum

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