CEMENT MANUFACTURING PROCESS

TRAINING FROM

P.O. ADITYA NAGAR-326520, MORAK, DISTT. KOTA (RAJ.)

Submitted to: Submitted by:

Mr. Pankaj Jain Sir Rahul Hada
H.O.D. Of Mechanical Mechanical Engg.
Department 15EAJME086
 INTRODUCTION OF BIRLA GROUP

Mangalam Cement Limited was promoted in the year 1978 by the famed
House of Syt B.K. Birla, the most eminent and illustrious industrialist of the
country. It is a professionally managed and well established cement
manufacturing company enjoying the confidence of consumers
because of its superior quality product and excellent customer service.
 PRODUCT OF MANGALAM BIRLA CEMENT
 Portland Pozzolana Cement ( PPC )
This is a special blended cement, produced by inter-grinding higher strength Ordinary Portland Cement
clinker with high quality processed fly ash - based on norms set by the company's R&D division. This
unique, value-added product has hydraulic binding properties not found in ordinary cements.

 43 Grade Cement
This is an Ordinary Portland Cement which surpasses the requirements of IS: 8112 -1989. This is the most
commonly used cement in all constructions including plain and reinforced cement concrete, brick and
stone masonry, floors and plastering. It is also used in the finishing of all types of buildings, bridges,
culverts, roads, water retaining structures, etc.

 53 Grade Cement
This is an Ordinary Portland Cement which surpasses the requirements of IS: 12269-53 Grade. It is
produced from high quality clinker ground with high purity gypsum. It provides high strength and
durability to structures because of its optimum particle size distribution, superior crystalline structure and
balanced phase composition.
BIRLA CEMENT PLANTS IN INDIA
 PROCESS USE IN CEMENT MANUFACTURING
 Raw Material Handling
 Blasting
 Crushing
 Quality Check
 Reject Belt Conveyor
 Circular Pre Blending
 Grinding
 Blending Silo
 Pre Heating
 Calcinations
•  Cooling
 Clinker Storage
 Cement Milling
 Packaging
 Transportation
 RAW MATERIAL HANDLING
Limestone is the basic raw material used in the manufacturing of cement. Good quality
cement grade limestone is abundantly available in mines within the cement factory
premises, which is spread over an area of 400 hectares.
 BLASTING
Limestone is obtained from mines through the process of heavy blasting conducted under
strict supervision and safety precautions. The limestone obtained from mines is of such
superior quality that removes the need to add clay or any other additional raw material
that is generally added during the process of cement manufacturing.
 CRUSHING
The limestone in the form of huge stones is loaded in dumpers and transported to the
Crushers. This machine is use to crush the huge stones into smaller and manageable
chunks that are 20 mm in size.
 QUALITY CHECK
Limestone obtained from the crusher undergoes a rigorous quality check using
Gamma Metrics Machine and Cross Belt Analyzer.
 REJECT BELT CONVEYOR
The engineers at cement plant ensure that unsuitable limestone is dumped using
Reject Belt Conveyor.
 CIRCULAR PRE BLENDING
The engineers at cement plant ensure that only the best quality of limestone is sent to the
Circular Pre Blending.
 GRINDING
Using an accurate weighing mechanism, the material is fed into the Loeschemill / Vertical
Roller Mill. It is a vertical steel mill with huge rollers used for grinding the material.
 BLENDING SILO
Powder form of raw material of different grade is mixed homogeneously in the blending
silo with the help of air slides.
 PRE HEATING
The ground raw material is fed into a six stage pre heater, where it meets the hot gases
rising from the kiln. The pre heating of material before the calcinations stage helps save
energy.
 CALCINATIONS
This is the most critical stage in the cement manufacturing process. The raw material is fed
into the kiln, which is a huge rotating furnace, using coal/pet – coke as fuel, the kiln at
cement factory heats the raw materials to a temp of 1400 degree Celsius, which is almost
one fourth of the mean surface temp of Sun.
 COOLING
Subsequent to the intense heating, the raw material is now sent to a CFG cooler that
brings the temp of the material down to 200 degree Celsius. The sudden cooling of the
material result in the formation of grey colored nodules known as Clinkers.
 CLINKER STORAGE
Clinker, which is pre structured Reinforced Cement Concrete, is now sand to Clinker Silo to
avoid the weathering effects.
 CEMENT MILLING
Clinker and Gypsum are fed to cement mill in definite proportion with the help of weigh
feeder.
 PACKAGING
Cement is packed into HDPE/PP bags with the help of Automatic Electronic Packers.
Supplied by ventomatic, Italy.
 TRANSPORTATION
Before the cement begs leave for the various sites across the country, they pass through
an Electronic Weigh Bridge for final Weight verification.
FLOW CHART DIAGRAM
ROW MATERIAL HANDLING
ROW MATERIAL HANDLING