MANGALAM CEMENT LTD Industrial Visit report
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Concept of Cement
The word ËœCEMENTâ„¢ may be defined as a substance, which can join two or more pieces of same other substance together to form a unit mass. Cement is a fine powder which when mixed with water and allow to set and harder can join different components together to give a strong structure mechanically. Thus cement can be used as founding material for bricks or for founding solid particles of different sizes (rubble masonry ) to form a monolish.
It was about 150 years ago or so that ËœCementâ„¢ as we know and use it today was invented or prepared . Mr Joseph Aspadin of England first of all patented the manufacture of an improvement type of cementations material for construction of buildings in the year 1824 and gave it the name Portland Cement. This was because of the fact that hardened stone from the cement; Joseph Aspadine invented resembled Portland Stone found in England. However some other persons also claimed that they had made similar cement. Each of them adopted a different process of his own. It is however at the end of Nineteenth Centhury that the process of manufacturing Portland Cement was adopted on modern lines as we know it today.
The basic raw material used in the manufacture of Portland cement are limestone and clay both of wihich occur in abundance. In addition, the requirement of the product may need one or more of the corrective materials like laterite, bauxite, iron ore etc. In addition additive are sometime also used to suit specific needs
Portland Cement are made of grinding a mixture of limestone and clay matter burning . the mixture at a very high temperature, cooling the resultant product called Clinker and then grinds the same to an impalpable powder. The essential constituents of Portland cement are lime, slica ,alumina and iron oxide.Some gypsum is also added during the final grinding operation. Usually Portland cement are divided into the following seven classes.
In the hierarchy of organization chart. The Managing Director lays down the companyâ„¢s policies including the quality system and gives direction for managing the companyâ„¢s activities. Managing Director has authorized President for all the activities pertaining to the operation and administration of the plant.
President has overall responsibilities for laying down companyâ„¢s quality objectives; he is also responsible authorized for providing the essential resources and personal for implementation of the quality system He reports to managing director. He is overall inchcharge of all the personnel & HRD activities and also working as factory Manager.
Head . (Tech) is authorized & responsible for guiding and supporting quality systems related activities pertaining to Mechanical, Electrical,Instrumentation and powder generation .
Head (coml. & fin) is overall responsible for marketing companyâ„¢s products through a network of divisional offices and depots. He is authorized and responsible for guiding & supporting the accounting & finance activities
Down below in the hierarchy the functional heads & their functional staff is there to assist Unit Head & to perform the functional activities.
i. Ordinary Portland cement
ii. Moderate heat Portland cement
iii. Rapid hardening cement
iv. Low heat Portland cement
v. Oil well cement
vi. White cement
vii. Sulphate resisting cement
The method of manufacturing of all types of Portland cements is practically the same they vary in chemical composition to impart the desired properties of a particular type.
MANGALAM CEMENT-AT A GLANCE
Mangalam Cement Limited belongs to the B.K. Birla group companies. it is a professionally manage and well-established cement manufacturing company enjoying the confidence of consumers because of its superior quality product and excellent Customer Service.
The Company has added one more feather to its cap by commissioning its state-of-the-art new Cement Plant with German Technology for producing 7 lacs tones per annum at the existing site at Morak, Dist, kota Rajasthan under the name of Neer Shree Cement.
Krupp Polysius, Germany and their counter parts Krupp Industries India. Ltd,have joined hands with Mangalam Cement Ltd, to produce Birla Uttam Premium, 33, 43 & 53 Grade Portland Cement using ultra modern technology with unique features like Vibrating Screen.Stacker Reclaimer. X-Ray Analyzers. Computerized Central Control Room, Vertical Roller Mills & Precalcinator Kiln. Roll Press Electronic Packing with automatic Truck and Wagon Loading Machincs. Now the cement manufacturing capacity is over 1 Million tones per annum.
MANAGALAM MARKETING POLICY
.Stay in Business
.Stay in profitability
.Make our Brand Visible In the Market
.To cater to market Demand
ORGANISATIONAL SET UP OF MAGALAM CEMENT
Location : Morak 6.5 Km from Kota
Year of Incorporation : Mangalam Neer Shree
Commerical Production : Mangalam Neer Shree
Total Project Cost : 400 Crores
Capacity : Mangalam Neer Shree
1200 MT/Day 3000 MT/Day
Man Power : Staff Worker
Brand Name : Birla Uttam
Product Manufactured : OPC 53 Grades
OPC 43 Grades
OPC 33 Grades
Registered Office & Plant : P.O.Aditya Nagar Morak
Distt. Kota (Raj.)
Head Office : 9/1 R.N Mukerjee Road.
Generally speaking crushing denotes the size reduction process that breaks down the material to particle size suitable as feed for the next main stage i.e. grinding. In present day cement manufacturer with due regard to the possibilities of the reduction machineries. Employed crushing is taken to mean reducing the particle size to between 80 mm to 20 mm.
After mining the limestone is comes to crusher section. At first raw materials drops with the help of dumper in limestone hopper. From hopper this material goes to Apron feeder 212AF1 this apron feeder convey the material to Grizzly (212VG1). In this Grizzly two perforate plates are fixed, that called top and bottom grizzly in top grizzly having 100 mm dia holes. From this holes of plates, less than 100 mm material is screen and fall to bottom grizzly. Above 100 mm material will gone to crusher for crushing, in the bottom grizzly plates has 75 mm dia holes. This plate has further screening the material. Above 75 mm sized material is goes to crusher and less than 75 mm material is goes to conveyor belt (212BC1). From Crusher (212CR1) and conveyor belt (212BC1) convey the material to 212BC2 belt. Here one vibrating screen (212VS1)is provided for screening the material. In this vibrating screen two perforated plates are provided top and bottom side. From top plate above 50 mm size material 212BC5 belt and less than 50 mm sized material comes to bottom perforated plate. From bottom perforated plate less than 10 mm sized material goes to rejected belt(212BC4) and above 10 mm material goes to 212BC5 belt. After 212BC5 belt one anther belt 222BC2 convey the material to belt 222BC3 and 222BC3 drop this material to 222BC4. After this material finally goes to stacker belt 222BC5.
Working of crusher(212CR1):-
This crusher is single rotor impact type crusher. It is supplied by Larsen and tubro ltd.has a single rotor driven by DC motor power transmission is through v belts. This motor having 6 nos.blow bars shaped likes on it. Each weighing 550Kg.
(a) In crusher front and rear arms has adjust the crusher gap.
(b) Grinding path:- It fixes on stand. In grinding path 21 bars are fixed with lock. These bars are adjusting the gap of top and bottom grinding path.
The material falls on blow bars, these blow bars are rotating with great speed and it shuttered in to pieces. Again it strikes the crusher wall and is further crushed. It leaves the crusher only when it has been reduced to the required size. The crushed material is then pass to belt conveyor, which takes it to the stacker.
The under size material from the vibrating screen is screened away as reject, if it is wet and muddy as it may clog the vibrating screen and if dry, it is sent to vibrating screen of smaller size which separates very fine clips and dust from the limestone and throws it away as reject.
UNIT NAME: NSC Crusher
EQUIPMENT CRUSHER: Apron Feeder, Grizzly, Impact Arm Crusher, Screen, Screw Conveyor, Discharge Chute, Exhaust Fan, etc.
TECHNICAL DATA FOR CRUSHER
APRON FEEDER Motor rating: 30 KW, 1450 RPM Cage
Equipment: Apron Feeder Induction Motor
Quantity: 1 ho IMPACT ARM CRUSHER
Make: L&T-TENG Make: L&T
Modal: T50 Crusher Modal: APEM 1622
Max. Denise Capacity:660 TPH Capacity: 500 TPH
Inclination of conveyor: 20 Degree ROTOR DETAILS
Material: Lime Stone Dia X Width: 1600 mm X 2250 mm
Location of conveyor: Blow Hopper Peripheral speed: 32 m/sec
Max. Height of fall: 6000 mm Motor Speed: 1000 RPM
Bulk Density: 1.4T/H^3 Type of blow bar: Cont (S-type)
Fan width inside skirt brooded: 1700mm No. of blow bar: 6
Material layer height: 814 mm DOUBLE VIBRATION SCREEN
Duck Speed: 45 KW, 150 RPM, Direct Make: Radiant
Control Motor Size: 1524 mm X 14876 mm
Vibrating Grizzly Screen Feed Rate: top- 60 mm bottom 15 mm
Size 1828 mm X 4876 mm Indication: 15^o
Make: L&T Motor rating: 15 KW, 1450 RPM
(Cage Induction Motor)
Feed Rate: 660 TPH
Duck Opening: Top 200 mm
Bottom: 220 mm
3. STACKER RECLAIMER AND RAW MILL HOPPER
The Intermediate storage of raw materials between the quarry and the raw mill has traditionally formed a stockpile from which a steady of material for processing in the cement works has been maintained. In addition, it has in recent years become increasingly important for the purpose of pre blending of crushed stone. Over the years, a large number of system and machine have been developed and form these have evolved certain typed of blending bed, which will be described here.
These material stockpiles are used both for storing and also for prehomogenization of the material to be stocked. The material stockpile of one pile can be reclaimed while the other stockpile is stocked.
The crushed limestone, from the crushing unit is transported to stacker section by means of belt conveyor (222BC5) and reach to boom of stacker. Boom belt (222BC6) is a drop this material on ground, on its side and make a pile. These pile length is 105 mtr. and width is 35 mtr. Stacker moving to and for continuously on a rail track. Stacker has a controlled relay drum (CRD) which supplying the power to stacker. It has a loop car, connected with bogie by a pin. Loop car has a taper portion, material falls on this taper portion, which comes from 222BC5, and finally it falls on ground like straight line by the help of boom belt and makes pile. The work of stacker is to make pile.
Reclaiming of the blending bed stockpiles is carried by means of a movable reclaimer, system disc cutter. The material is reclaimed from the stockpile by the forward movement of the scrapper-traveled gears, connected with the reversible rake car on the scraper bridge. The rake are mounted to the take car and the material discharged by the scraper chain drive.
By this method of the reclaimer, it can also be employed in the cased of in-homogeneous material without any disadvantage in material processing.
Reclaimer is also supplied by CIMMCO its capacity of 350 TPH and having 135 buckets. This reclaimer is moving steady and slowly in the direction of pile. By the help of buckets, reclaimer reclaims the limestone from stockpile to raw mill hopper through belt (232BC2). Reclaimer has a harrow, whose function is loose the material from the stockpile. This harrow is fixed on rack car with the help of harrow teeth material coming down with loose position. Harrow is having speed is 10 mtr/ minute.
UNIT NAME:- RECLAIMER
EQUIPMENT RECLAIMER: Bogie, Power, CRD, Control, CRD Harrow, Rack Car. Bucket, etc.
TECHNICAL DATA FOR RECLAIMER
RECLAIMER RACK CAR
Reclaiming rate: 350 TPH Squirrel Cage Port
Rail span: 31.5 m Make: Bharat Bijlee
No. of driven wheels: 2 Type: SC
Wheel dia: 630 mm Power: 15 KW
Effective rail head width required:80 mm Nominal speed: 1500 V/Hz
C/C distance of scrapper chain: 33 m Type: Electro hydraulic
Scrapper blade Brake Clink dia: 200X 85 mm
Width: 1100 mm Scrapper Chain
Height: 300 mm Single cage motor
Pitch of chain: 250 mm Make: Siemens
Speed of chain scrapper Type: Squirrel Cage
Conveyor: 0.45 m/sec. Max. Power: 55KW
Rack Travel: 14.5 m/min. Nominal speed: 1800 RPM
Chain drive: 55 KW Nominal voltage: 415/50
Travel drive: Reclaim 2 X 0.1 KW
Fast: 2 X 5.5 KW
Rack Drive: 1 X 15 KW
UNIT NAME:- STACKER
EQUIPMENT STACKER:- Boom Belt, CRD, Bogie, Loop car, etc.
TACHNICAL DATA FOR STACKER
STACKER LOOP CAR
Stacking rate: 600 TPH Make: Electrozardo
Boom Length: 19.5 m Type Dwg No.EZ-764/2
Track Gauge: 4.0 mtr Dimension: Dia 3400mm
No. of wheels:4 Width: 52mm
No.of driven wheels:2 Torque rating: 4.5 n-m
Wheel dia: 630 mm Nominal votage: 415V apron
Effective roll hand: 80 mm Conveying data: 600 TPH (rated)
Belt e/c distance for boom:21.5 m Belt width:1000 mm
Belt width 1000 mm Belt spreed :1.65 m/see Approx
Belt quality: 315/3 nylon or ESP STACKER BOOM
Belt Cover thickness:5 & 2 mm Squirrel eage motor
Top and Bottom Make: Bharat Bijlee
Belt Speed: 1.75 m/see.Max. Type: SC(as per motor)
Belt through: 30 deg Power:36 KW
Travel Speed: 1.5.0 m/see Nominal speed: 1500 RPM
Belt drive: 30 KW Voltage: 415/50
Travel drives: 2 X 75 KW Double shoe break: s
Make Techno Cars Type: Electro hydraulic
Brake drum die:300 mmf
RAW MILL HOPPER
Transporation of raw material from one place to their respective storage hopper is also done with the help of belt conveyor. The hopper are made of concrete having pin gates and weigh feeders at lower side. They are also equipped with load cell and gamma ray instruments to defect quantity of material of hopper.
The material comes through reclaimer by the help of belt conveyor (232BC2) and goes to raw mill hopper High Grade Lime Stone,Bauxite and Blue Dust are transported to respected feed hopper. In this section we have 4 nos. hopper as mentioned below.
1. Morak limestone hopper : -
Morak Limestone is coneyed from reclaimer to feed hopper with the help of belt conveyor (232BC2).
2 & 3 Blue Dust and Bauxite Hopper : -
From the same dump hopper, blue dust and bauxite are conveyed to Raw Mill Hopper with the help of belt conveyor (232BC7). On this belt one Jaw Crusher (232JCI) is fixed which reduce the material to required size. From Jaw Crusher, material falls on belt (232BC6) & belt(232BC7) and then material is dropped to another belt conveyor 232BC8. After 232BC8, one reversible belt 232BC9 is fixed on upper side of hopper. When this belt conveyor moves in reverse direction the blue dust goes in blue dust hopper, and when this belt moves in forward direction bauxite moves in bauxite hopper.
High Grade Lime Stone (HGLS) hopper:-
From HGLS dump hopper material comes to belt conveyor 232BC5. The material is dropped to BC7 and then to BC8 belt. On discharge of belt 232BC8, one ËœYâ„¢ discharge chute is provided which diverts the HGLS to different hopper. These raw mill hoppers arehaving four different weigh feeders, which fixed on the lower side of various hopper. With the help of weigh feeder and belt conveyor, the material is dropped on a belt 312BC1 in a required composition. The material goes to vertical raw mill with the help of belt conveyor 312BC2 & 312BC3. On the belt conveyor (312BC2 & BC), two magnetic separator (312MS1 & MS2) are also provided, which separate the metal parts from feed material. These weigh feeders have load cell, which show the weight of material. Weigh feeder has limit switches which gives the indication Central Control Room (CCR) for proper running. For controlling the speed of belt it has reducer.
NSC RAW MILL HOPPER
UNIT NAME: NSC RAW MILL HOPPER
EQUIPMENT RAW MILL HOPPER: Weight Feeder,Chute, Load Cell, Reducer, Stroage Hopper etc.
TECHNICAL DATA FOR RAW MILL HOPPER
Weigh feeder Belt: Equipment: weigh feeder Length: 1000 mm
Oil Quantity:5 ltr. Feed hopper
Fr. Of change in two year IN RCC CONSTRUCTION
Gear Box Stroage Capacity: 500T,200 T&100 T
Make Red Icon Material Stored: Low Grade lime,
High Grade Lime Stone & Laterite
Size: A337 Feed Hopper in Steel Construction
Ratio: 60:1 Storage Capacity:100 T &100 T
REDUCER Scrapper Chain
Make: Gyrox Material Storage Bauxite &
5. VERTICAL RAW MILL
RAW MIX GRINDING, BLENDING AND STORAGE
By Grinding is understood the communting of materials to a powder. The purpose of the preparatory processing of raw materials is to convert these chemically and miner logically different materials, usually supplied to the plant in coars lumps into raw mill or slurry of homogenous composition. Reducing the raw materials to a fine powder conventionally meal is necessary in order to prepare a homogenous mixture which will quickly be converting in the Klin into a homogenous clinker containing no free lime. The crushed product is further reduced by grinding to a fineness reduced by grinding to a fineness below about 0.2 mm size, in which condition it is called raw meal and is read for feeding to klin
VERTICAL RAW MILL (VRM)
The Krupp Polysius Roller Mills belong to the category of Vertical Mill and are particularly suitably for the grinding of medium-hard to soft minerals but may yet be used for grinding comparatively hard substances. This roller mill is ideally suited for combined grinding and drying.
The conveyor belt (312Bc3) conveying the raw mix to VRM. On this belt (312BC3) equipped with magnetic separator and metal detector just before the VRM. Magnetic separator consists a permanent magnet hanging over the belt and facing the raw materials. The belt moves on two pulleys around the magnet the belt has angle plate, which pushes the iron pieces and magnet pick it up those pieces and transfer away by a chute. Metal detector detects the presence of any metal, which is not separated by magnetic separator. It function automatically and belt gets stopped. The chute damper changed automatically and the inlet of VRM is closed. Belt gets started and the material with metal piece move out with it, belts stop again. The damer changes and opens to VRM belt again started and continuous to feed Raw Mix. This thing avoids any damage to the rollers and mill parts.
The material to be ground is feed to the roller mill and its falls directly on to centre of the grinding bowl and for conversion it carried under the rollers by the rotation of the bowl. By the centrifugal force the crushed material is flung outwards over the edge of grinding the grinding bowl and entered in the stream to the dynamic separator located above the grinding chamber.part of the materials to be ground is feed via a bucket elevator to the separator or the feed chute.
The Separator classifies the material entered in the gas stream into finalized product and oversized. The oversized material falls back on to the center of grinding bowl , while the finished product is carried by the gas stream to the ESP where it is precipitated.
In this mill two roller parts run on a rotating grinding bowl. The principle of the two twin roller units leads to a lower speed differential between the rollers and the grinding bowl. This cut down the spillage material between rollers and the grinding
bowl and their by minimizes wear. Water is sprayed inside mill to maintain a bed of ground raw mix on the table and to avoid much friction and abrasion. The hot air coming from the gas- conditioning tower. At the top vertically suspended air separator maintains suction lift fines and leaves coarse.
The roller are very heavy and lined with high chrome steel plates. Theys are supported on nitrogen charge cylinder acting as a stock absorber; nitrogen is used because of its mertness and heavy nature etc.
The ESP fans RPM maintained to proper draught in the roller mill. Exhaust gases coming out from the fith stage cyclone of suspension preheated are made to pass through gas conditioning tower where the fine particles of Klin feed are scrubbed with water. The temperature of the exhaust gas is lowered from 325 to 250 C app.
The draught in the VRM is app. 570mm WG. The scrubbed material is transported to the blending silo by means of a flow conveyor and bucked elevator. One another standby conveying system (Aero-pole) is also provided.
NSC VERTICAL RAW MILL ( RRM)
UNIT NAME : VERTICAL RAW MILLE
TECHNICAL DATA FOR VRM
VERTICAL RAW MILL. Water Spray System
For Raw Material Drying And Grinding Max.Throughput: 7500L/H
Capacity: 175 TPH Max.Pressure:10 bar
Size of mill: RM46/23 Motor rating for centrifugal
Pump: 5.5 KW, 2900 RPM
Dia of grinding bowl: 4600 mm
Roller dia: 2300 mm Bearing Protection Air Supply
Type of gear box: Planetary KMP-560 Volume: 900 Cu. M /h
Power of input to box: 1910 KW Max. Static pressure: 60 M bar
Speed of table: 25.4 RPM Outlet damper: Manually operate
Power of main motor: 2300 KW Motor rating: 3.7 KW, 2880RPM
Speed of main motor: 990 RPM
Type of coupling (output) overrunning clutch
VERTICAL BUCKET ELEVATOR
Feed material: re-cycled material
Feed size max.-0-10 mm max.
Moisture contents -8% max.
Through put: 380 TPH
Bucket width: 1250 mm
Shaft centers :30 m
Elevating speed: 1.22m/ sec.
GRAVEL GATE VALVE (HEATED)
Material handled: mixed limestone
Moisturcontent: 8% max
Through put: 230 TPH
Internal dia of valve: 1250 mm
Internal length of valve:1250
Gearbox rating: 11 KW
Gearbox ratio: 178.87
Motor rating: 11KW, 1450 RPM
Bulk density: 1.4-1.6 T/Cu.m.
The table is rotated by an electric motor with the help of a gearbox
Power of drive 1,910 KW Feed size 75+- mm
Output Capacity 175 TPH Type Ram 46/23/345
Input RPM 990 Output Ram 25.4
Gear Ratio 38.8 Gearbox KMP 560
Roller dia 2,300 mm Table dia 4,500 mm
6RCALCINATION, BURNING AND KILN FEED
It was recognized quite early that the heat liberated in the rotary kiln can,besides used for the actual processing feed material,advantageously be utilized for preheating the material.
The Pre-calcination principle and its applications have been developed more particulary in japan and Europe. A feature which all pre-calcinations system have in common is that the supply of fuel is divided between two firing units i.e. two burners pipe or sets of burners, one is in the kiln and other in the suspension pre-heater.
Process:-Every Cyclone stage basically performs the following two funcations:-
- It heats up the raw meal in the gas stream.
- It separates the raw meal and discharged it via the meal chute.
The ËœAâ„¢ type cyclone is fed from above the exit gas containing raw meal when leaving the calciner flows via the calciner bend to the cyclone. In the cyclone the raw meal is separated and passed on by the meal chute to the Kiln inlet.the exit gas flows through the dip pipe and the intermediate piece into the next higher gas duct.
The ËœBâ„¢ type cyclone is fed from the blow. The raw meal fed into the gas duct is conveyed into the cyclone by exhaust gas. In this cyclone the raw mill is separated and passes through the meal chute.
The Pre-heater is five-stage suspension type pre-heater. The Kiln feed material with air reaches to the top of silo may be diverted to the silo. It enters into the output gas stream, from cyclone no. 4. The hot gas stream from cyclone no.5A and 5B simultaneously efficient heat exchange takes place between the raw material and hot gas than the are separated in the twin cyclones.
Gas makes it way to GCT through the pre-heater fan and the raw meal passes down to enter outlet gas steam of the cyclone no.3 is lifted by it and enters cyclone no.4. Swirl in it exchanging heat and separates from air. The air passes up and material passes down to exit gas stream of cyclone no.2. The same process is followed. The gas enters in cycione no.3 heat exchange takes place material is pass down to the exit gas stream of cyclone no.1, material is lifted to cyclone no.2. The gas passes up and the preheated Kiln feed material enters pre-calciner from cyclone.
In this system of preheating. Exit gases of kiln are used to heat up the kiln feed. In this manner lot of heat energy is utilized in preheating. The temperature of kiln feed is maintained step by whenits move down. The top cyclones are high efficiency cyclones, so that no material leaves the pre-heater.
The rotary kiln is designed for the burning of pulvernulent, small size or sludgy feed material .
For this purpose the kiln hood at the outlet of the rotsry kiln accommodating a special rotary kiln burner. The hot secondary air coming from the down stream cooler and entering the rotary kiln hood is mixed with the primary air of the primary air of the rotary kiln burner and passed through the rotary kiln in counter flow to the feed material.
The inclination and rotation of the rotary kiln make the feed material fed in at the kiln inlet flow towards the outlet. The down stream kiln hood serves as an air seal and as a connection to the cooler.
For the protection of the rotary kiln shell and the attached parts a well as far the prevention of incisive heat losses, the rotary kiln is provided with a special refractory lining which is adjusted to the requirements of the individual zones.
The fed material enters the rotary kiln through the inlet housing. The inclination and rotation of the kiln cause the material to move in counter flow to the hot gas towards the outlet and from there into cooler. In this process through the following reaction zones:-
Clinker zing zone
The presence and the length of these zones are mainly depending on the composition of material to be burned, the pre-heater and the downstream cooler system. Diameter and the length of the rotary kiln depend on the desired through output and are considerable influenced by the chosen pre-heater and cooling system. The quality of refractory lining of the rotary kiln pipe is adjusted to the length of the reaction and temperature zone and it specially determined for every individual plant.
The heat quantity required for the different reaction stages is generated by the rotary kiln burner at the rotary kiln outlet. The combustion air required is high temperature secondary air coming from the cooler. The hot gases flow through the rotary kiln and reach the inlet housing via the rotary kiln inlet. The heat is transmitted to the feed material by the contact between hot gas and material and by its contact with the refractory brick lining. In the kiln temperature not more than 1000-1200 deg.c. The kiln is supported on four rollers. At the place of contact between kiln and rollers,there are two tiers of the kiln.
The hot cement clinker discharged from the kiln is further treated in clinker cooler. What all types of cooler have is common is that the cooling air flows directly-in counter current or cross-current-through the clinker and that some or the heated air from the cooler is fed as combustion air to the kiln.
The reciprocating grate cooler serves for the cooling of small sized or granulated burned material. An excellent cooling effect is achieved in that cold air is blown through the cooler grate and through the burned material lying on grate.
The burnt material discharge from the kiln falls through the inlet shaft of the cooler on the entry to the grate. Due to special design of grate entry the material to be cooled forms a uniform bed. Over stationary and moveable grate plateâ„¢s rows the burned material is transported by the forward feed movement of the moveable grate plates rows to the end of the cooler.
The oscillating frame with the moveable grate plates rows is driven on both sides, the number of the strokes per minute is infinitely variable.
The cooling air is generated by several fans. Normally one fan is allocated to each air chamber, thereby providing a targeted aeration of the grate and the material to be cooled.
The heated up cooling air is captured in the upper section of the cooler is available for further use as a secondary air for the kiln or as tertiaryair. The great riddling is reclaimed from collecting hoppers installed under the air chambers which are equipped with dust tight discharge elements. The discharge elements are compulsory controlled. They provie a ceiling against the over pressure in the air chamber and permit a batch wise reclaiming of the grate ridding. Thse are finally return to cooled material down stream of the clinker pressure using a material handling facility.
On leaving the reciprocating grate, the coled material is screened and the oversized particles are fed to the crusher using a grate bar chute. The crusher throws the crushed material partly back onto the reciprocating grate.
The bearing and lubrication points of the cooler are supplied with grease by the automatically working centre lubrication system. The outlet openings of the running axles in the lower housing walls are incased with sealing air housings. These have an over pressure towards the inside cooler area and protect the bearing arrangement of the axles against dust and overheating.
The reciprocating grate cooler is equipped with an automatic control system. Proceeding from the pressure of the first or second air chamber of the first grate, the reciprocating of the cooling grates is controlled. Under the grate cooler, there are deep bucket conveyors. Which collect clinker from the cooler and transfer to clinker stockpile. Dust collectors are provided top of the stockpile to avoid air pollution. There is one ESP also installed which can separated the dust and air. Air is sending in to atmosphere and dust particles are transported to clinker stockpile by help of flow conveyor and deep bucket conveyor.
STORAGE:- The clinker stockpile is covered with shade to protect clinker from Bin. The CSP has 14 feed hopper are called ËœZero Hopperâ„¢ in which material is fed with the help of Pay loader.
UNIT NAME: NSC KILN
EQUIPMENT: GCT, ESP, Clinker, Tertiary air duct, Cooler, Pre-heater, Cyclones etc.
TECHNICAL DATA FOR KILN
NSC ROTARY KILN GEARTH GEAR/PINION ASSEMBLY
Size: 4 MTR Dia X60 M TR. Length No. of teeth for pinion:25
Slop:3.5%RPM : 3 max. No. of teeth for girth gear: 160
Slop: 3.5% RPM: 3 max. Pinion width: 490 mm
Power: 330 KW, DC Drive girth gear width: 440 mm
Gearbox: SDN 710 (EMG-make) module: 36
Output: 2000 TPD
CAPACITY OF KILN FLOW CONVEYOR
Feed: 120 TPH Max. power of Drive: 3.7, RPM : 13.5
Type of kiln material-input to output 15 Capacity: 35 TPH
to 20 min. Speed: 20/ min.
PREHEATER FAN GCT SCREW CONVEYOR
Capacity: 128 m^3/ sec. Capacity:30 TPH
Power of drive: 1250 KW Gear box : U 1200 radicand
RPM: 1000 Ration: 70:1
Bearing Housing: BRG no.2233611 Oil type: SP320
Oil used: 1 Sq 150 (Sp-150)
Quantity: 10 litre DEEP BUCKET CONVYOR
TERTIARY AIR DUST Material Conveyed: Cliner
Duct Size: 1740 mm Capacity: 84T/H normal, 175 T/H max.
No. of throttle flaps: 1 Bulk Density: 1.3 T/Cu.m
Size of flaps: 4740 mm Lump Size: 0.50 mm
Actuator output torque to throttle: Flap Conveying Speed: 0.249 m/sec.
Width of deep buckets: 630 mm
Inclination of Conveyor: Horizontal
Speed of Drive unit: 3.62 RPM
Shaft Centers :25 m Approx.
CLINKER CRUSHER ELECTRO STATIC PRECIPTATOR
Dia of hammer: 1450 mm Gas before ESP :112 Cu. M/sec.
Circle: 3090 mm Referring to: 250 deg/C.
No. hammer: 30 Dust load at inlet: 20 gms/cu.sp.
Drive transmission: V belt Clean gas dust content: 150 mg/n.cu.m
MECHANICAL COOLER DRIVE GATE-1
Torque to be transmitted: N-M
Drive Stroke :120 mm
Gear box transmission ratio:28.1
Power of motor:110 kW
Speed of motor:240-1450 RPM variable
VERTICAL COAL MILL VERTICAL COAL MILL AND COAL TRANSPOARTION
Introduction and process:
In order to prevent any foreign matter from entering the roller mill, each of the belt conveyors upstream of the coal crushing system and upstream of the coal storage bin is equipped with a magnetic separator located above the belt and metal detector. The magnetic separator arranged above the belt continuously removed magnetic tramp material from the coal. The metal detector signalizes the presence of non-magnetic metal pieces in the feed materials.
From the storage bin that is carried in a load cell bearing the coal is enter acted in proportional quantities by a table feeder equipped with a variable speed drive.
The feed material to the ground is feed to the roller â€œmill through a suitable air lock. The material falls on to the grinding bowl and is carried under the grinding rollers by the rotation of the bowl. A grinding feed is formed by the dual grooved bowl and vertically adjustable dam rings. The ground material is then flung outer wards over the edge of grinding bowls, entered in the stream of air flowing through the nozzle rings and is carried to the sea-pool dynamic separator located directly above the grinding chamber. There the oversized particles are separated from the finished product. Changing the rotor case speed can very the fineness of the finished product. The oversized material falls back on to the center of the grinding bowl, which the finished product is carried to the separator (filter) by the air stream.
Material dropping through the nozzle ring is routed to the trap material trap by meal of the separator. In normal mill operation, this reject material is undesirable. In case of operating abnormalities such as an emergency shutdown of the grinding system however. Coal can also drop through the nozzle ring.
A duct between the trap and the upper mill housing can pick up the dropped coal and recycle it to the grinding process.
The grinding is performed by four grinding rollers set in pairs and a grinding bowl, which is rotated by a special gear unit (combined spur and bevel gear or planctary bevel unit).During the grinding process the material is caused to form a so called bed between the grinding roller and grinding bowl.
Each grinding roller has its own antifriction bearing and is mounted on an axle, which in turn is fixed in the roller carrier. The roller pairs are positioned by pins aligned in housing brackets, which permit vertical motion and pivoting along the horizontal axis. Thus, they can self-adjust to changes in the grinding bed depth so that always the grinding surface of the roller remains fully effective.
It the inner grinding roller is raised by coarse feed material, then the outer roller of this pair correspondingly presses down with more force on the material. The free motion of the roller pairs and the resulting good adaptability to the bed ensure a low-vibration running of the roller mill.
The finished material separated in the filler is to the finished product transport system.
This plant is an air- swept grinding system, i.e. the ground material is carried out of the roller mill by constant air stream and transported to the separator (filter) via the SEPOLE dynamic separator. The carrier stream is produced by the air circulating fan which is arranged downstream of the separator. Downstream of the air circulating fan the gas stream is divided into exhaust air flow and recirculation flow (return gas ). The exhaust airflow is delivered to the exhaust air stack.
This moist coal is also dried at the same time as being ground. The hot gas required for drying is supplied by the rotary kiln and degusted in an electrostatic precipitator. The degusted hot gas flow is mixed with the circulating flow (return gas ) diverted downstream of the air circulating fan and is then through the grindind system via the nozzle ring.
As the carrier air stream is constant, the re-circulating flow (return gas) and the exhaust airflow are variable functions of the respective coal moisture. At a maximum coal moisture level the hot gas flow and the exhausted airflow are large and the re-circulating flow is small possibly even zero.
If the coal moisture level decreases, the gas flow proportions are changed to the reverse.
In our plant, from coal yard coal is transferred to coal intake hopper. From coal intake hopper coal is transferred to a belt conveyor by a reciprocating feeder. Belt conveyor drops this material to vibrating screen, which by passes the undersize and oversize in an impact crusher and transferred to raw coal bunk. Finished ground coal from vertical coal mill transferred to storage silo. In this process required hot gases received from pre-heater fan through. ESP and having temperature of 225 deg.c (approx.). The fine particles lifted away by the hot air and pass through the explosive vent and are taken into bag house.
The explosive vent is preventing any damage to the damage to the plant in case of any coal fire and explosion. There are three aero-poles, two of which are working and one is standby. Co<2 inebriation is also available here to prevent fire.
NSC COAL MILL
UNIT NAME:- NSC COAL MILL
EQUIPMENT:- Table Feeder. Motor, Gear Box, Reducer, Coal Mill Fan, Grinding Bowl, Roller and Belt Conveyors etc.
TECHNICAL DATA FOR COAL MILL
VERTICAL COAL MILL VERTICAL COAL MILL MOTOR
Type: RMK 23/11/95 Polysius Type: DC Induction Motor
Power Drive: 390 KW Frame: KHOC 2OO LN
Output Capacity: 18 TPH Power: 30 KW
Type of gear box: KMP-280 (Flender) RPM: 1000
Input RPM: 990 voltage: 460
Output RPM: 35.44
COAL MILL FAN VERTICAL COAL MILL TABLE FEEDER
Power of Drive: 450 KW Capacity: 50 TPH
RPM: 1000 Power of drive: 5.5 KW DC Drive
Gear Box: KMP-280 (Flender) RPM:32 to 320 output
Power of drive: 390 KW Type of oil: SP-460
Input RPM:280 (Flender) Oil quantity:95 ltre.
Voltage: 390 coupling type F-flute fai 90
Oil No. Servo mesh SP-320 VERTICAL COAL MILL REDUCER
Ratio : 60:l
8. CEMENT MILL
By grinding is understood comminuting of materials to a powder. The clinker discharge from the kiln has to be ground to a fine powder which with the admixture of some gypsum is the finished product of the whole process Cement. This final clinker grinding operation is often suffered to as finish grinding. This final clinker grinding is, more particularly, to increase the specific surface of the material-which conforming to a desired particle size distribution- to such an extend as to obtain adequate reactivity in the finished product (the cement) itself. The single compartment tube mill is a ball mill. The material to be ground is passed through is passed through the grinding compartment and mechanically discharge through a discharge lifter diaphragm.
The material to be ground is fed through the inlet device directly into the grinding compartment of the single compartment tube mill. The grinding is effected by a special mill lining and the grinding media.
The special mill lining ensures that the ball charge becomes finer towards the mill outer. The ground material is discharge from the mill through the discharge lifter diaphragm via the discharge device. The air swept through the mill system serves to the draw of the heat generated in the grinding process and to support the material flow.
The water injection also draws off such heat wearing parts can be taken into the tube mill through the manholes. Any required inspection of the grinding compartments is also performed through the main holes. From clinker stockpile clinker is transported to clinker hopper at Poly-com feed hopper by the help of belt conveyor and same manner gypsum is also conveyed to gypsum hopper from gypsum hopper from gypsum yard after crushing and screening. Clinker and gypsum hopper are equipped with weigh feeder. Which are transfer clinker and gypsum in required proportion ratio to roller press with the help of belt conveyor for initial grinding? These belt conveyor are equipped with magnetic separator and metal detector to separate any metal piece. A bypass belt is there, which may takes this material to poly-com or as reject depending on choice. In the Air separator the material is drop from the top. The rotated fan produced centrifugal force produced on the material which distributes it even way to in between a stationary case and rotating vans, the fan suck the air with the particles inside separator and then transported to multi cyclone. In multi cyclones fine particles are separated. The fine material is transported to bin by air slides and coarse material is recycled to Poly-com. The fine material is transported to cement storage silo and coarse material to cement mill. ESP is also provided here which separated fine dust from air and passes them to aero-pole or bucket elevator. The cement is transported to cement silo. There are two cement silos. The cement is transported either silo depending on its grade by means of P.G.Conveyor.
NSC CEMENT MILL
UNIT NAME:- NSC CEMENT MILL
Com, Rolling Mill, Gear box Vertical, Bucket Elevator, Cement Mill Silo, ESP and Screw Conveyors etc.
TECHNICAL DATA FOR CEMENT MILL
HIGH PRESSURE GRINDING ROLL COMBINED PRECISION BEVEL AND (POLYCOM) SPUR GEAR BOX
Size:17/8/10 Max:output:92 KW
Dia of roll:1700 mm Transmission ratio: 80%
Roll width: 1000 mm Power of motor: 110 KW
Through put: 650T/H Speed motor: 1450 RPM
Roll speed: 1.6 m/sec.
Compressed air: 1 Cu.m/h, 6.8 bar MAGNETIC SEPARATOR (FOR
SEPRATING STRAY IRON FROM
Suitable for belt width: 1200 mm
Input power:1260 KW Operating high: 250 mm from belt surface
Type of drive motor:AC slip ring Magnet type: permanent magnet
Drive motor rating : 2 X 50 KW
Drive motor speed: 980 RPM
Reduction ratio: 54: 44: 1
WATER SUPPLY SYSTEM OF MILL
Max. through output ; 3000 L/H
Capacity: 115 TPH Max. pressure: 10 bar
Mill dia: 3.8 m Blower for water spray: 6 Cu.m. / min.
Mill length: 10.65 m Motor rating: 3.7 KW. 2880 rpm
No. of chamber: single
Type of mill: Close Circuit
Make: Polysius Material: Filter Dust
Type of bearing side shoe bearing % of Bulk density: 0.6 T/Cu.m.
grinding media: 35%
Slide shoe oil: Servo mesh SP 220 capacity: 2.0 T/H
VERTICAL BUCKET ELEVATOR ELECTROSTATIC PRECIPITATOR
Feed Material: Clinker flakes Amount of dust laden air:31000 Cu.m/h
Feed size max.: 32-35 mm Tem: 95-105 deg.
Moisture content: 1% Dust load at inlet: 700-800 gm/Cu.m.
Throughput: 725 T/H Dust load at outlet: 100 mgm/n Cu.m.
Bucket width: 1400 mm
CEMENT MILL SILO
Elevating speed: 1.25 m/sec Capacity: 5000 Cu.m.
Shaft centers: 30 m Internal dia: 24 m
Filling height: 36 m
Overall height: 38 m
9. PACKING PLANT
What type of packaging is chosen for the dispatch of cement will depend on local circumstance and on the most favorable transport facilities available Road, Rail or Water (Ship or Barge).
In principal, there are three possibilities packing in sacks or bags, dispatch in bulk and ËœBig Big. Packing Plant is the important part of Cement Industry. NSC plant, two sources are used to send the cement on a particular place.
1. Truck loading:- In this process the cement bags are transported by Truck/Trolla.
2. Wagon Loading:- In this process the cement bags are transported by Railway wagon rakes from works to required place.
For above those transportation system there is separator wagon and truck loading machines are available.
From cement storage silos the material comes to weigh bin and goes to bucket elevator by the help of rotary air lock and P.G. Conveyor. From bucket elevator material comes to vibrating screen. Vibrating screen-screen the fines and send to hoppers and remaining coarse material is called reject material. From hopper this fine material goes to electronic packer by the help of rotary air lock. On where by the electro process, cement packs in bags. This packer is six spout packers. Electronic packer machine has load cell which fills only 50 kg. cement in every bag. The cement bags are transferred to the belt conveyor, which takes these bags to telescopic conveyor. Telescopic conveyor has option to load the bags in trucks end or load to railway wagon. Loading is done by telescopic conveyor operator by a loader. After loading the bags are counted and dispatched. Dust collectors are also provided where is needed to clean the atmosphere.
NSC PACKING PLANT
UNIT NAME:- NSC PACKING PLANT
EQUIPMENT:- Bucket Elevator, Screw Conveyors, vibrating Screen Bag Filter ,Hopper, Packing Machine and belt Conveyor etc.
TECHNICAL DATA FOR PACKING PLANT
BUCKET ELEVATOR ELECTIONIC PACKER
Capacity: 125 TPH Type: 6 RS-6 SPOUT
No. of buckets:110 capacity: 90 TPH- 1800 Bags/h
No.of U links: 220 Com. Air required-5 bar,5kg/Cm<2
No.of chain: 220 Circuit voltage:220 V
Gear box: FMG makes SPN:250 Sense of rotation clockwise & anticlockwise
Solenoid valve: 24 DC
Output RPM: 27.02
Capacity: 40 litre
TRUCK LOADING MACHINE
Top drum bearing:22222CK Machine: Truck Loader
Bottom drum bearing: 1219KSH:219 Model: TLM-1020
Inlet coupling RWN: 144/FMG Conveying material: Cement bags of
Output coupling RWN: 500/FMG
Bag size: 650Lg X 450 width X
150thick Conveyor belt speed:10252
Size :400 pitch Gross weight: 6.5 T
Motor : 37 KW, RPM: 1430 Hoist capacity:5.0 T
Gear box: Radicon U-600 Lifing speed: 0.1 m/sec
Ratio:60:11 Lateral speed of feed conveyor: 0.13m/sec
VIBRATING SCREEN WAGON LOADING MACHINE
Make: Enexco Engg (P) Ltd Equipment wagon loading machine model:B-
Size: 1000X2500mm Material handled :Cement bags of 50 Kg
Grease:EP2 Filled Bags size:650 Lg X450 width X150
Motor: 3.7 KW, RPM: 1400 Capacity: 1800,Bag speed : 1025 m/sec
Wire mesh jail: 5X5 mm(Sq.) Travel speed: 1025 /sec.
Travel length : 100m
Rubber belt: M-24 Grade
Width: 600 mm
Motor:505 KW, RPM:1500
Gear box: Radicon worm reducer
Type: U-600, Ratio: 30:11
Lubrication: Servo Mesh SP320
MECHANICAL PARTS IN CEMENT INDUSTRY
As employed here, the term relates to material banding device which even continuously. The material itself may be carried along in a continuous flow air in individual receptacles,which may be very closely spaced or further apart or indeed some considerable distance apart and possibly detachable.
(A) SCREW CONVEYOR: screw conveyors (alsoknown as spiral or worm conveyors) are used for the handling of granular or powdered bulk materials on horizontal or slightly inclined(ascending or descending) conveying paths. The material is pushed along in a trough, so that in this respect the conveying action is similar to that of a flight conveyor. the loading capacity of the screen conveyor is determined by the diameter of the helix, its pitch is rotational speed,the loading and the nature of the material to be loaded.
(B) ELECTROSTATIC PRECIPITATOR: In cement industry normally ESP controls fineness and separate the fine dust from air. Electrostatic precipitator are used in cement works more particularly for the removal of dust from the exit gases of cement kilns and from the exhaust air discharge by dryers,combined grinding and drying plants, finishing mills with water infection.
In the ESP the dust laden gas is made in the horizontal direction, while it passes through one or more high voltage electric fields formed by alternate discharge electrodes and plate type collecting electrodes. Whereas the later are earthned, the discharge electrodes are maintained at a high direct(DC) voltage of about 50 to 110 KV, provided by various types of high tension rectifier equipment under the action of the electric field the dust particles, which have become electrically charged by negative gel ions which are formed at the discharge electrodes and attach themselves to the particles, fly to the collecting electrodes and are deposited there. The dust is disloged from these electro by tapping and thus fails into the receiving hoppers at the base of the precipitator casing.
© BAG FILTER: mostly filters used in cement industry are generally bag type i.e. tube with 1 feet diameter or less and upto 30 feet high; they consist of woven or fitted cloth made from particles in the sub-micron range at high efficiencies of 99.5%. depending on the kind of fabric, these filters can be applied to gas temperature upto 550Ã‚Â°F. the dust laden gas flows through a porous medium-the filter fabric and deposits particles in the voids. After filling the voids a coke starts to build up on the fabricâ„¢s surface, which does most of the filtering. During the pre-coating period which lost only moments, the efficiency way drops. When the dust layer on the fabric becomes too thick, an increase in pressure drop results; this required cleaning of the fabric.
(D) AIR SEPRATOR: The dispersion separator (also called the mechanical air sepraton) is the most representative air separator in the cement industry. This kind of separator utilized a distribution plate to disperse the feed material into the separating space. The action of an air current of a velocity upon a mass particle is proportional to the sutface presented by this particle to the air current, this to the square of the mean dimensions of the particle. The action of the force of gravity upon on mass particle is proportional to the volume, thus to the cube of the mean dimensions of the particle. The mechanical air separator feed passes through the ballon feed spout and drops by gravity to the distribution separator main fan creates a continuous circulating air current into which the distribution plate disperses the separator feed.
Air velocity, volume of air and speed of rotation are important factors in the separating of the fine particles from the coarse ones.
(E) GAS CONDITIONING TOWER (GCT):-The main use of GCT is to separate the air and fine dust. In GCT water is sprayed and stored compressed air. By this process of water spraying dust take humidity and gets down by the help of screw conveyor and air slide dust particles reach to storage silo. Free compressed air goes to cyclone by the outlet duct.
(F) BELT CONVEYOR:-Belt Conveyor have been used for a great many years as handling devices for bulk material. They are most widely used continuous conveyor because they are adoptable,versatile , reliable and economical. Belt conveyors moves on rollers with the help of rubber belt conveyors material transfer to one place to another place.
(G) BUCKET ELEVATOR:- Bucket Elevator of various kinds have come in the wide spread use in the cement and lime manufacturing industry, more particularly for the handling of hot and abrasive materials.When material is required to convey vertically so we can use Bucket Elevator. In cement plant generally we are using two type of bucket elevator.
a) Belt Bucket Elevator:-Cotton fabric belts as fraction elements used to be employed for Bucket elevator of the self loading type which scooped up the material by the digging action by the bucket for the lading of light fine grained material.
b) Chain type Bucket Elevator:-This is the only type of Bucket Elevator that can be used for the loading of hot materials. Besides bushed chains, round link chains are also extensively used their advantages being the smaller chain pitch giving quieter running on passing round the sprockets or chain wheels. For high capacity bucket elevator it is necessary to use suitably heat-treated steel chain of the round link type in order to keep the amount of wear at point of articulating within acceptable limits.
(H) DEEP BUCKET CONVEYOR:- The simplest type of chain conveyor for transfer the bulk material is the Deep Bucket Conveyor. It is conveying the hot and abrasive materials. We cannot use rubber belt conveyor for transportation of hot material,hence we can use Deep Bucket Conveyor.It has MS Buckets, which can travel on track.
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