DG Cement Khairpur Internship Report (More Info Added and More Explained)

Internship Report 2010
Internship Report
DG Khan Cement Company,
Khairpur Plant Chakwal
Tutmash Shafi Akhtar

SP07-BEC-85
Department Of Chemical Engineering

COMSATS Institute Of Information
technology, Lahore
Tutmash Shafi Akhtar (SP07-BEC-85) 1
Department Of Chemical Engineering, CIIT Lhr
:: Table Of Contents ::
Serial Area Page

No. No
1 Introduction D.G. Khan Cement
Company Ltd
2 Portland Cement And Clinker

Composition
3 History Of Cement
4 Types Of Cement
5 General Steps involved in Production
6 Quarry and lime stone crusher
7 Storage yard (Operation of stacker,
reclaimer & side scrapper)
8 Raw mill feed area, Raw mill, EP &
conditioning tower
9 Labortories
10 Coal yard, Coal mill feed area, coal
mill, storage of coal
11 CF Silo, low bin, preheaters cyclones

and precalciner
12 Kiln and cooler

13 Cement mill feed area, gypsum crusher
14 Cement mills
15 Packing plant
16 Setting & Hardening of Cement
17 Uses of Cement
18 Safety
19 Envirnmental Effects
20 Suggestion to the Management

Acknowledgement
My greatest thanks to Allah Almighty. Allah who bestowed me with the ability
and potential to complete this Internship. Before I go into thick of the things, I
would like to add a few deepest words for the people who were part of this
report in numerous ways… people who gave unending support right from the
stage the report was assigned. Particularly I also wish to thank the managerial
staff at DG Cement who helped me to gain a lot of information regarding the
company and cement industry and also who provide me an opportunity to learn
and understand the working of organization as an internee. I am also thankful to
Mr. Aleem (Trainee Engineer) and Mr.Umar Rehman (Trainee Engineer) who
played a role of polar star for me in the organization and whose experience taught me a lot about
the industry and the organization.
And finally deepest and warmest appreciation to the whole team of DG Khan Cement Company
Executive Summary
Dera Ghazi Khan Cement Company Limited is a strategic business unit of Nishat Group, which is
the largest industrial group in Pakistan. D.G. Khan Cement Co. is market leader with respect to
market share with about 11.4% market share. Apart from its competitors; its product is high priced
yet it has highest market share because of good quality. Its plant is situated in Dera Ghazi Khan and
Khair Pur and head office is situated at Lahore. Factory site Unit 1and 2 that is situated in very
remote area of Punjab, yet it proved a blessing for the company. Because it has all three basic raw
materials i.e. Lime stone, Shale, and Gypsum at one place.
It has three plants working two in D.G. khan and one in Khair Pur. First plant is old one and it is
Japanese plant. The other two plants are of F.L.Smiths, Denmark. Presently it has a total Installed
capacity of 14000 tpd(tons per day).Presently the company is also exporting the cement to
Afghanistan, Iraq, UAE and Russia. The team of the D.G. Cement is story of success of D.G.
Cement. The whole team is self-motivated and had played a vital role in the success of the
company.

D.G. Khan Cement Company Ltd

Introduction
D.G. Khan Cement Company:
D.G. Khan Cement Company Limited (DGKCC), a unit of Nishat group, is the second largest
cement-manufacturing unit in Pakistan with a production capacity of 13,400 tons clinker per day. It
has a countrywide distribution network and its products are preferred on projects of national repute
both locally and internationally due to the unparallel and consistent quality. It is list on all the
Stock Exchanges of Pakistan.
DGKCC was established under the management control of State Cement Corporation of Pakistan
Limited (SCCP) in 1978. DGKCC started its commercial production in April 1986 with 2000 tons
per day (TPD) clinker based on dry process technology. Plant & Machinery was supplied by UBE
Industries of Japan.
Expansion -Khairpur Project

The Group has also set up a new cement production line of 6,700 TPD clinker near Kalar Kahar,
Distt, Chakwal, the single largest production line in the country. First of its kind in cement industry
of Pakistan, the new plant have two strings of pre-heater towers, the advantage of twin strings lies
in the operational flexibility whereby production may be adjusted according to market conditions.
The project equipped with two vertical cement grinding mills. The cement grinding mills are first
vertical Mills in Pakistan. The new plant is not only increasing the capacity but also providing
proximity to the untapped market of Northern Punjab and NWFP besides making it more
convenient to export to Afghanistan from northern borders.
Power Generation
For continuous and smooth operations of the plant uninterrupted power supply is very crucial. The
company has its own power generation plant along with WAPDA supply. The installed generation
capacity is 23.84 MW.
Environmental Management
DG Khan Cement Co. Ltd., production processes are environment friendly and comply with the
World Bank’s environmental standards. It has been certified for “Environment Management
System” ISO 14001 by Quality Assurance Services, Australia. The company was also certified for
ISO-9002 (Quality Management System) in 1998. By achieving this landmark, DG Khan Cement
became the first and only cement factory in Pakistan certified for both ISO 9002 & ISO 14001...
Cement :
a cement is a binder, a substance that sets and hardens
independently, and can bind other materials together. The
word "cement" traces to the Romans, who used the term opus
caementicium to describe masonry resembling modern
concrete that was made from crushed rock with burnt lime as
binder. The volcanic ash and pulverized brick additives that
were added to the burnt lime to obtain a hydraulic binder
were later referred to as cementum, cimentum, cäment and
cement.
Portland cement :
(often referred to as OPC, from Ordinary Portland Cement) is the most common type of cement in
general use around the world because it is a basic ingredient of concrete, mortar, stucco and most
non-specialty grout. It is a fine powder produced by grinding Portland cement clinker (more than
90%), a limited amount of calcium sulfate (which controls the set time) and up to 5% minor
constituents as allowed by various standards.
Portland cement clinker :
is a hydraulic material which shall consist of at least two-thirds by mass of calcium silicates
(3CaO.SiO2 and 2CaO.SiO2), the remainder consisting of aluminium- and iron-containing clinker
phases and other compounds. The ratio of CaO to SiO2 shall not be less than 2.0. The magnesium
content (MgO) shall not exceed 5.0% by mass
History:
Portland cement was developed from natural cements made in Britain in the early part of the
nineteenth century, and its name is derived from its similarity to Portland stone, a type of building
stone that was quarried on the Isle of Portland in Dorset, England.
Joseph Aspdin, a British bricklayer from Leeds, in 1824 was granted a patent for a process of
making a cement which he called Portland cement. His cement was an artificial cement similar in
properties to the material known as "Roman cement" (patented in 1796 by James Parker) and his
process was similar to that patented in 1822 and used since 1811 by James
Frost who called his cement "British Cement". The name "Portland cement" is
also recorded in a directory published in 1823 being associated with a William Lockwood, Dave
Stewart, and possibly others.
Aspdin's son William, in 1843, made an improved version of this cement and he initially called it
"Patent Portland cement" although he had no patent. In 1848 William Aspdin further improved his
cement and in 1853 he moved to Germany where he was involved in cement making. Many people
have claimed to have made the first Portland cement in the modern sense, but it is generally
accepted that it was first manufactured by William Aspdin at Northfleet, England in about 1842.
The German Government issued a standard on Portland cement in 1878
Early uses:
It is uncertain where it was first discovered that a combination of hydrated non-hydraulic lime and
a pozzolan produces a hydraulic mixture (see also: Pozzolanic reaction), but concrete made from
such mixtures was first used on a large scale by Roman engineers. They used both natural
pozzolans (trass or pumice) and artificial pozzolans (ground brick or pottery) in these concretes.
Many excellent examples of structures made from these concretes are still standing, notably the
huge monolithic dome of the Pantheon in Rome and the massive Baths of Caracalla. The vast
system of Roman aqueducts also made extensive use of hydraulic cement.[3] The use of structural
concrete disappeared in medieval Europe, although weak pozzolanic concretes continued to be
used as a core fill in stone walls and columns.
Types Of Cement :
Sulphate Resistant Cement:

Sulphate Resistant Cement is used in projects such as dams that are exposed to high amounts of
sulfates. It is also used wherever there are constructions that are in direct contact with clay soil,
which contains a large amount of sulfate salt, such as foundations and pillars. Sulphate Resistant is
a pre-blended, ready-to-use cement base grout containing non-ferrous fluidities and anti-shrinkage
compounds blended with siliceous aggregate and Portland cement. A highly sulphate resistant
cement, with an extremely low C3A content, is utilized in the manufacture of Sulphate Resistant
Grout. This special cement is very resistant to attack from sodium and magnesium sulphates found
in ground water.
Hydraulic cement :
Hydraulic cements are materials that set and harden after being combined with water, as a result of
chemical reactions with the mixing water, and that, after hardening, retain strength and stability
even under water. The key requirement for this strength and stability is that the hydrates formed on
immediate reaction with water be essentially insoluble in water. Most construction cements today
are hydraulic, and most of these are based on Portland cement, which is made primarily from
limestone, certain clay minerals, and gypsum in a high temperature process that drives off carbon
dioxide and chemically combines the primary ingredients into new compounds.
Non-Hydraulic cement :
Non-hydraulic cement is cement which cannot harden while in contact with
water, as opposed to hydraulic cement which can. Non-hydraulic cements are
created using materials such as non-hydraulic lime and gypsum plasters, and oxy chloride, which
has liquid properties Non-hydraulic cements include such materials as (non-hydraulic) lime and
gypsum plasters, which must be kept dry in order to gain strength, and oxy chloride cements, which
have liquid components. Lime mortars, for example, "set" only by drying out, and gain strength
only very slowly by absorption of carbon dioxide from the atmosphere to re-form calcium
carbonate through carbonization.
Portland cement blends :

These are often available as inter-ground mixtures from cement manufacturers, but similar
formulations are often also mixed from the ground components at the concrete mixing plant.
Portland Blast furnace Cement contains up to 70% ground granulated blast furnace slag, with the
rest Portland clinker and a little gypsum. All compositions produce high ultimate strength, but as
slag content is increased, early strength is reduced, while sulfate resistance increases and heat
evolution diminishes. Used as an economic alternative to Portland sulfate-resisting and low-heat
cements.
Portland Flyash Cement contains up to 30% fly ash. The flyash is pozzolanic, so that ultimate
strength is maintained. Because flyash addition allows a lower concrete water content, early
strength can also be maintained. Where good quality cheap flyash is available, this can be an
economic alternative to ordinary Portland cement.
Portland Pozzolan Cement includes fly ash cement, since fly ash is a pozzolan, but also includes
cements made from other natural or artificial pozzolans. In countries where volcanic ashes are
available (e.g. Italy, Chile, Mexico, the Philippines) these cements are often the most common
form in use.
Portland Silica Fume cement. Addition of silica fume can yield exceptionally high strengths, and
cements containing 5-20% silica fume are occasionally produced. However, silica fume is more
usually added to Portland cement at the concrete mixer.
Masonry Cements are used for preparing bricklaying mortars and stuccos, and must not be used in
concrete. They are usually complex proprietary formulations containing Portland clinker and a
number of other ingredients that may include limestone, hydrated lime, air entrainers, retarders,
waterproofers and coloring agents. They are formulated to yield workable mortars that allow rapid
and consistent masonry work. Subtle variations of Masonry cement in the US are Plastic Cements
and Stucco Cements. These are designed to produce controlled bond with masonry blocks.
Expansive Cements contain, in addition to Portland clinker, expansive clinkers (usually

sulfoaluminate clinkers), and are designed to offset the effects of drying shrinkage that is normally
encountered with hydraulic cements. This allows large floor slabs (up to 60 m square) to be
prepared without contraction joints.
White blended cements may be made using white clinker and white supplementary materials such
as high-purity metakaolin.
Colored cements are used for decorative purposes. In some standards, the
addition of pigments to produce "colored Portland cement" is allowed. In
other standards (e.g. ASTM), pigments are not
allowed constituents of Portland cement, and colored cements are sold as "blended hydraulic
cements".
Very finely ground cements are made from mixtures of cement with sand or with slag or other
pozzolan type minerals which are extremely finely ground. Such cements can have the same
physical characteristics as normal cement but with 50% less cement particularly due to there
increased surface area for the chemical reaction. Even with intensive grinding they can use up to
50% less energy to fabricate than ordinary Portland cements.
Non-Portland hydraulic cements :

Pozzolan-lime cements. Mixtures of ground pozzolan and lime are the cements used by the
Romans, and are to be found in Roman structures still standing (e.g. the Pantheon in Rome). They
develop strength slowly, but their ultimate strength can be very high. The hydration products that
produce strength are essentially the same as those produced by Portland cement.
Slag-lime cements. Ground granulated blast furnace slag is not hydraulic on its own, but is
“activated” by addition of alkalis, most economically using lime. They are similar to pozzolan lime
cements in their properties. Only granulated slag (i.e. water-quenched, glassy slag) is effective as a
cement component.
Supersulfated cements. These contain about 80% ground granulated blast furnace slag, 15%
gypsum or anhydrite and a little Portland clinker or lime as an activator. They produce strength by
formation of ettringite, with strength growth similar to a slow Portland cement. They exhibit good
resistance to aggressive agents, including sulfate.
Calcium aluminate cements are hydraulic cements made primarily from limestone and bauxite.
The active ingredients are monocalcium aluminate CaAl2O4 (CA in Cement chemist notation) and
Mayenite Ca12Al14O33 (C12A7 in CCN). Strength forms by hydration to calcium aluminate
hydrates. They are well-adapted for use in refractory (high-temperature resistant) concretes, e.g. for
furnace linings.
Calcium sulfoaluminate cements are made from clinkers that include ye’elimite
(Ca4(AlO2)6SO4 or C4A3 in Cement chemist’s notation) as a primary phase. They are used in
expansive cements, in ultra-high early strength cements, and in "low-energy" cements. Hydration
produces ettringite, and specialized physical properties (such as expansion or rapid reaction) are
obtained by adjustment of the availability of calcium and sulfate ions. Their use as a low-energy
alternative to Portland cement has been pioneered in China, where several million tonnes per year
are produced. Energy requirements are lower because of the lower kiln temperatures required for
reaction, and the lower amount of limestone (which must be endothermically decarbonated) in the
mix. In addition, the lower limestone content and lower fuel consumption leads to a CO2 emission
around half that associated with Portland clinker. However, SO2 emissions are usually significantly
higher.

“Natural” Cements correspond to certain cements of the pre-Portland era,
produced by burning argillaceous limestones at moderate temperatures. The
level of clay components in the limestone (around 30-35%) is such that large amounts of belite (the
low-early strength, high-late strength mineral in Portland cement) are formed without the formation
of excessive amounts free lime. As with any natural material, such cements have very variable
properties.
Geo polymer cements are made from mixtures of water-soluble alkali metal silicates and
aluminosilicate mineral powders such as fly ash and metakaolin.
Steps Involved in Cement Production :
A limestone prehomogenization pile being built by a boom stacker A completed limestone prehomogenization pile
Precalc iner
Typical clinker nodules

Cement Crushing
Quarry:
Quarry is the place from where raw material in extracted. Drilling and blasting is done to extract
the material.A hole of about 10-15 m is drilled and ammonium nitrate in filled as an explosive in
these holes. When this explosive is ignited the rocks are broken into pieces of different sizes. These
pieces sre then loaded on the dumper trucks and conveyod to the crusher. It is located about 3-4
Km from the plant.
Quarry and raw materials:
The following raw material is required in the production process:
1. Lime stone: This raw material is company owned and is extracted from the
nearby quarry Unit. Limestone has the highest composition in the cement
product. 76% of the cement constitutes of limestone.
2. Clay: Clay is another natural resource. This raw material is also company
owned. 24% of cement composition comprises of clay
3. Iron Ore, Bauxites and silica sand: Iron Ore is the only resource that is bought from
contractors. Iron Ore, Bauxites and silica sand are added in small quantities less then one percent
and it helps to strengthen the cement.
4. Gypsum: Gypsum acts as a retarding agent. It slows down the hardening

process which in turn gives the constructor enough time to use it.
Proportions of different Raw Materials:

There are basically three main raw materials that are used for the production of cement.
In addition to that, a small proportion of other additives such as silica and Bauxites are also added.
1. Limestone 76%

2. Clay 24%
3. Iron ore (less than 1%)
4. Silica sand (less than 1%)
5. Bauxites (less than 1%)
Lime stone and clay are extracted from the same place. Iron ore is bought from a contractor.
Limestone Crusher: (EV 200*300) (Hammer Crusher)

Capacity : 1500 tons/hr
Supplier : FLSmidth
Description:
Raw material such as limestone, clay, marl and shale
are dumped into hoppers by dump trucks and entered
into a hammer crusher through an apron feeder. Inside
hammer crusher there are hammers each having a
weight of 100-102 kg. They rotate at a speed of 1200-
1300 rpm and is capable of crushing feed of very large
sizes. Pivoted hammers are mounted on a horizontal
shaft, and crushing takes place by impact between the
hammers and breaker plates. Heavy-duty hammer
crushers are frequently used in the cement industry.
These crushers are of two types, with and without grates the crushers used in use in Pioneer
Cement have grates beneath them, this is a semicircular grizzly bar placed just close to the crusher
assembly. Material is broken first by impact against hammers and then by rubbing action (attrition)
against screen bars.
There are number of disks attached to the axle, between them is a gap in which hammers are fitted
on multiple shafts running across close to edges of disks. Hammers and bushing pins are placed
alternately to allow clearance and avoid extra energy needed to run the hammer crusher
Bag Filter :
It separate dust from air. It consists of a
box with 2 chambers, with a separation
between them, the lower chamber has
inlet of dust laden air, from upper
chamber multiple fabric bags with metal
structure inside them hangs into lower
chamber, in upper chamber there is a
purging mechanism. A suction fan suck
air from upper chamber, the air enter from
lower chamber and after passing through
bags it enter upper chamber and then to
suction fan,
The air when pass through the bags get
filtered the dust stick to the bag, after a

particular time purging is done which is reversing the flow of air with the help
of high pressure air, this lead to falling down of dust, at bottom of lower
chamber. The lower chamber have a hopper type bottom into which a screw
conveyor is present which move the settled dust to one corner where a downward
opening exist from where it is dropped back to the conveyor line. The purpose of
bag filter is to avoid pollution plus recovery of material, leading to efficiency,
Composition analyzer ;
A composition analyzer is installed upon the feed conveyor belt. This analyzer
detects the composition of the feed before it goes to the storage pile. The
radioactive material used id “Clifornium”. Its half life is 2.5 years and its price is
84,00000. This element emits rays which pass
through the feed and are deflected back to the analyzer, which then checks the
composition. The composition of eacs material is specific.
Magnetic separator :
A magnetic separator is installed on the feed belt. It
attracts and removes metal objects from the feed
which are collected in the bin.
Storage Yard:
The crushed material is stored in the form of piles in the storage yard. There are 6
piles in the storage yard. Mixed piles are used in larger quantity where as high
grade and additive piles are used in small quantity.
 2 Mixed piles (limestone & clay)
 2 High grade (pure limestone)
 Iron ore (additive)
 Bauxite (additive)
Stacker :
A stacker is a large machine used in bulk material handling
applications. A stacker's function is to pile bulk material
such as limestone, clay, and laterite.
It operates on a rail-like structure with movable wheels,
stacking of material can be performed in stationary or
moveable mode.

.A stacker is a device which form conical piles of the crushed material. Feed is
conveyod to the stacker through conveyor belts. This stacker then moves too an
fro to make a pile. The stacker belt is called “Jib” in engineering terms.
Now, for conveying this material from piles to the conveyor follweing equipment
sre used :
 Side scrapper
 Reclaimer
Side scrapper :
Side scrapper is a device which picks the crushed feed
from the piles through its feed belt called “Hoist”. This belt
has a number of small buckets of low capacity. When this
belt moves, the buckets picks feed from the pile and put it
on the belt conveyor. Side scrapper in used for those piles
which are required in low quantity like bauxite and iron
ore.
Reclaimer :
A re-claimer is a large machine used in bulk material handling. Its function is to
recover bulk material from a stockpile, which has been stacked by the stacker. Re-
claimer travel on a rail between stockpiles in the stockyard. It’s electrically
powered by means of a trailing cable.
Scrapper types reclaimer:It has two ams called “Harrows” These harrows are
inserted into the pile, when they move sideward, the feed drops down the pile. This
feed in then collected by high capacity buckets installed in the bottom of the
reclaimer. These buckets pick the feed and put it on the the belt conveyor. It is a
large capacity equipment and for those piles which are required in high quantity
like Mixed Pile.
Types of Reclaimers :
1)Bridge type:
This type of reclaimer lies across the pile and run on the tracks laid on both sides
of pile shed. . Bridge type reclaimers blend the stacked product as it is reclaimed.
This is used to reclaim chevron piles which are actually made of layers of material
2) Boom type:
The rail track is only on one side of the pile and the scrapper move on one side of
pile scrapping the material and loading it onto the conveyor belt running on the
sides of pile

Raw mill Feed area :

The raw mill feed area consists of 4 feed hoppers:
 Mixed feed hopper
 Pure limestone hopper
 Bauxite hopper
 Iron ore hopper
The capacity of first two hoppers is 800 tons
while the other two hoppers have a capacity of
600 tons. The feed from each pile is conveyed to
the hoppers through conveyor belts in relevant hoppers. Each hopper has 4 load
cells.
Load Cells : These are sensing devices which tells the load being put on the
hopper by the feed.
From these hoppers, the feed in required proportions is transferred by the belt
conveyor to the Raw Mill. A lot of dust is produced during the conveying of
material, to avoid this problem Bag Filters are installed. A
Magentic separator is also intalled to reomove metal
impurities.
Raw Mill:
Capacity: 500 tons/hr
Motor power : 4300 kw
Supplier : FLSmidth

Sections Of Raw Mill:

There are 3 sections of a raw mill.
 Table with 3 rollers
 Bottom scrapper
 Separator
Table:
The raw feed from the belt conveyor directly falls on
the rotating table of the raw mill. The table contains 3
crushing rollers. The raw fed is crushed to fine powder
with these rollers. The coarse particles are collected at
the bottom of raw mill and are sent to to the vibrator
from where they are sent to to the raw feed belt
conveyor and again recycled to the ram mill for
recrushing. The vibrator is use to handle the quantity of the material being put on
the belt.
Seperator :
At the top of the raw mill, there is separator section. Hot
gases from the kiln comes from the bottom of the raw mill
and lift very fine particles with it. A suction fan with motor
power of 4500 kw produces suction and sends dusty air into
the cyclones at the top. Here the dusty air rotates and
particles are separated from the air. These particles are
collected at the bottom of the cyclone and sent to the CF
silo with the help of air slides. The air which still contains
dust particles are separated in Conditioning tower and
Electrostatic precipitator.
Bottom separator:
Some fine particles from raw feed fall on the table, these particles are collected by
means of a bottom scrapper and sent to the CF silo.

Conditioning tower:
The air from the cyclones still contains the dust particles which must be separated
before the air is exhausted to the atmosphere. Air from the separator is passed
through conditioning tower. In conditioning tower, water is sprinkled through very
fine nozzles. The particles in the air get wet and settle down. These particles are
then conveyed to the CF silo via screw conveyor.
Electrostatic precipitator :
The clean air from the conditioning tower still contains some particles which have
to be removed. These particles are separated from air by passing it through the
Electrostatic precipitator.
In Electrostatic precipitator there are 2 corona wires which are mesh like. These
wires are negatively charged. There is a positively charged electrode in the centre
which is equidistant from
both corona wires. Dusty air passes through these corona wires and the particles
get negatively charged. The negatively charged particles in air are then attracted by
the positively charged

electrode and the particles stick with it and clean air is exhausted from the
chimney.
Working of the electrostatic precipitator:

Based on the application of electrostatic charge to a particle and then subjecting it
to oppositely charged surface, it works on the phenomena of attraction between
opposite charges. the dust laden gases flows through a chamber in which it passes
through high voltage electric fields formed by alternate discharged electrodes and
plate type collecting electrodes. Subjected to electric field the dust particles get
charged and fly to collecting electrodes and get deposited there. The dust is
dislodged by hammering and drops down in the collecting hopper.
High temperature and moisture effect the resistively of dust making it less
favourable for collection. Conditioning tower reduces resistively of dust.
It works well at t<130c and 15% moisture. Electrostatic precipitator uses the
phenomena of attraction between + - to separate fines from air. The air along with
dust is charged at anode and then is subjected to – terminal, the particles being
solid stick to the –plates, which are hammered after an interval to separate the dust
and it settle down and are conveyed by screw conveyor and air slides to steel silo
from where it is directly sent to cement Mill

Cleaning of the electrostatic precipitator:
In order to remove particles from the electrode . A “Wrapping” device is used.
This device hits the electrode as a hammer and particles fall down from it. These
particles are collected and conveyod to the CF silo via screw conveyor.
Labortories :
There are different laboratories for the determination of quality and strength of the
cement. Different types of tests are conducted to determine different properties of
the product. Also different types of fuels are tested for their inherent properties: for
example:
 Fineness of coal
 Humidity level of coal
 Calorific value of coal
 Composition of feed material and product
 Settling time of cement
 Residual material
Following are the different labs avalible.
Sample prepration lab:
In sample prepration lab, different samples of cement are prepared and tested. Raw
material in put in an equipment called “Swing mill”. A swing mill is a grinding
mill. This grinding mill has a special type of vessel in which material is ground to
very fine powder.
Press mill :
The ground material is put into a circular dye and placed into a press mill. The mill
exerts pressure on it and a rigid dye is produced which a metallic circular outer
layer. The press mill exerts a pressure of 150 KN on the dye to produce a sample.
X-ray analysis :
Now, the sample dye is put into an x-ray analysis machine to determine its
composition. Thesample is place for 2 mins in the machine. The x-ray machine is

controlled by a computer software. This software restricts the machine to
determine upto a limit of 6 to 8 elements. After 2 mins , the percentage of each
element in a particular sample is shown on the computer screen. The x-ray
machine is very fast in producing accurate results.
Chemical testing lab :
Chemical testing of a cement sample is done to determined its composition. It was
a slow and time consuming process, but nowdays x-ray analysis is used due to its
speed and accuracy.
In chemical testing lab inspite of x-ray analysis, samples are also tested by manual
experimentation.
For this purpose a distillation unit with a capacity of 25 litrers is used to get
distilled water for experimentation. If normal tap water is used, it may be hard,it
can alter the sample composition and may produce error full results. Two muffle
furnaces at 1200 °C and 1600 C° are used to determine the residual matter, volatile
matter and moisture content.
Physical testing lab :

In physical testing lab, physical tests of different cement samples are done to
check its properties.
Following are the equipment available is physical testing lab:
 Weigh balance  Tensile strength machine
 Turbula mixer  Water bath and curing tank
 Compression testing machine
 Motor mixer
Coal yard :
Coal yard is the area where coal is stored which is used for burning purposes.
There are different piles for the storage of local and imported coal. The coal is
impoted from South Arica, and Indonesia. The coal is handled by a loader, the
loader picks up the coal and throws on a sieved net which separates bigger pieces
of coal and stones form it, before it goes to the tunnel.
From the tunnels the coal is placed on the belt conveyor which takes it to the coal
mill feed area. Pet coke which is hard is also used in the coal feed.
Coal mill feed area :

After the impurities are removed from the coal, it is chuted on the belt
conveyor .A bag filter is employed which sucks the coal dust and thus prevents
the coal from being wasted. The coal is then shifted to the coal storage hopprs.
Coal storage hoppers :
There are 3 hoppers for the storage of coal. Two hoppers are for the storage of
local coal and the other is for the imported coal. All the three hoppers have a
capacity of 250 tons. The coal required in different proportions are chuted on the
belt conveyor from the hoppers. A bag fiter is employed to
remove coal dust. A magnetic separator is employed to remove
metal impurities. This belt conveys the raw coal to the raw coal
mill.
Coal mill: ATOX 25

Specifications of coal mill :
Capacity : 52 ton/hr (coal mix)
26 ton/hr (pet coke)
Supplier : FLSmidth
Motor : 600 KW
Sections of a coal mill :

There are 3 sections of a coal mill similar to the raw mill.
(1) Table (2) Rollers (3) Bottom scrappers
The coal on the belt conveyor falls on the table of the mill where rollers grind it to
a fine powder. A blower of very high power pushes very fine particles towards the
two fine storage bins. From the 1st storage bin the coal is sent to the kiln for its use
in the burner and from 2nd storage bin it is sent to to the precalciner for
calcinations.
CF Silo (continuous flow) :

The fine particles from the conditioning tower
and electrostatic precipitator and the powdered
feed from the raw mill are conveyed to the

bucket elevator. The bucket elevator picks this feed and take it to the top of
the CF silo and then throws it in.
Specifications of a CF silo :
Length = 54 m Dia = 22.4 m
Capacity = 25,500 tons
Air circulations :
After the feed is stored in the silo bin. Now for the movement of feed in the bin,
air is blown from the bottom through different points in CF silo. These points are
located at the base of the CF silo.
Due to air circulations, fine particles are sent to air slides from where they are
transferred to Low bin (Loss of weight bin). The capacity
of low bin is 118 tons. The feed from the low bin is sent
to a bucket elevator which lifts it to the preheator.
Pre-heaters:
The bucket elevator puts the material on the top of of 2nd
cyclone. The hot gases from the kiln flow with very high
velocity in countercurrent direction. The hot gasses lift
the particles from the particles from the top of 2nd cyclone
and put it on the top of the 1sr cyclone. From there the
material falls on the top of the 3rd cyclone and
sends it into the 2nd cyclone. Then the material falls on the
top of 4th cyclone and hot gases take it into the 3rd cyclone.. then the material falls
on the top of the 5th cyclone and hot gases take it into the 4th cyclone and finally
into the 5th cyclone preheater.During this complete cycle, the hot gases foe in the
countercurrent direction. Thses cyclones serve the purpose of
preheating the feed material with hot gases of kiln.
There are total 10 cyclone preheaters . 5 are on the right side of the
precalciner and 5 on the left of the precalciner. The temperature of
feed increases as the feed flows downwards the preheaters.
Pre-calciner:
The feed from the 5th cyclone preheater falls into the precalciner
which has burner with a supply of coal and furnace oil. Here the
calcinations of feed material takes place due to burning. Exchange of heat also
takes place in the pre-calciner. CO2 is evolved and exhausted in the atmosphere
and the feed is entered into the kiln riser at high temperature. Some of the feed
directly goes to the kiln without going to the pre-calciner through separate pipes.
Kiln :
The preheated feed from the kin and the preheaters enter into the kiln riser. From
the kiln riser the feed enters into the kiln.
A Rotary kiln is a pyroprocessing device used to raise materials to a high
temperature (calcinations) in a continuous process. Materials produced using
rotary kilns
Principle of Operation:
The kiln is a cylindrical vessel, inclined slightly to the horizontal, which is rotated
slowly about its axis. The material to be processed is fed into the upper end of the
cylinder. As the kiln rotates, material gradually moves down towards the lower
end, and may undergo a certain amount of stirring and mixing. Hot gases pass
along the kiln, sometimes in the same direction as the process material (co-
current), but usually in the opposite direction (counter-current). The hot gases may
be generated in an external furnace, or may be generated by a flame inside the kiln.
Such a flame is projected from a burner-pipe (or "firing pipe") which acts like a
large Bunsen burner. The fuel for this may be gas, oil or pulverized coal.
Specifications of the rotary kiln :

The rotary kiln has a length of 66 m and dia of 5.5 m.its inclination is 4 %.
Its rotating spped varies according to the quantity of feed entered. Around the
inner dia of the kiln there is refractory lining to prevent the shell from damage and
to control the environment temperature. Outside the kiln there are induced draft
fans which turn on automatically when the shell temperature increase more
then a certain limit.
Kiln Motors:
There are two kiln bases on which motors are installed which impart rotary motion
to the kiln.
Kiln burner :
On the other end of the kiln , there is huge
burner having a supply of coal, furnace oil
and air. The burner emits a flame which is
prolonged with high pressure air. The
flame burn the material and the product is
formed.
Zones of a rotary kiln :
There are different zones in the rotary kiln
namely :
(1) Alex (2) Victor (3) Magkor.
 Alex : In this zone, feed from the precalciner and preheaters enter into the
kiln.
 Victor : It is the main reaction zone where the conversion takes place by
burning.
 Magkor : In this section clinker formation takes place of the burned
material
Alex Victor Magkor
Sections of a rotary kiln

The ash due to the burning of coal also goes with the product which causes LSF
(limestone factor) to reduce from the required limit. That’s why the material which
enters the kiln has a higher %age
of limestone because it is balanced with the ash of coal. The hot gases from the
kiln are not wasted but used in different equipment in the plant. The feed is
dropped into the kiln and it travel downwards due to downward inclination
and revolution of the kiln, hot gases resulting from the combustion of fuel ked to
the desired reactions in the kiln. There are different zones
Kiln zones:
there are four zone of the kiln.
1) Calcinations zone
2) Transition zone
3) Burning zone
4) Cooling zone
1) Calcination zone
This is the first zone of the kiln in which feed enters from the pre-heater.
Temperature of this zone is about 600-1000co.In this zone, low alumina bricks are
installed. In this zone, decomposition of calcium carbonate and magnesium
carbonate occurs which are present in limestone.
CaCO3 CaO + CO2
MgcCO3 MgO +CO2
2) Transition zone
After calcination, the next zone is the transition zone in which high alumina bricks
are used. In this zone material liquifycation starts. It is the peak point of
calcination fallowed by clinkerization. Temperature of this zone is about 1200-
1300C.
3) Burning zone

After transition, burning zone is starts and the liquid enters from the transition
zone changes into clinker. Temperature of this zone is about 1350-1450 C.
Here megnasite bricks are used for the insulation purpose.
4) Cooling zone
This zone is located below the burner of the kiln for the cooling of clinker. The
temperature in this zone is about 1400-1450c0.
A clinker with 25-30% liquid in raw mix is considered an ideal raw meal for kiln
lining, fuel saving and rapid C3S formation.
Kiln Reactions:
Following are the sequences of chemical reactions which occur in kiln.
(I)Decomposition of raw materials up to 1300 oC
Up to 500 c dehydration of water occurs.
From 600-800co dissociation of CACO3 and MgCO3 occurs.
From 800-900co formation of C2S occurs.
From 1100-1200 formation of C3A and C4AF occurs.
Liquid formation at 1250-1280 C.
(ii) Alite (C3S) formation in the burning zone (1280-1450co).

(iii)Cooling of clinker.
Kiln hood:
The hot material form the kiln falls into the kiln hood at the end which has an
angular sieve. When material passes through it it attains the shape of clinker. Now
this clinker is sent to the cooler.
Refractory Lining :
The purpose of the refractory lining is to insulate the steel shell from the high
temperatures inside the kiln, and to protect it from the corrosive properties of the
process material. It may consist of refractory bricks. The refractory selected
depends upon the temperature inside the kiln and the chemical nature of the
material being processed. The refractory life is prolonged by maintaining a coating
of the processed material on the refractory surface. . A typical refractory will be
capable of maintaining a temperature drop of 1000°C or more between its hot and
cold faces. The shell temperature needs to be maintained below around 350°C in
order to protect the steel from damage, and continuous infrared scanners are used
to give early warning of "hot-spots" indicative of refractory failure
Type and properties of bricks used in rotary kiln:

There are many types of bricks but in PCL two type of bricks are used
1) High alumina bricks
2)Magnetite bricks

1) High alumina bricks
They are high refractory whose refractiveness increases with increase of alumina
content, having high mechanical strength at high temperature. They are resistant to
spalling. From the kiln feed inlet, high alumina bricks are lined from 2m to 37m.
They are being imported from Germany.
2) Magnesite bricks
They are extremely high refractory and high thermal resistance. They are chemical
bonded to the kiln surface and are resistant to spalling. From the kiln feed inlet,
magnesite bricks are lined from 38m to 63m.
3) Castables:
It is an unshaped refractory. It is composed of refractory aggregate with high
temperature resistance binder i.e. high alumina, which upon addition of water
produces concrete. The binders used are calcium aluminates having about 45%
alumina content. Such binders are suitable for making insulation castables. Good
refractory concrete with rapid hardening, high strength and abrasion resistance is
achieved.
Clinker cooler :
The clinker cooler is used to lower the clinker temperature. There are ID fans
which take fresh air from the atmosphere and send it to the cooler. At the bottom
of the cooler there are reciprocating rails which move with the help of hydraulic
motors. These rails convey the clinker forward to the clinker crusher.
Dust collection :
A suction fan is installed which sucks the product dust from the cooler and send it
to the electrostatic precipitator. In EP dust is removed and clean air is exhausted to
the atmosphere through a chimney. The dust particles are to the deep pan conveyor
by a screw conveyor.
Clinker crusher :
When the clinker cools and hardens then it is sent to the clinker crusher installed
after the cooler. Big stones of clinker are crushed to
small pieces. The crushed clinker is dropped on the deep
pan conveyor at the bottom of the conveyor which
conveys it to the clinker storage.
Clinker storage :
The clinker from the deep pan conveyor is stored in the
clinker storage. Its capacity is 110,000 tons. Its length is

60 m and its width is 46 m. There are 3 gates at the bottom of the clinker
storage from where the clinker is
sent to cement mill through belt conveyor. Besides the main clinker storage bin,
there is a temporary clinker storage hopper with a capacity of 1400 tons. If the
temporay hopper is also full then the clinker is removed from the hopper and
dumped into clinker storage yard.
Cement mill feed area :

There are 2 cement mills and 6 hoppers (3 for each mill) in the cement mill feed
area.
The 1st hopper contains the clinker which is major constituent of the cement. The
cement contains 95 % clinker which is conveyed through weigh feeder to the main
belt conveyor which takes it to the cement mill.
Gypsum addition :
The crushed gypsum from a separate crusher is conveyed by belt conveyor to the
cement mill. It is mixed in the clinker while crushing. Gypsum is added to about 4
– 5 %. Its purpose is to increase the settling time of the cement.
Mixing of additive :
The additive which is pure limestone is also added in the cement mill. Its added to
about 2 %. Its function is to increase strength of cement.
A bag filter collects dust from the main belt and a magnetic separator remove
metallic impurities from entering into the cement mill.
Metal detector ;
To protect the cement mills from damage, a metal detector is installed which
analyzes the feed and if a metal object is found it opens the dividend gate
automatically and sends the feed containing metal objects to
the rejected bin, which is again recycled to the main belt and
magnetic seperatoe removes it.
Cement Mills :
Cement mills specifications OK 36-4 :
 Capacity : 175 ton/hr
 Motor power : 3400 kw

 Supplier : FLSmidth
The feed which is free from impurities falls on the table of cement mill which contains
three rollers. Each roller has weight of 35 tons and the clearance between table and rollers
is 0.5 mm. These rollers move hydraulically using nitrogen gas as hydraulic fluid.
The rollers crush the feed to a very fine powder. The air slides conveys the ground product
to the bucket elevator which lifts it to enter into the 1st storage silo.
Storage silos :
Specifications of storage silos :
 Capacity : 21,000 tons
 Length : 45 m
 Dia : 22.4 m
There are 3 cement storage silos in which crushed
cement is stored uptill packing.. To convey the cement
to the other 2 silos air slides are used. From these silos
the cement enters air slides by air circulations through
blowers. Now these air slides take the cement to the
packing plant.
Air slide: It a rectangular tube with two sections, the partition between them is of
a fabric layer, pressurized air is injected in the lower section, in the upper chamber
fine powder is dropped, due to pressure difference the air penetrate through
the fabric, the position of this slide is sloped downwards, this air entrainment
lead to powder movement.
Air lift:
This operates by fluidizing the powder and elevates it to desired height, the air
from compressors flow through the pipes in which powder is dropped into the pipe
thus air act as a carrier.
Packing Plant :
The packing plant comprises of 6 packers and 12
terminals. Each packer has a capacity of 100 tons/hr.
The cement bags are attached manually to the rotating
packer which fills the cement bag. When the bag is
filled upto the required weight , it automatically falls
on the conveyor balt which takes the bags to the roller
conveyor. From these rollers the bags slide to
different channels and finally cement bags are loadsed
on the trucks fro dispatch.
Setting and hardening of Cement:

Cement sets when mixed with water by way of a complex series of chemical
reactions still only partly understood. The different constituents slowly crystallise
and the interlocking of their crystals gives to cement its strength. Carbon dioxide is
slowly absorbed to convert the portlandite (Ca(OH)2) into insoluble calcium
carbonate. After the initial setting, immersion in warm water will speed up
setting. In Portland cement, gypsum is added as a compound preventing cement
flash setting.
Uses Of Portland Cement :

The most common use for Portland cement is in the production of concrete.
Concrete is a composite material consisting of aggregate (gravel and sand),
cement, and water. As a construction material, concrete can be cast in almost any
shape desired, and once hardened, can become a structural (load bearing) element.
Users may be involved in the factory production of pre-cast units,
such as panels, beams, road furniture, or may make cast-in-situ concrete such as
building superstructures, roads, dams. These may be supplied with concrete mixed
on site, or may be provided with "ready-mixed" concrete made at permanent
mixing sites. Portland cement is also used in mortars (with sand and water only)
for plasters and screeds, and in grouts (cement/water mixes squeezed into gaps to
consolidate foundations, road-beds, etc.).When water is mixed with Portland
Cement, the product sets in a few hours and hardens over a period of weeks. These
processes can vary widely depending upon the mix used and the conditions of
curing of the product, but a typical concrete sets in about 6 hours and develops a
compressive strength of 8 MPa in 24 hours. The strength rises to 15 MPa at 3 days,
23 MPa at 1 week, 35 MPa at 4 weeks and 41 MPa at 3 months. In principle, the
strength continues to rise slowly as long as water is available for continued
hydration, but concrete is usually allowed to dry out after a few weeks and this
causes strength growth to stop.
Safety:
When traditional Portland cement is mixed with water the dissolution of calcium,
sodium and potassium hydroxides produces a highly alkaline solution (pH ~13):
gloves, goggles and a filter mask should be used for protection, and hands should
be washed after contact as most cement can cause acute ulcerative damage 8-12
hours after contact if skin is not washed promptly.The reaction of
cement dust with moisture in the sinuses and lungs can also cause
a chemical burn as well as headaches, fatigue, and lung cancer.
The development of formulations of cement that include fast-
reacting pozzolans such as silica fume as well as some slow-
reacting products such as fly ash have allowed for the production
of comparatively low-alkalinity cements (pH<11) that are much
less toxic and which have become widely commercially available,
largely replacing high-pH formulations in much of the United
States. Once any cement sets, the hardened mass loses chemical
reactivity and can be safely touched without gloves.
Sampling fast set concrete made

from Portland cement

Environmental Effects :
Portland cement manufacture can cause environmental impacts at all stages of the
process. These include emissions of airborne pollution in the form of dust, gases,
noise and vibration when operating machinery and during blasting in quarries,
consumption of large quantities of fuel during manufacture, release of CO2 from
the raw materials during manufacture, and damage to countryside from quarrying.
Equipment to reduce dust emissions during quarrying and manufacture of cement
is widely used, and equipment to trap and separate exhaust gases are coming into
increased use.
Environmental protection also includes the re-integration of quarries into the

countryside after they have been closed down by returning them to nature or re-
cultivating them.
An independent research effort of AEA Technology to identify critical issues for

the cement industry today concluded the most important environment, health and
safety performance issues
facing the cement industry are atmospheric releases (including greenhouse gas
emissions, dioxin, NOx, SO2, and particulates), accidents and worker exposure to
dust.
The CO2 associated with Portland cement manufacture falls into 3 categories:
• CO2 derived from decarbonation of limestone,

• CO2 from kiln fuel combustion,
• CO2 produced by vehicles in cement plants and distribution.
Source 1 is fairly constant: minimum around 0.47 kg CO2 per kg of cement,

maximum 0.54, typical value around 0.50 worldwide.
Source 2 varies with plant efficiency: efficient precalciner plant 0.24 kg CO2 per
kg cement, low-efficiency wet process as high as 0.65, typical modern practices
(e.g. UK) averaging around 0.30. Source 3 is almost insignificant at 0.002-0.005.
So typical total CO2 is around 0.80 kg CO2 per kg finished cement. This leaves
aside the CO2 associated with electric power consumption, since this varies
according to the local generation type and efficiency. Typical electrical energy
consumption is of the order of 90-150 kWh per tonne cement, equivalent to 0.09-
0.15 kg CO2 per kg finished cement if the electricity is coal-generated.
Overall, with nuclear- or hydroelectric power and efficient manufacturing, CO2

generation can be as little as 0.7 kg per kg cement, but can be as high as twice this
amount. The thrust of innovation for the future is to reduce sources 1 and 2 by
modification of the chemistry of cement, by the use of wastes, and by adopting
more efficient processes. Although cement manufacturing is clearly a very large
CO2 emitter, concrete (of which cement makes up about 15%) compares quite
favorably with other building systems in this regard
Suggestion to the management
 Low safety measures.
 Waste of energy.
 Regular inspection and maintainance of plant should be done
 Proper accommodation and messing should be provided to the internees
 The internees must be given adequate computing facilities.
 Transport should provide to internees
Refrences:
Trainee Engr.Mr.Aleem
Trainee Engr.Mr.Umar Rehman
www.dgcement.com.pk
www.cementpk.com
www.logicsphere.com www.springerlink.com


DG Cement Khairpur Internship Report (More Info Added and More Explained)

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Internship Report 2010

Tutmash Shafi Akhtar

Department Of Chemical Engineering

Serial Area Page

2 Portland Cement And Clinker

11 CF Silo, low bin, preheaters cyclones

12 Kiln and cooler

Tutmash Shafi Akhtar (SP07-BEC-85) 2

Tutmash Shafi Akhtar (SP07-BEC-85) 3

D.G. Khan Cement Company Ltd

Expansion -Khairpur Project

Portland cement clinker :

Sulphate Resistant Cement:

Portland cement blends :

Expansive Cements contain, in addition to Portland clinker, expansive clinkers (usually

Non-Portland hydraulic cements :

Tutmash Shafi Akhtar (SP07-BEC-85) 8

Steps Involved in Cement Production :

Tutmash Shafi Akhtar (SP07-BEC-85) 9

The following raw material is required in the production process:

4. Gypsum: Gypsum acts as a retarding agent. It slows down the hardening

Proportions of different Raw Materials:

Tutmash Shafi Akhtar (SP07-BEC-85) 10

Limestone Crusher: (EV 200*300) (Hammer Crusher)

Tutmash Shafi Akhtar (SP07-BEC-85) 11

Tutmash Shafi Akhtar (SP07-BEC-85) 12

Tutmash Shafi Akhtar (SP07-BEC-85) 13

Raw mill Feed area :

Tutmash Shafi Akhtar (SP07-BEC-85) 14

Sections Of Raw Mill:

Tutmash Shafi Akhtar (SP07-BEC-85) 15

Tutmash Shafi Akhtar (SP07-BEC-85) 16

Working of the electrostatic precipitator:

Tutmash Shafi Akhtar (SP07-BEC-85) 17

Tutmash Shafi Akhtar (SP07-BEC-85) 18

Physical testing lab :

Tutmash Shafi Akhtar (SP07-BEC-85) 19

Coal mill: ATOX 25

Sections of a coal mill :

CF Silo (continuous flow) :

Tutmash Shafi Akhtar (SP07-BEC-85) 20

Specifications of the rotary kiln :

Alex Victor Magkor

Sections of a rotary kiln

Tutmash Shafi Akhtar (SP07-BEC-85) 24

(ii) Alite (C3S) formation in the burning zone (1280-1450co).

Type and properties of bricks used in rotary kiln:

Tutmash Shafi Akhtar (SP07-BEC-85) 25

Tutmash Shafi Akhtar (SP07-BEC-85) 26

Cement mill feed area :

Tutmash Shafi Akhtar (SP07-BEC-85) 27

Setting and hardening of Cement:

Uses Of Portland Cement :

Sampling fast set concrete made

Tutmash Shafi Akhtar (SP07-BEC-85) 30

Environmental protection also includes the re-integration of quarries into the

An independent research effort of AEA Technology to identify critical issues for

• CO2 derived from decarbonation of limestone,

Source 1 is fairly constant: minimum around 0.47 kg CO2 per kg of cement,

Overall, with nuclear- or hydroelectric power and efficient manufacturing, CO2

Trainee Engr.Mr.Umar Rehman

Tutmash Shafi Akhtar (SP07-BEC-85) 32

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